Presently, flexural transducers are designed and operated exclusively in ambient atmospheric conditions. They are used up to around 50 kHz, where the wavelengths in fluids are relatively long, thus reducing measurement resolution. Flexural transducers which can operate effectively at higher frequencies are therefore desirable, but also to withstand higher pressure and temperature levels associated with more hostile environments encountered in many industrial and aerospace applications. The major objective of this research is the development of such flexural transducers, known as high-frequency flexural ultrasonic transducers (HiFFUTs).
The flexural transducer is a uni-morph device, composed of a piezoelectric driver material in the form of a ceramic disc bonded to a metal cap. The transducer configuration is shown in Figure 1, where the principle of operation is centred on the vibration of the piezoelectric element, which is coupled to the metal cap through a bonding agent, subsequently causing bending of the metal cap, with a significant level of vibration amplification. The vibration response of the cap can be considered analogous to standard plate modes of vibration, convenient for the numerical modelling of flexural transducer behaviour. One significant advantage of flexural transducers over more conventional ultrasonic transducers is that since the vibrating metal cap is coupled to the loading medium, the effective impedance is much lower than the acoustic impedance of the cap material. This enables the transducer to couple efficiently to low impedance media, and operate with lower input voltage. Flexural transducers have been utilised for a variety of applications, including in proximity sensing environments such as car-parking systems, and for non-destructive evaluation.
Figure 1: Schematic of a flexural transducer.
The principal modes of vibration of a flexural transducer are shown in Figure 2, which exhibits two axisymmetric modes, termed (0,0) and (1,0), and two asymmetric modes, designated as (0,1) and (1,1). Higher order modes exist, such as the (2,0) axisymmetric mode.
Figure 2: Plate modes of vibration.
The cap membrane is considered as a thin plate which is clamped around the circumferential edge. The transverse displacement of the cap membrane plate can be determined through the following differential equation:
The rigidity of the cap membrane can be calculated using the following relationship, where E is the Young's modulus, h is the cap membrane thickness, and v is the Poisson's ratio:
The angular modal frequency can hence be determined using the following equation, where lambda is a Bessel function constant relating to the mode shape, a is the cap membrane radius, D is the rigidity of the cap membrane, and rho is the density of the cap membrane material. To convert the omega expression to frequency, this entire relationship should be divided by 2Pi.
HiFFUT Design Tool
This section provides an expedient and rapid estimator for basic HiFFUT design and operating parameters, for the fundamental axisymmetric operating modes of vibration, and for three common cap materials. This is a predictor based on the vibration modes of an edge-clamped plate, and should be used as a guideline only, since physical device parameters will affect the vibration characteristics of a HiFFUT. The predictor makes use of the equations presented above to generate the operating frequency in each case, and take account of the rigidity of the cap membrane. The higher the rigidity, the less compliant the membrane is, and hence less efficient for propagating ultrasound energy. This is important to consider in the design of HiFFUTs. Note that when specifying the membrane diameter, this does not include the side-wall geometry. Also, the operating mode frequency is calculated in terms of kHz, and so is presented to three decimal places. The estimator is provided below, followed by the supplementary information important for the design and fabrication of HiFFUTs.
Estimator of HiFFUT Operating Frequency
|HiFFUT Membrane Diameter (mm):|
|HiFFUT Membrane Thickness (mm):|
|HiFFUT Membrane Material:|
|Axisymmetric Mode of Vibration:|
|Modal Frequency (kHz):|
The key design considerations for HiFFUTs are:
- Environmental conditions, in particular pressure and temperature. This should be determined prior to any design process. The type of fluid will also be important to define, for example air, oil, or gas.
- Frequency and mode of operation. The operating frequency can be selected prior to HiFFUT design using the tool above, by manipulating the cap membrane material and dimensions. One solution may be to exploit higher order vibration modes, such as the (1,0) or (2,0) modes rather than the (0,0) mode, in the generation of high frequencies.
- Amplitude of sound propagation. The achievable vibration amplitude of the HiFFUT will depend on the cap material and physical dimensions of the HiFFUT and its components. A sufficiently robust transducer design will be required, to ensure the ability to operate the transducer at high amplitudes.
- Losses and efficiency. The thickness of the HiFFUT cap and the diameter of the radiating membrane affect the resonance frequency. The mechanisms by which these parameters affect resonance frequency have been reported, but less is known regarding how they affect transducer efficiency. The design and simulation of transducer performance should consider ceramic dielectric loss, in addition to internal mechanical loss. The electromechanical coupling coefficient is a useful property for assessing HiFFUT performance.
- Cap radiating membrane material, and associated geometry. The elastic properties of the cap material affect the vibration response of the HiFFUT, where the Youngs modulus, Poissons ratio, and density of the material are most signicant. There is flexibility in the choice of cap material, the most popular being stainless steel, aluminium and titanium, as provided in the design tool. The material and the cap dimensions will affect the vibration behaviour of the HiFFUT, but the vibration motion predominantly relies on how the membrane layer is defined, where the side-wall of the cap provides far less influence. Higher pressure environments may necessitate thicker membranes, depending on the design, but the cost of this is reduced compliance, and hence a lower efficiency. As the cap membrane diameter is increased, the magnitudes of the modal frequencies generally reduce. A compromise between cap membrane diameter and resonance frequency is hence required. A larger cap diameter enables a higher amplitude of vibration to be achieved for a specific excitation signal, but for a lower resonance frequency. However, a cap membrane diameter which is too small will make transducer fabrication difficult, for example with respect to soldering electrode connections.
- Driver material, and associated geometry. High pressure and temperature levels restrict the types of active driver which can be efficiently used in HiFFUTs. Strategies for shielding piezoelectric ceramics should be considered, or the use of alternative forms of active driver materials. Furthermore, the thickness of the driver element, such as the piezoelectric ceramic, should be lower than that of the cap, to ensure sufficient flexure in operation in the generation of the axisymmetric modes of vibration. However, the cap cannot be of a thickness which restricts the bending motion to generate the mode shapes.
- Mechanical coupling. The problems surrounding the bonding of flextensional and cymbal type transducers has been extensively reported. Transducers can be very sensitive to bond layer inhomogeneities, differences in deposited thickness, and the type of bonding agent used. The method of bond layer deposition, and any pre-treatment such as degassing and surface preparation, should be considered. Alternatively, an entirely different coupling mechanism may be an appropriate solution.
- Backing material. The choice of backing material, and backing layer thickness, both depend on the dimensions of the cap material and HiFFUT dimensions.
This research is being conducted with the invaluable support and partnership of key industry organisations.
Dynoptic Systems Ltd
EES Research Ltd
EES Research Ltd is a UK owned Research & Development company with over 25 years experience developing process measurement and control instrumentation for a diverse range of industries. Our expertise includes; ultrasonic, capacitance and radar techniques for level and flow measurement. EES Research has experience in many areas including; Water, Mining, Petrochemical, Transport, Information systems, Communications systems and many others.
Research and Development, Process Control Instrumentation, Process Instrumentation, Process Measurement Instrumentation
Dr Noel Kerr, Managing Director
Email: noel at eesresearch dot com
Telephone: +44(0)7971 273000
Headquarters: EES Research Ltd, Lochiel, Llaneilian Rd, Amlwch Port, Anglesey, LL68 9HU, United Kingdom
FLEXIM Instruments Ltd.
Katronic Technologies Ltd
Katronic develop and manufacture portable and fixed installation ultrasonic flowmeters with the intention that the measurement of flow should be quick, easy and straightforward. Katronic ultrasonic flowmeters can measure on pipes of all standard acoustically conductive materials over a large diameter range and are suitable for process liquids from pure water to chemicals and effluents.
Rob Turner, Engineering Manager
National Nuclear Laboratory
Documents and Downloads
Key documents, publications and resources are provided in this section for download. In addition, documents relating to the regular project meetings with the industrial partners have been made available.
S. Dixon, L. Kang, M. Ginestier, C. Wells, G. Rowlands, and A. Feeney, "The electro-mechanical behaviour of flexural ultrasonic transducers," Applied Physics Letters, vol. 110, no. 22, p.223502, 2017.
T.J.R. Eriksson, S.N. Ramadas, and S.M. Dixon, "Experimental and simulation characterisation of flexural vibration modes in unimorph ultrasound transducers," Ultrasonics, vol. 65, pp. 242-248, 2016.
T.J.R. Eriksson, S.M. Dixon, and S.N. Ramadas, "Metal cap flexural transducers for air-coupled ultrasonics," In 41st Annual Review of Progress in Quantitative Nondestructive Evaluation: Volume 34, AIP Publishing, vol. 1650, no. 1, pp. 1287-1291, 2015.
T.J.R. Eriksson, S.M. Dixon, and S.N. Ramadas, "Flexural mode metal cap transducer design for specific frequency air coupled ultrasound generation," In 2013 IEEE International Ultrasonics Symposium (IUS), pp. 1602-1605, 2013.
This research is a fellowship project funded by the Engineering and Physical Sciences Research Council (EPSRC), grant number EP/N025393/1, led by Prof Steve Dixon, with Dr Andrew Feeney and Dr Lei Kang as Research Fellows, and Jonathan Harrington providing technical expertise.
EPSRC Grants on the Web information: http://gow.epsrc.ac.uk/NGBOViewGrant.aspx?GrantRef=EP/N025393/1
The information on this web-page is managed and regularly updated by Dr Andrew Feeney.
- Email: a dot feeney at warwick dot ac dot uk.
- Web-page: www2.warwick.ac.uk/fac/sci/physics/staff/research/andrewfeeney/