Fastener hole inspection using 2D phased array

Fastener hole cracks, resulting from stress concentration around the hole, are potential sources of failure in mechanical structures. Traditionally, inspection involves manually moving a single ultrasonic probe around the hole or using an eddy current probe to move through the hole. However, single ultrasonic probe inspection is time-consuming and needs skilful operators. Eddy current inspection requires the removal of the fastener in advance and does not allow easy crack sizing and visualization. This paper proposes a novel approach that combines a 2D phased array with a coupling block to enable complete fastener hole inspection from a single array position. A single full matrix capture (FMC) data set is collected, from which 3D volumetric images are formed. To obtain clear images of the geometry and potential defects, half-skip and multi-skip total focusing method imaging algorithms are investigated together with transmitter–receiver pairs selection methods to detect different target features. Experimental results demonstrate that the proposed inspection approach can eliminate dead zone problems and capture all target information from a single inspection position. These methods show great potential in enhancing the efficiency and reliability of fastener hole inspections.