Abstract: Automated real-time characterization of resistance spot welds using ultrasound-based nondestructive evaluation requires a computational process and system to accurately and rapidly interpret the ultrasonic data in real time. Such a process can be automatically learned using artificial intelligence, from a dataset of exemplary ultrasonic data from nondestructive evaluation of resistance spot welds for which a corresponding ideal evaluation of each weld is provided. The process can then be implemented into a system to automatically interpret data from non-destructive evaluation in real-time. The ideal evaluation of each weld requires identification a large set of features that are observable in the ultrasonic signature and comprehensively characterize the corresponding weld process.

Abstract: A spot-welding electrode assembly includes an electrode, an electrode cap at an outer end of the electrode, and a plurality of transducer elements positioned inward of the electrode cap. The transducer elements may be micro-elements. A method for monitoring a weld formed by a spot-welder includes passing current from an electrode assembly through a stack-up, transmitting an ultrasonic wave from each of a plurality of sources in the electrode assembly to a plurality of points in the stack-up, and monitoring the ultrasonic waves to monitor the weld formation.

Abstract: A method is provided for assessment of quality of an adhesively-bonded lap joint, wherein the joint includes a first metal plate, a second metal plate and an adhesive therebetween. The method includes sending ultrasonic waves normally to the surface of a sample outside of the joint where the sample has a first sample metal plate with the same properties as does the first metal plate at an assessment point of the joint. Reflected waves from the sample joint as a reference waveform are recorded. Wideband ultrasonic waves are sent normally to the surface of the joint at the assessment point. Reflected waves of the ultrasonic waves from the joint are recorded. A waveform of the reflected waves from the joint and reference waveform are analyzed to determine an informative parameter. The informative parameter is compared with a threshold value to assess quality of the joint.

Abstract: A method for imaging a flowing media within static regions includes obtaining a plurality of signals using the speckle properties of the flowing media. The plurality of signals are compared to one another such as by subtraction. The static regions are removed from the plurality of signals by the comparison. The remaining signals are combined (such as by summing) to produce an image of the flowing media.