A cleanroom-free approach towards a robust CMUT-based High Resolution 3D NDT system

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Although ultrasound is a common Non-Destructive Testing (NDT) technology, there exists real demand for significant improvement in performance and capability. This project aims to develop a disruptive and robust technology to enable high accuracy inspections that are not achievable using current technologies. Manufacturing of products often involves jointing of metal or different materials. A common process to perform this task is welding, which melts and joins the workpieces by applying energy to the area of interest. Two types of welding process, namely laser welding and electron beam welding, have been widely used to produce delicate metallic devices. Some examples are electronic packaging, connectors for equipment, and medical components. However, shrinkage and stress due to temperature change can produce cracks in the weld. Because the weld joint is small and is usually not easily accessible, it is very difficult to use conventional ultrasonic probe to perform inspection. Currently, these weld joints are often examined by metallurgical sectioning of the device, which is a destructive solution. We propose to develop a cleanroom-free Capacitive Micromachined Ultrasound Transducers (CMUTs) to facilitate the ultrasonic NDT of laser welding and electron beam welding in small devices. The CMUT is the ideal solution because of its attributes such as high frequency, high bandwidth, and a high degree of miniaturization. The availability of fabless and robust CMUT will not only provide a huge improvement in detection performance; it will also be economical, robust and allow huge design flexibility and quick turnaround design and fabrication time. The proposed research will propel Canada to the fore-front of NDT technology, help Canadian industries to be more competitive, reduce cost, create new market and generate employment opportunities.