Undetected inclusions in engineering components cause tremendous industrial expenses in maintenance and repairs each year, with additional risks of catastrophic failures. This paper introduces a powerful method for inclusion imaging and reconstruction in irregularly-shaped components, based on a cutting-edge imaging technique—full waveform inversion (FWI). We propose an ultrasonic scanning setup for nondestructive evaluation (NDE) that fits a variety of components with different shapes and sizes. The FWI theoretical expressions are summarized, aiming for creating clear explanations for the NDE and material characterization communities. Systematic analysis of the FWI performance using different setups has been conducted, and a variety of case studies show different aspects of complexity that the FWI technique can address. Multiple inclusions have been successfully reconstructed in gears, exhibiting the potential of applying the proposed technique in overcoming various NDE challenges related to the rapidly growing structural and material complexity nowadays.

工程部件中未检测到的夹杂物每年都会在维护和维修方面造成巨大的工业费用，并带来灾难性故障的额外风险。本文介绍了一种基于尖端成像技术——全波形反演 (FWI) 的强大方法，用于不规则形状组件中的包含成像和重建。我们提出了一种用于无损评估 (NDE) 的超声波扫描设置，它​​适合具有不同形状和尺寸的各种组件。总结了 FWI 理论表达式，旨在为 NDE 和材料表征社区创建清晰的解释。已经对使用不同设置的 FWI 性能进行了系统分析，并且各种案例研究显示了 FWI 技术可以解决的复杂性的不同方面。