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Non-destructive Evaluation (NDE) is the process of using non-invasive procedures to inspect or characterize an object without altering its form, fit, or function. Ultrasonic testing is one of the most popular NDE techniques due to its wide range of applicable materials and non-hazardous operations to personnel or equipment. One of its disadvantages, traditionally, is the requirement for manual, in contact, inspection and extensive technical knowledge to interpret the results. This dissertation addresses these problems through experimental validation of a two-part inspection technique: passive transfer function defect detection followed by synthetic aperture imaging defect quantification. First, results from full-scale experiments on rails up to 80 mph are used to validate the high-speed, non-contact, passive defect detection prototype. Next, results from a real-time ultrasonic imaging prototype for rail flaw sizing are used to demonstrate fast, straightforward, quantification of defect geometry.Passive ultrasonic inspection and ultrasonic imaging are complementary technologies: the first is for high-speed detection of suspect regions but does not label the type or size of defects; whereas, the second is for defect verification of suspect regions and visually displays the precise defect size and orientation. The ability to quickly inspection regions of interest and subsequently accurately quantify the extent of damage is integral for a reliable and cost-effective resource management program.

The friction stir welding and its weld properties such as tensile, micro structure of weld, grain size, and fine mixture of two alloys at to joint using testing methods. To determine the weld quality and conclude properties such as weld quality, weld strength, maximum stress that weld can withstand during operation conditions. There are various processes that involve testing the welded joint from which many are the destructive ones that are used to find the tensile strength, hardness of the joint, bending test and other tests. This paper gives an overview on how important is the fine mixture of the samples that undergo friction stir welding and how it impacts the welded sample properties. Friction stir welding creates more opportunities that are related in understanding the quality of the joint such as testing methods to increase the production by faster analysis of defects. This testing method effectively utilizes that modern computation and means to boost the production. This level of understanding creates the path to innovate new techniques to resolve industry level problems in quality control. As the non-destructive testing methods provided with no loss of the testing specimen and understanding the quality of the material after they are assembled. Such initial developments made the usage of NDT in quality control and effective results to determine the quality.

The present work addresses the ultrasonic NDT of rails, more precisely of the rail foot. The practical constraint is that transducers must be located on the rail head, whereas the region of interest is the rail foot. Thus, there is no direct acoustic path between the transducers and the region of interest. As classical delay and sum methods cannot be applied to such cases, the goal of the paper is to numerically assess the potentiality of the topological imaging method to investigate the rail foot. Three specific typical rail foot defects are investigated, namely, longitudinal vertical cracks, corrosion pits and rail injuries. Simulating eight transducers with different polarizations, the images obtained show that the detection and approximate location of the various defects are possible.

Crack orientation is a vital factor in the behavioral study of fractures, especially the study of crack propagation in structures that are under dynamic or fatigue loading. Indeed, many non-destructive testing (NDT) techniques have been developed recently for the detection of cracks such as the eddy current testing (ECT). However, the crack orientation has not been undertaken into consideration. In this paper, a NDT based on eddy current using 3D finite element modeling, is proposed for the determination of the crack orientation. The idea of this proposed technique benefits from the influences of crack orientation, which can be observed on the components of eddy current and the related magnetic flux density following the x, y axes, for the estimation of the crack angle orientation based on an interpolation criteria. The obtained results through the presented simulation prove the validity of the proposed technique for the detection of crack angle orientation.

Inadvertently and intentionally incorrect welding films are very common in X-ray non-destructive testing (NDT) of welding engineering. The forgery welding films were handed in by welding workers and pretended these films were X-ray photographed on the welding seams that need to be inspected, but actually, these films were X-ray photographed on other welding seams that are of high quality and had passed the X-ray imaging inspection. If some welding seams escape inspection due to forgery, these will cause many potential safety hazards. The current forgery detection method is manual inspection, which is very time-consuming and laborious. An automatic forgery detection method for X-ray non-destructive testing of welding was proposed. Three solutions were used to prevent forgery: they were the markers recognition for avoiding erroneous submission, the fingerprint extraction for identifying welding seam uniquely, and the overlap matching for preventing intentional forgery. This paper proposed a concept of welding seam fingerprint. The welding seam features were extracted based on an improved SPP-net deep learning model. Those deep learning features of welding seam were called as the welding seam fingerprint. The proposed method can automatically accomplish the forgery detection, which can greatly reduce the workload of manual detection and make the welding inspectors focus their attention on the welding defects inspection rather than on the forgery prevention.

In this article, the construction and experimental behavior of an Internet of Things (IoT)-compatible steel health monitoring system are examined. Falling under the general category of nondestructive testing, this new sensor is combined with an energy harvester to produce an autonomous automated device that can measure, store, and transmit measuring data without any need for human intervention. Based on common principles like the Hall effect, the monitoring system is put to use, and its results are presented.

Lamb wave propagation must be understood comprehensively for simply evaluating delamination during ultrasonic testing. However, the difference between wave propagation, visualized using laser Doppler vibrometer and pulsed-laser scanners, has not been sufficiently investigated, and knowledge of optimal conditions for evaluating delamination is limited. Thus, in this study, the mode conversion and multiple reflections of Lamb waves propagating in a delaminated cross-ply laminate were visualized using different laser scanners, delamination depths, and wave incident angles. Delamination was characterized using maximum-amplitude map postprocessing under specific conditions. Further numerical analysis revealed that owing to multiple reflections of the antisymmetric mode in incident and mode-converted waves, standing waves were generated in the delaminated sublaminate. Dispersion curve and flexural stiffness calculations confirmed the conditions required for high-amplitude standing waves, thereby providing guidelines for simply and reliably evaluating delamination during inspections.

With the rapid development and application of the laser ultrasonic technology in nondestructive testing in recent years, thermo-elastic waves in diverse waveguides have captured a multitude of attention. However, they are mainly focused on one-dimensional and half-space structures. In engineering, there are also a lot of two-dimensional structures, such as joist steel, straight bars and rings. However, rare attention is paid on thermo-elastic waves in these structures. Accordingly, in the context of Green–Lindsay (G–L) generalized thermo-elasticity theory, a modified double orthogonal polynomial approach is exploited to investigate thermo-elastic waves in bars with a rectangular cross-section. The dispersion, attenuation and displacement curves of thermo-elastic waves are illustrated. Subsequently, influences of the cross-section size and relaxation time on wave characteristics are analyzed. Results indicate that the cross-section size and relaxation time have a significant influence on thermo-elastic waves. The phase velocity and attenuation values of thermal wave modes decrease as the relaxation time increases. These results obtained can be utilized to guide the laser ultrasonic nondestructive testing for this kind of structures.

Insulating joint is an essential component for pipeline cathodic protection system. During the safety confirmation before the excavation of the station foundation pit, a pipeline company found that the insulating joint was failed due to leakage. In order to determine the causes of leakage, data verification, tests and failure component analysis were carried out. The results show that: (1) the leakage point cannot be detected by NDT, hydraulic pressure test, and hydraulic pressure + bending test, and the gas leak test in the water container demonstrates two leakage points on the fixing sleeve of the insulating joint; (2) the insulating joint has an unfilled cavity, and the mechanical holes on the fixing sleeve are blocked by bolts, which are inconsistent with the assembly drawing; and (3) the leakage of the insulating joint was caused by the sealing failure during assembly or service, which allowed some gas to gather in the cavity between the flange and the fixing sleeve and then leak through the gap between the mechanical hole and the bolt. Accordingly, it is suggested that (1) manufacturers should strictly follow the process when producing insulating joints, the product structure be consistent with the assembly drawing, the product inspection be done according to requirements, and NDT be done on all welding areas; and (2) the insulating joint be leak-tested in the water container where possible.

During the laser additive manufacturing (LAM) process large temperature gradients can form, generating a mismatch in deformation that can lead to high level of residual stress. The stress can have irreversible effects such as warping and cracking of parts during and post manufacturing. One of the most important LAM parameters that should be controlled carefully in order to effectively manage residual stress is the scanning strategy. This study presents an evaluation of six different scanning strategies, namely reciprocating, 90° reciprocating, line, screwing, reciprocating overlapping and island scanning strategies with respect to their effect on residual stress. Laser ultrasound technology, as an advanced nondestructive testing method, is applied to measure the residual stress distribution under different scanning strategies for the first time. The surface wave generated by laser is used to evaluate the plane stress state within the surface layer of the specimen. The results show that the island scanning strategy is found to contribute to the least average residual stress, and lowered residual stress by up to 45% relative to the line scanning strategy. The overall stress level is island

Development of a nondestructive evaluation (NDE) method to detect nascent hydrogen embrittlement (HE) in electroplated high-strength steel parts is becoming important for the aerospace industry. This research investigates the feasibility of surface acoustic waves (SAWs) measurements to distinguish between cadmium (Cd) plated SAE 4340 steel samples with low and high HE susceptibilities. SAWs were generated with a 10 MHz piezoelectric transducer and detected by line scans via a laser Doppler vibrometer setup. Using signal processing algorithms in MATLAB, SAW velocities as well as attenuation coefficients were estimated. Depth profiles of steel hardness near coatings were also evaluated using Vickers microindentation tests. Average steel hardness in not-baked samples was slightly increased. Cd coatings were characterized by laser and optical microscopy methods. Small variations found in thickness and surface roughness of the Cd coatings among the samples did not significantly affect the NDE results. On average, samples in the not-baked condition (high HE risk) exhibited lower SAW attenuation coefficients compared to immediately baked and late-baked conditions (low HE risk). However, it was not possible to distinguish between the manufacturing conditions of individual samples due to overlaps in attenuation measurement results. SAW velocities as estimated by the cross-correlation method were found to be not sensitive to manufacturing conditions.

Out-of-plane waviness is one of the most common defects which degenerates the strength, stiffness, and fatigue life of hybrid glass–carbon fiber–reinforced polymer composites (FRPs). An accurate and high-speed non-destructive testing method is highly desired for large composite structures in industries. Ultrasonic phased array is a great candidate for such application. This paper applies the wavenumber algorithm to image the waviness in hybrid FRP plates which are a multi-layered medium. The central frequency of 5 MHZ is chosen in order to maximize the ply resonance. Transducers are migrated virtually to each interface between glass and carbon plies in order to overcome the difficulty of wave propagation analysis in such multi-layered system. The wavenumber algorithm demonstrates a better computational performance compared to that of the traditional total focusing method (TFM) in time domain up to 6 times. The glass ply depth and waviness angle can be more accurately presented with relative errors less than 1.5% and 14.8%, respectively. In addition, the resin-rich defect characterization is also achievable with a maximum error of 14.4%.

Several methods have been used to detect defects or debonds nondestructively in materials or construction. Each of these nondestructive testing methods has advantages and limitations. Generally, they are suitable for testing a certain range or a specific type of material and structure and some of them require careful analysis to identify the features of the defects. The present work proposes a nondestructive testing method based on electro-acoustic technique (NDTPEA) to detect internal defects of dielectric materials, which can identify the defects from the original stress wave generated at the internal defect surface. Electric polarization occurs in the dielectric under the action of a high-voltage electric field. When the intensity of the electric field changes suddenly, the polarization charge generates a stress wave. If there are defects, such as cracks and debonding, in the medium, the position and size of the internal defects of the insulating material can be determined according to the stress wave. The waveform and velocity of stress wave is measured by a PVDF film. According to the velocity and time of the stress wave in the dielectric, the position of the internal defects or debonding of the specimen can be determined. The maximum error for measuring the wave transmission time is 1 ns, and the maximum measurement error in the defect thickness direction was 0.00253 mm. In the NDTPEA, the detected wave originates from the vibration of the polarized charge at the defect, i.e., the defect is the source of the stress wave. The measured stress wave does not undergo any reflection or refraction, and the waveform is truly regular, without coupling factors. The wave shape and time characteristics can all reflect the characteristics of the defects.

As a type of novel surface engineering technology, the application of cold spraying in the manufacturing and remanufacturing of high-end precision parts is very suitable. However, the disadvantage of low interface bonding strength can easily induce coating peeling at the coating/substrate interface under the effect of applied loads. Therefore, finding a suitable nondestructive testing method is significant to evaluate the cold-sprayed coating peeling process and provide prediction results. To achieve this aim, magnetic Barkhausen noise (MBN) testing was used in this paper because of its high sensitivity to microstructure variation. The Ni-Zn-Al2O3 ferromagnetic coating deposited on the ductile cast iron substrate was prepared by cold spraying. Based on the wavelet coherence analysis, the frequency of MBN signals induced by magnetic domain movement was mainly concentrated in the range of 1–4 kHz. The spectrum power between 1 kHz and 4 kHz was extracted as the characteristic value, and the linear fitting relationship between the characteristic value and applied load was established. When the power reaches the threshold value range of 3.106×10−8–3.557×10−8 W, the probability that the interfacial stress exceeds the coating/substrate bonding strength and that Ni-Zn-Al2O3 coating peeling occurs is 95%. Combined with the microstructure and morphology analysis, the mechanism of cold-sprayed coating peeling was revealed, and the underlying reason for MBN signal variation was explained. This research can accurately evaluate the ferromagnetic cold-sprayed coating peeling process and the interface bonding strength.

Lamb wave-based damage identification and localization methods hold the potential for nondestructive evaluation and structural health monitoring. Dispersive and multimodal characteristics lead to complicated Lamb wave signals that are challenging to be analyzed. Deep learning architectures could identify damage-related features effectively. Convolutional neural network (CNN) is a promising architecture that has been widely applied in recent years. However, this data-driven approach still lacks a certain degree of physical interpretability and requires a large number of parameters. In this article, an interpretable Lamb wave convolutional sparse coding (LW-CSC) method is proposed for structural damage identification and localization. First, toneburst signals at different center frequencies are considered in the first convolutional layer. The network convolves the waveforms with a set of parametrized functions that implement band-pass filters, which performs more physical interpretability compared to conventional CNN model. Subsequently, the damage features are extracted according to the multi-layer iterative soft thresholding algorithm for multi-layer CSC model, which could realize a deeper network without adding parameters unlike CNN. Finally, Lamb wave-based damage localization is visualized using an imaging algorithm. The experimental results demonstrate that the proposed method not only enables improvement of the classification accuracy but also achieves structural damage localization accurately.

Numerous studies show that all the requirements for technical diagnostics of the state of heating networks and technological objects are currently satisfied by nondestructive testing methods, which are based on observation and automated registration of processes' temperature. Heat flow meters have a number of advantages compared with other devices that are based on nondestructive testing methods. They are distinguished by high sensitivity to changes in the thermophysical characteristics of controlled objects, the ability to conduct control without using an external energy source, efficiency, compactness, and ease of use. Several modifications of heat flux meters (HFM) based on a thermoelectric battery cell of a special design have been developed. A distinctive feature of HFM design is the presence of a thermoelectric battery converter equipped with a temperature-dependent and heating element whose active junctions are aligned with the receiving plate and whose passive junctions are in thermal contact with the heating element. An experimental model of an underground heat-insulating structure has been assembled to study the influence of the temperatures of the coolant and the environment, the depth of the pipelines, their technical parameters and the parameters of the surrounding soil on the nature of the distribution of the density of thermal radiation from the soil surface over heating networks. Experimental work on the calibration of thermocouples used to determine the temperature change in the soil and the calculation of the calibration coefficient of thermocouples and heat flow meter was carried out. The results of the study of the distribution and temperature change soil are presented. The developed device is designed to analyze the state of thermal insulation of heating networks' underground pipelines.

Purpose The major problem that limits the widespread use of WAAM technology is the forming quality. However, most of the current research focuses on post-process detections that are time-consuming, expensive and destructive. This paper aims to achieve the on-line detection and classification of the common defects, including hump, deposition collapse, deviation, internal pore and surface slag inclusion. Design/methodology/approach This paper proposes an in-process multi-feature data fusion nondestructive testing method based on the temperature field of the WAAM process. A thermal imager is used to collect the temperature data of the deposition layer in real-time. Efficient processing methods are proposed in this paper, such as the temperature stack algorithm, width extraction algorithm and a classification model based on a residual neural network. Some features closely related to the forming quality were extracted, containing the profile image and width curve of the deposition layer and abnormal temperature features in longitudinal and cross-sections. These features are used to achieve the detection and classification of defects. Findings Thermal non-destructive testing is a potentially superior technology for in-process detection in the industrial field. Based on the temperature field, extracting the most relevant features of the defect information is crucial. This paper pushes current infrared (IR) monitoring methods toward real-time detection and proposes an in-process multi-feature data fusion non-destructive testing method based on the temperature field of the WAAM process. Originality/value In this paper, the single-layer and multi-layer WAAM samples are preset with various defects, such as hump, deposition collapse, deviation, pore and slag inclusion. A multi-feature nondestructive testing methodology is proposed to realize the in-process detection and classification of the defects. A temperature stack algorithm is proposed, which improves the detection accuracy of profile change and solves the problem of uneven temperature from arc striking to arc extinguishing. The combination of residual neural network greatly improves the accuracy and efficiency of detection.

Bu çalışmada, çelik üzeri alüminyum kaplanmış (ACS: Aluminum Clad Steel) tel olarak nitelendirilen iletken tellerin tahribatsız muayene sürecinde kullanılmakta olan çevreleyici bir prob tasarımı yapılmıştır. İletken materyallerin üretim ve kalite kontrol süreçlerinde tahribatsız muayene yöntemlerinden olan girdap akımları sistemleri yaygın bir şekilde kullanılmaktadır. Bu sistemlerde, materyal türüne bağlı olarak farklı tipte probların tasarlanması ve kullanılması mümkündür. Boruların, tellerin ve plaka şeklindeki iletken materyallerin muayenesi için sırasıyla dahili, çevreleyici ve yüzey prob türleri kullanılmaktadır. Bu problar ile iletken yüzeylerindeki süreksizlikler tespit edilip, proba ait bobinlerin indüktans değerlerinde meydana gelen değişiklikler elektronik donanımlar ile analiz edilerek materyalin kalite kontrolü sağlanmaktadır. Bu çalışmada, tel yüzeylerindeki çeşitli kusurların algılanabilmesi için hassas bir prob tasarımı gerçekleştirilmiştir. Tasarlanan proba ait indüktans değerleri, iki ve üç boyutlu sonlu elemanlar analizi (SEA) kullanılarak hesaplanmış ve elde edilen bu değerler karşılaştırılmıştır. Proba ait indüktans değişimi, içerisinde farklı türden kusurlar içeren numune ACS teller varken bir LCR metre vasıtasıyla ölçülmüş, bu değerler tabloda verilmiş ve değişim grafiği çizdirilmiştir. Aynı zamanda, prob ile bir empedans köprü devresi kurularak bobin üzerinde meydana gelen voltaj indüklenmesindeki değişim sonuçları osiloskop çıktısı olarak verilmiştir., In this paper, an encircling probe design used in the inspection of conductive wires, which are qualified as aluminum clad steel (ACS) wire is made. The eddy current systems are widely used for the quality control of conductive materials as one of non-destructive testing methods. In these systems, it is possible to design and to use different types of probes according to the material type. Internal, encircling and surface probe types are used for the inspection of pipes, wires and plate conductive materials, respectively. The discontinuities on the conductor surfaces are detected and the changes in the inductance values of the coils of probes are analyzed with the electronic hardware and the quality control of the material is ensured. In this study, a sensitive probe design is realized to detect various defect on wire surfaces. The inductance value of the designed probe is calculated by using two and three dimensional finite element analysis (FEA) and the obtained results are compared. The inductance change of the probe was measured by an LCR meter while the probe contained sample ACS wires with different types of defects, these values are given in the table and the change graph is plotted. In addition, an impedance bridge circuit was set up with the probe and the results of the change in voltage induction on the coil are given as an oscilloscope image.

The basic defects of turbines in the water, oil and aerospace industries are very obvious. Turbines play a key role by rotating the impeller. In some turbine engines, impellers are used instead of axial compressors, and the impeller play a key role in investigating defects that can increase its performance and life of the turbine. The blades have different dimensions and shapes and are installed on the impeller by bolt and nut connections. The shape, dimensions and number of blades vary depending on the power required. In the present study, corrosion defect on the turbine impeller was performed with one of the non-destructive tests, which was an ultrasonic test. The defect is considered to be corrosion, which occurs mostly in turbines in the oil and water industries, and its examination in non-destructive testing will be an attractive challenge. Corrosion defects occur with work and rotational performance of the impellers long-term. Measuring the diameter by ultrasound, which is a new method in this test, the amount of corrosion will be detected. In this article, 20 turbines with defective blades were tested. The defect was simulated by Comsol software to prove the experimental work. According to various tests about the size of the defect, the new solution can determine the approximate life and efficiency hours of each turbine to a large extent. Diagrams were drawn to determine efficiency hours of each turbine based on rate and size of corrosion diameter, that have effect on defect. The experimental and simulation results were significantly consistent, and size of corrosion diameter was obtained by ultrasound waves that it is a new method in ultrasonic testing.

High schools in the United States are taking a fresh look at the future of career and technical education with the implementation of new learning pathways that lead directly to the workforce, including the nondestructive testing (NDT) industry. These programs directly connect high school curriculums with post-secondary education and employment, reaching kids as young as junior high. This resurgence in technical education can be traced to the current demand for “new collar” jobs—jobs that require a post-secondary degree, although not necessarily a four-year college degree. The demand for new collar jobs continues to increase, as millions of jobs requiring only a high school diploma have disappeared. Harvard’s influential Pathways to Prosperity report, released in 2011, warned that nearly two-thirds of new jobs of the 2010s would require more than a high school education—yet only 40% of Americans had obtained an associate’s or bachelor’s degree by their mid-20s (Harvard 2011). In response, a new vision of 21st century vocational training is emerging across the United States. Vocational education has traditionally taught students how to weld or how to fix a car. Today’s career and technical education encompasses a wide variety of industries and skills. Students are learning to code software, design websites, or operate robots and artificial intelligence systems that have replaced manual labor jobs across much of the economy. Through new technical and career programs, high school students have the opportunity to learn valuable skills, gain job experience and support from participating sponsor companies and mentors, and complete coursework to graduate with a high school diploma and, often, an associate’s degree as well. This article explores new high school technical and career programs in Texas, Minnesota, and North Carolina that specifically provide a pathway to careers in NDT. These new initiatives are fueled by the desires of students, parents, and educators for options outside of the traditional four-year college path, as well as urgent workforce needs within industry. Support from local industry and academia (such as community colleges) are essential to the success of the programs.

Implementing a new program is often the most challenging stage of an education organization. The seasoned project manager or entrepreneur knows the maintenance of a program, process evaluation, and prioritizing actions into the next phase of planning are the signs of a robust program. This is the same process for the implementation and maintenance of a nondestructive testing (NDT) program. This paper will focus on the critical considerations for the design, implementation, and maintenance of an NDT program in community colleges. In addition, the paper will describe the measures needed to assess the program’s effectiveness and the student learning outcomes for technicians.

This study mainly aims to investigate the applicability of the combination of air-coupled surface-wave and computer-vision techniques to the evaluation of self-healing in in situ concrete members. Small-scale beam specimens were made from ordinary concrete and concretes with solid- and liquid-type capsules; the capsules were employed as self-healing agents. To monitor the crack healing progress, surface-wave tests using an air-coupled transducer and contact receivers were conducted on each specimen in uncracked, cracked, and healed conditions after 7, 14, 28, and 63 days of water immersion. Additionally, a computer-vision technique involving image binarization and registration was applied to measure high-resolution crack information. The specimens containing the micro-capsules showed superior healing performance compared to the ordinary concrete specimens. After 63 days of self-healing, the spectral energy transmission ratio increased up to about 80% of the uncracked, while the crack area decreased up to about 94% of the fully cracked. The healing rate was estimated using the change in spectral energy transmission ratio strongly correlated with that estimated using the change in crack area.

The coin-tap method performs nondestructive testing by measuring the width of the tapping response pulse on the surface of the material. Existing studies have shown that defects in the material will cause the width of the tapping response pulse to increase. However, experiments have confirmed that different detection positions in the defective area will show different values of the width of the tapping response pulse, and the physical laws behind it have not been studied yet. To discuss its physical meaning, a mathematical model of the defective area is established, a method for calculating the width of the tapping response pulse is proposed, and a composite honeycomb structure with preset defects is used for data testing. Both the test results and the calculation results show that the pulse width of the tapping response will decrease with the increase of the defect depth and the deviation of the tapping position from the defect center. The consistency between the calculated results and the experimental results shows that the established defect model and pulse width calculation method can better explain the distribution law of the pulse width of the tapping response in the defective area.

Fundamental elements of wave mechanics are covered with respect to Acoustic Emission (AE) analysis in Nondestructive Evaluation (NDE) and Structural Health monitoring (SHM). Emphasis is placed on a...

Nowadays, measuring residual stress in welded parts is of great importance in the industry. Based on the measured residual stress and the operational conditions of the part, a suitable factor of safety is defined for the design. Destructive methods have most often been used to determine residual stresses. Given limitations such as high cost, non-destructive testing (NDT) methods have replaced destructive methods in recent years. The ultrasonic method has attracted much attention in recent years for determining residual stress. In addition to its simplicity, low cost, and the need for only a few pieces of equipment, this method has additional advantages such as the ability to measure residual stress at various depths. In this paper, the feasibility of the ultrasonic method in measuring residual stress in the fusion welding of two aluminum sheets was studied and compared with the simulation result. The longitudinal residual stress was measured using the ultrasonic method via 1, 2, 4, and 5 MHz transducers at a depth near the surface. An ultrasonic wedge based on Snell’s equation was built to create the LCR wave and transmit it into the part. Next, the results obtained from the ultrasonic measurement were compared with those obtained through the numerical simulation in Abaqus software. Overall, it was found that the ultrasonic simulation method could predict with high accuracy the residual stress at various depths of the part. Furthermore, the results demonstrated that the accuracy of this method declined with an increase in the ultrasonic frequency.