Silicon micromachining techniques permit batch fabrication of
microphones that are small, reproducible, and inexpensive. However, many such sensors have limited bandwidth or are too fragile to be used in a humid, wet, or dusty outdoor environment. Microphones using capacitive micromachined ultrasonic transducer (CMUT) membranes and radio frequency (RF) detection overcome some of the problems associated with conventional micromachined microphones. CMUT membranes can be vacuum-sealed and still withstand atmospheric pressure and submersion in water. In addition, the membrane mechanical response is very flat from dc up to hundreds of kilohertz. A very sensitive RF detection scheme is necessary to detect the small changes in membrane displacement that result from utilizing smaller membranes. In this paper, we present the theory and recent experimental results of RF detection with CMUT membranes. Measurements of a sensor with 1-mm2 area demonstrate a flat output response of the acoustic sensor from a fraction of 1 Hz to over 100 kHz, with a sensitivity at 1 kHz of 65 dB/Pa in a 1-Hz noise bandwidth.
Conventional methods of ultrasonic non-destructive evaluation (NDE) use liquids to couple sound waves into the test samples. This either requires immersion of the parts to be examined or the use of complex and bulky water squirting systems that must be scanned over the structure. Air-coupled ultrasonic systems eliminate these requirements if the losses at air-solid interfaces are tolerable. Micromachined capacitive ultrasonic transducers (cMUTs) have been shown to have more than 100 dB dynamic range when used in the bistatic transmission mode. In this paper, we present results of a pitch-catch transmission system using cMUTs that achieves a 103 dB dynamic range. Each transducer consists of 10,000 silicon nitride membranes of 100 micrometers diameter connected in parallel. This geometry result in transducers with a resonant frequency around 2.3 MHz. These transducers can be used in transmission experiments at normal incident to the sample or to excite and detect guided waves in aluminum and composite plates. In this paper we present ultrasonic defect detection results from both through transmission and guided Lamb wave experiments in aluminum and composite plates, such as those used in aircraft.
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