Multi-mode high resolution TFM imaging of microdefects based on laser ultrasonic full matrix capture

•Theoretical and simulation analyses were conducted on the acoustic directional characteristics of laser ultrasonic reflection and mode conversion.•The combination of multi-scale principal component analysis and phase coherence methods effectively suppresses blind spots and artifacts.•High resolution imaging of submillimeter side drilled holes (SDHs) and blind holes (BHs) has been completed, and the size quantification of defects was successfully achieved. The identification and visualization of submillimeter microdefects have long been a critical focus within the realm of ultrasonic testing. The utilization of high-frequency signals is imperative due to the small acoustic interaction structure. An additional benefit of using lasers is their non-contact nature and ability to utilize multiple imaging modes, effectively reducing false or missed detections and enhancing credibility. This study proposes an advanced optimization algorithm for imaging and quantitative evaluation of submillimeter microdefects using laser ultrasonic full matrix capture (FMC) and total focusing method (TFM). The analysis of acoustic directionality under laser excitation and detection provides a foundation for mode selection. In preprocessing, the multi-scale principal component analysis (MSPCA) method is introduced to suppress coherent noise and blind spots. Moreover, phase coherence methods are implemented to further reduce mode artifacts, background noise, and residual surface acoustic wave (SAW). Additionally, multi-mode imaging and mode fusion are achieved using reflected longitudinal waves, reflected shear waves, converted longitudinal waves, and converted shear waves. Experiments were carried out on two different types of microdefects, namely side drilled holes (SDHs) and blind holes (BHs), resulting in high resolution TFM imaging with a minimum BH size of 0.3 mm. The outcomes demonstrate the efficacy of MSPCA in suppressing coherent noise, with further enhancement in imaging quality after phase coherence weighting. In addition, the −6 dB threshold of multi-mode images also provided the size information. This research is poised to contribute to the resolution of quality assessment challenges in powder metallurgy, welding, and additive manufacturing processes.