A study on non-destructive testing of complex composite materials using ultrasonic phased arrays, integrating acoustic field physics and artificial intelligence

The inherent anisotropy, multilayered heterogeneous interfaces, and pronounced scattering characteristics of composite materials induce complex distortions during ultrasonic wave propagation. These physical phenomena pose significant challenges to high-precision non-destructive testing (NDT). This paper systematically reviews the technological evolution of phased array ultrasonic testing (PAUT) for complex composites, tracing its trajectory from conventional beamforming to advanced full matrix capture (FMC) and total focusing method (TFM) imaging. By addressing three core challenges—anisotropic velocity deviations, interfacial refraction coupled with mode conversion, and structural scattering noise—this review provides a comprehensive analysis of the physical mechanisms and performance boundaries inherent in current solutions. Specifically, we evaluate cutting-edge methodologies, including adaptive acoustic field correction, ray tracing, multimodal fusion imaging, and phase coherence enhancement, with a strong emphasis on their practical applicability and inherent limitations in complex structural assessments.