19th World Conference on Non-Destructive Testing 2016

High Resolution Phased Array Imaging using

the Total Focusing Method
Wolfram A. Karl DEUTSCH 1, Werner ROYE 1, Helge RAST1, Philippe BENOIST2
1
KARL DEUTSCH Prüf- und Messgerätebau GmbH + Co KG, Wuppertal, Germany
2
M2M-NDT, Les Ulis, France
Contact e-mail: [email protected]

Abstract. Ultrasonic Phased Array techniques are applied in medical and technical
fields for many years now. Due to increasing computer performances nowadays also
advanced imaging techniques can be applied, delivering higher image resolutions
compared to traditional sector scans and linear scans which are only based on focused
sound beams. The total focusing method (TFM) is a signal processing algorithm using
data acquired in full matrix capture mode (FMC). All computations are achieved at a
refresh rate up to 30 frames per second. With TFM imaging different ultrasonic modes
can be defined for longitudinal waves, shear waves and even sound paths with mode
conversions, like Long-Long-Trans (LLT), for example. The LLT-technique has the
potential to replace traditional tandem techniques due to its advantage concerning
space requirements, as only one array probe is needed. Practical results will be
demonstrated and discussed within the presentation.

Introduction

The well-known traditional Phased Array Techniques “Sector Scan” and “Linear Scan”
provide acoustical images with lateral resolutions of 2 or 3 wavelengths, if the sound beams
are focused accordingly.
By means of the Total Focusing Method (TFM) a resolution of 1 wavelength can be
obtained, if a large aperture with e.g. 64 elements is applied.

1 The Total Focusing Method

1.1. Principle

The total focusing method (TFM) is a signal processing algorithm using data acquired in full
matrix capture mode (FMC). A computation zone is specified for the data reconstruction.
This zone is meshed, and for each point on this grid, the focal laws are calculated for the
entire set of elements of the phased array probe. All recorded signals are time-shifted
accordingly before summation at every point of the grid. The loop ends when the
reconstruction is done for each point of the mesh. The main advantages of FMC-TFM are
direct imaging of a large area in one probe position combined with optimal focusing and
spatial resolution.

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 Fig. 1: TFM principle
Although a lot of calculations are performed, scanning is possible at a refresh rate of
30 frames per second.
TFM can provide a lateral resolution of 1 wavelength, if enough elements, e.g. 64,
are applied. Figure 2 presents a test result on the phased array calibration block according to
ASTM E 2497 with a vertical row of side drilled holes of 1 mm diameter. In the actual case
a probe was used with a sound frequency of 5 MHz, which yields a wavelength of 1.2 mm.
The TFM-B-Scan image clearly resolves the 1 mm holes.
Furthermore TFM enables the linear array probe to “look” into all directions, due to
the fact that each element with its small pitch generates a sound beam with an extremely large
divergence. Figure 2 proves that the entire vertical row of holes is imaged with the sideward
probe position:

Fig. 2: ASTM block and TFM result

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 1.2 Analysis and Sizing capabilities with TFM

The above mentioned ASTM calibration block also contains a row of holes with a diameter
of 1.5 mm. A TFM-B-Scan is presented in Figure 3. If 2 cursors are selected in the B-Scan,
the distances are indicated, here: Δx = 1.5 mm:

Fig. 3: Reflector size determination

2 TFM Applications

2.1 Inspection of a welded T-Joint

In the following the inspection of a welded T-Joint is presented. T-Joints are often critical
concerning insufficient through-welding (in the actual case the weld contains an artificial
disbond).

Fig. 4: Inspection of a T-joint using an array probe with 64 elements

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 natural flaw
back wall
disbond
back wall

TFM-B-Scan,
ROI for the
C-Scan
acquisition

Fig. 5: C-, B- and A-Scan obtained with TFM

Fig. 6: Complete TFM-B-Scan: Even the weld contour is imaged

2.2 Inspection of a friction weld on a tow-bar of vehicles

Another type of weld inspection concerns the weld of tow-bars of vehicles. The bar with the
tow-ball is welded to the shaft, which is mounted on the car. This weld has to provide highest
strengths concerning all types of stresses.
The test is carried out using a 5 MHz array comprising 32 elements. The wedge is
adapted to the shaft diameter of 40 mm. Water irrigation ensures a constant coupling. Using
TFM the probe can be mounted very near to the weld.
The customer has designed a mechanical system with the probe holder which enables
the shaft rotation. A complete testing around 360° needs 10 seconds, at a scan speed of
approx. 13 mm/s

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 weld

probe with wedge

Fig. 7: Test setup for the weld inspection on tow-bars

Fig. 8: TFM test results, left OK, right NOK

2.3 Testing of Bearing Rings

For the ultrasonic testing of bearing rings very high test sensitivities are required, e.g. FBH’s
with a diameter of 0.5 mm and a depth of 0.5 mm in front of the back wall. The GEKKO
provides a high contrast and signal-to-noise ratio, due to a very low inter-channel crosstalk
of -50 dB, thus fulfilling this requirement.
However, if the back wall is inclined, which is often the case with bearing rings, the
small echoes close to the back wall interfere with the echo of the inclined back wall.
Therefore, such reflectors cannot be detected, neither with conventional monoelement probes
nor with the traditional phased array sector and linear scans. In this case, TFM is the only
successful method, see following figures:

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Fig. 9: Test block with inclined back wall containing 2 FBH's Ø 1 mm (1 mm deep)
and Ø 0.5 mm (0.5 mm deep)

Fig. 10: Indications of the 2 FBH's at the inclined back wall

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 Fig. 11: Acoustically zoomed image of the FBH Ø 0.5 mm with depth 0.5 mm

2.4 Testing of castings

Steel and light alloy castings often contain shrinkage cavities. Due to their dendritic surfaces
the ultrasonic reflection is poor. If the DGS or DAC method are applied for defect size
estimation according to the testing standards for castings, we often find a severe under-sizing.
TFM however, transmits in and receives from various directions, thus enabling a
much better reflection of the dendrites, which ensures a more acccurate defect size
determination, compared to the conventional amplitude based methods DGS and DAC.

Fig. 12: Testing of castings with TFM

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 2.5 TFM with mode conversion

The GEKKOalso supports TFM-techniques which consider mode conversions. One example
is presented below:

L
L

Fig. 13: Test block with vertical FBH

The test block according to Figure 13 contains a vertical FBH which is traditionally used as
test reflector for tandem techniques with two angle beam probes. For different depths the
distance between the tandem probes must be changed or various probe pairs must be applied,
which makes the tandem technique often cumbersome.
With a linear array probe and the LLT-technique (Long-Long-Trans) only a single
probe is needed, simplifying the probe handling.

Fig. 14: Left: Indication of vertical wall, Right: Indication of vertical FBH, 10 mm in front of the vertical wall

Summary

In contrast to the traditional phased array sector scans and linear scans the Total Focusing
Method provides lateral image resolutions of only one wavelength if arrays with 64 elements
are applied. The Total Focusing Method permits sideward imaging of reflectors due to the
fact that each array element generates a divergent sound beam, thus “looking” into all
directions.
Beside a short description of the basic principle of TFM several practical examples
are shown concerning the inspection of special welds, bearing rings with special geometries
and castings, where TFM yields a better sizing of shrinkage cavities.