15th Asia Pacific Conference for Non-Destructive Testing (APCNDT2017), Singapore.

High Resolution Phased Array Imaging using the Total Focusing Method

S. Kierspel†, Wolfram A. Karl Deutsch †, Helge Rast†, Philippe Benoist1, Venkat A2

† KARL DEUTSCH Pruef- und Messgeraetebau GmbH + Co KG Wuppertal, Germany

1M2M-NDT, Les Ulis, France

2
NDT Instruments, Singapore

Abstract.

Ultrasonic Phased Array techniques are applied in medical and technical fields for many years. 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
80 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). 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.

Keywords: ultrasonic phased array, TFM, high resolution, imaging, sizing

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 TFM

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, see Figure 1. 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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Although lots of calculations are performed, scanning is possible at a refresh rate of 80 frames per
second. TFM can provide a lateral resolution of 1 wavelength, if enough elements, e.g. 64, are applied.
Figure 1 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. Here 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 1 proves
that the entire vertical row of holes is imaged with the sideward probe position:

Figure 1: TFM principle, ASTM block and TFM result.

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 2. If two cursors are selected in the B-Scan, the distances are
indicated, here: ∆x = 1.5 mm:

Figure 2: Reflector size determination.

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2 TFM applications

2.1 Inspection of a welded T-joint (1)

In the following the inspection of a welded T-joint is presented. T-joints are often critical concerning
insufficient through-welding. The sample shown here is a real specimen taken from a steel construction
without artificial flaws or disbonds. Figure 3 shows the cross section of the T-joint and the position of
the probe (5 MHz, 64 elements, 0,6 mm pitch, delay line of rexolite 30 mm thickness). A TFM scan
was done with a scan length of 165 mm. Figure 4 shows the corresponding C-scan image, the TFM
image at a position of 55 mm scan length and the D-scan section close to the probe center. The
combination of all three scans gives a clear indication of a good weld. In Figure 5 the same combination
of images show an area from 80 mm to 145 mm scan length, where the disbonded zone is enlarged.
Geometrical indications like weld surface and backwall can easily be identified.

Figure 3: Weld inspection on a T-joint with 5 MHz and 64 elements probe.

OK

Figure 4: C-scan with TFM and D-scan of a good weld section with visible weld contours.

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NOK

Figure 5: C-scan with TFM and D-scan of a weld section with enlarged disbonding.

2.2 Inspection of a welded T-joint (2)

In the next example a situation is described where there is access to another T-joint from one side only.
The inspection task is to determine the depth of the weld and to measure out the area without bonding.
In Figure 6 the inspection setup and schematic description of the inspection task is given. The plates
(thickness 6 mm) are placed perpendicularly on each other without weld preparation.

Figure 6: T-joint with probe access only from one side (weld in red circle) Probe with 10 MHz and 32 elements

Areas without bonding can also be detected with phased array sector scans, and by using a position
encoder creating a C-scan also allows the determination of the lengths of the bad areas. But to measure
out height and area of the disbonded zones is not accurate. A TFM scan in TTT mode delivers accurate
results of the lengths and the height and thus the unbonded areas, see Figure 7.

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Figure 7: Left: Inspection with phased array sector scan, Right: TFM scan, identical scan length and probe track

2.3 Inspection of connection weld on a tow-bar for 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.

Conventional ultrasonic inspection cannot not be applied as a small unwelded area in the center of the
weld remains due to the welding process. This area produces signals that cannot be distinguished from
real defects. Phased array inspection with sector scans can determine this area by position but
geometrical conditions (bending of the ball rod) does not allow enough offset for the probe positioning.

A TFM inspection setup was developed and 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 placed close to the weld. A mechanical system with probe holder enables
the shaft rotation, see Figure 9. A complete testing around 360° needs 10 seconds, at a scan speed of
approximately 13 mm/s. A C scan rollup is displayed and shows good or bad indication, see Figure 8.

Figure 8: TFM results, left OK, right NOK

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Figure 9: Rotating system with weld [1], probe [2], irrigation hoses [3] and encoder [4]

2.4 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 portable phased array flaw
detector GEKKO form M2M / KARL DEUTSCH provides a high contrast and signal-to-noise ratio,
due to a very low inter-channel crosstalk of -50 dB, thus fulfilling this requirement.

Figure 10: 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), probe with 10 MHz and 64 elements, pitch 0,6 mm

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However, if the back wall is inclined (see Figure 10), which is often the case with bearing rings, 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 Figure 11:

Figure 11: Left: Indications of the 2 FBH's at the inclined back wall, Right: Acoustically zoomed image of the
FBH Ø 0.5 mm with depth 0.5 mm

2.5 Inspection 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 methods 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, see Figure 12.

Figure 12: Testing of castings with TFM

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2.6 TFM with mode conversion

TFM computation can also consider different kinds of mode conversions. The following example
describes a vertical reflecter inside a specimen. This has been simulated with a test block containing a
side drilled hole, see Figure 13. This setup 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.

L
L

Figure 13: Testblock with vertical flat bottom hole

With a linear array probe and the LLT-technique (Long-Long-Trans) only a single probe is needed,
simplifying the probe handling, see Figure 14.

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

3 Summary

In contrast to traditional phased array sector and linear scans the Total Focusing Method provides lateral
image resolutions of only one wavelength if arrays with 64 elements are applied. TFM 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.

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