Randy Scheib

Regional Technical Sales

Southeast

Region

Introduction to TOfD & Phased Arrays

Industrial Applications

4 May 2006: used with permission of

[email protected] • www.rd-tech.com Randy Scheib
 What is an Ultrasound ?
Ultrasound is defined as any sound that is above the
range of human hearing.

This Human limit is 20 KHz

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 What is an Ultrasound?
Ultrasonic vibrations travel in the form of a wave.
The basic parameters of a continuous wave include
the wavelength (λ) and the period (T) of a complete cycle.

Amplitude
Time or
Distance

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Properties of Sound Waves

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 What is an Ultrasonic Transducer?
 A Transducer by definition is a device that converts one form of
energy into another form of energy
 An Ultrasonic transducer takes a high voltage/low amperage
electrical pulse and converts it into the mechanical energy of an
Ultrasonic transmission. This device can also work in reverse

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 What is TOFD?

 Time-Of-Flight Diffraction (TOFD) relies

on the diffraction of ultrasonic energies
from 'corners' and 'ends' of internal
structures (primarily defects) in a
component being tested.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 TOFD Signals

Transmitter Receiver
Lateral wave

Upper tip

Lower tip

Back-wall reflection

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 TOFD History

 Developed in UKAEA Harwell in ~70’s

 Manufactured commercial Zipscan
 Used very effectively in nuclear PISC II and
DDT trials
 => Showed good detection and excellent
sizing
 Recently “adopted” by petrochemical and
other industries
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Data Visualization (TOFD)
A-scan

Indication

Lateral Back-wall
4 May 2006: used with permission of Randy Scheib
wave
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 Near Surface Crack

1 2

The crack blocks the Lateral Wave

And the lower tip appears on the A-scan
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Incomplete Root Penetration

1
2

1 2 3 4

Note the two signals from the top & bottom

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Lack of Root Penetration

1
1

2
3

2
3

Note the inverted phase between LW and defect

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Technique Description
Phased Array (combined scan)

This configuration allow the inspection

of the weld without removing the Cap
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Technique advantages

 The inspection is done in a single pass  Fast

scanning
 TOFD  High precision sizing technique

 Real time A,B, and C-Scan imaging

 Quick defect evaluation by clear imaging

 PA Lateral position of defect

 PA Focus Depth adjustable

 Complete aproach because of combination of

2 techniques: TOFD and Phased Array

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Introduction to Phased Array

The implementation of high speed electronics, real

time imaging, and composite probe development.

4 May 2006: used with permission of

[email protected] • www.rd-tech.com Randy Scheib
 Phased Array Definition

 A mosaic of transducer elements in which

the timing of the elements' excitation can be
individually controlled to produce certain
desired effects, such as steering the beam
axis or focusing the beam.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Key Concept

 Phased arrays do not change the physics of

ultrasound
 PA’s are merely a method of generating and
receiving a signal
 If you obtain X dB using frequency Y with
conventional UT, you should obtain the
same signal amplitude and frequency
response using PA’s.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 How Phased Arrays Work

 Ultrasonic phased arrays consist of a series

of individual elements, each with its own
connector and time delay circuit.
 Elements are acoustically insulated from
each other.
 Elements are pulsed in groups with pre-
calculated time delays for each element, i.e.,
“phasing.”

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Design Parameters of Phased-Array Probes

 A linear array (1D) is

basically a long
conventional probe…

 Cut in many small

elements, that can be
individually excited.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Beam Focusing

•large range of
focal depth
(focusing)

• adjustable each
pulse.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Beam Steering

• large range of
inspection angles
(sweeping)

• multiple modes
with a single
probe (SW, LW)

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Phased Array Probes

 Linear arrays are the most common type

and can perform scanning in one dimension
or plane
 Matrix arrays can scan in two dimensions,
and offer considerably more flexibility but
add a considerable amount of complexity
 Circular and sectorial-annular arrays are
specific for normal beam inspections, e.g.,
billets, forgings.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Common Probe Geometry
Linear

1D linear array 2D matrix

Circular

1D annular array
4 May 2006: used with permission of Randy Scheib
2D sectorial annular

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 Focal Law
An internal or external calculator
produces a file called a
FOCAL LAW
The Focal Law defines the elements
to be fired, time delays, and voltages
for both the transmitter and receiver
functions.
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Pulse – Receive Physics

Beam forming or focusing requires precise pulsing and time

delays. The exact opposite timing is required when Receiving.
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Electronic Scanning
 The ability to move the beam along one
axis of an array without any mechanical
movement.
 The movement is performed only by time
multiplexing the active element group
 The beam movement depends on the
probe geometry and could be:
 linear scanning
 sectorial scanning
 lateral scanning
 combination

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Illustration of Sectorial Scanning

4 May 2006: used with permission of Randy Scheib

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 Sectorial Scans (S-scans)

 Sectorial scanning is the ability to scan a complete sector

of volume without any probe movement.
 Useful for inspection of complex geometries, or those with
space restrictions
 Combines the advantages of a wide beam and/or multiple
focused probes in a single phased array probe

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Sectorial Scanning Animation
 This illustration shows a turbine blade root being inspected
using S-scans.

4 May 2006: used with permission of Randy Scheib

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 Schematic Representation of
Dynamic Depth Focusing

Mechanical Displacement

FOCUS DEPTH (PULSER)

Beam displacement

DYNAMIC FOCUSING (RECEIVER)

c = velocity in material

DDF is an excellent way of inspecting thick components in

a single pulse. The beam is refocused electronically on its
return.
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Dynamic Depth Focusing Animation

4 May 2006: used with permission of Randy Scheib

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•Click toPerform Demonstration
edit Master text styles
–Second level
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•Third level
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»Fifth level

4 May 2006: used with 32of

4 May 2006: used with permission
permission of•Randy
[email protected] www.rd-tech.com
Scheib Randy Scheib
 Portable Phased Array Applications
 Austenitic weld inspections
 Turbine root inspections
 Butt weld inspections
 T-weld inspections of bridge
structures
 HIC – Hydrogen Induced Crack
 Flange corrosion under gasket
 Nozzle inspections
 Bridge bolt inspections
 Spindle/shaft inspections
 Thread inspections
 Landing gear inspections
 Laser weld inspections
 Composites

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Construction Welding: Inspection of Small Diameter
Austenitic Piping
 OmniScan PA instrument, two
5MHz 16 element probes using a
splitter/umbilical, and a
mechanical scanner.
1.5mm
hole on
near
side of
the
weld

Piping from 0.5 to 8 inch dia ID notch on the weld centerline

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Construction Welding: Fillet welds

Construction and
maintenance of bridge
structures

 Manual inspection using one

small phased-array probe
 Linear scan at ~25 mm/s, one
side at a time
 Inspection with 40- to 70-
degree refracted angle
 Real-time display of S-scan and
A-scan
 Accurate depth measurement of
fillet welds
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Construction Welding: Sample crack and S-scan
image

Corner Crack
4 May 2006: used with permission of Randy Scheib

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 OmniScan for Pipeline Welds

•Works with manual

scanner
•All data saved
•Perform a scan line
for each linear angle

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Bolts - PA Sectorial Scan
PA Probe

15 Degree
Beam

Threads
15 Degree Beam
Notch #1 Notch #1

0 Degree
Beam

360 Groove 360 Groove

Mode Conversions

Notch #2 Notch #2

End of Bolt End of Bolt

4 May 2006: used with permission of Randy Scheib 0 Degree Beam

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 Road Arm Spindles / Shafts

Pictures from the

field showing the
broken road-arms
on the vehicle

Road Arm Lower Spindle

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Road Arm - Global View
10° Law

Transition 10 MHz
Volume
corrected
Sectorial scan
Notch from 0º to 10 º
Taper
16 Elements,
Pitch 0.4mm

Taper

Start of threads
10° Law
End
0° Law 0° Law
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Component Testing : Thread inspection
Very rapid scanning and “go no-go”
Threads Ultrasound waves
Offset

Tip Window Pipe (cross-section)

Metal

0°
Bottom Window
Threads
Tip Window
Metal

30°
Bottom Window

Energy Calculation
Tip Window
Metal Windows Delimitation
90°
Bottom Window

Tip Window

180°
Bottom Window

Figure 1

amplitude
pattern
thread
assessment

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Aerospace: Landing gear inspection

Phased arrays offer major cost savings

over MT.
 Manual inspection using one small
phased array probe
 Linear scan ~12 mm/s
 Inspection using 40 to 65o refracted
angle
 Real time display of A-scan, B-scan
and S-scan
 Storage of linear scan for analysis.
 Less than three hours vs. a minimum
of 1 week.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Aerospace: Laser Weld inspection
In-construction inspection of laser
welding with phased array.
 Manual inspection using encoded
water box and pre-focused phased
array probe
 Linear scan of 10m in single scan
at ~25 mm/s
 0o electronic scanning
 Real time display of C-scan
display
 Storage of C-scan data for
analysis

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Aerospace: Composite inspection
 Carbon composite exam 6mm thick.
 Sample simulates lay-up tape commonly
found during the manufacturing process.

Instant C-scan and S-scan – Note: Backwall dropout and near surface flaw
4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Aerospace: T-Joint Composite
Flaw

Taper

The advantage with

this inspection
technique is speed
and POD.

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

Aerospace: Aluminum to Aluminum Bond

Bond Areas

4 May 2006: used with permission of Randy Scheib

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 Additional Applications
 Rail Thermite Welds
 Automotive Field
 Replace mechanical failure analysis
 Slug Weld C-scan Imaging
 Spot Weld C-scan Imaging
 Component Testing
 Braze Welds
 Flaws

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Summary

 Many applications for portable phased arrays

 And more applications keep coming

 Advantages:
 Speed
 Imaging
 Flexibility
 Simplicity
 Data storage
 Reproducibility

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology

 Thanks !
Any Questions?

4 May 2006: used with permission of Randy Scheib

Leader in Array Technology