Advanced Ultrasonic Inspection

OlympusNdt
Nick Bublitz

What is Phased Array?

Advanced Ultrasonic
Industrial PA
technique used for flaw
detection, sizing, and
imaging.
Allows for electrical
manipulation of probe
characteristics by
introducing time shifts to
sent and received signals
Utilizes multi-element
(array) probes for
increased capabilities over
conventional ultrasonics.
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Medical PA

Advantages of Phased Array

Electronic scanning (raster) possible without
moving probe.
Increased control of beam characteristics.
Simultaneous inspection with multitude of
angles using one probe.
Can better inspect complex geometries or
limited access areas.
Can replace costly and hazardous
radiography applications.

Phased Array

Phased Array Probe Configuration

It is like having many small conventional UT probes

integrated inside a single probe.

128 elements !

How Does Phased Array Work?

Elements are pulsed in

groups with
precalculated time
delays for each element
(i.e., phasing).

Single Trigger Pulse

Time

Modern software allows an

operator to input test parametersMaterial, wave type, desired
angles etc and all calculations
are done by the software. Probe
recognition and Wedge databases
further simplify setup.

How Phased Arrays Work - Beam Steering

Electronic Scanning modes

35-70 degrees

Sectorial scan

Linear/ Electronic scan

45 degree

Combinations
Advanced software options (i.e.: Multi group) allow for many
different combinations to be performed to increase detection,
speed up inspections, or fulfill code requirements.

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Sectorial Scan

The ability to scan a

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

Allows for a swept

range of angles
Allows for full volume
inspection without
probe movement.

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Electronic/Linear Scanning
Allows movement of beam along probe array without
physical movement of probe by multiplexing.
Each beam will be at the same angle from its respective
exit point.
This can mimic conventional UT rastering towards and away
from a weld, but does it electronically, allowing for movement of
the probe in only one direction (ex. Line scan down the length
of the weld), simplifying automation and
encoding.
Also used to cover large areas more rapidly.
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Linear Electronic Scan

The movement of the

acoustic beam is along the
axis of the array, without
any mechanical
movement.

The beam movement is

performed by time
multiplexing of the active
elements. Arrays are
multiplexed using the
same focal law.
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Large Area Scans

Single crystal

PA 128 element

VS

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Key Concept

Phased arrays do not

change the physics of
ultrasound
PAs are merely a
method of generating
and receiving a signal

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Imaging
An important part of a phased
array system is imaging. Usually
imaging is created from the raw
A-scan Amplitude or TOF data.

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Imaging Linear Electronic Scan

By using the electronic

scanning capability of
the phased array
technology, imaging
d
becomes possible
without mechanical
movement.
Arrays are multiplexed
using the same focal
law and the resulting Ascan of each beam is
color-encoded and
displayed in a linear Sscan.

Beams 1 2 3 4 5 6 7 8 9 10 1112 13

Beams 1 2 3 4 5 6 7 8 9 10 1112 13

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Imaging Linear Electronic Scan

A linear electronic scan can also be performed with a steering

angle (15 in the image below).
Linear Angle S-scan

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Imaging Sectorial Scan

Using a small angle step value, the sectorial scan

resolution is very precise.

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Each beam goes back to a single conventional A-Scan

Imaging On Omniscan

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Phased Array Instruments

Omniscan

Tomoscan Focus LT

1000i
Quickscan PA

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 Manual

Applications

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Manual Inspections

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Radiography

Root Crack

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Phased Array technique

Porosity

Phased Array technique

Radiography

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Double V Images Tomoview

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Semi-automated Inspections

Addition of scanners and encoders to record data

Provides digital data of weld inspections that is repeatable and
auditable using the Omniscan or computer based software
-Tomoview
Allows advanced software features including weld overlays,
sizing algorithms, custom displays, advanced measurement tools,
etc.
Low cost portable systems now allow NDT service companies
and fabrication shops to offer advanced AUT solutions that are
have historically been cost prohibitive and required an enormous
amount of expertise
Use of phased array technology allows low cost magnetic oneline scanners to replace fully automated raster scanning
motorized equipment by using S-scans and E-scans for coverage

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Imaging with Encoders

Side view of weld-S scan
A scan

Top view of weld-Cscan

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Small wheel encoders

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Multi-Probe Capable Scanners

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Fully Automatic

Fully automated
phased Arrays
Benefits include
Best quality data
Most repeatable
results

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Driven by Focus LT or OmniScan

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Pipe Wizard- Zonal Technique

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What about Codes?

ASME
Case 2235 Use of Ultrasonic Examination in Lieu of RT for
ASME Sec VIII Pressure Vessels
Case 2600 Use of Linear PA S-scan per Art. 4 Sec V
Case 2557 Use of Manual PA S-scan per Art. 4 Sec V
Case 2599 Use of Linear PA E-scan per Art. 4 Sec V
Case 2541 Use of Manual PA per Art. 4 Sec V
Case 2558 Use of Manual PA E-scan per Art. 4 Sec V
Case 181 Use of Alternative UT Examination Accept
Criteria for ASME B31.3
Case 179 Use UT in Lieu of RT for B31.1 Applications <
inch in Thickness
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Code\Procedure Compliance (continued)

ASME Code Case 2235 allows for the use of UT (Phased Array) in lieu of RT if the
inspection can be demonstrated on a representative calibration or manufactured defect
specimen.
The short version of this is that from one or more probe positions or scans, if the
calibration targets of flaws can be detected and sized, the technique is allowed to be
used in lieu of RT.

Courtesy of AIT

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Other Codes
API- Many API inspections possible
including zone discrimination (1104) with the
right equipment
AWS- was codified in 2006 (Manual) but
requires engineers approval each caseencoded annex submitted- we are working
with AWS now on other code work
ASTM- E-2491- published recommended
practice for setting up PA

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Calibrations

To fulfill codesmust have full

sensitivity/wedge
delay/ TCG/DAC
across all angles
Must be realistically
accomplishedquick/easy (OmniScan
Wizards)
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Sensitivity Calibration Example

Before

After

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Code Compliance
When used by certified personnel, Olympus
Phased Array Systems are cable of meeting
the basic requirements of any code with
respect to all the following parameters.

Vertical and Horizontal Linearity

Time of Flight Calibration
Sensitivity Calibration
ACG (Angle Corrected Gain as defined by the
ASME)

TCG Calibration
DAC Calibration
Velocity Calibration

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Scan Plans

In order for advanced

inspections to be
successful setup must
be quick and easy and
documented

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What is Tofd- TOFD Basics

Tofd is a wide beam longitudinal wave technique using TOF

Information for sizing. It utilizes diffraction versus reflection

The incoming wave

vibrates the defect.
Each point of the
defect generates new
elementary spherical
waves called
diffraction
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TOFD Basics Continued

Incident
wave

Diffracted
waves All directions
Low energy

Reflected
wave

FLAW

Diffracted
waves
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Independent
of incidence
angle

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Why use TOFD in a Phased Array Inspection?

In most instances, particularly on thin welds, TOFD is not necessary and
the phased array is sufficient. However on thicker welds whether it is
required or not, it is extremely useful for the following reasons:

Where weld bevel design does not allow a pulse echo A-scan to intersect the
weld bevel at near perpendicular angles, the probability of detection and over
all inspection quality is severely reduced on the fusion line. TOFD uses
diffracted rather than reflected signals and is not dependent on flaw orientation.
Setting up a TOFD channel on the Omniscan MXU takes less than 5 minutes
and calibration is typically performed in analysis mode after the inspection.
Of the 256 available focal laws (A-scans) in the Omniscan, the TOFD channel
uses only one. Low overhead on the acquisition rate and file size.
TOFD is an industry accepted technology that has been in use for decades.
The ASME, AWS, and API codes have either specific rules for TOFD or
alternative rules for computer based inspection techniques that allow flexibility
in inspection strategy if a qualification is performed. TOFD is an excellent tool
for fulfilling these requirements.
For thick welds that are difficult to cover on one line scans, TOFD can provide a
large coverage area reducing acquisitions and probe changes.
For some codes such as ASME CC2235, the technology used for detection can
be different than that of sizing. This is a great combination for PA and TOFD
!TOFD - BIG VALUE - LOW COST - EASY!

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Why use TOFD in a Phased Array Inspection?

The 30 degree V weld can easily be

inspected using standard PE techniques
from the phased array without the use of
TOFD. A 60 degree linear scan would
intersect the weld bevel perpendicular
providing a very high probability of
detection throughout the entire weld
volume when inspected from both sides.

For weld bevels that have a vertical

plane, PE scan plans without the use of
TOFD would have a low probability of
detection on the vertical fusion lines.

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Tofd and Phased Array

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Phased Array Offline Analysis- Tomoview

Tomoview Full- Includes capability to acquire data through an Omniscan MXU or Focus LT
and all analysis Features.
Tomoview Analysis- Includes all analysis features without the ability to acquire data.
Tomoview Weld LT- Limited version specifically designed for analysis of Omniscan data files
with most common analysis tools and limited customization.
Tomoview Viewer- Free version that can be provided to customers or inspectors for basic
data file screening without advanced tools.

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Phased Array Offline Analysis- Tomoview

An essential tool used in the

offline analysis of phased array
data files is the volumetric data
merge. The C-scan below is
the sum of all focal laws used
in the scan plan. In this
example over 200 focal laws on
6 linear scan channels from 2
probes. The ability to merge all
focal laws into one C-scan
allows all focal laws on all
channels to be analyzed in
seconds in one display.

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Phased Array Offline Analysis- Tomoview

From the Merged

C-scan, individual
flaws are analyzed
on the relevant
channels using Bscans, D-scans and
S-scans.
Additionally, every
A-scan from every
focal law is
available on
customized views
designed for the
particular
application.
The typical
WeldROVER
application would
use 2 or 4 phased
array channels from
probes on both
sides of the weld
combined with 1 or
2 TOFD channels.

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Thank you!