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4. Main Concepts of Phased Array Ultrasonic
Technology
This chapier gives a brief history of industrial phased arrays, the principles
pertaining to ultrasound, the concepts of time delays (or focal laws) for
phased arrays, and Olympus NDT R/D Tech® phased array instruments.
The advantages and some technical issues related to the implementation of
this new technology are included in this chapter.
‘The symbols used in this book are defined in the Glossary of Introduction to
Phased Array Ultrasonic Technology Applications.
141 — Historical Development and Industrial Requirements:
The development and application of ultrasonic phased arrays, as a stand-
alone technology reached a mature status at the beginning of the twenty-first
century.
Phased array ultrasonic technology moved from the medical field? to the
industrial sector at the beginning of the 1980s? By the mid-1950s,
piezocomposite materials were developed and made available in order to
‘manufacture complex-shaped phased array probes 41
By the beginning of the 1990s, phased array technology was incorporated as a
new NDE (nondestructive evaluation) method in ultrasonic handbooks!
and training manuals for engineers! The majority of the applications from
1985 to 1993 were related to nuclear pressure vessels (nozzles), large forging
shafts, and low-pressure turbine components.
New advances in piezocomposite technology,16 micro-machining,
microelectronics, and computing power (including, simulation packages for
probe design and beam-component interaction), all contributed to the
revolutionary development of phased array technology by the end of the
‘Main Concepts of Phased Array Ultrasonic Technology 51990s. Functional software was also developed as computer capabilities
increased.
Phased array ultrasonic technology for nondestructive testing (NDT)
applications was triggered by the following general and. specific power-
generation inspection requirements:724
1. Decreased setup and inspection time (that is, increased productivity)
Inceeased scanner reliability
3. Incteased access for difficult-to-reach pressurized water reactor / boiling,
‘water reactor components (PWR/BWR)
4. Decreased radiation exposure
5. Quantitative, easy-to-interpret reporting requirements for fitness for
purpose (also called “Engineering Critical Assessment” —ECA)
6. Detection of randomly oriented cracks at different depths using the same
probe in a fixed position
7. Improved signal-to-noise ratio (SNR) and sizing capability for dissimilar
metal welds and centrifugal-cast stainless-steel welds
8. Detection and sizing of small stress-corrosion cracks (SCC) in turbine
components with complex geometry
9. Inereased accuracy tn detection, stzing, location, and ortentation of
critical defects, regardless of their orientation. This requirement dictated
‘multiple focused beams with the ability to change their focal depth and
sweep angle.
Other industries (such as aerospace, defense, petrochemical, and manufac
turing) required similar improvements, though specific requirements vary for
each industry application?>9
Al these requirements center around several main characteristics of phased
array ultrasonic technology:
1. Speed. The phased array technology allows electronic scanning, which is
typically an order of magnitude faster than equivalent conventional
raster scanning.
2. Flexibility. A single phased array probe can cover a wide range of
applications, unlike conventional ultrasonic probes.
3. Electronic setups. Setups are performed by simply loading a file and
calibrating. Different parameter sets are easily accommodated by pre-
prepared files.
4. Smait probe dimensions. For some applications, limited access is a major
issue, and one small phased array probe can provide the equivalent of
multiple single-transducer probes.
6 Chapter15. Complex inspections. Phased arrays can be programmed to inspect
geometrically complex components, such as automated welds or nozzles,
with relative ease. Phased arrays can also be easily programmed to
perform special scans, such as tandem, multiangle TOFD, multimode,
and zone discrimination.
6. Reliable defect detection. Phased arrays can detect defects with an increased
signal-to-noise ratio, using focused beams. Probability of detection (POD)
is increased due to angular beam deflection (S-scan).
7. Imaging. Phased arrays offer new and unique imaging, such as $-scans,
which permit easier interpretation and analysis.
Phased array ultrasonic technology has been developing for more than a
decade. Starting in the early 1990s, R/D Tech implemented the concepts of
standardization and transfer of the technology. Phased array ultrasonic
technology reached a commercially viable milestone by 1997 when the
transportable phased array instrument, Tomoscan FOCUS™, could be
operated in the field by a single person, and data could be transferred and.
remotely analyzed in real time.
The portable, battery-operated, phased array OmniScan® instrument is
another quantum leap in the ultrasonic technology. This instrument brings
phased array capabilities to everyday inspections such as corrosion mapping,
‘weld inspections, rapid crack sizing, imaging, and special applications.
1.2 Principles
‘Ultrasonic waves are mechanical vibrations induced in an elastic medium
(the test piece) by the piezocrystal probe excited by an electrical voltage.
‘Typical frequencies of ultrasonic waves are in the range of 0.1 MHz to
50 MHz. Most industrial applications require frequencies between 0.5 MHz
and 15 MHz,
Conventional ultrasonic inspections use monocrystal probes with divergent
‘beams. In some cases, dual-element probes or monocrystals with focused
lenses are used to reduce the dead zone and to increase the defect resolution.
Inall cases, the ultrasonic field propagates along an acoustic axis with a single
refracted angle.
A single-angle scanning pattern has limited detection and sizing capability
for misoriented defects. Most of the “good practice” standards add
supplementary scans with an additional angle, generally 10-15 degrees apart,
to increase the probability of detection. Inspection problems become more
difficult if the component has a complex geometry and a large thickness,
and/or the probe carrier has limited scanning access. In order to solve the
‘Main Concepts of Phased Array Ultrasonic Technology 7inspection requirements, a phased array mullicrystal probe with focused
‘beams activated by a dedicated piece of hardware might be required (see
Figure 1-1).
ee
Figure 1-1 Example of application of phased array ullrasonic technology on a complex.
geometry component. Le: monocrystal singe-angle inspection requires mutiangle scans and
‘robe movement; right: near array probe can sweep the focused beam trough the
appropriate region ofthe component without probe movement.
Assume a monoblock crystal is cut into many identical elements, each with a
pitch much smaller than its length (e< W, see chapter 3). Each small crystal or
‘element can be considered a line source of cylindrical waves. The wavefronts
of the new acoustic block will interfere, generating an overall wavefront with
constructive and destructive interference regions.
‘The small wavefronts can be time-ielayed and synchronized in phase and
amplitude, in such a way as to create a beam. This wavefront is based on.
constructive interference, and produces an ultrasonic focused beam with steering
capability. A block-diagram of delayed signals emitted and received from
phased array equipment is presented in Figure 1-2.
8 Chapter1Me Ee
+AU flit
Figure 1-2 Beam forming and te delay for pulsing and receiving multiple beams (same
phase and amplitude).
‘The main components required for a basic scanning system with phased
array instruments are presented in Figure 1-3.
LUTPAinsrumert | —|
(Tomescan IPA)
+ | scannermaniulae|
Figure 1-3 Basic components of a phesed array system and their interconnectivity.
‘Main Concepts of Phased Array Ultrasonic Technology 9)An example of photo-elastic visualization’? of a wavefront is presented in
Figure 1-4, This visualization technique illustrates the constructive-
destructive interference mentioned above.
waves at 24
‘Longitudtnal
waves at 40"
Ccouresy of Mater Research Insitute, Carat
Figure 1-4 Example of photoelastic wavefront visualization in a glass block fora linear array
probe of 7.5 MHz, 12-element probe witha pitch of2 mm, The 40° refacted longitudinal waves
is folowed by he shear wavefont at 24°:
The main feature of phased array ultrasonic technology is the computer-
controlled excitation (amplitude and delay) of individual elements in a
inultielement probe. The excitation of piezocomposite elements can generate
beams with defined parameters such as angle, focal distance, and focal spot
size through software.
To generate a beam in phase and with constructive interference, the multiple
wavefronts must have the same global time-of-flight arrival at the
interference point, as illustrated in Figure 1-4, This effect can only be achieved
if the various active probe elements are pulsed at slightly different and
coordinated times. As shown in Figure 1-5, the echo from the desired focal
point hits the various transducer elements with a computable time shift. The
echo signals received at each transducer element are time-shifted before being
summed together. The resulting sum is an A-scan that emphasizes the
response from the desired focal point and attenuates various other echoes
from other points in the material.
‘© At the reception, the signals arrive with different time-of-flight values, then
they are time-shifted for each element, according to the receiving focal
law. All the signals from the individual elements are then summed
10. Chapter 1together to form a single ultrasonic pulse that is sent to the acquisition
instrument.
‘The beam focusing principle for normal and angled incidences is
illustrated in Figure 1-5,
© During transmission, the acquisition instrument sends a trigger signal to
the phased array instrument. The latter converts the signal into a high
voltage pulse with a preprogrammed width and time delay defined in the
focal laws. Fach element receives only one pulse. The multielement
signals create a beam with a specific angle and focused at a specific depth.
‘The beam hits the defect and bounces back, as is normal for ultrasonic
testing,
Be
Nanking arte STE
‘igure 1-5 Beam focusing principle for (a) normal and (b) angled incidences.
The delay value for each element depends on the aperture of the active
phased array probe element, type of wave, refracted angle, and focal depth.
Phased arrays do not change the physics of ultrasonics; they are merely a
method of generating and receiving.
‘There are three major computer-controlled beam scanning patterns (see also
chapters 2-4):
+ Electronic: scanning (also called E-scans, and originally called linear
scanning): the same focal law and delay is multiplexed across a group of
active elements (see Figure 1-6); scanning is performed at a constant angle
and along the phased array probe length by a group of active elements,
called a virtual probe aperture (VPA). This is equivalent to a conventional
ultrasonic transducer performing a raster scan for corrosion mapping (see
Figure 1-7) or shear-wave inspection of a weld. If an angled wedge is
used, the focal laws compensate for different time delays inside the
‘wedge. Direct-contact linear array probes may also be used in electronic
angle scanning, This setup is very useful for detecting sidewall lack of
fusion or inner-surface breaking cracks (see Figure 1-8).
Main Concepts of Phased Array Ultrasonic Technology 11Electronic Sean
Figure 1-6 Left: electronic scanning principle for 2ero-degree scanning. In this case, the virtual
[robe aperture consists of four elements. Focal law 1 is active for elements 14, while focal
law 5's active for elements 5-8. Right: schematic for corrosion mapping with zero-degree
¢lectonic scanning; VPA = 5 elements, n= 64 (see Figure 1-7 for ulrasonic display).
Figure 1-7 Example of coresion detection and mapping in 2-D part with electronic scanning et
zero degrees using a 10 MHz linear array probe of 64 elements, p= 0.6 mm.
12. Chapter 1Figure 1-8 Example of electronic scanning with loncitudinal waves for crack detection in a
forging at 15 degrees, 5 MH2 probe, n= 82, p= 1.0mm,
Sectorial scanning (also called $-scans, azimuthal scanning, or angular
scanning): the beam is swept through an angular range for a specific tocal
depth, using the same elements. Other sweep ranges with different focal
depths may be added the angular sectors voulkl have different sweep
values (see Figure 1-9). The start-and-finish-angle range depends on
probe design, associated wedge, and the type of wave; the range is
dictated by the laws of physics.
Figure 1-9 Left. principle of sectorial scan. Right: an example of ultrasonic data display in
volume-corrected sectorial scan (S-scan) detecting a group of stress-corrosion cracks
(range: 33° 058°)
Main Concepts of Phased Array Ultrasonic Technology 13+ Dynamic depth focusing (also called DDE): scanning, is performed with
ditferent focal depths (see Figure 1-10). In practice, a single transmitted
focused pulse is used, and refocusing is performed on reception for all
programmed depths. Details about DDF are given in chapter 4.
Depth Focusing
Courts of Onto Powor Gneraton Ine, Canada
Figure 1-10 Left principle of depth focusing Middle: a stress-corrosion crack (SCC) tip sizing
With longitudinal waves af 12 MHy at normal incidence using depth-ocusing focal laws
Right: macrographic comparison.
1.3 Delay Laws, or Focal Laws
In order to obtain constructive interference in the desired region of the test
piece, each individual element of the phased array virtual probe aperture
must be computer-controlled for a firing sequence using a focal law. (A focal
luco is simply a file containing elements to be fired, amplitudes, time delays,
etc) The time delay on each element depends on inspection configuration,
steering angle, wedge, probe type, just to mention some of the important
factors.
An example of time-delay values in nanoseconds (10s = a millionth part
from a second) for a 32-element linear array probe generating longitudinal
waves is presented in Figure I-11. In this image, the detection of side-drilled
holes is performed with both negative (lef) and positive angles (right). The
delay value for each element changes with the angle, as shown at the bottom
of this figure.
4 Chapter 1Figure 1-11 Example of delay value and shape for a sweep range of 90° (45° to +45°). The
linear phased array probe has 32 elements ands programmed to generate longitudinal waves
to detec ive side-criled holes. The probe Fas no wedge and isn direct contact with the test
piece.
Direct-contact probe (no wedge) for normal beam. The focal law delay has a
parabolic shape for depth focusing. The delay increases from the edges of the
probe towards the center. The delay will be doubled when the focal distance
is halved (see Figure 1-12), The element timing has a linear increase when the
element pitch increases (see Figure 1-13). For a sectorial (azimuthal) scan
without a wedge, the delay on identical elements depends on the element
position in the active aperture and on the generated angle (see Figure 1-14).
ow
Tie dyn
®
Figure 1-12 Delay values (ff) and depth scanning principles (igh for a 32-element linear
‘array probe focusing at 15 mm, 20 mm, and 60 mm longitudinal waves.
Main Concepts of Phased Array Ultrasonic Technology 15eee 8 a8
Tiedt
Figure 1-14 Left an example ofan element positon and focal depth fora probe with no
‘wedge (ongitudnal waves between 15° and60°). Right an example of delay dependence on
‘generated ngle,
Probe on the wedge. If the phased array probe is on a wedge, the delay value
also depends on wedge geometry and velocity, element position, and
refracted angle (see Figure 1-15).
‘The delay has a parabolic shape for the natural angle given by Snell's law (45°
in Figure 1-16), For angles smaller than the natural angle provided by Snel’s
law, the element delay increases from the back towards the front of the probe.
For angles greater than the natural angle, the delay is higher for the back
16 Chapter 1elements, because the beam generated by the front elements follows a longer
‘path in the wedge, and thus the front elements have to be excited first.
Figure 1-15 Example of delay value and its shape for detecting tree side-drilled holes with
shear waves. The probe has 16 elements end is placed on @ 37° Plexiglas® wedge (natural
angle 45° in steel).
Figure 1-16 Example of delay dependence on refracted angle and element position for a
phased ara probe on a 7° Plexiglas® wedge (= 5 mm)
Delay tolerances. In all the above cases, the delay value for each element must
be accurately controlled. The minimum delay increment determines the
‘maximum probe frequency that can be used according to the following ratio:
Main Concepts of Phased Array Ultrasonic Technology 17Atay = 2 [in microseconds, ps] ay
‘The delay tolerances are between (5s and 2ns, depending on hardware
design.
Other types of phased array probes (for example, matrix or conical) could.
require advanced simulation for delay law values and for beam feature
evaluation (see chapter 3),
1.4 Basic Scani
g and Imaging
During a mechanical scan, data is collected based on the encoder position.
‘The data is displayed in different views for interpretation.
‘Typically, phased arrays use multiple stacked A-scans (also called angular
B-scans) with different angles, me of flight and ume delays on each sinall
plezocomposite crystal (or element) of the phased array probe,
‘The real-time information from the ‘otal number of A-scans, which are fired
at a specific probe position, are displayed in a sectorial scan ot S-scan, or in a
electronic B-scan (see chapter 2 for more details).
Both S-scans and electronic scans provide a global image and quick
information about the component and possible discontinuities detected in the
“ultrasonic range at all angles and positions (see Pigure 1-17).
Courtesy of OnteroPower Generator In, Canad
Figure 1-17 Detection of thermal fatigue cacks in counter-bore zone and platting data into
3. specimen.
18 Chapter 1Data plotting into the 2-D layout of the test piece, called corrected S-scans, oF
true depth S-scans makes the interpretation and analysis of ultrasonic results
straightforward. S-scans offer the following benefits:
+ Image display during scanning
‘© Tiuesdepth representation
© 2D volumetric reconstruction
Advanced imaging can be achieved using a combination of linear and
sectorial scanning, with multiple-angle scans during probe movement. S-scan
displays, in combination with other views (see chapter 2 for more details),
lead to new types of defect imaging or recognition. Figure 1-18 illustrates the
detection of artificial defects and the comparison between the defect
dimensions (including shape) and B-scan data after merging multiple angles
and posit
Figure 118 Advanced imaging of artificial defects using merged data: defects and scanning
patter (too); merged B-scan display (bottom).
A combination of longitudinal wave and shear-wave scans can be very useful
for detection and sizing with little probe movement (see Figure 1-19). In this
setup, the active aperture can be moved to optimize the detection and sizing
angles.
Main Concepts of Phased Array Ultrasonic Technology 19Figure 1-19 Detection and sizing of misriented defects using a combination of longitudinal
wave (1) and shear wave sectorial scans (2),
Cylindrical, elliptical, or spherical focused beams have a better signal-to-noise
ratio (discrimination capability) and a narrower beam spread than divergent
beams. Figure 1-20 illustrates the discrimination of cluster holes by a
cylindrical focused beam.
—
=
Figure 1-20 Discrimination (resolution) of cluster holes: (2) top view (C-scan);(b) side view
€-scan)
Real-time scanning can be combined with probe movement, and defect
plotting into a 3-D drafting package (see Figure 1-21). This method offers:
© High redundancy
© Defect location
© Accurate plotting
© Defect imaging
20. Chapter 1‘+ High-quality reports for customers and regulators
© Good understanding of defect detection and sizing principles as well the
‘multibeam visualization for technician training
courtesy Ont Power Generation In, Canad
Figure 1-21 Example of advanced data ploting (top) in a complex pat (middle) and a zoomed
‘isometric cross section with sectoral scan (botiom) 35
‘Main Concepts of Phased Array Ultrasonic Technology 211.5 Limitations and Further Development of Phased Array
Ultrasonic Technology
Phased array ultrasonic technology, beside the numerous advantages
‘mentioned at the beginning of this chapter, has specific issues listed in Table
1-1, which might limit the large-scale implementation of the technology:33
Table 1-1 Limitations of phased array ultrasonic technology and Olympus NOs approaches to
‘overcome them,
+ Standardize the prodction kine
+ Price will drop 102-8 times vs.
‘conventional UT.
Limi srtware upgrades
Probes too expensive
‘wath long lead delivery
Tsuea probe design guideline, @
‘new book on PA probes and
‘heir applications
+ sranaaraize me prove
smarnaacturing, for welds,
Pec 12 10 20 umes ene
lexpensive than contenttonal
22 Chapter 1‘Table 1-1 Limitations of phased array utrasonic technology and Olympus NDT's approaches to
‘overcome them, (Cont)
Teme ‘Specific alle ‘Olympus NDT approach
Reundany of eat data mates | (amphi postion ne gt,
fis imerpecatonaclyss tine | snuging ecerdyna per)
consi + Develop 2D and 3D direct,
Data anaes and |apro signals dito mate | soqston an plot
ting iste [A Tccoleoganenmtyssand | capbaity™ (2e Figure 121
position. sand Figure 122)
Data plotting in tne based + Use say tracing and incorporate
Jacquisition istime-consiming. | theboundary conditions and
mode converted into analysis.
tools
[Active partapation ational
‘and intemational
standasdization committees
(ASME, ASNT, APL FAA, 50,
IW, EN, AWS, EPRI. NRC)
lenased aay techniques ase |e Simplify the procedure for
Jstticutttointegeateinta existing | cabiration
sonot {standards due tothe complenty of [« Create basic setups for existing
‘standardized /fhistechnology: codes
standards arenot available. J+ Vakidate the system on.
Hrroceduses ave too specific. opemhind tale hed om
Iitiatives >"
+ Create guidelines for equipment
substitution
+ Prepare generic procedures
Compared to the time-of-flight-difftaction (TOFD) method, phased array
technology is progressing rapidly because of the following features:
Use of the pulse-echo technique, similar to conventional ultrasonics
Use of focused beams with an improved signal-to-noise ratio
Data plotting in 2-D and 3D is directly linked with the scanning
parameters and probe movement.
Sectorial scan ultrasonic views are easily understood by operators,
regulators, and auditors.
Defect visualization in multiple views using the redundancy of
infonnation in S-scan, E-scans, aud other displays offers a powerful
imaging tool.
Combining difierent inspection configurations in a single setup can be
used to assess difficult-to-inspect components required by regulators.
Main Concepts of Phased Array Ultrasonic Technology 23Figure 1-22 shows an example of the future potential of phased arrays with
3-D imaging of defects.
Figure 1-22 Example of -D ultrasonic date visualization ofa side-riled hole on a sphere 4
Olympus NDT is committed to bringing a usertriendly technology to the
market, providing real-time technical support, offering a variety of hands-on
training via the Olympus NDT Training Academy, and releasing technical
information through conferences, seminars, workshops, and advanced
technical books.
Olympus NDT new line of products (OmniScan® MX 8:16, 16:16, 16:128,
32:32, 3232-128, TomoScan FOCUSLT™ 32:32, 32:32-128, 64:128,
QuickScan™, Tomoscan III PA) is faster, better, and significantly cheaper. The
price per unit is now affordable for a large number of small to mid-size
companies.
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