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Phased Array Module 1

PAUT PCN EXAM BOOK 3

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73 views

Phased Array Module 1

PAUT PCN EXAM BOOK 3

Uploaded by

rajakumark_3
Copyright
© © All Rights Reserved
Available Formats
Download as PDF or read online on Scribd
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Lavender International NDT Phased Array Training Course 07/11/2006 Module 1 Phased Arrays Not The Answer To Every Application Author: Tim ARMITT, Lavender International NDT, Unit 7, Penistone Station, Sheffield, $36 6HP, UK, Abstract, Phased Arvay has been the buzz forthe last few years within the NDT world but is it any good? We frequently read papers on applications or receive literature from suppliers of equipment expressing the excellence of ultrasonic phased array technology but seldom does any of this contain information as to limitations of phased array technology. ‘This presentation has been prepated from a realistic perspective giving a practical insight into the world of phased arrays and discusses the usefulness 9 this technology including clarification of misnomers found throughout our industry. 1, Introduction Phased arrays have been banded about for some time now but few people know that the first phased array unit was actually patented in 1959. The medical industry has been pioneering many of our industrial imaging systems for years and phased arrays are no exception, Our industry however has been relatively stow to grasp the new technology, most of which can be attributed to two main factors, computer power and cost! Only this last decade have we more readily been utilising the phased array technology to expedite inspection solutions previously unobiainable. Thanks to our medical colleges and some large industrial organisations we are now able to obtain at reasonable cost detection capabilities and imaging solutions that may revolutionise the way we perform NDT. This of course sounds great but is this real or just the fantasy of a brilliant marketing machine? This paper is aimed at giving a balanced assessment of phased array technology from a non-sales bias and pointing out some typical misconceptions that some of our NDT fraternity circulate, ‘The paper will guide you through some of the myths, misnomers and terminology that surround the ‘black art’ of ultrasonic phased array technology. Module 1 rav 1 September 2006 Page 1 of 15 Lavender international HOY Phased Wray Training Course 07/11/2006 2, One scan sees all Firstly one myth that unfortunately has been used by some individuals is that use of one swept angle (other wise known as seeforial) scan ranging though a wide range of angles can detect all defects in a component or weldment in one single line pass from either side of the joint! This simply is not true! Phased array technology is not changing the laws of physics but merely exploiting some laws required to manipulate the ultrasonic beam, Basic principles of angle of inci angle of reflection are of paramount importance when producing an inspection technique where fixed angle scans or linear electronic scans are concemed. Fixed angle electronic linear scans should be used to interrogate fusion faces at normal incidence planes to the bevel faces. Subsequently this can be complemented by at least one or two other angle beams, This does not mean that you cannot obtain tip diffraction as a mode of detection when striking a flaw obliquely. However let us merely remind ourselves that diffraction responses are very weak in comparison to reflected echocs and therefore require significant increases in amplification, Unfortunately high levels of gain give problems in that reflected responses are well in excess of full screcn height and saturate most digitised computer processors. This means in essence that analysis of saturated indications will result in over sizing the indication and offline analysis tools cannot compensate for saturated signal amplitudes. Fig 1: Use of two swept angle seans detects only one defect In order to demonstrate this basie concept a simple experiment was performed, A single swept angle scan ranging from 45 t070 degrees was collected as a line scan at fixed offset parallel to the weld (fig 1). Data was viewed carefully using offline analysis software and only one major flaw was observed. The weld was re-inspected using fixed angle electronic linear scan translating element excitation along a 64 clement array to produce a 60 degree refracted wave front in the test item. This beam was incident perpendicular to the weld fusion face resulting in detection of flaws previously unscen with the sectorial swept angle scan (fig 2). Module 1 rev 1 Soptember 2006 Page 2 of 15 wendar ‘nternationsl NDE Phased Attay Fraining Course 07/11/2006 ‘Two linear fixed angle scans detect both detects Use of offline analysis software enabled more than one scan to be superimposed over each other (merged) with a weld outline diagram superimposed on top (overlaid) thus demonstrating the detection and imaging capability of suitably deployed phased array technology. Inspection sensitivity was established at 3mm diameter side drilled hole response set fo 80% full sereen height plus 6dB. In order to have obtained tip difitaction responses from the flaw missed during the swept angle scans the gain setting would have needed to be inereased by approximately18dB resulting in gross saturation of the other flaw responses. A technique to compensate for this is to run more than one set of focal laws typified by simultaneously collecting data from swept angle and linear angle scans in one pass along the weld, Optimum results are obtained when the linear scan angle is selected to approach fusion faces at a perpendicular approach thus reflecting all specular responses back to the array transducer. 3. Focussed beams Another misconception is that just because phased arrays enable specific focussing the operator therefore has to focus the beam, This cannot be further form the truth and carries significant rske{yhen incorrect focussing is applied! that major defects can aud Frequently ar mised! ine has to remember that for the most the last fifty years of ultrasonic testing revolved predominantly around utilising single crystal unfocussed transducers. Only specific applications such as near surface interrogation or precise sizing requirements dictated application of dual element transducers which inherently ate all focussed. And even the simple application of these many people still get wrong! Imagine using a digital camera and seleeting the macro function, this will enable the ability to scrutinise in great detail objects very close to the lens. However it would not be possible using the macro facility to view images of distant landscapes because everything would be out of focus and extremely blurred. This is very similar to applying focusing ultrasonic beams including the use of phased arrays. Module 1 rev 1 September 2006 Page 3 of 15 ayender international ND Phased Aday Training Course: 07/11/2006 {x | Target hote ye | clearly detected |” © : i ae ee Fig 3: 3mm side drilled hole clearly resolved Figure 3 shows how focussing at a target 10mm deep into a 30mm thick ferritic steel sample produces a highly resolved image. The second illustration (figure 4) shows how this intense focussing using a 32 element excitation resulted in completely missing the 3.2mm diameter hole located at a 20mm depth in the material. This is illustrated in the simulated beam profile showing how the ultrasonic intensity is localised due to focussing at a defined depth in the test material. Such a misuse of phased array equipment focussing is caused by generating focussed depths with a large active aperture of excited elements that produced a very tight depth of field with localised ultrasonic sensitivity. completely missed Fig 4: 31mm side drilled hole not detectable The solution is simple! Scanning to detect defects should be done with the beam focussed at the maximum test range or further and in this case using fewer active elements. Module 1 rev 1 September 2006 Page 4 of 15 07/11/2006 Lavender fnternational NDY Phased Avay Cralning Comes \ Acoustic pressure ye more evenly Hole at an

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