Total Focusing (TFM) for the Ultrasonic Testing (UT) of drawn arc stud welding

Abstract

This article describes the results obtained applying ultrasonic testing (UT) with phased arrays (PAUT) using full matrix capture (FMC) and total focusing method (TFM) for the inspection of drawn arc stud welding. Weld studs are usually directly applied on the top of a metal slab using a dedicated welding gun. This procedure involves heating the end tip of the stud using a strong electric arc created by a positive electric current. This welding procedure shall comply to various normative requirements, but on the other side there is not a clear reference to any applicable non-destructive method (NDT) to control the quality of the weld seam. Shear connectors are normally used in concrete/steel composite structures to allow the combined action of the concrete slab and the steel profile thereby increasing both the stiffness and strength of the structure. Flaws in this connection would result in severe bending and cracking of the entire structure. This article proposes an advanced UT method to inspect the weld between shear connections and metal slab using FMC. Data acquired with FMC are processed by TFM algorithms improving image resolution, signal to noise performances and allowing 3D data imaging. The combined use of PAUT searching units and signal processing with high resolution measurement shows a great potential in industrial NDT applied to civil engineering, resulting in a more effective, reliable, and faster inspection methodology than many other methods, such as radiographic testing (RT).