Phased Array Ultrasonic Probe Research Articles

Automatic PAUT crack detection and depth identification framework based on inspection robot and deep learning method

Orthotropic steel bridge decks (OSD) are widely acclaimed for their lightweight, high load-carrying capacity, and adaptability, making them a popular choice in steel structure bridges. However, the complex nature of their structure makes them susceptible to fatigue cracking, posing significant safety concerns. To address the issues above, this study employs a robot equipped with an ultrasonic phased array probe to automate the detection of internal cracks within Orthotropic Steel Decks (OSD). A Deep Convolutional Generative Adversarial Network (DCGAN) is utilized to augment the training dataset of Phased Array Ultrasonic Testing (PAUT) images. The YOLO series algorithms are applied and compared for crack localization, with YOLO v7-tiny exhibiting the highest accuracy and speed. Integrating attention mechanisms into the YOLO v7-tiny algorithm to facilliate rapid and high-precision crack detection. Analyzing the echo region with an echo intensity bar enabled the identification of crack depth, with an identification error within 5%.

3D Hybrid modeling for the ultrasonic phased array inspection of porosity in heavy plates: Simulation and experimental validation

Quantitative NDT modeling and simulation tools are important in design and fabrication of ultrasonic phased array probes with optimum characteristics and reduce the number of experimental efforts and development time. In order to achieve high accuracy (Amplitude deviation < 1 dB) with a low computational time in the simulation, the modeling tools require not only the high-frequency approximation of the ultrasonic wave propagation but also the high-precision electro-acoustic coupling model. This paper describes a computationally efficient 3D time-dependent hybrid model for the simulation of ultrasonic phased array inspection of porosity in heavy plates. This method combines the results of both 3D finite element analysis (PZFLex-FEA) and the semi-analytical ultrasonic simulation “Ray-Tracing”. As a first step, we demonstrate the FEA modeling of an ultrasonic phased array probe, which includes the full 1-3 piezocomposite design with the arrangement of array elements, conducting electrodes, multi-phase backing material, acoustical matching layer and electrical circuit of a 50 Ohm coaxial cable. In the current FEA simulation, we considered the acoustical and electrical cross-talk between the adjacent elements of an ultrasonic array sensor. In the second step, the FEA-simulated ultrasonic pulse-echo signal and its frequency spectrum of an array element in the farfield region are further used as the reference input signal in the CIVA-UT software to simulate the imaging of porosity in heavy plates, quantitatively. The design of the 3D wedge-geometry of the application specific array sensor is modeled and optimized using the CIVA raytracing and multi-phase backing models. The real excitation pulse of the industrial ultrasonic testing equipment “ROMIS (ROSEN Modular Inspection System)” is also included in the simulation to achieve high accuracy in the current hybrid modeling. The dependency of the detectability of the porosity on the frequency of the array sensor and the active element group so-called “Virtual Probe” are quantitatively analyzed. Finally, the 3D hybrid model simulated Time Corrected Gain (TCG) curves of the porosity like defects in the reference steel plates are compared with the real experiments and a good quantitative agreement is achieved.

Flow Front Monitoring in High-Pressure Resin Transfer Molding Using Phased Array Ultrasonic Testing to Optimize Mold Filling Simulations.

During the production of fiber-reinforced plastics using resin transfer molding (RTM), various characteristic defects and flaws can occur, such as fiber displacement and fiber waviness. Particularly in high-pressure RTM (HP-RTM), fiber misalignments are generated during infiltration by local peaks in the flow rate, leading to a significant reduction in the mechanical properties. To minimize or avoid this effect, the manufacturing process must be well controlled. Simulative approaches allow for a basic design of the mold filling process; however, due to the high number of influencing variables, the real behavior cannot be exactly reproduced. The focus of this work is on flow front monitoring in an HP-RTM mold using phased array ultrasonic testing. By using an established non-destructive testing instrument, the effort required for integration into the manufacturing process can be significantly reduced. For this purpose, investigations were carried out during the production of test specimens composed of glass fiber-reinforced polyurethane resin. Specifically, a phased array ultrasonic probe was used to record individual line scans over the form filling time. Taking into account the specifications of the probe used in these experiments, an area of 48.45 mm was inspected with a spatial resolution of 0.85 mm derived from the pitch. Due to the aperture that had to be applied to improve the signal-to-noise ratio, an averaging of the measured values similar to a moving average over a window of 6.8 mm had to be considered. By varying the orientation of the phased array probe and therefore the orientation of the line scans, it is possible to determine the local flow velocities of the matrix system during mold filling. Furthermore, process simulation studies with locally varying fiber volume contents were carried out. Despite the locally limited measuring range of the monitoring method presented, conclusions about the global flow behavior in a large mold can be drawn by comparing the experimentally determined results with the process simulation studies. The agreement between the measurement and simulation was thus improved by around 70%.

Normal calculation of artillery cradle before the robot arm assisted ultrasonic phased array automatic detection

This study is interested in the normal calculation of artillery cradle. When the beam axis of ultrasonic phased array probe cannot detect the workpiece surface vertically, the detection result is usually inaccurate. Thus, in order to determine the normal of the surface to be detected, a method based on visual point cloud to calculate the normal of artillery cradle is proposed in this paper. The proposed method solves two key problems. One is to sparse the point cloud while preserving the tiny information on the surface. A mesh division method along the uv direction is proposed. The disordered point cloud data in 3D space are connected into regular polygon meshes. While establishing the local relationship of point cloud data, it also maintains the overall integrity of point cloud data. The other is to calculate the normal vector of the point cloud. The local plane fitting method based on the least square method calculates the normal at a point of the point cloud. At this time, the calculated normal are nondirective. When there is no abrupt curvature change near the calculated point cloud, the direction of the normal is determined based on the same slope at two adjacent points. The calculated point cloud normal vector is compared with the actual normal vector of the mathematical model. The maximum deviation between the theoretical value and the actual value of the normal vector is 0.465°, and the average deviation is 0.302°. The experimental results show that the proposed method can be used to detect the actual normal of artillery cradle.

Fibre volume fraction screening of pultruded carbon fibre reinforced polymer panels based on analysis of anisotropic ultrasonic sound velocity

Composites have become the material of choice in a wide range of manufacturing applications. Whilst ultrasound inspection is a well-established non-destructive testing (NDT) technique, the application to composite imaging presents significant challenges stemming from the inherent anisotropy of the material. The fibre-volume fraction (FVF) of a composite plays a key role in determining the final strength and stiffness of a part as well as influencing the ultrasonic bulk velocity.In this work, a novel FVF determination technique, based on the angular dependence of the sound velocity with respect to the composite fibre direction, is presented. This method is introduced and validated by inspection of pultruded carbon fibre reinforced polymer (CFRP) panels commonly used in the manufacture of high-power wind turbine blades. Full matrix capture (FMC) data acquired from a phased array (PA) ultrasonic probe is used to generate calibration data for samples ranging in FVF from 60.5% to 69.9%. Sample velocity, as a function of propagation angle, is used to estimate the FVF of samples and ensure they fall within the desired range. Experimental results show values of 61.1, 66.1 and 68.3%, comparing favourably to the known values of 60.5, 66.3 and 69.9% respectively.The work offers significant potential in terms of factory implementation of NDT procedures to ensure final parts satisfy standards and certification by ensuring any FVF inconsistencies are identified as early in the manufacturing process as possible.

Towards using convolutional neural network to locate, identify and size defects in phased array ultrasonic testing

Machine learning algorithms are widely used in image recognition. In Phased Array Ultrasonic Testing (PAUT), images are typically formed through constructive and destructive superpositions of signals backscattered from flaws or geometric features. However, all PAUT data acquisition schemes require several emissions and the duration of the acquisition may be too slow in high-speed manufacturing. In this study, the Faster R-CNN was used to identify, locate and size flat bottom holes (FBH) and side-drilled holes (SDH) in an immersed test specimen using a single plane wave insonification. The training was performed on segmented and classified data generated using GPU-accelerated finite element simulations. SDH and FBH of different diameters, depths and lateral positions were included in the training set. The thickness of the test specimen was also variable. An ultrasonic phased array probe of 64 elements was simulated. All elements of the phased array probe were fired at the same time and the time traces from each element were recorded. The individual time traces were concatenated to form a matrix, which was then used in the training. This inspection scenario enables fast acquisition of data at the expense of poor lateral resolution in the resulting image. The trained neural network was initially tested using finite element simulations. Results were assessed in terms of the intersection of the union (IoU) between the ground truth geometry and the predicted geometry. With the simulated cases, the thickness of the test specimen was detected in all cases. When using a 40% IoU threshold, the detection rate of the FBH was 87% while only 20% for the SDH. The smallest detected FBH had a 0.56 wavelength depth and a lateral extent of 1.04 wavelength. Drawing a box using the −6dB drop method around the FBH always led to an IoU under 15%. On average, the lateral extent of the FBH using the −6dB method was three times larger than the diameter predicted by the proposed method. Then, the training was continued with a small augmented dataset of experiments (equivalent to 3% of the simulated dataset). In experiments, the results show that the test specimen was always correctly identified. When using a 40% IoU threshold the experimental detection rate of the FBH was 70%. The smallest detected defect in experiments had a depth of 2 wavelengths.

Evaluation of material degradation using phased array ultrasonic technique with full matrix capture

This paper presents a new approach based on phased array ultrasonic technique (PAUT) with full matrix capture (FMC) to effectively measure acoustic properties such as ultrasonic wave velocity and attenuation coefficient and to evaluate material degradation. This paper also proposes the use of PAUT with FMC, to simultaneously generate and detect ultrasonic waves such as longitudinal, shear, and Rayleigh waves in the material. A theoretical model is developed to derive the analytical solution of ultrasonic waves induced in the material by an ultrasonic phased array probe. Based on the theoretical prediction, experiments are carried out on AISI 316L stainless steel specimen of 3 mm thickness, and a 2D finite element model is built to verify the generation and detection of these waves. Furthermore, measurements of acoustic properties are carried out on the specimen using the proposed approach as well as the conventional ultrasonic testing (CUT) technique and their sensitivities are compared. The measurements of time-of-flight and back-wall echo amplitude are more accurate with the proposed approach than the CUT technique, which makes the former technique better than the latter for the evaluation of material degradation. Finally, experiments are performed on AISI 316L specimen degraded with different levels of tensile stress to verify the capability of PAUT with FMC. The results show that the velocities and attenuation coefficient increase with an increase in tensile stress until material fracture. This phenomenon is interpreted as resulting from microstructural changes such as dislocations during material degradation. From the experimental results, it is proposed that PAUT with FMC can potentially be used to evaluate early-stage materials degradation.

Flexible 위상배열초음파 탐촉자를 이용한 불균일 표면 시편의 Total Focusing Method 영상화 연구

접촉식 탐촉자를 사용하는 일반적인 초음파검사에서 검사체에 굴곡이 있거나 불균일한 표면 형상을 가지고 있는 경우 탐촉자와 검사체 사이에 틈새가 발생한다. 탐촉자와 검사체 사이의 틈새에 의한 불균일한 접촉 상태로 인해 초음파 빔이 왜곡되고 감도가 감소되며 결함검출 능력이 저하되는 문제점이 발생하게 된다. 이번 연구에서는 이러한 문제를 해결하기 위해 2차원 flexible 위상배열초음파 탐촉자를 이용하여 표면 형상이 반영된 Total Focusing Method(TFM) 이미지를 합성하는 기법을 개발하였다. 탐촉자 내부에 장착된 변위 센서를 이용하여 표면 형상을 측정하였고, Half Matrix Capture(HMC) 기법으로 수집된 데이터와 측정된 표면 형상 데이터의 후처리를 통해 표면 형상 반영 TFM 이미지를 합성하였다. 일반 위상배열초음파 검사와 비교하였을 때 표면 형상 반영 TFM 기법이 굴곡을 가진 표면에서 결과 이미지의 감도와 선명도가 향상되는 것을 확인할 수 있었다.

Correction of B-scan distortion for optimum ultrasonic imaging of backwalls with complex geometries

Ultrasound undergoes refraction and reflection at interfaces between media of different acoustic refractive indices. The most common ultrasonic method (pulse-echo) monitors the reflected energy to infer the presence of flaws, whereas the lower amplitude of refracted signals is ignored. When the reflector is orientated normally with respect to the ultrasonic beam, the received echo signal shows the maximum amplitude. The pulse-echo method also relies on monitoring the amplitude of the backwall echo to identify or confirm the presence of defects. This works well for parts with constant thickness and with planar backwalls. Unfortunately, parts with complex backwalls are common to many industrial sectors. For example, applications such as aerospace structures often require parts with complex shapes. Assessing such parts reliably is not trivial and can cause severe downtime in the aerospace manufacturing processes or during in-service inspections. This work aims to improve the ultrasonic inspectability of parts with complex backwalls, through sending ultrasonic beams from the frontwall side. Ultrasonic phased array probes and state-of-the-art instrumentation allow ultrasonic energy to be sent into a part at wide ranges of focusing depths and steering angles. This allows for tracking of the backwall profile, thus hitting it normally and maximising the amplitude of the reflected echo at any point. However, this work has shown that a cross-sectional scan resulting from multiple ultrasonic beams, which are sent at variable incidence angles, can present significant geometrical distortion and cannot be of much use for accurate defect visualisation and sizing. This paper introduces a generalised algorithm developed to remove geometric distortions and the effect that variable refraction coefficients have on the transmitted and received amplitudes. The algorithm was validated through CIVA simulations for two example parts with complex backwalls, considering isotropic materials.

Measurement of Acoustic Basic Parameters of Polyethylene Pipe

The acoustic characteristics testing, research and analysis on steel reinforced polyethylene composite pipes is conducted in this paper to provide strong basis for design of suitable phased array ultrasonic probe. The acoustic characteristic parameters are tested first, and the sound velocity is measured through twice reflected echo from the bottom surface. At the same time, the variation of the longitudinal wave velocity of the PE100 material under different temperature conditions is measured. The values of critical angle and acoustic impedance of the PE100 material are calculated by measuring the sound velocity. Then, the attenuation coefficient of the probes with different frequencies in the PE100 material is measured by the simulation calculation method and the actual measurement method, and the measurement attenuation coefficient of each frequency is further calculated. The results show that: (1) the sound velocity of PE100 material is 2,340m/s and the attenuation coefficient is 0.3dB/mm; (2) phased array ultrasonic inspection method can be used to make vertical incidence of longitudinal wave and avoid non-existence of the second critical angle; (3) 2MHz is the best frequency to inspect the body of steel reinforced polyethylene (PE) pipe.

An ultrasonic guided wave excitation method at constant phase velocity using ultrasonic phased array probes

High-order ultrasonic guided wave modes have recently been attracting interest in a variety of nondestructive testing applications, ranging from thickness gauging to bond characterization. Accurate control of the transmitted ultrasonic guided wave mode is paramount when working at frequencies above the cutoff of the first high-order mode. The high number of modes available makes this range of frequency-thickness products difficult to exploit in practice. Many papers and textbooks have showed that multielement probes, such as comb transducers, are able to target a specific wavelength which depends on the elementary pitch. This method can be enhanced by adding an elementary delay law. However, this method of excitation has major drawbacks as the areas of excitation in a dispersion curves depends on the frequency and the technique is not unidirectional. This paper demonstrate that a conventional phased array transducer for which the elementary pitch is small relative to the targeted wavelength is able to excite high order guided wave modes at a constant phase velocity (independently of the frequency). The aim is to excite different regions of the dispersion curves by controlling the input signal bandwidth and the angle of the generated beam. The paper describes the theoretical background and details the differences between the various methods of excitation of ultrasonic guided waves, especially with the comb transducer method. Finite element simulations are presented to verify the analytical predictions and quantify the unidirectional and diffraction properties of the transmitted beam. Experiments conducted on an aluminum plate show striking agreement with finite element simulations, including the possibility of exciting a single mode in a narrow region at high frequency-thickness products. Experiments conducted on a CFRP plate demonstrates that the method can be adapted to other materials.

Full Matrix Capture를 이용한 위상배열초음파 탐촉자 비활성 소자 영향 분석 방법

Full Matrix Capture를 이용한 위상배열초음파 탐촉자 비활성 소자 영향 분석 방법

Wavenumber Imaging of Near-Surface Defects in Rails using Green's Function Reconstruction of Ultrasonic Diffuse Fields.

Wavenumber imaging with Green’s function reconstruction of ultrasonic diffuse fields is used to realize fast imaging of near-surface defects in rails. Ultrasonic phased array has been widely used in industries because of its high sensitivity and strong flexibility. However, the directly measured signal is always complicated by noise caused by physical limitations of the acquisition system. To overcome this problem, the cross-correlations of the diffuse field signals captured by the probe are performed to reconstruct the Green’s function. These reconstructed signals can restore the early time information from the noise. Experiments were conducted on rails with near-surface defects. The results confirm the effectiveness of the cross-correlation method to reconstruct the Green’s function for the detection of near-surface defects. Different kinds of ultrasonic phased array probes were applied to collect experimental data on the surface of the rails. The Green’s function recovery is related to the number of phased array elements and the excitation frequency. In addition, the duration and starting time of the time-windowed diffuse signals were explored in order to achieve high-quality defect images.

Design and optimisation of a phased array transducer for ultrasonic inspection of large forged steel ingots

Large steel forgings are used in numerous industries. This paper investigates the possibility of adapting ultrasonic phased array testing to the inspection of forged steel blocks with dimensions of up to 1000 mm in every direction. The paper looks at two objectives in order to provide the best inspection performance: (1) the ultrasonic phased array probe optimisation and (2) the ultrasonic wave transmission sequence in a total focusing method imaging scenario. The CIVA software suite was used to optimise the phased array probe element count and width in a full matrix capture configuration. Based on the simulation results, a 32-element transducer was then built and tested in a 777 mm forged steel block using full matrix capture, plane wave and Hadamard transmission sequences. It was observed that plane wave and Hadamard sequences transmit significantly more energy inside the test sample because the elements are emitting simultaneously, therefore leading to an improved signal-to-noise ratio. However, the horizontal resolution was a strong limitation for every transmission sequence, especially for plane waves, because of the limited range of angles available in a block of large dimensions. The Hadamard transmission sequence was shown to represent the best compromise in terms of defect reflected amplitude, signal-to-noise ratio and resolution. The experimental results were compared with simulations and were found to be in very good agreement.

가압기 노즐 이종금속 용접부의 구조적 오버레이 용접부에 대한 위상배열 초음파기법의 현장 적용

Abstract Weld overlay was first used in power plants in the US in the early 1980s as an interim method of repairing the welds of flawed piping joints. Weld overlaid piping joints in nuclear power plants must be examined periodically using ultrasonic examination technology. Portable phased array ultrasonic technology has recently become available. Currently, the application of preemptive weld overlays as a mitigation technique and/as a method to improve the examination surface condition for more complex configurations is becoming more common. These complex geometries may require several focused conventional transducers for adequate inspection of the overlay, the original weld, and the base material. Alternatively, Phased array ultrasonic probes can be used to generate several inspection angles simultaneously at various focal depths to provide better and faster coverage than that possible by conventional methods. Thus, this technology can increase the speed of examinations, save costs, and reduce radiation exposure. In this paper, we explain the general sequence of the inspection of weld overlay and the results of signal analysis for some PAUT (phased array ultrasonic testing) signals detected in on-site inspections.

Long Range Detection of Defects in Composite Plates Using Lamb Waves Generated and Detected by Ultrasonic Phased Array Probes

This article presents a technique for the generation and detection of Lamb waves guided along large plate-like structures made from various types of materials (metal, polymer, fibre-reinforced composite, etc.). A multi-element matrix ultrasonic probe is driven using the well-known phased array principle, for launching and detecting pure Lamb modes in/from specific directions along the plate, which are arbitrary for isotropic materials and limited to specific directions for anisotropic materials, e.g. principal directions or directions for which both phase and group velocities are collinear. The probe is gel-coupled to the tested specimen and allows quick inspection of large area from its fixed position, even of zones with limited access. The technique, which takes into account the frequency dispersive effects, is different than SHM-like (Structural Health Monitoring) inspection, since all transmitting or receiving elements are grouped together in a localized area defined by the active surface of the probe, and not permanently attached to the tested structure. The use of a multi-element probe, for long range Lamb waves-based inspection, is also distinctive from that usually performed, which consists of very local inspection of a material by steering the ultrasonic beam below and nearby the probe. A prototype is presented, as well as measurements of its performances in terms of modal selectivity and directivity. Finally the detection and localisation of a through-thickness hole in a large aluminium plate, of a delamination-like defect in a carbon epoxy composite plate and of an impact damage on a stiffened composite curved plate are shown.

Correlation-based imaging technique using ultrasonic transmit–receive array for Non-Destructive Evaluation

This paper describes a novel array post-processing method for Non-Destructive Evaluation (NDE) using phased-array ultrasonic probes. The approach uses the capture and processing of the full matrix of all transmit–receive time-domain signals from a transducer array as in the case of the Total Focusing Method (TFM), referred as the standard of imaging algorithms. The proposed technique is based on correlation of measured signals with theoretical propagated signals computed over a given grid of points. In that case, real-time imaging can be simply implemented using discrete signal product. The advantage of the present technique is to take into account transducer directivity, dynamics and complex propagation patterns, such that the number of required array elements for a given imaging performance can be greatly reduced. Numerical and experimental application to contact inspection of isotropic structure is presented and real-time implementation issues are discussed.

횡파 위상배열 초음파 탐촉자 설계 및 성능 평가

일반적으로 위상배열 초음파검사 기법을 이용한 배관 용접부검사에서는 높은 검사 각도를 효과적으로 발생하기 위하여 ��지를 사용하게 된다. 그러나 용접부 또는 접근이 제한된 부위에 대한 검사는 위상 배열 초음파 탐촉자에 ��지를 부착하게 되면 ��지의 전단 길이로 인하여 검사체적을 포함하지 못하는 등의 문제점이 발생하게 된다. 따라서 ��지를 사용하지 않고 높은 검사 각도를 발생할 수 있는 횡파 위상배열 초음파 탐촉자를 적용해야 할 필요성이 있다. 본 연구에서는 굴절각도가 높은 횡파를 발생할 수 있는 위상배열 초음파 탐촉자를 설계하고 제작하여 다양한 깊이의 EDM 노치가 가공된 시험편에서 결함이 정확하게 검출되고 평가될 수 있는 지를 확인하였다. 결과적으로 본 연구에서 설계된 횡파 위상배열 초음파 탐촉자는 다양한 깊이의 결함을 검출하고 신뢰성 있는 정밀도를 나타내었으므로 향후 접근제한이 예상되는 발전설비 구조물의 검사에 적용된다면 효과적인 검사 결과를 보여줄 것으로 기대된다. Typically, a wedge is involved to generate effectively high inspection angle in pipe weld inspection using phased array ultrasonic technique. But the usage of this wedge for weld or access limited area can cause coverage limitation for the examination volume because of the wedge front length. Therefore, the shear wave phased array probe which can generate high inspection angle without wedge is essentially necessary. In this paper, the shear wave phased array ultrasonic probe which can generate high inspection angle designed by modeling and manufactured from the modelling result. And this shear wave probe tested whether it can detect and sizing for EDM test block that contains various depth. As results, the experimental results show that the designed shear wave phased array probe can detect and size with reliable accuracy. Therefore if this phased array probe apply in field inspection, it is expected that it show more reliable inspection result for plant structure having access limitation.

Phased array ultrasonic NDT system for tubes and pipes

One or more phased array ultrasonic probes in the shape of conical section arcs, or an entire conical section ring, emit beams at a fixed incident angle with respect to the outer surface of a tube or pipe under inspection. At any given moment, these beams strike the tube at a single small entry zone from number of different directions. After being refracted at the inspection angle corresponding to the fixed angle of incidence, defects having longitudinal, transverse and oblique orientations are detected in the three-dimensional volume of the tube wall. The number of entry zones required for complete coverage of the outer surface of the tube is a function of the size of the tube, the speed at which it passes through the inspection station and the rate of rotation of the tube.

Cross-coupling Properties of Ultrasonic Phased Array Probe

The frequency dependence of cross-coupling is described for a phased array probe developed for sector-scanning endoscopic ultrasonic diagnosis. The sweep frequency range is set from 0.5 MHz to 10.5 MHz for a 48-element phased array transducer with a center frequency of 5 MHz. Cross-coupling measurements were carried out on various piezoelectric elements at different positions in the probe. The relationship between the cross-coupling and the position of piezoelectric elements as determined by the measurements shows good agreement with the results of static-mode finite-element method (FEM) calculations.