Achievement of

Dynaray and UltraVision 3

2010
www.zetec.com

Configuration : up to 256 phased array beam

forming channels, in Tomoscan III housing

Up to 4 Hypertronics connectors, compatible with

existing probes

16 conventional UT channels available through

Lemo00 adapter

Modular concept, allowing for reduced

configurations and upgrading :

Non-multiplexed :

64/64PR
128/128PR
256/256PR

Multiplexed:

64/256PR

- Specification

4096 Focal law

16

: 20 MB/s

Digitization frequency: up to 100 MHz

(Bandwidth)

(Excitation pulse) :

0.20 ~ 25 MHz (-6 dB)

200 V (on 50 load)

(Pulse width) : 1,000 ns

A- (A-scan length) : 256,000 points

& (Linear and Logarithmic mode)

DDF(Dynamic Depth Focusing)

(Automatic self-diagnostics)
3

UltraVision 3 Key Features

User Interface similar to UltraVision 1.1
easy transition for experienced operators

Full 3D capability for inspection development, data visualization

and analysis
Native support of complex geometries
Large data files (up to 20 GBytes)
Support for position dependant focal law groups
Controls

(other hardware scheduled in 2010)

Open architecture, using UltraVision SDK (scheduled)

UltraVision 3 Full 3D Capability

UltraVision 3 offers the necessary tools for
phased array beam forming and 3D UT
data visualisation in complex components

3 .

UltraVision 3 Full 3D Capability

3D User Interface of Advanced PA Calculator

fully integrated in UltraVision 3
6

UltraVision 3 Full 3D Capability

Selection of pre-defined weld configurations,

with operator adjustable parameters
7

UltraVision 3 Full 3D Capability

Selection of pre-defined complex components,

with operator adjustable parameters
8

UltraVision 3 Full 3D Capability

Calculation and visualization of focal law groups

in pre-defined complex geometries
9

UltraVision 3 Full 3D Capability

Selection of custom complex geometry components,

imported as CAD files (*.SAT format)
10

UltraVision 3 Full 3D Capability

Calculation of optimized focal law groups for flexible array

in custom components with complex geometry,
11

UltraVision 3 Full 3D Capability

Acoustic beam simulation for nominal (shown) and optimized focal laws,
in custom components with complex geometry
12

UltraVision 3 Full 3D Capability

Top View

Side View

End View

Classic visualisation of UT and phased array data with projection views

13

UltraVision 3 Full 3D Capability

3D UT visualisation of phased array UT data in pre-defined

weld configurations (shown) and complex geometries (scheduled)
14

UltraVision 3 Full 3D Capability

crack

weld root

3D UT visualisation of phased array UT data in pre-defined

weld configurations (shown) and complex geometries (scheduled)
15

- Amplitude Resolution
A-scan signals from phased array probes with at least 16 elements
are recorded with 16 A-scan
16-bit amplitude resolution = 65536 (216) amplitude levels
(Comparison: Z-Scan PA has 10-bit amplitude resolution = 1024 (210) amplitude levels)

UltraVision software visualizes

8-bit amplitude resolution = 256 (28) amplitude levels
8
Up to 48 dB softgain (8 x 6 dB) can be used without affecting UT
signal quality 48dB
(Comparison: Z-Scan PA allows for up to 12 dB softgain)

No more issues with sizing of saturated indications,

no more time-consuming rescans required



16

- Amplitude Resolution
24
dB
Gain00
dB
Gain
dB
24
Softgain48
0 dB
Softgain

At 48 dB Softgain, NO DIGITIZATION EFFECTS

DYNARAY (16 bits amplitude resolution)
At 24 dB Softgain, NO DISTORTION
17

- Amplitude Resolution
Gain
Gain 024dB
dB
24
dB
Softgain
Softgain 0
0 dB
dB

Z-Scan PA (10 bits amplitude resolution)

At 24 dB Softgain, the signal is considerably distorted,
and digitization effects are visible
18

- Beam Forming
256 simultaneously active beam forming channels,
allow for efficient use of multiple large aperture 1D
linear array probes, preferably in combination with
DDF (Dynamic Depth Focusing)

256
1 DDF
.

19

Large 1D Linear Arrays

Full thickness examination of heavy-wall steel
components or welds: T = 300 mm

Example:
5 MHz, 1D linear array probe
Sectorial scanning from -20 to 20 LW
Comparison of 32-element aperture (24 x 12 mm)
and 128-element aperture (96 x 12 mm)

20

Large 1D Linear Arrays - Simulations

Beam dimension:
0
50
100
150
200
250

Focal
Depth

Dprim
(mm)

Dsec
(mm)

50 mm

2.0

4.0

100 mm

4.0

8.0

150 mm

6.0

12.0

200 mm

8.0

16.0

250 mm

10.0

20.0

300 mm

12.0

22.0

300
350
400

Probe 5 MHz, active aperture 24 x 12 mm,

focusing from 50 mm to 300 mm depth
21

Large 1D Linear Arrays - Simulations

Beam dimension:
0
50
100
150
200
250

Focal
Depth

Dprim
(mm)

Dsec
(mm)

50 mm

1.0

4.0

100 mm

1.0

8.0

150 mm

1.0

12.0

200 mm

2.0

16.0

250 mm

2.0

20.0

300 mm

2.0

24.0

300
350
400

Probe 5 MHz, active aperture 96 x 12 mm,

focusing from 50 mm to 300 mm depth
22

Large 1D Linear Arrays - Experiment

1D Linear array, 5 MHz, 128 elements, total surface 96 x 10 mm
1 , 5 MHz, 128, 96 x 10 mm

500mm
3mm, 50~400mm

SDH = 3 mm,
at 410 mm depth

128 active elements

32 active elements
23

Large 1D Linear Arrays - Conclusions

Large aperture 1D linear array allows for enhanced
focusing at long sound paths: better lateral resolution,
better SNR


DDF is very useful, to combine excellent detection
capability and inspection speed
DDF

24

- Beam Forming
256 simultaneously active beam forming channels,
allow for fully exploiting the 2D matrix array
technology
256
2
.

25

2D Matrix Arrays - Principles

In primary and secondary planes, beam
steering, focusing and linear scanning can be
performed electronically

, ,

Primary Plane

Secondary Plane

Primary steering capability : refracted angle

:
Secondary steering capability : skew angle
:

The 2-plane steering capability can be used to vary refracted angle and skew angle
of the ultrasonic beam simultaneously
,
In practice, between 8 and 16 elements are required in each plane to combine
adequate steering capability and sufficient active aperture (acoustic energy)
8~16
().

26

2D Matrix Arrays
Examination of components containing cracks at various orientations

Example:( / )
2D matrix array, 5 MHz, active aperture 20 x 15 mm
Wedge for nominal 45LW
Sectorial scanning from 20 to 60 LW
Skewing from nominal - -45 to nominal + 45
Comparison of probes with 6 x 5 and 18 x 14 elements
5MHz 20 x 15mm 6 x 5

18 x 14

27

2D Matrix Arrays Simulations

60LW
40LW
20LW
skew30
45
0
15
skew

2D array, 5 MHz, 6 x 5 elements

2D array, 5 MHz, 18 x 14 elements

28

2D Matrix Arrays Experiment

2D matrix array, 5 MHz, 18 x 14 elements,
active surface 20 x 15 mm,
focal laws 20 to 60LW at 3 skew angles
Probe oriented to notch :
tip & corner detected by nominal skew
Probe mechanically skewed 45 :
edge of specimen detected by -45 skew
tip & corner detected by +45 skew

Aluminium test specimen, wall thickness 50 mm

Far-surface notch (h = 10 mm)
Skew -45

Nominal skew

Skew +45
29

2D Matrix Arrays Weld Inspection

Examination of CS and SS piping welds (T = 50 mm), in lieu of RT, for
both circumferential and axial flaws
CS/SS RT ( 50mm)
Proposed inspection technique: ( )
2.25 MHz, dual 2D matrix array probe, 2 x 63(7 x9) elements
Sectorial scanning from 40 to 70 SW
Skewing from nominal - 60 to nominal + 60
Multiple line scan using two probes, on either side of the weld
,

30

2D Matrix Arrays Weld Inspection

Circumferential flaws, nominal beam orientation

R: 9 x 5

T: 9 x 5

Dual array (separate T/R)

Active aperture: 2 x (9 x 5) elements.
Refracted angle : 40 to 70 SW, resolution 1
Skew angle : nominal (90)
31 focal laws (beams)

50
70
40 SW
60

Top View

Side View
31

2D Matrix Arrays Weld Inspection

Circumferential flaws, optional skewed beams

T/R: 9 x 7 T/R: 9 x 7

Single array (T/R)

Active aperture: 9 x 7 elements
Refracted angle : 40 to 70 SW, resolution 1
Skew angle : nominal 20 (70, 110)
62 focal laws (beams)
50 SW
Skew
+20
Skew
20

Top View

Side View
32

2D Matrix Arrays Weld Inspection

Axial flaws, various skewed beams

T/R: 6 x 6 T/R: 6 x 6

Single array (T/R)

Active aperture: 6 x 6 elements
Refracted angle : 40 to 60 SW, resolution 2
Skew angle : nominal 35, 45, 55
66 focal laws (beams)
50SW
SW
50
Skew
+55
-55
Skew +35
-35
+45
-45

Top View

Side View
33

2D Matrix Arrays Weld Inspection

Summary : all flaws, all beam orientations

2.25 MHz, 2D array, 40- 70 SW

skews: nominal (90), 20, 35, 45, 55 (2 x 159 focal laws)

Complete Weld inspection in less than 15 minutes !!!

Comparison: typically 6 hours for conventional UT,
typically 2 hours for 3 probe PA technique

34

2D Matrix Arrays Conclusions

Using 2D matrix arrays with a sufficient number of
elements allows for adequate steering capability in
both planes and sufficient active aperture (acoustic
energy) to efficiently detect mis-oriented cracks
(/)
,
mis-oriented cracks

35

- Low-Frequency Operation
DYNARAY offers all features required to
efficiently drive low-frequency arrays:
Dynaray

Bandwidth from 0.20 MHz to 25 MHz (at -6 dB)
Excitation pulse 200 V (at 50 Ohm)
Pulse width up to 1,000 ns
High PRF, even for long pulses at 200 V
200V PRF
36

Cast SS Weld Inspection - Principles

MAJOR PROBLEMS CAUSED BY ANISOTROPIC COARSEGRAIN STRUCTURE:
High, and variable attenuation of sound beam
High ultrasound noise, caused by reflection on individual
grains
Low-pass filtering effect
Beam skewing, beam distortion
Local variations of metal structure induce local variations of
UT propagation properties

37

Cast SS Weld Inspection - Principles

Inspection solution : low-frequency TRL PA

38

Cast SS Weld Inspection - Principles

Transmit-Receive configuration yields better sensitivity, SNR, due
to convolution of beams (reduces ultrasonic noise level)
TR-

TRL probe generates compression waves, less affected by
anisotropic structure than SV waves (reduces attenuation, beam
distortion and local propagation variations)

Low frequencies (0.5 1.5 MHz), for reduced attenuation

Use of large bandwidth probes : reduces attenuation and effect of
low-pass filter

39

Cast SS Weld Inspection - Principles

2D Phased Array technology allows for :
2
Optimized focusing, at different depths, improves sensitivity in the
near-surface and intermediate regions, and may improve flaw sizing and
characterisation
,

Optimized beam steering: capability to generate beams at different
refracted angles and different skew angles will improve detection
capability
/

40

Cast SS Weld Inspection - Principles

RECENT TECHNICAL PROGRESS:
No major breakthroughs, but numerous incremental
improvements

Low-frequency TRL PA probes show better inspection capability
and efficiency than conventional TRL probes (and any other UT
probe)
TRL PA

UT inspections from OD, with state-of-the art techniques, equipment

and software, can in most cases reliably detect large circumferential
cracks (25 to 50% T)
( 25-50%)

41

Cast SS Weld Inspection - Validation

Dual 2D array probe, 0.5 MHz (Courtesy of PNNL)

on SCSS Calibration block MU-6 (Courtesy of EPRI)
42

Cast SS Weld Inspection - Simulations

Dual 2D array probe, 0.5 MHz, 2 x 32 elements, aperture 2 x (75 x 39 mm)

35LW
45LW
55LW

43

Cast SS Weld Inspection - Simulations

Dual 2D array probe, 0.5 MHz, 2 x 32 elements, aperture 2 x (75 x 39 mm)

20
10
45LW, skew 0

44

Cast SS Weld Inspection - Validation

45LW beam, SDH at 3T/4 in SCSS Calibration block MU-6

45

Cast SS Weld Inspection - Validation

Center frequency = 0.51 MHz

Bandwidth = 57%

45LW beam, Corner reflection in SCSS Calibration block MU-6

46

Cast SS Weld Inspection - Experiment

35LW beam, EDM Notch (h=6.5 mm) in SCSS block TRM MU-7

47

Cast SS Weld Inspection PZR Surge Line

(Courtesy of PNNL)

Pipe
CCSS
Elbow
SCSS

Flaw

Flaw Type

Flaw Location

Flaw
Orientation

1-1

Thermal Fatigue

Weld Center Line

Circumferential

1-2

Thermal Fatigue

Pipe Side Near Fusion Line

Circumferential

1-3

Thermal Fatigue

Weld Center Line

Circumferential

1-4

Thermal Fatigue

Weld Center Line

Circumferential

Flaw
Length
4.0 in.
(10.2 cm)
2.0 in.
(5.1 cm)
2.0 in.
(5.1 cm)
6.0 in.
(15.2 cm)

Flaw Depth
(Height)

Degree
Location

35% T

45

30% T

120

30% T

210

30%50% T

300

48

Cast SS Weld Inspection PZR Surge Line

(Courtesy of PNNL)

30

45

60

Dual 2D matrix array probe, 0.8 MHz, 2 x (10 x 5)

Custom development PNNL / Zetec
49

Cast SS Weld Inspection PZR Surge Line

(Courtesy of PNNL)
Top View
Thermal fatigue, at WCL
35% T, L = 4.0 inches
Thermal fatigue, Pipe Side
30% T, L = 2.0 inches

End View

Side View

Inspection from Pipe side, Merged data 30 to 70 LW

50

Key Features Summary (I)

Challenging Applications

Inspection Methodology

& UltraVision 3
Specifications & Features

Complex geometries
One-pass weld inspections
(axial & circumferential flaws)
Turbine blade roots

2D matrix arrays, allowing for

variations of refracted angle &
skew angle

Up to 256 simultaneous
beam forming channels
Up to 4096 focal laws

Rough & wavy weld surfaces

Complex geometries
(nozzles, J-welds, )

Flexible array probes

Conformable wedges
Custom footprint wedges

Focal law calculation through

complex surfaces
Position dependant focal laws
Up to 4096 focal laws
3D visualisation capability

Cast SS welds & components

Complex DM welds

Low-frequency TRL PA probes

Bandwidth 0.20 25 MHz

200 V excitation pulse
High PRF at low frequencies

51

Key Features Summary (II)

Challenging Applications

& UltraVision 3

Inspection Methodology

Specifications & Features

RPV welds
Other vessel welds

Multiple phased array probes

Large data files, up to 20 GBytes

Data flow up to 20 MBytes/s
16-bit A-scan data
On-line data processing
Parallel firing
Interleaved averaging
Channel related resolution

All types of R&D work

Any phased array UT technique

High processing capability

16-bit A-scan data
Open architecture
Individual A-scans available

Any inspection requiring long

soundpaths (shafts, axes, )

Conventional UT techniques
Phased array UT techniques

200 V excitation pulse

Up to 256,000 points in A-scan
16-bit A-scan data

52