Ultrasonic Phased Array Inspection of
Newly Fabricated Welds
B. Zeller, B. Morningstar and E. Sjerve
IRISNDT Corp.
3rd Annual Conference on Materials and Welding
Calgary, Alberta
July 9th – 10th, 2007
July 2007 1
Phased Array
Omniscan Portable Phased Array Unit
• Battery operated, lightweight
• Field-rugged design for indoor/outdoor use
• Complete stand alone unit
(no computer connection, mouse or keyboard necessary)
July 2007 2
What are Phased Arrays?
•Allows electronic modification of probe characteristics.
•Can produce a variety of different sound beam
characteristics from a single probe
•Any UT technique for flaw detection and sizing can be
applied using phased array probes.
July 2007 3
Why Use Phased Array?
• High speed electronic scanning so faster inspection
• Greater flexibility for inspection of complex geometries
• Superior analysis and display capabilities
• Phased Array in Lieu of RT - Piping (ASME B31.3)
• Phased Array in Lieu of RT - Pressure Vessels (CC2235)
• No radiation, so no need for windows
July 2007 4
Phased-Array Probes
•A linear array (1D) is
basically a long
conventional probe
•Which has been cut into
many small elements that
can be individually
excited
July 2007 5
Phased Array Zero Degree Beam
• No phase delay
• Produce zero degree sound beam
July 2007 6
Beam Indexing
• Activate subset of elements
• Electronic rastering
July 2007 7
Angled Wave Generation
Direction of energy
• Activate elements with linear phase delay
• Generates angled waves
• Amount of energy in angled wave is less than at 0
degrees (for the same gain)
July 2007 8
Focusing
Focussed to cross
at this point
• Activate elements with nonlinear phase delay
• Generates focus of the sound beam
July 2007 9
Linear 1D Probes
Numerous probe designs
• Size and shape depend on
number and size of elements
• PA and transducer technology
allows any shapes: flat, curved,
conical, elliptical . . .
• Standard PA probes for
Omniscan have an upper temp
limit of 40° C
July 2007 10
Phased Array Wedges
•To generate shear waves.
•Generate shear waves at
specific angle (eg. code
angles) but PA probe can
x1
vary angles (within an
approx. 30° range).
•Contoured wedges for
smaller diameter piping
applications.
July 2007 11
A-Scan Display
• Simple presentation showing amplitude of the ultrasonic
signal vs time/distance of a single sound beam
• Commonly used with conventional ultrasonic machines.
July 2007 12
B-Scan Display
• Time/Distance of sound beam vs distance of scan
• Side view: a cross-section through one vertical slice showing the depth
of reflectors with respect to their linear position.
July 2007 13
C-Scan Display
• Length of scan vs length of index
• Top view: Colour represents the signal amplitude at each
point in the test piece mapped to its x-y position.
July 2007 14
Sectorial Scan Display
Phased Array Probe
N Angles N Angles
BW
BW
• True depth vs projected sound path
• Side view: A 2D display cross-sectional view made from a
series of A-scans that have been plotted with respect to
projected distance, time delay and refracted angle.
July 2007 15
S-Scan Display
Example Application
Typical Display
• Sweep sound through multiple angles and focus on
area of interest
July 2007 16
Phased Array Inspection of
Piping and Pressure Vessel Welds
•Phased Array in Lieu of RT -
Pressure Vessels (CC2235)
•Phased Array in Lieu of RT -
Piping (ASME B31.3/Case 181)
•Phased Array Screening,
Manual UT Acceptance
•Rapid Inspection, Good POD
•No Radiation Windows
Necessary
July 2007 17
PA Inspection of Pressure Vessel Welds
• Code in place is ASME CC2235
• Accept/reject depends on classifying flaw as surface or sub-surface.
• Materials 0.5 in to 1.0 in thick: the max. flaw length allowed is 0.25 in.
• For thicker materials, calculation becomes more complex.
July 2007 18
PA Inspection of Piping Welds
344.6.2 Acceptance Criteria. A linear-type discontinuity is
unacceptable if the amplitude of the indication exceeds the
reference level and its length exceeds:
(a ) 6 mm ( 14 in.) for T W ≤ 19 mm ( 3 4 in.);
(b) T W 3 for 19 mm < T W ≤ 57 mm (2 14 in.);
(c) 19 mm for T W > 57 mm.
• Code in place is ASME B31.3 (344.6.2 or Case 181)
• 344.6.2 - Linear indications must have sufficient amplitude and length
to be rejectable.
• Case 181 may be used as well. Similar to CC2235 for pressure vessels.
July 2007 19
July 2007
AB WM T-7 T
45 S T E EL
of weld.
AB W M T-7 T
45 S T E EL
A B W MT -7T
45 ST E E L
ABWMT-7T
60 STEEL
ABWMT-7T
60 STEEL
ABWMT-7T
60 STEEL
ABWMT-7T
60 STEEL
Weld Inspections – Conventional UT
• Single angle probe must be scanned to cover full volume
20
Weld Inspections – Phased Array
Access to both sides:
SA1 N55S IHC
SA1 N55S IHC
Double-sided scan
Preferred
SA1 N55S IHC
Single-sided scan:
eg. Pipe to Fitting
SA1 N55S IHC
O O
70 40
July 2007 21
Electronic Scanning-Shear Wave
Conventional Automated UT - Phased Array
• Reduces inspection times: faster than automated conventional
ultrasonic systems.
• Can use optimum angles for weld inspection, e.g. for lack of
penetration on automated welds.
July 2007 22
Single-Sided Weld Inspection
• No indications – only geometry
July 2007 23
Single-Sided Weld Inspection
• Indications found. Cursors aid in sizing
July 2007 24
Double-Sided Weld Inspection
SA1 N55S IHC
SA1 N55S IHC
O
70 O
40
• Capture data from both sides in one scan.
• Software can merge data from both sides into a
single 3D volumetric representation of weld.
July 2007 25
Double-Sided Weld Inspection - Examples
• Scan of calibration block with known defects.
• Some indications stronger one side. Manual UT follow-up important
July 2007 26
Double-Sided Weld Inspection - Examples
• Scan covers large area – appears compressed. Zoom to examine.
• Good example of cap geometry. Examine more closely in next slide.
July 2007 27
Double-Sided Weld Inspection - Examples
• Only one side displayed for clarity.
• Indication at edge of weld cap. Manual UT confirmed cap geometry.
July 2007 28
Double-Sided Weld Inspection - Examples
• Scan on same pressure vessel. Same length of scans.
• Indications found. Examine more closely in next slide.
July 2007 29
Double-Sided Weld Inspection - Examples
• Only one side displayed for clarity.
• Indication not root or cap geometry. Manual UT confirmed defect.
July 2007 30
Phased Array Advantages
Portable phased arrays have
major advantages for:
• High speed inspections
• Set-up flexibility
• Multiple inspection angles
and wave modes
• Limited access inspections
• Code inspections in lieu of
RT (no radiation windows)
July 2007 31
