Development of Phased Array Ultrasonic System for Non-Destructive Testing of Nuclear Components

C.
H Mohammed Koya
KMEA Engineering College
(Approved by AICTE and Affiliated to the Mahatm a Gandhi University)
Under the Technical Management of NeST Group Creating Innovative Solutions
SEMINAR REPORT
DEVELOPMENT OF PHASED ARRAY ULTRASONIC

SYSTEM IN NON DISTRUCTIVE TEST OF NUCLEAR
COMPONENTS
Submitted by
SALEEMA.N.A
In partial fulfillment for the award of the

Degree of Bachelor of Technology in
Electronics and Communication Engineering
Of M.G. University, Kottayam
Department of Electronics & Communication Engineering

C.H Mohammed Koya
KMEA ENGINEERING COLLEGE

EDATHALA
2010
C.H Mohammed Koya
KMEA Engineering College
(Approved by AICTE and Affiliated to the Mahatm a Gandhi University)
Under the Technical Management of NeST Group Creating Innovative Solutions
CERTIFICATE
This is to certify that the seminar entitled
DEVELOPMENT OF PHASED ARRAY ULTRASONIC

SYSTEM IN NON DISTRUCTIVE TEST OF NUCLEAR
COMPONENTS
submitted by
SALEEMA.N.A
Of seventh semester
Electronics And Communication Engineering
in partial fulfillment of the requirements for the award of B.Tech degree in
Electronics And Communication of KMEA Engineering College
of Mahatma Gandhi University, Kottayam.
Prof Rajan K Varghese Mrs. Arya Dev i Dr. Rajesh V.G

HEAD OF THE DEPARTMENT INTERNAL GUIDE PRINCIPAL
ECE Dept. Lecturer, ECE Dept. K.M.E.A Engi neering College,
Edathala
.
ACKNOWLEDGEMENT
First of all I thank the Almighty for his enlightening presence

throughout my seminar work and helping me in completing it
successfully.
I wish to convey my gratitude to ”Prof. C.I.Abdul Rahiman,Director,

KMEA Engg college” for his contribution towards the successful
completion of the seminar.
I express my gratitude to my beloved “Principal, Dr. Rajesh V.G” for

the invaluable support offered to me.
I extend my sincere thanks to “Prof. Rajan K Varghese, Head of

Dept.,Electronics And Communication Engg for his guidance.
I would also like to express my sincere thanks to my coordinator of the

seminar Mr. Sunny Kunnumpuram & Mrs. Dhanya for their valuable
suggestions and help throughout the seminar.
I also thank each and everyone who have helped me directly and
indirectly for the successful completion of my seminar.
ABSTRACT
Prevention of trouble is a matter of vital importance, particularly in the operation of nuclear and
other power plants. With the increase in plant life, assessment of the remaining life of plant
components has become an important subject. Nondestructive inspection is an essential testing
method for the safe, long-term operation of plants. Ultrasonic testing (UT) is generally used to inspect
the piping systems and pressure vessels of power plants. The UT method shows satisfactory
capabilities in detecting and sizing (evaluation of the size of defect) of defects in the portions which
have simple geometry and allow ultrasonic waves to propagate smoothly. However, this method is not
suitable for testing of parts such as stainless steel castings that do not allow easy propagation of
ultrasonic waves, or complex geometry parts that do not allow the testing probe to scan freely. As an
advanced UT method, research on phased array UT technology is being conducted worldwide.
Because ultrasonic-wave beams of the phased-array UT can be electronically controlled, it is possible
to detect defects even in the complex geometry parts by electronically scanning, and also to enhance
the space resolution by focusing the beam. This paper describes the development of the probe as the
basic technology for the phased-array UT method by referring to the fabrication technique of the
piezoelectric composite which is the key element in the probe, probe design considerations, and
examples of practical applications of this testing method.
CONTENTS
1. Introduction : 1
: 2-9
2. The technology
3. Principle : 10 - 14
4. Working : 15 - 20
5. Phased array ultrasonics in NDT : 20 - 21
6. Applications of phased array ultrasonics : 22 - 24
7. Advantages
: 25 - 26
8. Phased array limitations : 27
: 28
9. Conclusion
10. Reference : 29
Seminar report 2010 1 phased array ultrasonic system in NDT
INTRODUCTION
Ultrasonic testing has been in use for many years. Scanning techniques using both contact and
immersion methods are often used during manufacturing and also during periodic in-service
inspection programs to determine component quality. But because of a variety of component
configurations and potential flaw geometries it is often necessary to perform several inspections,
each with a different probe configuration, to assure adequate defect delectability. It is possible
that a properly designed phased array probe can perform several different inspections without
changing hardware thereby reducing inspection times. This presentation reviews the design and
operation of ultrasonic phased array transducers and the necessary features to achieve the desired
performance. An example situations in which these probes have already been implemented
effectively is also discussed.
Many people are familiar with the medical applications of ultrasonic imaging, in which high
frequency sound waves are used to create highly detailed cross-sectional pictures of internal
organs. Medical sonograms are commonly made with specialized multi-element transducers
known as phased arrays and their accompanying hardware and software. But the
applications of ultrasonic phased array technology are not limited to medical diagnosis. In
recent years, phased array systems have seen increasing use in industrial settings to provide
new levels of information and visualization in common ultrasonic tests that include weld
inspection, bond testing, thickness profiling, and in-service crack detection. This paper
provides a brief introduction to how phased array systems work and how they can be
employed in industrial ultrasonic nondestructive testing.
There has been a lot of hue and cry about phased array ultrasonics, and hence analyzing the true
capabilities and limitations of this technology becomes paramount. This twofold article attempts
to unveil the potential and market for the same.
Productivity and quality are the buzz words in industrial environments and ultrasonic
nondestructive testing (NDT) is certainly the answer to quality control and in-service inspection.
Ultrasonic technology is used to measure wall thickness, detect hidden cracks and other
anomalies affecting structural integrity, and analyze basic material properties. The history of
ultrasonics dates back to the early 1950s for industrial applications, but it was the medical
industry in the 1970s that really triggered the concept of phased arrays and invested a subsequent
amount of time, money, and research and development in the same. The medical industry is still
the most enthusiastic user of the phased array ultrasonic technology and the success of the same
in medicine was conceived by various industries for NDT, however the commercialization of the
technology for industrial applications happened only over the last decade. This article discusses
the technology at length, and the trends shaping the future of the same with quotes from major
industry participants along with Frost & Sullivan’s exclusive analysis of the same.
Dept of ECE KM EA Engg college

THE TECHNOLOGY

Phased Array technology

The basis of Phased Array technology forms a probe with a large number of transducer elements which can
be arranged either linearly or 2-d imensionally, and can be activated individually, Figure 1. Moreover, a
mu lti-channel ultrasonic instrument is required, which at best is provided with its own pulser and amplifier
for each transducer element. Third ly, programmable electronics ensure that the in dividual transducer
elements can be phase activated.
Therefore it is now possible to control the sound field of a phased array.
Figure 1: Phased-Array
Sound field control
Linear scanning
The individual transducer elements are activated from one side to the other with constant phasing.
Without moving the probe the workpiece is therefore scanned in the plane of the linearly arranged
elements, Figure 2.

Figure 2: Linear scan
Steering
Because of the timed activation of the transducer elements a wave front is also generated
obliquely to the surface, Figure 3.
Figure 3: Steering sound field
. The steering range of the sound field thus generated may be regulated by suitable control of the
phasing, but is limited by a decrease in the acoustic pressure as the angle increases, and by
interfering grating lobes.
Due to the additional use of a wedge delay, transversal waves are reverberated in the preferential
direction predetermined by the wedge angle. The sound field can also be steered in the range of
35 to 75°, which is typical for the weld inspection.

Electronic Phasing Used to Steer a Sound Field
Focussing
The sound field of a phased array can be focussed in two ways. If all the transducer elements are
activated in parallel, a sound field is created which is identical to that of a single element probe
with the same transducer size.
This results in the maximum near field length N. If the number of the transducer elements
connected in parallel is now reduced, a reduced near field length N’ is automatically obtained
from the size of the aperture. The second possibility involves phased activation of the transducer
elements from outside to inside, thus creating a forced, concave wave front with a preferred
focus: the near field length is reduced in a similar manner to the effect of a lens.
Electronic Phasing Used to Ge nerate a Focused Sound Field
Combinations
Scanning, steering and focussing can be combined almost arbitrarily. Thus a maximum of
flexibility in terms of sound field control can be achieved, rendering the use of several probes to

perform a test operation unnecessary in practice. Ultrasonic testing becomes faster and hence
more economical.
Reconstruction
A decisive factor in correctly evaluating the signal of a phased array is the reconstruction of the
signals on the receiving side. If the transducer elements are activated in a certain time pattern, a
predetermined sound field is obtained, and any reflectors in this range supply echoes which are
now received “unsorted” from all transducer elements of the probe. A time pattern must now also
be used on the receiver side to ensure that the signals received from the transducer elements are
synchronised with the pulser timing. Only now can the associated reflector layers required for a
graphic representation be determined or the echoes.
The time pattern which has been calculated for a certain sound field control is also designated in
phased array technology as the “delay laws”. The individual transducer elements are activated
with the constant pulse repetition frequency predetermined by the system (PRF between 10 and
20 kHz). For a certain desired sound field control a finite number n of pulsing-receiving cycles is
now obtained with the time pattern calculated by the delay laws.
Within this cycle of n transmitted and received sound pulses the desired range of the work piece
is tested and the graphic representation of the test results calculated at the end of the cycle. This
results in the much narrower cycle frequency of PRF/n Hz. In Figure 5 the angle is steered in 16
steps, one for every 4 focus depths: One cycle = 64 shots. At PRF = 10 kHz a cycle frequency of
156 Hz is therefore produced – fast enough for manual ultrasonic testing.
Result representations
 A-scan
The A-scan continues to be used in phased array, but it has a different significance here. In the
standard application a so-called “total A-scan“ is represented which shows the maximum echo
amplitudes of an entire cycle. It is also possible to represent the A-scan for a specifically selected,
individual shot k of the cycle, e.g. that for an angle of incidence of exactly 45° or that for a
predetermined focal depth of the sound field.
The individual A-scans are generally stored in the device memory within a certain time during
recording. All the A scans may then be considered individually “off line” in an evaluation mode
after the actual test.
 B-scan
The B-scan or sectional scan in the plane of incidence of a linear scan is represented immediately
after each cycle. All echoes in the scanning range are represented true to scale with their
amplitudes in a predetermined colour scale. If the probe is also moved transversely to the
scanning direction across the test object, thereby recording the probe position, the test results are

stored “in slices” and at the end there are test results of a certain volume from which even a 3D
representation of the workpiece can be generated, if necessary.
Since the coordinates of flaw echoes are available in 3-dimensional form when scanning with an
encoder, a 3rd view of the test results is also possible: the projection onto the workpiece surface
perpendicular to both scanning directions. However, this representation of the test results is not
described as a B-scan in most cases, even though it also represents a side view of the tested
volume. This representation is sometimes also described as an “end view”.
When related to the weld inspection this representation enables the flaw length to be determined
in the seam direction, Figure 4.
Figure 4: Representati on of the result
 S-scan
The sector scan or S-scan is also a B-scan, but one which only represents the steering range of the
probe scanned true to scale over one cycle, Figure 5. This is the representation that is normal in
medical diagnostics. In the weld inspection all the reflectors are represented in the steering range
of the sound field. If necessary, the scanned representation must be suitably adapted for reflecting
the sound field on the bottom of the plate -> reflection of the sector = volume-corrected sector
representation.

Figure 5: Sector representation with angle probe
 C-scan
The C-scan is a top view of the workpiece. The echoes stored in the volume range represented are
projected onto surface. Here two variations are possible: Either the echo amplitudes or the sound
paths (D-scan, depth scan), are represented, each coded with a colour or grey scale, Figure 4.

Portable Phased Array Instrument
A Phased Array instrument differs considerably from a conventional ultrasonic testing instrument
with A-scan representation. After many years of successful application of the phased array
technology in automatic testing systems from GE Inspection Technologies (formerly
Krautkrämer), there will be a portable Phased Array instrument which is universally applicable but is
of particular interest in weld inspection because of its dimensions, Figure 6.
Figure 6: PHASOR 1

PRINCIPLE

Principle of operation and features
A conventional UT probe consists of a single piezoelectric element, while that for phased-array
UT has multiple piezoelectric elements. Each piezoelectric element is independently controlled in
its S/R timing to synthesize a waveform for control of ultrasonic wave beams. The electronic
scanning shown in Table 1 is an example of scanning made by delaying the sending timing of the
right-hand side piezoelectric element. The table shows that the composite wave front inclines to
the right side, as a result of which the beam can be transmitted in a similar way to ordinary angle
probe. With regard to the electronic focusing, composite wave front is focused on a given point
by delaying the beam transmitting timing of the piezoelectric elements located in the middle of
array, resulting in a similar effect to that given by a focusing probe. In this way, the phased-array
UT method makes it possible to freely change the angle of incidence and the position of focusing
of the ultrasonic beam, and is thus expected to be used to inspect areas to which the conventional
UT method is not applicable ( FIG:TABLE)
Method Electronic scanning Electronic focusi ng
Control principle
Probing speed increases as a resul t of Space resolution (detecting

minimization ability) is improved by
Features of difficult-to-inspect areas by ultrasonic-wave beam
scanning at various angles of focusing .
refraction and by electronic scanning.
Principle and feature of phased-array UT

Phased array ultrasonics is a novel and improvised method of generating and receiving
ultrasound. It uses multiple ultrasonic elements and electronic time delays to create beams by
constructive and destructive interference. The technique typically incorporates a multi-element
array transducer that generates a sweeping beam that can examine a part from various angles and
focal points to create a detailed picture of internal conditions. Typical components of a complete
system include probes, beam formers, acquisition modules, and imaging modules. Furthermore,
for automated systems, drivers and scanners are included and for semi-automated systems, a
manual scanner and encoder are required.
The individual transducer elements (usually 16, 32, or 64) are pulsed in groups with programmed
time delays, creating interacting beam components that add and cancel in predictable ways;
hence, the term "phasing." The operator can sweep the beam through a selected volume of the test
piece by varying the sequence in which the elements are pulsed, and also dynamically focus
maximum sound energy at selected depths corresponding to potential flaw locations. The array
transducer receives the complex pattern of returning echoes and further processing is done by the
instrument software to create either a cross-sectional or a planar view of the parts interior.
Phased arrays can operate in three different modes: manual, semi-automated, and automated. (As
with other types of ultrasonic testing, phased arrays can also operate in immersion.) The arrays
can perform beam sweeping through an angular range (S-scans), beam scanning at fixed angle (E-
scans), beam focusing, lateral scanning, and a variety of other scans depending on the array and
programming. Each element consists of an individually wired transducer, with appropriate
pulsers, multiplexers, and A/D converters and the elements are acoustically isolated from each
other. The phased array system is computer-controlled, typically with user-friendly software such
that the operator can simply program the required inspection parameters. Usually, a wedge is used
to optimize inspection angles and minimize wear. Phased arrays are particularly useful for regions
with limited access, rapid inspection of components such as welds, imaging and storing data, and
for sizing cracks by tip diffraction.
Principle of operation of phased array (PA). The PA probe consists of many small elements, each
of which can be pulsed separately. In the figure the element on the right is pulsed first, and emits
a pressure wave that spreads out like a ripple on a pond (largest semicircle). The second to right
element is pulsed next, and emits a ripple that is slightly smaller than the first because it was
started later. The process continues down the line until all the elements have been pulsed. The
multiple waves add up to one single wave front travelling at a set angle. In other words, the beam
angle can be set just by programming the pulse timings.

Weld examination by phased array. TOP: The phased array probe emits a series of beams to flood
the weld with sound. BOTTOM: The flaw in the weld appears as a red indication on the
instrument screen.
Phased Array (PA) ultrasonics is an advanced method of ultrasonic testing that has applications in
medical imaging and industrial nondestructive testing, originally pioneered by Albert Macovski
of Stanford University. [1] In medicine a common application of phased array is the imaging of the
heart (images of the fetus in the womb are usually made by curvilinear array, a multi-element
probe that does not actually phase the signals). When applied to metals the PA image shows a
slice that may reveal defects hidden inside a structure or weld.
Electronic Scanning
We have presented phased array design techniques capable of beam steering and beam
focusing under electronic control. Our original scenario included scanning transducers
over the test piece and there may be some situations in which electronic beam steering is
not able to access some locations withis the testpiece. In such situations, electronic
scanning can be used to increase coverage. In Figure 6, it is desired to inspect a 100
degree sector of a metal tube. A 5 MHz signal incident to the tube wall at 15 degrees is
necessary to detect tube wall cracks. A sixteen element aperture, 13 mm square, is
sufficient to achieve the requires steering and focusing. Due to the circular geometry of
the tube, it is not possible to steer the beam to a different angular location without
changing the angle of incidence, which is unacceptable. Electronic scanning, as shown in
Figure , provides the solution.

Fig : Phased Steering, Focusing, and Scanning Co mbined in One System
The original 16-element array is replaced with a 128-element array using the original
element size resulting in an array 8 times the length of the original. With the addition of a
multiplexing circuit in the array, any contiguous 16 elements can be phased.
Additionally, the array can be formed in a circular arc concentric with the testpiece so
that the sound field of any 16-element group using tha same phase pattern will impinge
the tube at the same angle but a different location.
Additionally, electronic scanning is faster because no physical probe motion is required.

If desired, the beam could initially operate at one end of the array, and then jump to the
other end of the array with no lost time.

WORKING

What is a phased array system?
Conventional ultrasonic transducers for NDT commonly consist of either a single active element
that both generates and receives high frequency sound waves, or two paired elements, one for
transmitting and one for receiving. Phased array probes, on the other hand, typically consist of a
transducer assembly with from 16 to as many as 256 small individual elements that can each be
pulsed separately. These may be arranged in a strip (linear array), a ring (annular array), a circular
matrix (circular array), or a more complex shape. As is the case with conventional transducers,
phased array probes may be designed for direct contact use, as part of an angle beam assembly
with a wedge, or for immersion use with sound coupling through a water path. Transducer
frequencies are most commonly in the range from 2 MHz to 10 MHz. A phased array system will
also include a sophisticated computer-based instrument that is capable of driving the multi-
element probe, receiving and digitizing the returning echoes, and plotting that echo information in
various standard formats. Unlike conventional flaw detectors, phased array systems can sweep a
sound beam through a range of refracted angles or along a linear path, or dynamically focus at a
number of different depths, thus increasing both flexibility and capability in inspection setups.
Typical phased array probe assemblies

Typical multi-element construction
How do they work?
In the most basic sense, a phased array system utilizes the wave physics principle of phasing,
varying the time between a series of outgoing ultrasonic pulses in such a way that the individual
wave fronts generated by each element in the array combine with each other to add or cancel
energy in predictable ways that effectively steer and shape the sound beam.
This is accomplished by pulsing the individual probe elements at slightly different times.
Frequently the elements will be pulsed in groups of 4 to 32 in order to improve effective
sensitivity by increasing aperture, which reduces unwanted beam spreading and enables sharper
focusing. Software known as a focal law calculator establishes specific delay times for firing each
group of elements in order to generate the desired beam shape, taking into account probe and
wedge characteristics as well as the geometry and acoustical properties of the test material. The
programmed pulsing sequence selected by the instrument's operating software then launches a
number of individual wave fronts in the test material. These wave fronts in turn combine
constructively and destructively into a single primary wave front that travels through the test
material and reflects off cracks, discontinuities, back walls, and other material boundaries like
any conventional ultrasonic wave. The beam can be dynamically steered through various angles,
focal distances, and focal spot sizes in such a way that a single probe assembly is capable of
examining the test material across a range of different perspectives. This beam steering happens
very quickly, so that a scan from multiple angles or with multiple focal depths can be performed
in a small fraction of a second.
The returning echoes are received by the various elements or groups of elements and time-shifted
as necessary to compensate for varying wedge delays and then summed. Unlike a conventional
single element transducer, which will effectively merge the effects of all beam components that

strike its area, a phased array transducer can spatially sort the returning wavefront according to
the arrival time and amplitude at each element. When processed by instrument software, each
returned focal law represents the reflection from a particular angular component of the beam, a
particular point along a linear path, and/or a reflection from a particular focal depth. The echo
information can then be displayed in any of several formats.
Example of angled beam generated by flat probe by

means of variable delay
Example of focused linear scan beam
What do the images look like?
In most typical flaw detection and thickness gaging applications, the ultrasonic test data will be
based on time and amplitude information derived from processed RF waveforms. These
waveforms and the information extracted from them will commonly be presented in one or more
of four formats: A-scans, B-scans, C-scans, or S-scans. This section shows some examples of
image presentations from both conventional flaw detectors and phased array systems.
A-Scan displays
An A-scan is a simple RF waveform presentation showing the time and amplitude of an

ultrasonic signal, as commonly provided by conventional ultrasonic flaw detectors and waveform
display thickness gages. An A-scan waveform represents the reflections from one sound beam
position in the test piece. The flaw detector A-scan below shows echoes from two side-drilled

holes in a steel reference block. The columnar sound beam from a common single-element
contact transducer intercepts two out of the three of the holes and generates two distinct
reflections at different times that are proportional to the depth of the holes.
Generalized beam profile Straight beam A-scan image
A single-element angle beam transducer used with a conventional flaw detector will generate a
beam along one angular path. While beam spreading effects will cause the beam diameter to
increase with distance, the area of coverage or field of vision of a conventional angle beam will
still basically be limited to one angular path. In the example below, a 45 degree wedge at one
fixed position is able to detect two of the side-drilled holes in the test block because they fall
within its beam, but it is not possible to detect the third without moving the transducer forward.
Generalized beam profile Angle beam A-scan image

A phased array system will display similar A-scan waveforms for reference, however in most
cases they will be supplemented by B-scans, C-scans, or S-scans as seen below. These standard
imaging formats aid the operator in visualizing the type and position of flaws in a test piece.
B-Scan displays
A B-scan is an image showing a cross-sectional profile through one vertical slice of the test piece,
showing the depth of reflectors with respect to their linear position. B-scan imaging requires that
the sound beam be scanned along the selected axis of the test piece, either mechanically or
electronically, while storing relevant data. In the case below, the B-scan shows two deep
reflectors and one shallower reflector, corresponding to the positions of the side drilled holes in
the test block. With a conventional flaw detector, the transducer must be moved laterally across
the test piece.
PHASED ARRAY ULTRASONICS IN NDT

Nondestructive Testing (NDT)
Nondestructive testing is performed on in-service and out-of-service equipment to identify

potential failure mechanisms which could become a safety or reliability issue. TechCorr
specializes in providing nondestructive testing services to the upstream, midstream and
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generation, structural fabrication and civil works. Each of our offices has mobile radiography
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projects. In addition we offer a much more encompassing nondestructive testing offering in each
of the regions we operate depending on the areas primary activity. You can rely on TechCorr to
provide quality personnel with experience.
Nondestructive Testing (NDT) Conventional NDE services offered include but not limited to:
* Liquid Penetrant Testing

* Magnetic Particle Testing
* Radiographic Testing
* Ultrasonic Testing
* Visual Inspections
* Acoustic Emission Testing
In ultrasonic testing (UT), very short ultrasonic pulse-waves with center frequencies ranging
from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect internal
flaws or to characterize materials. The technique is also commonly used to determine the
thickness of the test object, for example, to monitor pipework corrosion.

Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be
used on concrete, wood and composites, albeit with less resolution. It is a form of non-destructive
testing used in many industries including aerospace, automotive and other transportation sectors

APPLICATIONS OF PHASED ARRAY

ULTRASONICS

The first major application of the phased-array UT is inspection of complex geometry parts.
When conventional UT is used, the inspecting areas must be scanned entirely with the probe. If
the inspecting area includes any portion having a straight part that is too short to probe, such a
difficult-to-probe portion has to be omitted from inspection. However, such conventionally
difficult portions can be inspected by using the beam scanning function of the phased-array
UT instead of scanning with probe. The second application is inspection of parts made
of high-noise materials such as stainless steel castings and weldings. Coarse grain crystals
contained in these parts deflect and scatter the ultrasonic waves and lower the propergation. By
focusing an ultrasonic wave beam on these parts, the defect echo level is made clear and the
signal-to-noise ratio is improved. In addition to the above, when piezoelectric elements
of a phased-array UT probe are divided into groups, speed of inspection can be increased by
switching each group electrically instead of scanning with probe.
Phased array ultrasonics is used for various applications spanning a gamut of end-user industries
such as aerospace, automotive, primary metals, construction, petrochemical, power, and a host of
other industries among others. Applications include and are not limited to the following:
Pressure vessel inspection

T-weld testing of bridge structures
Pipe mill inspection
Corrosion cracking in turbine roots
Landing gear testing
Inspection of complex geometries
Corrosion mapping
Flange sealing face inspection
Shaft and axle inspection
Nozzle weld inspection
FLAW DETECTION ON TUBES AND BARS
For flaw detection on tubes and bars, shear wave testing is used. The cross section of a tube is
shown on Figure2. The right hand side of the drawing shows the detection of a crack on the inside
surface of the tube. A similar arrangement on the left side shows the geometry of flaw detection
on the outside surface of the tube. The shear wave can bounce several times between the I.D. and
O.D. surfaces of the tube and any internal flaws in the path of the beam are detected as well.
Notice that the right hand transducer produces a shear wave that travels clockwise inside the tube,
while the left hand transducer produces a shear wave traveling counter clockwise.

To assure the most reliable flaw detection both clockwise and counter-clockwise arrangements
are used simultaneously. In order to generate a shear wave the transducer is positioned with an
offset. The right amount of offset depends upon the sound velocity in the material of the tube and
the sound velocity in the water. The required offset can be calculated using a simple formula or
read from a table as a function of the tube diameter and material. With this arrangement,
longitudinal cracks can be detected. In order to detect transverse cracks the transducer has to be
located over the center of the tube and angled in a plane containing the center line of the tube as
shown on Figure 3.
The full circumference of the tube can be scanned if it is rotated around the center. The same
result can be obtained if the set of transducers is rotated around the same center. By moving the
tube along the centerline, a full body test is achieved.

ADVANTAGES

Phased-array technology offers the capability for high-speed electronic scanning without
moving parts and greater flexibility for inspecting complex geometries. Moreover, the beams can
be steered, scanned, and focused electronically, and these methods offer significant technical
advantages over conventional ultrasonics, and other NDT methods.
Advantages over radiography

No radiation safety issues
Better detection of planar defects
Vertical sizing capability
Near real-time displays
Great flexibility in parameter range
Compliant with all known codes
Advantages over conventional ultrasonics

High speed, excellent data storage, and more cost-effective. (Equipment costs are
similar; higher instrumentation costs are offset by lower mechanical costs for
phased arrays)
Better imaging, displays, and interpretation
Better probability of detection
Easier defect sizing and much more flexibility
Many more angles and scan patterns available
High repeatability and reproducibility
Easy and comprehensive reporting
Overall, the use of phased arrays permits optimizing defect detection while minimizing inspection
time, thereby improving productivity.

Phased Array Limitations

Are there limits on this control? Can the beam be steered or focused anywhere?
Let's assume that the aperture of our 1-D phased array is square and contains 16
elements. The sound field emitted by a square aperture, for the purposes of this
discussion, is similar to that of a circular disk about the same size. We start the design
process by selecting the frequency most suitable for detection of the reflector type we
expect to encounter. This is identical to the frequency selection process used for single-
element systems.
Now, let's consider beam steering. As shown in Figure 5, steering is caused by the
constructive interference of wave fronts emitted by the 16 elements at different times. In
Figure 5, the wave fronts from each element are shown being circular and uniform in
amplitude. This is not the case. Remember that the energy is concentrated on the axis of
each element - as the angular deviation from the element axis increases, the amplitude
decreases. We also said that the rate at which this occurs is greater for large elements
than for small elements (at constant frequency). Therefore as a phased array is steered off
axis, the amplitude will decrease at the same rate as the individual elements making up
the array. To steer to large angles, small individual elements are necessary. This is the
second design criteria in phased arrays - determine the maximum necessary steering
angle and set the individual element width so that at that angle the beam amplitude from
the individual element is reduced by no more than 6 dB.
Finally, the number of elements in the group must be determined. This is dependent on
the necessary focal requirements. For example, assume the region to be interrogated is 50
mm thick. Therefore, we want to be able to focus at depths as great as 50 mm in the test
piece. The sound field of a phased array element group is approximately equal to that of a
single element having the same size and frequency as the group. We know from our
discussion above that we can only focus within the near field length. We must include a
sufficient number of elements in the phased array group that the near field extends at
lease to 50 mm.

CONCLUSION
The phased-array ultrasonic testing method that permits scanning and focusing of ultrasonic-
wave beams for the purpose of inspecting the complex geometry parts and the parts made of
high-noise materials which have been difficult with the conventional UT method. Specifically,
the following technologies have been established:
(1) Fabrication of high-sensitive piezoe lectric composite

by utilizing micro fabrication technique
(2) Establishment of optimal designing procedures

using sound field analysis
Furthermore, the newly developed UT probes were actually used to inspect the complex geometry
parts of piping and the parts made of stainless steel castings, and this demonstrated that they were
applicable to the inspection of the parts for which conventional UT methods have been unusable.
Currently, uses the phased-array UT probes in the inspections of elbow parts and nozzle stub
welds in actual plants for verification of their effectiveness.
MHI intends to continue to design other types of UT probe suitable for inspection of pipings and
pressure vessels different in shape and size and, at the same time, to improve the UT flaw
detection technology by making use of the advantages of phased-array UT method. The
performance of the current phased-array UT technology, especially in its flaw detecting ability
and size-determining ability in various fields of practical applications.
Phased array ultrasonic nondestructive evaluation is the subject of a good deal of research, which
may soon make it easier than ever to integrate testing into assembly lines, taking the technology
to new corners of the industry. Increased sensitivity, higher computing power, and better imaging
are improving the quality of information and ease of use.
Phased arrays are increasingly finding use in NDT, and whether they are a panacea to all NDT
problems or a gimmick remains to be seen; there is no question of speculation. Watch out for the
next article (Part 2), which features Frost & Sullivan’s analysis on the future and the market for
phased array ultrasonics, along with exclusive quotes from industry experts. Phased array
ultrasonics is expected to revolutionize the NDT industry in the coming years, and it has followed
the line of improvement that most other electronic-driven tools have followed. Continuous
research has also led to improved electronics, software, and scan-and-display capabilities. These
are further expected to improve and change the landscape of the NDT industry. These are some of
the trends shaping the future of phased array ultrasonics technology.

REFERENCE
\
Sugiyama, S., Application of Micromachining to Sensors, J.
IEEE Japan Vol. 117 No. 12 (1997) pp.828-831
Bley, P. et al., The LIGA Process: A Microfabrication

Technology, FED Journal Vol. 5, No. 1 (1994)
Saneyoshi, J. et al., A Technical Handbook of Ultrasonic

Testing (A Newly-rivised edition), The Nikkan Kogyo
Shinbun, Ltd. (1985) pp.368-369
Birks, A., Non Destructive Testing Handbook, second edition,

v. 7, Part 3: Tests with closely positioned transducers, ASNT
publication
"Inventor of the Week: Albert Macovski, Medical Imaging Systems".

web.mit.edu/invent. 2000-08. http://web.mit.edu/invent/iow/macovski.html.
Retrieved 2007-03-11.

Development of Phased Array Ultrasonic System for Non-Destructive Testing of Nuclear Components

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DEVELOPMENT OF PHASED ARRAY ULTRASONIC

In partial fulfillment for the award of the

Department of Electronics & Communication Engineering

KMEA ENGINEERING COLLEGE

DEVELOPMENT OF PHASED ARRAY ULTRASONIC

Electronics And Communication Engineering

in partial fulfillment of the requirements for the award of B.Tech degree in

Electronics And Communication of KMEA Engineering College

of Mahatma Gandhi University, Kottayam.

Prof Rajan K Varghese Mrs. Arya Dev i Dr. Rajesh V.G

First of all I thank the Almighty for his enlightening presence

I wish to convey my gratitude to ”Prof. C.I.Abdul Rahiman,Director,

I express my gratitude to my beloved “Principal, Dr. Rajesh V.G” for

I extend my sincere thanks to “Prof. Rajan K Varghese, Head of

I would also like to express my sincere thanks to my coordinator of the

5. Phased array ultrasonics in NDT : 20 - 21

6. Applications of phased array ultrasonics : 22 - 24

8. Phased array limitations : 27

Dept of ECE KM EA Engg college

Dept of ECE KM EA Engg college

Phased Array technology

Sound field control

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Figure 2: Linear scan

Figure 3: Steering sound field

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Electronic Phasing Used to Steer a Sound Field

Electronic Phasing Used to Ge nerate a Focused Sound Field

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Dept of ECE KM EA Engg college

Figure 4: Representati on of the result

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Figure 5: Sector representation with angle probe

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Portable Phased Array Instrument

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Dept of ECE KM EA Engg college

Principle of operation and features

Method Electronic scanning Electronic focusi ng

Probing speed increases as a resul t of Space resolution (detecting

Principle and feature of phased-array UT

Dept of ECE KM EA Engg college

Dept of ECE KM EA Engg college

Dept of ECE KM EA Engg college

Fig : Phased Steering, Focusing, and Scanning Co mbined in One System

Additionally, electronic scanning is faster because no physical probe motion is required.

Dept of ECE KM EA Engg college

Dept of ECE KM EA Engg college

What is a phased array system?

Typical phased array probe assemblies

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Typical multi-element construction

How do they work?

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Example of angled beam generated by flat probe by

Example of focused linear scan beam

What do the images look like?

An A-scan is a simple RF waveform presentation showing the time and amplitude of an

Dept of ECE KM EA Engg college

Generalized beam profile Straight beam A-scan image

Generalized beam profile Angle beam A-scan image