Conferencia Mexicana De
Pruebas No Destructivas
Unlocking New Applications
w/ PAUT Transducers
Steve Strachan – Sensor Networks, Inc.
8/21/2019
09/15/2024 1
Agenda
Phased Array vs. Conventional UT Overview
Types of Phased Array UT Transducers
Phased Array UT Transducer Manufacturing
• Development
• Design
• Prototype
• Manufacture
Applications for Phased Array UT Transducers
Conclusion
Phased Array vs. Conventional UT
Que es?: Using multiple channels of ultrasound
(instead of a single channel) to be able to detect,
measure, and image anomalies in a specimen under
evaluation
Como funciona?: Using high end portable or
stationary equipment capable of firing multiple
channels of ultrasound
Por que?:
• Increased POD (Probability of Detection)
• Image and measurement capability
• Speed at which one can inspect
• Larger area inspection ability
• Ability to more easily inspect complex
geometries & materials
Phased Array vs. Conventional UT
Conventional UT Equipment & Data Phased Array UT Equipment & Data
Phased Array vs. Conventional UT PROBES
Conventional UT Probes ($150-$3,000) Phased Array Probes ($3,000-$80,000)
How does Phased Array UT Work?
How does Phased Array UT Work?
Different Phased Array Types
Phased Array Nomenclature
Key Points
• Big Aperture to
focus deep
• Small elements
to steer far
How to BUILD a Phased Array UT Transducer?
https://www.youtube.com/watch?v=jkVTafD-e98
Transducer Story … in real life!
Incident: April 18, 2018 a critical
failure of a Boeing 737 engine on
Southwest Airlines flight number 1380
forced an emergency landing, in New
York LaGuardia airport where multiple
people were injured and a woman was
killed.
https://abcnews.go.com/US/plane-makes-emergency-landing-philadelphia/story?
id=54530003
Problem Statement
Root Cause: Stage 1 fan blade
developed a fatigue crack which
resulted in loss of containment
(ejected blade)
Solution Requirements: Need
inspection method to test existing fleet
of engine blades in the field as
accurately as possible as QUICKLY AS
POSSIBLE
The Solution …
Fracture Mechanics Analysis: Engine
manufacturer able to duplicate
incident
Samples Manufactured: Had EDM
notches put into new specimen to
mimic fatigue crack, sent to SNI to
have modeled, designed, and
prototyped
The Solution …
UT Beam Modeling Computer Aided Design for Transducer
The Solution …
PAUT – TFM/FMC ... Great Technology …
Total Focusing Method or Full Matrix Capture
Total Electronic Focusing (FMC): FMC specific
(TFM): electronic focusing data-acquisition process
which consists of using ultrasonic array
adapting the receiving probes where each
delay laws to focus at element in an array is
many points which form a successively used as the
grid, after a single pulse transmitter, while all
which generates a large elements are used as
and/or divergent receivers for each
ultrasonic beam transmitted pulse
PAUT – TFM/FMC ... But it’s all about the Probe!
Advantages of TFM/FMC:
• Optimal focusing and spatial
resolution everywhere Element Steering Element Spacing
• Direct imaging of a large area
for one probe position
• All reachable angles with the
array simultaneously
• Defect characterization
• Comprehensive imaging of Depth/Focusing Frequency
defect
• 3D imaging
PAUT – TFM/FMC & HTHA
High Temperature Hydrogen
Attack (HTHA):
• Petrochemical industry inspection
application
• Characterization of stress or
corroded areas in hydrogen service
above 200C in carbon steel assets
• Until now, probability of detection
was <1%
• Today utilizing TFM/FMC & high
end PAUT transducers, POD has
increased to >10% DLA 10 MHz Probe: Pitch & Catch PA AL-TFM 5 MHz Probe: Pulse Echo PA 64E with
64E w/ small pitch used in LW mode small pitch used in SW mode for improved
for improved TFM imaging TFM imaging in HAZ under weld cap
Phased Array Nuclear Bolt Inspection
Overview:
• Segmented-Annual Array
• 360 degree electronic scanning
• Displaced manual & motorized
scanning
Custom Phased Array Transducers
Custom Phased Arrays:
• Nasa
• Composite Backscatter
• 253 discrete .125” transducers
• 4.5” Radius
• 10 MHz Alpha Transducers
• Complex 5-Axis CNC Milling
• Compound-radius Wedges
• $80K selling price
Designing the New … Improving the Old …
Strain Relief: The most
common failure of Phased
Array transducers is
undoubtedly the strain relief
• Lasts @ 550K vs. 50K
cycles
• Improve lifespan of
transducers by 10x
Designing the New … Improving the Old …
Low-Noise Wedges: Investing R&D
into new noise-dampening material
w/ similar acoustic impedance as
the wedge itself
• Increased Signal-to-Noise
• Highly attenuative
• Radiused for OD, ID, or other
complex radii exams
Conclusion
Understanding when to use conventional UT vs. Phased Array
Phased Array UT Transducers come in all different shapes, sizes, and
configurations …
Select the RIGHT PROBE for the job
Custom solutions are being built all the time … test the boundaries!
Muchas Gracias!
Sources:
• https://www.olympus-ims.com/en/
• https://www.aos-ndt.com/product/fmc-tfm/
• https://www.m2m-ndt.com/en/technology/pa-techniques/tot
al-focusing-method-tfm
/
• https://
www.slideshare.net/ZetecNDT/principles-of-full-matrix-captur
e-fmc-and-total-focusing-method-tfm-in-ultrasonic-inspections
[email protected]
