AFNDT - MARTY - Practical application of ultrasonic array technology

4th AFNDT

2006

Dr. Pierre MartyPractical Application of Ultrasonic Array Technology

Practical Applications of Ultrasonic Array Technology

Dr. P. N. MartySonatest NDE

Advanced UT Products

4th AFNDT

2006


Content

Available Technology Sensors Technology Examples How it works Applications Benefits and Conclusion

4th AFNDT

2006


Available Technology

Phased Array Harfang X-32

Multi-element RapidScan II: Very fast C-scan

with dry-coupling ULTRAN IPass NCU

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2006


Encoded contact arrays

Probes with wedge

Pitch-catch

Sensor Technology

X-32 Phased Array Probes – Direct Contact

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2006


Wheel probes

Sliding and radii array

Sensor Technology

RapidScan II - Direct Contact

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2006


Automated Dry-coupling Array system

Full Coverage Automated System

Contour following up to a radius of curvature of 1 m

No Z-axis control required, 100 mm of translation

Improvement on conventional gimbals capable of scanning over sample edges and cut outs

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2006


Immersion Application

Highly reliable and fast pulse-echo application, with the highest performance.

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Non-Contact Array Technology

Suitable for flat materials rolling on a production line or flat panels for: in-process or post-process analysis for defects, physical properties, etc.

Gas matrix Piezoelectric Composites: The most efficient piezoelectric material with ZERO CROSS COUPLING

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Understanding Array Technology

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L-Scan: Linear Scanning

Immersion like test Composite material

RapidScan II Air-coupled array/systems

Delays

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L-Scan Example

Corrosion mapping

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S-Scan: Sectorial Scanning

35

40

45

55

65

75

Delays Angled beam inspections Welds D path

X-32 Phased Array Systems

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S-Scan: Weld Inspection

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Example: Lack of Penetration

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Practical examples

Nuclear Application

Weld testing

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Nuclear App.: J-Tube Examination

Millstone Power Station, Connecticut, USA

Problems:Degradation on the Steam Generator Feed-ring beneath the J-Tube fillet welds.

Feed-ring base material is experiencing severe erosion due to localized flow velocities

The J-Tubes are made of inconel as well as the fillet weld.

Challenges: High Dose area, Geometry, limited access

4th AFNDT

2006


Challenges

“X”

“S”

“D” θ

“L”

High Dose area, Difficult Geometry, limited access

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The Solution

Point of Maximum ExtensionSound Path Cursor

Extractor Cursor

• Phased array for speed and remote control.• Pitch and catch technique with two 16-element probes in one casing;• Scanning with 40 to 85 degrees sweep

Dual 2.4 MHz 16-element probes with wedge

4th AFNDT

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Conclusion: J-Tube Examination

A reduction of 63% inspection time, $140,000 saved, in J-Tube examination costs.

A reduction of up to 70% in radiation exposure time and dose;

“Millstone actually performed examinations on 2 of the 4 feed-water rings and there was excellent data correlation with the previous automated examinations. ” – Richard Fuller, Level III in charge of the inspection.

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WindCraft Tower – Weld Testing

Wind turbine towers are typically around 60-90m tall.

Weight 100-200 Tonnes Made in 3-4 sections One plant makes around 25

sections /week Lots of Welds

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Weld Inspection

Sector Scan Inspection: all defects found at once

Greatly increases speed

Approx 6 hours or so per tower.

Reduced Bottleneck

Manual PA to replace manual traditional UT

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2006


Conclusion 1: Advantages of Arrays

Speed: scanning with phased arrays is much faster than single probe conventional mechanical systems, with better coverage;

Flexibility: set-ups can be changed in a few minutes, and typically a lot more component dimensional flexibility is available;

Inspection angles: a wide variety of inspection angles can be used, depending on the requirements and the array;

Small footprint: small matrix arrays can give significantly more flexibility for inspecting restricted areas than conventional probes

Imaging: showing a “true depth” image of defects is much easier to interpret than a waveform. The data can be saved, analyzed and re-displayed as required.

Quality: recording and imaging gives a 100% coverage with all angles, and data can be reviewed later.

4th AFNDT

2006


Conclusion 2

Don’t just think of Advanced UT & Array for ‘otherwise impossible’ applications

They offer real advantages (Financial, Quality) in many applications with an existing solution.

They apply to such a broad range of applications that investment in the technology ( system cost, training, procedures, personnel) is justified, and quickly compensated by productivity gains.

4th AFNDT

2006


Advanced UT Solutions @ Sonatest

Many different advanced array based systems can be used, it is not just about phased array

Portable phased arrays (X32), C-Scan Mapping (RapidScan2) Immersion systems (Atlantis) Non-Contact (Ultran) AUTOMATED (R32, RapidScan, Atlantis, Ultran)

Choice is controlled by codes, component requirements, budget and knowledge.

Many possibilities for robotics: • Wheels, sensors, • Magnetic wheel scanners, • Robots.

4th AFNDT

2006


The Sonatest Group thanks you for your attention.

We would like to invite you to our stand.

AFNDT - MARTY - Practical application of ultrasonic array technology

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