(a) Phased Retiree 1 (b) Employed Full-Time. 1 (c) Phased ...
Practical Ultrasonic Phased Array High Temperature ...€¦ · Focal Law Calculation...
Transcript of Practical Ultrasonic Phased Array High Temperature ...€¦ · Focal Law Calculation...
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Practical Ultrasonic Phased Array High Temperature Technique Development
Robert Ginzel 1, Mohammad H. Marvasti 2 and
Anthony N. Sinclair 2
1 Eclipse Scientific2 Department of Mechanical and Industrial
Engineering, University of Toronto
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Introduction
Enhanced failure mechanisms
� Economic damages
� Life loss
Regular non-destructive testing (NDT) is required
� On-line inspection
� Phased array ultrasound
Industrial systems operating at high temperatures
� Power plants
� Petrochemical plants
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Phased Array Inspection – Scan Plan
Plastic wedgePA probe
Weld section
Test pieceUltrasonic
waves
� Select wedge-array system
� Select optimum beam angles
� Ensure full coverage
� Ray tracing software
� Focal law (elements delay times)
� Plane waves and focused beam
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High Temperature Inspection Challenges
1. Operation (Assembly)
2. Beam formation inaccuracy
� Wedge (high temp resistant material)
� Protecting the array (local cooling )
� Velocity/Angle changes
� Beam skew
Significant thermal gradient
inside the wedge
Cooling
Jacket
5L64-A12
Array
High Temperature
Wedge
� Non valid focal laws
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Temperature Distribution Model (FEM)
Boundary conditions (steady state)
1. Temperature (piece surface)
2,3,4. Convective cooling
Natural convection ( surrounding Air)
5. Temperature (cooling jacket effect)1
5
3
2
4
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Temperature-Velocity Changes
@ 5MHZ
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Beam Skew Modeling
Ray Theory Tracking a Single Point on the Wave Front
V(x,y): local wave speed
φ: local angle with respect to x-axis
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Focal Law Calculation Algorithm-Plane Wave
Element time delays
� Calculate the relative time delays for
excitation of each element
� Use a few sample points on the wave front
for calculations
� Obtain the wave paths, calculate the length of
the paths and use sound velocity in the block
and the wedge
� Interpolate the travel times along the array-
line points to obtain travel times associated
with each element
� Calculate travel time of the waves emitted
from each element to the wave front
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Model Results
� Non-linear time delay Pattern
for HT inspection
� Incorrect time delays on array
elements of up to 100 ns
WA12-HT55S-IH-G
5L64-A12
� Phase error of up to 50% of the
wave period
� destructive interference, significant
distortion of the desired beam profile,
and poor imaging resolution.
� φs=60o , Using elements
1-16 of the array
� Pulse central frequency of 5 MHz
(period of 200 ns)
100 ns
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Algorithm Validation-Experimental Concept
Transmission
Delays
Reception
Delays=
Φs
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Algorithm Validation – Experiment Set Up
Hot Plate
WA12-HT55S-IH-G5L64-A12
InsulationAngled
block
Focus LT and Tomoview
� Enter calculated delays
manually for each element
(transmission)
� Collect the received signal by
each element (reception)
� Comparing the reception
and transmission delays
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Algorithm Validation – Experimental Results
� Results of 15 repeated
experiments
� Random errors of up to
±13 ns
� Bias errors of up to 10 ns
WA12-HT55S-IH-G
5L64-A12
� φs=60o , using elements
1-16 of the array
� Received delays on
elements 8 and 16� Our experimental results and theoretical
results agree within the expected error
limits
� Pulse central frequency of
5 MHz (period of 200 ns)
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Focal Law Calculation Algorithm-Focused Beam
Element Time Delays
� Calculate the relative time delays for
excitation of each element
� Use a few sample points on the wedge-piece
interface for calculations
� Obtain the wave paths, calculate the length
of the paths and use sound velocity in the
block and the wedge
� Interpolate the travel times along the array-
line points to obtain travel times associated
with each element
� Calculate travel time of the waves emitted
from each element to the focal point
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Model Results
WA12-HT55S-IH-G
5L64-A12Elements 1-16
180 ns
174 ns
147 ns
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Algorithm Validation-Experimental Concept
� Sweep focused beam
(40o-70o in 1o increments)
� Using elements 1-16
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Algorithm Validation – Experimental Results
� Four holes are resolved
(Local amplitude peaks)
� Amplitude peaks at 44o, 49o, 56o
and 66o refraction angles
� Application of conventional delays at
150oC led to non-optimal focusing
� Correct high temperature delays led
to peak shifts toward the expected
locations
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ConclusionConclusion
Future WorksFuture Works
3. Implement the new algorithm in automated scanning system
1. Test up to 350oC
2. Develop standards for high temperature inspections
� Application of conventional array
focal law at elevated temperaturesIncorrect time delays,
distortion of the beam profile
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Elevated Temperature Inspection System Overview
1. Select the high temperature wedge-array system
4. Calculate focal laws
5. Perform the scan via application of the calculated focal laws
6. Time adjust the scan results for correct flaw positioning
2. Build a scan plan for the inspection
3. Calculate temperature profile in inspection system
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Acknowledgement
This work was sponsored by Eclipse Scientific and theCanadian Natural Sciences and Engineering ResearchCouncil (NSERC).