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
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Content
Available Technology Sensors Technology Examples How it works Applications Benefits and Conclusion
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Available Technology
Phased Array Harfang X-32
Multi-element RapidScan II: Very fast C-scan
with dry-coupling ULTRAN IPass NCU
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Encoded contact arrays
Probes with wedge
Pitch-catch
Sensor Technology
X-32 Phased Array Probes – Direct Contact
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Wheel probes
Sliding and radii array
Sensor Technology
RapidScan II - Direct Contact
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Immersion Application
Highly reliable and fast pulse-echo application, with the highest performance.
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Understanding Array Technology
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
L-Scan: Linear Scanning
Immersion like test Composite material
RapidScan II Air-coupled array/systems
Delays
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
L-Scan Example
Corrosion mapping
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
S-Scan: Sectorial Scanning
35
40
45
55
65
75
Delays Angled beam inspections Welds D path
X-32 Phased Array Systems
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
S-Scan: Weld Inspection
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Example: Lack of Penetration
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Practical examples
Nuclear Application
Weld testing
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
Challenges
“X”
“S”
“D” θ
“L”
High Dose area, Difficult Geometry, limited access
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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.
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
4th AFNDT
2006
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
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
Dr. Pierre MartyPractical Application of Ultrasonic Array Technology
The Sonatest Group thanks you for your attention.
We would like to invite you to our stand.
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