NDE Associates, Inc.

- Ultrasonic Testing - Phased Array

Phased Array Ultrasonic Testing (PAUT)

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PAUT for Weld Inspections

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SERVICES OFFERED
NDE Associates offers the following services for Phased Array inspections
Phased Array for Weld Inspections
Phased Array of Complex Components
Phased Array for Defect Sizing

"Ultrasonic Phased Arrays for Weld Testing",

Paper Copyright by Materials Evaluation,
ASNT, Columbus, Ohio.

Phased Array in Lieu of Radiography

Phased array technology offers an attractive option to perform UT in lieu of
radiography. This main advantage being that phased array inspection does not
interfere with surrounding work. Radiography requires barricading a perimeter during
the exposures.
Why use Ultrasonic Phased Arrays ?
Unlike conventional and automated ultrasonic testing, which is performed for fixed
angles of 45, 60 and 70 degrees, phased array testing can cover all angles in this
range. This is significant as a single phased array inspection can cover all angles from
40 to 75 degrees and displays the image in real time. The real time image is direct
superimposition of the ultrasonic illumination on the test piece and is easy to
interpret. Using swept angle S-scans, PAUT requires smaller surface distance for
inspection compared to AUT or manual UT. PAUT can cover a large cross-section of the
test piece from a single probe location. On the contrary, AUT either requires raster
scanning or multiple probes placed over a range of surface distance to cover the entire
cross-section of the test piece. When properly used, phased arrays can be used on all
ultrasonic applications and result in a highly reliable NDT inspection.
Phased Array Tests on Weld flaws
We have tested the capability of phased arrays for detection of defects in weld test
samples. These samples include plate and pipe sections. Weld flaws in these samples
include toe cracks, center line crack, LOF, LOP, slag and porosity. Tests were
conducted using two different systems. Test results showed that both systems
successfully detected all the defect types. Defects were definitely easy to detect and
interpret with the phased arrays compared to the conventional A-Scan machine proving
the reliability of phased arrays for weld inspection. For further reading see "Ultrasonic
Phased Arrays for Weld Testing", Paper Copyright by Materials Evaluation, ASNT,
Columbus, Ohio.

ID Crack detected on 0.5 inch thick plate

vee weld.

Phased Array Testing of Butter Welds

Butter welds are commonly used for subsea applications. These can include both carbon
steel and A625 butter welds. The most common flaw in butter welds is lack of fusion
(LOF) between the beads. These welds can be easily inspected using phased arrays. The
inspection is done by scanning a PAUT probe from the ID surface of the pipe. Refracted
shear waves are used for carbon steel butter welds and A625 welds are inspected using
refracted L-waves. L-waves are also used when the ID has a A625 clad. The technique
reliably detects flaws in butter welds.

LOF detected on 0.5 inch thick 8 inch dia

pipe.

PAUT Inspection Technique. The probe

mounted on a radiused wedge is scanned
from the pipe ID surface.

Indications detected by PAUT in butter

welds verified by Liquid Penetrant Testing

Crack sizing with Phased Arrays.

Accurate sizing of flaws requires a small focal spot size at the defect location. The
three figures above show improvement in sizing with increased probe aperture: 12 mm,
18 mm and 24 mm. Probe frequency is 5MHz. Accurate flaw sizing requires probes
with high frequencies and large apertures. As a rule of thumb for flaw sizing, the
phased array active aperture should at least be 0.4 times the part thickness and a
preferred frequency of 5 MHz. Therefore, to inspect a 2 inch (50 mm) plate, the
active aperture of the probe should be at least 20 mm. Smaller probes will result is
large beam spread and over sizing sizing of flaws. (Note: Active aperture is the element
size x no. of elements that are active, eg: a probe with sixteen 0.75 mm elements has a
active aperture of 12 mm. In case, only 12 consecutive elements are used, the active
aperture drops to 9 mm )

http://www.nde.com/phased_array_applications.htm[22/07/2013 8:46:56]

Inspection of Turbine Steam Chest for

thermal fatigue cracking. Instrument: Phasor

NDE Associates, Inc. - Ultrasonic Testing - Phased Array

Improvement in Flaw Sizing with increased PA Aperture (Top Left) Root Crack - 3 mm
(0.120") (Top right) 5 MHz, 12 mm aperture. Flaw shown by dark black lines is oversized
to almost double its size. (Bottom left) 5 MHz, 12 mm aperture. (Bottom right) 5 MHz,
24 mm aperture. Flaw correctly sized.

See also PA Technology

NDE Associates, Inc.

515 Tristar Drive
Webster, TX 77598
Phone: 281 -488 -8944
Fax: 281 -488 -8485

http://www.nde.com/phased_array_applications.htm[22/07/2013 8:46:56]