APPLICATIONS 2:

MATERIALS
CHARACTERIZATION

Classification of ultrasonic Applications

Low frequency-high intensity
20kHZ<f<100kHz
10-12Wm-2<I<103Wm-2

Applications:
Welding
Cleaning
Food industry
Concrete testing
Temperature and pressure
measurements

High frequency-low intensity

100kHz<f<100GHz
103Wm-2<I<1010Wm-2
Applications:
NDT testing
Level meters
Thickness measurements
Holography
Intelligent processing of
materials
Residual stress
measurements

An industrial technique whereby two pieces

of plastic or metal are joined together
without melting
The frequency of USW vibrations is 10kHz to
75kHz
Used in electronic, automotive and
aerospace industry

Working principle
The transducer generates the
ultrasonic vibration
The ultrasonic vibrations are
transmitted into the work piece
through coupling system or
sonotrode
The sonotrode tips contacts the
work piece and transmits the
vibratory energy into it
The vibrating energy is passed
into the work piece for welding
During this transfer energy, a part
of the energy is dissipated in the
anvil support structure

 -Can be used to join

dissimilar material
-Can be used to join the
same material
The main limit is the
thickness of the materials

2.0 Ultrasonic flowmeters

A device to measure the flow velocity of

total fluid.
Different installation to suit piping design.
Sensitive to change of flow pattern.
Measurement affected by particles flow.
Fast response
Clamp-on available

Working principle
A device to measure the flow velocity , volume or mass
flow of a liquid or a gas
A transit time device which apparently measures the
Delta T or time of flight path

Another Type of Installations

Time of flight suitable for clean liquid and

gases

Doppler- suitable in liquids having a second

phase eg: sewage, sludge

Open channel- measure the height of a liquid

surface as the fluid flows

Correlation-widely used in multiphase flows in

the oil & gas industries

Fluid oscillatory-detect the change in amplitude

modulation

Working principle-Doppler

The basic principle of operation employs

the frequency shift (Doppler Effect) of an
ultrasonic signal when it is reflected by
suspended particles or gas bubbles
(discontinuities) in motion.
utilizes the physical phenomenon of a
sound wave that changes frequency
when it is reflected by moving
discontinuities in a flowing liquidultrasonic sound is transmitted into a pipe
with flowing liquids, and the
discontinuities reflect the ultrasonic wave
with a slightly different frequency that is
directly proportional to the rate of flow of
the liquid
Current technology requires that the liquid
contain at least 100 parts per million
(PPM) of 100 micron or larger suspended
particles or bubbles.

Schematic Diagram of Doppler

3.0 nondestructive test(ndt)

NDT testing characterizing material
thickness, integrity, or other physical
properties by means of high-frequency
sound waves for quality control.

A pulser/receiver is an electronic device that can produce high

voltage electrical pulses to drive transducer to generates high
frequency ultrasonic energy.

The reflected wave

signal is transformed
into an electrical signal
by the transducer

Sound energy
propagates
through the
materials in the
form of waves.

Energy reflected by
the flaw surface due to
discontinuity (cracks)

It is sensitive to both surface and subsurface

discontinuities.
The depth of penetration for flaw detection or
measurement is superior to other NDT methods.
Only single-sided access is needed when the
pulse-echo technique is used.
It is highly accurate in determining reflector
position and estimating size and shape.
Minimal part preparation is required.
Electronic equipment provides instantaneous
results.
Detailed images can be produced with automated
systems.
It has other uses, such as thickness measurement,
in addition to flaw detection.

Limitations
Surface must be accessible to transmit ultrasound.
Skill and training is more extensive than with some other
methods.
It normally requires a coupling medium to promote the
transfer of sound energy into the test specimen.
Materials that are rough, irregular in shape, very small,
exceptionally thin or not homogeneous are difficult to
inspect.
Cast iron and other coarse grained materials are difficult
to inspect due to low sound transmission and high signal
noise.
Linear defects oriented parallel to the sound beam may
go undetected.
Reference standards are required for both equipment
calibration and the characterization of flaws.

4.0 Ultrasonic level gauge

Use wave propagation to detect

the present of fluid at designated
location.

Normally will be low or high level

modes

Retrievable for calibration.

Working principle

Open detection
Conceal Type

5.0 Ultrasonic leaks detection

A Leaks
Specialist
carried out
leaks
detection
activities in
Heat
exchanger
tubes

Advantages
Enhanced leaks detection speed for tubes, connection
and pitting (fine holes).
Less cost
It occupies less space and reduces labour
It can be occupied in cleaning hazardous substances
without the contact of the workers
Environmentally pollution free
High safety with less complaints

Working principle
Ultrasonic leak detectors work like simple
microphones that are sensitive to highfrequency sounds ranging from 20-100 kHz.

piezoelectric crystal element as a sensor,

minute high-frequency sound waves excite
or flex the crystal

In order to test tube and shell

condensers with ultrasound, we
must first understand how they
work

Four Ways to Test

There are four basic methods for
testing a heat exchanger, two online,
scan and contact, and two off-line,
pressure and tone

Advantages
It is non invasive technique for measuring the liquid/oil level
in any storage/process tanks
It can be controlled in a remote
It is easy and continuous on-line measurements even in
corrosion/hazardous zone

RESEARCH PROJECT:
Stepped cell test ultrasonic

Stepped cell test ultrasonic

Used to determine the cloud point of palm oil
Cloud point is one of the parameter for quality control of
palm oil
Conventional method used visual observation of physical
changes on palm oil sample- colour

Working principle
Cloud point of palm oil can be
determined when big changes
in velocity and absorption of
ultrasonic occur
Velocity and absorption of
ultrasonic waves different
when it is incident on a
different medium

Experimental set up

Results
Cloud point detected
by ultrasonic method
higher than
conventional method
Ultrasonic method can
detected the changes
of palm oil structure
earlier than
conventional method