Some Guidelines on Selecting Arrays

How to design your inspection system

(also see module “How Phased Arrays Work”)

info@rd-tech.com • www.rd-tech.com
 Objective of these Guidelines

 This module is aimed at showing the viewer the

process for selecting the optimum element size
and shape.
 It also gives some examples of element selection
for specific applications and practical limitations.
 This section will illustrate some of the technical
issues and limitations on selecting arrays:
 Element size
 Frequency
 Element positions

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 Common Probe Geometry
Linear

1D linear array 2D matrix

Circular

1D annular array 2D sectorial annular

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Implications of Element Size on Beamforming

 Point A is OK because all

A rays are within elemental
A beamwidth
B  Point B yields unexpected
results because rays are
outside elemental
α beamwidth

d
0.41λ
sin (α ) =
d
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 Phased Array Basics

 For linear scans, arrays are multiplexed using the same focal law.
 For sectorial scans, the same elements are used, but the focal laws are
changed.
 For Dynamic Depth Focusing, the receiver focal laws are only changed
in hardware.
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 Implications of Element Size

 Element size (especially width) is a key issue. As

size decreases:
 Beam steering capability increases.
 The number of elements increases rapidly.
 Manufacturing problems may arise. Minimum element
size ~0.15-0.20 mm.
 Limiting factor often is budget, not physics or
manufacturing.
 Main manufacturing problems occur at high
frequencies.

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 Element Frequency

 Simple approach:
 If conventional UT uses, say, 10 MHz, plan on
using the same frequency for arrays.
 If conventional UT uses a 10-mm aperture, plan
on using similar aperture with PAs (e.g.,
10 elements of 1-mm width).
 With phased arrays, in practice, it may be
possible to obtain better signals using
higher frequencies and a larger aperture
(=> tighter, optimized focal spot).
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 Element Positioning

 Typically arrays use “side-by-side” elements with

only acoustic insulation as gap.
 Grating lobes generally minimized by selecting
suitable element width.
 To reduce costs, may use “sparse array,” with
larger gaps between elements.
 Sparse arrays tend to produce stronger grating
lobes.
lobes Can minimize using random arrangements
of elements.

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Inter-Element Spacing Controls Grating Lobes
5 MHz, Focal Point at 50 mm, Array Width = 20 mm
Wavelength = 0.3 mm in Water

A. 33 elements, 0.6-mm wide B. 9 elements, 0.6-mm wide

side by side spaced 2.4 mm apart
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 Array Shape

 Depends on application
 Most applications use linear arrays, e.g.,
weld inspections
 Special applications require special arrays,
e.g., sectorial-annular, matrix.

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 Determining the Optimum Array

1. Analyze application: angles of inspection,

coverage, inspection rate, ….
2. Determine ultrasonic frequency, aperture,
immersion vs. contact, ….
3. Typically, this information defines array.
4. Reality check includes engineering and
finance.

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 Phased Arrays
– Practical Considerations

 A phased-array probe is defined by:

 Frequency (F)
 Total aperture in the steering direction (D)
 Height (aperture in the mechanical direction) (h)
 Quantity of individual elements (n)
 Width of individual elements (d)
 Spacing from centre to centre between two successive
elements (sp)
 Wedge

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 Phased Arrays
– Beam Steering
 Capability to change the angle of the beam created by the probe. This is
related to the divergence of the individual element of the probe.
 Two parameters: width of the element and frequency

 >> d <d =d

Beam steering as beam divergence is defined by:
-6 db: Sin (  ) = 0.514 /d : divergence half-angle
-20 db: Sin (  ) = 0.8 /d
The smaller the individual elements, the larger the steering capability of the
array.

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 Phased Arrays
– Quantity of Elements

The quantity of elements in a phased-array probe is always

a compromise between:
Desired working range of the probe
Focusing capability
Steering capability
Electronic system capability
Cost

For example, to create a probe with a large working range

and a large steering capability, a large amount of elements
will be needed, which might exceed the electronic
capability of the system, or the budget.

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 Some Typical Array Specifications

 Gas Pipelines
 Pipe Mills (ERW welds)

 High and low frequency array limitations

 Also see Presentations – Aerospace for

Titanium Billets and Aircraft Fasteners

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 Gas Pipeline Weld Arrays

 Standard design is two 60-element, 1-mm

spacing linear arrays, 7.5 or 5 MHz.
 Advantages:
1. Can use standard instrumentation
(128 channels)
2. Gives good coverage for pipes from 6 mm
to 32 mm (most candidates)
3. Provides adequate beam steering for all
normal pipeline weld applications.

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Weld Inspection Using Ultrasonic Phased Arrays

 Weld inspections typically use one

array on each side of the weld.
 Arraysare programmed to either
focus on particular facets of the
welds, or to perform code-type
inspection.

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 ERW Pipe Mills: Array Selection

 Use of 2 curved array probes (one

on each side of the weld seam)
 2 techniques used:
 Electronic DEFLECTION to generate
the incidence angle
 Electronic SCANNING of the beam
around the weld sector

Inspection with:
45 SW
70 SW
0 LW for profilometry
Coupling check
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Use of Curved Array Probes
Optimum array uses 0.6 mm
element spacing at 5 MHz
(cf. 1 mm for gas pipelines at
7.5 MHz)
Satisfies coverage, beam steering,
and other criteria.

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 High and Low Frequency Arrays

 High frequency:
 17-20 MHz arrays manufactured
 Minimum element size approx. twice λ (~0.2 mm
width)
 Cannot steer well; only focus and linear scanning
 Low frequency:
 Matrix arrays of 1-1.5 mm at 1.5 MHz
 Great steerability
 => Potential limitations of manufacturing
technology mainly at higher frequencies

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 Summary

 Correct array choice critical for good

inspection system
 Element dimensions and spacing depends
on coverage, beam steering required, and on
grating lobes
 Budget often limiting factor

 Technical limitations at higher frequencies

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