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Proceedings of the National Seminar & Exhibition on Non-Destructive Evaluation

NDE 2009, December 10-12, 2009

Manual Phased Array Ultrasonic Technique for Weld Application

S. Anandamurugan
GE Inspection Technologies, JFWTC, Bangalore, India

Abstract
Conventional ultrasonic technique has been used as a technique for weld inspection since 1960s. In the early 1990s the concept of phased array ultrasonic inspection started being applied for industrial applications. This paper deals with the manual phased array inspection of welds and how it helps in improving productivity and probability of detection in weld applications. Manual phased array technique can interpret the weld specimen with the imaging of B-Scan, S-scan and C-scan. The impact of weld overlay, origin line and leg line on the phased array image will help the inspector in ease of interpretation of defects and in the analysis of the nature of weld defects like toe crack, root crack, side wall lack of fusion, incomplete root penetration etc., It also helps in identifying the location of weld defects with great precision. This paper discusses in detail, the use of manual phased array technique for weld applications, procedure for sector scanning of welds and the results obtained. Keywords: Phased Array, Ultrasound, Ultrasonic, Inspection, Weld, Testing, Sector Scan

1. Introduction
In the field of ultrasonic testing A-scan signal acquisition is the basis for flaw detection and interpretation. The A-scan signal is used as the raw data for the imaging of volumetric inspection called B-scan and C-Scan. But it needs mechanical scanning systems to acquire the A-scan data at multiple locations. The B-Scan and C-scan in industrial applications are mostly implemented in the automated ultrasonic inspections. With the recent improvement in the technology and software the portable instruments are upgraded with imaging facility which can be used for the manual inspection. Phased Array ultrasound is used in medical systems for the imaging of human tissues. This technology has been transferred to industrial application but the technique followed in medical systems cannot be transferred as it is, because of the wide range of materials used in industrial application. Hence the complexity of implementing the phased ultrasonic testing is higher for the industrial applications. In the earlier days phased array ultrasonic testing was implemented in automated ultrasonic inspection system. After successful outcome of automated phased array ultrasonic inspection the technology has been migrated to manual phased array inspection. Usage of phased array probes lead to drastic change by reducing the number of probes and inspection time rapidly. The multiple focusing and beam steering capability of phased array probes increases: Overall sensitivity Probability of detection Coverage of bigger volume at single position of probe

2.

Manual Phased Array Technique

The usage of manual phased array inspection will be more helpful for the inspectors who does manual weld inspection with conventional A-scan ultrasonic testing. Because manual phased array inspection would be more user friendly than automated UT. The mode of scanning is as same as conventional A-scan, hence this would help the field inspectors to transit from conventional A-scan to phased array imaging in the conventional manner. Manual phased array inspection has relatively lesser mechanical investment cost than automated ultrasonic testing and avoids the mechanical complexity of automated ultrasonic testing. 2.1 Phased Array Imaging For generating phased array ultrasound, composite piezo-electric elements are wired with the electronic circuit. Each and every element is configured by the software algorithm called delay law or focal laws. The delay law will define the time delay for each element according to the beam steering and beam focusing. The set of A-scan data is processed as a image to form the S-scan and angle corrected B-scan. Phased array ultrasound can steer the beam from -89 to 89 and focus the beams at different depths. The phased array ultrasound is categorized into two types: i) Linear Scan and ii) Sector Scan. Linear scan is the movement of beam according to the element step with the fixed beam angle. Sector scan is the steering of angle with multiple beams with the fixed virtual probe (i.e., set of elements grouped together to form the virtual probe aperture). So without moving the probe, we can configure the scan plan such that the distance

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Fig. 2.1 : Linear Scan on SDH & Image

Fig. 2.2 : Sector scan image on SDH & Image

between the element start and element stop is covering the volumetric distance with beam steering. The representation of linear scan and sector scan image on side drilled hole (SDH) is shown in the Figs. 2.1 and 2.2. The phased array ultrasonic images are captured using the GEIT portable phased array ultrasonic instrument called Phasor XS and the Phasor XS post analysis software called Rhythm UT viewer. This paper describes about the weld inspection using sector scan. Section 2.2 and 2.3 describes the significance and advantages of sector scan. 2.2 Beam Coverage Phased array sector scan will cover the wide range of volume from single point. By placing the probe at a single

point , wider volume of part will be covered. Hence the productivity of phased array ultrasonic inspection is relatively higher than manual conventional ultrasonic testing. The side drilled holes located at different depth and at different horizontal offset is capture from a single probe position is shown in the Fig. 2.4. 2.3 Beam Focusing By focusing a sound beam we can achieve a higher sensitivity and resolution. The term focus is a concentration of the beam to a size of focal point diameter. In phased array we can define the focal depth according to the area of interest. Hence the sensitivity and resolution of the inspection will be increased. Figures 2.6 and 2.7 depicts

Fig. 2.3 : AL block for angle beam calibration

Fig. 2.4 : Sector scan image on SDH

Fig. 2.5 : Sensitivity Cal Block

Fig. 2.6 : Unfocused sector

Fig. 2.7 : Focused sector

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the sensitivity and resolution of SDH at various focal depth. The sensitivity and the resolution of the side drilled hole at 30 mm is highest at the focal depth = 60 mm.

3. Scan Setup for Weld Inspection

In conventional ultrasonic testing generally we use the probe with the angle of 30, 45, 60 and 70 as a standard UT probes. Based on the weld geometry the skip and full skip distance will be marked on part. Inspector move the probe between skip to full skip distance in the raster scan format. In manual phased array ultrasonic testing the probe has to be mounted on the prefixed angular wedge, hence it transmits shear wave inside the material for weld inspection. The ultrasonic beam can be steered from 35 to 80 for the entire weld coverage. Based on the weld geometry the scan plan has to be configured in the phased array instrument. The coverage of weld can be assured with the software tool called ray tracing. The scan plan has to be defined in such a manner that the optimum distance has to be calculated from the weld centre line (WCL) to the wedge front. With the fixed optimum distance the scan plan has to be designed on the ray tracing tool such that the lower angle hits at the top edge of heat affected zone (HAZ) with the full skip. Each beam will be steered at different angle and hit at the different depth of the weld specimen. By keeping the probe with reference to optimum distance moving the probe with line scanning will cover the entire weld. Hence it improves the scanning speed when compare to conventional A-scan inspection by line scanning instead of doing raster scanning. Based on the scan plan, the parameters of part, probe and scanning pattern has to be configured in the instrument. The weld dimensions has to be configured as weld overlay. The weld overlay will draw the profile of the weld on the sector image. This will be useful for the inspector to spot the weld location immediately, when

there is a defect indication. Origin line will be used to locate the weld centre line. The leg lines and measurements will make the user to easily the interpret the depth of defect from the scanning surface and horizontal location of the defect from weld centre line. The advantage of sector scan inspection of weld is the scanning speed and easier differentiation of weld defects from the root and the weld cap. Whenever the defect occurs the user has to spot the location and evaluate the defect. 3.1 Procedure for Manual Phased Array Inspection of Welds Choose the probe frequency based on the thickness of the weld The probe should be positioned such that the angle start should hit the overcap heat affected zone at full skip and the angle stop should hit at the root of the weld. If the angle hitting at root of the weld is greater than 60 then weld has to inspected with additional line scanning at new probe position. Probe should be positioned such that the angle hitting at root is lesser than 60. Fix the optimum distance between the weld centre line and wedge front by using ray tracing tool or mathematical calculation. Set up the scan plan by fixing the angle start and angle stop to cover the entire weld Plot time corrected gain (TCG) by using reference block of same material and same thickness with the artificially induced defects (SDH) at th, th and th of depth from scan surface. Draw the optimum line from weld centre line on the weld to be scanned Place the probe on the weld specimen and move the probe on straight line to scan The weld should be scanned on both left and right side from weld centre line

Fig. 3.1 : Raster Scanning

Fig. 3.2 : Sector scan setup

ig 3.3

: Line Scanning

Fig. 3.4 : PL 11414

Fig. 3.5 : PL 11415

Fig. 3.6 : PL 11416

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Table 1 : Weld Specimen

Weld Serial Number PL 11414 PL 11415 PL 11416 Manufacturer Sonaspection Sonaspection Sonaspection Weld Type Single V Single V Single V Weld Material Carbon Steel Carbon Steel Carbon Steel Weld Thickness 6 mm 12 mm 25 mm Length 300 mm 300 mm 300 mm

Table 2 : Scan Setup for Weld Specimen

PL 11414 Scan Type Angle Start Angle Step Angle Stop Distance: WCL to Wedge Front Sector 50 1 75 9 mm PL 11415 Sector 40 1 75 20 mm PL 11416 Sector 35 1 70 40 mm

Mark the region where the indication comes on sector scan image and analyze the region with conventional Ascan by 6 dB or 20 dB drop method to find the length of the defect 3.2 Equipments Used 16x64 Phasor XS with top view enabled GEIT 16 element linear flat 4 MHz probe 115-500-015 GEIT shear wave wedge 115-350-024 Aluminum test block for depicting defects in sector scan Carbon steel reference block with SDH
Fig. 4.2 : Scan setup of weld 11414

PPA = -0.59 mm shows that the defect is located at 0.59 mm from weld centre line towards the scan side. PDA = 4.31mm shows that the defect is located at the depth of 4.31 mm from scan surface. 4.2 Weld PL 11414 Incomplete Root Penetration

4.

Interpretation of Defects

This section depicts the representation of different type of weld defects on sector scan. The material depth and surface projection measurement will ease the user to spot the location of the scan. PPA Minimum surface projection distance of all beams that are currently captured by Gate A PDA Minimum material depth of all beams in scan that currently captured by Gate A 4.1 Weld PL 11414 Centre Line Crack

Fig. 4.3 : Incomplete Root Penetration Indication [Phasor XS Screenshot]

Fig. 4.4 : Scan setup of weld 11414

Fig. 4.1 : Centre line crack indication [Phasor XS screenshot]

PPA = -0.34 mm shows that defect is located at 0.34 mm from weld centre line PDA = 5.11 mm shows that defect is located at depth of 5.11 mm from scan surface

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4.3 Weld PL 11414 Lack of Root Fusion

4.5 Weld PL 11415 Side Wall Lack of Fusion

Fig. 4.5 : Lack of root fusion indication [Phasor XS screenshot]

Fig. 4.9 : Side wall lack of fusion indication [Phasor XS screenshot]

Fig. 4.6 : Scan setup of weld 11414

Fig. 4.10 : Scan setup of weld 11415

PPA = 1.20 mm shows that defect is located at 1.20 mm from weld centre line PDA = 5.63 mm shows that the defect is located at the depth of 5.63 mm from scan surface (i.e., Root of the weld) 4.4 Weld PL 11415 Toe Crack 4.6

PPA = -7.53 mm shows that the defect is horizontally located at 7.53 mm from weld centre line PDA = 2.15 mm shows that the defect is located at the depth of 2.15 mm from scan surface Weld PL 11416 Root Crack

Fig. 4.7 : Toe crack indication [Phasor XS screenshot]

Fig. 4.11 : Root crack indication [Phasor XS screenshot]

Fig. 4.8 : Scan setup of weld 11415

Fig. 4.12 : Scan setup of weld 11416

PPA = -7.44 mm shows that defect is located at 7.44 mm from weld centre line PDA = 0.18 mm shows that the defect is located at the depth of 0.18 mm from scan surface (which is the cap of the weld)

PPA = 2.31 mm shows that defect is located at 2.31 mm from weld centre line PDA = 22.06 mm shows that the defect is located at the depth of 22.06 mm from scan surface (i.e., Root of the weld)

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4.7. Weld PL 11416 Side Wall Lack of Fusion

With the sector scan of 35 degree to 70 degrees: Defect 1 has been capture with the scanning on left side of weld centre line Defect 2 has been captured with the scanning on right side of weld centre line Defect 3 has to be captured by normal beam inspection on weld overcap using 0 degree linear scan For the volumetric inspection data encoded top view can be done. The uncorrected top view is plotted as beam index versus scan index. The encoder movement is plotted as abscissa and the beam index is plotted as ordinate. Phasor XS captures the gate A and gate B data and it will be plotted as beam index versus scan index based on the Amplitude or Time of Flight for color mapping. Figure 4.23 shows the top view of weld scan on left side of the weld centre line. Side wall lack of fusion starts from 140 mm in the top view. Figure 4.24 shows the top view of weld scan on right side of the weld centre line. Root crack starts from 22 mm to 40 mm in the top view.

Fig. 4.13 : Side wall lack of fusion indication [Phasor XS screenshot]

Fig. 4.14 : Scan setup of weld 11416

PPA = -10.23 mm shows that defect is located at 10.23 mm from weld centre line PDA = 10.43 mm shows that the defect is located at 10.43 mm from scan surface 4.8. Representation of weld 11416 and its C-scan The given below Fig. 4.15 shows the schematic representation of weld plate specimen 11416. The plate has 3 defects as shown in the Fig. 4.15 Defect 1 Root Crack Defect 2 Side Wall Lack of Fusion Defect 3 Porosity

5. Codes and Standards for Phased Array Inspection

Codes and standards are evolving for the industrial phased array ultrasonic inspection. the existing codes and standards for phased array ultrasonic inspection ASTM E2491-06 Standard guide for evaluating characteristics of phased array ultrasonic examination instruments and Systems ASTM E2700-09 Standard Practice for Contact Ultrasonic Testing of Welds Using Phased Arrays ASME Code Case 2235-9 - Use of Ultrasonic Examination in Lieu of Radiography

Fig. 4.15 : Representation of weld 11416

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center line will make the inspector to easily mark the defect location from post analysis, which assists for decision making. The GEIT software suite called Rhythm UT can be used for the post analysis of Phasor XS data and defect sizing, dimensioning of defects and advance reporting of the weld scanning. With the advancement in software technologies and imaging capabilities the entire inspection is upgraded with the ease of use and increase in productivity and probability of detection.
Fig. 4.16 : Top view of weld 11416 Rhythm UT screenshot

7.

Acknowledgement
Ted Ballenger, Phased Array Product Manager (Retired), GE Inspection Technologies, Lewistown, United States Jerome POIRIER, Senior Application Leader / Engineering Team, GE Inspection Technologies, Limonest, France MT Shyamsunder, Principal Scientist, WTC Material Systems Technologies, GE Global Research Centre, Bangalore, India Smita Taneja, CoE Manager, GE Inspection Technologies, Bangalore, India

Fig. 4.17 : Top view of weld 11416 Rhythm UT screenshot

References
ASME Code Case 2558 Case of ASME Boiler Pressure Vessel Code. Use of Manual Phased Array Escan Ultrasonic Examination per Article 4 Section V
1. Michael BERKE and Johannes BUECHLER, Practical Experiences in Manual Phased Array Inspections, 17th World conference on Non Destructive Testing, (25-28 oct 2008), Shanghai, China Jerome POIRIER and Robert WARD, Qualification of Manual Phased Array Ultrasonic Technique for Pipe Weld Inspections in Nuclear Power Plant, 17th World conference on Non Destructive Testing, (25-28 oct 2008), Shanghai, China ASTM E2491-06 Standard guide for evaluating characteristics of phased array ultrasonic examination instruments and Systems ASME Code Case 2235-9 Use of ultrasonic examination in lieu of radiography. Krautkramer J and Krautkramer Hf, Ultrasonic Testing of Materials, 4th fully revised edition, (2003) Phasor XS user manual, Revision 7, (2008)

6. Conclusion
With the manual phased array inspection on weld we can save more time with line scanning than raster scanning, henceforth the productivity can be increased. The defect oriented at any angle can be easily detected and represented in the image with the electronic steering capability, henceforth the probability of detection is increased. With the advancement in software to draw the weld overlay on the image; the depth measurements with respect to scanning surface and the surface measurement with respect to weld

2.

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