Inspection of Complex Geometries Using Flexible Ultrasonic Phased Array Probes

Jeffrey Wells | Product Specialist – Phased Array Applications and Solutions ASNT, 11/03/2016

Agenda 1.  Introduction

2.  Typical Test Methods

3.  Flexibility Testing

4.  Flex Array Inspection

5.  Conclusion

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Introduction §  Flexible Array Technology

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Flexible array is a new technology that takes the capability of a standard rigid phased array probe and makes it flexible. The goal is to have a probe that can be flexed to help ensure that the elements are always perpendicular to the inspection surface.

Introduction § Market offering

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A variety of market offerings provide unique options for acoustic and mechanical solutions.

Typical Test Methods §  Test Conditions

–  Test multiple ultrasound methods on one part

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Composite Part: •  25 mm outside radius

•  Thickness range: 2–15 mm

•  12.7 mm square insert defects

•  Defect’s depths are at 0.5 mm, 7.5 mm, and 15 mm

Typical Test Methods § Single Element (UT) Probe

–  Set up is quick –  Sizing is accurate –  Inspection time is very long –  Full coverage is difficult to achieve and confirm

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Typical Test Methods § Curved Phased Array (PA) Probe

–  Set up is slow and cumbersome –  Sizing length is drastically oversized –  Inspection time is quick –  Full coverage of radius is not simple to confirm

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Flex Testing § Check the flex limitations of the probe

§ Record the maximum flex for convex and concave parts

§  Test the probe to confirm no degradation in acoustic performance

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•  Minimum concave bend diameter: 0.5 inch (12.7 mm)

•  Elements are flexed on convex part

•  Elements face inward

Flex Testing § Check the flex limitations of the probe

§ Record the maximum flex for convex and concave parts

§  Test the probe to confirm no degradation in acoustic performance

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•  Minimum convex bend diameter: 1.57 inch (40 mm)

•  Elements are flexed on convex part

•  Elements face outward

Flex Array Inspection § Mechanical Setup

–  Flex probe couples quickly and easily to the part

–  Sizing is very accurate

–  Inspection time is fast than other methods

–  Full coverage is easy to achieve; users can also inspect a portion of the flats concurrently

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Flex Array Inspection § Acoustic Performance

–  Detects midwall defects –  Good signal-to-noise ratio (SNR) –  Sizing of 12.5 mm (0.5 inch) flaws is very accurate

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Flex Array Inspection § Acoustic Performance

–  Near-surface detection (NSD) is possible down to 0.5 mm (0.020 inch)

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Conclusion 1.  Flexible array offers a simple mechanical setup.

2.  Near-surface detection on CFRP is good down to 0.020 inches with resolution down to a depth of 1.5 mm.

3.  Flexible probe is a good candidate to be implemented on low volume contact inspection.

4.  Implementation of holders can expand the capability and reliability of flex probe use in production or inspection settings.

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