Imaging using Ultrasound - I

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1 Imaging using Ultrasound - I Prof. Krishnan Balasubramaniam Professor in Mechanical Engineering Head of Centre for NDE Indian Institute t of Technology Madras Chennai , INDIA balas@iitm.ac.in Wb Web: t

2 Advantages of UT Testing can be carried out from a single side, Using guided waves, inaccessible regions can be inspected, A high degree of penetration is possible in many commonly-used materials, which is in contrast with the lower degree of penetration encountered with radiological testing of metals; High sensitivity to planar defects such as delaminations and disbonds. Accuracy in locating and measuring defects; The ability to detect and size very small defects; and Compatibility with automatic scanning devices and with micro- processors and computers.

3 Drawbacks of UT Operators must be properly trained, highly experienced and possess a high hdegree of reliability and integrity. Time consuming since most of the time a point by point scanning is used to cover large surfaces. A fluid coupling is normally required between the ultrasonic sensor and the component.

4 Oscillation

5 Amplitude Movment of Ball.vs. time 1 CYCLE Time

6 Frequency Time One full One full oscillation T

7 ANALOG to DIGITAL Analog Digital

8 DAQ System Analog Digital

9 Digitization Basics Horizontal Resolution (Sampling 100 khz.) Vertical Resolution (Bits =16 bits) Amplitude Range (+10V to 10V) Gain (10 db) Multiplexing Effective bits R v = 20/2 16 = 3.05* 10-4 V v R h = 1/100*10 3 =10-5 s

10 Digital Signal Analysis Acquire digital data using DAQ. Process Data for Noise Reduction. Extract Features Multi-parameter Discrimination. Damage Estimation. Damage Reporting

11 Signal Domains and Feature Extraction Time Domain Features Peak to Peak Amplitude, +Peak/-Peak, Pulse Duration,.. Envelope Domain Features Energy, Skewness, Kurtosis,. Frequency Domain Features Peak Frequency, Mag of Peak Freq., Slope of Phase Spectrum. EXAMPLE

12 Domains of an RF Signal g The figure below shows the RF signal and the Amplitude Spectrum. Controls such as Zeropadding, Undersampling, phase wrap/unwrap, window type, are provided. The signal can be windowed by dragging the ends of the red bar over the RF signal.

13 Y-Feature Discrimination Analysis It can be observed dby looking at the two feature scatter plot, that the samples 1 and 2 are clustered near the origin (0,0) location while the Samples 3 and 4 are at relatively large distance from the origin. X-Feature

14 Defect Discrimination Extraction of Signal Shape will allow for discrimination between defect types.

15 ULTRASONIC PULSE ECHO

16

17 RAW DATA MEDIAN FILTERED DATA

18 Inclusion Detection System High Resolution Ultrasonic Imaging, can provide g g g p volumetric imaging of inclusions and small cracks at a resolution of 50 microns depending on Frequency.

19 Micro Imaging CASTINGS

20 Ultrasonic Image of CC Billet Collaboration between Tata Steel and IIT Madras

21 COMPOSITES: Fiber Orientation Imaging

22 C-scan Imaging LCA Wing Courtesy: National Aerospace Laboratory, Bangalore

23 Aerospace Applications C-Scan of Impact tdamage

24 C-Scan of fcomposite Joint

25 Time Gated C-Scans D. Hsu, et.al

26 Time Gated Results

27 Directional Filter Banks (DFB) for Peening Structural Feature noise Split An Image containing all Information about the Fibers + An Image containing no Information about the fibers Defect Automation Defect information Desired frequency Desired frequency Desired frequency Response for extracting Response for extracting Response for extracting image features along -45 image features along 45 image features along 0

28 Fiber Reinforced Composites Results Original Image containing information regarding g both fibers and defects Residual Image Containing no Fibers Fibers Extracted Using DFB

29 Diffraction Like light wave, the acoustic waves will bend around corners. The corners will act as point sources and hence may emanate waves called as tipdiffracted waves. The amplitudes are comparably smaller.

30 FDTD Animation

31 Principle of TOFD Incident wave Diffracted wave from defect top Diffracted wave from defect bottom Reflected wave Transmitted wave

32 Principle of TOFD Incident wave Diffracted wave from defect top Diffracted wave from defect bottom Reflected wave Transmitted wave

33 Time of Flight Diffraction Technique (TOFD)

34 Experimental setup Fig. Illustrates the principle of TOFD. Two longitudinal probes with angle (broad beam) is placed on each side of the flaw. The distance between the probes is calculated on the basis of the thickness of the sample and angle of the probe.

35 Mathematical model Through wall size and depth of the crack t 2 S Through wall size and depth of the crack d S 2 2 ) ( 2 C S L t 2 C a d S t ) ( 2 C d S t C H S t bw C C S t C d d S t C a

36 TOFD Research issues TOFD was invented in the early 1970s by M.G.Silk AEA Technology, Harwell Laboratory, United Kingdom At present many commercial TOFD systems are available. ALL THESE SYSTEMS WORKS WELL FOR THICK SECTIONS (THICKNESS GREATER THAN 15 mm)

37 D-Scan

38 D-Scan Imaging

39 Time of Flight Diffraction (TOFD) Uses a more reliable and reproducible time-offlight for location and sizing ii cracks. Feature TO X- Manual Auto FD ray UT UT defect detection (POD %) False Call rate (FCR %)

40 Data Visualization (theoretical) LW A-scan D-scan BW Lateral Back-wall wave Courtesy: Olympus NDT (R/D Tech, Canada)

41 Data Visualization (TOFD) D-scan A-scan Indication Lateral Back-wall wave Courtesy: Olympus NDT (R/D Tech, Canada)

42 Incomplete Root Penetration Note the two signals from the top & bottom Courtesy: Olympus NDT (R/D Tech, Canada)

43 Lack of Root Penetration Note the inverted phase between LW and defect Courtesy: Olympus NDT (R/D Tech, Canada)

44 Lack of Fusion, Side Wall Note the two signals from the top & bottom Courtesy: Olympus NDT (R/D Tech, Canada)

45 Lack of Fusion, Interpass Courtesy: Olympus NDT (R/D Tech, Canada)

46 TOFD Imaging Probe Sample

47 TOFD B-Scan representation a b mm x 0.5 mm c. Lateral wave defect Back wall Probe angle 65 deg Distance between probes 25mm Mode converted echo

48 Distorted image due to beam width Defect Size Defect position Distorted image

49 B-Scan images of various defects 35 deg probe, 2.25 MHz frequency

50 PSCT Flaw Sizing Procedure Flaw Arc Modeling Template Matching With TOFD Data Crack Tip Location Cross-correlation

51 Point Source Correlation Technique (PSCT)

52 Weld Sample Results Speci men Thic kness (mm) Experimentally measured crack depth using manual and automatic sizing in fatigue samples Manual Sizing (mm) Automatic Sizing (mm) 5 MHz 10 MHz 5 MHz 10 MHz deg deg deg deg deg deg deg deg

53 Shear Wave-TOFD SURFACE CRACK EMBEDDED CRACK

54 S-TOFD on Realistic Crack

55 S-TOFD vs TOFD vs Actual Defect Configuration EDM EDM EDM Fatigue Fatigue Actual Depth (mm) Measured Depth / (%error) Manual-L Manual-S L + ESIT S+ESIT (28) (18) (8) (4) 1.75 * (14.28) (14.29) (3.43) (1.71) 1.75 ** (12.57) (9.14) (4.57) (1.14) (1) (0.4) (2.28) (0.38)

56 New Additions to TOFD Developed new automated sizing algorithms ESIT and PSCT. Extended TOFD method to relatively thin plates/welds (up to 3 mm) using ESIT and PSCT algorithms. Improved sizing robustness, particularly for small size flaws. Shear TOFD for near surface crack sizing.

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