Research on Phased Array Ultrasonic Technique for Testing Tube to Tube-Sheet Welds of Heat Exchanger

2016 ◽  
Author(s):  
Weican Guo ◽  
Shengjie Qian ◽  
Zhangwei Ling ◽  
Dongsheng Hou
Keyword(s):  
Heat Exchanger ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Incomplete Fusion ◽  
Testing System ◽  
Ultrasonic Frequency ◽  
Ultrasonic Technique ◽  
Tube Sheet ◽  
Element Size ◽  
Array Probe

The tube to tube-sheet weld is the main connection structure of heat exchanger. This paper presents the phased array ultrasonic technique for testing the tube to tube-sheet welds of heat exchanger. The optimization analysis of phased array parameters and the simulation on the acoustic field with CIVA software were completed. The mentioned phased array parameters included array elements, array element size, deflection angle, ultrasonic frequency and so on. An ultrasonic testing system was designed and fabricated in accordance with the structure of heat exchange tube and fillet welds position. The ultrasonic C-scan was carried out by the ultrasonic testing system with its circumferential scanning by a mechanical scanning device while the axial electronic linear scanning by the phased array probe. At last, tests on samples with the porosity and incomplete fusion flaws were performed by the ultrasonic testing system. Experimental results showed that the phased array ultrasonic technique could effectively detect the porosity flaws and the incomplete fusion flaws in the tube to tube-sheet welds of heat exchanger.

Inner Detection of Corrosion by Ultrasonic Phased Array in Underground Compressed Natural Gas Storage Well

2016 ◽  
Author(s):  
Cunjian Miao ◽  
Weican Guo ◽  
Zhangwei Ling ◽  
Ping Tang
Keyword(s):  
Natural Gas ◽  
Ultrasonic Testing ◽  
Phased Array ◽  
Testing System ◽  
Ultrasonic Frequency ◽  
General Corrosion ◽  
Entire Cross Section ◽  
Compressed Natural Gas ◽  
Corrosion Condition ◽  
Ultrasonic Phased Array

Compressed natural gas (CNG) storage well is a kind of pressure vessel buried underground. The detection of corrosion, which may be induced by the surrounding soil and different medium, is important for the safety security of the well, and protects it from CNG leakage or casing explosion. Among non-destructive examination techniques for corrosion detecting, the ultrasonic techniques are popularly utilized, in which the phased array approach can offer distinct advantages. To investigate both reliability and applicability of the phased array technique in the storage well, a complex design with a 512-element ultrasonic phased array that covered the entire cross-section was discussed, and phased array parameters were determined, including array elements, array element size, ultrasonic frequency and so on. An ultrasonic testing system was designed based on the above design, including a frame for holding phased array probes, a specific vessel for storing ultrasonic cards and other components, and an in-pipe robot designed for instruments’ moving in the storage well. The general corrosion condition described by thickness images were captured by the ultrasonic testing system with B, C and D-scan functions, in which circumferential electronic linear scanning was performed by the phased array probes and axial scanning was done by a mechanical scanning device. A method for minimizing the external pressure from water column necessary for coupling was put forward in the scanning and detection process. The sample for CNG storage well with artificial defects was built in laboratory environments and experiments were conducted to validate detection effects, and the phased array technique provided good sensitivity and efficiency, which may lead to a successful application in CNG storage well examination.

scholarly journals Design Considerations for the Use of Ultrasonic Phased Array Probes in Weld Inspection

2000 ◽  
Author(s):  
Paul A. Meyer
Keyword(s):  
Ultrasonic Testing ◽  
Phased Array ◽  
Design Considerations ◽  
Array Probe ◽  
Ultrasonic Phased Array ◽  
Weld Inspection ◽  
Service Inspection

Ultrasonic testing of metal welds has been in use for many years. Scanning methods using both contact and immersion methods are often used at the time of manufacture and also during periodic in-service inspection programs. But because of a variety of component configurations and potential flaw geometries it is often necessary to perform several inspections, each with a different probe configuration to assure adequate defect delegability. It is possible that a properly designed phased array probe can perform several different inspections without changing hardware thereby reducing inspection times. This presentation reviews the design and operation of ultrasonic phased array transducers and the necessary features to achieve the desired performance. Situations in which these probes have already been implemented effectively are also discussed.

Development of an Ultrasonic Phased Array Testing System That Can Evaluate Quality of Weld Seam of High-Quality ERW Pipes

2012 ◽  
Author(s):  
Yutaka Matsui ◽  
Yukinori Iizuka ◽  
Masahito Suzuki ◽  
Eiichi Urahata ◽  
Tomohiro Inoue ◽  
...  
Keyword(s):  
Ultrasonic Testing ◽  
Phased Array ◽  
Weld Seam ◽  
Testing System ◽  
Beam Size ◽  
High Quality ◽  
Ultrasonic Phased Array ◽  
Weld Seams ◽  
Focused Beam

A high sensitivity ultrasonic testing system for inspection of the weld seam of ERW pipes was developed. The factors that affect the quality of the weld seam were investigated using an ultrasonic C-scan method with a focused probe and samples sliced from weld seams. As the result, it was found that a scattered-type penetrator consisting of micro oxides is a key factor in the quality of the weld seam. Absorbed energy in the Charpy impact test can be evaluated by the ultrasonic echo amplitude with the optimized focused beam size (about 1mm2) to detect the scattered-type penetrator. In order to evaluate the density of the scattered-type penetrator in weld seams with the optimum focused beam size for pipe, a point focused beam tandem method was developed by applying the ultrasonic phased array technique. The sensitivity of the developed method is 20dB higher for a standard artificial through drilled hole whose diameter is 1.6mm. A precise seam tracking system was also developed for application of the point focused beam tandem method to the actual ERW pipe manufacturing process. Since the allowance for applying the focused beam to the weld seam is very narrow, i.e., about 1mm, a circumference multi-point simultaneous receiving technique and thermal image-type seam detection technique were developed. The developed ultrasonic testing system has been in operation at the 24″ ERW mill at East Japan Works (Keihin District) of JFE Steel Corporation since March 2011. The combination of the ultrasonic testing system and an oxide control technique now contributes to production of high-performance, high-quality ERW pipe “Mighty Seam®” for use in frigid environments.

scholarly journals Ultrasonic Testing of Rough Surfaces Using Phased Array Probe

2021 ◽  
Vol LVIII (1) ◽  
Author(s):  
Yordan Mirchev ◽  
Mitko Mihovski ◽  
Pavel Chukachev
Keyword(s):  
Ultrasonic Testing ◽  
Phased Array ◽  
Rough Surfaces ◽  
Array Probe

Using Phased Array Ultrasonic Testing in Lieu of Radiography for Acceptance of Carbon Steel Plate Welds

2014 ◽  
Author(s):  
Traci L. Moran ◽  
Michael T. Anderson ◽  
Anthony D. Cinson ◽  
Susan L. Crawford ◽  
Matthew S. Prowant ◽  
...  
Keyword(s):  
Carbon Steel ◽  
Ultrasonic Testing ◽  
Nuclear Power ◽  
Phased Array ◽  
Steel Plate ◽  
National Laboratory ◽  
Pacific Northwest National Laboratory ◽  
Nuclear Regulatory Commission ◽  
Incomplete Fusion ◽  
Replacement Method

The Pacific Northwest National Laboratory (PNNL) is conducting studies for the U.S. Nuclear Regulatory Commission (NRC) to assess the capability, effectiveness, and reliability of ultrasonic testing (UT) as a replacement method for radiographic testing (RT) for volumetric examination of nuclear power plant (NPP) components. This particular study focused on evaluating the use of phased-array (PA) UT on carbon steel plate welds. Welding fabrication flaws included a combination of planar and volumetric types; for example, incomplete fusion, lack of penetration, cracks, porosity, and slag inclusions. The examinations were conducted using PAUT techniques applied primarily for detection and flaw type characterization. This paper will discuss the results of using PAUT in lieu of RT for detection and classification of fabrication flaws in carbon steel plate welds.

Research on Flexible Phased Array Technique for Testing the Inserted Fillet Welds

2020 ◽  
Author(s):  
Shengjie Qian ◽  
Hu Chen ◽  
Shengyong Xu ◽  
Dingyue Chen
Keyword(s):  
Phased Array ◽  
Detection Efficiency ◽  
Detection System ◽  
Internal Surface ◽  
Fillet Welds ◽  
Ultrasonic Frequency ◽  
Beam Focusing ◽  
Testing Method ◽  
Common Structure ◽  
Element Size

Abstract It is difficult to guarantee the welding quality of inserted fillet welds because of its special geometry and complicated stress condition. For the low detection efficiency of the conventional ultrasonic testing method, the false detection and the missed detection of the flaws occur frequently. For the above reasons, a new testing method is presented in this paper which based on the common structure characteristics of inserted fillet welds. The key point of this new method is to put the flexible phased array on the internal surface of the tube during the detection. The beam focusing model of flexible phased array is theoretically analyzed. The simulation on the acoustic field and defect response with CIVA software are completed to determine the phased array parameters, including array elements, array element size, deflection angle, ultrasonic frequency and so on. Then, a special ultrasonic detection system is designed and fabricated for testing the inserted fillet welds. In addition, the specimen of the inserted fillet welds with artificial flaws is manufactured and experiment research is carried out. Finally, the quality detection of actual product is successfully implemented. The results indicate that this technique can effectively detect the typical flaws such as crack, slag, porosity, etc.

Phased Array Ultrasonic Testing of Inconel 625 Produced by Selective Laser Melting

2021 ◽  
pp. 1-12
Author(s):  
Ahmed Allam ◽  
Christopher Sugino ◽  
Matthew Harding ◽  
D. Paul Bishop ◽  
Alper Erturk ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
Ultrasonic Testing ◽  
Laser Power ◽  
Phased Array ◽  
Inconel 625 ◽  
Laser Melting ◽  
Power Fluctuation ◽  
Large Defect ◽  
Array Probe ◽  
B Scan Images

Abstract We investigate the use of phased array ultrasonic testing (PAUT) as an offsite non-destructive quality assurance technique for parts made by Selective laser melting (SLM). SLM is a popular additive manufacturing (AM) approach for fabricating high value metallic components with complex geometries. Slight variations in the laser power during fabrication might lead to internal defect development within the part, which could compromise its mechanical strength and fatigue life. PAUT is employed to detect typical internal porosity generated in Inconel 625 samples due to laser power fluctuation during SLM. The typical defect size, shape and distribution are first identified using metallography and X-ray computed tomography (XCT). B-scan images of the defect region is then generated experimentally using a 5 MHz linear UT phased array probe. Finite elements simulate wave propagation using geometries obtained from XCT images. The simulation results are compared to the experimental imaging of large defect regions and then used to generate total focusing method images of isolated clusters of 50-200 µm defects. The testing technique illustrates a successful application of PAUT for quality inspection of SLM parts.

Development of Ultrasonic Testing System of Rubber Roll for the Paper Manufacture

2005 ◽  
Vol 59 (9) ◽  
pp. 1293-1301
Author(s):  
Shigeki Watanabe ◽  
Mitsunao Ariji ◽  
Kazuo Kobayashi
Keyword(s):  
Ultrasonic Testing ◽  
Testing System
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