Ultrasonic Testing

ultrasonic testingUltrasonic Testing, very short ultrasonic pulse-waves with center frequencies ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to detect internal flaws or to characterize materials. The technique is also commonly used to determine the thickness of the test object, for example, to monitor pipework corrosion.

Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be used on concrete, wood and composites, albeit with less resolution. It is a form of non-destructive testing used in many industries including aerospace, automotive and other transportation sectors.

How it works
In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed over the object being inspected. The transducer is typically separated from the test object by a couplant (such as oil) or by water, as in immersion testing.

There are two methods of receiving the ultrasound waveform, reflection and attenuation. In reflection (or pulse-echo) mode, the transducer performs both the sending and the receiving of the pulsed waves as the “sound” is reflected back to the device. Reflected ultrasound comes from an interface, such as the back wall of the object or from an imperfection within the object. The diagnostic machine displays these results in the form of a signal with an amplitude representing the intensity of the reflection and the distance, representing the arrival time of the reflection. In attenuation (or through-transmission) mode, a transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after traveling through the medium. Imperfections or other conditions in the space between the transmitter and receiver reduce the amount of sound transmitted, thus revealing their presence.

At a construction site, a technician tests a pipeline weld for defects using an ultrasonic phased array instrument. The scanner, which consists of a frame with magnetic wheels, holds the probe in contact with the pipe by a spring. The wet area is the ultrasonic couplant that allows the sound to pass into the pipe wall.

Non-destructive testing of a swing shaft showing spline cracking

Features

Advantages

  1. High penetrating power, which allows the detection of flaws deep in the part.
  2. High sensitivity, permitting the detection of extremely small flaws.
  3. Only one surface need be accessible.
  4. Greater accuracy than other nondestructive methods in determining the depth of internal flaws and the thickness of parts with parallel surfaces.
  5. Some capability of estimating the size, orientation, shape and nature of defects.
  6. Nonhazardous to operations or to nearby personnel and has no effect on equipment and materials in the vicinity.
  7. Capable of portable or highly automated operation.

Disadvantages

  1. Manual operation requires careful attention by experienced technicians.
  2. Extensive technical knowledge is required for the development of inspection procedures.
  3. Parts that are rough, irregular in shape, very small or thin, or not homogeneous are difficult to inspect.
  4. Surface must be prepared by cleaning and removing loose scale, paint, etc, although paint that is properly bonded to a surface usually need not be removed.
  5. Couplants are needed to provide effective transfer of ultrasonic wave energy between transducers and parts being inspected unless a non-contact technique is used. Non-contact techniques include Laser and Electro Magnetic Acoustic Transducers (EMAT).
  6. Inspected items must be water resistant, when using water based couplants that do not contain rust inhibitors.