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www.ultrangroup.com
Non-Contact Ultrasound
PLASTICS, RUBBER AND FOAM ANALYSIS
Application Note AN-305-2
SecondWave™ M510 Ultrasonic Analysis System
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
2
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
SecondWave™ M510 shown with single and multi-channel transducers on different materials
Introduction
Contact or water immersion ultrasound does provide
significant information about materials quality and
properties. But, it cannot be applied to the early stages
of materials formation - when they are tacky or fragile.
It is also not reliable for materials that are porous, liquid
sensitive, or when any type of contact with a material is
cumbersome. Non-Contact Ultrasound (NCU) is the
most desirable choice for such applications.
Ultran has been working to facilitate NCU since 1978. In
1997, Ultran created internationally patented
piezoelectric transducers characterized by phenomenal
efficiency in air and other gases with frequencies from
50 kHz to 5.0 MHz. Complementing the NCU
transducers are Ultran’s equally novel ultrasonic imaging
systems and analyses software. The SecondWave™
M510 is a focused non-contact ultrasonic analysis
system that is customer-friendly and understands the
significance of materials testing and analysis, including
the speeds required to accomplish a task.
The M510 supports through transmission, same-side
and pulse-echo techniques. M510 single and multi-
channel systems have been fully configured and
installed for on-line (production line) and off-line
(benchtop) QC analysis of plastics and rubber from
uncured to cured stages and finished products.
M510 Capabilities
Inhomogeneous mixing of elastomers and additives
High resolution defect detection in tires, plastic, foams,
and composites
Applicable to very thick and attenuative materials
Density/porosity, and mechanical properties
SecondWave™ M510 Components
NCU Transducers
Ultran’s transducers boast the highest efficiency devices
among non-contact transducers – approaching those of
conventional contact transducers. Frequency Range: 50
kHz - 5.0 MHz. Active dimensions: 1.0 mm - 500mm.
with planar, point, parabolic, and compound beam
geometry. Robust lightweight construction.
Scanning: Vertical or horizontal acoustic bench, single or
multi-transducer multi-axis scanning frames.
System Instrumentation
4U industrial grade unit incorporating Intel Core2 Quad
processors, 2 GB RAM, RAID5 Serial ATA hard drives and
redundant power supplies. Integrated are:
Pulser: PCI-based 375V RF toneburst pulser with 50 kHz
to 5 MHz range, adjustable bursts, voltage and PRF.
Receiver: Internal 1-8 channel low-noise amplifier with
80 dB gain and 10 MHz bandwidth, multi-value low and
high pass filters.
DAQ: 14 bit Analog to Digital Converter with 50 MHz
sample rate and on-board 256 MB storage. Multi-axis
encoder inputs for motion synchronized acquisition.
Software
SecondWave™ Studio: Windows XP-based A-Scan and
C-Scan software with user-friendly GUI. Displays rolling
single and multi-channel C-Scans. Capture and storage
of full-wave data for scans. Project Manager with
multiple access levels. SQL Database integration.
SecondWave™ Research Studio: C-Scan and A-Scan
post-processing software. Generates cross-sectional
material profiles. Parametric correlation to determine
material density, porosity and fiber orientation. Image
processing functions to find and highlight defects.
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
3
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Non-contact ultrasound techniques
Direct transmission
Same side transmitter-receiver – pitch-catch
T R
Longitudinal/Shear
Waves
Surface WavesAIR
Single transducer – pulse-echo
AIR
Quantitative detectability example
Defect, crack, delamination detection
Velocity, time-of-flight, thickness measurements
Oblique incidence & refraction for shear wave and
anisotropy measurements
Defect, delamination,
corrosion detection
Location of discontinuities
Surface profiling
Surface acoustic analysis
Reflectance measurements
Depth measurement
Object identification
Air + Test
Material
Transmission
Surface
Reflections
Thickness
Reflections
Detection of side drilled holes (varying
from 0.5 to 6.3 mm) in 10 mm PMMA
with direct NCU transmission – 1.0 MHz
Ultrasonic reflection image
AIR
T
R
AIR
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
4
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Observations and case studies by direct transmission and same side NCU imaging All images are raw, without special or post-signal processing, and in most cases no signal averaging was used
Plastic sheets and tiles – overt defect detection and texture evaluation – figures 1 and 4
Fig. 1. 1.5 mm side drilled
hole in 10 mm polystyrene.
1.0 MHz
Fig. 2. 1.5 mm plastic grain
filled polyester.
500 kHz
Fig. 3. Fiber orientation in
SMC panel.
500 kHz.
Fig. 4. Anisotropic behavior
in SMC panels.
500 kHz.
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
5
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Rubber and tire – Heterogeneous mixing, hardness, defects, etc. – figures 5 to 9
Fig. 5. 10 mm poorly mixed
rubber.
500 kHz.
Fig. 6. 7 mm silica filled
rubber with subtle
variations.
1.0 MHz.
Fig. 7. 1 mm rubber varying
in hardness – left 10D, right
20 D.
1.0 MHz
Fig. 8. Steel belted tire
section.
Top: 1.0 MHz
Middle: 500 kHz
Fig. 9. Tire section
without re-enforcement.
1.0 MHz
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
6
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Polymer foams – texture and defects – figures 10 to 14.
Fig. 10. 80 mm
polyurethane foam with
porosity/density variations.
140 kHz
Fig. 11. 150 mm
polyurethane foam with
gross defects
140 kHz
Fig. 13. High resolution
imaging of 19 mm
polystyrene foam varying
in density.
200 kHz
Fig. 12. High resolution
imaging of 100 mm
polyurethane foam
varying in density, also
with internal defects.
200 kHz
Fig. 14. Surface texture of a fine celled foam. 3.0 MHz
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
7
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Thin Polystyrene Foams (Fig 15) – Defect Detection and Texture Analysis
Multi-layer rocket motor insulation (Fig 16)
Non-Contact Ultrasound: Plastics and Rubber
Application Note AN-305-2
8
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Conclusions
Ultran’s SecondWave™ M510 ultrasonic imaging and
analysis system is characterized by a wide range of
frequencies from 50 kHz to 5.0 MHz. This makes it
possible to apply non-contact ultrasound (NCU)
plastics and rubber products all the way from early
stages of their formation to finished products. The
M510 is a powerful tool for materials process analysis
and QC, directly saving you cost, energy, and
materials, besides assuring the quality and reliability
of your materials.
What Ultran provides
We supply complete NCU systems suitable for
customers’ needs. These include specifically
designed transducer libraries so that our customers
can start characterizing all their materials from Day 1.
Ultran also supplies custom NCU systems geared for
production (online) configured to customers’
applications and environment of testing.
Under agreements, Ultran will transfer science and
technology - targeted to customer needs. We offer
hands-on training to all our customers.
We maintain a fully-stocked ultrasound materials
analytical laboratory and we are fully equipped to
provide feasibility, in-depth analysis, and R&D for our
customers.
Sales representatives
HEAD OFFICE
The Ultran Group
3100 Research Drive
State College, PA 16801 USA
Tel: +1.814.466.6200
Fax: +1.814.466.6847
Email: [email protected]
ITALY
Pierluigi Carni
Via B. Angelico, 1
24047 Treviglio – BG, Italy
Tel: +39 340 9125410
Email: [email protected]
UK
Sonatest NDTS
Jenny Hough
Units 1-3 Prospect House, Colliery Close,
Ireland Business Park,
Staveley, Chesterfield, S41 8NG, UK
Tel: +44 (0) 1246 474269
Fax: +44 (0) 1246 474089
Email: [email protected]
JAPAN
Ken Automation
Tatsuya Yaoita
Hiranuma 1-11-12
Yokohama KMH Bldg., Nishi-Ku
Yokohama - 220-0023
Tel: +81.45.290.0432
Fax: +81.45.321.6590
Email: [email protected]
CHINA
Matrix U/E Technologies Inc.
Jiang Yunxi
Chaoyang District, Beijing Wangjing Litse emerging
industries in Park District No. 106 Building 402B
Tel:+86-10-64391208-819
Mobile: 0086-13910978697
E-Mail: [email protected]
INDIA
Simon Amallraja
President - SMD
PET Aviation Systems P Ltd.
Mobile: +91 98663-43309, +91 98480-43309
Tel: +91-40-2370-2840, Fax: +91-40-2370-2837
Email: [email protected]
Tel: +91.(022) 2497.5580