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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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