sirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments Fundamentals of Ultrasonic Imaging and Flaw Detection Pubksh Date; Feb 11,2010] 192 Ratings | 266 out of 5 | AP por Overview Ultrasonics refers to any study or application of sound waves higher in frequency than the human audible range. Music and ‘common sounds that are considered pleasant are typically 12 kHz or less, while some humans can hear frequencies up to 20 kHz, Ultrasonic waves consist of frequencies greater than 20 kHz and existin excess of 25 MHz. They are used in many applications including plastic welding, medicine, jewelry cleaning, and nondestructive test. Within nondestructive test, Ultrasonic waves give you the ability o"see through" solid/opaque material and detect surface or internal flaws without affecting the material adversely. Table of Contents 41, Basics of Ultrasonic Test 2. Ultrasonic Wave Modes 3, Snell's Law 4. Acoustic Impedance 1. Basics of Ultrasonic Test Ultrasonic wavelengths are on the same order of magnitude as visible light, giving them many of the same properties of light. For example, ultrasonic wavelengths can be focused, reflected, and refracted. Ullvasonic waves are transmitted through air, water, and solids such as steel by high-frequency particle vibrations. These waves are transmitted in homogenous solid objects ‘much like pointing a flashlight around a room with various objects that reflect light, The directed energy in an ultrasonic wave is. reflected by boundaries between materials regardless of whether the material is gas, liquid, or solid. Ultrasonic waves are also reflected by any cracks or voids in solid materials. These reflected waves, which are caused by internal defects, can be compared to the reflected waves ‘rom the external surfaces, enabling the size and severity of intemal defects to be identified, Generating and detecting ultrasonic waves requires an ullrasonic transducer. Piezoelectric ceramics within ultrasonic transducers are "struck" — similar to the way tuning forks are struck to generate an audible note — with electricity, typically between 50 and 1000 V— to produce the ultrasonic wave. The ultrasonic wave Is carrled from the transducer to the unit under test (UUT) by a couplant— typically water, oll, or gel — and is reflected back to the transducer by both external surfaces and internal defects. hntpatwww. com ite paper 3a68fen “sirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments Ultrasonic “a Transducer ut SP Sooo noo eben ------- ‘When operating in pulse-echo mode, ultrasonic transducers act as both emitters and receivers. The reflected ultrasonic waves vibrate the piezoelectric crystal within the ultrasonic transducer and generate voltages that are measurable by data acquisition hardware, When operating in through-transmission mode, two ultrasonic transducers are used; one transducer generates the wave and the other receives the wave. Ina typical application, the ultrasonic transducer is struck with a high-voltage pulse, which lasts on the order of § us, and then the system listens for the echoes. The system listens on the order of 10 to 15 us. Even in the most advanced systems, the transducers are pulsed every 500 us. ‘The most primitive method to analyze the reflected ultrasonic signals is time-of-flight (TOF) display, or A-scan. Discontinuities that are closer to the ultrasonic transducer are received sooner than those further away from the transducer, The figure below depicts the TOF display from the previous example, hntpatwww. com ite paper 3a68fen asirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments Volts Back surface reflection Flaw reflection Units of Time ‘The x-axis on the A-scan is not lypically units of time but is converted to distance. This conversion is accomplished by measuring, or looking up, the speed of sound through the material that the ultrasonic wave is traveling through and performing the conversion. Although there are a few exceptions, the speed of sound through a material is governed largely by the density and elasticity of the material. For most materials, the speed of sound within homogenous material is easy to research and find, Most ultrasonic nondestructive test applications range from 400 kHz to 25 MHz. The frequency of the ultrasonic sensor is chosen based on several factors including detectable flaw size, depth of penetration, and grain size of the material. Materials made of fine-grained material, such as metals, permit deep penetration by ultrasonic waves of all frequencies, However, coarse-grained material, including many plastics, scatter high-frequency ultrasonic waves. The higher the frequency, the smaller the flaws the system detects, but the depth of penetration decreases. 2. Ultrasonic Wave Modes Back to Top ‘Two predominant types of waves, or wave modes, are generated within a material with ultrasonic waves: longitudinal and shear, Longitudinal waves (L-waves) compress and decompress the material in the direction of motion, much like sound waves. in air, Shear waves (S-waves) vibrate particles at right angles compared to the motion of the ultrasonic wave. The velocity of shear waves through a material is approximately half that of the longitudinal waves. The angle in which the ultrasonic wave ‘enters the material determines whether longitudinal, shear, or both waves are produced. hntpatwww. com ite paper 3a68fen 37sirarzo16 Fundamentals of Ulrasoric imaging and Flaw Detection - Nationa Instruments Ultrasonic / Transducers\, Plastic Wedge TT rN | ‘N Particle Motion KG KK “Ns S-Wave Direction Direction Ultrasonic beam refraction and mode conversion are comparable to light as it passes from one medium to another. Remember how the straw in the glass of water looks broken if observed from the side? The same phenomenon occurs with ultrasonic waves as they are passed into a UUT. The figure below depicts an ultrasonic transducer that transmits an ultrasonic wave through water into a block of steel, Because the direction of the ultrasonic wave is at a 90-degree angle with the surface of the steel block, no refraction occurs and the L-wave is preserved. Ultrasonic Transducer L-Wave I Water Soundbeam As the angle of the ultrasonic transducer is altered, refraction and mode conversion occur. Inthe figure below, the ultrasonic ‘transducer has been rotated 5 degrees. The longitudinal wave from the transducer is converted into two modes, longitudinal and shear, and both wave modes are refracted. Notice that the waves are refracted at different angles. In this example, the L- hntpatwww. com ite paper 3a68fen 4sirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments wave is approximately four limes the transducer angle and the S-wave is just over two times the transducer angle. Angles that create two wave modes are not appropriate because they cause the ultrasonic transducer to receive multiple echoes, making it difficult to analyze the data, Ultrasonic Transducer Refraction L-Wave Angle 20°_! ‘ca fi Refraction | y S-Wave Angle 11; Refraction and mode conversion occur because of the change in L-wave velocity as it passes the boundary from one medium to another. The higher the difference in the velocity of sound between two materials, the larger the resulting angle of refraction. L-waves and S-waves have different angles of refraction because they have dissimilar velocities within the same material. As the angle of the ultrasonic transducer continues to increase, L-waves move closer to the surface ofthe UT. The angle at which the L-wave is parallel with the surface of the UUT is referred to as the first critical angle. This angle is useful for two reasons. Only one wave mode is echoed back to the transducer, making it easy to interpret the data. Also, this angle gives the test system the ability to look at surfaces that are not parallel to the front surface, such as welds, hntpatwww. com ite paper 3a68fen 87sirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments Ultrasonic 4 Transducer Incident Y Angle 15° S Refraction Angle 34, 3. Snell's Law Back to Top the first critical L-wave and S-wave refraction angles are calculated using Snell's law. You also can use this law to dete angle for any combination of materials. Sin 0, ey Sin Op Vp Where: 8, = angle of the refractad beam in the UUT incident angle from normal of beam in the wedge or liquid Vi= velocity of incident beam in the liquid or wedge Vp = velocity of refracted beam in the UUT For example, calculale the first critical angle for a transducer on a plastic wedge that is examining aluminum, \V1= 0.267 cmips (Vor L-waves in plastic) \Vp= 0.625 emius (for L-waves in aluminum) 8, = 90 degree (angle of L-wave for frst ertical angle) ors unknowm Sin0, _ 0.267 Sin(90°) 0.625 6, = 25.29° ‘The plastic wedge must have a minimum angle of 25.29 degrees to transmit only S-waves into the UUT. When the S-wave hntpatwww. com ite paper 3a68fen ersirarzo16 Fundamertls of Ulrasorc imaging and Flaw Detection - Nationa Instruments angle of refraction is greater than 90 degrees, all ultrasonic energy is reflected by the UUT. 4. Acoustic Impedance Back to Top ‘When performing ultrasonic testing, itis important to understand how effectively ultrasonic waves pass from one medium to another. Generally, when an ultrasonic wave is passed from one medium to another, some energy is reflected and the remaining energy is transmitted. The factor that describes this relationship is referred to as acoustical impedance and the acoustical impedance ratio. Z=0V where Z= acoustical impedance p= density \V= velocity of sound through medium For reference, air has low acoustical impedance, water has higher impedance than air, and steel has higher impedance than water. The acoustical impedance ratio is the impedance of the second material divided by the first. The higher the ratio, the more energy is reflected. For example, when ultrasonic waves are passed from water to steel, the acoustical impedance is approximately 20 to 1; whereas, when ultrasonic waves are passed from air to steel, the acoustical impedance is approximately 100,000 to 1. Almost 100 percent of the ultrasonic energy is reflected when passing ultrasonic waves from air to a solid such as steel, making air a very poor ultrasonic couplant. hntpatwww. com ite paper 3a68fen m