OmniScan MX2 Training Program

Beam Forming Basics

OmniScan MX2 Training – Beam Forming Overview
u After populating the focal law calculator with the parameters of the
probe, wedge, and material velocity, the software can be configured for
the beam formation. This is the purpose of the focal law calculator. Also
called group creation wizard in the OmniScan MX2 software.
u The OmniScan MX2 has a built in group set up wizard that will walk the
user step by step through the group creation process populating the
probe, wedge, and material parameters before beam formation.
u Beam formation or focal law generation will determine the size, shape,
and angles of our sound beams. (A-scans).
u Beam formation includes both angle steering and beam focus combined
together for an array of A-scans in a group.

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OmniScan MX2 Training – Beam Forming Overview cont.

u Groups of A-scans or focal

laws come in many
configurations as a function of
software calculators,
instrument capability, and
probe capability.
u The OmniScan MX2 refers to
beam sets as “Groups” and
directly supports sector and
linear scan groups in the
software.
u Other types of groups can be
imported into the OmniScan
MX2 from an external focal
law calculator.

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OmniScan MX2 Training – Group Formation
u The OmniScan MX2 supports both linear and sector scan groups for 1D
linear array probes and has an 8 group, 256 focal law limit.
u Both sector scans and linear scans have unique advantages and limitations
regarding weld coverage, number of focal laws, range of angles, A-scan
density, ability to reproduce conventional results, and ability to minimize
number of required groups for the inspection.
u Additionally, one of the most important factors in determining the scan plan
strategy is the ability to calibrate the group using traditional calibration
blocks with SDHs and notches to improve inspection results and comply with
construction codes used throughout many industries.

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OmniScan MX2 Training – Group Formation - Sector vs. Linear Group
Sector Scan Definition
 Focal laws of different angles
generated using the same elements.
 A-scan density and coverage is
defined by the range of angles (45-
70) and angle resolution. (45, 46, 47,
etc)
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Linear Scan Definition
 Focal laws generated over a series of
elements using the same angle.
 A-scan density and coverage is
defined by the element step
resolution. (1 element, 2 element,
etc)
OmniScan MX2 Training – Group Formation - Sector vs. Linear Group
Sector Scan Advantages
 Large coverage area from small
footprint on component.
 Improved flaw characterization from
multiple angles.
 Small element count required for
instrument and probes. (16, 32)
 Fewer focal laws required for
coverage of weld area.
Linear Scan Advantages
 Produces same result as
conventional UT raster scan (X,Y).
 Ease of calibration due to only one
angle.
 Compliance with existing codes
referencing one angle inspections.
 Beam to beam resolution is the same
regardless of sound path.
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OmniScan MX2 Training – Group Formation - Sector vs. Linear Group

Sector Scan Disadvantages Linear Scan Disadvantages

 Beam to beam resolution worse as sound  Requires many focal laws. (49 as pictured
path increases. below)
 Limitations in ability to calibrate multiple  Poor coverage with one angle\one group.
TCG points for long sound paths.  Multiple groups required for same coverage
 Limitations in ability to calibration wide resulting in long set up and calibration time,
angle range for long sound paths. and big data file.
 Requires instrument with large multiplexer.
(XX:64, XX:128)

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OmniScan MX2 Training – Beam Steering Limits
u Beam steering is limited by the probe element size and aperture, the wavelength,
physics of UT (Snell’s law) and most importantly, the ability to calibrate each A-scan
in the group to the satisfaction of the application or procedure.
u The calibration process, like conventional UT, includes maintaining the velocity at a
known angle (Does not mode convert) and ability to correct the wedge delay,
sensitivity, and build a TCG (If required) for every A-scan in the group.

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OmniScan MX2 Training – Beam Steering Limits cont.
u The maximum steering angle at -6dB can be defined from the beam spread equation
below. Small elements have greater beam spread and retain more energy at higher
angles than that of larger elements.
u As element size decreases so does energy and more elements must be pulsed
together to maintain the same sensitivity.
u This is a similar to conventional UT. The smaller the single element crystal, the wider
the beam spread.

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OmniScan MX2 Training – Beam Steering Limits cont.
u The limits of beam steering and focusing are dependent on many factors including
size of aperture, size and number of elements, material properties, size of
calibration reflector, etc
u The OmniScan MX2 calculator does not attempt to define the steering limits of any
probe\wedge combination because there are too many variables in the inspection
requirements including what is an acceptable A-scan signal to noise ratio for any
one customer’s application.

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OmniScan MX2 Training – Verification of Beam Angle and Exit Point
u Beam steering angle (Refracted angle) is verified in phased array inspections exactly
like conventional UT.
u The beam steering limits of a particular probe\wedge\aperture is reached when the
highest and lowest angle of the group are not able to be verified within 1 degrees.
u The real exit point of the beam is verified with an IIW block and compared with the
calculated value in the software. Once the exit point is validated the angle can be
verified on the other side of the IIW block.
u This process is explained in detail a later section. Repeat….exactly like UT.

Exit point of beam Verified exit point is used

to measure real angle in
Index offset calculated
material (40 degrees)
by software and
verified on IIW block

40 degree A-scan
40 degree A-scan

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OmniScan MX2 Training – Beam Focusing Overview
u Sound beams can be focused like light rays with the energy focusing at a given
point and then expanding beyond it.
u The depth of focus is changed by varying the applied delays on the elements and is
built into the focal law along with the angle steering.
u The maximum depth or sound path that a beam can be focused is defined by the
near field which is a function of element size, frequency, and material velocity.
u The effective sensitivity is improved by a smaller beam diameter with more energy
at the focus point.
u Increasing the size of the aperture or creating the same aperture using more
smaller elements increases the sharpness of the focused beam and improves
results.

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OmniScan MX2 Training – Beam Focusing – Near field
u Beam focusing is only possible within the near field of the probe.
u The near field is different in the active and passive axis of the array and can be
calculated with the formula below.
u Most methods for calculating the near field should be considered close
approximations due to simplifying the formula and not taking into account every
probe parameter.
u Do not be surprised if every manufacturer’s software calculates a slightly different
near field value for the same probe and aperture.

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SAMPLE - OmniScan MX2 Training – Beam Focusing vs. TCG
u The near field calculation that defines the maximum beam focus limit is not
the limit of the useful sound path for inspection purposes.
u Like conventional UT, most of our code based phased array inspections
such as ASME, API, etc are performed with an unfocused probe and a TCG
or DAC to compensate for sensitivity (Amplitude) over time (Sound path).
u Use of a TCG for code based inspections reduces the benefits of focusing.
A focal point is selected within the TCG range that can accommodate all
points.

1 2 3 4

1
2 1 2 3 4
3
4

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OmniScan MX2 Training – Inspection Focus Strategies
u Different focusing strategies can provide optimized results for different
applications.
u There are five primary types of focusing associated with phased array
inspection:
1. Depth focusing. Defined from the bottom of the wedge in depth and different
for every angle.
2. Sound path focusing. Defined by the uncorrected sound path and the same for
every angle.
3. Projection focusing. Defined by the surface distance from the wedge face.
4. Focal plane focusing. Defined by an X,Y position in the material.
5. Unfocused. Any value that is beyond the near field of the probe\aperture.

Depth Sound Path Projection Focal Plane

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OmniScan MX2 Training – Inspection Focus Strategies cont.
u The OmniScan MX2 focal law calculator only supports depth focusing and
un focused group.

u Sound path, projection, and focal plane focusing can be imported into the
OmniScan MX2 from an external focal law calculator using the memory card.

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OmniScan MX2 Training – Advanced Inspection Focus Strategies
u The majority of OmniScan MX2 applications including weld inspection are
well suited for depth focusing and do not benefit significantly from other
focus strategies.
u An example of an application that would benefit from a specific focal plane
other than depth is the dissimilar metal weld inspection in inconel using a
low frequency longitudinal angle beam sector scan for maximum penetration
and focus on the far side weld bevel.

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OmniScan MX2 Training – Advanced Inspection Focus Strategies - WSY
u Another example of an application that would benefit from an advanced
focusing strategy is the phased array version of the conventional UT 30-70-
70 (WSY) technique used for internal crack detection and sizing in the power
generation industry.
u A 55-70 longitudinal wave sector scan is focused in a vertical plane
(Projection) at a fixed distance from the wedge face. (Pictured in red in front
of the probe)
Projection focal plane

Crack tip (70 degree)

CE1 CE2

Crack base (55 degree)

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OmniScan MX2 Training – Adv. Insp. Focus Strategies – Near surface
u The Hydroform inspection system uses a shallow depth focus to maximize
near surface detection and resolution.
u 1.5mm surface resolution on carbon steel components is possible from the
Hydroform system with the aid of shallow depth focusing, small aperture,
water column and high frequency probe.
u In this application turbine components are inspected for porosity and laminar
flaws before complex machining.

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OmniScan MX2 Training – Verification of Beam Parameters
u In addition to standard IIW and similar calibration blocks, there are industrial
standards such as ASTM E2491 that specify techniques and calibration
block designs for verification of the phased array beam profile.
u Beam profile, beam steering limits, beam focusing, element activity, etc can
be verified similarly to the requirements of conventional UT with specialized
reference standards.

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 OmniScan MX2 Training – Phased Array Calculator Review
u At this point in the training all of the hardware parameters
and basic software considerations required to prepare a
phased array beam set or group in the OmniScan MX2 have
been described. (Probe, wedge, material, and beam
forming)
u The OmniScan MX2 like its predecessors is a UT instrument
before it is anything else, and with the exception of software
to manage the information unique to phased array it is very
similar to a modern single channel conventional flaw
detector with better imagery, more software features, and
much greater power.
u The use of the OmniScan MX2 setup and calibration
wizards will make managing all of the parameters required
for the phased array inspection fast and efficient permitting
the focus to remain on the application……..and not the
software.

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OmniScan MX2 Training – Phased Array Calculator Review
Question:
What are the essential parameters for the phased
array calculator?
1. Probe parameters.
2. Wedge parameters.
3. Material Velocity
4. Beam Formation.

Answer: All of the above.

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