MX2 Training Program 5C Focal Law Wizard

OmniScan MX2 Training Program
The Focal Law Wizard

OmniScan MX2 Training – Focal Law Wizard Overview
u The focal law wizard is the third wizard in our process after all
parameters of the material, probe, and wedge have been entered
in the part and set up wizards.
u The focal law wizard is designed for a step by step method of
populating the beam parameters. These parameters are also
available in the focal law sub menu.
u The focal law wizard is where beam formation, steering, and
focusing are programmed for the current group.
u The wizard will walk the user through each step for group
creation to include:
– Selection of group type (Sector, linear, linear at 0 degrees).
– Selection of longitudinal or shear wave velocity.
– Selection of element quantity and position (Aperture).
– Selection of angular coverage and resolution. (45-70 degrees, .5 degree)
– Selection of focal depth.
– Selection of gate position.
2
OmniScan MX2 Training – Focal Law Wizard Overview
u Each step in the wizard process is completed prior to selecting next. Each task is
explained in the next series of slides. Below is the focal law wizard progression.
3
Focal Law Wizard – Law Configuration
u The three options for law configuration are:
1. Sectorial.
2. Linear.
3. Linear at 0 degrees.
u The linear at 0 degrees option is used for
corrosion and composite C-scan inspections and it
is limited to one group only in the .Ops file.
u Other option such as linear spread can be
imported from an external focal law calculator.
u The legs option is relative to the ray tracing
feature of the report and is addressed in a later
section. This is normally set to 1 or 2 legs for
weld inspection and will limit ray tracing in gate A
to the number of legs selected.
4
Focal Law Wizard – Wave Type
u The wave type is a function of velocity for the material type selected in the part and
weld wizard.
u The wave type is also relative to the wedge. Wedges are normally designed with an
incident angle for either shear wave or longitudinal inspection.
u Shear wave wedges are designed with an approximate incident angle of 36 degrees
for a natural 55 degree refracted angle in carbon steel. This allows for good beam
steering from approximately 35-70 degrees.
u Longitudinal angle beam wedges are designed with an approximate incident angle
of 20 degrees for a natural 60 degree refracted angle in carbon steel. This allows for
good beam steering from approximately 30-80 degrees.
u Longitudinal straight beam wedges are designed with a 0 degree incident angle for a
+\- approximately 30 degree beam steering or linear configuration.
5
Focal Law Wizard – Probe Element Quantity
u The probe element selection step in the wizard
will determine both the size of the beams
(Aperture) and the position of the beams on
the probe (1st element).
u Element quantity selection cannot exceed the
total elements available in the probe or the
maximum pulsers available in the MX2
acquisition module (16:XXX or 32:XXX).
u The aperture is equivalent to the diameter or
size of a conventional probe. Element
quantity X element pitch = aperture.
u The element quantity must be sufficient for
beam steering and energy which is usually a
minimum of 4 elements for straight beam and
8 elements for angle beam.
u Increasing the element quantity increases the
aperture which in turn extends the near field
and ability to focus farther.
6
Focal Law Wizard – Probe Element Quantity cont.
Question:
How can I determine if the element quantity is sufficient for beam formation?
Answer:
The exact same way we verify beam parameters in conventional UT. The
quality of the A-scan (S/N ratio) and the verification of the angle and exit
point using a standard reference block. The limits of beam steering and
aperture for any probe\wedge combination are dependent on many
parameters and cannot be predicted by the software.
7
Question:
How can I reproduce the beam size of a 10mm conventional probe using
phased array?
Answer:
Aperture (Size) = element pitch X element quantity.
For a .6mm pitch probe, 9.6mm = .6mm pitch X 16 elements.
For a 1mm pitch probe, 10mm = 1mm pitch X 10 elements.
8
Question:
In the previous example, which probe can be calibrated to a wider sector scan?
(45-65, 40-70, etc)
Answer:
The .6mm pitch probe would have a wider range of beam steering due to the
smaller element pitch. Both apertures would have the same near field length
(Max focal depth) but the .6mm X 16 aperture set up would have improved
focusing within the same range because it is using more elements.
9.6mm = .6mm pitch X 16 elements.
10mm = 1mm pitch X 10 elements.
9
Question:
The application requires reproducing the same 12mm probe size that was
used with a conventional UT probe. What is the advantage of a 16:XXX
instrument over a 32:XXX instrument given the optimum probe?
Answer:
The 32:XXX using more elements of a smaller pitch probe will have
significantly improved beam steering range, energy, and focusing.
32 elements X .6mm = 19.2mm aperture (32:XXX acquisition module)

16 elements X 1.2mm pitch = 19.2mm aperture (16:128 acquisition
module)
Because the near field calculation is the same for both examples, the
maximum focal length would be the same. But more elements of a smaller
pitch within the same aperture improves focusing significantly.
10
u Below we see two examples that demonstrate the benefit of more elements
of a smaller pitch with the same size aperture. (16:XXX vs. 32:XXX)
u The signal in the red gate A is a crack tip of a 20% through wall ID
connected crack in a 25mm thick carbon steel weld. The gain is increased
so that the crack tip signal is at 80% amplitude.
u The 32:XXX acquisition module example shows a clear improvement in
sizing accuracy by producing a clearer image of the crack tip and improved
signal to noise ratio than that of a 16:XXX acquisition module.
u Using more elements of a smaller pitch required a probe with more elements
and a compatible acquisition module for the MX2 with more pulsers.
27 elements × .6 mm pitch probe = 16 mm aperture (32:XXX) 16 elements × 1 mm pitch probe = 16 mm aperture (16:XXX)
11
Focal Law Wizard – Probe 1st Element Position
u The position of the beam set within the probe is defined by the first
element position.
u For probes with a large element quantity (64, 128) the aperture can be
programmed at any position.
u It is a common inspection strategy to use two sector scan groups from the
same probe for coverage. One from the front of the probe for 1st leg
coverage of the ID (First element position 49), and one from the back of
the probe for 2nd leg coverage of the OD (First element position 1).
Element 49
Element 1
12
Focal Law Wizard – Probe 1st Element Position cont.
Question:
For manual inspection is it better to program the sector scan at the front or back of
the probe\wedge?
Answer:
The front of the wedge. In the example below using a start element position of 49
allows the 16 element aperture beam to exit the wedge as close to the weld as
possible.
Element 49 is the last element on the probe that will still allow a 16 element
aperture. Total probe elements (64) – aperture (16) + 1 element = maximum first
element position (49).
First element 49
13
Focal Law Wizard – Beam Min and Max Angle
u Depending if sector or linear was selected, the beam angle form will change
for the required parameters.
u For a linear scan only one angle is available in the focal law wizard.
u The minimum and maximum steering angles are defined by the ability to
maintain angle and velocity, and ability to calibrate it for sensitivity and TOF.
u This is a function of physics, not software. For a given
probe\wedge\aperture, programming an angle beyond the steering range or
first\second critical angle (Snell’s law) will result in a poor quality A-scan,
mode conversion due to velocity change, angle error, and inability to
calibrate.
14
Focal Law Wizard – Beam Min and Max Angle cont.
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 phased array calibration process, like conventional UT, includes
maintaining the velocity at fixed angles (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.
15
Question:
Why can’t the software predict what is an unacceptable steering range for a
given probe\wedge\aperture combination? 20-85 degrees?
Answer:
Because the beam does not terminate when it reaches a maximum steering
angle. It slowly deteriorates as it approaches or exceeds the steering range.
Depending on the sound path required, the size of the calibration reflector,
the required A-scan quality for the application, etc., what is acceptable for
one customer may not be acceptable for another and the software does not
attempt to limit it.
Also, for some applications there is still value in detection in a beam or group of
beams even though they have mode converted, cannot be calibrated, and
the depth and surface readings are not valid. (Which thing does not belong
here inspection).
16
Question:
What factors most affect the ability of a probe\wedge\aperture combination to
improve beam steering?
Answer:
Probe element pitch and beam aperture. The smaller the element pitch and
aperture, the better the beam steering up to the limits of physics (Snell’s law)
and the critical angles.
17
Focal Law Wizard – Beam Angle Step Resolution
u The beam angle step resolution is directly relevant to the number of A-
scans generated within the first and last angle of a sector scan.
u More focal laws or higher A-scan density within the sector scan improves
sizing and flaw characterization.
u The step resolution is normally .5, 1, or 2 degrees but is also possible at a
smaller resolution such as .1, .2, or .25 degrees.
u When using a small step resolution such as .1, .2 or .25, the 256 focal law
limit of the MX2 is quickly reached for multi probe or multi group
inspections.
u More A-scans in the Ops file as a result of wide angle coverage or small
step resolution will also increase the data file size, reduce PRF, and reduce
acquisition speed. It is important to program the group for the needs of the
application. More is not always better.
18
Focal Law Wizard – Beam Angle Step Resolution cont.
u Below we can see the affect that beam angle step resolution has on the
resulting number of focal laws or A-scans generated for a similar 45-70
degree sector scan.
14 total A-scans (45, 47, 49.....)
26 total A-scans (45, 46, 47.....)
51 total A-scans (45, 45.5, 46, 46.5.....)
101 total A-scans (45, 45.25, 45.5…..)
251 total A-scans (45, 45.1, 45.2, 45.3…..)
19
u In this example there are 4 groups of phased array data and 4 groups of TOFD data
to provide 1mm detection and sizing for a 100mm thick ASME vessel inspection.
u The two phased array groups covering the ID are at a 1 degree resolution.
u The two phased array groups skipping off the ID for OD coverage are at a ½ degree
resolution.
u Because the OD coverage groups have a longer sound path, the groups are
programmed at ½ degree resolution (2X as many A-scans) to maintain the same
sizing ability as the ID groups.
20
u Below the affect of beam angle resolution for a typical 45-70 degree S-scan on a
30mm V weld is displayed.
u Beam angle resolution is directly related to sizing accuracy and ability to characterize
flaws.
u The ability to distinguish between a crack and root non-fusion, or porosity and lack of
fusion is greatly enhanced by a higher A-scan density within the S-scan.
u For inspections where flaw characterization and sizing is not a consideration the
scan speed and file size can be optimized by reducing the angle resolution to 1 or 2
degrees creating fewer A-scans within the S-scan.
45-70 degree S-scan at 1 degree resolution 45-70 degree S-scan at 1/2 degree resolution
21
u The image to the right is a
crack tip detected at the
same scan sensitivity for a
1 degree resolution and a
.25 degree resolution
sector scan group.
u The ability to size and
characterize flaws is
improved with the
increased A-scan density
within the sector scan.
u The .25 degree resolution
group will more clearly
locate and size the crack tip
data due to more A-scans
within the same angle
range (45-65 degrees).
22
Focal Law Wizard – Beam Angle Focus Depth
u In phased array inspection, the beam size, angle, and focal plane are capable of
being manipulated within the limits of physics, the software, and the hardware.
u The OmniScan MX2 only supports depth focusing.
u Focusing of any other type can be achieved by importing the focal laws from an
external calculator.
u The maximum distance that the beam can be focused is defined by the near field
calculation below.
u Any number entered into the focus depth field that is greater than the near field will
result in an unfocused beam.
23
Focal Law Wizard – Beam Angle Focus Depth cont.
u The benefits of a 32:XXX acquisition module over a 16:XXX are enormous
when long focal lengths are required for an application.
u Maximum estimated near field calculations in sound path for common
probes in carbon steel without consideration of the wedge:
5Mhz .6mm probes (A10, A2, A12)

» 10 elements = 44mm
5Mhz 1mm pitch probes (A14, PWZ3)

24
Focal Law Wizard – Beam Angle Focus Depth cont.
Question:
What is the difference between a 16:XXX and a 32:XXX MX2 acquisition
module with regard to beam formation?
Answer:
Ability to create larger apertures, focus farther, and improved flaw
characterization and imaging. Maximum focal depth (Near field) is listed
for each aperture below without considering the wedge.
5Mhz .6mm probes (A10, A2, A12 probes)
5Mhz 1mm pitch probes (A14, PWZ3 probes)

25
Focal Law Wizard – Set Gate A Position
u The gate position is not related to the focal law calculator. It is included in
this step of the wizard as a shortcut for the normal setup process.
u The gate position is critical because it will generate the C-scan and
determine the signal to calculate readings such as DA, PA, SA.
u In the example below on a 25mm thick weld inspection, the gate starts at
the area of interest and has a width that would terminate at the end of the
second skip.
u The red box around the gate parameter indicated it is relative to gate A.
Gate B is green and gate I is yellow.
u Gate functions are covered in detail in a later section.
26
OmniScan MX2 Training – Use of Focal Law Wizard
1. Select Menu>Wizard>Focal Law>Start.
2. Law Configuration = Sectorial.
3. Legs = 2.
4. Select Next.
5. Wave type = Shear wave.
6. Select Next.
7. Element Quantity = 16
8. First Element = 1
9. Select Next.
10. Min Angle = 45, Max Angle = 70, Angle Step = 1, Focus Depth = 50mm.
11. Select Next.
12. Gate Start = 5mm, Gate Width = 20mm
13. Select Next.
14. Select Generate.
27
OmniScan MX2 Training – Use of Focal Law Wizard cont.
u Upon successful completion of the part and weld, group set up, and
focal law wizards the default display of A-S-C is displayed with
default UT settings.
28
OmniScan MX2 Training – Focal Law Wizard Movie
29
Free Download Manager.lnk

MX2 Training Program 5C Focal Law Wizard

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MX2 Training Program 5C Focal Law Wizard

Uploaded by

Copyright:

Available Formats

OmniScan MX2 Training Program

The Focal Law Wizard

9.6mm = .6mm pitch X 16 elements.

10mm = 1mm pitch X 10 elements.

32 elements X .6mm = 19.2mm aperture (32:XXX acquisition module)

14 total A-scans (45, 47, 49.....)

26 total A-scans (45, 46, 47.....)

51 total A-scans (45, 45.5, 46, 46.5.....)

101 total A-scans (45, 45.25, 45.5…..)

251 total A-scans (45, 45.1, 45.2, 45.3…..)

5Mhz .6mm probes (A10, A2, A12)

5Mhz 1mm pitch probes (A14, PWZ3)

5Mhz 1mm pitch probes (A14, PWZ3 probes)

You might also like