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Opposite Phased Transducer – OPT for Sizing of Defects

Conference Paper · December 2004

DOI: 10.13140/2.1.3606.9120

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 Advances in Ultrasonic Methods II

Opposite Phased Transducer – OPT for Sizing of Defects

Authors: J. Pitkänen, VTT Industrial Systems, Finland; V. Kniazev, Wave Process Simulation
System Laboratory, Russia; P. Kauppinen, VTT Industrial Systems, Finland

ABSTRACT

Defect sizing is an important task giving input to fracture mechanics evaluation. The exact
evaluation of sound field in the ultrasonic testing is one of the main elements in order to
analyse precisely defects in materials. At the moment the sizing of defects by NDT-methods
and fracture mechanics evaluation are closing each other. This sets for NDT high
requirements in minimising sizing errors. Sizing accuracy is affected by the size of the sound
field.
There are several applicable methods available for sizing: SAFT, acoustic holography,
tip diffraction, amplitude drop method. In SAFT and acoustic holography applications the
sound field is calculated according to the back propagation of sound waves from an object
(defect, flaw). The echoes are calculated according to their origin. In tip diffraction technique
the external sides of defect are determined based on direct echoes coming from the crack tips.
The tip signal is combination mainly of 3 different signals: diffraction signal (1), scattered
signal from the crack tip volume (2) and micro-reflection from tip areas (3). Normally the
sizing using tip signals is most accurate method. Several methods can use tip diffraction
signals like TOFD, SAFT and manual or mechanised conventional ultrasonic inspection
systems with normal angle probes or mode conversion probes like SLIC, ADEPT or Creeping
wave probe. In the amplitude drop technique sizing is affected by the sound field size to
defect size ratio as well as different characteristics of the defect.
Opposite phased transducer (OPT) is based on sound field determination in design
phase. The sound field is calculated using ultrasonic modelling software and the sound field is
very narrow also for a long sound path distance. This feature is used in sizing using opposite
phased transducer. The approach is described in this paper.

INTRODUCTION

One of the main targets of using focusing in ultrasonic testing is to improve the accuracy of
determination of co-ordinates, size and shape of different defects in the testing objects. As a
rule, the accuracy improvement is associated with the use of ultrasonic transducers having
optimal acoustic characteristics.
Focusing radiators have been most extensively explored by now, and are widely used
for the establishment of acoustic fields with predetermined geometry, for example, for
acoustic energy concentration in the required direction. In a number of practical applications,
multi-element transducers based on the regulation of amplitudes and phases of exciting
signals in certain elements are used (Phased array, PA). Such approach allows to test main
characteristics of the directivity (polar) pattern. However, these acoustic systems are complex,
expensive, and require the availability of additional devices and inspectors need long time
training for proper use for those equipments.

MODELLING OF OPPOSITE PHASED TRANSDUCER

The Idea OPT

The analysis of a wide range of ultrasonic radiators has resulted in the study of the acoustic
field with the “reverse focusing”, that can be established by means of changing to the opposite
of the phase value belonging to one of the exciting signals from two symmetrically arranged
ultrasonic sources. The acoustic axis of the considered opposite phased transducer has a
narrow “zero region” – a region, where acoustic pressure is in the zero vicinity, see Figure 1.
Thus, whereas there is a narrow axial beam of relatively high amplitude in the focusing
systems, in the opposite phased transducer there is a narrow axial gap of the acoustic pressure
amplitude. These characteristics encouraged an application of the opposite phased radiator in
order to improve the accuracy of determination of co-ordinates, and size and shape of
different defects.
In practice researched acoustic processes have a non-stationary pulse wave nature and
considered planar defects may have intermittent structure. Also in this case the opposite
phased transducer gives good performance for sizing of the defects.
For succession of the carried out researches a relative positioning of transmitters (1, 2)
and the receiver (3) in an opposite phased transducer and also relative orientation of planar
defect are fully corresponded to the definition represented on Figure 3.

Case А Case В

Figure 1 - Directivity (Polar) pattern of the opposite phased radiator (left) and radiation fields
of the Opposite Phased Radiator (right).

Computer simulation of sound fields of the OPT

For theoretic reasoning of the opposite phased radiator application, acoustic fields
calculations with the help of Modification of the Numerical Finite Difference Method
(MFDM) developed specifically for ultrasonic applications [1] were made. An unquestionable
flexibility of most part of numerical methods – their capability to interpret whole classes of
wave tasks in a uniform manner – also served as a basis for the MFDM usage.
For simulation of acoustic fields of a normal (direct beam) opposite phased radiator it is
enough to use a two-dimensional (2D) scalar wave model of ultrasonic propagation:
1 ∂2 p
∇ × p− 2 2 =Φ
2

c ∂t
(1),
where р - pressure, Ф - external action, с - ultrasonic velocity, and t - time. As initial data, a
rectified opposite phased distribution of an amplitude of ultrasonic oscillations under the
radiator plates that takes place in real transducers was used, and a pulse radiation pattern was
taken into account. This model and an MFDM numerical algorithm were successfully
implemented in the CAD “IMPULSE” [2], with the help of which a study of properties of
acoustic fields of a normal opposite phased radiator was conducted.
 Figure 1 (right) show the radiation field (the field of maximal modular values of the
sonic pressure of the finite-difference grid during whole simulation time) simulation results
for two cases:
- two symmetrical radiator plates are located immediately adjacent to each other in one
plane (case A);
- two symmetrical radiator plates are located at an angle of 7 degrees to each other
(case B)
It is seen from the figures that in both cases we have a comparatively narrow zero region. In
the second case, the maximums of the sonic pressure amplitude of each opposite phased half
of the radiation field are subtended towards the radiator’s axis. If we place a receiving crystal
between two transmitter crystals, in reflection from the plane, that is perpendicular to the
radiator’s geometric axis, an electric signal on the receiving plate Arec will be close to zero as
a result of cancellation effect of the received opposite phased pulses. Its Arec value will
become different from zero, when symmetry of the radiation field, or symmetry of acoustic
properties, or geometry of the medium of ultrasonic waves propagation with respect to the
radiator’s axis is broken.
This property of an opposite phased radiation of ultrasonic waves was used as the basis
for the application of an opposite phased transducer and an appropriate method of non-
destructive testing for the improvement of accuracy of co-ordinates determination and defect
size assessment. In case of scanning with an opposite phased transducer along the object’s
surface, in the event of the availability of plane defects on it, the following wave processes are
observed. When the transducer is moved along the surface of the testing object 4 (see Fig. 2),
one of the radiator plates happens to be the first plate that is close to the defect (Position I):
for example, Radiator 1 and the ultrasonic pulse, that is radiated by it, is reflected from defect
5, and a pulse from radiator 2 goes inside the object. In this case amplitude of the received
signal is growing as a result of the increase of the defect area from which an ultrasonic pulse
is reflected. An increase continues until the second ultrasonic pulse starts reflecting from the
defect. This transition corresponds to the transducer position, when the defect edge is located
in the centre of the zero region of the radiation field (position II).
Then after reflecting from defect 5 the second ultrasonic pulse gets onto receiver 3
simultaneously with the first pulse. Since these pulses are radiated in an opposite phase, they
start attenuating each other, while they are being received simultaneously. As the transducer
is moving over the defect, an impact of the second reflected pulse is increasing. As a result,
the total amplitude Arec, received by the receiver 3 is reduced during transition from position
II to position III. Thus, a maximum of the received signal Arec is achieved at the moment
when the defect edge is on the transducer’s acoustic axis, that is ultrasonic pulses of one of
the radiators are reflected from the defect, and pulses from the second radiator are going
inside the testing object. In case of moving away from the defect similar processes are
observed, but in reverse order. As a result, the defect beginning and end correspond to the
position of the opposite phased transducer, when maximal amplitude of the received signal is
registered.
It is important to note that the closer the radiators are to each other, the steeper are the
fronts in the vicinity of the zero region of the radiation field. If the radiators are located at the
distance from the transducer’s acoustic axis that is comparable with their dimensions, the
required front steepness can be achieved by placing the radiators at a small angle to the
transducer’s acoustic axis, see Figure 1, case B. All this is more likely to result in the
recording of a maximal value of Arec and accordingly will allow determine the co-ordinates
of the defect edges more accurately. The wave propagation is shown in the figures 4 and 5
from the normal single crystal probe and OPT-probe. It can be seen in the modeling the effect
shown in the figure 2. For evaluation of the planar defects two types of planar defects are
considered:
- semi-infinite continuous planar defect,
- semi-infinite multi defect consisting of small defects alternating with step 0.8 λ,
where λ - ultrasonic wave length.
 For comparison of efficiency of the various type radiators application computer
simulation was carried out for single and proposed opposite-phased transducers.
In the case of normal radiation of compress waves it is enough to use the same 2D
scalar wave model (1). On the defect surface it is set the boundary condition such as
Neumann (soft boundary condition) and on boundary of simulation area - open boundary
condition.
The figure 5 illustrates the amplitude distribution from the modeling results. It can be
seen that in both cases the reflection in case of the opposite phased transducer shows clear
change of the amplitude, which can be positioned very accurately. This effect can be used in
many applications for sizing purposes. Especially in long range inspection this can be maybe
used for more accurate sizing as well in normal length sizing of the cracks. The sizing of the
defect height is more complicated case and it can also be modeled.

Figure 2 - An illustration of wave processes taking place during scanning with an opposite
phased transducer (1), radiators (2), receiver (3), testing object (4), defect (5).
 Figure 3 - An illustration of modeling wave front with an normal ultrasonic probe and
opposite phased transducer (1), radiators (2), receiver (3). The figure illustrates the reflection
phenomena from semitransparent planar reflector.
 Figure 4 - An illustration of modeling wave front with an normal ultrasonic probe and
opposite phased transducer (1), radiators (2), receiver (3). The figure illustrates the reflection
phenomena from the planar reflector.
 Arec/Ao, %
30
Local maximum
detected by the 25

opposite phased 20

transducer at Single crystal

corner of the defect 15
probe
10

0 X, mm
-10 -5 0 5 10 15
I II III

Figure 5 - The modeled amplitude distribution in the neighborhood of the different reflector –
planar and semitransparent planar reflector.

The analysis of computer simulation results

The results of computer simulation represented on Figures 3 and 4 show wave dynamics of
the ultrasonic pulses propagation on an example of four sequential time frames t1, t2, t3 and
t4 and for three scanning positions of single (Case A) and opposite phased (Case B)
transducers. Position I - transducer approaching to defect. Position II - transducer acoustic
axis is above defect edge. Position III - transducer is above defect almost completely.
The obtained results once again confirm idea of application of an opposite phased
transducer for the planar defect sizing, originally based on intuitive ray tracing interpretation
of occurring acoustic processes, Figures 3 and 4, but already in consideration with their non-
stationary pulse wave nature. The wave nature of these processes can be observed on an
example of a diffraction of ultrasound at edge of both defects and complicated diffraction
structure of the acoustic field scattered on a surface of multi defect.
In Figures 3 and 4 the narrow axial zero zone is well visible at radiation from an
opposite phased transducer and also sequence of the opposite phased pulse reception and
them inter compensated effect. It is obvious that in principle the intermittent structure of multi
defect has not changed the scattered field picture.
Figures 3 and 4 show qualitative dynamics of wave processes extremely well. For a
quantitative estimation of an opposite phased transducer application for planar defect sizing it
was carried out comparison of association of received signal amplitude from scanning
position for single and opposite phased transducers. This comparison is represented on Figure
5 where an abscissa axis corresponds to a deviation of a transducer acoustic axis from defect
edge (X), and a ordinate axis - to amplitude of an integrated value of sound pressure under a
received plate concerning the radiated signal (Arec/Ao). The marked positions of transducers
(I, II and III) correspond to similar positions for Figures 3, 4 and 5.
It is evident that in these two cases both for planar defect and for multi defect an
absolute maxim of received signal Arec/Ao corresponds to such position of an opposite
phased transducer where its acoustic axis is directly above defect edge (Position II).
Single crystal transducer shows defect edge only approximately. In case of multi defect
we observed oscillations of received signal amplitude Arec/Ao at scanning by single
transducer above its surface (Position III and so on). These oscillations are caused by wave
effects of scattering from multi defect and they can reduce errors in defect sizing compared to
normal amplitude based techniques.
All these performances prove more advantage of opposite phased transducer application
for accurate sizing of continuous and intermittent planar defects.
A B
Figure 6 - SAFT (A) and SUMIAD (B) equipment.

THE EQUIPMENT USED FOR EXPERIMENTAL WORK

SAFT-equipment is based on a CPS-software which permits the acquisition, analysis and

reporting of ultrasonic inspection data, figure 6a. Ultrasonic data can be acquired by using
semiautomatic or automatic testing equipment.
The equipment uses a 2d-saft algorithm or pseudo 3d-saft view, which is actually a
combination of pictures of 2d-saft reconstruction, not a genuine 3d-saft reconstruction. The
software includes also SAFT-module for curved surface.
The dynamic range of the equipment is 100dB, it is a 1-channel system, the usable
frequency range is from 0.5 MHz to 20 MHz. The maximum sampling frequency is 160 MHz.
The range of measurement is about 2.5 m for longitudinal waves in ferritic steel.
The SAFT-equipment contains a PCUS11-ultrasonic card which controls the data
acquisition. Also external ultrasonic equipment can be used with this equipment. The system
is easily adapted to different manipulators. The system has been used together with a linear
wire-based co-ordinate equipment (semi-automated inspection), with different types of pipe
scanners and also with a scanning device, used for the inspection of the outer surface of
reactor pressure vessel.
The SUMIAD-system can provide 1/4/8/16 ultrasonic channels options, figure 6b. The
ultrasonic pulsers and receivers are based on a modular multi-channel ultrasonic flaw detector
(pulsers and receivers independent), which is programmed and calibrated individually and in
different ways depending on the particular inspection procedure. The ultrasonic part is fully
controlled from the DAS. It can be operated locally or remote controlled (up to 150 meters).

MEASUREMENTS

Here are shown some applications where opposite phased transducer, figure 7, has been used
to measure some simple reflectors. The main goal of these measurements was to prove that
the opposite phased transducer behaves as modelled and shown in Figures 1 - 5. Three
notches of depths 2 mm, 4 mm and 6 mm are shown in Figure 8. In the figure the minimum
value of the amplitude is seen in the middle of the indication. This is showing the real position
of the defect. This means that in case of crack this can be localised very accurately compared
e.g. to normal 0°L probe. It can be used also for defect sizing but the frequency must be
suitable for the defect size in concern.
The opposite phased transducer has also its limitations. In case of an area containing
several cracks, the measured sound field can be used to define the borders of the cracked area
as can be seen in Figures 9 and 10. In Figure 10 is shown the raw data which is giving as
much information as SAFT-reconstructed image in Figure 11. This indicates as shown
theoretically that the sound field is narrow and very little can be achieved in the
reconstruction for sizing purposes.
Figure 7 - Opposite phased transducer with a SAFTmeasurement arrangement for onsite
application.

Figure 8 - Notches measured with an opposite phased transducer.

 Figure 9 - Notches measured with an opposite phased transducer (raw data).

Figure 10 - Notches measured with an opposite phased transducer (SAFT reconstruction

data).
 It is seen in Figure 11 that the measured amplitude of the opposite phased transducer is
following the modelled behaviour. From the notch which goes along the surface only the end
of the notch is seen. This feature can be used for sizing interface defects (laminations). Both
in the case of a single defect and multi defects the minimum amplitude is seen in the middle
of the defect. For single defects this method is an easy way to size the defect.

Figure 11 - The measured amplitude distribution from the notches of the specimen shown in
Fig. 10.

DISCUSSION AND CONCLUSIONS

In this paper is discussed the potential of opposite phased transducer for accurate defect sizing
using amplitude dependence of the sound field properties. This technology is easy to adapt as
well in conventional ultrasonic equipment as well as to complicated systems like phased array
equipments. For a single defect this method is easy to apply for sizing purposes. In the case of
several defects the transducer frequency must be high enough to improve the detection and
separation capability of small defects. The frequency used in these measurements was 2 MHz,
which can't be applied for detection of tip signal of a small crack. The opposite phased
transducer can be used e.g. for detection of laminations and other interface defects. When the
normal structure has a grating, it is possible to design opposite phased transducer for the
accurate inspection of the material between gratings. The use of the OPT for another types of
reflector will be reported in the near future. The sound field is very narrow and only slowly
opening even in the case of long sound path distances. The behaviour of opposite phased
transducer has been modelled with software using numerical finite difference method
(MFDM) and the behaviour is shown in practical measurements.

REFERENCES

1. Kniazev, V. D. Computer Calculation of the Reflection of Ultrasonic Waves from

Planar Flaws. Proceedings of the Seminar on Nondestructive Testing -88 (in Russian).
Riga, 1988, pp. 65-66.
2. Alyoshin, N., Kniazev, V. and Zemlyanski, A. Computer-aided Design of Ultrasonic
Nondestructive Methods and Techniques. Proceedings International Conference
“Computer Methods and Inverse Problems in Nondestructive Testing and Diagnostics
CM NDT-97”. Minsk, 1997. pp. 238-243.
3. Pitkänen, J, Kauppinen P., Kniazev, V., Opposite phased transducer – novel type of
transducer Review of progress in Quantitative Nondestructive Evaluation Volume 23A,
27.July - 1. August 2003, Green Bay Wisconsin USA, pp 721-728.

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