TFMiTM Part 2: Improved Imaging with 3D Rendering

More info about this article: http://www.ndt.net/?id=26388

Paul Holloway1 and Ed Ginzel2

1.
Holloway NDT & Engineering Inc, Georgetown, Ontario, Canada
e-mail: paul@hollowayndt.com, website www.hollowayndt.com
2
Materials Research Institute, Waterloo, Ontario, Canada
e-mail: eginzel@mri.on.ca

Abstract
In a recent publication [1], the advantages of using simultaneous processing of multimodal Total Focussing Method
(TFM) data were provided. The resulting images provide improved characterisation and sizing of indications. In
this paper we illustrate how the process can be used to produce high resolution images that can be rendered in three
dimensions (3D) using an open-source software, Slicer. TFMi (the simultaneous processing of TFM across multiple
modes) is used to process full matrix capture (FMC) scanning data on a test coupon with a fabricated crack that
transitions from a surface-breaking to a subsurface flaw. Merging the scan samples along the length of the coupon
from probe positions on both sides of the weld, a detailed 3D solid of the flaw can be generated. This is compared
to several cross-sectional photos to illustrate the detail possible when using the technique.

Keywords: ultrasonic, phased-array, FMC, TFM, total focussing method, rendering

1. Introduction

Flaw characterization is one of the main objectives when performing ultrasonic examination.
Determination may be based on weld type, flaw location, amplitude, echo dynamics, and
variations in angular response. The inspector is tasked with interpreting many factors, usually
simultaneously, to determine the type and size of a flaw to compare with code acceptance
criteria. While they may be able to correctly interpret an A-scan or S-scan, these basic instrument
displays are not intended to produce true visual representations of the actual flaw.

Much research has been performed in the pursuit of improving ultrasonic imaging techniques
[2,3,4]. In field portable instruments, the most recent advancement has been full matrix capture
(FMC) and reconstruction techniques such as the total focus method (TFM). The use of TFM
provides the advantage, as the name suggests of optimum focusing capability at all points within

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a region of interest. This is extremely valuable for detection and accurate sizing of flaws but does
not always produce images that can be understood by untrained people.

In a recent publication [1], the authors presented the foundations of a technique that uses
simultaneous processing of multimodal TFM data. This technique, named “TFMi”,
demonstrated how the product of multiple propagation modes provides the user with improved
geometric fidelity versus single modes, increased confidence in analysis, and improved signal-to-
noise in the resultant image.

An illustration of the effectiveness of TFMi imaging on a real weld crack is shown in Figure 1.

Figure 1: TFM results using individual modes (L to R: 2T, 3T, 4T) and intermodal result (far right: TFMi TM)

Typically, manufacturers of equipment demonstrate the features of TFM using machined targets
such as slots, surface notches and side drilled holes. These are convenient to illustrate the
capability of TFM algorithms to represent position, shape and size of known features.
Diffraction patterns from side drilled holes are ideal because they have similar characteristics
over a wide range of angles of incidence. However, the smooth face of a machined notch or slot
tends to produce weak signals compared to real flaws with irregular surfaces. Idealized targets
can be poorly imaged as a result of specular reflections away from the receiving elements. Small,
sharp-tipped, or faceted planar flaws are not only more able to generate diffracted signals with a
somewhat omnidirectional pattern, but they are also more representative of real flaws.

To demonstrate TFMi in a realistic situation, a cracked weld sample was fabricated, scanned
using FMC and then the data processed using TFMi. It was then further processed using Slicer
[6], an image processing software commonly used in medical imaging. The Slicer processing
provides a 3D image of the indication that can be viewed in 3D viewing software and exported to
STL (STereoLithography) format that can be used to make a 3D model of the flaws.

This paper demonstrates the effectiveness of TFMi on a real, complex weld flaw and the added
potential for 3D rendering of solid models based on TFMi data.
2. Equipment and Materials

1. Phased array instrument (Sonatest Veo3)

2. Transducer (Vermon-NDT A5L32-31)
3. Wedge (Olympus SA31-N55S-IHC)
4. Steel plate cracked weld (16mm thick)

The cracked weld in the steel plate was made by welding two 19mm thick plates prepared with a
single V weld bevel preparation to approximately half thickness. The half-welded plate was then
placed in a vise and bent continuously until the weld fractured along the full length. Then, the
plate was aligned to match the crack facets and the weld completed on the upper surface. This
left a surface breaking crack on the opposite surface. Then half of the crack weld length was
ground to about half of the crack depth and back-welded to form a subsurface crack. The top and
bottom surfaces were then milled flush leaving the plate 16mm thick.

This provided a complex flawed weld sample with a surface-breaking root crack on the bottom
which propagated up into a subsurface centreline crack. An image of the plate and probe
positioning created using ESBeamTool software is seen in Figure 2.

Figure 2: Cracked plate sample

3. Scanning and TFMi Imaging

The plate was scanned from both sides of the weld using FMC and all 32-elements of each
transducer. Image reconstruction was performed with TFMi using a 4-mode combination of 2T,
3T, 4T, and 5T. The data was captured and displayed showing the TFMi frames, Top, and End
views as shown in Figure 3 to Figure 6. The TFMi images provided information suitable for
assessment of size and extent measurements and showed good correlation between the left (Skew
90) and right (Skew 270) orientations.
 Figure 3: Scan view orientation Figure 4: Screen layout

Figure 5: Top and End View on weld model Figure 6: TFMi data view

4. Construction of 3D Model Using Combined TFMi Data

The TFMi data from each side of the weld were exported as comma separated value (.csv) files
and used to construct a 3D rendered image of the flaw using Slicer software. This was
accomplished by first exporting each frame of the TFMi data as a 2D grid of amplitude points,
then combining the corresponding data from the opposite skew. Effectively, this process
represents the combination of 8 individual TFM propagation modes (4 used by each TFMi
process). The Slicer views of the reconstructed volume are seen in Figure 7.
 Figure 7: Slicer Top-Side-End view with rendered 3D view of merged scans 90° and 270° skews

To produce a 3D model, threshold amplitude levels must be selected to isolate relevant signals
from background noise. The raw TFMi data has a relatively high signal-to-noise ratio to begin
with due to the nature of combining and amplifying coherent signals (Figure 8, left). Application
of a nonlinear filter compresses the dynamic range for improved resolution of low amplitude
reflectors (Figure 8, center). Threshold levels are then applied to the filtered data to isolate the
flaw signals (Figure 8, right).

Figure 8: TFMi data processing (left: unfiltered, center: nonlinear filter applied, right: threshold)
To illustrate the detail available by TFMi and the Slicer rendering and segmentation capabilities,
the STL image was then exported to a CAD drawing package where a box was placed around it
to provide the viewer with a reference that represents the original block. From the CAD drawing
package, it was then possible to export the 3D image as a 3D PDF file that can be viewed as part
of this presentation. The 3D PDF file has been embedded in this PDF file and allows the viewer
to move the rendered flaw and the box representing the original cracked sample. When the
mouse cursor is placed over the 3D image, the toolbar seen across the top in Figure 9 appears
and the person viewing can adjust the viewing parameters including pan, tilt, rotate, zoom and
cross-sectional views. Figure 9 is the inserted 3D PDF view.

Figure 9: 3D PDF image showing crack in a box and viewing parameter toolbar
Following the generation of the STL file using Slicer, additional rendering software can be used
to visualize the flaw. A material similar to amber was selected to provide some transparency and
ability to highlight the level of detail from the TFMi processing (Figure 10, Figure 11).

Figure 10: End view of 3D model and corresponding Skew 270 TFMi data

Figure 11: 3D model based on TFMi data (combining both skews)

5. Validation

To assess the accuracy of TFMi, the steel weld sample was sectioned and macro-photographed in
several locations. Figure 12 indicates the plate before sectioning and after sectioning.
 Figure 12: Bottom view of flawed plate before sectioning (left) and after sectioning (right)

Figure 13 to Figure 19 show the cross sections of the weld and flaw profiles alongside
corresponding TFMi frames. Measurements were made on the flawed sample and compared to
measurements made in Sonatest UTStudio+ analysis software. Some section faces are viewed
“looking backwards”, and as such the orientations of Skew 90 and Skew 270 appear reversed.

Skew 90
Skew 270

4.8mm

Figure 13: 1-2a (30mm)

Figure 14: 2-3a (60mm)

Skew 90
Skew 270

4.9mm

Figure 15: 2-3b (62mm)

Skew 90
Skew 270

4.9mm
2.8mm
 Figure 16: 3-4a (75mm)

Figure 17: 4-5a (100mm)

Skew 90 Skew 270

Figure 18: 4-5b (102mm)

Figure 19: 5-6a (135mm)

The TFMi data clearly show the flaw is intermittent around 100mm to 130mm. This is evident in
Figure 10 and Figure 18.

The 3D model generated in Slicer using the combined data from both the left and right sides can
be overlaid on section views as shown in Figure 20. The overlays displayed in yellow are the
combined results of the Skew 90 and Skew 270 TFMi data and are effectively the cross-sectional
data by which the 3D model was generated in Slicer. The 3D model cross section has excellent
correlation with the cut sections from the weld specimen.

Figure 20: Effect of combining TFMi images from both sides of the weld

6. Comparison with TOFD

A time of flight diffraction (TOFD) scan was performed on the sample prior to sectioning. A pair
of 10MHz, 6.4mm diameter transducers mated to 60° longitudinal wave TOFD wedges were
used. The data is shown in Figure 21. The top and bottom tips of the indications were measured
along the length of the TOFD scan and are overlayed on the TFMi data in Figure 22.
 Figure 21: TOFD data along entire scan length

Figure 22: Comparison of flaw profiles using TFMi and TOFD

The TOFD and TFMi results are well correlated, and the reduction of the flaw around 100 to
130mm is easily observed using both methods.

7. Conclusions

TFMi and 3D rendering provide useful tools to represent flaw details. Accurate details and
improved geometric fidelity can be beneficial to engineers required to compute failure analyses
in risk-based-inspections.

Development of TFMi was a joint project between Holloway NDT & Engineering Inc. and
Sonatest.
8. Acknowledgements

We would like to express our thanks to Jonathan Lesage for preparing Python code to process the
CSV files and to Jessie Groom for guidance on preparing segmentations in Slicer. We would also
like to thank Shane Turcott at Steel Image in Dundas, Ontario for cutting and preparation of the
samples.

References

1. Holloway, P., Ginzel, E., TFMiTM: Using Intermodal Analysis to Improve TFM Imaging,
https://www.ndt.net/article/ndtnet/papers/TFMi_-
_Using_Intermodal_Analysis_to_Improve_TFM_Imaging.pdf, NDT.net May, 2021
2. Zhang, J., Drinkwater, B.W., Wilcox, P.D., Hunter, A.J, Defect detection using ultrasonic
arrays: The multi-mode total focusing method. NDT E Int. 2010, 43, 123–133.
3. Zhang, Y.D., Shen, X., Demirli, R., Amin, M.G., Ultrasonic Flaw Imaging via Multipath
Exploitation. Advances in Acoustics and Vibration, Volume 2012, Article ID 874081
4. Pörtzgen, N., Imaging of Defects in Girth Welds using Inverse Wave Field Extrapolation of
Ultrasonic Data, Laboratory of Acoustical Imaging and Sound Control, Faculty of Applied
Sciences, Delft University of Technology, Delft, The Netherlands, 2007
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(1), January 2018, pages 349-360
6. 3D Slicer Image Computing Platform, www.slicer.org