ESP Advanced NDT Training Program

PHASED ARRAY AND TOFD

PART 1.1 :BACKGROUND

PRINCIPLES
 Topics to be covered

Client LOGO
Introduction
ASME Boiler and Pressure Vessel Code has
attempted to keep up with technology
changes in NDT
Visit - www.asme.org
Introduction
Provision is made in the Appendices for
Computer Imaging Techniques (CITs)
◦ Synthetic Aperture Focusing Technique
◦ Broadband Holography Technique
◦ Phased Array Technique
◦ Amplitude Time-of-Flight Locus Curve
◦ Time-of-Flight-Diffraction
Introduction
Some of the systems are for sizing only
(SAFT, ALOK, Holography)
Phased-array and TOFD are capable of
being used for both detection and sizing
so provide the biggest advances to
increasing speed and reliability of UT
examinations
Code Expectations
Weld inspection is addressed by ASME
Section V Article 4 for all UT
examinations referenced by all Sections of
the ASME Code
Providing that the equipment, and
procedure used meet the descriptions in
Article 4 the advance options are open for
use! This is specifically stated in T-421.2
Code Expectations

Computer imaging techniques

Refer to
Page 48 of the 2007 version T-452
Code Expectations
But it is only necessary to inspect a weld in
accordance with Article 4 when the
referencing Code Section requires it!
The same applies to radiography, it is only
done when required by the referencing
Section of the Code!
◦ UNLESS…..
Code Expectations
In special cases UT may be used instead of
radiography!
These are described in the Code Case 2235-
9 (original was Code Case 2235 issued in
1996)
◦ The Code Case states:
Code Expectations – CC 2235-9
TOFD and PA Options and Solutions

RD Tech was one of the first UT equipment

manufacturers to provide options for the
CITs and Code Case
TOFD Overview

First described by Silk in 1977

◦ Using diffracted signals from crack tips
◦ Developed at NNDTC Harwell, Oxford,
England
◦ Brian Hawker, Peter Carter, Phillip
Charlesworth, and Andrew Temple also
worked at Harwell and contributed to the
development
of TOFD
TOFD Overview
TOFD is an Ultrasonic technique that relies
on the detection of diffracted signals rather
than (specular) reflected signals
Developed as a requirement of the UK
Nuclear industry needing a higher precision
in flaw sizing (length)
TOFD Overview
Forward Diffraction
Technique
Traditional grey scale
TOFD presentation
TOFD Glossary
TOFD- Time Of Flight Diffraction, a pulse-echo
UT technique

Transmit (Tx, P1) Probe- the probe used to induce

the chosen wave type into the material to cause
diffracted waves off any defects present in the
material being inspected (Usually but not limited
to longitudinal waves)

Receive (Rx, R1) Probe – the probe used to detect

the diffracted waves produced by the interaction of
the sound waves induced by the Transmit probe
and a defect
TOFD Glossary
PCS – Probe Center Spacing is measured distance
between the exit points of the transmit and receive
probe wedges when they are used in the TOFD jig
to do an examination (consistent spacing is
required)

Lateral Wave – is a weak bulk wave generated at

the edge of the sound beam with compression
velocity run just below the surface of the material
with a frequency content lower than that of the
waves of the center of the beam
TOFD Glossary
A-Scan - A display in which signal amplitude is
represented in the y-axis and the travel time of the
signal is represented as a displacement on the x-
axis
B-Scan- the B scan is normally used as a
transverse section through a weld and is taken in
the scanning direction
D-Scan- the D scan is a longitudinal view and is
taken in the index direction which is orthogonal to
it
TOFD Glossary
Non Parallel Scan- is a TOFD scan normal to the direction of the
beam along a weld or flaw
Parallel Scan - is a TOFD scan in the direction of the beam
transversely across a weld or flaw
Diffraction - Definition

Modification or deflection of sound beam

Sound striking defect causes oscillation

Ends of defect become point sources

Not strongly dependant on orientation of defect

Diffraction
Weaker signal than reflected (by as much as
20dB)

Sharp defects provide best emitters

Tips signals are located accurately

Time of flight of tip signals used to size

Diffraction

The incoming wave

vibrates the defect.

Each point of the

defect generates new
elementary spherical
waves.
 Waves
Incident
wave Diffracted
waves All directions

Low energy
Reflected FLAW
wave Independent of
incidence angle

Diffracted
waves
 Waves
Photo-elastic visualization

Diffracted
waves

FLAW

Diffracted
waves
 Signals
Transmitter Receiver

Lateral wave

Back-wall reflection

LW BW

Upper tip Lower tip

Note phase change
Signals
Signals Received
◦ Lateral wave
◦ Subsurface
◦ Back-wall echo
◦ Mode converted (shear wave) echo
Define top and bottom of part
 Signals
+ White

A-scan
Amplitude

Time

- Black

One A-scan picture is replaced by one Time

gray-coded line
Signals A-scan
LW

B-scan BW

Upper Back wall

surface
 Signals
Lateral Wave

Back-wall Echo
 Choosing an Angle
 Optimum Upper tip q ≈ 64°
 Optimum Lower tip q ≈ 68°

Angle selected is a
compromise for depth
May require selecting
several “zones” for best
results

From Charlesworth & Temple

 Flaw Tip

Flaw lengths parallel to the surface can be

measured from the TOFD image by fitting
hyperbolic cursors similar to SAFT correction
by SAFT post-processes the data
Advantages of TOFD Technique

Wide coverage area using a pair of transducers

Accurate flaw sizing; amplitude-independent since

sizing technique uses time-of-flight information

Capable of very fast scanning – often used for on-

line volume inspection
Advantages of TOFD Technique

Setup is independent of weld configuration

 No need to use complementary angles

Sensitive to a variety of defects

 Volumetric and non-volumetric

Not sensitive to defect orientation

Since sizing is amplitude-insensitive, acoustical coupling

is less critical
Limitations of TOFD Technique
No more accurate at estimating flaw length in scan
direction than PE
Limited coverage results from two potential dead zones
◦ Dead zone near the surface as a result of the lateral wave.
◦ Dead zone at the backwall resulting from the width of the
backwall reflection
Weak signals, sensitive to grain noise and interference
◦ Interference problems can be solved with averaging
Limitations of TOFD Technique
No simple amplitude threshold for determining reportable
indications
 All TOFD inspection data has to be visually analyzed in order to
select reportable indications

Pitch/catch technique so must couple 2 probes

simultaneously

Considerable TOFD data experience and training are

required for reliable analysis of TOFD data
Limitations of TOFD Technique
Because very small changes in signal response provide the
basis of defect detection, very course gain materials are
less suited to inspection with TOFD

Flaw characterization using only TOFD is very restricted

TOFD Industrial Trials
PISC I, II, III – Program for the Inspection of Steel
Components was initiated in 1973 in Britain
NIL – Netherlands Institute of Welding TOFD trial of
plate material 6 -15 mm thick (1993 – 1995)
PANI – Program for Assessment of NDT in Industry was
carried out over a 3 year period in Britain (1999)

Overall, studies showed that TOFD had higher Probability

of Detection (POD), lower False Calls Rate (FCR) and
greater reliability (probability of correct classification) than
other NDT methods.
TOFD Codes
American Standard: ASME Section VIII
◦ Code Case 2235 (2000 edition)
◦ Automatic ultrasonic testing (AUT) now
permitted in lieu of radiography for vessel
material of 12.7 mm or greater thickness
◦ Code Case 2235 permits a variety of UT
inspection techniques based on TOFD and
Pulse Echo provided a Performance
Demonstration is successfully attained
TOFD Codes
European Standard: CEN ENV 583-6
(2000)

◦ ENV 583-6 Non-destructive testing -

Ultrasonic examination part 6: Time of Flight
diffraction technique as a method for defect
detection and sizing
◦ Recommends probe characteristics
(frequency, crystal size, nominal angle)
with regards to wall thickness
◦ Standard is at draft issue now
TOFD Codes
British Standard: BS 7706 (1993)

◦ Guide to Calibration and setting-up of the

ultrasonic TOFD techniques for detection,
location and sizing of flaws
◦ Guide to help with interpretation of TOFD
data
◦ Also includes examples of typical weld
defects
Conclusions
◦ Not all flaws can be detected or accurately
sized
◦ It is essential to have experienced TOFD
personnel
◦ TOFD lends itself well to automation for data
acquisition but requires manual interpretation
of the collected data for analysis
◦ TOFD data should be used in conjunction with
pulse echo data for defect characterization
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Visualisation of TOFD
• TOFD Still Sequences
Any Questions