Phased Array Scan Planning

Considerations for Weld Inspection

University of Ultrasonics
Olympus Scientific Solutions Americas Webinar
February 4th, 2014
Short Course Outline
• Scan Planning Introduction
• Basic Scan Plan Requirements
• Basic Methodology
• Hands-on Demonstration
Scan Plan History
• Scan planning is deeply rooted in day-to-day conventional
UT routines:
– Evaluating Transducer Characteristics
– Determining proper “pullback”/skip distance for Angle Beam
– Beam overlap for C-Scan coverage
– Focal Spot Size Calculations
Scan Plans???
• Before ANY Phased Array Inspection is
performed a SCAN PLAN should be in place.
– Scan Plans – A documented inspection strategy (plan
of attack) to provide repeatability for inspections.
These will aide in evaluating the material and provide
insight to individuals reviewing data.
Scan Plan Importance
• Variability of Phased Array inspections can create issues in
consistency, repeatability, and personnel training

• The above scan plan includes several scan plan variables, can you find
them???
Phased Array Variability
• Sectorial Scanning
• E-Scanning
• Encoded vs. Manual
• Aperture Determination
• Multi-Channel/Grouping
• Focusing effects
• Transducer Selection
– Frequency & Beam
Spread Considerations
• Angle Selection
 Scan Planning
Code Perspective
Scan Plan Variables
• Phased Array Scan plans should
provide at minimum:
– Part Details (Weld Design,
Curvatures, Connections)
– Probe and Wedge to be Used
– Focal Law Configuration to be
Used (Including initial instrument
settings)
– Index Offset Info
– Number of Scans
– Direction of Scans
ASME Example Requirements
• Section V
Article 4
• Requirements
of Scan
Planning in
Appendix V
AWS Example Requirements
 D1.1
 Info Related to
Scan Planning
under Part G
 Testing
Procedure under
Annex S
API Example Requirements
 1104
 Info Related to
Scan Planning
 Procedure
specific
 Specialized
Calibration
Requirements
 Phased Array
Scan Plan Equipment
Scan Plan Essentials
• Forming a scan plan involves 3 essential variables:
– Part Configuration
– Probe & Wedge Selection
– Focal Law Selection
• Information may be hand-drawn or plotted via software
Hand-Drawn
• Pros:
– Accounts for errors in Equipment
– Plots actual beam index point
– Focal Law adjustments visualized
• Cons:
– Time Consuming
– Visual Measurements
– Requires Equipment
– Actual Inspection piece may vary
 Software
• Pros:
– Fast and efficient
– Easier Part Drawing/Dimensioning
– Traceable & Transferable
– Flexibility on Custom Parts
• Cons:
– Equipment Variations
– Part Variations
– Estimation of Focal Laws
– Manual Prove up required
Equipment Selection
• Choosing the proper equipment is as much scan
planning as choosing the proper angles or focal laws.
• Transducers should be proper for material properties
• Wedges should allow for good contact and transmission
• Instruments should be capable of handling both
Element Configuration
• Differences in array patterns will provide unique beam
characteristics
A
• 4 Primary Variables: e
– Element Qty. - A
– Element Size - E H
– Pitch - P
– Elevation - H p g
“VPA” Considerations - Focusing
• Focusing in Phased Array is 16 element 32 element
dependent upon the Aperture used aperture aperture
and Pitch of those elements
• Larger Pitch Transducers and Higher
Aperture sizes will provide better
focusing
• Sometime necessary when Height
Sizing is important
 “VPA” Considerations - Steering
• Steering in Phased Array is
dependent upon the amount of
beam spread from individual
elements
• Over steering a transducer can
lead to grating lobes, resolution
losses, and increased errors in
refracted angle
• Smaller Element Sizes and
Reduced Pitches aid in steering
Curvature Considerations
• Caution should be taken in using Phased Array in Axial
or Long Seam weld inspections
• Smaller equipment is easier to use as the compensation
through focal laws may not be necessary
• Larger wedges create non-linear focal law calculations
that sometimes require the addition of special software
 Phased Array
Scan Plan Creation
Scan Plan Thoughts
• From the perspective of the technician, a scan plan
provides instruction for probe placement and focal law
creation
• With no direct code instruction and high variance on
Phased Array use, this leaves more room for
interpretation and how to provide these instructions
• 2 Extremes of Scan Plan Creation
– Minimalistic
– Flood Method
Minimalist Scan Plans
• From a Code standpoint, coverage is the only requirement and the
minimalist approach fulfills only that basic necessity

• Pros: High-Speed, minimal setup time, ease of analysis

• Cons: May require manual follow up, risk of undercalling, difficulties in flaw characterization
Flood Scan Plans
• From a Detection standpoint, flaw orientation is always
variable and is best detected by multiple beam positions

• Pros: High Resolution, Increased Probability of detection, Improved Sizing

• Cons: Slow Scan speeds, Longer Analysis/Setup times
Scan Plan Focal Law Methodology
• First need a plan of attack….
– How am I to approach the inspection? (Single side
access…duel side access..etc.)
– What types of flaw mechanisms are potentially present?
– What incident angles will best reveal the potential flaw
mechanisms?
– FLAWS ARE ANGULAR DEPENDANT
• Most codes simply state full volumetric coverage including the
Heat Affected Zone is required….. This is too vague.
• Breaking that required coverage into specific areas and
specific angles will provide consistency and reliability.
Scan Plan Methodology Welds
• More than just coverage!!!!
• Must interrogate specific parts of the joint with specific angles
which will provide optimum responses to suspected flaw
mechanisms.
• General coverage principles for Weld Inspection
– Root Coverage
– Fusion Zone Coverage
– Heat affected zone coverage
– Volumetric
• This does NOT indicate that 4 scans on each side must be
configured.…The number of scans is determined by your
proof of coverage.
Scan Plan Methodology continued
• 1. Weld Root Interrogation – First objective is to index close
to the weld toe with the intent of weld root interrogation
– Primary Flaw Types: Lack of penetration, Root or ID Cracks,
Centerline Cracking in Double Vee Weld
– This is the most critical part of a weld joint and the first objective
to cover in scan planning.
– First have to consider the joint type and the potential flaws.
– This also assures maximum 1st leg inspection coverage.
Scan Plan Methodology continued
• 2. Fusion Zone Coverage – second objective is to ensure the
fusion zone is covered WITH SPECIFIC ANGLES.

• Primary Flaw Types: Lack of side wall fusion, Sidewall Cracking

• With conventional ultrasonics, the optimum bevel incident angle (BIA) is

considered between 5 and 7 degrees of normal incidence with some
dependency on the frequency of the sound wave.

• Studies have found that with Phased Array, the optimum BIA with
• Sectorial Scans = +/-10 degrees of normal incidence
• E-Scans = +/-5 degrees of normal incidence.
Scan Plan Methodology continued
• Example:
– With a 30 degree bevel – perfect bevel incidence would result
from a 60 degree refracted shear wave.
– Fusion Zone to be covered with refracted waves between 50
and 70 degrees (+/- 10 of 60 degrees.)

70
50
Scan Plan Methodology continued
• 3. Heat Affected Zone (HAZ) Coverage – The total code specified
area of interest must be covered. ASME specifies the weld zone
plus 1” or “t” whichever is less for materials less than 3” thick.

– Primary Flaw Types: CRACKING

– Studies have identified that optimum responses from a notch corner

result from shear waves between approximately 35 and 58 degrees.

– Plan for these angles to interrogate the HAZ zone.

– Occasionally, HAZ coverage may be specified as being achieved on the

probe side for a given index position.
Scan Plan Methodology continued
• 4. Volumetric Coverage – If the previous three steps
are complete, this will be sufficiently covered without
addition considerations.
– This is for slag and porosity detection which are typically omni-
directional type reflectors (similar to a Side-drilled hole, omni-
directional reflectors tend to reflect sound regardless of the angle
of attack).
 Thank You!
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