Focusing with Phased Array The aim of this article is to provide a brief introduction to focusing used during Phased Array inspections in general industry (Weld and Plate Inspection). AUTHOR: PAUL GROSSER - DIRECTOR, NDT ATTAR (One of the numerous advantages of Phased Array (PA) over conventional Ultrasonics (UT) is the ability to focus the beam to increase sensitivity and resolution over a range of thicknesses. Natural Beam Profile (Unfocused) ‘The shape of the unfocused beam Is controlled by those factors that control the Near Zone. In Phased Array these are: = Wavelength, determined by velocity and frequency + Probe Element Pitch, distance between centre of elements + Aperture Active Elements, number of elements electronically fired to form a single array. Conventional Focusing (Mechanical) «= Has the capability to converge the acoustic energy into a small focal spot * Inn unfocused conventional probe, the Focal point is the end of the Near Zone * Focusing cannot occur beyond the Near Zone + The increase in sensitivity is a function of the reduction of the beam width when the beam is focused * Focusing decreases the depth of field (DoF), the distance between the nearest and farthest reflectors in a beam that provide acceptable sensitivity for detection + Focusing generally done mechanically, ata fixed distance. Phased Array Focusing (Electronic) = Has the capability to converge the acoustic energy Into a small focal spot + Allows for focusing at several depths, using a single probe = Can only perform in the steering plane, when using a ID-array + Focusing decreases the depth of field (DoF), the distance between the nearest and farthest reflectors in a beam that provide acceptable sensitivity for detection + Focusing cannot occur beyond the Near Zone + Active Aperture = element pitch x number active elements + Focusing performed electronically Figure 1: Showing effect of aperture size on Near Zone and beam profile Figure 2: Depth Comparison: + Probe | is unfocused at 48.6mm (NZ depth). Probe 2 s focused e25mm depth + 25mm: Probe 2 increased sensitivity as compared to Probe | 175i: Probe 2 lower sensitivity as compared to Probe | (reduction in DOF Industrial Eye May/June 2016Determination of Beam Diameter Focusing the beam within the Near Zone results in reduction in the diameter of the beam at the focal point. This reduction in beam diameter increases overall sensitivity at this point due to the increase in sound energy power unit area. ‘The formula for calculation of beam diameter within the near zone is: BD = 0.88 Fe/tA Where: BD = Beam diameter (rm) F ocal Depth (mm) c peed of sound (km/s) f = Frequency (MHz) A = Aperture size (mim) In Figure 3, you can see that the beam diameter reduced from 4.2mm at the Near Zone unfocused depth, to 1.6mm at the focal depth of 30mm. This results in an increase of sound intensity by a factor of 6.9. lis econ aes Maximum depth of focusing with focused at 30mm depth Phased Array + 30mm Aperture 2 Increased sensitivity as compared to Prabe The following tables show the maximum denth of focusing + 13mm: Aperre 2 owe sensi 25 compare Aperture for a range of typical PA setups Table 1: Zero Degree, Contact - No Wedge ‘The formula for calculation of near zone is: Frequency | Pitch | Active | Aperture | Velocity | Max aka are) [rm | Elemeces | size |’) | Foca Where: nm) NZ = Near Zone (mm) 5 06 [16 96 59 [195 A= Aperture size (mm) 5 06 [32 1925.9 | 781 = Wavelength (mm) 5 0.75 |16 12 5.9 [305 5 0.75 [32 24 5.9 [122.0 5 1 ie [16 5.9 [542 5 1 [se [32 59 [2169 ‘Table 2: Zero Degree, Perspex Wedge 20mm Thick Frequency | Pitch | Active Aperture Wedge Near Material | Max (MHz) (mm) Elements Size Velocity Zone In | Velocity | Focal | (nm) | (km/s). Wedge’ | (km/s). | Depth in | (mm) Material | um) Ee CS 96 [27/200 _|59 [104 5 0.6 [32 192 [27 (200 (5.9 168.9 5 0.75 [16 12 27200 [5.9 [20a 5 075 [sz (2a 27200 (5.9 | 129 5 ieee 16 27 [200 (39 [45.1 5 1 (se fae [too so aor Industrial Eye May/iune 2016 B‘Table 3: Angle Scan - 45 Degrees, Assumed Element Height in Wedge 10mm Frequency | Pitch [Active | Aperture | Wedge Material [Refracted |Max | (sttiz) | (mm) | Elements | Size Velocity |()in Wedlge Velocity | () in Focal (mm) (km/s) | Wedge (mm) | (km/s) | Material | Depth in Material LL (mm) | 5 6 je 9s lar pee [as [a2 [4s 16.2 5 06/32 19.2 27, 36.6 [125 (3.2 45 92.6 5 0.7516 2 27 (366 [125 (3.2 45 30.5 5 0.75_|32 [za 27 [366 [125 [3.2 45 149.8 5 1 ite 16 27 [366 [125 [3.2 45 a4 | 5 1 [32 32 27 [366 (i2s ‘| 32 45 273.6 ‘Table 4: Angle Scan - 70 Degrees, Assumed Element Height in Wedge 10mm Frequency | Pitch | Active | Aperture | Wedge | Incident | NZ Material | Refracted | Max (MHz) | (mm) | Elements | Size Velocity |()in | Wedge Velocity |) in Focal (mm) (m/s) | Wedge (mm) (km/s) _| Material Depth in Material (um) 5 o6 [16 96 2752s [lea | 32 70 45 5 06 [32 19.2 27 [sas lea (3.2 70 ALS 5 075 [16 12 27 525 [164 3.2 70 ns 5 0.75 [32 24 27 525 [164 [32 70 2 | 5 16 16 27825 [16a (3.2 70 264 5 1 [32 32 27525 ‘(164 [3.2 70 129.0 Discussion Conclusion From the above tables the following observations are clear: + Probe Pitch and Number of Active Elements have major affect on the maximum depth of focusing. = Wedge size and starting element will have a pronounced affect on maximum depth of focusing. + Inspections at increasing angles will have a pronounced affect on maximum depth of focusing. ‘As the large majority of Phased Array units sold to date (over 80%) have a Maximum Active Aperture of 16 elements, the restriction is generally in the phasing unit rather than probe parameters. “The above tables show the parameters of the most commonly used phased array probes. Recent developments in probes designed with large element pitches have significantly increased the possible available active aperture. These include the Olympus NDT probe range A3 & A4 that use element pitches between 1.2mm, and 2.8mm. 34 Focusing with phased array provides significant improvements in inspection sensitivity and resolution at the cost of depth of field, Note: Options such as Dynamic Depth Focusing (ODF) can be used to increase depth of field. ‘Maximum Depth of focusing is much less that most inspectors expect and is limited by probe selection and phasing hardware. “An understanding of the physics behind the focusing allows inspectors to use suitable configurations to maximise the inspection capability.” Industrial Eye May/lune 2016,