Ultrasonic Inspection

Detection and sizing

Detection and sizing

The detectability of a reflector is depending on:

the size and the distance in the material

the angle with the sound beam

the surface of the reflector

the wavelength of the sound beam

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 Detection and sizing
Size: Different size = different response

Detection and sizing

Distance: Different distance (same size) = different response

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 Detection and sizing
Angle with the sound beam: angle between sound beam and
reflector is of great importance for the amount of energy
returning

cladding

bad fusion steel

Detection and sizing

Angle with the sound beam: angle between sound beam and
reflector is of great importance for the amount of energy
returning

steel

A rough or jagged surface of a reflector will scatter the sound

in all directions and therefore less sound will reach the
transducer, and will give a smaller indication.
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 Detection and sizing
Dimension of the smallest defect that can be detected is
mainly depending on the wavelength

λ
Drmin ≈
2
c
Drmin ≈
2f
A lower sound velocity and/or a higher frequency will
give a better defect detectability

Detection and sizing

Examples of minimum detectable defect size

Transducer frequency Drmin in steel (mm)

(MHz)
Longitudinal Transversal

1 2.95 1.60

2.5 1.18 0.64

5 0.59 0.32
7.5 0.39 0.21
10 0.30 0.16

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 Detection and sizing

Examples of defects in castings

sand, slag and gasinclusions

pipe and shrinkage cracks

cold shut

core material

variations in wallthickness

variations in crystal structure

Detection and sizing

Examples of defects in rolled products

seams

laminations

fins

variations in crystal structure

Examples of defects in forgings

fins

stress cracks

variations in structure
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 Detection and sizing

Examples of defects in welds

slag and gasinclusions

lack of fusion

lack of penetration

cracks

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Detection and sizing

Indication position

Presence of unknown obstructions (i.e. laminations) can

cause incorrect positioning of detected indications

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 Detection and sizing

Ultrasonic sizing techniques based on loss of

reflection energy

near field far field

N
20 % of energy

50 % of energy

Maximum energy

50 % of energy

20 % of energy

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Detection and sizing

6 dB drop sizing

Based on half the beam on the flaw and

half the beam off the flaw

Defect edge is determined by position where

amplitude is reduced to 50% of maximum
amplitude, which is equal to a reduction of 6 dB

Usable when the dimension of the defect is equal

to or larger than the beam width at the defect
location

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 Detection and sizing

6 dB drop sizing
a b c

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Detection and sizing

6 dB drop sizing, determination of defect size

defect

probe

probe movement

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 Detection and sizing

20 dB drop sizing

Based on use of the beam edge where the energy is

reduced to 10% (= 20 dB) of the maximum

Used to size flaws that produce smooth reflaction

with no resolvable facets

Usable when the dimension of the defect is less

than the beam width at the defect location

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Detection and sizing

20 dB drop sizing

β h

h = L ∗ cos β ∗ sin β

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 Detection and sizing

Ultrasonic sizing techniques based on equivalent

reflector sizes

Based on comparison of echo with

reference reflector size

DAC – Distance Amplitude Correction

TCG – Time Corrected Gain

DGS – Distance Gain Size (AVG)

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Detection and sizing

Ultrasonic sizing techniques based on diffraction

signals

Tip Diffraction Technique

Time of Flight Diffraction Technique (TOFD)

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 Detection and sizing

Tip Diffraction technique

Based on the detection of diffraction signals

originating from the tip of a defect

Weak signals compared to reflection signals

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Detection and sizing

Time of Flight Diffraction technique

Based on the detection of diffraction signals

Separate transmitter and receiver

Depth measurements based on time of flight of signals

Most reliable sizing method of ultrasonic testing

Tx Rx

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