OmniScan MX2 Training Program

Phased Array
Acoustic Wedge Verification
OmniScan MX2 Training – Acoustic Wedge Verification Overview
u The procedure is designed for acoustic verification of wedge angle and
height of the first element required for the phased array calculator.
u This is useful for verification of an unknown, modified, or homemade
wedge. It is also useful for wedges that are significantly worn to the point
the wedge angle has changed and the height of the first element is
causing problems with the focal law beam quality and wedge delay
calculation.
u Although the calibration wizards can correct wedge delay and account for
minor angle error, best results in phased array inspection are achieved by
populating the calculator with precision parameters for a calculated (Not
calibrated) beam angle and wedge delay.
u The calibration process cannot correct wedge angle error and it adverse
affects on the beam.

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OmniScan MX2 Training – Acoustic Wedge Verification Overview
u When all relevant parameters of the probe, wedge, and material are entered into
the MX2 phased array calculator, the software will calculate the correct beam exit
point in the wedge and wedge delay for each focal law very accurately.
u The wedge delay calibration process is only to account for minor machining
tolerances and changes to the height of the first element and wedge angle due to
wear.
u Although the probe parameters and component velocity are variables in the
calculation, It is only for wedge parameters that we must calibrate and correct the
beam delay either manually or through use of the calibration wizards

54.97 usec

50mm

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OmniScan MX2 Training – Acoustic Wedge Verification Overview
u The MX2 database requires the following parameters for a wedge entry:
– Wedge model.
– Wedge angle.
– Wedge orientation. (Normal or reverse)
– Height of element #1 of the probe (h1).
– Wedge material velocity.
– Primary and secondary offsets (x,y).

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OmniScan MX2 Training – Acoustic Wedge Verification Overview
u Normally wedges are selected from the database in the MX2 software that contains
all common Olympus wedges.
u The database allows for new entries for custom wedges, wedges from
manufacturers other than Olympus, or wedges that have significantly changed due
to wear and must be identified as unique.
u Wedges in the database are based on wedge model only. Custom wedges or new
entries are based on wedge model and serial number.

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OmniScan MX2 Training – Acoustic Wedge Verification Overview
u Upon exiting the MX2 wizard, the overwhelming majority of problems related to
beam quality, angle error, delay error, and miscalculated focal laws are the result
of wedge parameters.
u Probe parameters and material velocity are either fixed, auto detected from the
probe chip, or are not affected by wear and machine tolerances.
u For any wedge of known velocity, both the wedge angle and height of the first
element can be verified acoustically.
u Only the wedge angle can be verified by measuring it mechanically. The height of
the first element is not visible through the probe housing.

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OmniScan MX2 Training – Acoustic Wedge Verification Overview
u REPEAT !!!
u The overwhelming majority of problems related to beam quality, angle error, delay
error, calibration difficulties, and miscalculated focal laws are the result of wedge
parameter errors or tolerances.
u This includes wrong wedge\modified wedge\changed wedge\worn
wedge\misidentified wedge.
u For PA troubleshooting, after verification of probe and material velocities….start to
troubleshoot the wedge.
u Even new wedges can have a machining tolerance that could be detrimental to a
precision measurement in some cases.

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OmniScan MX2 Training – Acoustic Wedge Verification Setup
u Verification of the wedge angle and height of the first element in relation to the
bottom of the wedge is accomplished by creating a focal law or A-scan for each
individual element for the entire probe so the wedge can be measured.
u The phased array group is configured for a contact inspection (No wedge) that is
essentially inspecting a rexolite component. Enter the following:
– >Probe\Part>Probe>AutoDetect>On (Or manually select probe with AutoDetect>Off)
– >Display>Selection>UT Mode>Sound Path
– >Display>Layout>A-S-[C] >Show C-scan>Off
– >UT Settings>General>Start>0mm, >Range>35mm
– >UT Settings>Velocity>2330 m\s (Rexolite velocity)
– >UT Settings>Receiver> Filter>Select appropriate filter.
– >Focal Law>Config>Law Config>Linear, Pulser>1
– >Focal Law>ElementQty>1, First Element>1, Last Element>64, Element Step>1
– >Focal Law>Angle>0 (No angle or focus is possible with a 1 element aperture)
– >Gate> Ensure gate A is covering the reflection from the first and last element’s wedge reflection.

u This setup is also available by loading the data file that accompanies this section
(AcousticWedgeVerify.opd) onto any MX2 with current software and deselecting
pause.
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OmniScan MX2 Training – Acoustic Wedge Verification Setup
u Open data file “TP-WedgeAcousticVerify.opd” using OmniPC to reproduce the
same measurements and results from the example in the next series of slides.

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OmniScan MX2 Training –Wedge Verification Height Measurement
u The display should look like the image
below. In the A-S-[C] layout each
individual element can be seen with a
reflection from the wedge. Element 25
u The following images are taken from

19.63mm
MX2-TF-AcousticWedgeVerify.opd and
can be reproduced using OmniPC.
u In this example the height of element
25 (VPA 25) is measured using the SA
reading in peak mode (19.63mm).
u Similarly the height of any element in
relation to the bottom of the wedge can
be measured the same way.
u The formula used for acoustic Wedge to probe
VPA 25 interface
verification will require this reading on
the first and last element of the probe.

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OmniScan MX2 Training – Acoustic Wedge Verification Formula
u Using the measurements from the following slide, the following formula
is used to acoustically verify an unknown wedge angle and\or height of
the first element that are required for the MX2 wizard (Or any PA
calculator) to return an accurate beam, beam exit, and wedge delay.

H(2)

H(1)

(H2-H1)
Sin (Wedge Angle) =
(Total Elements -1) X (Element Pitch)

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OmniScan MX2 Training – Acoustic Wedge Verification Procedure
u Measure and record the height of the first and last element in relation to the bottom
of the wedge. Save readings for the formula on next slide.

VPA 1 (First Element) VPA 64 (Last Element)

u The accuracy of this procedure is dependent on a known constant velocity of the

wedge material (Rexolite=2330 m/s).
u One of several reasons Rexolite is used for phased array wedges is that it is an
isotropic material that has a consistent constant velocity in each axis regardless of
angle. 12
OmniScan MX2 Training – Acoustic Wedge Verification Example
u Using the readings from the following slide, the following formula is used to
acoustically verify both the wedge angle and height of the first element.

(H2-H1)
Sin (Wedge Angle) =
(Total Elements -1) X (Element Pitch)

(33.46mm-11.15mm)
Sin (Wedge Angle) =
(64 -1) X (.6mm)

Sin (Wedge Angle) = 0.5902

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OmniScan MX2 Training – Acoustic Wedge Verification Example
u The inverse sin function is used to convert the result of the formula to degrees
for the real wedge angle.

Sin (Wedge Angle) = 0.5902

Real Wedge Angle = 36.17 degrees

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OmniScan MX2 Training – Acoustic Wedge Verification Example
u The resulting angle and height are then compared to the database or wedge
sheet. In this case the measured values of the SA2 wedge closely match
database and need not be modified, but would result in improved results.
u The wedge is either determined to be correct or within tolerance, or a new
wedge with the actual values is created resulting in more precise readings and
improved beam quality.

Real measured height of

Element 1 = 11.1mm
Real calculated wedge
angle = 36.17 degrees

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Acoustic Wedge Verification – Tips for Improved Results - Gate

u Ensure that the gate mode and

position is appropriate for what you are
measuring.
u When using peak mode ensure that
neither the first or last element A-scan
is saturated (>100% amplitude)
u Ensure that the gate start and width is
tight over the area of interest of the
wedge reflection.

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Acoustic Wedge Verification – Tips for Improved Results - UT
u Select appropriate filters based on probe frequency
for improved measurement and less noise.
u Program a high point count in the A-scan for
improved precision for the height of 1st and last
element measurement.
u Set range tight over area of interest for
measurement readings.

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Acoustic Wedge Verification – Tips for Improved Results – UT
u Acoustic verification of wedge height is also needed when the rexolite lens that
is necessary inside the probe housing of mechanically focused arrays is not
accounted for in the wedge parameters for the phased array calculator.

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Acoustic Wedge Verification – Tips for Improved Results - UT
u Use a manual TCG so that the amplitude of both the first element and last
element wedge reflection are approximately equal with neither saturated for
best precision measurement.

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OmniScan MX2 Training – Acoustic Wedge Verification Movie

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 Good Luck!

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