OmniScan SX \ MX2 Training Program

Phased Array Beam Forming

V4.3R2
OmniScan SX \ MX2 Training – Phased Array Wedges Overview
 Phased array wedges perform the same function as conventional UT wedges by
coupling sound energy from the probe to the material at the desired refracted angle
and wave type.
 Phased array wedges come in all shapes and sizes for various applications and are
an essential part of the inspection.
 Phased array wedges are used to assist the probe in beam formation for shear wave
and longitudinal wave inspections, just like conventional UT.
 1D Wedges typically used in OmniScan SX\MX2 applications come in 3 varieties:
1. Shear wave angle beam.
2. Longitudinal wave angle beam.
3. Longitudinal wave straight beam.
OmniScan SX \ MX2 Training – Beam Forming Overview

 After populating the focal law calculator with the parameters of the probe,
wedge, and material velocity, the software can be configured for the beam
formation. This is the purpose of the focal law calculator. Group setup wizard)
 The OmniScan XS\MX2 has a built-in group set up wizard that will step the user
through the process of populating the probe, wedge, and material parameters
before beam formation.
 Beam formation or focal law generation will determine the size, shape, and
angle of the beams. (A-scans).
 Beam formation combines both angle steering and focusing.
OmniScan SX \ MX2 Training – Beam Forming Overview cont.

 Groups of A-scans or focal laws

come in many configurations as a
function of software, instrument
capability, and probe capability.
 The OmniScan SX\MX2 refers to
beam sets as groups and
supports sector and linear scan
groups in the calculator.
 Other types of groups can be
imported into the OmniScan
SX\MX2 from an external focal
law calculator.
OmniScan SX \ MX2 Training – Group Formation

 The OmniScan SX\MX2 supports both linear and sector scan groups for 1D linear
array probes and has an 8 group, 256 focal law limit.
 Both sector scans and linear scans have unique advantages and limitations
regarding weld coverage, number of focal laws, range of angles, A-scan density,
ability to reproduce conventional results, and ability to minimize number of required
groups for the inspection.
 Additionally, one of the most important factors in determining the scan plan strategy
is the ability to calibrate the group using traditional calibration blocks with SDHs and
notches to improve inspection results and comply with construction codes.
OmniScan MX2 Training – Group Formation - Sector vs. Linear Group

Sector Scan Definition Linear Scan Definition

 Focal laws of different angles
generated using the same elements.
 A-scan density and coverage is
defined by the range of angles (45-
70) and angle resolution. (45, 46, 47,
etc.)
 Focal laws generated over a series of
elements using the same angle.
 A-scan density and coverage is
defined by the element step
resolution. (1 element, 2 element,
etc.)
OmniScan SX \ MX2 Training – Group Formation - Sector vs. Linear Group
Sector Scan Advantages
 Large coverage area from small
footprint on component.
 Improved flaw characterization from
multiple angles.
 Small element count required for
instrument and probes. (16, 32)
 Fewer focal laws required for
coverage of weld area.
Linear Scan Advantages
 Produces same result as
conventional UT raster scan (X,Y).
 Ease of calibration due to only one
angle.
 Compliance with existing codes
referencing one angle inspections.
 Beam to beam resolution is the same
regardless of sound path.
OmniScan SX \ MX2 Training – Group Formation - Sector vs. Linear Group

Sector Scan Disadvantages Linear Scan Disadvantages

 Beam to beam resolution worse as
sound path increases.
 Limitations in ability to calibrate
multiple TCG points for long sound
paths.
 Limitations in ability to calibration wide
angle range for long sound paths.
 Requires many focal laws. (49 as
pictured below)
 Poor coverage with one angle\one
group.
 Multiple groups required for same
coverage resulting in long set up,
calibration time, and big data file.
 Requires instrument with large
multiplexer. (XX:64, XX:128)
OmniScan SX \ MX2 Training – Beam Steering Limits

 Beam steering is limited by the probe element size and aperture, the wavelength,
physics of UT (Snell’s law) and most importantly, the ability to calibrate each A-scan
in the group to the satisfaction of the application or procedure.
 The calibration process, like conventional UT, includes maintaining the velocity at a
known angle (Does not mode convert) and ability to correct the wedge delay,
sensitivity, and build a TCG (If required) for every A-scan in the group.
OmniScan SX \ MX2 Training – Beam Steering Limits cont.

 The maximum steering angle at -6dB can be defined from the beam spread equation
below. Small elements have greater beam spread and retain more energy at higher
angles than that of larger elements.
 As element size decreases so does energy and more elements must be pulsed
together to maintain the same sensitivity.
 This is a similar to conventional UT. The smaller the single element crystal, the wider
the beam spread.
OmniScan SX \ MX2 Training – Beam Steering Limits cont.
 The limits of beam steering and focusing are dependent on many factors including
size of aperture, size and number of elements, material properties, size of calibration
reflector, etc.
 The OmniScan SX\MX2 calculator does not attempt to define the steering limits of
any probe\wedge combination because there are too many variables in the
inspection requirements including what is an acceptable A-scan signal to noise ratio
for any one customer’s application.
OmniScan SX \ MX2 Training – Verification of Beam Angle and Exit Point
 Beam steering angle (Refracted angle) is verified in phased array inspections exactly
like conventional UT.
 The beam steering limits of a particular probe\wedge\aperture is reached when the
highest and lowest angle of the group are not able to be verified within 1 degrees.
 The real exit point of the beam is verified with an IIW block and compared with the
calculated value in the software. Once the exit point is validated the angle can be
verified on the other side of the IIW block.
 This process is explained in detail a later section. Repeat….exactly like UT.

Verified exit point is used to

measure real angle in
material (40 degrees)
Exit point of beam
OmniScan SX \ MX2 Training – Beam Focusing Overview
 Sound beams can be focused like light rays with the energy focusing at a given
point and then expanding beyond it.
 The depth of focus is changed by varying the applied delays on the elements and is
built into the focal law along with the angle steering.
 The maximum depth or sound path that a beam can be focused is defined by the
near field which is a function of element size, frequency, and material velocity.
 The effective sensitivity is improved by a smaller beam diameter with more energy
at the focus point.
 Increasing the size of the aperture or creating the same aperture using more
elements of a smaller pitch increases the sharpness of the focused beam and
improves results.
OmniScan SX \ MX2 Training – Beam Focusing – Near Field

 Beam focusing is only possible within the near field of the probe.
 The near field is different in the active and passive axis of the array and can be
calculated with the formula below.
 Most methods for calculating the near field should be considered close
approximations due to simplifying the formula and not taking into account every
probe parameter.
OmniScan SX \ MX2 Training – Beam Focusing vs. TCG
 The near field calculation that defines the maximum beam focus limit is not the limit
of the useful sound path for inspection purposes.
 Like conventional UT, most of our code based phased array inspections such as
ASME, API, etc. are performed with an unfocused probe and a TCG or DAC to
compensate for sensitivity (Amplitude) over time (Sound path).
 Use of a TCG for code based inspections reduces the benefits of focusing. A focal
point is selected within the TCG range that can accommodate all points.

1 2 3 4

1
2 1 2 3 4
3
4
OmniScan SX \ MX2 Training – Inspection Focus Strategies

 Different focusing strategies can provide optimized results for different applications.
 There are five primary types of focusing associated with phased array inspection:
1. Depth focusing. Defined from the bottom of the wedge in depth every beam. (A-scan)
2. Sound path focusing. Defined by the sound path from the beam exit point.
3. Projection focusing. Defined by the surface distance from the wedge face.
4. Focal plane focusing. Defined by an X,Y position in the material.
5. Unfocused. Any value that is beyond the near field or maximum focus distance of the
probe\aperture.

Depth Sound Path Projection Focal Plane

OmniScan SX \ MX2 Training – Inspection Focus Strategies cont.

 The OmniScan SX\MX2 focal law calculator only supports depth focusing.

 Sound path, projection, and focal plane focusing can be imported into the OmniScan
 SX\MX2 from an external focal law calculator using the memory card.
OmniScan MX2 Training – Advanced Inspection Focus Strategies

 The majority of OmniScan SX\MX2 applications including weld inspection are well
suited for depth focusing and do not benefit significantly from other focus strategies.
 An example of an application that would benefit from a specific focal plane other than
depth is the dissimilar metal weld inspection in inconel using a low frequency
longitudinal angle beam sector scan for maximum penetration and focus on the far
side weld bevel.
OmniScan SX \ MX2 Training – Advanced Strategies – WSY \ ID Creeper
 Another example of an application that would benefit from an advanced focusing
strategy is the phased array version of the conventional UT 30-70-70 (WSY)
technique used for internal crack detection and sizing in the power generation
industry.
 A 55-70 longitudinal wave sector scan is focused in a vertical plane (Projection) at a
fixed distance from the wedge face. (Pictured in red in front of the probe)
Projection focal plane

Crack tip (70 degree)

CE1 CE2

Crack base (55 degree)

OmniScan SX \ MX2 Training – Focus Strategies – Near surface
 The Hydroform inspection system uses a shallow depth focus to maximize
near surface detection and resolution.
 1.5mm surface resolution on carbon steel components is possible from the
Hydroform system with the aid of shallow depth focusing, small aperture,
water column and high frequency probe.
 In this application turbine components are inspected for porosity and laminar
flaws before complex machining.
OmniScan SX \ MX2 Training – Verification of Beam Parameters

 In addition to standard IIW and similar calibration blocks, there are industrial
standards such as ASTM E2491 that specify techniques and calibration
block designs for verification of the phased array beam profile.
 Beam profile, beam steering limits, beam focusing, element activity, etc can
be verified similarly to the requirements of conventional UT with specialized
reference standards.
OmniScan SX \ MX2 Training – Phased Array Calculator Review

 At this point in the training all of the hardware parameters and

basic software considerations required to prepare a phased array
beam set or group in the OmniScan SX\MX2 have been described.
(Probe, wedge, material, and beam forming)
 The OmniScan SX\MX2 like its predecessors is a UT flaw detector
before it is anything else, and with the exception of software to
manage the information unique to phased array it is very similar to
a modern single channel conventional flaw detector with better
imagery, more software features, and much greater power.
 The use of the OmniScan SX\MX2 setup and calibration wizards
will make managing all of the parameters required for the phased
array inspection fast and efficient permitting the focus to remain on
the application……..and not the software.
OmniScan SX \ MX2 Training – Phased Array Calculator Review

 Question: What are the essential parameters for the phased array focal law
calculator?
1. Probe parameters.
2. Wedge parameters.
3. Material velocity.
4. Beam formation.

 Answer: All of the above.

 Questions or comments:
PhasedArraySupport@Olympusndt.com

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V4.3R2