volumetric inspection of welds using the total focus method · background - mit inspection system 5...
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R.L. ten Grotenhuis, C.M. Moes, A. Hong, A. Sakuta
Ontario Power Generation Inc.,
Inspection & Maintenance Services Division
Volumetric Inspection of Welds Using the Total Focus Method
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Agenda
• Background
• Inspection task
• Inspection system
• MIT Approach to Inspection
• Derivation, additional considerations & error sources
• Results of experiments
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Background - Inspection Task
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Background - Inspection Task
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Background - MIT Inspection System
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Full Matrix Capture data acquisition
+
Total Focus Method data analysis
Matrix Inspection Technique
=
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Background - MIT Results
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Individual weld cross sections
assembled into 3D representation
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Inclusion in WeldCould TFM beam
forming be extended
to image
discontinuities in the
weld volume?
7
Weld inclusion identified in multiple adjacent frames
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Objective
• Provide full volumetric inspection capability
for arbitrary weld geometry
1) Exterior surface breaking
2) Isolated internal discontinuities
3) ID surface breaking
• Subset: image ID breaking indications
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Full Matrix Capture
• Generates n2 matrix of A scans
• Represents maximum amount of data
collected (very large data files)
• All other techniques derived from FMC
• Fundamental constraint – ability to get
sound into and back from inspection
volume
• Well suited to automated analysis
methods
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Derivation
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Mode Combinations – Single Skip
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• Single skip creates 8 possible mode combinations, two skips create 16 mode combinations
• Computational burden – Is it worth it?
• Application specific
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Additional Considerations
• Dynamic range of signals
• Signal suppression
• Phase inversion of reflected signals
• Mode conversions – phase error
• Parameter errors
• Conditional summation
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FMC data set – 5 mm x 1 mm EDM notch
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Dynamic Range
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Interface ~ 100% FSH - Reference
Interior L-wave reflection: 8.2% FSH ~ -22 dB
L-wave tip diffraction: 1.4% FSH ~ -37 dB
L-wave corner trap: 1.9% FSH ~ -34 dB
Mode Conv. Corner trap: 2.8% FSH ~ -31 dB
S-wave corner trap: 8.7% FSH ~ -21 dB
Note: Water TCG curve active
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Signal Suppression
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8 mm EDM notch - 25 mm CS Block
L-L, no suppression L-L, L-L-L, no suppression All modes, suppression
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Phase Inversion & Mode Conversion
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• Phase inversion – reflection at low impedance
interfaces - cancellation of intended signals
• Solution – monitor number of reflections –
invert signals as necessary
• Mode conversion – phase error ppl flight time in
mode
• Possible solution – frequency domain processing
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Phase Inversion - cancellation
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Phase Inversion
not accounted for
Phase Inversion
accounted for
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Error Sources
• L-Wave velocity
• S-Wave velocity
• Exterior surface coordinates
• Interior surface coordinates
• Couplant velocity
• Transducer element delays
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Error
< 0.4%
< 0.3%
< 0.02 mm
< 0.05 mm
?
?
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Conditional Summation
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Combined – note
cancellation effect
Contributions from
elements on right side
Contributions from
elements on left side
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Example - 1 mm Notch in 5 mm block
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Conditional summation vs Correlation
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Example - 1 mm EDM Notch in 5 mm block
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Images formed separately
then combined (logical
operators)
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Example - 1 mm EDM Notch, 6 mm Step
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Composite image with
EDM notch Original image
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Examples - HAZ Crack
• 1 mm HAZ crack
imaged adjacent
weld23
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Examples - Crack with Excess Root Pen.
• Crack and excess penetration
imaged at weld root near intrados
of bend
• Improvement in ID coordinate
accuracy would yield better imaging
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Conclusions
• Ability to image surface breaking discontinuities
using TFM beam forming has been demonstrated
• EDM notches in blocks, implanted flaws in weld
samples
• Additional complicating factors must be taken into
account
• Errors can accumulate rapidly – accuracy is key
to successful imaging
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Thank –you
Questions?
The End