Brady J. Engle

Equivalent flaw time-of-flight diffraction sizing with ultrasonic phased arrays

Ultrasonic phased array transducers can be used to extend traditional time-of-flight diffraction (TOFD) crack sizing, resulting in more quantitative information about the crack being obtained. Traditional TOFD yields a single length parameter, while the equivalent flaw time-of-flight diffraction crack sizing method (EFTOFD) described here uses data from multiple look-angles to fit an equivalent degenerate ellipsoid to the crack. The size and orientation of the equivalent flaw can be used to estimate the actual crack size.

Nondestructive characterization of pipeline materials

There is a growing need to quantitatively and nondestructively evaluate the strength and toughness properties of pipeline steels, particularly in aging pipeline infrastructure. These strength and toughness properties, namely yield strength, tensile strength, transition temperature, and toughness, are essential for determining the safe operating pressure of the pipelines. For some older pipelines crucial information can be unknown, which makes determining the pressure rating difficult. Current inspection techniques address some of these issues, but they are not comprehensive. This paper will briefly discuss current inspection techniques and relevant literature for relating nondestructive measurements to key strength and toughness properties. A project is in progress to provide new in-trench tools that will give strength properties without the need for sample removal and destructive testing. Preliminary experimental ultrasonic methods and measurements will be presented, including velocity, attenuation, and ...

Quantitative ultrasonic phased array imaging

When imaging with ultrasonic phased arrays, what do we actually image? What quantitative information is contained in the image? Ad-hoc delay-and-sum methods such as the synthetic aperture focusing technique (SAFT) and the total focusing method (TFM) fail to answer these questions. We have shown that a new quantitative approach allows the formation of flaw images by explicitly inverting the Thompson-Gray measurement model. To examine the above questions, we have set up a software simulation test bed that considers a 2-D scalar scattering problem of a cylindrical inclusion with the method of separation of variables. It is shown that in SAFT types of imaging the only part of the flaw properly imaged is the front surface specular response of the flaw. Other responses (back surface reflections, creeping waves, etc.) are improperly imaged and form artifacts in the image. In the case of TFM-like imaging the quantity being properly imaged is an angular integration of the front surface reflectivity. The other, improperly imaged responses are also averaged, leading to a reduction in some of the artifacts present. Our results have strong implications for flaw sizing and flaw characterization with delay-and-sum images.When imaging with ultrasonic phased arrays, what do we actually image? What quantitative information is contained in the image? Ad-hoc delay-and-sum methods such as the synthetic aperture focusing technique (SAFT) and the total focusing method (TFM) fail to answer these questions. We have shown that a new quantitative approach allows the formation of flaw images by explicitly inverting the Thompson-Gray measurement model. To examine the above questions, we have set up a software simulation test bed that considers a 2-D scalar scattering problem of a cylindrical inclusion with the method of separation of variables. It is shown that in SAFT types of imaging the only part of the flaw properly imaged is the front surface specular response of the flaw. Other responses (back surface reflections, creeping waves, etc.) are improperly imaged and form artifacts in the image. In the case of TFM-like imaging the quantity being properly imaged is an angular integration of the front surface reflectivity. The other, imp...

ULTRASONIC FLAW SIZING - AN OVERVIEW

The time-of-flight diffraction (TOFD) technique is one of the most common sizing methods in practical use by industry today. This method was developed over 40 years ago and is based on the technology and state of knowledge present at that time. A combination of phased arrays and equivalent flaw sizing methods are proposed as the foundation for a new generation of sizing methods that go beyond TOFD sizing.

Techniques and software tools for estimating ultrasonic signal-to-noise ratios

At Iowa State University’s Center for Nondestructive Evaluation (ISU CNDE), the use of models to simulate ultrasonic inspections has played a key role in RD and (2) a Fortran-based engine for computing defect signal and backscattered grain noise characteristics. The latter makes use of several models including: the Multi-Gaussian Beam Model for computing sonic fields radiated by commercial transducers; the Thompson-Gray Model for the response from an internal defect; the Independent Scatterer Model for backscattered grain noise; and the Stanke-Kino Unified Model for attenuation. The initial emphasis was on reformulating the research-grade code into a suitable modular form, adding the graphical user interface and performing computations rapidly and robustly. Thus the initial inspection problem being addressed is relatively simple. A normal-incidence pulse/echo immersion inspection is simulated for a curved metal component having a non-uniform microstructure, specifically an equiaxed, untextured microstructure in which the average grain size may vary with depth. The defect may be a flat-bottomed-hole reference reflector, a spherical void or a spherical inclusion. In future generations of the software, microstructures and defect types will be generalized and oblique incidence inspections will be treated as well. This paper provides an overview of the modeling approach and presents illustrative results output by the first-generation software.

Model-Based Software for Simulating Ultrasonic Pulse/Echo Inspections of Metal Components

Under the sponsorship of the National Science Foundation’s Industry/University Cooperative Research Center at Iowa State University, an effort was initiated in 2015 to repackage existing research-grade software into user friendly tools for the rapid estimation of signal-to-noise ratio (S/N) for ultrasonic inspections of metals. The software combines: (1) a Python-based graphical user interface for specifying an inspection scenario and displaying results; and (2) a Fortran-based engine for computing defect signals and backscattered grain noise characteristics. The later makes use the Thompson-Gray Model for the response from an internal defect and the Independent Scatterer Model for backscattered grain noise. This paper provides an overview of the ongoing modeling effort with emphasis on recent developments. These include: treatment of angle-beam inspections, implementation of distance-amplitude corrections, changes in the generation of “invented” calibration signals, efforts to simulate ultrasonic C-scans; and experimental testing of model predictions. The simulation software can now treat both normal and oblique-incidence immersion inspections of curved metal components having equiaxed microstructures in which the grain size varies with depth. Both longitudinal and shear-wave inspections are treated. The model transducer can either be planar, spherically-focused, or bi-cylindrically-focused. A calibration (or reference) signal is required and is used to deduce the measurement system efficiency function. This can be “invented” by the software using center frequency and bandwidth information specified by the user, or, alternatively, a measured calibration signal can be used. Defect types include flat-bottomed-hole reference reflectors, and spherical pores and inclusions. Simulation outputs include estimated defect signal amplitudes, root-mean-squared grain noise amplitudes, and S/N as functions of the depth of the defect within the metal component. At any particular depth, the user can view a simulated A-scan displaying the superimposed defect and grain-noise waveforms. The realistic grain noise signals used in the A-scans are generated from a set of measured “universal” noise signals whose strengths and spectral characteristics are altered to match predicted noise characteristics for the simulation at hand. We present simulation examples demonstrating recent developments, and discuss plans to improve simulator capabilities.Under the sponsorship of the National Science Foundation’s Industry/University Cooperative Research Center at Iowa State University, an effort was initiated in 2015 to repackage existing research-grade software into user friendly tools for the rapid estimation of signal-to-noise ratio (S/N) for ultrasonic inspections of metals. The software combines: (1) a Python-based graphical user interface for specifying an inspection scenario and displaying results; and (2) a Fortran-based engine for computing defect signals and backscattered grain noise characteristics. The later makes use the Thompson-Gray Model for the response from an internal defect and the Independent Scatterer Model for backscattered grain noise. This paper provides an overview of the ongoing modeling effort with emphasis on recent developments. These include: treatment of angle-beam inspections, implementation of distance-amplitude corrections, changes in the generation of “invented” calibration signals, efforts to simulate ultrasonic C-scans...

Relationship between near-surface ultrasonic shear-wave backscatter and grain size in metals

Backscattered ultrasonic microstructural noise can be used to estimate grain size in metals. However for normal-incidence immersion measurements the ring-down of the front-wall echo creates a ”dead zone” where backscattered grain noise cannot be quantified. This poses a problem for near-surface grain sizing efforts. In this paper we explore the use of mode-converted 45-degree shear waves for near-surface grain sizing using a water immersion setup. We discuss how to accurately relate grain noise arrival time with depth of sound penetration in the metal. Then for a set of Ni-alloy specimens having near-equiaxed microstructures we correlate various backscattered noise attributes with grain sizes determined from micrographs. These noise attributes include both time-domain and frequency-domain characteristics. The backscattered grain noise attributes correlate well with grain size, and are relatively insensitive to modest changes in the transducer tilt angle.

Ultrasound Scatter in Heterogeneous 3D Microstructures

This paper reports on a computational study of ultrasound propagation in heterogeneous metal microstructures. Random spatial fluctuations in elastic properties over a range of length scales relative to ultrasound wavelength can give rise to scatter-induced attenuation, backscatter noise, and phase front aberration. It is of interest to quantify the dependence of these phenomena on the microstructure parameters, for the purpose of quantifying deleterious consequences on flaw detectability, and for the purpose of material characterization. Valuable tools for estimation of microstructure parameters (e.g. grain size) through analysis of ultrasound backscatter have been developed based on approximate weak-scattering models. While useful, it is understood that these tools display inherent inaccuracy when multiple scattering phenomena significantly contribute to the measurement. It is the goal of this work to supplement weak scattering model predictions with corrections derived through application of an exact co...

Ultrasonic and magnetic Barkhausen emission measurements for characterization of pipeline steels

To ensure that the aging pipeline infrastructure in the USA can be safely operated, the mechanical properties of the pipe materials must be verified. It is hypothesized that characterization of the pipeline steels and their microstructures through nondestructive methods will allow for the estimation of the mechanical properties of interest, namely yield strength, tensile strength, toughness, and ductile-to-brittle transition temperature. This work will discuss how material properties, such as microstructure and chemical composition, affect the mechanical properties as well as strategies for measuring the material properties nondestructively using magnetic Barkhausen emission and ultrasonic velocity and attenuation measurements. Preliminary results on a limited sample set will be shown and challenges encountered will be discussed.

Ultrasonic measurement models for imaging with phased arrays

Ultrasonic imaging measurement models (IMMs) are developed that generate images of flaws by inversion of ultrasonic measurement models. These IMMs are generalizations of the synthetic aperture focusing technique (SAFT) and the total focusing method (TFM). A special case when the flaw is small is shown to generalize physical optics far field inverse scattering (POFFIS) images. The ultrasonic IMMs provide a rational basis for generating and understanding the ultrasonic images produced by delay-and-sum imaging methods.