Developments in Ultrasonic Phased Array Inspection III

Ultrasonic Phased Array Inspection of Welded Pipes Using Wave Mode-Converted at the Inner
Surface of the Pipe
R. Long, P. Cawley, Imperial College, UK; J. Russell, Rolls-Royce, UK

ABSTRACT
The ultrasonic inspection of welded pipework found in the nuclear industry often proves challenging.
The inability to access both sides of the weld might warrant the use of waves that are mode converted
at the inner surface of the pipe to propagate a wave at the desired angle which would maximize a
specular reflection from a defect with a postulated inclination. Even where access to both sides of a
weld is available, inspections using mode converted waves might be preferred rather than using waves
that propagate directly through the weld since the structural complexity of austenitic stainless steel
welds can disturb the ultrasonic wave propagation. As most phased array controllers and stand alone
software do not readily provide for focused mode conversion inspections a solution was developed to
use Full Matrix Capture (FMC) and process the data ourselves. Inspections were modeled using the
CIVA software and compared to experimental results conducted on a welded test piece.

INTRODUCTION
Rolls-Royce and Imperial College, London are working together to develop a phased array inspection
of a welded pipe with a completely undressed weld cap [1,2]. The target application is a section of
large bore stainless steel pipe-work with a wall thickness of greater than 50mm and contains an
austenitic weld. Defects can occur anywhere within the weld and Heat Affected Zone (HAZ) of the
pipe-work. Any inspection should be capable of finding flaws with a through-wall dimension of 10%
of the pipe wall thickness. For defects occurring on the lower or upper fusion face, ideally we would
like to use waves that are reflected and mode converted at the inner surface of the pipe. However, most
commercial phased array controller software does not currently provide for this. In addition, we would
like to superimpose the B-scan images over the region of the component that is being inspected to aid
defect location. For focused on-the-skip and mode conversion inspections, no known currently
available phased array controller software allows this. In order to conduct such inspections and display
results in a manner that we would like, our solution was to use Full Matrix Capture (FMC) [3] and
process the data ourselves. FMC is a data acquisition technique which involves the collection of the
complete set of time-domain data (A-scans) for all combinations of transmit and receive elements.

Comformable phased array Membrane device

The application of conventional phased array inspection is usually performed using a solid wedge
placed between the transducer and component under test to refract the ultrasonic beam into the test
piece. The beam is steered and focused to a chosen location by applying delay laws to the individual
transducer elements. For inspections above an undressed weld cap there will be a mismatch between
the profile of the surface under test and the plane base of the wedge. This will produce an irregular
coupling layer leading to beam distortions and a loss of sensitivity which contribute to reduce the
inspection performance. A cost effective solution that we have chosen is to couple a standard phased
array to the surface under test via a water path which is made more convenient by encapsulating the
fluid with a conformable synthetic rubber membrane [4, 5]. A single device is used for surface profile
measurement (required for updating of delay laws) and inspection, allowing rapid scanning of
components with irregular surfaces without the need for multiple angled probes and time consuming
mechanical scanning. Figure 1 shows a photograph of the 3rd generation membrane device that
incorporates a standard linear 2 MHz, 128 element, 0.75 mm pitch phased array probe from Imasonic
France [6]. For the through weld inspections, the device housing is designed such that the phased array

is angled at 18 and the fluid stand-off of the first element to the surface under test is set at 20mm. For
mode conversion inspections the phased array was angled at 7 and the fluid stand-off set at 7mm.
These parameters have been chosen to minimise the possibility of an internal reflection appearing in
the Bscan images [7]. The design allows a constant pressure configuration using a header tank of
water to provide adequate pressure for the membrane to conform over the irregular surfaces of interest,
such as weld caps. The membrane material used is a low loss castable polyurethane rubber, with an
acoustic impedance similar to water, which has been developed with the help of Rolls-Royce, Derby,
UK. The device housing has been designed to allow the membrane to be readily changed should this
prove necessary. An integrated irrigation system pumps water from an isolated reservoir through eight
narrow bore tubes that direct water, which acts as an acoustic couplant, onto the surface under test.
When testing above an irregular surface profile the use of delay laws computed for a plane surface
may lead to beam splitting and loss of the original focal point [4]. The inspection performance can be
recovered with the application of updated delay laws requiring knowledge of the surface profile under
test. A convenient method is to utilise the phased array incorporated in the membrane device to scan
and to measure the surface profile at each test location [1].

Header tank for constant pressure encapsulated

Low profile Imasonic
2MHz 128 element phased array
water column

Couplant distribution
rd

Irrigation feed

Figure 1 - Photograph of 3 generation conformable phased array membrane device

mounted on welded test piece seen in constant pressure configuration and featuring couplant
distribution.

Immersion Phased Array

80 el - 2MHz- angle 8o
7mm
Upper Fusion face
Approx 60mm

Defect 2
Defect 1

Defect 1 =135mm
Defect 2 =185mm

Lower Fusion face

Figure 2 - Set up for obtaining simulated and experimental data showing phased array
arrangement and stainless steel block where each test piece comprises one of the defects
shown.

Modelling of test scenario using CIVA software

The CIVA software [8] was used to obtain simulations for phased array inspection of defects on the
weld fusion face. A single FMC data set was obtained for inspection of each defect, which when
processed using software developed by Imperial College, provided inspection possibilities using
direct, on-the-skip or mode converted waves for various incident angles and aperture sizes. This is one
of the advantages of obtaining FMC data over conventional data in that a multitude of inspections
scenarios can be obtained from one data set [9]. The intention of the exercise was to model proposed
primary inspection techniques for each defect, which are normally based on a specular reflection that
provides the greatest amplitude. The FMC data also allowed processing to find possible secondary
inspection techniques to aid confidence that a given defect has been identified and may additionally
provide for defect sizing without the need for additional probes or scanning.
Figure 2 shows a schematic of the pipe wall with the two defects that will be considered for
this paper. Defect 1 and Defect 2 represent an 8mm through wall lack of fusion defect on the lower 25
degree and upper 10 degree weld fusion face respectively. For these simulations the phased array was
modelled as an 80 element immersion array with a 1.25mm pitch angled at 7 and with a 7mm standoff to the surface under test. The phased array is positioned such that the inspection of a given defect
does not require that waves first propagate through the weld material.
The simulated results for inspection of Defect 1 are shown in Figure 3 with amplitude
displayed on a logarithmic scale. A single simulated FMC data set was obtained and processed with
beam forming optimised for inspections that use focused direct longitudinal (L), direct shear (T)
waves, mode converted shear into longitudinal waves (TL) and on-the-skip shear waves (TT). The Bscan shown in Figure 3a displays the crack tip diffraction resulting from the L wave along with later
arrivals attributed to TL and T wave interactions, whose images also fall on the lower weld fusion
face. Inspecting with a direct longitudinal wave could result in false calls for additional defects. Even
so, if well understood, techniques such as this can provide defect confirmation or crack sizing if the
signal is sufficiently high amplitude, and has high enough signal to noise to provide confidence that
any signals are related to the defect. Similarly the T wave inspection (Figure 3b) displays additional
features in the B-scan. The primary inspection technique for this defect uses TL wave inspection.
Investigations suggest that a technique using TT wave approach would be a possible secondary
technique for crack sizing and defect confirmation.
The simulated results for inspection of Defect 2 are shown in Figure 4. Beam forming was
optimised for inspections that use focused L, T, mode converted shear into longitudinal waves, with
direct longitudinal wave reflected off the defect (TLL) and TT wave inspections. The technique using
TLL wave inspection (Figure 4c) is the preferred primary inspection technique for this defect.
Applying similar reasoning as described earlier, the technique that uses TT wave inspection would be
a possible secondary technique for crack sizing and defect confirmation.

Noise was not included in the CIVA simulations, so whether the techniques investigated could provide
adequate defect responses in practice had to be found by experimental results.

(a)

Direct L
45 deg 30el

L TL
T
(b)

Direct T
45 deg 30el

TLL

(c)

Mod con TL
29 deg 25el

TL
TLL

(d)

On-skip TT
40 deg 30el

TT
TL

Figure 3 - Simulated results for inspection of Defect 1 with delay laws optimised for (a)
direct longitudinal waves, (b) direct shear waves, (c) mode converted shear into longitudinal
waves and (d) on-the-skip shear waves. Results normalised on a logarithmic scale with
background set to 20dB below the maximum amplitude in Bscan image.

(a)

Direct L
73 deg 14el

(b)

Mod con TL
29 deg 24el

TL

TLL

(c)

Mod con TLL

29 deg 24el

TLL

(d)

On-skip TT
45 deg 24el

TT

Figure 4 - Simulated results for inspection of Defect 2 with delay laws optimised for (a)
direct longitudinal waves, (b) mode converted shear into longitudinal waves, (c) mode
converted shear into longitudinal wave with direct longitudinal wave reflected off defect and
(d) on-the-skip shear waves. Results normalised on a logarithmic scale with background set
to 20dB below the maximum amplitude in Bscan image.

EXPERIMENTAL DATA
All experimental testing has been completed on flat plate welded testpieces with the weld cap left
undressed to replicate the target application. Each test piece was manufactured by Sonaspection UK
[10] from two flat stainless steel plates of greater than 50mm thickness, with lower and upper weld
fusion faces of 25 and 10 degrees respectively. An Electric Boat (EB) insert was used in the base of
the weld giving a more uniform, but not flat, root. The first 6mm of the weld was laid using Manual
Metal Arc (MMA) welding and the rest by Tungsten Inert Gas (TIG). Surface breaking defects were
machined using Electro-Discharge Machining (EDM) with a gape of 0.3mm. Lack of Side Wall
Fusion defects were embedded using an in-house Sonaspection technique. The defects reported in this
paper are Defect 1 and Defect 2 (both 8mm through the wall dimension) shown in Figure 2, which lie
on the lower and upper fusion faces respectively. The 3rd generation membrane device was used for
the inspections that incorporated a standard linear 128 element, 2 MHz, 0.75mm pitch phased array
probe from Imasonic, France [5]. The phased array is angled in the device housing at 7 and the height
of the first element above a plane surface is 7mm. A Peak NDT phased array controller [11] was used
to obtain experimental FMC data. The application of fluid coupling via the irrigation holes in the
membrane device base plate was utilised for these results. A single FMC data set was obtained for
each inspection, which was processed and displayed using the Imperial College software. The
sampling frequency used was 25MHz. All Bscans were normalised to the maximum amplitude in the
image and are shown on a logarithmic scale.

The experimental results for inspection of Defect 1 are shown in Figure 5. The weld fusion face is
drawn in for reference only and should not be taken to be an accurate representation. The background
was set at 15dB down from the maximum amplitude seen in the Bscan image. When using the primary
TL inspection technique, shown in Figure 5a, a strong response is observable in the image suggesting
the presence of a defect located on the lower fusion face. Figure 5b shows the confirmation of defect
presence by the secondary TT technique, which also provides for defect sizing using the separation
distance of the signals diffracted from the crack tips. The background was set at 9dB down from the
maximum amplitude seen in the Bscan image. The amplitude of the defect response for the secondary
technique is 6dB down from the primary technique, resulting in a lower signal to noise ratio.
The experimental results for Defect 2 are shown in Figure 6. The backgrounds for the primary
and secondary inspection techniques were set at 15dB and 9dB respectively. The presence of a defect
lying on the upper fusion face is identified using the primary TLL technique and is confirmed by the
secondary TT technique. Figure 6b shows the confirmation of defect presence by the secondary TT
technique, which also provides for defect sizing using the separation distance of the signals diffracted
from the crack tips. The amplitude of the defect response for the secondary technique is 8dB down
from primary technique.
Fluid
Steel

Phased Array

(a)

Weld fusion
face profile

Fluid
Steel

(b)

Weld fusion
face profile

Defect confirmation

Defect Identification
15dB

Phased Array

0dB 9dB

0dB

Figure 5 - Experimental results for inspection of Defect 1. (a) Primary TL inspection using
29 degree incident shear wave and 32 element aperture (b) secondary TT inspection using 44
degree incident shear wave and 50 element aperture. Results normalised on a logarithmic
scale to maximum the amplitude in Bscan image.

Fluid
Steel

Phased Array
Weld fusion
face profile

Defect Identification
15dB

(a)

Fluid
Steel

Phased Array

(b)

Weld fusion
face profile

Defect confirmation

0dB 9dB

0dB

Figure 6 - Experimental results for inspection of Defect 2. (a) Primary TLL inspection using
29 degree incident shear wave and 30 element aperture (b) secondary TT inspection using 40
degree incident shear wave and 42 element aperture. Results normalised on a logarithmic
scale to maximum the amplitude in Bscan image.

(a)
Phased Array

Phased Array

Fluid

Weld fusion
face profile

Dominant feature
due to irregular surface

(b)

Weld fusion
Fluid face profile
Steel

Steel

Specular Reflection
off Defect 10

Specular Reflection
off Defect 10

12dB

0dB 12dB

0dB

rd

Figure 7 - Experimental results using 3 generation membrane device on welded test piece
for the negative direction inspection of Defect 1 using 65 degree direct longitudinal wave
primary inspection technique and 40 element aperture. Bscan images shown for a) plane
surface delay laws and b) delay laws updated for approximate weld cap profile. Results
normalised on a logarithmic scale to maximum the amplitude in Bscan image.

Some experimental results are shown in Figure 7 for the inspection of Defect 1 using waves that are
required to propagate through the weld material on their way to the defect. The 3rd generation
membrane device was used for obtaining the results incorporating a 128 element, 2MHz, 0.75mm
pitch phased array from Imasonic France [6]. The phased array was angled at 18 and the fluid standoff of the first element to the surface under test is set at 20mm. A Peak NDT phased array controller
[11] was used to obtain experimental FMC data. The FMC data was processed for beam forming using
a 65 direct longitudinal wave which provides a specular reflection off a defect lying on the lower
fusion face.
Figure 7a shows experimental results for the through weld inspection where plane surface
delay laws are used for beam forming. The background was set at 12dB down from the maximum
amplitude seen in the Bscan image. The Bscan displays a feature, seen on the right hand side, whose
amplitude dominates the reflection off the defect. This feature is due to some of the waves propagating
through the weld cap profile for apertures on the far right of the phased array. Figure 7b shows the
experimental results where the delay laws have been updated for the surface profile under test
measured using the same phased array incorporated in the membrane device. The effect is to remove
the dominant feature from the Bscan image such that now the reflection off the defect can be readily
identified. The SNR for the reflection relative to the background noise is 7dB which is half that
achieved in the results when using the mode conversion technique shown in Figure 5a. The reason is
that the wave propagation through the structural complexity of austenitic stainless steel welds is
disturbed and produces back scattering. In addition the location of the defect from the position of the
reflection becomes uncertain. Rolls-Royce and Imperial College, London are working together to
develop a solution to this problem [12].
Experimental results confirmed that the use of primary and secondary inspection techniques
can be useful in identifying and confirming the presence of a defect. The more differing techniques
that can be used on any one inspection the greater the confidence when calling the presence of a
defect. An advantage of obtaining FMC data over conventional data is that a multitude of inspection
scenarios can be obtained from one data set. Results show that focused waves that are reflected and
mode converted at the inner surface of the pipe have often proved most appropriate for these
inspections, though most commercial phased array controllers do not currently provide for this.

CONCLUSION
Focused waves that are reflected and mode converted at the inner surface of the pipe often prove most
appropriate for inspection of defects that might lie on the weld fusion face of welded pipe work. The
results for inspections using focused mode converted waves have shown significant improvement of

SNR ratio over waves that are required to directly propagate though the weld material. It is hoped that
in time commercial phased array controller beam forming and results presentation software will
readily provide for mode conversion inspections. For our research UT phased array inspection data
was acquired as FMC which allowed us control over data processing and display of results. A single
FMC data set provided a multitude of inspection possibilities from which inspections were chosen
which displayed the best defect response. When inspecting critical components, an advantage of FMC
data over conventional methods is that the complete data set can be archived for future processing
when advanced algorithms might allow improved identification of defects.

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