February 2011

Training-
Probes, Wedges and Scanners
Milton Keynes
February 2011

Introduction
However good a piece of equipment, it is
only as good as the signal it receives from
the probe, and the probe can only
perform properly when it is held in the
right place.
Selection of the correct probe / Wedge /
Scanner setup is critical

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Lessons from Monoelement

probe use
Luckily, The physics is the same...
Equations for beam width, near field length
etc. are exactly the same.
Large probes give a tighter beam and
stronger signals
High Frequency probes give better
resolution
Low frequency probes give better
penetration and less scattering, especially in
difficult materials such as austenitic steels,
cast iron or composites
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What can the veo do?

Current version is 16:64
16 channels, so 16 probe elements in any
one focal law.
64 multiplexor channels, so can connect a
total of 64 probe elements:
One probe with up to 64 elements
Two probes with up to 32 elements
Four probes with up to 16 elements (not yet)
Plus 2 standard single or dual element
probes, or 2 pairs of TOFD Probes

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Phased array Probes

Critical array features:
Frequency
Number of elements (dont have to use
them all)
Element Pitch
Element length
(Probe elevation)

Constraints
Need to do the ultrasonics OK
Probe size is often an issue
Either want it as small as possible
Or need to scan over a certain length
Number of elements that the
instrumentation can drive

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Frequency
What you know from standard UT is still
relevant:
For most applications use 2 to 5 MHz
Sonatest probes are usually 2.25 or 5 MHz
Some others are 2, 3.5, 4
Use 7.5 or 10 MHz for high resolution
Occasionally use 1 or 1.5 MHz for difficult
materials

Number of elements
Depends on what we want to do:
For sector scans:
Generally need just the number of elements the
system will drive (16 for veo)
Often want the probe to be as small as possible
For linear scans
Length of array is often the issue (Coverage of
Region of interest )
Divide into as many elements as we can address
(64 for veo)

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Element Pitch
Element width is normally approx 90% of
pitch
Need to fit in the space available
Small elements dont give much power
Large elements are overly directional
remember that the steering envelope of an
array corresponds to the sound field from a
single element on its own. If element size is
approx same order as wavelength this is not
normally an issue
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Probe ranges
Sonatest DAAH
Sonatest other
Other manufactures
Other Instruments / adapters

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Sonatest DAAH Probes

The Sonatest DAAH Probe range was
launched in 2006, Currently there are
two sizes:
Type 1, Approximately 25mm array length
e.g. 5 MHz, 32 x 0.8mm
Type 5, Approximately 50mm array length
e.g. 5MHz , 64 x 0.8mm

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DAAH System
Array Heads in various frequencies, some with
integral wedges
External wedges probes:
T1-PE-2.25M20E1.2P
T1-PE-5.0M32E0.8P
T1-PE-7.5M44E0.6P
Also available with 17 or 35 degree wedges less elements
T5-PE-5M64E0.8P
T1, T5 Cables to suit:
Hypertronics (X.32, M2M, Tomoscan, Dynaray etc)
IPEX (veo, OmniScan)
Dual T1 cables available for dual probe or Pitch-
catch operation (Some restrictions)

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DAAH System numbering

T1 = Type 1
5.0 = Frequency (MHz)

0.8 = Pitch (mm)

0 = Axial
Diameter (mm)

T1-PE-5.0M22E0.8P-35W0D

35 = Wedge Cut Angle

22 = Number of Elements

PE = Pulse-Echo
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DAAH Probes

Integral
External wedge LW

Integral
SW

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Other Sonatest Probes

Sonatest is current working to produce or
source a variety of Phased array probes
to meet requirements not covered by
DAAH probe range
Where possible these will be equivalent
to existing competitors probes which
have been included in key specifications
More Info to follow

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Other manufacturers probes

A number of manufacturers make probes
for the Omniscan, including:
Imasonic, Blatek, Sonaxis, Vermon,
GE, Olympus, Doppler, Alba

All of these should be compatible with the

veo

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Using adapters
A variety of adapters are available, more
are being produced.
Some of the Olympus adapters are not
compatible with the recessed socket on
the veo
GE adapter (115-500-015)
looks awful but works
well and allows Phasor
probes to be used

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Wedges
Angle
Size
Shape
Damping quality / wedge noise etc
Temperature
Irrigation
Wear resistance
Scanner fixings

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Wedge Angle
Use Flat wedges for Thickness
gauging/ corrosion scanning and
Composite Inspection. Define by
thickness get repeats the same as a
delay line probe, so usable range is
approximately twice the wedge
thickness
Angle wedges are normally made so
that the refracted angle without
steering is around 55-60 degrees
Be careful some manufacturers
define wedge angle by refracted
angle, so a 55 degree (refracted) and
35 degree (cut) wedge may be the
same thing...
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Wedge Angle
Use low angle wedges (15-20
degree cut angle) for
longitudinal wave inspection,
Use high angle wedges (35-40
degree cut angle) for shear
wave inspection,
For special purposes may
also have a roof angle
(unusual)
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Size
Has to fit the probe...
Not too narrow to minimise echoes.
Generally wedges are just made to fit one
size of probe

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Shape
Key point is curvature, or lack
of it.
Testing along pipe less than
approx 24 inch (60cm) OD
requires axially curved wedges
Testing longitudinal welds in
less than approx 48 inch pipe
requires a circumferentially
curved wedge [Not yet
supported in veo]

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Damping & Wedge noise

Because Phased array wedges have to work
at a range of angles there is always some
noise. Much easier if you are only worrying
about one angle...
Hard to predict, some designs much better
than others.
Generally the bigger the wedge the more
room for sound to be absorbed.
Integral wedge probes not generally as good
as external wedge, but very convenient
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Temperature Resistance
As with monoelement probes key points
are:
Selection of material
Plenty of space to allow a reasonably low
temperature gradient.
Minimising contact time.
So far havent done much phased array
work at high temperatures, no obvious
reasons why not, but still in development
stage.

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Irrigation
Because of the large size of phased array probes and
the range of angles generated it is important to have
consistent coupling for good results.
For small probes manually applied couplant can be
fine.
For larger probes and
long scans it is usually
necessary to use
pumped water
coupling.
Some wedges have
fittings and channels
to facilitate this

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Wear Resistance / Fixings

Phased array wedges are relatively
expensive, and wear can make the
standard focal laws invalid.
To reduce the this some wedges
incorporate domed stainless steel pins at
the wear face.
Wedges for use with scanners or
encoders normally have fixing locations.
Make sure these are specified if needed.

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Standard DAAH wedges

Do NOT have
Wear Pins
Irrigation channels
UNLESS specified
Do have scanner fixing points

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So What DO I specify?
Most of the time:
Corrosion mapping:
T1 or T5, 5 MHz (or 7.5 MHz T1) w/ flat wedge (12.7
or 25.4mm to suit thickness)
Composites:
T1 or T5, 2.25 (T1 only ATM) or 5 MHz w/ flat wedge
Weld Inspection in Carbon steel
T1, 2.25 or 5 MHz w/ 35 degree wedge
Weld Inspection in Austenitic Steel
T1, 2.25 MHz w/ 17 degree wedge
These recommendations will evolve as we
add probes for specific applications.
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Remember:
Key point is to give customer a good
solution to his application
At the moment our range of probes is
limited.
We ARE working on this.
We can source probes from a variety of
suppliers
Make sure we get what works.
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Encoders & Scanners

It is difficult to hold probes and
manipulate them consistently by hand
With multiple probe set ups its usually
impossible
Scanning mechanisms enable
Accurate positioning
Movement at constant speed
Recording of position

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Categories
Encoders
Simple Scanners (TOFD etc)
Versatile manual scanners
Special purpose scanners
Motorised scanning systems

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Encoders
Sonatest Quicktrace Encoder
Designed to work with DAAH T1 probes
Developing adapters for other probe types.
Simple, reliable, IP rated

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TOFD Scanners
Phoenix range
TOFD Calliper
WREN Scanners
Plus all Phoenix versatile scanners are
configured for TOFD as standard

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Calliper & WREN

Single axis probe holder for TOFD inspection of
plate or pipe welds
Position data from sprung wheel encoder
Plastic or metal wedge options available
Operates on girth and seam welds
TOFD caliper has easy clip in mounting, no tools
required
Kit includes 2 probes and set of wedges for 45, 60,
and 70 operation
WREN scanner available at 4 or 8 lengths
WREN wedge design has additional sprung
gimballing for misaligned welds and enables <
PCS
All wedges include couplant irrigation

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TOFD scanners - key points

Need to select Probe frequency see
TOFD discussion
For accurate measurement set PCS
distance correctly and keep stable
For many applications the preamp is
helpful
Can usually manage without for demos etc,
but

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Versatile Scanners
Phoenix Range
Mini Mag
Multi Mag
Mag Man

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MiniMag
Magnetic-wheeled scanner
Holds up to 4 probes
Probes independently sprung
and gimballed
Accurate tracking
Operates in any orientation on
flat plate through to 3 OD
pipe
Positional encoder output
Can be supplied with TOFD,
Phased Array and pulse-echo
probes and wedges, inclusive
of gimballing and couplant
feeds.

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MultiMag

TOFD & Phased Array

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MultiMag Scanner
Compact scanner for more difficult to
access areas
Typical configuration is to hold 2 TOFD
probes and 2 phased array probes for
vessel and pipe weld inspection
Can be configured with offset probes for
testing pipe to elbow welds
Fits standard or low profile toolposts
Magnetic wheel bogeys included lateral
suspension for unaltered operation on
stepped or misaligned welds
Same accessories available as Magman
including guide chain and laser pointer
Latest version includes angular
adjustment of probe brackets for small
OD pipe
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MagMan Mk III

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MagMan Mk III Scanner

Latest version of popular manual scanner is
adaptable for inspection of both girth and seam
welds
Ideal scanning aid for phased array, TOFD, and
pulse-echo inspection of ferritic welds
Operates on plate or pipe down to 2 OD
circumferentially or 9 OD longitudinally
Holds up to 12 probes simultaneously
Accessories available for maintaining scanner
alignment - guide chain and laser pointer
Splash proof, spring loaded encoder included.
Probes sprung loaded and gimballed to maintain
excellent surface contact.
For use with any instrumentation and any
TOFD & P/Array manufacturers probes and wedges.

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Specifying Phoenix Scanners

Basic Configuration:
2 Probes (30mm fitting TOFD)
Veo encoder
Key options:
Extra Probes (check max for scanner type)
Phased array Toolposts specify DAAH or other
type
Transverse adapters
Guiding Chain and Guide fitting to suit scanner
Laser Guide
Spares Kits
Refer to Catalogue / Price Lists
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Special Purpose Scanners

Eclipse
Sonatest Scanning Tank
Phoenix Bracelet scanner

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Eclipse
Special purpose Scanners

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Sonatest Scanning Tank

Designed for Rapidscan
Use multiple scans at constant spacing
If used with veo currently need PC with
Rapidscan software to combine multiple
scans
Component
size: 50 x 30
x 3cm

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Phoenix Bracelet scanner

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Phoenix Bracelet scanner

Small bore manual weld scanner
Pipe diameters ranging from 0.5 to 4
Has a radial clearance of 0.5
Option of either single
or dual probe inspection
techniques
Rubber wheels provide
smooth circumferential
movement around pipe
Probes and wedges are
easily inter-changeable

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Motorised scanners
Currently need external control, veo just
treats as encoder
UT Studio Pro will add motor control
Many Options available

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Phoenix Magscan
Motorised dual axis scanner
Typical automated
inspections include girth
welds, pipe to elbow welds,
and corrosion mapping
Operates on pipe diameters
from 4 OD to flat

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Phoenix Magscan
Scan speed up to 2/sec in both axes
10 axial scanning
Strong magnetic wheels for use on
painted surfaces, supplied with
ferritic keep plate
Adapter rail available to use standard
MagMan / MultiMag toolposts
Optional accessories include motor
controller for use with any UT
instrument, couplant pump, laser
pointer, guide chain, additional probe
mounting brackets

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Any Questions

?
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