Inspection of metals throughout different metalworking processes like casting, forging, or welding has been an integral part of the quality control process for industries. This is to make sure that the metal component is up to the industrial standard and can perform the operation reliably without any defects hindering the process. Many inspection processes have been introduced and adopted but one of the most effective in ensuring material integrity of cast and forged metal stock, tubes, and plates is ultrasonic testing (UT).   

Newly cast or forged metal can have many sources of defects. Some of them may arise from inaccurate heat treatment, lack of proper vents, lack of metal cleanliness, or presence of inclusion. The result: wide range of defects including pores, cracks, and inclusions.

Ultrasonic inspection has been extremely effective in examining the quality of these metals. The utilization of advanced instruments, scanners, and probes has made ultrasonic detection of defects in metals easier with the ability to identify minute flaws in reduced time and in greater detail.   

Learn more about NDT inspection of pipes, tubes, and other steel products.

Ensuring Structural Integrity with Ultrasonic Detection of Defects in Metals

Many industries use the non-destructive testing (NDT) method of ultrasonic inspection for its efficiency and accuracy in identifying flaws. It does so by introducing high-frequency ultrasonic waves through the transducer to the metal being tested. The reflected wave can be analyzed to identify the potential defects in the structure. The major advantage in utilizing this method is that the structure can be inspected during any phase of the manufacturing process be it pre- or post-service.

Learn more about ultrasonic testing.

In metal inspection, ultrasonic testing can facilitate seamless volumetric inspection at each phase of the manufacturing process from raw material to the finished part in order to support productivity and efficiency goals.

Ensuring Material Integrity with Ultrasonic Testing

Structural integrity is compromised when metal surface depletes due to stress or environmental conditions. The common issue we observe in such cases is the formation of cracks or microfractures. These can be visually undetectable and can be potentially dangerous if present on components like turbine blades or wheels and axles. Phased array ultrasonic testing (PAUT)— with its controlled and focused inspection ability—can identify these cracks and fractures in metal surfaces with great precision. The use of multiple transducers facilitates larger coverage and rapid inspection to ensure efficient crack detection.

Read more about ultrasonic crack detection equipment in infrastructure and transportation. 

Thickness measurement is essential to identify potential corrosion or erosion in metals. This type of defect can mostly be observed in pipelines, or ship hulls, or storage tanks. Phased array ultrasonic testing can be beneficial for industries that require the identification of small changes in thickness that may result from metal loss. Utilizing time-of-flight-diffraction (TOFD) or pulse-echo technique, ultrasonic probes can identify small changes in metal thickness. However, it is necessary to note that ultrasonic testing can have thickness limitations and may not be suitable for extremely thin metals.

Learn more about thickness measurement with ultrasonic testing.

Metal stock or plates commonly have defects like inclusions which can give rise to cracks or porosity in the metal. Slag, sand, or flux materials can get included during welding or casting of the metal. With PAUT testing, these small inclusions ingrained in the metal can be easily identified. Locating the inclusion is important in identifying the quality of the metal.

Learn more about detecting non-metallic inclusions with ultrasonic testing.

Inspecting Welds for Ultrasonic Detection of Defects in Metals 

Not very different from processes like casting or forging, fabrication through welding can also significantly affect the properties of the metal and give rise to potential defects in the structure. While much destructive and non-destructive testing has been utilized for the inspection, phased array ultrasonic testing has been able to provide highlyprecise and accurate inspection results.

Learn more about the destructive and non-destructive testing of welds.

The differing properties of dissimilar metals can lead to the issues in welding like lack of fusion, inclusion, porosity, and cracking. Across different industries, an inspection of dissimilar metals has been done with the help of phased array ultrasonic testing which can effectively identify, locate, and size the flaws providing industries with the opportunity to promote safety and cost-efficiency.

Learn more about inspecting dissimilar metal welds.

The major challenge in boiler tube weld inspection can be operation downtime and resources. Phased array ultrasonic inspection acts upon these drawbacks by providing volumetric inspection and rapid analysis ability for a varying range of tube diameters. PAUT with TOFD enables accuracy and precision for better defect detection and characterization.

Learn more about boiler tube inspection.

In various industries, phased array ultrasonic testing has been used not only to inspect the final product but also to inspect metals in the manufacturing progress. This gradual inspection of metal can be beneficial in improving the quality of the finished component. PAUT detection of defects in metals is effective in reflecting defects in the metal to make sure safety and productivity be the primary focus of the industry. 

Zetec has been a leading provider of NDT instruments, probes, and scanners for decades assisting you with assessing the quality of your metal structures. To learn more about our ultrasonic inspection solutions, contact us today.

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When we look at industries such as manufacturing, oil and gas, or railway we can see a wide range of materials and complex geometrical components being used across different environmental conditions to fulfill operational goals. Components made from stainless steel to high-density polyethylene (HDPE) serve these operational goals in-situ or in the field and require a thorough investigation for safety and quality assurance. Capturing the potential flaws in these material components in different operating conditions requires non-destructive testing (NDT) equipment to have flexibility and portability, in addition to accuracy and precision. 

With portable test equipment, the NDT process can become easier to conduct for routine operations, virtually anywhere. The ability to provide mobility and flexibility to technicians during the NDT process—without increasing the operational downtime—are some of the main reasons why industries are seeking to adopt portable test equipment. 

How Portable Test Equipment Can Benefit NDT Inspection  

Industries and infrastructures are advancing in both technology and design. These advancements, however, are also making manufacturing and design standards more stringent to ensure the quality and safety of the components being used. Industries have long used NDT methodologies for inspecting components prior to or during operation as a quality check or preventative maintenance approach. However, there have been challenges when inspection needs to expand to on-site testing or testing for complex geometries. 

Increased safety standards can also mean the technicians are required to perform increased and advanced inspections in a limited amount of time. To meet the needs, industries may be required to input more time and resources into additional NDT equipment or manpower. With an investment in portable test equipment, NDT processes in industries can be made much more efficient. 

Portable NDT equipment can make data acquisition, processing, and analysis easier irrespective of the location. Portability can also allow for more volumetric coverage with technicians easily carrying it from one side of a component to the other, for example.

When NDT equipment is portable and equipped with advanced features, different types of flaws and discontinuities can be located with ease, improving the reliability of results. 

Qualities To Look For in Portable Test Equipment

Industries seeking ideal portable test equipment should look for speed, ease of use, and accuracy to enhance NDT inspection. Not only can these attributes simplify the inspection process for technicians, but they also can enhance productivity and reduce the incurred costs. Other desirable features include:

• Portability: Compact, lightweight, even handheld instruments make NDT accessible in remote or hard-to-reach work sites, such as offshore drilling rigs. Without having to set up large instruments on a daily basis, or transport additional gear, technicians can save time and increase inspection coverage. The flexibility of battery-powered instruments also enables inspection of complex geometries such as bends or elbows in pipes without the need for a power source. 
• Versatility: Equipment should be compatible and versatile to test different types of flaws that may be present in a component, such as those that may be detected during corrosion mapping or weld inspection.  
• Enhanced data handling: The ability to collect a large number of data and easily process them in real-time for faster decision making. Integrated analysis software with pre-set tools can be big time-savers. There should also be data processing and storage abilities to support offline data analysis.  
• High-resolution imaging: High-resolution imaging with advanced visualization and easy-to-read display makes a detailed analysis of the A-scans or C-scans easier and enhances the probability of defect detection. This increases reliability in the inspection results.   
• Ergonomical: If an NDT instrument is portable and flexible, it provides ergonomic benefits to the technicians, as they can conduct an inspection without having to adjust based on the geometrical complexity of the component. 

Portable Solutions Offer Flexibility and Reliability

With a wide range of inspection needs and multiple standards to meet, testing equipment that packs multiple features in one solution can be a great asset for industries. Portable testing equipment provides flexibility, control, ease of use, durability, and accuracy to help industries and asset owners save time and money while improving efficiency. With portable equipment such as TOPAZ and a handheld instrument such as the MIZ-21C, Zetec has also been redefining NDT to deliver quality inspection results. Portable test equipment is the safe and simple, yet modern answer to complex inspection needs. 

Zetec is a leading name in nondestructive testing and has been providing portable test equipment to help industries achieve quality standards with effective NDT.  To learn more about our cutting-edge technology of the highest quality—contact Zetec today.

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HDPE, or high-density polyethylene pipe welding, is different from conventional welding than you may imagine. Butt welding of HDPE can be even more different. Butt welding HDPE involves the fusion of flat surfaces utilizing hot plates and is usually used for components such as HDPE pipes or tubes or fittings. However, this welding technique can provide challenges like welding flaws or loss of structural strength. So, inspection to assess the quality of the weld becomes necessary.

While there are many ways to inspect HDPE butt fusion welds, one of the most effective non-destructive testing (NDT) techniques involves using ultrasound technology. However, HDPE material has specific characteristics that can make ultrasonic inspection challenging. It’s therefore critical to implement a robust inspection strategy using multiple ultrasonic testing (UT) techniques to inspect for the flaws present in the weld and does so without affecting the weld strength to ensure the final component being used is of the highest quality. 

Butt Fusion Weld Mechanism in HDPE

Butt welding is the most common type of welding process used to join the HDPE pipes. The process involves the joining of two flat surfaces against each other. By flat surface, in HDPE pipes, it means the flat facing surfaces at the two ends of the pipe joined together utilizing high temperature and extreme pressure. 

During the heating process, the end of the HDPE pipe is pressed against a heated plate. Once the heated surfaces reach a molten state, the two surfaces are then bought together to join under controlled pressure. Once the molten parts fuse together to form a bond, the cooling process takes place for a specific amount of time, depending upon the dimension and thickness of the pipe. The heating, joining, and cooling processes are critical in ensuring the bond strength and achieving smoothness and quality of the weld.

Throughout each of these butt welding steps, there is also an equal possibility of flaw formation, mostly due to factors like lack of pressure or weld force, inaccurate temperature to achieve desired weld bead, misalignment, inadequate cooling time, improper surface cleaning, or presence of external inclusions in the material. The resulting flaws due to these factors may include:

• “Cold fusion” or partial bond due to inadequate weld force or temperature 
• Porosity and cracks resulting from a lack of surface preparation

These flaws need to be thoroughly identified if the HDPE component is used for an application safely. Phased array ultrasonic testing (PAUT) is an ideal inspection solution for HDPE butt fusion. 

Effective Inspection of HDPE Butt Fusion Weld

HDPE is an easy-to-use material that also offers excellent strength, corrosion resistivity, flexibility, and durability. This is one of the reasons why HDPE pipes are replacing the conventional carbon steel pipe systems in industries like water supply, oil and gas, geothermal, power generation, and many more. However, for the proper functioning of the operation, these industries need to be sure about the quality of the welds in HDPE pipes and look out for flaws. The different types of flaws including porosity, cracking, inclusion, and lack of bond, can be effectively identified through the application of multiple techniques of PAUT testing.  

The attenuative properties of HDPE require inspection with lower frequencies as compared to that of the carbon steel. Therefore, inspection with pulse-echo and tandem PAUT, as well as Time of Flight Diffraction (TOFD) is recommended. PAUT with TOFD offers volumetric inspection ability with high flaw detection sensitivity. The data collected with the help of the PAUT probe enables interpreters to:

• Focus along the heat-affected zones and weld joints to check for any possible flaws.
• Identify the fusion weld bond strength or the lack thereof.
• Locate any inclusions or slags, pores, or voids.
• Minimize the effect of thickness variation or irregularities in the study of flaws with the help of a focused beam enabled by PAUT.

The use of PAUT probes can support accuracy in the inspection of HDPE butt fusion weld and enable fast-paced volumetric inspection which helps industries in quicker decision-making.

Learn more on the webinar: Ultrasonic Inspection Solution for HDPE Butt Fusion Joints.

UT Inspection of HDPE Butt Fusion Weld For Quality and Durability

The increasing use of HDPE pipes and fittings means more stringent standards and inspection requirements for the material. PAUT inspection enables accuracy and speed in flaw identification of the HDPE butt fusion weld to allow industries to leverage the excellent properties and advantages of the material to its full extent. In addition, by ensuring the weld’s strength and quality without any interruption, PAUT testing provides cost-effectiveness and productivity for the industrial operation that lasts.  

Zetec specializes in ultrasonic testing as well as many other inspection technologies and offers you excellent solutions related to HDPE butt fusion weld inspection needs. To learn more about our quality instruments and probes, contact us today. 

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When we talk about non-destructive testing (NDT), much of the emphasis seems to fall upon the technologies that simplify the data collection process. However, inspection, data collection, data evaluation, and analysis technologies make a complete team, and enhancement of the entire NDT process requires advancement in each of these individual steps.

While much technological advancement has been made to ease the scanning or data collection processes through more advanced inspection tools and probes, in recent years, industries have also started developing new tools and features to simplify data interpretation for increased speed and efficiency. With the help of features such as time-reversal and distance gain size tools from advanced testing instruments, NDT methods like ultrasonic testing (UT) are bound to be simpler and reliable through their excellent flaw detection and characterization ability.

Enhanced Data Interpretation with Advanced Testing Instruments

To perform NDT inspection, technicians often have to process a wide range of data formats such as scan images or signals. The analysis, however, can be complex, especially when dealing with composite materials, complex geometries, or variable thickness components. Advanced testing instruments can facilitate the simplification of the inspection and data analysis processes utilizing the following techniques.

Time Reversal Technique

For phased array ultrasonic testing (PAUT), the time-reversal technique combines advanced UT software, instrumentation and high-performance probes to deliver high-quality signals in real-time, especially in the inspection of complex composite structures. To do so, the technique utilizes time of flight from each individual transducer of the PAUT probe to create a surface profile of the component being inspected. The advanced software can analyze the reflected beam and varying times of flight to inspect for any delays in comparison with the surface profile. Utilizing delay laws, the time-reversal technique can successfully obtain the normal incidence despite the complexity of the surface geometry.

In the NDT data interpretation process, the time-reversal technique facilitates:

• Accuracy of data while compensating for probe misalignments
• Real-time image display
• Flexibility in the inspection of varying geometries and surface thickness
• Speedy inspection and reporting capabilities

Distance Gain Size Method

This method acts as a sizing technique in PAUT analysis and is mostly seen utilized in heavy forging and welding inspection. The technique utilizes a distance gain size (DGS) curve to compare the reflectivity of the flaw with the reflectivity of the flat bottom hole (FBH) at the same distance or depth from the probe to identify the equivalent reflector size (ERS). Small reflectors may include inclusions, FBH, or blowholes, while large ones can include backwall. 

While manual comparison is possible, advanced testing instruments facilitate the automated formation of curves and calculation of ERS. The comparison of the amplitude from the reflectors and the back-wall echo of the component with the DGS curve facilitates the evaluation and quantification of the flaws.  

With features such as the DGS tool in advanced testing instruments, NDT can facilitate data interpretation by: 

• Enabling calibration, taking into account the varying refracted angle and the focal depth 
• Calibration of the sensitivity setting for enhanced flaw detection
• Easy visualization of the DGS curve with an A-scan for enhanced data analysis

Identifying Opportunities with Advanced Testing Instrument for NDT 

An advanced testing software platform such as UltraVision from Zetec can take a complex inspection process and simplify testing procedures. For composites, using the time-reversal method, inspection personnel are able to analyze the varying reflected beams and compare them with the surface profile to accurately analyze the flaws. For large forgings, the distance gain size tool can easily compare the beam amplitudes and utilize the DGS curve to identify the intensity of the actual flaw. With the advanced data interpretation capabilities of each of these approaches, paired with advanced testing instruments, NDT technology can move in a way of acquiring accuracy and speed in inspection and interpretation. These improved tools not only enhance the reliability of results but also open up the way for advanced NDT instruments to further facilitate productivity.

Zetec has been a trusted source for advanced non-destructive testing instruments and services for decades and has been at the forefront of technological innovations that suit your NDT needs. For improved accuracy, efficiency, and reliability requirements—contact Zetec today.

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In recent years, phased array ultrasonic testing (PAUT) has advanced technologically and has helped industries deliver quality products. This non-destructive testing (NDT) technology has been able to improve the accuracy and efficiency in a safe and efficient manner—attributes greatly desired by industries like aerospace, automotive, petroleum, and power generation that have high-stake safety needs. For this very reason, innovation is a constant need for NDT.

In inspection technology like PAUT, 3D modeling and analysis is a relatively new concept. However, the benefits of simulation, control, coverage, and accuracy make 3D phased array ultrasonic interpretation a desired capability. 

How 3D Analysis Facilitates Phased Array Ultrasonic Testing Interpretation 

3D analysis software has long been used in many industries for design, calibration, and manufacturing. But the technology has not been so prevalent when it comes to 3D simulation for NDT. Image processing has traditionally been done with 2D software packages. In a 3D virtual environment, it is now possible to interpret the geometrical aspect of the component and flaw. Inspection techniques like phased array ultrasonic testing can especially be leveraged to its full potential with 3D interpretation for inspection of complex geometrical components.

Phased array ultrasonic testing has been used in industries for its capability to utilize multiple transducers in a single assembly to inspect a component in a controlled and speedy manner. With individual control of the transducers, PAUT probes have been able to collect data and present an accurate picture of the existing flaws and detect the material quality. Software like Zetec’s UltraVision facilitates a 3D environment where the creation of the actual inspection configuration is possible with the possibility of ultrasonic ray penetration and reflection tracing.  

3D Ultrasonic Ray Tracing

In a 3D environment, it is possible to import a CAD model of the inspection component or create one with the help of ultrasonic testing data. UltraVision provides a 3D ray-tracing tool that can utilize this 3D model to accurately analyze the probe location and beam angle to accurately assess: 1) positioning and characteristics of the flaw and 2) travel time of the reflected beam. In phased array ultrasonic testing interpretation, the 3D ray tracing can graphically represent the array of rays and their interaction with the flaw.  

The 3D environment also facilitates the provision for scanner simulation whereby multiple probes can be analyzed to identify the suitability of the inspection of a particular component. In combination with a 3D ray-tracing tool, technicians can create coverage maps and identify probe and beam trajectory to validate and optimize the testing and interpretation of geometrically simple or complex components. 

3D Visualization

3D visualization plays an important role in ensuring inspection accuracy and speed. With a 3D view of the component model, technicians can accurately locate and characterize the flaws in the most efficient way possible, which is especially beneficial in complex geometries. The data easily collected from the NDT scanners can be plotted or overlapped with the specimen model in the 3D environment for accurate orientation and positioning of the flaw. With easy visualization of the flaw, the inspection process can be completed in a fast and efficient manner.

Watch: Learn how the 3D environment on UltraVision software supports and adapts to a wide range of probes to improve the efficiency of inspection.

3D Solutions for Enhanced Phased Array Ultrasonic Testing Interpretation 

With industrial interest in the 3D work environment for NDT solutions on the rise, Zetec’s proven UltraVision software facilitates inspection enhancement with features like 3D simulation, 3D ray tracing, 3D data visualization, 3D model generation, and real-time imaging. 

With 3D, asset teams can not only improve their phased array ultrasonic testing interpretation ability but also improve coverage and validate inspection approaches for enhanced inspection design and implementation. 

Zetec’s advanced phased array ultrasound testing equipment provides a 3D environment for enhancing the accuracy and efficiency of your inspection needs. To learn more about our NDT solutions, contact us today!

Industries tend to look for material that can provide sufficient strength and toughness to ensure the integrity of a structure. Multilayer composites and laminates of metals fulfill this need for industries like aerospace, construction, automotive, and power generation through their excellent strength, corrosion resistance, and low coefficient of thermal expansion. 

However, to leverage the full potential of these multilayer materials, it is important that the bonds between the consecutive layers are intact, and the component as a whole is able to provide full mechanical strength. Any flaws or discontinuities between the layers can compromise the quality of the component and weaken it. On the other hand, detection of flaws on such multilayer material can be especially challenging. Inspection using ultrasonic testing (UT) technology is effective in fault detection and isolation for material integrity validation.  

Understanding the Nature of Flaws in Multilayer Materials

Multilayer materials, like composites or laminates, combine the properties of two or more materials to operate and perform a particular operation as a singular entity. The use of different material layers works to enhance the properties of the base material. However, in the manufacturing of composites, there is a possibility that flaws can occur. The most prevalent type of flaws may include:

• Delamination
• Poor bonding between the layers
• Foreign inclusions
• Porosity
• Cracks 

These flaws can occur in the material during the operation due to extreme temperatures, stress, fatigue, and dynamic loads, and the implications can be severe. To further complicate things, the attributes and locations of these flaws are difficult to detect because of the multiple layers. The non-homogeneity and anisotropic nature of the composites also add to the challenges of detection and identification.

There are various non-destructive testing (NDT) technologies like eddy current or acoustic emission testing that specialize in detecting specific kinds of flaws for select materials. However, in this case, UT, specifically phased array ultrasonic testing (PAUT), can prove to be ideal for early fault detection and isolation for multilayer material inspection.

Phased Array Ultrasonic Testing for Fault Detection and Isolation

Phased array ultrasonic testing is ideal for pre- or in-service material inspection to identify flaws through different types of materials. This advanced ultrasonic inspection method transmits a high-frequency beam through the transducer into the inspection component, the reflection of which can be examined for any deflection or variation, usually the indication of a flaw in the material. Across different material layers, the wave propagation can be different. But PAUT enables the identification of flaws through analysis of change in acoustic impedance across each material layer. This is helped by the pulse control and beam focusing ability which facilitates penetration to greater depths and improves the sensitivity of flaw detection.

An inability to identify or visualize a flaw is a major concern in such multilayer composites and laminates. Exposure to dynamic load can make it a possibility for further layers to be subjected to cracks and delamination. With the help of PAUT instruments, probes, and software, technicians can visualize the hidden layers, detect the flaws and localize them. In cases where PAUT is utilized as preventive maintenance, fault detection and isolation can be made easier with recurring monitoring of the system, observation for any variations, locating the flawed point, and characterization of the flaw. This way, an ultrasonic inspection can easily facilitate the test for material strength, consistency between layers, and bonding between the material layers. 

Ensuring Multilayer Material Integrity with Ultrasonic Testing  

Ultrasonic testing has proven itself to be ideal in terms of accuracy and reliability in flaw detection. While some NDT methods provide surface-level flaw detection, for composites and laminates, PAUT can inspect at different depths and inclinations across multiple layers with the same sensitivity to flaw detection. This ability to identify flaws of complex nature and assess material strength across multiple layers is highly advantageous for industries where UT can be leveraged as a quality control measure to ensure the integrity of the structure. 

Zetec has been a leading provider of high-performance NDT solutions for decades. Our eddy current testing solZetec is a leading ultrasonic testing equipment provider for a wide range of industries and applications. To find the NDT equipment which best suits your inspection needs, contact us today!

The implication of unattended flaws in manufacturing or infrastructural components can be detrimental in terms of human life, operational failure, or incurred costs. Non-destructive testing (NDT) technology has been an effective inspection tool for manufacturers and asset owners around the world, allowing them to detect damage and discontinuities and keeping costly disasters off the bay. NDT achieves all this without damaging the component or interfering with the production, all while improving the product quality.

Among many NDT technologies developed over the years, eddy current is undoubtedly one of the popular inspection technologies in many industries. Especially in high-stake industries like manufacturing, aerospace, or military, eddy current and eddy current array (ECA) testing solutions have proven their advantage with the ability to accurately identify flaws and irregularities, improve productivity, reduce cost, and ensure the safety of the equipment. 

The Value of Eddy Current Testing

Eddy current testing utilizes a simple concept of electromagnetic induction. A supply of alternating current excites a wound coil which induces a magnetic field around it. As the coil nears a conductive material, the magnetic field triggers the induction of opposing current—eddy current—in the material. Any flaw in the material is identified by the variation observed in the current flow. This simple mechanism, in turn, provides great benefits for industries as it facilitates:

• Identification of surface or near-surface flaws like cracks, inclusions, porosity, and so on
• Multi-layer flaw detection, irrespective of the presence of surface coating
• Minimal surface preparation
• Flexibility in the inspection of simple or complex geometrical structures with portable eddy current testing equipment

For industries, these features mean the ability to ensure quality control, reduce waste, improve productivity, and save costs.

Read more about the value of eddy current testing instrumentations for industries.

Use of Eddy Current Testing Across Industries

While the reasons may differ, the goal in industries like aerospace, defense, and manufacturing remains the same—flaw-free, quality products and equipment. Eddy current testing can help.

Eddy Current Testing in Manufacturing

Eddy current testing technology offers inspection of pipe, tubes, and heavy-duty machinery applicable across a wide range of manufacturing processes. With advanced eddy current probes and instruments, it is possible to detect metallurgical flaws and irregularities to ensure the quality and safety of the final product. With the accuracy and speed of the eddy current testing, manufacturers can achieve higher productivity, thus, higher returns. 

Read more on how eddy current testing can help manufacturers ensure quality.

Eddy Current Testing in Military and Defense

As the military and defense industry takes care of national security and intelligence, it is imperative that the artillery and equipment remain in top shape. Armored vehicles, naval vessels, aircraft, and missile systems are just some examples of infrastructure systems that need to be sturdy and durable to meet military demands. As these systems face high stress, it is extremely crucial to examine them for possible corrosion, cracks, inclusions, lack of bonds, etc.

Read more about eddy current testing solutions in the military and defense industry.

Eddy Current Testing in Aerospace Industry

For both civilian and military purposes, NDT testing is an important part of the aircraft manufacturing process. For manufacturing and maintenance purposes, aircraft need an inspection for material structures, turbines, jet engines, wheels, struts, propellers, airframes, longerons, etc. Eddy current testing can effectively identify corrosion or cracks that may be induced due to fatigue and stress in the components.

Read more on eddy current testing for aerospace inspection.

Longerons in aircraft help in carrying some of the load as well as support transfer of the load to the internal structure. Due to this reason, fatigue and stress cracking may be observed around the fasteners supporting the longerons. Hidden corrosion can also be an issue due to the multilayer nature of the structure. With eddy current testing, stress cracks and corrosion near the fasteners, or between the attached longeron surface can be easily identified.    

Learn more about eddy current testing of aircraft longeron. 

The aircraft wheel is another flaw-prone part due to its exposure to high temperature and stress, especially due to braking force. This condition can be a source of heat and fatigue-induced cracking. With eddy current array (ECA) probes, any indication of damage in the wheel hub can be detected accurately. The flexibility of the ECA probes also enables inspection for a wide range of wheel radius and along changing curves and angles to provide complete coverage.

Learn more about aircraft wheel eddy current inspection. 

Similar to wheels in aircraft, turbines, and rotor shafts are also subjected to extreme stress and vibration. This is mostly due to the high temperature and speed required for turbines to operate. This can lead to turbines being prone to cracks, which if not detected can lead to engine failure. Eddy current testing can ensure complete inspection to ensure material or weld quality.

Learn more about NDT inspection of turbine blades. 

Bolt hole inspection is an important part of aircraft or automotive safety assurance. Not only is the material adjacent to bolt holes prone to stress cracking, the multiple layers that the bolt combines also creates difficulty in identifying the exact layer of flaw initiation. With ECA testing, minor cracks or other irregularities can be identified in less time.

Read more about eddy current testing for bolt hole inspection.

Applications of Eddy Current Testing in Industries

Across the military, manufacturing, and aerospace industries, eddy current testing serves a similar purpose: assessing materials and parts to ensure safety.

Material such as galvanized steel is the popular choice of industries where corrosion is a problem. Mostly seen in the building of refineries, pipes, or naval ships for its corrosion-resistant properties, the material can still be prone to corrosion and cracking due to long-term exposure. Corrosion, cracks, and other surface and subsurface flaws can be easily identified with eddy current probes which can collect the current flow data on the metal. With powerful eddy current instruments, this data can be analyzed to identify issues in the galvanized steel and potential solutions to mitigate them. 

Read more about eddy current testing of galvanized steel.

The effectiveness of eddy current testing can also be seen in the measurement of coating thickness. The thinning of surface coating can present issues like corrosion that can affect the integrity of the components. The right eddy current testing instruments and probes can help in this precision-oriented and capture the minor change in thickness of the coating.  

Read more about eddy current testing for coating thickness measurement.

Welds are an integral part of many heavy-duty manufacturing industries and infrastructural projects. From airframes to storage tanks to marine hulls, welding is a necessary process. However, given the nature of different welding processes and differing parameters, inspection for cracks, inclusions, and lack of bonds becomes crucial.

ECA makes sure that the welded surface is inspected with accuracy and speed irrespective of surface conditions and geometries. The ability to identify minor flaws prevents potential operational failure.

Read more about eddy current testing for weld inspection.

Eddy Current Testing Solutions for Quality Results

Accuracy, precision, flexibility, and portability are some features that industries seek in their inspection technology. Zetec’s eddy current testing instruments, probes, and software can adapt to a wide range of industrial testing needs. Identifying the right eddy current testing solution is the key to ensure industry standards and deliver flawless products.

Zetec has been a leading provider of high-performance NDT solutions for decades. Our eddy current testing solutions can provide easy inspection and accurate analysis to fit your inspection needs. To learn more, contact Zetec today.

The industrial reliance on ultrasonic testing (UT) as their primary non-destruction inspection methodology is at its all-time high. This includes aerospace, construction, automotive, oil and gas, power generation, manufacturing, or nuclear industries where UT is utilized as an immediate quality control method. With UT capabilities expanding as a result of newer methods and technologies, the industrial repertoire of UT inspection seems to be ever-increasing.

Here we discuss the industrial usage of UT inspection and its applicability for a wide range of applications.

How Does the Ultrasonic Inspection Method Work?

Most industries make use of UT for the following purposes:

• Quality control
• Routine or emergency inspection 
• Preventive maintenance

For either of these purposes, the UT method assists by identifying the existing flaws such as cracks, corrosion, inclusions, porosity, or any other thickness or metallurgical change in the inspection material. UT does so by utilizing transducers that emit high-frequency ultrasonic waves, usually within the range of 0.1 to 15MHz, which pass through the material to diagnose it. The reflected wave received by the receiver is then analyzed to identify and characterize the flaws.

Having this data allows industries to skim out the defective batches and standardize the production process to ensure quality control.

How Different Industries Leverage the Benefits of Ultrasonic Testing 

In the upstream, midtown, or downstream oil and gas industry, UT inspection is used for inspection of pipes, storage tanks, welds, and more for preventing material or equipment failure, protecting pipelines and equipment, and ensuring the safety of workers, operation, and environment. Phased array ultrasonic testing (PAUT) and TOFD (Time of Flight Diffraction) make this possible through accuracy, precision, and speed in testing, ensuring quality and productivity.     

Read more about Ultrasonic testing for the oil and gas industry. 

Ultrasonic testing in manufacturing can broaden to many areas from automotive to heavy-duty manufacturing including pipes and tubes. Each of the manufacturing processes requires careful inspection of components to identify potential flaws. The powerful capabilities of UT instruments, probes, and software has been adopted by manufacturing industries as a quality control tool that analyzes the flaws for potential risks. This is crucial in improving safety, productivity, and in reducing manufacturing downtime.

Read more about how UT solutions help manufacturers maximize uptime and quality.

How is Ultrasonic Inspection Used in Industry: Transportation

Aerospace or aviation industries use ultrasonic testing for ensuring the quality of their wide component ranges, each of which is crucial for proper aircraft functioning. This includes assessing composite materials, complex geometries, and for components like engines, gears, airframe and fuselage, honeycomb structures, and many others. With flexible, portable, and powerful UT solutions, it is easier to perform a volumetric inspection on these complex structures to ensure each part is conforming to industrial standards.

Read more about NDT solutions for the aerospace industry.

Railways require proper inspection of their tracks for wear and tear, corrosion, and other flaws. Instruments with PAUT and TFM (Total Focusing Method) capabilities provide in-depth focusing and beam customization capabilities which help to achieve excellent coverage. The collected high-quality data and resulting 3D map support detection and characterization of major and minor flaws that can compromise the safety of the railway system.

Read more about using UT for railway track inspection.

In the manufacturing of automobiles, each part requires careful engineering and safety checks to ensure none of the parts are defective and can fulfill their proper functionality. With UT, the quality of welds, complex geometries, or composite structures can be easily assessed to ensure they are free of flaws.

Learn more about NDT in the automotive industry.

How is Ultrasonic Inspection Used in Industry: Power Generation

Power generation industries, be it nuclear or fossil fuels or wind energy, require many infrastructures with the capability to support high-temperature and pressure requirements. A small flaw can be catastrophic in these industries. Ultrasonic testing can support in-depth flaw detection to identify even the minor flaws in crucial components.

PAUT inspection can assess components like blades, towers, rotor shafts, and gearbox for the potential presence of corrosion, cracking, lack of bonds, etc. in the wind turbines and fossil fuel plants.

Read more about NDT for wind energy and fossil fuel plants.

Key components like blades, rotors, heat exchanger tubes, and vessels require inspection in nuclear power plants for potential pitting corrosion, cracking, or other flaws. In a nuclear facility, UT solution can help identify flaws in difficult-to-reach and hazardous areas with reduced risk of error.

Read more about NDT for nuclear inspection.

The versatility of ultrasonic testing has made it a trusted technology for quality control in a wide range of industries. With Zetec’s advanced UT solutions, these industries can identify flaws, perform pre- or in-service inspections, and maintain the quality standards of their product and services. 

Zetec provides exceptional ultrasonic testing solutions for a wide range of industrial applications. To find the NDT equipment which best suits your testing needs, contact us today! 

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With a wide range of non-destructive testing (NDT) techniques available, industries have strived to make an ideal selection of inspection solutions that best meets their accuracy and precision requirements. In applications like weld testing, phased array ultrasonic testing (PAUT) and radiography have set new inspection benchmarks in their own way.

The unique capabilities of phased array ultrasonic and radiographic NDT provide distinct advantages in the identification of flaws such as cracks, corrosion, porosity, and inclusions. Here we will discuss how these NDT methods compare in terms of efficiency in flaw detection.

An Overview of Phased Array Ultrasonic and Radiographic NDT

The phased array ultrasonic testing method utilizes a multi-element probe, with each element having the ability to pulse individually at a controlled timing and sequence. The controlled sequence enables the optimization of angle, focus, and sweep of the beam. The reflected beam is then processed to create an image that can accurately identify any flaws or discontinuities in the material. This ultrasonic testing method has mostly gained popularity in industries for its effectiveness in determining material thickness, corrosion, or erosion in various types of complex geometrical components.

Radiographic inspection with X-rays or gamma rays has also been used in a similar context to identify surface or internal flaws for weld quality verification. A portable device with an X-ray generator transmits the beam to the material and the detecting device captures the beam reflected from the surface. The captured data is instrumental in assessing the discontinuities as well as properties like the size of the flaw and material thickness.

PAUT has emerged as a preferred NDT choice for many industries and has been slowly replacing radiography as the primary inspection technique. Thus, it is worth weighing the advantages and disadvantages when comparing phased array ultrasonic testing vs radiography methods to meet inspection standards.

The Benefits of Using Phased Array Ultrasonic Testing vs. Radiography

Safe Inspection

The foremost advantage that phased array ultrasonic testing provides in comparison to radiography is the safer inspection environment that it delivers. Radiographic testing can lead to exposure to potentially harmful rays. The operating personnel may also be required, depending on environmental standards, to vacate the facility while radiographic testing is in progress.

The use of simple ultrasonic waves does not possess any environmental or safety hazards and technicians and operators can continue the NDT process without any risks of harmful exposures.  

Inspection Reliability

Radiographic inspection relies on many factors to deliver accurate inspection results, one of them being the orientation of the flaw with respect to the radiation beam. The X-rays analyze cracks as a thickness variation. When a crack is parallel to the path of the X-ray, it is difficult for the beam to sense the change in thickness. Thus, some flaws may remain undetected.

Phased array ultrasonic testing offers the ability to focus and steer the beam at different angles. This provides complete coverage and fosters the probability of flaw detection along different orientations, thus, increasing the reliability of inspection.  

Speed

Phased array ultrasonic inspection utilizes multiple transducers for inspection which results in a much faster scanning of the material.

In contrast, the radiographic method of inspection is much slower. Not only does it need the extra procedure of permits and clearance to perform, even after the image capture, there is also an elaborate process of negative development. This resulting monochromatic radiograph can also be a slow process to interpret for untrained eyes.

Inspection Complexity

Radiographic testing provides a benefit of applicability with a wide range of materials and assessment with a minimal amount of surface preparation. And, depending upon the orientation of the flaw, it also provides the ability to inspect and develop images for complex mechanical assemblies and hidden areas, thus reducing the complexity of the inspection.

PAUT also facilitates the identification of flaws in areas that are hidden from the probes in complex geometrical structures. But, its advanced steer and focus technique can allow flaws to be identified faster. 

Phased Array Ultrasonic Testing vs. Radiography: Which is the Better Choice?

Phased array is being used as an alternative to radiographic testing in industries including aerospace, oil, and gas, or power generation for the inspection of welds or planar flaws. As productivity and quality become the goal for industries, flexibility, reliability, safety, accuracy, and speed become major defining factors in the choice of NDT technology. In the choice between phased array ultrasonic testing vs. radiographic NDT, it is safe to conclude that the advantages of PAUT outweigh those of radiographic testing.

Zetec has been a leading provider of phased array ultrasound testing solutions to quickly and accurately detect flaws. To learn more about the latest PAUT products and innovations, contact Zetec today.

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Pipeline systems—commonly used in oil and gas or other petrochemical transportation—are Ultrasonic testing (UT) has been the ideal choice of NDT technology in many industries due to its ability to optimize the beam focus to identify and Pipeline systems—commonly used in oil and gas or other petrochemical transportation—are subjected to the possibility of serious corrosion and erosion that can lead to catastrophic failure. Routine inspection is required to prevent failure but complex geometries along the pipe curves and angles and hard-to-reach buried pipes create a challenge. To ensure the safety of such critical infrastructure, technicians and engineers rely on non-destructive testing (NDT) technology that is flexible and efficient.  

Ultrasonic testing (UT) has been the ideal choice of NDT technology in many industries due to its ability to optimize the beam focus to identify and characterize existing flaws with precision and accuracy. Pipeline inspection with focused acoustic modes expands upon traditional UT by improving the coverage and flaw identification ability.

Focused Acoustic Mode and Guided Wave Testing

In structures like metallic pipelines, acoustic mode plays an important role in acoustic wave propagation. Acoustic modes refer to the movement of atoms of crystalline lattice that enables longer wavelengths to propagate like acoustic waves in a continuous medium but disperse shorter wavelengths. For longer wavelengths, the relation between the frequency and wavevector, also known as dispersion relation, is linear. This linearity allows waves to travel for a long distance along the pipeline, guided by the boundaries, without any dispersion. 

These modes have enabled the use of NDT techniques like Guided Wave Testing (GWT) which can detect and localize the flaw in a rapid fashion—which is beneficial in the inspection of large infrastructures like pipelines. With GWT, a focused acoustic mode can be propagated at one point along the axis of the pipeline. The wave travels longitudinally along the length of the pipeline and with each reflected wave, it is possible to identify flaws at every angle or depth, even where NDT instrument access may or may not be possible.

Guided Wave Testing is one of the many ways ultrasound technology has been leveraged in industries. The combination of portable phased array ultrasound testing (PAUT) instruments with GWT capabilities is sure to enhance the quality of inspection in complex pipeline systems. 

Portable PAUT Instrument for Pipeline Inspection with Focused Acoustic Modes

Conventional UT instruments have been popular within industries for their coverage and flaw detection ability. Portable PAUT instruments take inspection efficiency a step further by guiding a focused acoustic mode propagation along the cylindrical pipelines for a long-range inspection ability. The use of portable PAUT instruments for pipeline inspections with focused acoustic modes facilitates:

•  Faster inspection of pipeline with long-distance inspection ability
•  Easy detection of corrosion, cracks, inclusions, and other types of flaws in insulated, exposed, or buried pipelines  without the need for extensive layer removal
•  100% coverage along complex geometries and varying material thickness
•  Focused acoustic mode with PAUT instrument for the improved probability of detection
•  High-resolution A-scan or C-scan imaging ability, allowing technicians to locate and identify the scale of a flaw

These benefits of portable PAUT provide a cost-efficient inspection option for industries with its fast inspection, in-service inspection ability, and also the opportunity to reduce cost on excavation or layer removal for gaining direct access to the infrastructure.   

Guided Wave UT for Pipeline Inspection with Focused Acoustic Modes

Accuracy in testing is contingent upon the right selection of instruments and tools. Portable PAUT instrumentation packaged with quality probes has enabled precision in pipeline inspection with its excellent sensitivity, long-distance inspection coverage, high-resolution visual feedback, and flexible testing capabilities. Pipeline inspection can be enhanced with the flexibility, accuracy, and efficiency of portable PAUT instruments with focused acoustic modes. 

Zetec has been a leading name for nondestructive testing solutions, especially with its versatile ultrasonic testing instruments. For ease of use, cutting-edge portable designs, and the highest quality—contact Zetec today.