Abstract: Disclosed is an apparatus and method for TFM post-processing of a FMC or HMC matrix acquired with an ultrasonic array probe. Post-processing is performed by calculating TFM beam forming amplitudes using round-trip delays to a focal point lying at depth d on a line at angle ? within the test object. Based on the beam forming amplitudes over a range of values of d within the imaging volume, a calculated A-scan is derived, which is equivalent to the response A-scan produced in conventional phased array imaging, but has the advantage of being focused at all points along the line. By post-calculation of calculated A-scans over a range of angles ? within the imaging volume, an imaging method is derived which is readily adapted to existing codes based on conventional A-scan imaging.

Abstract: Disclosed is a phased array ultrasound total focusing method in which the ultrasound energy is transmitted as plane waves and the response signals are processed as plane waves. The processing is adaptively corrected to account for geometric variations in the probes and the part being inspected. Methods are disclosed for measuring the geometric variations of the probes and the part.

Abstract: Disclosed is an ultrasonic inspection probe assembly comprising a water wedge and a flexible probe array assembly having a flexible acoustic module. The wedge is machined to match a test surface to be inspected and is configured to shape the acoustic module so that the active surface of the acoustic module is parallel to the test surface. Different wedges may be machined to match different test surfaces, but the same flexible probe array assembly may be used for all such surfaces.

Abstract: Disclosed is an inspection device and method of guiding an inspection probe according to a predetermined inspection plan. The device is couple with a probe which is to be moved according to the inspection plan on the test object, the device including an inspection guide unit having a guide control unit, a position encoding such as a 3-D camera and visual feedback eyewear. The method including facilitating a virtual display of the inspection plan onto the visual feedback eyewear, moving the probe following the virtual display of the inspection plan, sensing sensed probe positions in real time of the inspection using the 3-D camera and validating the sensed probe position against the inspection plan using the control module. Then the information of the step of validating, such as those spots at which the probe is moved out of the tolerance of the inspection plan, is displayed on the feedback eyewear.

Abstract: Disclosed is an apparatus and method for TFM post-processing of a FMC or HMC matrix acquired with an ultrasonic array probe. Post-processing is performed by calculating TFM beam forming amplitudes using round-trip delays to a focal point lying at depth d on a line at angle ? within the test object. Based on the beam forming amplitudes over a range of values of d within the imaging volume, a calculated A-scan is derived, which is equivalent to the response A-scan produced in conventional phased array imaging, but has the advantage of being focused at all points along the line. By post-calculation of calculated A-scans over a range of angles ? within the imaging volume, an imaging method is derived which is readily adapted to existing codes based on conventional A-scan imaging.

Abstract: Disclosed is an assisted analysis unit for facilitating phased array defect inspection. The analysis unit comprises an identification & merging module, and a sizing module. The modules are capable of displaying defect contours from multiple groups of indications, and of recommending defect merging candidates and defect sizing methods. However both modules also accept user input so that the final decisions rest with the operator.

Abstract: Disclosed is a composite focusing wedge for ultrasonic non-destructive testing/inspection. The composite wedge comprises a base made of machined or cast material, and a lens made of a material which is cast in liquid form and subsequently solidifies. The acoustic velocity in the base material is less than that in the lens material. The castable lens material conforms exactly to a convex machined or cast surface of the base, thereby forming a concave lower surface of the lens. A flat ultrasonic probe is coupled to a planar upper surface of the lens. The minimum distance between the lower concave and upper planar surfaces of the lens is less than one acoustic wavelength in the lens material. The ringdown time of reverberations between the two surfaces is then sufficiently short that there is no interference between the reverberations and signals from sub-surface flaws in the object being tested.

Abstract: Disclosed is an ultrasonic inspection probe assembly comprising a water wedge and a flexible probe array assembly having a flexible acoustic module. The wedge is machined to match a test surface to be inspected and is configured to shape the acoustic module so that the active surface of the acoustic module is parallel to the test surface. Different wedges may be machined to match different test surfaces, but the same flexible probe array assembly may be used for all such surfaces.

Abstract: Disclosed is a phased array ultrasound total focusing method in which the ultrasound energy is transmitted as plane waves and the response signals are processed as plane waves. The processing is adaptively corrected to account for geometric variations in the probes and the part being inspected. Methods are disclosed for measuring the geometric variations of the probes and the part.

Abstract: Disclosed is a composite focusing wedge for ultrasonic non-destructive testing/inspection. The composite wedge comprises a base made of machined or cast material, and a lens made of a material which is cast in liquid form and subsequently solidifies. The acoustic velocity in the base material is less than that in the lens material. The castable lens material conforms exactly to a convex machined or cast surface of the base, thereby forming a concave lower surface of the lens. A flat ultrasonic probe is coupled to a planar upper surface of the lens. The minimum distance between the lower concave and upper planar surfaces of the lens is less than one acoustic wavelength in the lens material. The ringdown time of reverberations between the two surfaces is then sufficiently short that there is no interference between the reverberations and signals from sub-surface flaws in the object being tested.

Abstract: A calibration method for calibrating a phased array probe that is used for testing girth welds for defects. The method utilizes a calibration device on which is defined a series of reflectors that correspond to a series of target zones. The phased array probe is placed via a wedge relative to the calibration device and the phased array probe is configured with an initial set of acoustic parameters which define at least a transmitting aperture, a receiving aperture and a beam steering angle. Using a Full Matrix Capture (FMC) acquisition process and a ray-tracing module, the values of the initial set of acoustic parameters are optimized to evolve a final set of acoustic parameters which the phased array probe utilizes for testing actual devices for weld defects.

Abstract: A method of using a 1.5D array ultrasonic probe as a component of an inspection system intended for different diameter cylindrical parts without mechanical adjustments of the probe is presented. In particular, the method is presented as a way to improve the near surface resolution over an extended range of cylindrical parts diameter and inspection depths/tubes wall thickness with respect to usual 1D arrays of fixed curvature along the elevation axis. The method relies on a customizable concentric firing pattern of the acoustic pulses with respect to the cylindrical part surface, and on adjustment of the aperture size of the said array. The intended effect is to sharpen and minimize the extent of the front wall echo and to optimize the response from an eventual flaw in the inspected range.

Abstract: A calibration method for calibrating a phased array probe that is used for testing girth welds for defects. The method utilizes a calibration device on which is defined a series of reflectors that correspond to a series of target zones. The phased array probe is placed via a wedge relative to the calibration device and the phased array probe is configured with an initial set of acoustic parameters which define at least a transmitting aperture, a receiving aperture and a beam steering angle. Using a Full Matrix Capture (FMC) acquisition process and a ray-tracing module, the values of the initial set of acoustic parameters are optimized to evolve a final set of acoustic parameters which the phased array probe utilizes for testing actual devices for weld defects.

Abstract: Disclosed is an inspection device and method of guiding an inspection probe according to a predetermined inspection plan. The device is couple with a probe which is to be moved according to the inspection plan on the test object, the device including an inspection guide unit having a guide control unit, a position encoding such as a 3-D camera and visual feedback eyewear. The method including facilitating a virtual display of the inspection plan onto the visual feedback eyewear, moving the probe following the virtual display of the inspection plan, sensing sensed probe positions in real time of the inspection using the 3-D camera and validating the sensed probe position against the inspection plan using the control module. Then the information of the step of validating, such as those spots at which the probe is moved out of the tolerance of the inspection plan, is displayed on the feedback eyewear.

Abstract: Disclosed in the present disclosure is a phased array system configured to ultrasonically inspect test targets complex surfaces while employing the surface profiling capability of phased-array linear and sectorial scans. Adaptive focusing is employed for inspecting the test target by using customized apertures according to the surface profiles to generate a plurality of beams that are evenly and thoroughly spaced along a scan line inside the test target.

Abstract: A touch screen is disclosed which responds to a user's touch for re-drawing, re-scaling, re-translating and re-positioning an impedance plane signal received from non-destructive testing equipment, such as an eddy current sensor. The impedance plane is manipulated by slidingne, two or more fingers simultaneously to an end position to effectuate a complete re-drawing operation of the image.

Abstract: A multi-frequency bond-testing system using acoustic probes in conjunction with NDT/NDI inspection instruments. Bond-testing of test objects is carried out at multiple discrete frequencies to produce a single, combined amplitude C-scan. Alternatively, or in combination, the system provides a single, combined phase C-scan to enable proper interpretation of the C-scans. Amplitude and/or phase readings on test objects are normalized at the selected frequencies relative to tests performed on a defect-free object at those frequencies. In this manner, the non-linear behavior of a bond-testing probe over a frequency range chosen for a given inspection is compensated for. The invention enables providing more easily interpretable and sharper images which enable a more reliable and faster reading and identification of defects in the test objects.

Abstract: A touch screen is disclosed which responds to a user's touch for re-drawing, re-scaling, re-translating and re-positioning an impedance plane signal received from non-destructive testing equipment, such as an eddy current sensor. The impedance plane is manipulated by slidingne, two or more fingers simultaneously to an end position to effectuate a complete re-drawing operation of the image.

Abstract: A method of using a 1.5D array ultrasonic probe as a component of an inspection system intended for different diameter cylindrical parts without mechanical adjustments of the probe is presented. In particular, the method is presented as a way to improve the near surface resolution over an extended range of cylindrical parts diameter and inspection depths/tubes wall thickness with respect to usual 1D arrays of fixed curvature along the elevation axis. The method relies on a customizable concentric firing pattern of the acoustic pulses with respect to the cylindrical part surface, and on adjustment of the aperture size of the said array. The intended effect is to sharpen and minimize the extent of the front wall echo and to optimize the response from an eventual flaw in the inspected range.

Abstract: Disclosed is an ultrasonic phased array non-destructive inspection system that includes a PA probe, a conventional PA inspection unit and a refraction angle verification unit. The PA inspection unit is employed to emit ultrasonic angle beams into an AWS IIW Block and to receive a set of corresponding echo signals reflected from the calibration block and to provide time-of-flight (TOF) values corresponding to each angle beam. The refraction angle verification unit then provides a true angle for each of the angle beams based on the ultrasonic and geometric characteristics of the block and the measured TOF values. Other calibration blocks such as the DSC and Nayships blocks can also be used for this purpose.