SAFT Ultrasonic Defect Sizing via Pre-calculated Amplitude Sum Interpolation
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Solution Overview
Problem
Current ultrasonic testing methods, such as SAFT, struggle to accurately assess the size of small defects due to limitations in amplitude sum comparisons and noise interference, making it difficult to evaluate defects that are small compared to the ultrasound wavelength or have directional reflections.
Innovation Solution
The method calculates amplitude sums for defects of varying sizes at representative positions using simulated ultrasonic echo signals and compares them to SAFT evaluations, enabling precise defect size estimation by interpolating SAFT evaluations of calculated echo signals, even for defects that would be lost in noise or appear as joint evaluations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic testing methods are used, then large defects can be detected, but small defects (comparable to or smaller than wavelength) cannot be accurately assessed
Solution Approach 1:
The patent pre-calculates amplitude sums for defects of various sizes and positions before actual testing. These pre-computed reference values are stored and later used to compare against measured SAFT amplitude sums, enabling accurate defect size assessment even for small defects that would be lost in noise during conventional testing.
Solution Approach 2:
The patent transforms the measurement approach by changing from direct amplitude comparison to comparing SAFT amplitude sums against pre-calculated reference amplitude sums for various defect sizes. This parameter transformation enables the system to assess defect sizes in the wavelength order and below, overcoming the conventional limitation.
2Measurement precision
If SAFT method is used to improve lateral resolution and defect separation, then amplitude sums are obtained but conventional defect size assessment methods cannot be applied
Solution Approach 1:
The patent creates a reference database by calculating amplitude sums for idealized defects of various sizes and positions. These calculated reference amplitude sums serve as templates that are compared against actual measured SAFT amplitude sums, enabling defect size assessment without requiring conventional assessment methods to be directly applicable.
Solution Approach 2:
The patent develops a universal assessment method that works for defects of all sizes, from large defects down to the wavelength order and below. By using SAFT amplitude sums as the common basis for both measurement and reference comparison, the method achieves versatility across different defect size ranges that previously required different assessment techniques.
3Ease of operation
If conventional amplitude evaluation is used, then assessment is simple but defects must not be too small or too directionally reflective
Solution Approach 1:
The patent introduces pre-calculated amplitude sums as an intermediary reference between the measured SAFT amplitude sums and the defect size assessment. This intermediary reference database bridges the gap between the complex SAFT measurements and the simple defect size determination, maintaining ease of operation while improving measurement precision for small and directionally reflective defects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the detection and evaluation of small defects, providing more information on material quality and enabling the testing of components for high loads in industries like energy engineering and aviation, with reduced computational effort and improved precision.
Implementation Method 1
The evaluation unit (3) is designed to carry out a SAFT (Synthetic Aperture Focusing Technique) evaluation for each measurement data set determined
Implementation Method 2
ultrasonic waves Mi are irradiated into the test object (1) at various measuring points via the test head (2) and the ultrasonic echo signals reflected back from the test object (1)
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a method and a device for evaluating defect variables in an object to be tested during an ultrasonic test. In the process, the invention also allows a controlled detection of defect variables on the basis of the SAFT method in particular. For this purpose, defects in an object to be tested are simulated on the basis of a specified test scenario, and the simulations are compared with real detected measurement values.