Ultrasonic Inspection Probe Arrangement for Minute Defect Sizing
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Solution Overview
Problem
Conventional ultrasonic inspection methods face challenges in accurately evaluating the height of minute defects due to low signal-to-noise ratios, especially in welded parts and thick materials, where the intensity of tip echoes is reduced and often masked by corner echoes, making it difficult to distinguish and measure the defect height reliably.
Innovation Solution
An ultrasonic inspection method using an angle beam method with a transmitting probe and a vertical beam method receiving probe, where the difference in path lengths of tip and corner echoes is measured to calculate the defect height, and array probes are employed to enhance the accuracy by determining refraction angles for maximum echo intensities, allowing for precise defect sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single probe method or conventional double-probe method is used for ultrasonic inspection, then the inspection system remains relatively simple, but the ability to accurately evaluate the height of minute defects is compromised due to low signal-to-noise ratios and difficulty in separating tip echoes from corner echoes
Solution Approach 1:
The inspection system is segmented into two separate probes: a transmitting probe that sends ultrasonic waves and a receiving probe that detects echoes. This separation allows independent optimization of transmission and reception paths, improving the ability to detect and measure tip echoes separately from corner echoes, thereby enhancing defect height evaluation accuracy without requiring overly complex integrated systems
Solution Approach 2:
The patent introduces a water layer as an intermediary medium between the probes and the inspected material. This water layer serves as a coupling medium that improves ultrasonic wave transmission and reception, particularly enhancing the detection of tip echoes from minute defects while maintaining a relatively simple inspection system configuration
2Loss of information
If the ultrasonic wave is transmitted at an oblique angle to detect corner echoes, then the inspection coverage is improved, but the tip echo intensity is reduced and masked by corner echoes, making it difficult to distinguish and measure defect height
Solution Approach 1:
The patent employs a water layer that exceeds the minimum coupling requirement, creating an excessive water gap between the probes and the material surface. This excessive water layer acts as an acoustic lens that focuses ultrasonic waves and enhances tip echo detection, allowing partial separation of tip echoes from corner echoes even when oblique angle transmission is used for comprehensive inspection coverage
Solution Approach 2:
The patent changes the acoustic parameters by introducing a water medium with different acoustic impedance than the solid material. This parameter change modifies the ultrasonic wave propagation characteristics, reducing corner echo intensity relative to tip echo intensity and improving the signal-to-noise ratio for defect height measurement
3Adaptability or versatility
If conventional ultrasonic inspection methods are used on welded parts and thick materials, then the inspection can be performed on challenging materials, but the signal-to-noise ratio deteriorates due to scattering of crystal grains and reduced tip echo intensity
Solution Approach 1:
The water layer serves as an intermediary medium that improves ultrasonic wave penetration into welded parts and thick materials. By providing a consistent acoustic coupling path through the water layer, the system overcomes the scattering effects of crystal grains in welded materials and maintains reliable tip echo detection across different material types and thicknesses
Solution Approach 2:
The separation of transmitting and receiving probes allows the system to be adapted to different material types (welded parts, thick materials, etc.) by adjusting probe positions and water layer thickness, while maintaining reliable defect detection through optimized reception of tip echoes that would otherwise be masked by material heterogeneity
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 enables accurate and simple sizing of minute defects by improving the signal-to-noise ratio and separating tip and corner echoes, even in challenging materials like welded parts and thick materials, providing reliable defect height measurements.
Implementation Method 1
transmitting an ultrasonic wave to a defect
Implementation Method 2
a wave diffracted from a tip of the defect
Implementation Method 3
a corner echo reflected from the defect
Implementation Method 4
receiving probe can receive the ultrasonic wave from the defect in a vertical direction
Implementation Method 5
determining refraction angles for maximum echo intensities
Data Source
AI summary
The invention is directed to an ultrasonic inspection method, an ultrasonic test method, and an ultrasonic inspection apparatus that enable sizing to be executed even for a minute defect using an ultrasonic wave. A holder holds a transmitting probe for executing an angle beam method and a receiving probe for executing a vertical beam method. A motor and a guide rail form a movement mechanism for the transmitting probe and the receiving probe. In an ultrasonic test mode, the transmitting probe executes the angle beam method and transmits and receives an ultrasonic wave. In a sizing mode, the transmitting probe transmits an ultrasonic wave and the receiving probe receives this wave. A tip echo of a wave diffracted from a tip of a defect on a sample and a corner echo reflected from a corner of the defect are measured from a waveform received by the receiving probe.