Phased Array Ultrasonic Weld Penetration Analysis
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Solution Overview
Problem
Current ultrasonic testing systems are inefficient and impractical for accurately determining weld penetration percentage in orthotropic steel deck (OSD) rib-to-deck joints, leading to incomplete inspections and potential fatigue cracking due to limited beam control and resolution.
Innovation Solution
A phased array ultrasonic testing system that calculates weld penetration depth by processing scan section data to determine the percentage of rib leg metal penetration, generating reports for spot inspections and remediation, allowing for quicker and more accurate assessments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic testing systems are used to inspect weld penetration in OSD rib-to-deck joints, then the inspection process is simplified, but the measurement precision and beam control are insufficient leading to inaccurate penetration percentage determination
Solution Approach 1:
The weld inspection process is segmented into multiple scan sections along the weld seam, with each section analyzed independently to determine penetration percentage. The phased array ultrasonic system divides the inspection into discrete measurement points, allowing precise local penetration assessment while maintaining overall weld quality control.
Solution Approach 2:
The ultrasonic beam is made dynamic through phased array technology, allowing real-time electronic steering and focusing of the beam without mechanical movement. This dynamic beam control enables precise penetration measurement at different weld locations while maintaining system compactness and reducing mechanical complexity.
2Productivity
If manual inspection methods are used for weld seam analysis, then device complexity is reduced, but the inspection time and productivity are significantly increased
Solution Approach 1:
The system performs automated analysis of ultrasonic scan data to determine penetration percentages without requiring manual interpretation. The computer automatically processes scan section data, calculates penetration measurements, and generates inspection reports, eliminating the need for manual measurement and analysis while maintaining high inspection speed.
Solution Approach 2:
Manual mechanical measurement methods are replaced with automated ultrasonic scanning and computer-based data processing. The system uses electronic signal processing and automated image analysis to determine penetration percentages, substituting manual operations with automated computational methods that increase productivity.
3Reliability
If comprehensive weld seam inspection is performed to ensure quality, then reliability is improved, but the inspection time and loss of time increase
Solution Approach 1:
The system performs preliminary automated analysis of ultrasonic scan data to identify potential penetration issues before final quality acceptance. By pre-processing scan sections and calculating penetration percentages automatically, the system ensures comprehensive quality coverage while reducing the time required for final inspection approval.
Solution Approach 2:
The ultrasonic scanning proceeds continuously along the entire weld seam without interruption, with real-time data processing and penetration calculation. This continuous inspection method ensures complete weld coverage for quality assurance while minimizing inspection time compared to discrete sampling methods.
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
Enables rapid and precise measurement of weld penetration, reducing the time required for inspections and ensuring compliance with building codes, thereby enhancing the integrity and durability of OSD systems.
Implementation Method 1
Ultrasonic weld analysis for orthotropic steel decking systems in bridges... ultrasonic testing systems are inefficient and impractical for accurately determining weld penetration percentage... phased array ultrasonic testing system that calculates weld penetration depth by processing scan section data
Data Source
AI summary
A system provides for the calculation of the penetration depth of a weld in an orthotropic steel decking system. Weld scan section data is accessed and each scan section along the weld seam is processed to find the amount of penetration as a percentage of the thickness of the rib leg metal at the weld location. The amount of penetration is calculated by finding ultrasonic reflections recorded as voxels that have the greatest magnitude within an area of contiguous magnitudes and then determining the location of those voxels relative to the weld geometry and distance along the thickness of the rib leg steel. A report for each section scan and the entire weld seam may be generated for review by a weld inspector that allows for spot inspections of specified areas along the weld seam for possible weld remediation.