Ultrasonic testing or UT is among the routine non-destructive testing that aids in defect detection, thickness, and material quality control. UT is used in every industry like aerospace, manufacturing, construction, and oil and gas. To use ultrasonic testing appropriately, you must have the right equipment. In this tutorial, we shall provide you with a general idea of the general equipment involved in ultrasonic testing, how it is applied, and why it assists us in getting good results.
1. Ultrasonic Flaw Detector
The most frequently employed equipment in UT is the ultrasonic flaw detector. It emits high frequency sound and receives the reflection from the test specimen. Detectors are utilized for flaw detection, i.e., cracks, voids, or inclusions in a structure.
Characteristics to Be Looked For in an Ultrasonic Flaw Detector:
- Large screen display to receive clear indications of the signal
- Adjustable frequency controls for different materials
- Digital storage facility for storage of test results
- Portable and rugged design for in-situ testing
2. Transducers (Probes)
Transducers or probes are the devices through which ultrasonic waves travel from and to their target. Probes offer accuracy and sensitivity during testing. Several probes are utilized depending on the application.
Typical Transducer Types:
Contact Transducers – Applied for contact testing of plane surfaces.
Angle Beam Transducers – Commonly priced for weld defect and crack monitoring.
Immersion Transducers – Applied to use in water or liquid-carried inspection where wave transmission is enhanced.
Dual–Element Transducers – Applied for thickness measurement and for corrosion detection.
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3. Couplant
Couplant is oil, liquid, or gel used to enable ultrasonic waves to be transmitted from transducer to material without air bubbles. Otherwise, the waves would be deflected and give wrong readings.
Common Types of Couplants Used Most
Gels and Oils – Used while conducting high-frequency testing.
Water – Usually used in the scenario of immersion test.
Petroleum-based Fluids – Most suitable in the scenario of use at elevated temperatures.
Effective utilization of couplants ensures sufficient signals and precise measurement in ultrasonic testing.
4. Calibration Blocks
Calibration blocks are used for calibrating and verifying the accuracy of ultrasonic testing equipment. Calibration blocks are constructed of the same material as the test piece and with specific known flaws or thickness transitions.
Types of Calibration Blocks:
Step Wedge Blocks – Used for examining different thicknesses of the material.
Notch Blocks – Used to assist in the identification of cracks in depth.
Reference Standards – Employed to precisely calibrate for very technical applications.
Repeating calibration is required for repeatable and consistent indication in ultrasonic inspection.
5. Data Logger or Display Unit
New ultrasonic inspection equipment features an onboard digital display unit and real-time output in B-scans or A-scans. More recent equipment also features data logging, wherein the measurements are stored and recorded for processing at a convenient time later.
Why a Data Logger is So Important:
- Facilitates easier comparison of long-term test data
- Simplifies reporting and documentation
- Simplifies effectiveness of inspection on a large scale
Easy, quick exhibition is required to make timely decisions in the field.
6. Power Supply and Battery Pack
Since most of the ultrasonic testing is to be carried out on-site, a high quality battery pack is extremely important. Rechargeable hour long lithium-ion batteries are provided in some of the equipment for ultrasonic testing.
The following should be the characteristics of an efficient Power Supply:
- Long battery life to support long test time
- Easy provision for easy charging to enable easy recharging
- Portability in operating with portable generators for performing out-site testing
- On-demand power avoids downtime in critical inspections.
7. UT Software
Professional-grade UT software assists professionals in results analysis expertise, reporting, and flaw detection more precisely. UT software with artificial intelligence and machine learning makes flaw detection better.
Benefits of UT Software:
- Evades the process
- Offers next-generation imaging technology for flaw detection
- Makes standardization easier
New packaging is easy to use and can be mounted on mobile equipment for use when needed.
8. Personal Protective Equipment
Safety must be the first priority in ultrasonic testing. The equipment operators should use appropriate PPE so that they are protected against injury in the form of chemical spillage, decibel exposure, and cuts.
Minimum PPE employed in Ultrasonic Testing:
Gloves – Hand protection against abrading surfaces and chemicals.
Safety Glasses – Protection for the eyes against inadvertent splashing.
Hearing Protection – Where there are loud factory environments.
Wearing the relevant protective gear ensures a safe working professional environment.
Ultrasonic testing is a highly effective flaw detection, material quality control, and failure prevention technique used in every industry. In the spirit of reaching the correct conclusions, however, there must be the proper equipment being utilized. From the flaw detectors and transducers to the calibration blocks and software, all the equipment is a very vital part of the testing process.
Investment in quality ultrasonic testing equipment provides the accuracy, efficiency, and safety of the inspectors while testing. Be an experienced inspector or a beginner to venture into the business of ultrasonic testing, quality equipment knowledge and its operation is the key to success for ultrasonic testing.
