Various industries want to use phased array ultrasonic technology for the inspection of stainless steel and other austenitic welds but many challenges exist including sound propogation. This presentation provides a recommended solution that addresses the challenges and delivers results.

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Stainless Steel
Weld Inspection
Application Solution

2. Overview
• Inspection Challenge
• Recommended Phased Array Ultrasonic (PA UT)
Solution
• Results
• Benefits of Zetec Solution
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3. • Various industries want to use PA UT for manufacturing
inspection (“in lieu of RT”) and for in-service inspection of
stainless steel (SS) and other austenitic welds : dissimilar
metal, Inconel, Corrosion-Resistant alloy (CRA)
• These welds are challenging for UT examination, because of
sound propagation issues in the coarse-grain austenitic weld
structure (see next slide)
• Reliable examination of austenitic welds requires careful
selection of inspection techniques
• Most elements of a “successful” inspection solution for
austenitic material are known to UT experts, but implementation
is still perceived as laborious and expensive (requires high-end
equipment and software, or multiple software packages)
Inspection Challenge
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4. • High, and variable attenuation
• High noise level, caused by
reflection on individual grains
• Low-pass filtering effect
• Beam skewing and distortion
• Local variations of material
structure
Inspection Challenge
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Propagation issues caused by anisotropic coarse-grain
structure of stainless steel and austenitic welds :
LW
SW

5. • Low-frequency 2D matrix array probes, to generate both
LW and SW beams, for complete weld coverage
Recommended PA UT Solution
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• High-performance portable PA UT unit, with
fully integrated support of 2D matrix arrays :
– On-board setup and adjustment of probe
and wedge configuration
– Visual feedback on focal laws
– Volumetric Merge for efficient data analysis
• Efficient deployment on-site, compatible with
automated and manually driven encoded
scanners

6. • Examination for circumferential flaws using dual 2D matrix
arrays (TRL mode), with frequencies between 1.5 and 3.5 MHz:
– Better sensitivity and SNR due to the “convolution” of T and R beams
– No dead zone or wedge echoes
• Refracted angles from 30° to 85°LW, covering the full thickness
• Effective inspection through coarse-grain weld material
Inspection Technique
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7. • Detection of axial cracks (e.g. IGSCC) in austenitic welds with
weld cap in place
• Single 2D matrix array probe, operating in pulse-echo mode,
generating skewed SW beams through base material
• Multiple skew angles and probe orientations to optimize detection
and coverage
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Inspection Technique

8. • Standard dual 2D matrix array probes: frequency and active
surface optimized for material attenuation and wall thickness
• Element configuration optimized for maximum steering
capability without side lobes
• Exchangeable wedge assemblies, contoured to match pipe OD
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2D Matrix Array Probes

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• Fully integrated, portable unit
• 64-bit computer, 2 x faster
• PA UT 32/128PR + 2 UT at 200 V
UltraVision TouchTM
Advanced software
• On-board support of 2D arrays
• « Propose Setup » tool
• Visual feedback on focal laws
• On-line Volumetric Merge
• Full data analysis capability
• 2GByte data files on-board
Zetec Instrument

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Results – SS Weld with Cap
PA UT data (30° to 85°LW) from 304 SS weld (T = 25 mm) :
all flaws detected from a single side with 2.25 MHz, 10x3 matrix array (TRL)

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Results – Axial Flaws
Merged PA UT data (SW) from axial ID crack in SS pipe weld (T = 23 mm):
Reliable detection using beams with multiple skews,
and accurate positioning of the crack in cylindrical geometry

12. 12© Zetec Inc. All rights reserved
• Standard 2D matrix array probes with proven design for
a wide range of austenitic weld configurations
• integrated portable PA UT system,
capable of performing 2-sided weld inspection using
TRL probes (32T/32R):
– High performance from on-board 64-bit computer
– Capability to record large data files (up to 2 GBytes)
• Efficient setup and optimization of inspection techniques
using only the on-board UltraVision Touch software
• Easy to deploy:
– Dynamic Merge views for on-line monitoring of inspection data
– Complete data analysis capability
– Indication Table & Report Generation
Benefits of Zetec Solution

13. Thank You!
Learn more at: www.zetec.com
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