Next Generation Phased Array UT Total Focusing Method (TFM)

Next Generation Phased Array UTTotal Focusing Method (TFM)

Gavin Dao and Alan CaulderAOS, Cincinnati, OH

Dominique Braconnier and John LorenzTPAC, West Chester, OH

Introduction• Preview of Advanced Imaging• What is Full-Matrix Capture (FMC)?• What is Total Focusing Method (TFM)?

– Standard TFM– Migration– Advanced FMC / TFM– Adaptive TFM

• Images• About AOS• OEM-PA

Conventional Phased Array UT

Phased Array Linear Scan

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FMC/TFM

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Conventional PA vs FMC/TFM

Conventional Phased ArrayFMC/TFM

FMC/TFM: Some Benefits

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• Beautiful Image!• Like a drawing of the test piece• Provides better perspective• Vertical Resolution Improved

– See next video• Lateral Resolution Improved

– 3 holes: Can see the small nuance of 3 mm center to center and 4 mm center to center

• Can see that the SDHs are 1 mm in diameter.

• Understand images a lot easier• Able to differentiate what is a real

defect vs geometry echoes

Our Technology

OEM-PAPhased Array UT

16/16, 32/32, 16/128, 32/128, 64/64128/128 and 256/256

OEM-MCMultichannel UT16ch and 32ch

OEM-PA + FMCAdvanced Imaging

FMC / TFMFast Data Rate at 140 MB/s!!!

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Advanced OEM Solutions (AOS)• Open concept: customize to application• OEM business model for cost effective solutions• Phased Array UT – manufacturer of full range of

instruments from standard to cutting-edge technology

www.aos-ndt.com

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OEMPA 128/128 with USB3• Super Fast Data rate!

– 160 MB/s (for high frame rate)• Full-Matrix Capture (FMC)• Total Focusing Method (TFM)

– Standard TFM– Migration TFM– Advanced TFM– Adaptive TFM– And more… (TFMp, SURE, Non Linear)

• Utilizes GPU– For faster TFM calculation speed

• Open! – Access raw data and low level parameters

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OEM-PA 256/256• Super Fast Data rate!

– 160 MB/s – Faster Scan Speeds

• DDF (Dynamic Depth Focusing)– Zone Focusing + DDF

• 3D Focal Law Calculator API– Matrix Phased Array Probes– Custom MPA Designs

• CTUT– Proprietary Technique for High

Speed In-Line inspections for Bar/Tube industry.

• Open! – Access raw data and low level

parameters

OEM-PA Configurations

Advanced PAUT 256/256 YES!

256/256 + FMC YES!

256/256 + FMC + 160 MB/s YES!

256/256 + Matrix Phased Array YES!

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Software

AOS Provides…• Software Development Kit (SDK)• Dynamic Link Libraries (DLL)• Application Programming Interface (API)• Full control of Phased Array Parameters• Receive each A-scan in a buffer that can be interfaced to your own software• Full Documentation Set

• Customize: Create a simple dedicated application. Don’t get stuck with an overly complex software where you only use 5% of the features

Develop Your Own Software

Use 3rd Party Supported Software

OR

Full-Matrix Capture (FMC)

PulsePattern

ReceivePattern

In this example, we have 4 elements…

4 x 4 = 16 Raw A-scans

Cycle 1 Cycle 2 Cycle 3 Cycle 4

More on FMCMatrix of Transmit / Receive Raw A-scans

Receive elements

1 2 3 4 5 6 7 ・・・

Transmit elem

ents

1

2

3

4

5

6

7

…

More on FMC• Not to confused with Matrix Phased Array

Receive elements

1 2 3 4 5 6 7 ・・・

Transmit elem

ents

1

2

3

4

5

6

7

…

Total Focusing Method (TFM)

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Mono-Static: Pulse/Echo

𝑜𝑜 𝑥𝑥, 𝑧𝑧 = �𝑖𝑖=1

𝑁𝑁

𝑦𝑦2𝑟𝑟𝑐𝑐 ,𝑢𝑢𝑖𝑖 ,

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Multi-Static

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Multi-Static• Point of computation (x,z) => time of flight with constant velocity• Reconstruction performed by focusing at each point (x,z) of the grid

• Flexible reconstruction grid :

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128el Probe with Alum Test Block

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Conventional Phased Array UT

Phased Array Linear Scan

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Conventional PA vs FMC/TFM

Conventional Phased ArrayFMC/TFM

FMC/TFM: Some Benefits

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• Beautiful Image!• Like a drawing of the test piece• Provides better perspective• Vertical Resolution Improved

– See next video• Lateral Resolution Improved

– 3 holes: Can see the small nuance of 3 mm center to center and 4 mm center to center

• Can see that the SDHs are 1 mm in diameter.

• Understand images a lot easier• Able to differentiate what is a real

defect vs geometry echoes

Advanced TFMAdvanced TFM• Use GPU for faster

calculation time• Efficient Pulse/Receive

method to capture raw data

• Optimized post processing

• Faster Frame Rates!!• High resolution!• Excellent SNR

Significant improvement over conventional FMC and TFM technique!!

TFM Video: Vertical Resolution

FMC / TFM

EDM Notch Test Piece

Lower Tip Echo

Upper Tip Echo

• Indication from upper and lower tip.

• Center of slit is difficult to see.

• Can be easily misinterpreted as two separate defects or SDHs very close together.

Conventional PA

Side By Side Comparison

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FMC / TFM

45°30°20°10°0°

Conventional PA

Lower Tip Echo

Upper Tip Echo

EDM Notch Test Piece

TFM Setup Wizard

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TFM Data Viewer

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Wave Modes: Pulse/Echo

Wave modes from one setup and data capture

Wave Modes: Pitch/Catch

Wave modes from one setup and data capture

Test Piece

Real Application: AUT Girthweld

Upstream SidePulse/Echo

Velocity and Geometry Matter!

Adaptive TFM

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Amazing Near Surface Resolution!

FBH:Diameter: 0.016” (0.4mm)MTD: 0.060”(1.5mm)

FMC/TFM: Titanium

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TFM Imaging: 1” Steel Bar

1” ThickVertical Crack 0.8”

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More about OEMPA• Flexible and Open Concept• Complete SDK• Fully documented API with Source Code• Compact Form Factor• Cost Effective• Ease of Integration• Excellent Signal-to-Noise Ratio• Advanced Features

OEMPA 64/64 is Small!!• With Enclosure: 105mm x 124mm x 112mm• Bare Module: 90mm x 110mm x 70mm • Height x Width x Depth

16/16 32/32 64/64 16/128 32/128 128/128 256/256

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OEM-PA 256/256• Super fast data rate!

– 140 MB/s – Faster scan speeds

• DDF (Dynamic Depth Focusing)– Zone Focusing + DDF

• 3D Focal Law Calculator API– Matrix Phased Array probes– Custom MPA designs

• Volume Focusing– Proprietary technique for high

speed In-Line inspections for bar/tube industry

• Open! – Access raw data and low level

parameters

OEM-PA Configurations

Advanced PAUT 256/256 YES!

256/256 + FMC YES!

256/256 + FMC + 140 MB/s YES!

256/256 + Matrix Phased Array YES!

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OEM

64/64*I/O Board and Power

Supply Boards not shown.

16/16

Original Equipment Manufacturer Re-brand Create your own product Add value with your own unique solution

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OEM-PA LITE

Dimensions:16/16 = 140 x 125 mm32/32 = 140 x 165 mm16/128 = 140 x 165 mm32/128 = 140 x 180 mm64/64 = 2 x 32/32 size

Small form factor Easier integration into a custom portable enclosure

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OEMMC: Multi-Channel UT• Board Dimensions = 11cm x 7cm• 3 Boards must be stacked (approx 3.5cm). 3 boards PWS, IO and Probe

Connect also must be accounted for, but it doesn’t need to be stacked.• Weight < 300g• Power < 15W (Ways of improving this, please consult with AOS)

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11cm

7cm

General Purpose PA Software

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General Purpose PA Software

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Wizard GUI

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Wall Thickness Inspection

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Specific Weld Inspection SW

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Summary of Benefits• Advanced Imaging

– FMC / TFM• Standard Technology

– Phased Array and multichannel UT

• Small Form Factor• Open Platform• Opportunity to

customize software• OEM model

Thank You!!

For More Details or Questions…

Gavin Daogavin.dao@aos-ndt.com

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