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Flaw Detector - Phased Array Flaw Detector

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  • Able to adjust the geometry of echoes which reduces false signals
  • Offer flexibility in controlling complex shapes
  • Enable inspectors to assess geometrically complex parts without moving any sensor or object
  • Allow inspectors to reduce the scanning speed of the object while increasing the control resolution

Phased Array Flaw Detector for Sale

Our company’s 1st Phased Array flaw detector was designed and manufactured in 2010, after years user feedback and technology improvement, the Flexcan Phased Array flaw detector has became the high performance and easy operate model. it’s TFT screen with high image resolution (1024*768 pixel, image can be shown more dedicate, flaw size and location can be shown with higher accuracy), the display refresh rate is 60Hz, ensures the image reflects the scanning position; Flexcan Phased Array flaw detector with 32 elements transmit and receive signal synchronously, it can real time display A-scan, C-scan, D-scan, S-scan and L-scan image, and it has max.300V transmit voltage (the emission power higher than domestic and foreign products).

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40 Years of Expertise

We have 40 years of experience in the professional production of ultrasonic flaw detectors, an annual output of more than 10,00 ultrasonic flaw detectors, thickness gauges, ultrasonic probes and calibration blocks.

Talented Engineers and support team

As of September 2021, we have a total of 125 employees, including nearly 45 professional and technical workers who are masters or doctorate degree holders.

Advanced production equipment

We have Complete machining workshop, CNC, CNC machine tools, and more than 50 other types of processing equipment,to ensure high-precision product parts.

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We provided excellent after-sales service, including fast delivery, online training,  immediate feedback of trouble shotting.

Phased Array Flaw Detector: The Complete Guide

Table of Contents

 

Have you ever wondered if there is a difference between conventional ultrasonic testing and phased array ultrasonic testing? 

Even though the ultrasonic testing method of inspection has been largely accepted in the manufacturing industry as an accurate quality assessment method, there are still many individuals who find it difficult to understand the difference in the various ultrasonic testing options.

The phased array flaw detectors are an advanced form of ultrasonic testing that offers several benefits over traditional ultrasonic testing. Despite the abundance of information around, many in the quality control and assessment field still lack sufficient information regarding this testing method. 

This ultimate guide will help garner the necessary information to understand the working and specific applications of the phased array flaw detectors.

So, if you are ready, let’s dive in together. 

I. What is Phased Array Flaw Detector?

Phased array ultrasonic flaw detector is an improved form of ultrasonic testing that has applications in industrial non-destructive testing. Familiar applications of phased array flaw detectors are to find flaws in products during the manufacturing process, such as welding and bonding in a non-invasive way.  However, where conventional non-phased array probes (also called monolithic probes) emit one single beam in a specific direction, ultrasonic phased array probes can emit multiple beams from a single probe in different directions. 

Also, for conventional monolithic probing of large materials, the probe has to be physically moved or scanned through the entire surface of the material. On the other hand, the phased array probing method does not require the movement of the probe since the beam generated can be electronically focused and swept over the material area of interest. 

You can control the beam because of the presence of multiple elements responsible for the generation of the individual pulse using computer-programmed timing.

II. Benefits of Phased Array Flaw Detector

Phased array flaw detectors offer unique benefits as a non-destructive method, especially as an advanced form of ultrasonic testing. Some of these benefits can include:

  • The ability to detect defects might be difficult for conventional ultrasonic testing to identify. 
  • It has the ability to adjust the geometry of echoes which reduces false signals.
  • Phased lattices enable inspectors to assess geometrically complex parts without moving any sensor or object.
  • It offers flexibility in controlling complex shapes.
  • A single transducer can generate beams with different angles to cover large areas during a test for defects. 
  • The access to greater coverage allows inspectors to reduce the scanning speed of the object while increasing the control resolution.

III. Phased Array Flaw Detector Basics

To fully understand the operations of phased array flaw detectors, you might need to understand some essential concepts and components. Understanding working on these individual components and how they effectively combine to identify the flaws within a product is critical. 

  • What is Phased Array Ultrasonic Testing? 

A phased array ultrasonic testing is a non-destructive test method generally based on a set of specialized ultrasonic transducer systems containing several individual elements (around 16 to 256) that can be vibrated individually in a predetermined pattern. These transducers are often used with different types of wedges in immersion testing or a contact mode. 

  • Beam angle

During a probe, transducers often generate ultrasonic sound waves that are reflected in the transducers. These waves are often projected at an angle for phased ultrasonic testing, and the angle it makes to the horizontal plane is referred to as the beam angle. 

  • Focal distance

Sometimes there is the need to narrow the beam diameter of the sound waves to a focal point to increase the sound energy for each area within the focal zone. The distance between the beam projection points and the focal point is also called the focal distance. This act often increases the sensitivity to small reflectors.

IV. How does Phased Array Flaw Detector Work?

Unlike the conventional monolithic ultrasonic flaw detector, a phased array flaw detector uses a system of multiple elements to initiate pulses and receive pulses as an array. 

The pulses that originate from these elements combine in their movement to form a single band of wave beams that can go in the desired direction. Likewise, at the receiving end, the multiple pulses are then combined to present a single result. 

Ultimately, phased array flaw detectors allow you to generate a massive number of ultrasonic beam profiles using a single probe assembly because it enables electronic beam steering and shaping. Additionally, the beam steering can be programmed dynamically to generate electronic scans.

V. What are the Advantages of Phased Array Testing as Compared with Conventional UT?

The advantages of phased array flaw detectors over traditional ultrasonic testing have to do with its ability to employ several elements to focus, steer and scan beams with a single transducer system. Ultrasonic phased array detectors can be used in almost every test that conventional ultrasonic flaw detectors can perform. 

  • Ultrasonic Testing (UT) 

With traditional ultrasonic testing, a single probe only generates a single beam in a fixed direction. Navigating a large area requires the inspector to physically scan or move the beam through the entire area or desired spots.

  • Phased Array Ultrasonic Testing (PAUT)

Conversely, the beam generated in phased array ultrasonic testing can be electronically controlled and moved without moving the probe, which makes the result more accurate, faster, and more comprehensive. Also, because the beams can be manipulated electronically, angular mapping can take signals from objects with limited assessment or complex geometry components.

It is often very useful in welding applications where multiple angles are required for accurate assessments of defects. Nonetheless, the signal-to-noise ratio experiences significant improvement in complex applications and when sweeping across multiple elements with rapid C-scan production.

VI. Where are Phased Array Flaw Detectors Used?

Phased array flaw detectors have been successfully used to monitor and identify defects in specific applications and industries over the years, and they continue to deliver accurate results. Some of these applications are highlighted below. 

  • Weld Inspection

Weld inspection is one of the most important applications of phased array flaw detectors, and this inspection is often done across an extensive range of industries, including power generation, aerospace, petrochemical, pipeline construction and maintenance, metal billet, and tubular goods suppliers, general manufacturing, and structural metals.

  • Thickness Measurement

Material thickness often contributes to certain characteristics, including its strength, durability, and load-carrying capacity. However, ensuring the thickness specification is met during manufacturing is another ball game. A phased array flaw detector can ensure that this parameter is met during the manufacturing process. 

  • Bond Testing

Bonding materials to form a single unit is a common manufacturing process, and the integrity of the bonding always contributes to the capacity of the final product. Phased array flaw detectors can be applied to confirm the integrity of the bonding and to ensure the overall strength of the final product is as per specification. 

  • Crack Detection

Crack detection is another important application that cuts across various industries while relying on phased array flaw detectors to carry out quality assessments specifically for cracks. Discontinuities like cracks are one major defect that frequently reoccurs in the manufacturing space either due to inefficient processes or a lack of technical expertise on the personnel. 

  • Corrosion Inspection

Phased arrays can also be effectively used to profile residual wall thickness in corrosion survey applications. 

Conclusion

In conclusion, the phased array flaw detector offers many advantages over the traditional ultrasonic flaw detector, including its ability to scan a large area without having to move the probe. This ability is especially useful for assessing the presence of flaws in very large areas and where the access to components is restricted and for scanning complex geometry and awkward looking objects. 

All these are possible based on the ability of phased array flaw detectors to generate multiple ultrasonic waves that are programmable and combined with moving in one direction. Likewise, the multiple returning signals can also be combined to one result to assess the component’s quality under examination accurately.

Now that you have all this information, the ball is in your court. What will be your next move? 

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