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Anomaly Detection Based Applications

1. HDPE Butt Fusion and Electrofusion Joint Inspection
2. Inspection of Thin-wall Feeder Tube Welds
3. Inspection of Forging Defects for Bearing Raceways
4. Wind Tower Weld Inspection
5. Weld Inspection at Elevated Temperatures
6. Hydro Turbine Blade Inspection
7. Through Cap Inspection of Fillet Welds Using Flexible Polymer Wedges

Phased Array Based Applications: HDPE Butt Fusion Joint Inspection (2” & 8” Pipes)

• Client Funded Development Projects
• Designed custom wedges with polymers with Acoustic Velocities close to water
• Inspection Technique qualified using sample with embedded real flaws

Phased Array Based Applications: HDPE Electrofusion Joint Inspection (2” & 8” Pipes)

• Client Funded Development Projects
• Designed custom wedges to detect Electrofusion Wires
• Inspection Technique qualified using sample with embedded real flaws

Phased Array Based Applications: Inspection of Feeder Tube Welds

• Contracted to develop code compliant PAUT procedure for feeder tube weld inspection (in lieu of RT)
• Inspection complicated by thin wall and tight OD curvature
• Extensive simulation used to optimize technique parameters
• Qualified technique with 95% POD on planar defects with only 4% false call rate
• Used in factory to optimize welding procedure

Phased Array Based Applications: Forging Defect Inspection for Bearing Raceways

• Contracted to develop inspection for near surface (0 – 3 mm deep) forging defects in bearing raceways
• Devised hybrid inspection process: highly focused PAUT inspection for 1 mm – 3 mm deep flaws plus Rayleigh wave inspection for 0 – 1 mm deep flaws
• Custom wedge designed to match curvature of raceway surface/house PAUT and Rayleigh wave probes
• Provided procedure and training materials
• Currently in use for quality control

Phased Array Based Applications: Wind Tower Weld Inspection

• Contracted to develop procedure for ISO code compliant inspection of wind tower welds
• Scan plans provided for dozens of weld unique weld configurations (both PAUT and ToFD)
• Compoud scans were used instead of sectorial scans to minimize number of set-ups required
• Remote training of international crews provided
• Remote auditing of data quality and analysis results ongoing

Phased Array Based Applications: High Temperature Inspection

• Developed phased array inspection system operating up to 350°C
Wedge, cabling, cooling jackets, couplant engineered to withstand elevated temperatures Positioning errors and degradation in focusing due to temperature dependent velocity gradient corrected by custom focal law exports

Phased Array Based Applications: Inspection of Hydro Turbine Blades

• Contracted to develop inspection procedure and calibration process for large hydro turbine blades
• Complex components with variable curvature requiring dozens of intricate scan plans
• Long travel paths required unique calibration block design
• Procedure used to perform ongoing inspections of newly welded components

PAUT Based Applications: Through Cap Inspection of Fillet Welds Using Flexible Polymer Wedges

• Technique developed using wedges made of flexible polymers to scan directly through the weld cap
• Focused ultrasonic beams (along nominal fusion faces and the center of weld) used for detection of fusion and volumetric defects
• Acceptable coupling achieved using a thin couplant layer pressed between the weld cap and the flexible wedge material
• Technique demonstrated by detection of incomplete weld penetration and crack like defects

Highlights of Projects
Phase Coherence Imaging (PCI) Based Applications Anomaly Detection UT Data Analysis Based Applications FMC/TFM Based Inspection Applications Phased Array Based Inspection Applications Wind Turbine Blade and Main Shaft Inspection Applications Software Based Solutions

For more information, email us at rad@acuren.com
or call (519) 372-1831 and ask for one of our innovation experts