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Review of Phased Array Ultrasonic Testing of Weld Joints

Year 2024, Volume: 4 Issue: 2, 77 - 92, 25.12.2024
https://doi.org/10.58771/joinmet.1525521

Abstract

Welding is a prevalent joining technique used on metals in industrial manufacturing. It is very important to detect welding defects that may occur without damaging the welding constructions. The conventional ultrasonic inspection is the most widely used non-destructive test method for the detection of weld defects. Phased Array Ultrasonic Testing (PAUT) is a significant method within the category of ultrasonic non-destructive testing methods because ultrasonic phased arrays offer significant technical advantages over conventional ultrasonic methods such as improved sensitivity, accurate characterization and faster inspection. The aim of this article is to provide a comprehensive review on analysing defects in welded joints by utilizing PAUT. Different studies in the literature related to the non-destructive testing of weld joints by PAUT have been reviewed. Various examples of how the type, depth, and size of welding defects are detected in a highly effective manner have been provided. As a result, it was concluded that phased array ultrasonic testing is a highly efficient technique compared to conventional ultrasonic methods for detecting welding defects.

References

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  • Arandjelovic, M., Djordjevic, B., Sedmak, S., Radu, D., Petrovic, A., Dikic, S., & Sedmak, A. (2024). Failure analysis of welded joint with multiple defects by extended Finite Element Method and Engineering Critical Analysis. Engineering Failure Analysis, 160. https://doi.org/10.1016/j.engfailanal.2024.108176
  • Bouzenad, A. E., Yaacoubi, S., Montresor, S., & Bentahar, M. (2022). A model-based approach for in-situ automatic defect detection in welds using ultrasonic phased array. Expert Systems with Applications, 206. https://doi.org/10.1016/j.eswa.2022.117747
  • Chabot, A., Laroche, N., Carcreff, E., Rauch, M., & Hascoët, J. Y. (2020). Towards defect monitoring for metallic additive manufacturing components using phased array ultrasonic testing. Journal of Intelligent Manufacturing, 31(5), 1191–1201. https://doi.org/10.1007/s10845-019-01505-9
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  • Deepesh, V., Purushothaman, A. V., Muthukumaran, S., & Sastikumar, D. (2019). Application of advanced volumetric non-destructive evaluation methods for the analysis of friction welded tube-to-tube plates using an external tool. Materials Today: Proceedings, 27, 2218–2224. https://doi.org/10.1016/j.matpr.2019.09.100
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  • Fu, Y., Wu, J., Liu, Z., Wang, R., Jiang, B., & Wen, W. (2019). Phased array ultrasonic test of vertical defect on butt-joint weld of CFETR vacuum vessel port stub. Fusion Engineering and Design, 141, 1–8. https://doi.org/10.1016/j.fusengdes.2019.02.010
  • Gao, C. X., Zhu, W. F., Xiang, Y. X., Zhang, H. Y., Fan, G. P., & Zhang, H. (2024). Ultrasonic Phased Array Imaging for Defects in Angle Blind Spots Based on the Solid Directivity Function. Journal of Nondestructive Evaluation, 43(1). https://doi.org/10.1007/s10921-023-01040-x
  • Hampson, R., Zhang, D., Gachagan, A., & Dobie, G. (2022). Modelling and characterisation ultrasonic phased array transducers for pipe inspections. International Journal of Pressure Vessels and Piping, 200. https://doi.org/10.1016/j.ijpvp.2022.104808
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  • Huggett, D. J., Dewan, M. W., Wahab, M. A., Okeil, A., & Liao, T. W. (2017). Phased Array Ultrasonic Testing for Post-Weld and OnLine Detection of Friction Stir Welding Defects. Research in Nondestructive Evaluation, 28(4), 187–210. https://doi.org/10.1080/09349847.2016.1157660
  • Inês Silva, M., Malitckii, E., Santos, T. G., & Vilaça, P. (2023). Review of conventional and advanced non-destructive testing techniques for detection and characterization of small-scale defects. In Progress in Materials Science (Vol. 138). Elsevier Ltd. https://doi.org/10.1016/j.pmatsci.2023.101155
  • Javadi, Y., Sweeney, N. E., Mohseni, E., MacLeod, C. N., Lines, D., Vasilev, M., Qiu, Z., Vithanage, R. K. W., Mineo, C., Stratoudaki, T., Pierce, S. G., & Gachagan, A. (2020). In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding. Materials and Design, 195. https://doi.org/10.1016/j.matdes.2020.108981
  • Jayasudha, J. C., & Lalithakumari, S. (2022). Weld defect segmentation and feature extraction from the acquired phased array scan images. Multimedia Tools and Applications, 81(21), 31061–31074. https://doi.org/10.1007/s11042-022-13030-8
  • Jodhani, J., Handa, A., Gautam, A., Ashwni, & Rana, R. (2023). Ultrasonic non-destructive evaluation of composites: A review. Materials Today: Proceedings, 78, 627–632. https://doi.org/10.1016/j.matpr.2022.12.055
  • Kumar, S., Menaka, M., Venkatraman, B. (2022). Dual Matrix Array Probe Based Phased Array Ultrasonic Testing for Inspection of Trimetallic Weld Joints.Transactions of the Indian Institute of Metals. Volume 75, pages 1573–1582, (2022)
  • Kim, Y. H., & Lee, J. R. (2024). Automated data evaluation in phased-array ultrasonic testing based on A-scan and feature training. NDT and E International, 141. https://doi.org/10.1016/j.ndteint.2023.102974
  • Kong, Y., Bennett, C. J., & Hyde, C. J. (2020). A review of non-destructive testing techniques for the in-situ investigation of fretting fatigue cracks. In Materials and Design (Vol. 196). Elsevier Ltd. https://doi.org/10.1016/j.matdes.2020.109093
  • Li, W., Zhang, W., Yang, G., & Chen, G. (2024). Application research on ultrasonic phased array detection algorithm for austenitic stainless steel with V-groove weld. Measurement: Journal of the International Measurement Confederation, 226. https://doi.org/10.1016/j.measurement.2024.114169
  • Li, W., Zhou, Z., & Li, Y. (2019). Inspection of butt welds for complex surface parts using ultrasonic phased array. Ultrasonics, 96, 75–82. https://doi.org/10.1016/j.ultras.2019.02.011
  • Mandache, C., Levesque, D., Dubourg, L., & Gougeon, P. (2012). Non-destructive detection of lack of penetration defects in friction stir welds. Science and Technology of Welding and Joining, 17(4), 295–303. https://doi.org/10.1179/1362171812Y.0000000007
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  • Mohseni, E., Javadi, Y., Sweeney, N. E., Lines, D., MacLeod, C. N., Vithanage, R. K. W., Qiu, Z., Vasilev, M., Mineo, C., Lukacs, P., Foster, E., Pierce, S. G., & Gachagan, A. (2021). Model-assisted ultrasonic calibration using intentionally embedded defects for in-process weld inspection. Materials and Design, 198. https://doi.org/10.1016/j.matdes.2020.109330
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Kaynaklı Birleştirmelerde phased array ultrasonik tekniğinin kullanımı Hakkında Derleme

Year 2024, Volume: 4 Issue: 2, 77 - 92, 25.12.2024
https://doi.org/10.58771/joinmet.1525521

Abstract

Endüstriyel imalatlarda metallerin birleştirilmesi amacıyla en yaygın kullanılan birleştirme tekniği, kaynaktır. Kaynaklı imalatların kaynak bölgelerinde oluşabilecek kaynak kusurlarının, önceden tespit edilmesi en önemli mühendislik süreçlerinden birisidir. Konstrüksiyona zarar vermeden kaynak kusurlarının tespit edilmesi amacıyla en yaygın kullanılan tahribatsız muayene yöntemi ise ultrasonik muayene tekniğidir (UT). Son yıllarda ultrasonik muayene teknikleri arasında hacimsel kaynak kusurlarının tespitinde en yaygın kullanılan tekniklerden birisi de phased array ultrasonik tekniğidir (PAUT). Bu tekniğin geleneksel ultrasonik muayeneye tekniklerine göre tercih edilmesinin başlıca sebepleri şunlardır: Daha ileri seviyede geliştirilmiş kusur tespit hassasiyeti, kusurların daha doğru ve net tespit edilebilmesi, çok daha geniş bir bölgenin daha hızlı bir şekilde muayene taramasının yapılabilmesi. Bu makalenin amacı kaynaklı konstrüksiyonlarda meydana gelebilecek hacimsel kaynak kusurlarının PAUT ile tespiti hakkında kapsamlı bir inceleme yapmaktır. Çeşitli literatür çalışmaları incelenerek, PAUT analizlerinin nasıl yapıldığı ile ilgili bilgi vermektir. Bu tekniğin geleneksel ultrasonik yöntemlere göre kaynak kusur türlerinin tespit edilmesinde, hataların boyutu, şekli ve derinliği ile ilgili bilgilerin elde edilmesinde ne kadar hassas, etkin ve verimli olduğunu göstermektir. Sonuç olarak, kaynak kusurlarının hacimsel tespitinde phased array ultrasonik muayenesinin, geleneksel ultrasonik tekniklere göre çok daha verimli, hızlı ve doğru analiz yapılabilmesi imkânını sağlayan bir teknik olduğu değerlendirilmiştir.

References

  • Ali, A. J., Jellani, A., Wadood, A., & Hussain, S. W. (2023). Challenges Associated to Uultrasonic Techniques in Characterization of Friction Stir Weld Defects in 27 mm Thick Al 6061-O Plates. Russian Journal of Nondestructive Testing, 59(1), 40–53. https://doi.org/10.1134/S1061830922600678
  • Arandelovic, M., Sedmak, S., Jovicic, R., Kozak, D., & Dordevic, B. (2021). Numerical simulation of crack growth in a welded joint with defects. Procedia Structural Integrity, 33(C), 850–857. https://doi.org/10.1016/j.prostr.2021.10.095
  • Arandjelovic, M., Djordjevic, B., Sedmak, S., Radu, D., Petrovic, A., Dikic, S., & Sedmak, A. (2024). Failure analysis of welded joint with multiple defects by extended Finite Element Method and Engineering Critical Analysis. Engineering Failure Analysis, 160. https://doi.org/10.1016/j.engfailanal.2024.108176
  • Bouzenad, A. E., Yaacoubi, S., Montresor, S., & Bentahar, M. (2022). A model-based approach for in-situ automatic defect detection in welds using ultrasonic phased array. Expert Systems with Applications, 206. https://doi.org/10.1016/j.eswa.2022.117747
  • Chabot, A., Laroche, N., Carcreff, E., Rauch, M., & Hascoët, J. Y. (2020). Towards defect monitoring for metallic additive manufacturing components using phased array ultrasonic testing. Journal of Intelligent Manufacturing, 31(5), 1191–1201. https://doi.org/10.1007/s10845-019-01505-9
  • Deepak, J. R., Bupesh Raja, V. K., Srikanth, D., Surendran, H., & Nickolas, M. M. (2021). Non-destructive testing (NDT) techniques for low carbon steel welded joints: A review and experimental study. Materials Today: Proceedings, 44, 3732–3737. https://doi.org/10.1016/j.matpr.2020.11.578
  • Deepesh, V., Purushothaman, A. V., Muthukumaran, S., & Sastikumar, D. (2019). Application of advanced volumetric non-destructive evaluation methods for the analysis of friction welded tube-to-tube plates using an external tool. Materials Today: Proceedings, 27, 2218–2224. https://doi.org/10.1016/j.matpr.2019.09.100
  • Drinkwater, B. W., & Wilcox, P. D. (2006). Ultrasonic arrays for non-destructive evaluation: A review. In NDT and E International (Vol. 39, Issue 7, pp. 525–541). https://doi.org/10.1016/j.ndteint.2006.03.006
  • Duernberger, E., MacLeod, C., Lines, D., Loukas, C., & Vasilev, M. (2022). Adaptive optimisation of multi-aperture ultrasonic phased array imaging for increased inspection speeds of wind turbine blade composite panels. NDT and E International, 132. https://doi.org/10.1016/j.ndteint.2022.102725
  • Feng, L., & Qian, X. (2020). Enhanced sizing for surface cracks in welded tubular joints using ultrasonic phased array and image processing. NDT and E International, 116. https://doi.org/10.1016/j.ndteint.2020.102334
  • Fu, Y., Wu, J., Liu, Z., Wang, R., Jiang, B., & Wen, W. (2019). Phased array ultrasonic test of vertical defect on butt-joint weld of CFETR vacuum vessel port stub. Fusion Engineering and Design, 141, 1–8. https://doi.org/10.1016/j.fusengdes.2019.02.010
  • Gao, C. X., Zhu, W. F., Xiang, Y. X., Zhang, H. Y., Fan, G. P., & Zhang, H. (2024). Ultrasonic Phased Array Imaging for Defects in Angle Blind Spots Based on the Solid Directivity Function. Journal of Nondestructive Evaluation, 43(1). https://doi.org/10.1007/s10921-023-01040-x
  • Hampson, R., Zhang, D., Gachagan, A., & Dobie, G. (2022). Modelling and characterisation ultrasonic phased array transducers for pipe inspections. International Journal of Pressure Vessels and Piping, 200. https://doi.org/10.1016/j.ijpvp.2022.104808
  • Haque, S. R. (2023). Investigation on welding defects of alloys using TIG and MIG welding. Hybrid Advances, 3, 100066. https://doi.org/10.1016/j.hybadv.2023.100066
  • Harara, W., & Altahan, A. (2018). Attempt Towards the Replacement of Radiography with Phased Array Ultrasonic Testing of Steel Plate Welded Joints Performed on Bridges and Other Applications. Russian Journal of Nondestructive Testing, 54(5), 335–344. https://doi.org/10.1134/S1061830918050054
  • Hu, D., Wang, Q., Xiao, K., & Ma, Y. (2012). Ultrasonic phased array for the circumferential welds safety inspection of urea reactor. Procedia Engineering, 43, 459–463. https://doi.org/10.1016/j.proeng.2012.08.079
  • Huggett, D. J., Dewan, M. W., Wahab, M. A., Okeil, A., & Liao, T. W. (2017). Phased Array Ultrasonic Testing for Post-Weld and OnLine Detection of Friction Stir Welding Defects. Research in Nondestructive Evaluation, 28(4), 187–210. https://doi.org/10.1080/09349847.2016.1157660
  • Inês Silva, M., Malitckii, E., Santos, T. G., & Vilaça, P. (2023). Review of conventional and advanced non-destructive testing techniques for detection and characterization of small-scale defects. In Progress in Materials Science (Vol. 138). Elsevier Ltd. https://doi.org/10.1016/j.pmatsci.2023.101155
  • Javadi, Y., Sweeney, N. E., Mohseni, E., MacLeod, C. N., Lines, D., Vasilev, M., Qiu, Z., Vithanage, R. K. W., Mineo, C., Stratoudaki, T., Pierce, S. G., & Gachagan, A. (2020). In-process calibration of a non-destructive testing system used for in-process inspection of multi-pass welding. Materials and Design, 195. https://doi.org/10.1016/j.matdes.2020.108981
  • Jayasudha, J. C., & Lalithakumari, S. (2022). Weld defect segmentation and feature extraction from the acquired phased array scan images. Multimedia Tools and Applications, 81(21), 31061–31074. https://doi.org/10.1007/s11042-022-13030-8
  • Jodhani, J., Handa, A., Gautam, A., Ashwni, & Rana, R. (2023). Ultrasonic non-destructive evaluation of composites: A review. Materials Today: Proceedings, 78, 627–632. https://doi.org/10.1016/j.matpr.2022.12.055
  • Kumar, S., Menaka, M., Venkatraman, B. (2022). Dual Matrix Array Probe Based Phased Array Ultrasonic Testing for Inspection of Trimetallic Weld Joints.Transactions of the Indian Institute of Metals. Volume 75, pages 1573–1582, (2022)
  • Kim, Y. H., & Lee, J. R. (2024). Automated data evaluation in phased-array ultrasonic testing based on A-scan and feature training. NDT and E International, 141. https://doi.org/10.1016/j.ndteint.2023.102974
  • Kong, Y., Bennett, C. J., & Hyde, C. J. (2020). A review of non-destructive testing techniques for the in-situ investigation of fretting fatigue cracks. In Materials and Design (Vol. 196). Elsevier Ltd. https://doi.org/10.1016/j.matdes.2020.109093
  • Li, W., Zhang, W., Yang, G., & Chen, G. (2024). Application research on ultrasonic phased array detection algorithm for austenitic stainless steel with V-groove weld. Measurement: Journal of the International Measurement Confederation, 226. https://doi.org/10.1016/j.measurement.2024.114169
  • Li, W., Zhou, Z., & Li, Y. (2019). Inspection of butt welds for complex surface parts using ultrasonic phased array. Ultrasonics, 96, 75–82. https://doi.org/10.1016/j.ultras.2019.02.011
  • Mandache, C., Levesque, D., Dubourg, L., & Gougeon, P. (2012). Non-destructive detection of lack of penetration defects in friction stir welds. Science and Technology of Welding and Joining, 17(4), 295–303. https://doi.org/10.1179/1362171812Y.0000000007
  • Ménard, C., Robert, S., Miorelli, R., & Lesselier, D. (2020). Optimization algorithms for ultrasonic array imaging in homogeneous anisotropic steel components with unknown properties. NDT and E International, 116. https://doi.org/10.1016/j.ndteint.2020.102327
  • Mirmahdi, E., Afshari, D., & Karimi Ivanaki, M. (2023). A Review of Ultrasonic Testing Applications in Spot Welding: Defect Evaluation in Experimental and Simulation Results. In Transactions of the Indian Institute of Metals (Vol. 76, Issue 6, pp. 1381–1392). https://doi.org/10.1007/s12666-022-02738-8
  • Mirmahdi, E., Khamedi, R., Afshari, D., & Khosravi, M. (2023). Investigating the Effects of Defects and the Effect of Geometric Anisotropy in Stainless Steel Pipes: Phased Array Ultrasonic Test, SH-wave. Journal of Pipeline Science and Engineering, 3(4). https://doi.org/10.1016/j.jpse.2023.100140
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There are 48 citations in total.

Details

Primary Language English
Subjects Resource Technologies
Journal Section Review Articles
Authors

Hüseyin Uzun 0000-0003-0137-6141

Desi Gustiani 0009-0001-5357-0475

Publication Date December 25, 2024
Submission Date July 31, 2024
Acceptance Date December 17, 2024
Published in Issue Year 2024 Volume: 4 Issue: 2

Cite

APA Uzun, H., & Gustiani, D. (2024). Review of Phased Array Ultrasonic Testing of Weld Joints. Journal of Marine and Engineering Technology, 4(2), 77-92. https://doi.org/10.58771/joinmet.1525521