Determination of an Optimal Examination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings
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1 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings GZfP Committee Ultrasonic Testing Subcommittee Automated UT
2 Automated Shaft Inspection System Saarschmiede, Völklingen
3 Terms Inde direction y Scan direction d y d : Increment in scan direction (efined by pulse repetition rate and eamination speed) d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam d
4 Automatisierte isc Inspection System Schmiedewerke Gröditz
5 Automated Shaft Inspection System GE Sensing & Inspection Technologies, Alzenau
6 Automated Shaft Inspection System KARL EUTSCH Prüf- und Messgerätebau GmbH + Co KG, BGH Siegen
7 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
8 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
9 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Automated UT Required for heavy rotor forgings Limited optimization regarding flaw reflection Recorded in distinct pattern Full volume coverage required Multiple Scans Required by VGB-R 504 M High inspection duration Low Sound Attenuation Limited pulse repetition rates Limited inspection speed Cost of ultrasonic inspection depends directly on eamination grid (both in scanning and inde direction)
10 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
11 Requirements in Current Standards EN : Non-destructive testing of steel forgings Requirement Inde direction y Scan direction d y Overlap of at least 10% of the effective active element size No requirement in scan direction Issues for AutoUT Apparently assumes a high pulse-repetition-rate and slow probe movement. d Shape and size of the sound bundle not considered
12 Requirements in Current Standards EN 583-1: Ultrasonic eamination - General principles Requirement Based on size of -6 db beam y Requirement in scan and inde direction The beam of two adjacent -6 db beams have to touch d y Issues for AutoUT Some zones are not inspected with the required sensitivity No formulas provided how to determine an eamination grid d
13 Requirements in Current Standards ASTM E Ultrasonic Testing of Wrought Products Requirement Based on size of -6 db beam y Inde direction: Overlap of at least 20% of the effective beam width size Scan direction: Scanning speed limited by detectability of the reference reflectors d y Issues for AutoUT Some zones are not inspected with the required sensitivity No formulas provided how to determine an eamination grid d
14 Requirements in Current Standards Summary EN SEP1923 ASTM A 418 EN IIW Handbook Overlap of at least 10% of the effective active element size Overlap of at least 15% of the active element size Indeing by 75 % of the transducer width The beam of two adjacent - 6 db beams have to touch ASTM E 2375 Overlap of at least 20% of the effective beam width size No requirement in scan direction (or only by limitation of scanning speed) Overlap of the beams however not considering the volume to be inspected Unclear: Effective element size Transducer width Some zones are not inspected with the required sensitivity No formulas provided how to determine an eamination grid
15 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Automated UT Required for heavy rotor forgings Limited optimization regarding flaw reflection Recorded in distinct pattern Full volume coverage required Multiple Scans Required by VGB-R 504 M High inspection duration Low Sound Attenuation Limited pulse repetition rates Limited inspection speed Cost of ultrasonic inspection depends directly on eamination grid (both in scanning and inde direction) Motivation Eisting standards define eamination grids for manual inspection Not simply transferable to automated Start of development of an Optimal Eamination Grid for the Automated Ultrasonic Inspection
16 GZfP Committee Ultrasonic Testing Subcommittee Automated UT UT System Manufacturers Peter Archinger, GMH Prüftechnik, Nürnberg Otto Alfred Barbian, Blieskastel r. (USA) Wolfram eutsch, Karl eutsch, Wuppertal r. sc. techn. Peter Kreier, Innotest, Eschlikon/CH Roland Reimann, AREVA NP, Erlangen Udo Schlengermann, Erftstadt Herbert Willems, NT Syst. & Services, Stutensee Forging Manufacturers (Users) Kay rewitz, Schmiedewerke, Gröditz r.-ing. Aleander Zimmer, Saarschmiede, Völklingen OEM Frank W. Bonitz, Westinghouse, Mannheim Mathias Böwe, BASF SE, Ludwigshafen Klaus Conrad, Siemens AG Energy, Mülheim r.-ing. Werner Heinrich, Siemens AG Energy, Berlin r. Johannes Vrana, Siemens AG Energy, München Research Institutes r. Gerhard Brekow, BAM, Berlin Wolfgang Kappes, Fraunhofer IZFP, Saarbrücken Hans Rieder, Fraunhofer ITWM, Kaiserslautern
17 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
18 efinition of an Eamination Grid Situation Longitudinal Section Longitudinal section through adjacent beams Horizontal Section A: irectly at the probe B: At the end of the near field C: At 3.5 times near field
19 efinition of an Eamination Grid Normalized Grid Rating R n efinition of R n R n = 1 Gapless (at least single sampling) 1 R n = d d 2 y 2 y y d y d d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam
20 efinition of an Eamination Grid Normalized Grid Rating R n efinition of R n R n = 2 At least double sampling 1 R n = d d 2 y 2 y y d y d d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam
21 efinition of an Eamination Grid Normalized Grid Rating R n efinition of R n R n = 0,5 Beams touching R n = 1 - Gapless 1 R n = d d 2 y 2 y R n = 2 ouble Sampling R n = 4 Quadruple Sampling d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam Overlap:
22 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
23 efinition of an Eamination Grid Average Grid Rating R d efinition of R d Eample: R d = 1 R d = d d y y π 4 y -6 db beam Area of -6 db beam R d = Area of e. grid Eamintion Grid d y d d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam
24 efinition of an Eamination Grid Average Grid Rating R d efinition of R d R n = 1; R d 1.81 R n = 1; R d 1.57 R d = d d y y π 4 d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam Optimized Eamination Grid
25 efinition of an Eamination Grid Average Grid Rating R d efinition of R d R d = d d y y π 4 Optimized Eamination Grid Optimized eamination grid in the case of: d = y ( 2 R ) ( 2 R ) n and d = y n Optimizing the Eamination Grid durchschnittliche Average Grid Rating Rastergüte Rd Rd 10,00 9,00 8,00 7,00 6,00 5,00 4,00 3,00 2,00 1,00 0,00 0,00 0,10 0,20 0,30 0,40 0,50 0,60 0,70 0,80 0,90 1,00 d/ Rn = 1 Rn = 2 Rn = 3 Rn = 4 d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam
26 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
27 efinition of an Eamination Grid Situation Longitudinal Section Longitudinal section through adjacent beams Horizontal Section A: irectly at the probe B: At the end of the near field Grid Rating C: At 3.5 times near field 1 R n = d d 2 y 2 y R d = d d y y π 4
28 efinition of an Eamination Grid How to calculate the sound bundle Basic Situation Normal Straight Beam Probe on a Plane Surface = 2 s tan ( ϕ ) ual Element Probe on a Plane Surface = 2 FB y = 2 FL6 6 d : Increment in scan direction d y : istance between two adjacent laps in inde direction, y : imensions of the ultrasonic beam s: Soundpath FB 6, FL 6 : Focal Width & Length
29 efinition of an Eamination Grid Situation Scans ifferent scans required aial/ radial radial radial / aial radial / tangential radial radial / tangential aial aial / tangential aial/ radial
30 efinition of an Eamination Grid Situation Situation Plane Conve Concave Normal ual Element Angle
31 efinition of an Eamination Grid How to calculate the sound bundle Angle Probe on a Plane Surface Probe moved on the surface of the component Eamination grid d an d y established at the surface Beam changes within the part α ' = 2 s cos cos( α ) sin ( 2 ϕ) ( 2 ϕ) + cos( 2 α ) φ φ s For the calculation of the eamination grid the projection of the beam to the surface is necessary
32 efinition of an Eamination Grid How to calculate the sound bundle Angle Probe on a Plane Surface Probe moved on the surface of the component Eamination grid d an d y established at the surface Beam changes within the part ' = 2 s cos cos( α ) sin ( 2 ϕ) ( 2 ϕ) + cos( 2 α ) α = s ϕ y 2 tan ( ) φ φ s
33 efinition of an Eamination Grid Situation Situation Plane Conve Concave Normal ual Element Angle
34 efinition of an Eamination Grid How to calculate the sound bundle Normal Straight Beam Probe on Conve Surface = 2 s tan ( ϕ ) = s ϕ y 2 tan ( ) π = ± ϕ ' arcsin sin( ) ϕ 1 s 1 ual Element Probe on Conve Surface = 2 FB = 2 FL6 6 y Corrected by: ' = s
35 efinition of an Eamination Grid How to calculate the sound bundle Angle Probe on a Conve Surface E.g. from the outer diameter surface π 1 ' = arcsin sin( α ϕ) arcsin sin( α ϕ) 2 ϕ + ± r r ( 1 1 α ) with r = s + ( 2) 2 s ( 2) cos( ) 2sin( α + ϕ) for α > 0 1 and r 1 2 sin ϕ for α = 0 1 2sin α ϕ for α < 0 with ' in the case s > / 2 cos( α ) + and ' in the case s / 2 cos( α ) 1 1 ϕ ϕ - α = 2 s tan( ϕ ) y 1
36 efinition of an Eamination Grid Situation Situation Plane Conve Concave Normal ual Element Angle
37 efinition of an Eamination Grid How to calculate the sound bundle Normal Straight Beam Probe on Concave Surface = s ϕ y 2 tan ( ) π = ' arcsin sin( ) ϕ ϕ 2 s 2 ual Element Probe on Concave Surface = 2 FB y = 2 FL6 6 Corrected by: ' = 2 ( + 2 s) 2
38 efinition of an Eamination Grid How to calculate the sound bundle Angle Probe on a Concave Surface E.g. from the inner diameter surface π 2 ' = arcsin sin( α + ϕ) arcsin sin( α ϕ) 2 ϕ r + r ( 2 2 α ) with r = s + ( 2) + 2 s ( 2) cos( ) = 2 s tan( ϕ ) y
39 efinition of an Eamination Grid Situation Situation Plane Conve Concave Normal ual Element Angle
40 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
41 etermination of the Eamination Grid Necessary Specifications For each scan Normalized Grid Rating R n (gapless recommended) Eamination zone Minimum soundpath s 1 Maimum soundpath s 2
42 etermination of the Eamination Grid Necessary Specifications For each scan Normalized Grid Rating R n (gapless recommended) Eamination zone Minimum soundpath s 1 Maimum soundpath s 2 etermination of Eamination Grid Calculation of the projection of the sound bundle dimensions both for s 1 and s 2 s 1 : 1, y1 s 2 : 2, y2 Calculation of the optimized eamination grid both for s 1 and s 2 considering the specified normalized eamination grid rating R n s 1 : d 1, d y1 s 2 : d 2, d y2 Selection of the actually used eamination grid d and d y
43 etermination of the Eamination Grid etermination of Eamination Grid Calculation of the projection of the sound bundle dimensions both for s 1 and s 2 s 1 : 1, y1 s 2 : 2, y2 Calculation of the optimized eamination grid both for s 1 and s 2 considering the specified normalized eamination grid rating R n s 1 : d 1, d y1 s 2 : d 2, d y2 Selection of the actually used eamination grid d and d y Check of Eamination Grid OK if both selected values are not bigger than the calculated values d vs. d 1, d 2 d y vs. d y1, d y2 Otherwise needs to be tested by calculating R n using d and d y for both 1, y1 and 2, y2
44 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight
45 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight
46 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight
47 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight
48 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight
49 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
50 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
51 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y1 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
52 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
53 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
54 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
55 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
56 etermination of the Eamination Grid Eample isc 1 = 1500 mm, 2 = 300 mm, L = 300 mm Eamination Grid Scan s 1 s y1 y2 R n d 1 d 2 d y1 d y2 d d y R n1 R n2 (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) Faces, aial, straight Faces, aial/tang., O, radial, straight O, radial, straight, dual-element, O, radial/tang., O, radial/tang.,
57 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Introduction & Motivation Requirements in Current Standards efinition of an Eamination Grid Normalized Grid Rating R n Average Grid Rating R d etermination of the Ultrasonic Beam imensions etermination of the Eamination Grid Summary
58 etermination of an Optimal Eamination Grid for the Automated Ultrasonic Inspection of Heavy Rotor Forgings Summary Current standards Not sufficient for the determination of an eamination grid for automated UT New GZfP Guideline US 07 Harmonizes the calculation of the eamination grid efines Normalized Grid Rating Average Grid Rating How to calculate the UT beam dimensions Optimizes the inspection speed Can be adopted to other applications
59 π = ± ϕ ' arcsin sin( ϕ) 1 s 1 R n = d d 2 y 2 y π 1 ' = arcsin sin( α ϕ) arcsin sin( α ϕ) 2 ϕ + ± r r ( 1 1 α ) with r = s + ( 2) 2 s ( 2) cos( ) 2sin( α + ϕ) for α > 0 1 and r 1 2 sin ϕ for α = 0 1 2sin α ϕ for α < 0 with ' in the case s > / 2 cos( α ) + and ' in the case s / 2 cos( α ) 1 1 Thanks for paying attention to all the formulas ' = s ' = 2 s cos cos( α ) sin ( 2 ϕ) ( 2 ϕ ) + cos( 2 α ) R d = d d y y π 4
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