Industrial Application Note
Rev. 2002-01

General Description of the Application

The bar manufacturing process generates typi­cal defects due to the fast production speed, the control casting process, the extrusion, and the finishing treatment. Online testing of bar products is needed early in the produc­tion to ensure the control of the process as well as the quality of the product. Testing should not only give accept/reject indica­tions; it should also help to control the qual­ity of the interior and the surface of the prod­uct, and provide real-time information on the manufacturing process.
The quality of the inspection is increasing due to new regulations and control levels. Different standards and codes apply for a same product depending on the type of industry it is destined to: automobile, aero­space, energy, and construction.
The new solution offered by R/D Tech uses the phased-array technology to ensure high-quality inspection. This technology offers a solution to meet the more demanding requirements to detect smaller defects while speeding up the inspection process.

Parts to Inspect
This system was designed for the online inspection of bars during the manufacturing process using the phased-array technology.
• Diameters ranging from 14 mm to 75 mm
    (0.55 in. to 3 in.)
• Carbon steel and stainless steel products

System Capability
• Volume inspection to detect small defects 0.35 mm x 5 mm
• Surface inspection
• High-speed inspection >1 m/s
• Fully automated inspection controlled by computer




Specialized mechanics for the inspection of small diameter (10 mm to 50 mm) bars to detect small defects (0.35 mm x 5 mm) in volume at high speed (>1 m/s).

Typical Inspection Requirements

Defects to Be Detected

Description of the Solution

Acoustic approach for the inspection of bars
• Four phased-array probes covering each 90 degrees
• High-accuracy centering during inspection
• Beam focus at different depth according to the diameter of the bar
• Electronic beam rotation for 360 degrees
• One set of four phased-array probes to cover a diameter variation of 25 mm

Mechanical requirements
• Cover diameters ranging from 10 mm to 100 mm
• Water cell for local immersion
• Continuous inspection with minimum end of bar untested
• Four degrees of freedom to adapt to tube movement
• Water cell with unique auto centering capabil­ity
• Positioning table to adapt to all diameters
• Pinch roller and automation with PLC to close and open powerful roller


Electronic scanning with a virtual aperture
of 16 elements moving along the length of the probe.

Curved phased-array probe covering 90 degrees of bar.


Electronic scanning with two angles for bar inspection: 0° LW and 40° SW. Electronic focusing at different depths to accommodate different diameters.


Two motorized pinch rollers on each side Cassette with autocentering device of the immersion tank. The immersion tank is equipped with two cassettes holding two phased-array probes each. The immersion tank includes a water management system at both ends.

Software
• Dedicated software with bar wizard, and oper­ator and supervisor levels
• Setup loading for complete system configura­tion
• Bar wizard for new bar diameter and wall thickness
• Electronic scanning function for sensitivity adjustment for each probe
• Automatic calibration sequence
• Data available on Microsoft® Access data table
• A-scan display and strip chart

Performance of the System
Defect detection

• Defect FBH 0.7 mm with SNR >15 dB
• Defect 0.35 mm x 5 mm with SNR >12 dB
• Inspection speed: 1.2 m/s
• End of bar not inspected: <10 mm
• Setup loading for each diameter
• Focusing at different depths according to the diameter of the bar to control
• Volume inspection with a focused ultrasound beam adapted to each diameter
• Inspection of surface defect using angle inspection; detection of surface defect 0.2 mm to 5 mm

Strip chart presentation of data from each probe.


Bar wizard to configure the setup for new bar diameter.

Strip chart showing FBH defect 0.35 mm.	For the supervisor level, A-scan, C-scan, and strip chart display. FBH 0.7 mm at different depths 2 mm to 15.5 mm with SNR from 10 dB to 15 dB.

System
• Cabinet
• 2 QuickScan PA 32:256
• PC and monitor
• Programmable logic controller (PLC)

Products used for this application

QuickScan PA
Designed for inline inspections, this rack-mountable high-speed R/D Tech phased array acquisition system offers solutions for various industrial applications such as ERW tube and full-body inspections.