What are Ultrasonic Phased Arrays?

Ultrasonic phased arrays use a multiple element probe whereby the output pulse from each element is
time delayed in such a way so as produce constructive interference at a specific angle and a specific
depth. These time delays can be incremented over a range of angles to sweep the beam over the
desired angular range. For example, 40 to 75 degree beam sweep would be produced by calculating the
time delays to produce constructive interference at 40, 41, 42 ...75 degs. This NDT technology is also
referred as Swept Beam Ultrasonic testing. The main advantages of phased array in NDE are:
1. Ability to sweep a range of angles
2. Ability to display the image in real time for the swept angles
3. Ability to focus

The above figure displays the concept of phased arrays. Time delays to the eight elements control
focusing and beam sweep. Focal spot size (shown by the shaded orange area) is controlled by beam
spread.

Checking Phased Array Probe Resolution. Resolution determines flaw definition and sizing
accuracy. Instrument: Phasor
PHASED ARRAYS FOR WELD INSPECTION
The concept of weld inspection is shown below. A probe is selected that illuminates the weld as shown

below. In the first leg, only the bottom half of the weld is illuminated. However, with reflection from
the ID surface the entire weld is illuminated and the complete weld volume can be inspected. For
example, the indication a in the weld is detected by the reflected sound and displayed as the mirror
image a- in the second leg. Similarly other flaws are displayed in the image.

Concept of phased arrays for Weld Inspection. Indication a detected by the reflected beam is
displayed as a mirror image a- in second leg
Examples of defects images detected in welds are shown below.

Root detected in first leg.

Image shows a strong ID crack signal

PHASED ARRAY TECHNOLOGY

The laws of physics apply to phased array as well as to classical ultrasonic testing.
Element Size: Maximum Sweep Range of Phased Arrays is determined by the element size. This is done
using the classical UT formula for calculating beam spread (). Smaller the element size, higher is the

sweep range. This is what gives Phased Arrays the ability to sweep large angles. Once the desired beam
sweep is achieved there is little point using smaller elements. A 5 MHz, 1mm element size will give an
approximate sweep of 70 degrees for S-wave in steel and 140 degrees for L-waves in steel. Reducing
the element size and thereby increasing the number of elements is of no significant benefit thereafter.
Focal limit is based on the wavelength and overall aperture of the probe. Same formulas apply as that
of classical UT probes. No focusing is possible beyond the near field. The near field of a 5 MHz, 12 mm
aperture probe using shear waves in steel is 60 mm.
Focal Spot Size The focal spot size is determined using the classical beam spread () formulas. The
focal spot size depends on the wavelength and probe aperture. The spot size becomes sharper with
reduced focal length (F), increased probe aperture and increased frequency. Distortion of focal spot
can occur from refraction and reduced elements.
Sin -6 = 0.51/D -6 is the half angle at the 6 dB drop points of the echo field
Sin -20 = 0.87/D -20 is the half angle at the 20 dB drop points of the echo field
A hole in a calibration block will show as an arc on the PAUT image and not as a hole (see the picture
below). This is because of the beam spread. Even if the beam is focused at the hole location, the beam
finite focal spot size controls the size measured by phased arrays.
PHASED ARRAY UT vs MANUAL UT
1. Manual UT produces a single A-scan at a specific angle. Manual UT evaluation requires plotting the
indication using the refracted angle, metal path and surface distance. PAUT displays images in real
time showing the depth and location of indication relative to the probe.
2. Manual UT is limited to a single refracted angle. PAUT simultaneously takes data from a range of
angles, eg 40 to 75 degrees and reconstructs an image in real time
3. PAUT image is easy to comprehend as it gives a display of the ultrasound superimposed on the test
piece
4. Using an encoder with the PAUT probe, all raw A-scan data can be stored. Once stored, the data can
be replayed. This is most important to retain a complete record of the inspection. There is no data
storage capability in manual UT.
PHASED ARRAY UT vs Automated UT (AUT)
1. AUT reconstructs the test piece cross-section (B-scan) after taking data using a single refracted
angle and scanning it back and forth on the test piece. PAUT reconstructs such image from a single
probe location with no scanning.
2. In many cases, especially for thin plates, a single line scan will perform the inspection. AUT always
requires either a 2-axis scan or multiple probes to reconstruct the image. Line scan done with PAUT
scanning is much simpler than raster scanning.
3. On applications that require16 to 32 probes with AUT, PAUT can be done with significantly lesser
number of probes, eg. one array on either side of the weld.
4. PAUT requires significantly less inspection space for scanning compared to AUT.
5. Both PAUT and AUT store raw A-scan data that can be replayed for analysis

Calibration on 1.6 mm dia side drilled holes using the Omniscan

FAQ on Phased Arrays
Q1. Which probe has a sharper focus: 16 mm aperture or a 12 mm aperture (both probes have same
frequency and number of elements).
A1. Focusing depends directly on the aperture. So the 16 mm has a sharper focus than the 12 mm
probe.
Q2. Which 5 MHz Probe has a sharper focus: (a)16 mm aperture-16 element or (b) 12 mm aperture -32
element.
A2. The 16 element probe (16 mm aperture) has a sharper focus than the 32 element (12 mm aperture)
probe. The increase in elements from 16 to 32 has a minimal effect on focusing. Sharper focusing is
from the larger aperture 16 mm vs 12 mm
Q3. If the 16 mm aperture-16 element probe has a sharper focus than the 12 mm aperture -32
element, then is there any advantage of using a more elements.
A3. The larger elements transforms to smaller element size. Smaller the element size greater is the
beam sweep. However, once the desired beam sweep is achieved there is minimal advantage of
increasing the elements. A 5 MHz, 1mm element size will give an approximate sweep of 70 degrees for
S-wave in steel and 140 degrees for L-waves in steel (based on 20 dB drop points).
Q4. Is it possible to focus past the near field ?
A4. No.
Q5. The software of my equipment allows me to enter a focal length that is greater than the near field.
Is that valid ?
A5. This entry will be meaningless.
Q6. Can the inspection be done past the focal length ?
A6. Yes inspection can be done; however there will be loss of resolution past the focal length.

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