An ultrasonic array is a single transducer that contains a number of individually connected elements. Recent years have seen a dramatic increase in the use of ultrasonic arrays for non-destructive evaluation. Arrays offer great potential to increase inspection quality and reduce inspection time. Their main advantages are their increased flexibility over traditional single element transducer methods, meaning that one array can be used to perform a number of different inspections, and their ability to produce immediate images of the test structure. These advantages have led to the rapid uptake of arrays by the engineering industry. These industrial applications are underpinned by a wide range of published research which describes new piezoelectric materials, array geometries, modelling methods and inspection modalities. The aim of this paper is to bring together the most relevant published work on arrays for non-destructive evaluation applications, comment on the state-of the art and discuss future directions. There is also a significant body of published literature referring to use of arrays in the medical and sonar fields and the most relevant papers from these related areas are also reviewed. However, although there is much common ground, the use of arrays in non-destructive evaluation offers some distinctly different challenges to these other disciplines.

Ultrasonic arrays for non-destructive evaluation: A review

Processing of ultrasonic array data is traditionally based on having parallel transmission circuits that enable staggered firing of transmitter elements to produce the desired wavefront. This paper describes an alternative approach in which the full matrix of time domain signals from every transmitter–receiver pair is captured and post-processed. Various post-processing approaches are modelled and assessed in terms of their ability to image a point-like reflector. Experimental results are then presented which show good quantitative agreement with the modelled results. An advanced processing algorithm is also implemented which allows the array to be focused at every point in the target region in both transmission and reception. This approach is shown to offer significant performance advantages for NDE.

Post-processing of the full matrix of ultrasonic transmit-receive array data for non-destructive evaluation

Review of progress, QNDE

Ultrasonic arrays allow a given scatterer to be illuminated from a wide range of angles and hence are capable of extracting significant information about the scatterer. In this paper a general imaging methodology, termed multi-mode total focusing method, is proposed in which any combination of modes and reflections can be used to produce an image of the test structure. Like the total focusing method, this approach is implemented by post-processing the full matrix of array data to achieve a synthetic focus at every pixel in the image. A hybrid model is used to predict the array data and demonstrate the performance of the multi-mode imaging concept. This hybrid model combines far field scattering coefficient matrices with a ray-based wave propagation model. This allows the inclusion of longitudinal waves, shear waves and wave mode conversions. It is shown that, with prior knowledge of likely scatterer location and orientation, the mode combination and array location can be optimised to maximise the performance of array inspections. A practically relevant weld inspection application is then described and its optimisation is discussed.

Defect detection using ultrasonic arrays: The multi-mode total focusing method

Ultrasonic imaging using full-matrix capture, e.g., via the total focusing method (TFM), has been shown to increase angular inspection coverage and improve sensitivity to small defects in nondestructive evaluation. In this paper, we develop a Fourier-domain approach to full-matrix imaging based on the wavenumber algorithm used in synthetic aperture radar and sonar. The extension to the wavenumber algorithm for full-matrix data is described and the performance of the new algorithm compared with the TFM, which we use as a representative benchmark for the time-domain algorithms. The wavenumber algorithm provides a mathematically rigorous solution to the inverse problem for the assumed forward wave propagation model, whereas the TFM employs heuristic delay-and-sum beamforming. Consequently, the wavenumber algorithm has an improved point-spread function and provides better imagery. However, the major advantage of the wavenumber algorithm is its superior computational performance. For large arrays and images, the wavenumber algorithm is several orders of magnitude faster than the TFM. On the other hand, the key advantage of the TFM is its flexibility. The wavenumber algorithm requires a regularly sampled linear array, while the TFM can handle arbitrary imaging geometries. The TFM and the wavenumber algorithm are compared using simulated and experimental data.

The wavenumber algorithm for full-matrix imaging using an ultrasonic array

Ultrasonic non-destructive testing of pieces of complex geometry with a flexible phased array transducer

Development of phased array techniques to improve characterization of defect located in a component of complex geometry

Application of phased array techniques to coarse grain components inspection

Real-time imaging, using ultrasound techniques, is a complex task in non-destructive evaluation. In this context, fast
 and precise control systems require design of specialized parallel architectures. Total focusing method (TFM) for ultrasound imaging has many advantages in terms of flexibility and accuracy in comparison to traditional imaging techniques. However, one major drawback is the high number of data acquisitions and computing requirements for this imaging technique. Due to those constraints, the TFM algorithm was earlier classified in the field of post-processing tasks. This paper describes a multi-FPGA architecture for real-time TFM imaging using the full matrix capture (FMC). In the acquisition process, data are acquired using a phased array and processed with synthetic focusing techniques such as the TFM algorithm. The FMC-TFM architecture consists of a set of interconnected FPGAs integrated on an embedded system. Initially, this imaging system was dedicated to data acquisition using a phased array. The algorithm was reviewed and partitioned to parallelize processing tasks on FPGAs. The architecture was entirely described using VHDL language, synthesized and implemented on a V5FX70T Xilinx FPGA for the control and high-level processing tasks and four V5SX95T Xilinx FPGAs for the acquisition and low-level processing tasks. The designed architecture performs real-time FMC-TFM imaging with a good characterization of defects.

Olivier Roy

Papers

Ultrasonic non-destructive testing of pieces of complex geometry with a flexible phased array transducer

Development of phased array techniques to improve characterization of defect located in a component of complex geometry

Application of phased array techniques to coarse grain components inspection

A multi-FPGA architecture-based real-time TFM ultrasound imaging

Control of the ultrasonic beam transmitted through an irregular profile using a smart flexible transducer: modelling and application.