Background removal and weld defect detection based on energy distribution of image

The lateral wave in ultrasonic TOFD （time of flight diffraction） image has a tail in transit time, which disturbs the detection and evaluation of shallow weld defect. Meanwhile, the lateral wave and back-wall echo that act as background add redundant data in digital image processing. In order to separate defect wave from lateral wave and prepare the way for following image processing, an algorithm of background removal method named as mean-subtraction is developed. Based on this, an improved method by statistic of the energy distribution in the image is proposed. The results show that by choosing proper threshold value according to the axial energy distribution of the image, the background can be removed automatically and the defect section becomes predominant. Meanwhile, diffractive wave of shallow weld defect can be separated from lateral wave effectively.

A novel technique for improving of ultrasonic TOFD data

Traditional ultrasonic TOFD （ time of flight diffraction） has the major shortcoming of low amplitude of diffractive wave which brings about lack of sensitivity for weld defect detection. Aimed at the technological limitation, a novel TOFD method is proposed by developing a focusing probe. Through the analyses and calculation of sound field distribution based on geometric acoustics, a cylindrical surface wedge is designed and produced. Artificial defect containing testing piece is made and tested using both traditional and focusing TOFD, and the received signal and image are compared. The result shows that the proposed focusing method can converge the emitted sound energy effectively and improve testing sensitivity greatly. Compared with traditional TOFD tested data, focusing TOFD tested defect wave in A-scan line and defect diffractive stripe in D-scan image can be identified easily.

Study and Evaluation of Advanced TOFD Method for Inspection of Polyethylene Pipes but Welding

Polyethylene material has some specification that makes very difficult any kind of inspection based on ultrasonic. The acoustic impedance and sound velocity in this kind of material are near to the materials commonly used in ultrasonic wedges. Also this kind of materials are highly attenuative materials for ultrasound. To inspection of polyethylene circumferential but welds and overcome to all the problems mentioned, the especial technique of TOFD （Time of Flight Diffraction） method which employs low frequency probe and concentrate on the inspection area that longitudinal waves turn into transverse waves has been used. The purpose of inspection is determining the exact location of surface and internal welding defects. For this purpose, two separate polyethylene pipes with 10 inch in diameter, 15 mm thickness and also 25 inch diameter, 28 mm thickness, were selected. In total 40 artificial defects which involve 28 side drill holes in deferent depths and 12 surface and sub-surface notches were created. All artificially created defects were detected with very good accuracy. Unlike the conventional TOFD method which have 2 to 3 mm dead zone, by using the above method even surface notch with 0.5 mm has been detected.