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Applications and Development of Ultrasonic Testing Technology
Release Date:
2021/12/18
1. Development of Ultrasonic Testing
Nondestructive testing using ultrasonic waves began in the 1930s. In 1929, Sokolov in the former Soviet Union employed ultrasonic techniques to detect internal defects in metallic objects. By the 1940s, Firestone in the United States introduced pulse-echo ultrasonic flaw detectors. By the 1960s, ultrasonic testing had become an effective and reliable nondestructive testing method and was widely adopted in industrial flaw detection. In the late 1980s, advances in computer and electronic technologies spurred the development of digital ultrasonic instruments, making test data more visual and precise. With the increasing level of industrial automation, nondestructive testing technologies can now be integrated into every stage of production, enabling online inspection. The gradual maturation of imaging technologies, phased-array technology, artificial intelligence, artificial neural networks, and adaptive techniques has further promoted the application and advancement of ultrasonic nondestructive testing.
Ultrasound refers to mechanical waves with frequencies greater than 20 kHz that can propagate through a continuous medium. Common ultrasonic testing methods include resonance testing, transmission testing, and pulse-echo testing.
When performing non-destructive testing using non-contact methods, the use of a couplant is intended to reduce ultrasonic wave attenuation at the interface between the transducer and the test surface, thereby enhancing penetration and improving inspection results. Common non-contact ultrasonic testing techniques include electromagnetic ultrasonic testing, air-coupled ultrasonic testing, and laser ultrasonic testing.
2. Applications of Ultrasonic Testing Technology
The advantages of ultrasonic testing in areas such as construction engineering, bearing condition monitoring, leak detection, and electrical testing effectively compensate for the shortcomings of traditional inspection methods, enabling ultrasonic testing to play its due role in preventive maintenance. For example:
2.1 Ultrasonic Testing for Concrete Defects
The fundamental principle underlying ultrasonic pulse testing for concrete defects is to assess such defects by analyzing relative changes in acoustic parameters—such as the travel time of the pulse wave, the amplitude of the received wave, and the frequency—under identical technical conditions. The velocity at which ultrasonic pulses propagate through concrete is directly related to its compactness: for concrete with a fixed mix proportion, age, and test distance, a higher sound velocity indicates greater compactness, whereas a lower velocity suggests reduced compactness. When voids or cracks are present, the integrity of the concrete is compromised, causing the ultrasonic pulse to bypass these discontinuities and reach the receiving transducer via an extended path. Consequently, the measured travel time increases, leading to an apparent increase in sound velocity or a decrease in the calculated velocity.
Based on the principles outlined above, a comprehensive analysis can be conducted by integrating measured concrete acoustic parameters with their relative changes to identify the location and extent of defects or to estimate their size. In the inspection work for the Binde Expressway project, the various measures and processing methods described above were employed to effectively address the challenge of blocked sonic logging tubes, thereby laying a solid foundation for the smooth progress of the project.
2.2 Bearing Condition Monitoring
Currently, ultrasonic testing is the most reliable method for detecting early-stage bearing damage. Ultrasonic signals precede increases in temperature or changes in power output; therefore, ultrasonic inspection can identify initial bearing fatigue, pitting and spalling on the raceway surfaces, and lubricant deficiency or excess. Ultrasonic testing allows simultaneous acoustic monitoring of the bearing and trend analysis. The frequency-modulation capability of ultrasonic testers enables easy tuning to the bearing’s characteristic frequency band and isolation of that signal, thereby minimizing noise interference during analysis. When testing bearings and rotating machinery, it is essential to establish a baseline sound level and define the acoustic environment, so that subsequent readings and sound signatures can be compared during monitoring to perform trend analysis.
2.3 Electrical Testing
Early detection of partial discharge in electrical equipment plays a crucial role in ensuring the safety of the equipment itself.
Common partial-discharge faults in electrical equipment include corona discharge, arc discharge, and tracking. Corona discharge and early-stage tracking do not generate heat and therefore cannot be detected with an infrared thermal imager; however, they do produce ultrasonic signals, which can be detected remotely using an ultrasonic detector. Arc discharge and severe tracking, on the other hand, generate both ultrasonic signals and heat, so they can be tested using either infrared or ultrasonic methods. Nevertheless, when partial discharge occurs inside the equipment, it cannot be detected by infrared imaging. It is thus evident that ultrasonic detectors can identify ultrasonic signals caused by insulation damage and loose connections even before an infrared thermometer can detect a temperature rise.
When ultrasonic testing instruments are used to inspect electrical equipment such as high-voltage transmission insulators, transformers, and switchgear, their sensitivity is exceptionally high. When the air surrounding an insulator becomes ionized, chemical reactions can occur, leading to corrosion of metal components and a reduction in the insulating performance of the insulator. Ultrasonic testing systems can enhance insulation inspection by detecting fault-related acoustic signals from insulators, bushings, transformers, terminal assemblies, lightning arresters, and other equipment.
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