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The Impact of Ultrasonic Probe Wear on Ultrasonic Testing and Its Repair Methods
Release Date:
2022/09/01
During ultrasonic flaw detection, the angled ultrasonic probe experiences friction against the test workpiece during operation. Depending on operator habits, the characteristics of the workpiece being inspected, and the frequency of use, the probe will exhibit varying degrees of wear. Once worn, the probe’s original performance characteristics are compromised.
I. Wear Modes of Ultrasonic Probes
The following figure illustrates several common forms of wear encountered in practical work:
II. Influence of Wear on Ultrasonic Flaw Detection Results
As shown in the figure above, wear on the ultrasonic probe leads to changes in its original characteristics, primarily manifested in an increase or decrease in the refraction angle K-value, a shift in the sound-beam incidence point (the probe’s front edge), and alterations in coupling performance (for flat-surface flaw detection, coupling deteriorates as the probe wears; however, when inspecting pipes or bars, coupling improves as the contact area increases).
As the beam refraction angle and the incidence point vary, the depth and location of defects as displayed on the ultrasonic flaw detector will also change. If coupling deteriorates while the equipment’s coupling compensation remains constant, probe sensitivity will decrease; conversely, improved coupling will increase sensitivity.
If, due to personal habit, inspections are frequently conducted from a fixed side to the opposite side, this can lead to wear and misalignment of the ultrasonic probe, causing beam deviation and resulting in errors in defect localization.
Changes in material properties can easily lead to missed detections or misjudgments, introducing uncertainty into nondestructive testing.
In cases of mild wear, this deviation can be corrected by adjusting the ultrasonic flaw detector settings on the test block; however, severe wear cannot be compensated for merely by adjusting the instrument settings. In such instances, the ultrasonic transducer must be replaced or repaired to rectify the issue.
III. Repair of Ultrasonic Probes
After the inspection work has been carried out for a certain period, in addition to routine commissioning, the ultrasonic probe should be repaired or replaced based on its degree of wear.
If the ultrasonic probe is only slightly worn, it should be lapped on coarse sandpaper to ensure that the contact surface of the probe remains parallel to the upper plane of the workpiece. Following this rough machining, fine polishing with wet sandpaper should be performed to guarantee surface finish and coupling quality.
After repair, the probe’s front edge and K-value shall be calibrated using ultrasonic test blocks, and a new DAC curve shall be generated to ensure the accuracy of flaw detection data.
If the ultrasonic probe is severely worn, the excess material should be removed on a grinding wheel to ensure that the working surface is parallel to the top surface (the piezoelectric element must not be exposed), followed by polishing with coarse and fine sandpaper to achieve a smooth finish.
Since the angled wedges of currently used ultrasonic oblique probes are typically made of acrylic, the repair should be carried out using an acrylic plate that is slightly larger in size than the probe’s surface to be repaired and has a thickness of approximately 3–5 mm. The surface of the acrylic plate must be smooth and free of scratches. The ultrasonic probe and the acrylic plate are then bonded together using chloroform, clamped securely with a bench vise to ensure a strong bond, and allowed to dry. Finally, any excess acrylic material is trimmed away, completing the repair.
After repair, the ultrasonic probe shall have its front edge and K-value determined in accordance with the procedures for new probes, and a new DAC curve shall be generated.
The repair method for severe wear is also applicable to the fabrication of specialized ultrasonic transducers. For instance, when inspecting weld seams in seamless steel pipes, a curved surface that matches the geometry of the test material can be first bonded to the ultrasonic transducer to ensure optimal acoustic coupling and prevent missed defects.
IV. Calibration of the Ultrasonic Probe
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