1. A high level inspection method with a handy instrument
AMSTERDAM
TECHNOLOGY
NDT Scan Solutions
Introduction spot- and projection weld inspection with the Mini Scanner
A high level inspection method with a handy instrument

2. AMSTERDAM
TECHNOLOGY
Raised in 2006 by:
vAmsterdam SES Software, Engineering and Systems for ultrasonic and Eddy Current inspection machines
Technolothgy BV Engineering of special machines and instruments for Non Destructive Technology

3. Overview of build immersion tank based inspection machines

4. Immersion tank scanners
Ultrasonic
Immersion tank scanners
High resolution
Complex shaped products
Focused transducers

5. Ultrasonic immersion tank scanner
A high quality inspection method
Practical inconveniences
Static position: The samples have to be transported to the scanner
The samples have to drown into the water
Limited tank dimensions
Time-consuming positioning of parts in the tank
Long inspection times
High investments

6. Project with DaimlerChrysler
Project description:
Design a portable ultrasonic scanner for spot weld inspection on location.
Specifications:
Short inspection time
No immersion of the inspected parts
High resolution C-scan presentation
For plate thickness from 0,5 mm
Handheld instrument

7. Mini Scanner A miniature “immersion tank” scanner.
The scanner head is filled with water and is sealed with a membrane.
Gel is used as an ultrasonic couplant.
Scan area: 10 x 20 mm
Resolution: 0,1 x 0,1 mm
Scan time: < 5 seconds

8. Diagram spot weld testing with the Mini Scanner
Red gate; sets the start position of the yellow gate
Yellow gate; In this area the maximum amplitude of the ultrasonic signal is measured
Moving ultrasonic
transducer
A color related to the value of the maximal amplitude in the yellow gate, is set as a pixel in the C-scan for each scan point.
Water
chamber
Mini
Scanner
Couplant
( gel ) IE WE BE
A-scan
presentation
IE=Interface Echo
WE=Weld Echo
BE=Back Wall Echo
The C-scan is picture, composed by the 100 x 200 colored pixels as generated in each scan point.
C-scan presentation
® Patent pending / all rights by Amsterdam Technology bv

9. Scanning method
Focused ultrasonic transducer moves in a water filled compartment in the scanner head
35MHz ultrasonic transducer
Diameter focus point < 0,1mm
Membrane sealed water chamber
Spiral shaped scanning pattern
High scanning speed
Gel as ultrasonic couplant
® Patent pending

10. Exchangeable scan heads
Straight scan head for perpendicular scanner position.
Mirror based scan head for angles scanner position.
Used for difficult to reached spot weld position

11. Mini Scanner System Scanner with control unit PC platform Windows XP
Touch Screen
USB data exchange

12. Plate thickness first plate
Spot weld test
High tension steel plate
Test parameters:
Shape of the spot weld nugget
Shape of the pore
A-scan on cursor position
- besides the weld -
Plate thickness first plate
In the yellow gate: back wall echo of the first plate

13. Spot weld test A-scan on cursor position Thickness
High tension steel plate
Test parameter:
Thickness of the spot weld
A-scan on cursor position
- in the nugget -
Thickness
In the yellow gate: No weld echo (good welded in that position)
In green gate: Back wall echo of the spot weld

14. Depth of the pore in the spot weld
Spot weld test
High tension steel plate
Test parameters:
Size of the pore
Depth of the pore
A-scan on cursor position
On the edge of a
pore in the weld -
Depth of the pore in the spot weld
In the yellow gate: Echo of a pore

15. Spot weld test
High tension steel plate
Measuring dimensions:
Size of the nugget
By drawing an ellipse around the contour the dimension is calculated
Cursor controlled dimension measurement in C-scan.

16. Spot weld test Test parameters:
High tension steel plate
Test parameters:
Indentation measurement by Time Of Flight (TOF)
Time Of Flight
Indentation
Time Of Flight (TOF)
Reference: A-scan of position beside the spot weld.

17. Plate thickness first plate
Arplas weld
Steel plate
Test parameters:
Shape of the Arplas weld
A-scan on cursor position
- besides the weld -
Plate thickness first plate
In the yellow gate: back wall echo of the first plate

18. Arplas weld A-scan on cursor position Thickness weld
Steel plate
Test parameter:
Thickness of the Arplas weld
A-scan on cursor position
- on the weld -
Thickness weld
In the yellow gate: No weld echo (good welded in that position)
In green gate: Back wall echo of the spot weld

19. Arplas weld A-scan on cursor position
Steel plate
7,20
Test parameter:
Detail of the Arplas weld
Detecting dimensions
(By moving the cursor)
1,05
A-scan on cursor position
- on the edge of the weld -
In the yellow gate: 90% weld echo
(green-red colored pixel, on the edge of the weld)

20. Software
Storage of A-scans (ultrasonic signal) for each scanning point
After event data evaluation possible by gate repositioning
Ultrasonic settings storable as pre-set for typical applications
Numerical wall thickness indication
Direct C-scan presentation
Two C-scan presentations with independent gate settings
No picture processing for C-scan presentation

21. Application: Nut welding
Welded nut (round) Welded nut (square)
-- The Mini Scanner was placed on the flat plate side --

22. Application: laser welding
Laser weld round (Alu plate) Laser weld round (Alu plate)
-- The Mini Scanner was placed on the flat plate side --

23. Application: Rivet inspection
Rivet in gearbox part .
-- The Mini Scanner could be placed on both sides of the part --

24. Application: Porosity check HP casting
A-scan beside a pore A-scan on a pore
High pressure cast aluminum 2.0 mm thickness
Since the mini scanner is used in the field a lot of new applications are coming up.

25. Inspection with the Mini Scanner
Applications
Multiple plate weld inspection
Plate thickness 0,5 -8 mm with standard transducers.
Weld between plates and massive parts
Conditions:
Scan head has to be placed on a flat surface
Accessibility scanner to the product
Use of gel allowable
De mini scanner kan toegepast worden op

26. Practical limitations
Even the mini scanner is subject to the physical limitations caused by the properties of ultrasonic pulse echo techniques, such as:
Insufficient reflection of the ultrasonic echo’s
Caused by:
Disturbance by sharp edges around the weld
Raw or dirty surface
Scanner not good in position during scanning

27. Latest developments Smaller model scan unit Lower weight: -40 %
Reduced scan time: -20%

28. Concluding Handy ultrasonic C-scan device for detailed weld inspection
Multiple ultrasonic signal evaluation modes
Storage of all ultrasonic data
Improved welding process control possible by inspection on location