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Non-Contact Ultrasound
CERAMIC ANALYSIS, INCLUDING
REFRACTORIES & FILTERS
Application Note AN-305-5
SecondWave™ M510 Ultrasonic Analysis System
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
2
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
SecondWave™ M510 shown with single and multi-channel transducers on different materials
Introduction
Contact or water immersion ultrasound does provide
significant information about materials quality and
properties. But, it cannot be applied to the early stages
of materials formation - when they are tacky or fragile.
It is also not reliable for materials that are porous, liquid
sensitive, or when any type of contact with a material is
cumbersome. Non-Contact Ultrasound (NCU) is the
most desirable choice for such applications.
Ultran has been working to facilitate NCU since 1978. In
1997, Ultran created internationally patented
piezoelectric transducers characterized by phenomenal
efficiency in air and other gases with frequencies from
50 kHz to 5.0 MHz. Complementing the NCU
transducers are Ultran’s equally novel ultrasonic imaging
systems and analyses software. The SecondWave™
M510 is a focused non-contact ultrasonic analysis
system that is customer-friendly and understands the
significance of materials testing and analysis, including
the speeds required to accomplish a task.
The M510 supports through transmission, same-side
and pulse-echo techniques. M510 single and multi-
channel systems have been fully configured and
installed for on-line (production line) and off-line (bench
top) analysis of green ceramics, green alumina,
refractory blocks, sintered ceramic tiles and compressed
powders.
M510 capabilities
High resolution detection of cracks and other
conditions in ceramic products
Green stage materials evaluation. Moisture estimation.
Determination of density/porosity, texture and other
properties
SecondWave™ M510 Components
NCU Transducers
Ultran’s transducers boast the highest efficiency devices
among non-contact transducers – approaching those of
conventional contact transducers. Frequency Range: 50
kHz - 5.0 MHz. Active dimensions: 1.0 mm - 500mm.
with planar, point, parabolic, and compound beam
geometry. Robust lightweight construction.
Scanning: Vertical or horizontal acoustic bench, single or
multi-transducer multi-axis scanning frames.
System Instrumentation
4U industrial grade unit incorporating Intel Core2 Quad
processors, 2 GB RAM, RAID5 Serial ATA hard drives and
redundant power supplies. Integrated are:
Pulser: PCI-based 375V RF toneburst pulser with 50 kHz
to 5 MHz range, adjustable bursts, voltage and PRF.
Receiver: Internal 1-8 channel low-noise amplifier with
80 dB gain and 10 MHz bandwidth, multi-value low and
high pass filters.
DAQ: 14 bit Analog to Digital Converter with 50 MHz
sample rate and on-board 256 MB storage. Multi-axis
encoder inputs for motion synchronized acquisition.
Software
SecondWave™ Studio: Windows XP-based A-Scan and
C-Scan software with user-friendly GUI. Displays rolling
single and multi-channel C-Scans. Capture and storage
of full-wave data for scans. Project Manager with
multiple access levels. SQL Database integration.
SecondWave™ Research Studio: C-Scan and A-Scan
post-processing software. Generates cross-sectional
material profiles. Parametric correlation to determine
material density, porosity and fiber orientation. Image
processing functions to find and highlight defects.
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
3
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Non-contact ultrasound techniques
Direct transmission
Same side transmitter-receiver – pitch-catch
T R
Longitudinal/Shear
Waves
Surface WavesAIR
Single transducer – pulse-echo
AIR
Quantitative detectability example
Defect, crack, delamination detection
Velocity, time-of-flight, thickness measurements
Oblique incidence & refraction for shear wave and
anisotropy measurements
Defect, delamination,
corrosion detection
Location of discontinuities
Surface profiling
Surface acoustic analysis
Reflectance measurements
Depth measurement
Object identification
Air + Test
Material
Transmission
Surface
Reflections
Thickness
Reflections
Detection of side drilled holes (varying
from 0.5 to 6.3 mm) in 10 mm PMMA
with direct NCU transmission – 1.0 MHz
Ultrasonic reflection image
AIR
T
R
AIR
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
4
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Observations and case studies by direct transmission and same side NCU imaging (All images generated without signal post-processing, and in most cases no signal averaging was used)
Green Ceramics: Density and moisture determination
Fig. 2. Moisture as a
function of time in
floor tile samples.
500 kHz
y = 536.21x - 190.68
R2 = 0.9751
700
720
740
760
780
800
820
840
860
1.65 1.7 1.75 1.8 1.85 1.9 1.95
Density (g/cc)
Velocity (m/s)
Fig. 1. Density of green
alumina from ultrasound
velocity - 500 kHz
Fig. 3. Density vs.
transmittance
relationship for
green and dry
samples of floor tiles
- 500 kHz
Fig. 4. Image of a
green floor tile,
presumably indicating
subtle density
variations
500 kHz
Fig. 5. Relative transmittance in
samples of green alumina
pressed at different pressures;
left at 9000 psi and right at
12,000 psi - 500 kHz
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
5
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Sintered Ceramics & refractories: Density and defect detection
Fig. 8. Fused silica refractory, assumed to be without defects. Note the left hand portion is severely cracked internally - 200 kHz.
Fig. 6. Relative transmission in
alumina varying in density. Left:
64.8%, 2.58 g/cc. Middle:
70.3%, 2.80g/cc. Right: 77.3%,
3.08 g/cc.- 500 kHz
Fig. 7. Alumina refractory,
without cracks (left) and with cracks (right.)
500 kHz
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
6
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Fig. 11. Fused silica kiln furniture.
Left: without defects, however, it
exhibits either gross porosity or internal
cracks.
Right: With severe internal cracks – with
the exception of small left hand region, it
is completely delaminated - 500 kHz.
Defective Non-Defective
Fig. 9. Power Metal (Green Iron Compact
Left: Transmission (dB)
Right: Velocity (m/s)
Fig. 10. Semiconductor alumina abrasive disc
-Subtle microstructure variations
-Higher transmission is indicative of low density
high porosity
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
7
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Fig. 12. Steel making refractory blocks. Left, with severe internal cracks and defects. Right, without defects - 200 kHz.
Non-Contact Ultrasound: Ceramics Analysis
Application Note AN-305-5
8
3100 Research Drive, State College, PA 16801 USA
Ph: +1.814.861.2001 Fax: +1.814.861.2045
www.ultrangroup.com
Conclusions
Ultran’s SecondWave™ M510 ultrasonic imaging and
analysis system is characterized by a wide range of
frequencies from 50 kHz to 5.0 MHz. This makes it
possible to apply non-contact ultrasound (NCU) for
ceramic and sintered metal evaluation all the way
from early stages of their formation to finished
products. Typical applications include crack
detection, moisture detection, porosity and texture
analysis, properties, etc. The M510 is a powerful tool
for materials process analysis and QC, directly saving
you cost, energy, and materials, besides assuring the
quality and reliability of your materials.
What Ultran provides
We supply complete NCU systems suitable for
customers’ needs. These include specifically
designed transducer libraries so that our customers
can start characterizing all their materials from Day 1.
Ultran also supplies custom NCU systems geared for
production (online) configured to customers’
applications and environment of testing.
Under agreements, Ultran will transfer science and
technology - targeted to customer needs. We offer
hands-on training to all our customers.
We maintain a fully-stocked ultrasound materials
analytical laboratory and we are fully equipped to
provide feasibility, in-depth analysis, and R&D for our
customers.
Sales representatives
HEAD OFFICE
The Ultran Group
3100 Research Drive
State College, PA 16801 USA
Tel: +1.814.466.6200
Fax: +1.814.466.6847
Email: [email protected]
ITALY
Pierluigi Carni
Via B. Angelico, 1
24047 Treviglio – BG, Italy
Tel: +39 340 9125410
Email: [email protected]
UK
Sonatest NDTS
Jenny Hough
Units 1-3 Prospect House, Colliery Close,
Ireland Business Park,
Staveley, Chesterfield, S41 8NG, UK
Tel: +44 (0) 1246 474269
Fax: +44 (0) 1246 474089
Email: [email protected]
JAPAN
Ken Automation
Tatsuya Yaoita
Hiranuma 1-11-12
Yokohama KMH Bldg., Nishi-Ku
Yokohama - 220-0023
Tel: +81.45.290.0432
Fax: +81.45.321.6590
Email: [email protected]
CHINA
Matrix U/E Technologies Inc.
Jiang Yunxi
Chaoyang District, Beijing Wangjing Litse emerging
industries in Park District No. 106 Building 402B
Tel:+86-10-64391208-819
Mobile: 0086-13910978697
E-Mail: [email protected]
INDIA
Speck Systems Ltd.
D Simon Amallraja
B-49, Electronics Complex
Kushaiguda, Hyderabad-500062
Tel: +91-40-27125305
Fax: +91-40-27122489
Email: [email protected]