3D Hybrid modeling for the ultrasonic phased array inspection of porosity in heavy plates: Simulation and experimental validation

Quantitative NDT modeling and simulation tools are important in design and fabrication of ultrasonic phased array probes with optimum characteristics and reduce the number of experimental efforts and development time. In order to achieve high accuracy (Amplitude deviation < 1 dB) with a low computational time in the simulation, the modeling tools require not only the high-frequency approximation of the ultrasonic wave propagation but also the high-precision electro-acoustic coupling model. This paper describes a computationally efficient 3D time-dependent hybrid model for the simulation of ultrasonic phased array inspection of porosity in heavy plates. This method combines the results of both 3D finite element analysis (PZFLex-FEA) and the semi-analytical ultrasonic simulation “Ray-Tracing”. As a first step, we demonstrate the FEA modeling of an ultrasonic phased array probe, which includes the full 1-3 piezocomposite design with the arrangement of array elements, conducting electrodes, multi-phase backing material, acoustical matching layer and electrical circuit of a 50 Ohm coaxial cable. In the current FEA simulation, we considered the acoustical and electrical cross-talk between the adjacent elements of an ultrasonic array sensor. In the second step, the FEA-simulated ultrasonic pulse-echo signal and its frequency spectrum of an array element in the farfield region are further used as the reference input signal in the CIVA-UT software to simulate the imaging of porosity in heavy plates, quantitatively. The design of the 3D wedge-geometry of the application specific array sensor is modeled and optimized using the CIVA raytracing and multi-phase backing models. The real excitation pulse of the industrial ultrasonic testing equipment “ROMIS (ROSEN Modular Inspection System)” is also included in the simulation to achieve high accuracy in the current hybrid modeling. The dependency of the detectability of the porosity on the frequency of the array sensor and the active element group so-called “Virtual Probe” are quantitatively analyzed. Finally, the 3D hybrid model simulated Time Corrected Gain (TCG) curves of the porosity like defects in the reference steel plates are compared with the real experiments and a good quantitative agreement is achieved.