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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


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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.



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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



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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



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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



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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



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Fig. 12. Steel making refractory blocks. Left, with severe internal cracks and defects. Right, without defects - 200 kHz.



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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


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


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


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


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