Flexible ultrasonic phased array probes can inspect complex composite part geometries. The document discusses: 1. Flexible array technology that allows probes to flex and keep elements perpendicular to surfaces. 2. Testing that showed a probe could flex to a minimum diameter of 12.7mm concave and 40mm convex without degrading performance. 3. Inspection of a composite part with a flexible probe that allowed fast, accurate inspections and detection of defects as small as 0.5mm.

1. Inspection of Complex Geometries Using
Flexible Ultrasonic Phased Array Probes
Jeffrey Wells | Product Specialist – Phased Array Applications and Solutions
ASNT, 11/03/2016

2. Agenda
1. Introduction
2. Typical Test Methods
3. Flexibility Testing
4. Flex Array Inspection
5. Conclusion
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3. Introduction
§ Flexible Array Technology
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Flexible array is a new technology that takes the capability of a standard
rigid phased array probe and makes it flexible. The goal is to have a probe
that can be flexed to help ensure that the elements are always
perpendicular to the inspection surface.

4. Introduction
§ Market offering
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A variety of market offerings provide unique options for acoustic and
mechanical solutions.

5. Typical Test Methods
§ Test Conditions
– Test multiple ultrasound methods on one part
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Composite Part:
• 25 mm outside radius
• Thickness range: 2–15
mm
• 12.7 mm square insert
defects
• Defect’s depths are at 0.5
mm, 7.5 mm, and 15 mm

6. Typical Test Methods
§ Single Element (UT) Probe
– Set up is quick
– Sizing is accurate
– Inspection time is very long
– Full coverage is difficult to achieve and confirm
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7. Typical Test Methods
§ Curved Phased Array (PA) Probe
– Set up is slow and cumbersome
– Sizing length is drastically oversized
– Inspection time is quick
– Full coverage of radius is not simple to confirm
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8. Flex Testing
§ Check the flex limitations of the probe
§ Record the maximum flex for convex and concave parts
§ Test the probe to confirm no degradation in acoustic performance
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• Minimum concave bend diameter:
0.5 inch (12.7 mm)
• Elements are flexed on convex part
• Elements face inward

9. Flex Testing
§ Check the flex limitations of the probe
§ Record the maximum flex for convex and concave parts
§ Test the probe to confirm no degradation in acoustic performance
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• Minimum convex bend diameter:
1.57 inch (40 mm)
• Elements are flexed on convex part
• Elements face outward

10. Flex Array Inspection
§ Mechanical Setup
– Flex probe couples
quickly and easily
to the part
– Sizing is very
accurate
– Inspection time is
fast than other
methods
– Full coverage is
easy to achieve;
users can also
inspect a portion of
the flats
concurrently
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11. Flex Array Inspection
§ Acoustic Performance
– Detects midwall defects
– Good signal-to-noise ratio (SNR)
– Sizing of 12.5 mm (0.5 inch) flaws is very accurate
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12. Flex Array Inspection
§ Acoustic Performance
– Near-surface detection (NSD) is possible down to 0.5 mm (0.020 inch)
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13. Conclusion
1. Flexible array offers a simple mechanical setup.
2. Near-surface detection on CFRP is good down to 0.020 inches with
resolution down to a depth of 1.5 mm.
3. Flexible probe is a good candidate to be implemented on low volume
contact inspection.
4. Implementation of holders can expand the capability and reliability of flex
probe use in production or inspection settings.
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