Friction Stir Weld (FSW) inspections can be challenging and time consuming. It typically requires 3 beam angles for flaws parallel to the weld center line (WCL). Standard solutions use multiple probes, and require each probe to be aligned and calibrated, which can be a long process. Some flaw types (transverse, skewed) are not reliably detected with standard probe design. Additionally, the surface condition and flashing can prevent adequate coverage of the weld area with a contact solution. Zetec offers the optimal solution for this type of inspection challenge, delivering a reliable and efficient inspection solution that includes rapid setup, quick calibration and fast inspection speed.

1. © Zetec Inc. All rights reserved
Friction Stir Weld
Inspection
Application Solution
July 2019

2. © Zetec Inc. All rights reserved
• Inspection Challenge
• Recommended Solution
• Optimized Probe Design
• Examination Techniques and Results
• Phased Array UT Hardware
• Benefits of Zetec Solution
Overview
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3. © Zetec Inc. All rights reserved
• Friction Stir Weld (FSW) inspection typically requires 3
beam angles for flaws parallel to weld center line (WCL)
• Standard solution uses multiple probes, and requires each
probe to be aligned and calibrated, i.e. a long process
• Some flaw types (transverse, skewed) are not reliably
detected with standard probe design
• Weld surface condition and flashing can prevent
adequate coverage of the weld area with contact solution
• Total inspection time is critical for global efficiency of
manufacturing process, thus requiring rapid setup and
calibration, and high inspection speed
Inspection Challenge
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4. © Zetec Inc. All rights reserved
• Optimized PA UT probe design, for improved detection
capability, and reduced # scanning sequences
• Immersion tank inspection for adequate coupling on
« as welded » surface condition
• High-end phased array UT units:
• for portable systems
• for permanent and scalable systems
• UltraVision Touch or UltraVision Classic for seamless
system integration and efficient data analysis
Recommended Solution
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5. © Zetec Inc. All rights reserved
• Optimized 1D linear array probe, 7.5 MHz, 128 elem.,
with small pitch and adequate elevation
• Capable of generating 0°LW and 45°SW for flaws ‖ WCL,
without probe inclination
• Capable of generating 45°SW for detection of
transverse flaws (when inclined in secondary plane)
Optimized PA UT Probe
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45°SW0°LW 45°SW

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• Linear electronic scanning using
3 beam angles, +45°SW, 0°LW, -45°SW
• All techniques (groups) can be applied
in a single scanning sequence
• Volumetric Merge of 3 groups for
efficient data analysis
Examination Techniques for Flaws ‖ WCL
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-45°SW+45°SW
0°LW

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• Linear electronic scanning using 2 beam angles, +45°SW, and -45°SW,
using probe inclination in secondary plane
• All techniques (groups) can be applied in a single scanning sequence
(2 probes required)
• Volumetric Merge of 2 groups for efficient data analysis
Examination Techniques for Transverse Flaws
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-45°SW
+45°SW

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Test Specimen (Bottom View)
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FBH 45°
T/2
ID #04. 05 & 06
Ø 0.4 mm / Ø 1.2 mm / Ø 2.0 mm
Notch 0° Root
ID #07. 08 & 09
Notch Root 10% WT
Mis-orientation
ID #12. 13 & 14
5% WT / 10% WT / 15% WT
22.5° / 45° / 90°
Notch
Length 6.35 mm
Width 0.5 mm
Aluminum FSW, T = 6.3 mm, containing planar and volumetric artificial
reflectors with various orientations, located at OD, ID, and mid-wall,

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Results – Flaws ‖ WCL
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Top View - 0°LW only
Top View – Merge 0°LW, +45°SW, -45°SW
Merged data group allows to detect all artificial reflectors with good SNR

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Results – Flaws ‖ WCL
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45°SW angle beam techniques generate tip diffraction signals,
allowing for accurate through-wall sizing of planar flaws
ID Notch (h = 1.65 mm)
Measured Height = 1.5 mm
ID Notch (h = 3.3 mm)
Measured Height = 3.2 mm

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Results – Transverse Flaws
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Top View
Dedicated inspection technique with inclined probe provides excellent detection
capability on transverse flaws
Side View End View

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• Fully integrated, portable unit, 32/128PR
• Battery operated
• UltraVision Touch, on-board software for
setup, acquisition and analysis
Phased Array UT Hardware
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• 32/128PR at 100V, 2 probe connections
• Parallel firing capability
• UltraVision Classic software for seamless
system integration using multiple units

13. © Zetec Inc. All rights reserved
• Optimized PA UT probe design for improved detection and
sizing capability, including transverse and skewed reflectors
• Adequate coupling on as welded surface condition
• Simplified calibration and improved repeatability
• High-end phased array UT units controlled by UltraVision
software platform, for setup, acquisition and data analysis
• Scalable solution: from one probe and acquisition unit, up to 3
probes and units for 3 x reduction of inspection time
Benefits of Zetec Solution
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14. © Zetec Inc. All rights reserved
Suggested Solution Kit
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Part
Number
Acronym Description
10053131 ZPA-IUT-TOPAZ-32/128PR-x64-KIT
Fully integrated portable Phased Array system featuring new 64 bits onboard
computer and up to 32 active channels on up to 128 elements probe for enhanced
inspection capabilities. This instrument can also either use the same 32
transmitters and receivers or can be operated in PR mode using up to 32 channels
as transmitters and 32 other receivers for advanced inspections. Phased Array
probes are connected on a solid Zero Insertion Force secured connector whereas
4 Lemo 00 connectors can be used simultaneously for pulse echo or TOFD
inspections. TOPAZ is operated via onboard UltraVision Touch for fast and easy
inspection setup as well as first level onboard analysis. This kit includes 2
batteries,1 carrying case,1 power cable NA, 1 power cable Europe, 1 Ethernet
cable, 1 AC adapter & 1 USB Flash drive
10058528
ZPA-PB1D-7.5L128E44.8-5-WAT-3.0M-
ZPAC
Dedicated 1D Linear Phased Array probe designed for Friction Stir Weld
Inspections - 7.5 MHz - 128 elements - Active aperture 44.8 mm x 5.0 mm -
Acoustic matching to water for immersion use - 3.0 m cable length - ZPAC
connector
10038857 ZPA-ACC-W-AL-55SW-IH-FL
Standard wedge for AL-type phased array probe - Designed for azimuthal
scanning from 40 to 70 degree using shear waves - 55-degree SW nominal angle -
Irrigation channels and probe holder fixtures
10038858 ZPA-ACC-W-AL-55LW-IH-FL
Standard wedge for AL-type phased array probe - Designed for azimuthal
scanning from 40 to 70 degree using Longitudinal waves - 55-degree LW nominal
angle - Irrigation channels and probe holder fixtures