ME-492 Non-Destructive Testing Laboratory Report

Transducer Performance Laboratory No.5

Written by: Eric S. Krage, Mitch Miller, & Ryan Hahn Instructor: Dr. Jikai Du

Class Section 01 Date Performed: 11/14/2012

South

Dakota

State

University Krage, Hahn,

Brookings SO 57007

&

Miller

Table of Contents
List of Figures, Tables and Experimental Apparatus Introduction Theory Experimental Procedure Experimental Results and Analysis Conclusion References and Appendix . 7 8 11 2 3 5

South

Dakota

State

University

Krage,

Hahn.

&

Miller

Brookings SO 57007

List of Figures Figure 1: Steel bloc with holes 10.71, 17.53, and 23.89mm from left to right respectively Figure 2: Wire across two plates to determine focal zone 3 4

Figure 3: Wire and Plate with holes setup as scanned Figure 4: Unfocused transducer in water

V
5 5

Figure 5: Focused Transducer "Spherical Dish" in water

List of Tables
Table 1 Ratio of two signals 8

Apparatus

Unfocused

Transducer

f = 1 MHz, D = 1.125"

Immersion Tank
Focused Transducer f Focused Transducer f Digital calipers

20 MHz, D = 1.5" 10 MHz, D = 3.0"

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SO 57007

Introduction
The purpose of this laboratory procedure is to learn and ,easure acoustic fields of !pcused and unfocused transducers. We will measure near field distance. focalleng.t~ focal zQ-ne, and b~ diameter. Also, we will measure the focal length variation due to acoustic velocity of the test material and water is examined. The immersion tank ith focused and unfocused transducers will be used as well as the ultrasound reflectors.

Test Samples

Figure 1: Steel bloc with holes 10.71,17.53, and 23.89mm from left to right respectiv

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SO 57007

Figure 2: Wire across two plates to determine focal zone

Figure 3: Wire and Plate with holes setup as scanned

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings 50 57007

Theoretical Information
,

, o ~/
~_JtJ..) .. Yv .
~-r

Near Field Transduce!((J2

The ear fiel ransducer is a device that converts energy in ultrasonic waves above the normal range 0 -uman audibility. This piezoelectric transdl~cer which converts electrical energy in to ultrasonic waves is changed by changing the srze f the transducer and the AC voltage applied. This produces very high frequency oscillation and producing high frequency waves. We define the point at which the waves are focused to be the focal zone and can be calculated using the equation to area and shape of the transducer and the velocity of the propagation media. The following figures, Figure 4 and 5 show the unfocused and focused ultrasonic t ansducers respectively. As we examine the difference between the two we notic the ca zone larger for the unfocused transducer indicated by the red rings in the cent of the image. L-t- aJ ?i".~ .
\ 10 v ....... - . SoundDl"C5$\Itelf\w~r(41oQ-izO"10mrn)

"
......................................................L

/
60 00 100 ZiI"'n 120 140 160 ISO 200 ISc1B

,'0

Figure 4: Unfocused transducer in water

SQtlM 10~ .__ ... _.- ,.... ~ .. I prcuore
III

w.rel

{"MHz,D

1Omtn)

.1 50

120

14<,

100

100

Figure 5: Focused Transducer "Spherical Dish" in water

D2 D2

it

N=-=

f
and ending points that are 6d8 from the

4l

4- *'-1-==-_-1

The length of the focal zone i efined by ~~2tarting focal point to be calculated us the follo,.ing.
F =N
z

*'

G.) .

Fa;

*' (..

1+0.5' ~

2)

""
~

Iof

f-r t='

Cu

SV ~

<l<l

a;

The -6d8 beam diameter for the focused transducer can be calculated using the following eqUati~

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SO57007

ED [-6dB]

= 0.2568'" D *-

If

p/

Finally we need to calculate the variations in the focal length that are due to the acoustic velocity of the test material. The change in the focal length can be predicted using the following equation.

WP=F-MP*'-

(,Ct-m)/
C ~.

Experimental Parameters Unfocused Transducer (f

= lMHz,

= 1.125")
parameters

The ultrasonic (-Scan system water immersion system was used. The transducer

were synchronized with the system software. The transducer was moved toward the aluminum plate until the front surface reflection was clearly seen. Then we adjust the angle manipulator using the two threaded knobs on the transducer to maximize the words make the incident waves normal to the surface of the was measure to be approximately 180mm. The measurements rface reflection in other terial. The near field distance were taken using the system _

software controlled stepper motors that allowed the transducer to scan over the materi~~~eing evaluaty.d.
/

eed
e.2-V'

1.
I:U l~

Focused Transducer (f = 20MHz, D = 0.25" F = 1.5")

-b"

t~ +y"
~1 ~

cry,,? \ ~

.1
q.

The next step was to replace the unfocused transducer with the focused one by unscrewing it from the stand in the immersion tank. The transducer was moved toward the aluminum plate until the front surface reflection could be clearly observed. The angle manipulator was again used to maximize the signal making the incident waves normal to the material surface. The transducer was then moved to ultrasound order to ensure the transducer difference was m a~ calculated.
C '" .tJ.t

reflector and the height and the x, y tositlon was rectified response. In in. the time it takes )~ ~
cl?f

adjusted to further maximize the reflection which resulted in a com pie parameter the focallen th was.measure for the signal to reach the ultrasound to be 51us.

reflector and return back to the transducer. The time . g.the time difference the measured focal length was

cid7-.z

Af

p(c~

F'Xp8"m~'"'

37.5"
s of 1.5", and
en it

Th is va Iu e is nea rly match ing with th e ma n ufa ctu rer specification

the gain value of the system was adjusted so the signal amplitude was 80% high on the monitor. To find the focal zone of the transducer it was moved in the sample and the distance was calculated/he amplitude of the signal

e..
Krage,

I Iength

Z direction over the

as at 40% of

South

Dakota

State

University

Hahn,

&

Miller

Brookings SO 57007

maximum on each side. Fz Zl - Z2 the transducer in the BD

= 34.96mm.

The beam diameter was measured by moving

= Xl -

X2

X direction along the sample to calculate the beam diameter such that = 0.9m. Note there will be asymmetries in the displacements due to the wave

generating an a<erage frequency of 20 MHz and lower as well but filtered u.sing a hi h ass filter to onl'i_allo

b.A+> ;,~~
cJ...J IJeW)

ip the high frequency. To eliminate this asymmetry a band pass filter could be used to f/lCt4') a narrow fre uenc band to be generated.
t

Focused Transducer

(f = 10MHz/ 0 = 0.50/1 F = 3.0/1)

The focal zone and the beam diameter of the 10MHz transducer was found using the same procedure and can be found in the appendix of this report. The lOMHz transducer was used to see the variation in the aluminum plate with the holes in it Figure 1. The NDT Automatio immersion tank system was set up to scan the entire part. The observation was do successfully and the three holes were viewed on the monitor at their relative depths.

Results Analysis
Unfocused Transducer
~2mm.

(f = 1 MHz/ 0 = 1.125/1)

~'i
~ted

14::)

t ;ll-/tt,/M:o

.,

The theoretical calculation of the near field distance of the transducer .

As previously noted the theoretical calculation can be seen in the

appendix. Note that the error between the values is rather large. The possible error is mainly due to human error like improper reading of wave signals. Also, some of the error may be due to the vibrations of the transducer motion system that is caused due to the speed of movement of the transducer in the immersion tank. ~

frqt(.G /
c/7'-f:

/'
J

Focused Transducer

(f

= 20M

Hz, 0

= 0.25# F = 1.5#) -r~

(/-7 tU2,...e;J

I<i<-{ CfoIblcUt-. ~ ..ftn..- .

-eP~"'7?~
C'l
-"?

The theoretical calculations of the focal zone and beam diameter shown in the appendix are ~ discussed. The error in the values is less than that of the unfocused transducer but still show and above average experimental error of 5% which is expected. This error seems to have come rom a small signal set up problem. Due to the small oscilloscope error the transducers were moved almost twice as far as nee tram . Other possible error could be in the alignmen
0

fl~o1'
.

~'"S:O

ucer with the sample surface causin an aberration in our suspected beam. Third and

fifth order spherical aberrations of the transducer surface itself can give rise to an error. These aberrations
U5.e-cLOJ

-uniform focal zone and beam diameter through the sample m~i~~,d __ I~
ttA40
~J.

/
~

causing signal distortions.

rft~/

J~

/l.d.-_

r''->'TV

Focused Transducer

(f = 10MHz/ 0 = 0.50/1 F = 3.0/1)

The 10MHz focused transducer values can be found in the appendix. The error was better within the experimental error which allows us to say that we have improved our testing

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SD 57007

techniques through this experiment in the allotted time. The NDT Automation

and have exhausted some of the changes needed. The

tJ-e to the lack of time to complete the experiment

remaining error is most likely human error

immersion tank system was setup to automatically

scan the entire Lab #1.

aluminum sample that has the three holes contained within. The signal generated by the immersion system represented the holes respective depth when refe~

Questions
The phenomena discovered in this lab was that sound waves passing through materials act very similar to the way light acts as it changes media. Like light, sound waves reflect, bounce off the boundary, and refract, change angles because of a speed difference other. The amplitude ratio oftwo signals corresponding to certain decibels is given in Table 1. in one medium versus the

Table 1 Ratio of two signals dB = 20 loglO(AR) Ratio 1.4142 2 4 100 Ratio 0.707 0.5 0.25 0.01 dB

-y'
-6 -12 -40

Conclusions
In conclusion the experiment was successful in understanding and utilizing the capabilities of system capabilities were

the focused and unfocused transducer. The design parameters were practiced in an immersion tank on a thread of wire and aluminum samples. The NDT Automation also practiced to evaluate the scanning procedure to automatically evaluate the samples.

Calculations
Unfocused Transducer 1MHz, D = 1.125" F = 1 MHz Diameter of Unfocused Transducer Frequency of Unfocused Transducer

South Dakota State University Brookings SO 57007

Krage, Hahn, & Miller

Cwater = 1.5 mm/us

j)'J."J

Velocity of sound in water Theoretical Near Field Distance

. . ,,,J

Nfield=
4i<

C, er -----..c:

= 136.09mm ~

oN!.

\JP~IV

ENL = 127.5mm ENH = 150mm

Nf' %difference =te
1 .(l

tr"'lj
= 6.3%

i~'~

Experimental Near Field Low Experimental Near Field High

B~'L
j

Percent Difference in Near Field

NJi.~fd

%difference

Ernr

N[cf31ri

= 9.3%

Percent Difference Near Field

ENE

Focused Transducer 20 MHz 105" Focal Length, D = 0.25" f = 20 MHz Diameter of Focused Transducer Frequency of Focused Transducer Focal Length of Focused Transducer Cwater = 1.5 mm/us Nfield=
})Z"l

Velocity of sound in water

4" CW(lt~r

134.41mm

Theoretical Near Field Distance

Fzone =Nfi81d

(~)z
NPiefd

*' (.

2 PL ) 1+0.5,,-.,-jY

18.92
/

Theoretical Focal Zone

Field

BDT = 0.2568

D ; ."

--P:-- = 0.461nm
Nfi~ld.

Theoretical Beam Diameter

BDexperimental = 0.58mm+0.5 = 1.08~ FZ,exp = 8.1mm+9.2mm %difference =, 1= 17.3mm /

..=

Experimental Beam Diameter Experimental Focal Zone Difference Between Beam Diameters

_1'._' BDexp

BD)

57.2%
-

FZT)- =8.6% / %difference =' ( 1 - --' FZ,eNr; ./

Percent Difference Focal Zones

Focused Transducer 10 MHz 3.0" Focal Length, D = 0.50" Diameter of Focused Transducer

South

Dakota

State

University

Krage,

Hahn,

& Miller

Brookings SO 57007

f= 10 MHz FL = 3.0" Cwater = 1.5 mm/us

Nfield

Frequency of Focused Transducer Focal Length of Focused Transducer Velocity of sound in water Theoretical Near Field Distance

= 'h C\"acer
'"

IJ"~f

= 268.82mm

Fzone =Nfi/31d

(----.!L)2 '" (
NPield

FL ). 1. 0.5*-,.,-"Freid

=~

Theoretical Focal Zone

BDT = 0.2568'"

Dl

:;< ~ ''Vfi&'ld

= O.92m1],1 L

Theoretical Beam Diameter

BDexp = 0.46mm+0.72 = 1.18mm/ FZ,exp =13.71mm+26.14mm %difference = =39.85mm

):

Experimental Beam Diameter Experimental Focal Zone Difference Between Beam Diameters

(1-

BD.T.
BDexp

= 21.6%

%difference

= :( 1-

--'

PZT). -

=5.1%

Percent Difference Focal Zones

FZ,f!Jf'P

Change in focal length using 10 MHz transducer Fw = 3.0" Cm = 6 mm/us Cw= 1.5 mm/us MP = 15.8 mm Focal Length in Water Sound Velocity in Test Material Sound Velocity in Water Thickness of plate Distance from top of block to focus energy on the bottom of aluminum block.

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SO 57007

10

References
Rose, Joseph L. Ultrasonic Waves in Solid Media. Cambridge [ u.a.: Cambridge Univ. 2004]

Appendix. Question 3

South

Dakota

State

University

Krage,

Hahn,

&

Miller

Brookings SD 57007

'

I I
J

\~---;----7

\~

=->

CTeJ\
$.~

=:.-

-)

S'~~

=)

WP "'-

F-~)
11

---------r