Introduction spot- and projection weld inspection with the Mini Scanner

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Introductionspot- and projection weld
inspectionwith theMini Scanner
AMSTERDAM
TECHNOLOGY
NDT Scan Solutions

• A high level inspection method with a handy
  instrument

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AMSTERDAM
TECHNOLOGY

• Raised in 2006 by
• vAmsterdam SES Software, Engineering and Systems
  for ultrasonic and Eddy Current inspection
  machines
• Technolothgy BVEngineering of special machines
  and instruments for Non Destructive Technology

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Overview of build immersion tank based inspection
machines
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• Ultrasonic
• Immersion tank scanners
• High resolution
• Complex shapedproducts
• Focused transducers

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• Ultrasonic immersion tank scanner
• A high quality inspection method
• Practical inconveniences
• Static position The samples have to be
  transported to the scanner
• The samples have to drown into the water
• Limited tank dimensions
• Time-consuming positioning of parts in the tank
• Long inspection times
• High investments

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• Project with DaimlerChrysler
• Project description
• Design a portable ultrasonic scanner for spot
  weld inspection on location.
• Specifications
• Short inspection time
• No immersion of the inspected parts
• High resolution C-scan presentation
• For plate thickness from 0,5 mm
• Handheld instrument

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• Mini Scanner
• A miniature immersion tank scanner.
• The scanner head is filled with water and is
  sealed with a membrane.
• Gel is used as an ultrasonic couplant.
• Scan area 10 x 20 mm
• Resolution 0,1 x 0,1 mm
• Scan time lt 5 seconds

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Diagram spot weld testing with the Mini Scanner
Yellow gate In this area the maximum amplitude
of the ultrasonic signal is measured
Red gate sets the start position of the yellow
gate
Moving ultrasonic transducer
A color related to the value of the maximal
amplitude in the yellow gate, is set as a pixel
in the C-scan for each scan point.
Water chamber Mini Scanner
Couplant ( gel )
IE
BE
WE
A-scan presentation
IEInterface Echo
WEWeld Echo
BEBack Wall Echo
The C-scan is picture, composed by the 100 x 200
colored pixels as generated in each scan point.
C-scan presentation
Patent pending / all rights by Amsterdam
Technology bv
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• Scanning method
• Focused ultrasonic transducer moves in a water
  filled compartment in the scanner head
• 35MHz ultrasonic transducer
• Diameter focus point lt 0,1mm
• Membrane sealed water chamber
• Spiral shaped scanning pattern
• High scanning speed
• Gel as ultrasonic couplant

Patent pending
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Exchangeable scan heads
Straight scan head for perpendicular scanner
position.
Mirror based scan head for angles scanner
position. Used for difficult to reached spot weld
position
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• Mini Scanner System
• Scanner with control unit
• PC platform
• Windows XP
• Touch Screen
• USB data exchange

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Spot weld test High tension steel plate

• Test parameters
• Shape of the spot weld nugget
• Shape of the pore

A-scan on cursor position - besides the weld -
Plate thickness first plate
In the yellow gate back wall echo of the first
plate
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Spot weld test High tension steel plate

• Test parameter
• Thickness of the spot weld

A-scan on cursor position - in the nugget -
Thickness
In the yellow gate No weld echo (good welded in
that position) In green gate Back wall echo of
the spot weld
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Spot weld test High tension steel plate

• Test parameters
• Size of the pore
• Depth of the pore

• A-scan on cursor position
• On the edge of a
• pore in the weld -

Depth of the pore in the spot weld
In the yellow gate Echo of a pore
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Spot weld test High tension steel plate

• Measuring dimensions
• Size of the nugget

By drawing an ellipse around the contour the
dimension is calculated
Cursor controlled dimension measurement in C-scan.
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Spot weld test High tension steel plate

• Test parameters
• Indentation measurement by Time Of Flight (TOF)

Indentation Time Of Flight
Time Of Flight (TOF)
Reference A-scan of position beside the
spot weld.
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Arplas weld Steel plate

• Test parameters
• Shape of the Arplas weld

A-scan on cursor position - besides the weld -
Plate thickness first plate
In the yellow gate back wall echo of the first
plate
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Arplas weld Steel plate

• Test parameter
• Thickness of the Arplas weld

A-scan on cursor position - on the weld -
Thickness weld
In the yellow gate No weld echo (good welded in
that position) In green gate Back wall echo of
the spot weld
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Arplas weld Steel plate
7,20

• Test parameter
• Detail of the Arplas weld
• Detecting dimensions
• (By moving the cursor)

1,05
A-scan on cursor position - on the edge of the
weld -
In the yellow gate 90 weld echo (green-red
colored pixel, on the edge of the weld)
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• Software
• Storage of A-scans (ultrasonic signal) for each
  scanning point
• After event data evaluation possible by gate
  repositioning
• Ultrasonic settings storable as pre-set for
  typical applications
• Numerical wall thickness indication
• Direct C-scan presentation
• Two C-scan presentations with independent gate
  settings
• No picture processing for C-scan presentation

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• Application Nut welding
• Welded nut (round)
  Welded nut (square)
• -- The Mini Scanner was placed on the flat
  plate side --

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• Application laser welding
• Laser weld round (Alu plate) Laser
  weld round (Alu plate)
• -- The Mini Scanner was placed on the flat
  plate side --

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Application Rivet inspection
Rivet in gearbox part . -- The
Mini Scanner could be placed on both sides of the
part --
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Application Porosity check HP casting
A-scan beside a pore A-scan on
a pore High
pressure cast aluminum 2.0 mm thickness
Since the mini scanner is used in the field a lot
of new applications are coming up.
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• Inspection with the Mini Scanner
• Applications
• Multiple plate weld inspection
• Plate thickness 0,5 -8 mm with standard
  transducers.
• Weld between plates and massive parts
• Conditions
• Scan head has to be placed on a flat surface
• Accessibility scanner to the product
• Use of gel allowable

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Practical limitations

• Even the mini scanner is subject to the physical
  limitations caused by the properties of
  ultrasonic pulse echo techniques, such as
• Insufficient reflection of the ultrasonic echos
• Caused by
• Disturbance by sharp edges around the weld
• Raw or dirty surface
• Scanner not good in position during scanning

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Latest developments Smaller model scan
unit Lower weight -40 Reduced scan time
-20
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• Concluding
• Handy ultrasonic C-scan device for detailed weld
  inspection
• Multiple ultrasonic signal evaluation modes
• Storage of all ultrasonic data
• Improved welding process control possible by
  inspection on location