Raptor Operator Manual - Zion NDT€¦ · Important Information First and foremost, we at NDT Systems, Inc. would like to thank you for your purchase of the Raptor. The Raptor is

Raptor Operators Manual

Important Information First and foremost, we at NDT Systems, Inc. would like to thank you for your purchase of the Raptor. The Raptor is a new category in Ultrasonic Flaw Detectors. The Raptor is not only a contemporary high speed flaw detector BUT, also includes a full featured C-Scan Imaging System within the same package. Leveraging three 32-bit microprocessors, the Raptor offers substantially more capabilities than ANY conventional flaw detector. Press the FLAW MODE key and the Raptor performs as any High Performance flaw detector would. Press the SCAN key and the Raptor becomes a full featured Flaw Detector AND Imaging System matching, and in some cases exceeding, the features of imaging systems costing more than $40,000, at standard Flaw Detector prices.

Operator Qualifications In order for the owner of this advanced technology instrument to fully benefit from the unique features of the Raptor, the assigned operator(s) must be experienced and well-founded in the fundamentals of ultrasonic testing. Operators should fully possess the qualifications of ultrasonic testing personnel as defined in Recommended Practice No. SNT-TC-1A, Personnel Qualification and Certification in Nondestructive Testing, available from the American Society for Nondestructive Testing (ASNT), 1711 Arlingate Lane, P.O. Box 38518, Columbus, OH 43228-0518, phone (614) 274-6003, FAX (614) 274-6899, telex 245347.

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Table of Contents 1 General Information .....................................................................................................................................1

1.1 Powering the Raptor...................................................................................................................... 2 1.2 Powering On and Off .................................................................................................................... 3 1.3 Display .......................................................................................................................................... 4 1.4 Keypad .......................................................................................................................................... 5

1.1.1 Upper section......................................................................................................................... 5 1.1.2 Lower section ........................................................................................................................ 5

2 Quick Start.....................................................................................................................................................7 2.1 Thickness....................................................................................................................................... 7 2.2 Flaw-Lin ........................................................................................................................................ 8 2.3 Flaw-Dag....................................................................................................................................... 9 2.4 Shear............................................................................................................................................ 10 2.5 Scan ............................................................................................................................................. 11

3 Menus ...........................................................................................................................................................13 3.1 Main ............................................................................................................................................ 14 3.2 Calibrate ...................................................................................................................................... 15 3.3 Mode............................................................................................................................................ 17 3.4 Thickness..................................................................................................................................... 18 3.5 Flaw-Lin ...................................................................................................................................... 19 3.6 Flaw-Dag..................................................................................................................................... 20 3.7 Shear............................................................................................................................................ 21

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3.8 Dag Setup.....................................................................................................................................22 3.9 Pulser............................................................................................................................................23 3.10 Receiver .......................................................................................................................................24 3.11 Tuning..........................................................................................................................................26 3.12 Scan..............................................................................................................................................27 3.13 Display .........................................................................................................................................28 3.14 Alarm ...........................................................................................................................................29 3.15 Setup ...........................................................................................................................................30 3.16 A-traces ........................................................................................................................................31

4 Thickness Mode........................................................................................................................................... 32 4.1 A Walk through using a 3/8” 5.0 MHZ Contact Transducer.......................................................32 4.1.1 ZERO & VELOCITY..............................................................................................................35 4.2 ECHO-ECHO Setup Using 3/8" 5MHz Contact Transducer ......................................................37 4.3 Procedures for Using Dual Element Transducers with Delay Lines. ..........................................40 4.3.1 Key Concept.............................................................................................................................40 4.4 Dual Element Delay Line ZEROing Procedure for Raptor .........................................................41 4.5 Dual Element Thru-Paint Measurements.....................................................................................42

5 Flaw Mode ................................................................................................................................................... 45 5.1 Flaw-Lin.......................................................................................................................................45 5.1.1 Start (F1) and End (F2) ............................................................................................................45 5.1.2 Thresh (F3)...............................................................................................................................45 5.1.3 Alarm (F4) ...............................................................................................................................45 5.1.4 GATE2 (F5) .............................................................................................................................46 5.1.5 GATE2 Start (F6), End (F7), and Thresh (F8) ........................................................................46

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6 Flaw-Dag ......................................................................................................................................................47 6.1 Manual Dag setup........................................................................................................................ 48 6.2 Auto DAG ................................................................................................................................... 51

7 Shear or Angle Mode ..................................................................................................................................53 7.1 Setup - Equipment....................................................................................................................... 53 7.2 A few items to be entered before starting the Calibration:.......................................................... 54 7.3 Calibration:.................................................................................................................................. 54 7.4 EBLK Adjusted ........................................................................................................................... 55

8 Setups............................................................................................................................................................59 8.1 FACTORY Setup Variables........................................................................................................ 59

9 Scanning .......................................................................................................................................................61 9.1 New CScan.................................................................................................................................. 61 9.1.1 Scan Area Definition............................................................................................................... 61 9.1.2 Start Scan................................................................................................................................. 63 9.1.3 Move Motors ........................................................................................................................... 64 9.1.4 Home Motors........................................................................................................................... 64 9.1.5 Speed/Strokes .......................................................................................................................... 65 9.1.6 Clear Scan ............................................................................................................................... 65 9.1.7 Image....................................................................................................................................... 65 9.1.7.1 Scale ........................................................................................................................................ 65 9.1.7.2 Color bar.................................................................................................................................. 66 9.1.7.3 Zoom ...................................................................................................................................... 67 9.1.7.4 B-Scan ..................................................................................................................................... 68 9.1.7.5 Histogram ................................................................................................................................ 69

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9.1.7.6 3D View...................................................................................................................................70 9.1.7.7 Measure....................................................................................................................................71 9.1.7.8 Units.........................................................................................................................................71 9.1.8 Close Scan................................................................................................................................71 9.1.9 Save Scan.................................................................................................................................72 9.2 New BScan...................................................................................................................................73 9.3 Load Scan.....................................................................................................................................74 9.4 Move ............................................................................................................................................74 9.5 Scanner.........................................................................................................................................75 9.6 Load Image ..................................................................................................................................76

10 SD Cards and Communications ................................................................................................................ 77 10.1 SD Cards .....................................................................................................................................77 10.1.1 An example Screenshot............................................................................................................77 10.1.2 File Menu.................................................................................................................................78 10.1.3 F2 to select external memory...................................................................................................79 10.1.4 Filename Entry.........................................................................................................................80 10.2 USB Port ......................................................................................................................................81

11 Appendix A Transducer Selection............................................................................................................. 83 11.1 Thickness Gaging Applications. ..................................................................................................84 11.1.1 Thickness Ranges.....................................................................................................................84 11.1.1.1 Single Element, Delay Line Transducers.............................................................................84 11.1.1.2 Single Element, Focused Immersion Transducers...............................................................85 11.1.2 Thickness Ranging from 0.030 inch (0.76mm) Upward. ........................................................85 11.1.2.1 Single Element Contact Transducers Hard-Faced Wear Plates...........................................85

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11.1.2.2 Single Element Contact Transducers with Membrane and Other Protective Devices. ....... 86 11.1.2.3 Dual Element Contact-Type Transducers. .......................................................................... 87 11.2 Flaw Detection Applications....................................................................................................... 88 11.2.1 Straight Beam Longitudinal Wave Tests................................................................................. 88 11.2.2 Angle-Beam Shear Wave Tests............................................................................................... 91 11.2.3 Through-Transmission Tests................................................................................................... 93 11.2.4 Immersion Tests. ..................................................................................................................... 94 11.3 Transducers for Non-Metallic Test Materials. ............................................................................ 94 11.4 Transducers for Specialized Applications................................................................................... 95

12 Appendix B Scanners ..................................................................................................................................97 12.1 MMS2.......................................................................................................................................... 97 12.2 FlexArm 2 ................................................................................................................................... 98 12.3 String Scan .................................................................................................................................. 99 12.4 VS1M X-Y ................................................................................................................................ 100 12.5 RCA-X Battery Powered Scanner............................................................................................. 101 12.6 P5-12 ......................................................................................................................................... 102

13 Appendix C Accessories............................................................................................................................105 14 Appendix D Specifications......................................................................................................................107 15 Appendix E Warranty ............................................................................................................................109

General Information

Raptor Operators Manual 1

1 General Information The Raptor is a high speed flaw detector that also includes a full featured C-Scan Imaging System within the same package. With three 32-bit microprocessors, the Raptor offers substantially more capabilities than any conventional flaw detector from any competitor. Press the key and the Raptor performs as any High Performance flaw detector would. Press the key and the Raptor becomes a full featured Flaw Detector and Imaging System matching and in some cases exceeding the features of imaging systems at standard Flaw Detector prices. The following is covered in this Chapter:

� Powering the Raptor � Turning the Raptor On and OFF � Display � Keypad

2 Raptor Operators Manual

1.1 Powering the Raptor The primary power source for the Raptor is a Li ion battery pack. The battery pack is inserted through an access panel in the top of the instrument.

Picture 1

The secondary power source for the Raptor is an externally connected Charger/AC adapter. The adapter plugs into a connector on the lower right side of the Raptor. If the adapter is plugged in with no battery in the battery compartment the battery charge indicator will indicate this by the symbol. If the Raptor is charging the battery or running on battery power the charge indicator will show where the blue is an approximation of the battery charge. The blue will turn red to warn the user when the battery drops below a minimum level.

CAUTION Use only the Inspired Energy Li Ion

battery pack supplied with this instrument and only charge this battery pack in the

instrument or in a supplied Inspired Energy charger.

General Information


1.2 Powering On and Off

The Raptor powers on by pressing the key briefly. When the Splash Screen is displayed press any key to proceed to the measurement screen. The Raptor powers off by holding the key for approximately 4 seconds. During this time the splash screen will come up and say “Powering Off” then the screen will go dark.


1.3 Display The Raptor display is a 480 X 640(VGA) color LCD that is sunlight viewable. The Raptor screen shown to the right is the home screen. The display is in 4 sections: Menu: The top portion of the screen shows the functions assigned to the soft keys F1 through F8. The functions shown change as the menus are stepped through. Measurement: The Thickness reading, Flaw information or Angle information will be displayed in this section Atrace/Imaging: A-trace information and/or Scanned images are displayed in this section. Information: Gain setting, Gain step, Battery life, and Date/Time are displayed in the Information section. .

General Information


1.4 Keypad The Raptor keypad is in 2 sections, an upper and a lower.

1.1.1 Upper section The upper section contains the F1 through F8 keys and an LED that echoes the Alarm LED.

1.1.2 Lower section The lower section contains dedicated keys, navigation keys, LED’s, and the spin encoder. The dedicated keys are the GAIN + and -, +dB, CAL, FREEZE, SETUP, FLAW MODE, SCAN, SCREEN CAP, ON OFF. The navigation keys include the ARROW keys, MENU ESC, and the ENTER key. The spin encoder is used for navigation and for changing parameters. The Spin Encoder comes through the circular opening in the lower section of the Keypad. The LED’s are for AC PWR, CHARGING, and ALARM.

Quick Start


2 Quick Start

2.1 Thickness The Raptor first starts in Thickness mode. To get to the Thickness menu from the Main menu press F2. This brings up the Mode menu. Next press F1 for the Thickness menu. The screen will look similar to the screen shot to the right. See Section 4 for more details. The ARROW keys may also be used to move through the menu options and select the highlighted item with the ENTER key.

Quick Start


2.2 Flaw-Lin To get to the Flaw-Lin menu from the Main menu press F2. This brings up the Mode menu. Next press F2 for the Flaw-Lin menu. The screen will look similar to the screen shot to the right. Alternatively, pressing the Flaw Mode key will bring up this screen. The ARROW keys may also be used to move through the menu options and select the highlighted item with the ENTER key. See Section 5 for more details.

Quick Start


2.3 Flaw-Dag To get to the Flaw-Dag menu from the Main menu press F2. This brings up the Mode menu. Next press F3 for the Flaw-Dag menu. The screen will look similar to the screen shot to the right. The ARROW keys may also be used to move through the menu options and select the highlighted item with the ENTER key. See Section 5 for more details.

Quick Start


2.4 Shear To get to the Shear menu from the Main menu press F2. This brings up the Mode menu. Next press F4 for the Shear menu. The screen will look similar to the screen shot to the right. The ARROW keys may also be used to move through the menu options and select the highlighted item with the ENTER key. See Section 5 for more details.

Quick Start


2.5 Scan To get to the Scan menu from the Main menu press F5. This brings up the Scan menu. Alternatively, press the SCAN button on the keyboard. The screen will look similar to the screen shot to the right. The ARROW keys may also be used to move through the menu options and select the highlighted item with the ENTER key. See Section 8 for more details.

Thickness Mode


3 Menus

As can be seen from the menu tree, functions on the Raptor can be accessed with only 2 to 3 keystrokes. Using the F1-F8 soft keys allows rapid movement through the menu tree. The soft key associations for each menu are called out next to the menu item.

F1 CalibrateF2 Mode F3 Pulser F4 Receive

F5 ScanF6 DisplayF7 SetupF8 Atraces

Main

F1 ZeroF2 VelocityF3 DelayF4 Range

F5 TrackingF6 Delay2F7 Range2F8 PRF

CalibrateF1 ThicknessF2 Flaw-LinF3 Flaw-DagF4 Shear

F5 Dag SetupMode

F1 Sing/DualF2 DampF3 Sqr/SpikeF4 Puls-Vlts

F5 Puls-WidF6 SyncF7 Invert Wav

PulserF1 RectF2 PolarityF3 DampF4 Gain-Inc

F5 +dB-IncF6 TuningF7 Reject

ReceiverF1 BackliteF2 FillF3 Peak-HoldF4 Units

F5 CopyF6 ClockF7 Alarm

DisplayF1 LoadF2 Save

Setup

F1 Thk-AlarmF2 Lo-ThkF3 Hi-ThkF4 Time

F5 Amp-AlmF6 Amp-Alm2F7 Buzzer

Alarm

F1 ThreshF2 PolarityF3 EchoF4 IP Blk

F5 Echo Blk1F6 Echo Blk2F7 Polarity2F8 Thresh2

Thickness

F1 StartF2 EndF3 ThreshF4 Alarm

F5 Gate2F6 StartF7 EndF8 Thresh

Flaw-Lin

F1 PeakF2 Pt#F3 XF4 Y

F5 AddF6 EraseF7 RstF8 DAC

Flaw-Dag

F1 AngleF2 Matl-ThkF3 SD-OffsetF4 Zero

F5 VelocityF6 Alarm

ShearF1 FrequencyF2 BandwidthF3 Puls DampF4 Sqr/Spike

F5 Puls-VltsF6 Puls-Wld

Tuning

F1 ResetF2 StartF3 Auto 80%F4 Accept Pt.

F5 EndF6 Del Pt.F7 Accept All

Dag Setup

F1 Atrace1F2 Atrace2

AtracesF1 New CscanF2 New BscanF3 Load ScanF4 Move

F5 ScannerF6 SpeedF7 Load Image

Scan

Figure 1 Menu Tree

Thickness Mode


3.1 Main

1. Calibrate – Brings up the Calibrate menu.

2. Mode – Brings up the Mode menu.

3. Pulser – Brings up the Pulser menu.

4. Receiver – Brings up the Receiver menu.

5. Scan – Brings up the Scan menu.

6. Display – Brings up the Display menu.

7. Setup – Brings up the Setup menu.

8. Atraces – Brings up the Atraces menu.

Thickness Mode


3.2 Calibrate

1. Zero – A fine delay function which allows for compensation of transducer wearsurfaces, coupling membranes and angle beam wedges. Adjustment is continuous from -100 to +100 microseconds.

2. Velocity – Sets the material velocity (inches/microsecond or mm/microsecond) used in calculations of thickness. NOTE: The VELOCITY value will be decreased by approximately one-half from reference velocity when ANGLE MODE is selected.

3. Delay – Used to adjust the start of the A-trace display along the horizontal axis. Gates that are synchronized with the A-trace will also delay accordingly.

4. Range – Used to determine how much time (distance) is represented on the horizontal axis of the A-trace display. Increasing or Decreasing the RANGE will cause the A-trace display to expand or contract.

5. Tracking – When Tracking is ON, the Track window will follow the echo at the point of thickness trigger. This is where the Threshold line triggers on the echo. The Gage will automatically center the echo in the center of the Track window regardless of the actual

Thickness Mode


thickness being measured. When Tracking is OFF the Track window does not follow the echo but rather defines an area of Zoom which will not operate in a dynamic fashion. In this regard, the echo will move left or right throughout the Track window. If the echo moves outside the area defined by the vertical cursors there will be no echo displayed on the lower screen.

6. Delay2. – This control adjusts the independent time base Delay for the Tracking window. This operates with Tracking Mode ON or OFF.

7. Range2 – This control adjusts the independent time base Range for the Tracking window. The total Range for the Track window can not exceed the set Range of the Main Trace window. For instance if the Main Trace is set to 3” the Track window can not be set to 4”. Usually the Track window is something like 20-40% of the Main Trace window. This operates with Tracking Mode ON or OFF.

8. PRF – Used to adjust the Pulse rate.

Thickness Mode


3.3 Mode

1. Thickness – Brings up the Thickness menu and changes Measurement and A-trace sections to Thickness Mode.

2. Flaw-Lin – Brings up the Flaw-Lin menu and changes Measurement and A-trace sections to Linear Flaw Gate Mode.

3. Flaw-Dag – Brings up the Flaw-Dag menu and changes Measurement and A-trace sections to Dynamic Flaw Gate mode.

4. Shear – Brings up the Shear menu and changes Measurement and A-trace sections to Shear Wave mode.

5. Dag Setup – Brings up the Dag Setup Menu

Thickness Mode


3.4 Thickness

1. Thresh – Increases or decreases the Measurement Threshold level. Any echo or echo half cycle with amplitude equal to or greater than the Thickness Gate Threshold will be measured for distance. The threshold gate is the bar on the left of the A-Trace frame extending to the first echo in the figure.

2. Polarity – Determines if triggering is on the positive or negative half cycle.

3. Echo – Allows the selection of a multiple echo from which the thickness measurement will begin. Selections are IP to 1st, 1st to 2nd, and 2nd to 3rd.

4. IP blk – Used to increase or decrease the length of the gate that is used to block out any unwanted signals after the Initial Pulse. Adjustment of the IP blk will allow proper setup for IP to 1st back echo measurements in the thickness mode.

5. Echo blk1 – Increases or Decreases the length of the echo blocking gate that is used to block out any unwanted signals from the 1st echo in the thickness mode.

6. Echo blk2 – Increases or Decreases the length of the echo blocking gate that is used to block out any unwanted signals from the 2nd echo in the thickness mode.

7. Polarity2 – Sets the polarity of Echo blk1.

8. Thresh2 – Sets the threshold for Echo blk1.

Thickness Mode


3.5 Flaw-Lin

1. Start – Adjusts the horizontal position of the leading edge (start) of Gate1.

2. End – Adjusts the horizontal position of the trailing edge (end) of Gate1.

3. Thresh – Sets the threshold level of Gate1. Adjustable from 0% to 100% of full screen height in 1% increments.

4. Alarm – Brings up the Alarm menu (see 1.4.7.1 for more details).

5. Gate2 – Enables Gate2.

6. Start – Adjusts the horizontal position of the trailing edge (end) of Gate2.

7. End – Adjusts the horizontal position of the trailing edge (end) of Gate2.

8. Thresh – Sets the threshold level of Gate2. Adjustable from 0% to 100% of full screen height in 1% increment.

Thickness Mode


3.6 Flaw-Dag

1. Peak (only available in rectified display modes) – Peak hold has 3 settings: Off, Hold 2 Sec, and Hold Cont.

HOLD 2 SEC - Captures and displays the peak echo envelope for a period of 2 seconds. After this time the envelope reduces (washes) to the baseline again. Useful in temporarily holding echo results as the user continues scanning. HOLD CONT - Captures and holds the echo envelope, continuously adjusting it for any echo peak over the last displayed value. If the echo never exceeds the displayed echo envelope, the envelope will not be adjusted.

2. Pt# – Selects the gate geometry point to adjust (1-20).

3. X – Adjusts the Horizontal position of the selected point.

4. Y – Adjusts the Vertical position of the selected point.

5. Add – Creates an additional point of geometry (up to 20 total points).

6. Erase – Removes the selected point from the geometry.

7. Rst – Resets geometry to 2 linear points.

8. DAC – Enables Distance Amplitude Correction for the signals beneath the gate geometry.

Thickness Mode


3.7 Shear

1. Angle – Allows user entry of the refracted beam angle (for flaw triangulation measurements) of the transducer being used. Adjustable from 0 to 90 degrees in 0.1 degree increments.

2. Matl-Thk – Allows entry of the nominal thickness of the material being tested (used for flaw triangulation measurements). Adjustable from 0.01. To 50.00 inches.

3. SD-Offset – Permits the user to enter the sound path offset in order to compensate for wedge or shoe distance. This offset is subtracted from the actual Surface Distance to allow for more accurate flaw location.

4. Zero – Fine delay function which allows for compensation of transducer wear, coupling membranes and angle beam wedge. Adjustment is continuous from 0 to 20,000 nanoseconds.

5. Velocity – Sets the material velocity (inches/microsecond or mm/microsecond) used in calculations of thickness. NOTE: The VELOCITY value will be decreased by approximately one-half from reference velocity while in Shear MODE.

6. Alarm – Brings up the Alarm menu (see 1.4.7.1 for more details).

Thickness Mode


3.8 Dag Setup

1. Reset – Deletes all points in the DAG gate.

2. Start – Begin setting up the DAG gate in Auto mode..

3. Auto 80% – Sets the current point to 80% of screen height.

4. Accept Pt – Accept the current point.

5. End – Completes the DAG setup.

6. Del Pt – Deletes selected point.

7. Accept All – Accepts all entered points.

8. DAC – Toggles DAC

Thickness Mode


3.9 Pulser

1. Sing/Dual – Selects between single or dual element transducers. Dual setting can also be used for thru transmission applications.

2. Damp – Changes receiver damping through these values: 25, 50, 75, 100, 125, 150, 175, 375 ohms. As each new value is switched in, the effect on the waveform in the A-trace display can be observed. Use Damping to visually optimize the receiver / transducer performance.

3. Sqr/Spike – Selects between Square pulser and Spike pulser.

4. Puls-Vlts – Sets the pulse amplitude.

5. Puls-Wid – Sets the pulse width when using the Square pulser.

6. Sync – Selects between IP sync and IF sync.

7. Invert Wav – Inverts the A-Trace waveform.

Thickness Mode


3.10 Receiver

1. Rect – Sets the rectification mode for the echo signal on the A-trace display. Four selectable waveform types scan be displayed :

1.1. +HW - Positive half-wave rectified – +HW when selected, displays only the positive portion of the RF signal on the A-trace display.

1.2. - HW - Negative half-wave rectified – -HW when selected, displays only the negative portion of the RF signal on the A-trace display.

1.3. FW - Fullwave rectified – FW when selected, displays a superimposed -HW signal on a +HW signal on the A-trace display.

1.4. RF - Non rectified radio-frequency – RF when selected, displays both the +HW and -HW signals, non-rectified.

2. Polarity – Sets the polarity of the primary threshold.

Thickness Mode


3. Damp – Changes receiver damping through these values: 25, 50, 75, 100, 125, 150, 175, 375 ohms. As each new value is switched in, the effect on the waveform in the A-trace display can be observed. Use Damping to visually optimize the receiver / transducer performance.

4. Gain-Inc – Sets the value the Gain increments or decrements when GAIN +/- keys are used.

5. +dB-Inc – Sets the value the +dB key changes the gain when pressed.

6. Tuning – Brings up the Tuning menu (see 1.4.5.1 for more details).

7. Reject – Allows suppression of unwanted low amplitude signals, such as electrical or material noise. Reject is adjustable from 0 to 100% in 1% increments of screen height of the A-trace display.

Thickness Mode


3.11 Tuning

1. Frequency – Selects the frequency range of the receiver to match the transducer: A broadband frequency range (BB) of 0.5 to 20MHz, tuned channels of 0.5, 1.0, 2.0, 2.5, 5.0, 10.0, and 15.0 MHZ (nominal) are selectable.

2. Bandwidth – Sets the Bandwidth to narrow or wide.

3. Vid Filt –Sets the video filter to low, med, or high.

4. Puls Damp – Changes receiver damping through these values: 25, 50, 75, 100, 125, 150, 175, 375 ohms. As each new value is switched in, the effect on the waveform in the A-trace display can be observed. Use Damping to visually optimize the receiver / transducer performance.

5. Sqr/Spike – Selects between Square pulser and Spike pulser.

6. Puls-Vlts – Sets the pulse amplitude.

7. Puls-Wid – Sets the pulse width when using the Square pulser.

Thickness Mode


3.12 Scan

1. New Cscan –Brings up the setup screen for Cscans.

2. New Bscan – Brings up the setup screen for Bscans.

3. Load Scan – Loads a previously saved scan setup and data.

4. Move – For motorized scanners, moves the motors.

5. Scanner – Available scanner selection.

6. Speed – Accesses the speed menu.

7. Load Image – Loads a previously saved screenshot.

Thickness Mode


3.13 Display

1. Backlite – Adjusts the LCD backlight between 3% and 100%.

2. Fill – ON - Fill the waveform when in +HW, -HW or FW mode. OFF - Display waveform in outline mode.

3. Peak-Hold – Peak hold has 3 settings: Off, Hold 2 Sec, and Hold Cont. HOLD 2 SEC - Captures and displays the peak echo envelope for a period of 2 seconds. After this time the envelope reduces (washes) to the baseline again. Useful in temporarily holding echo results as the user continues scanning. HOLD CONT - Captures and holds the echo envelope, continuously adjusting it for any echo peak over the last displayed value. If the echo never exceeds the displayed echo envelope, the envelope will not be adjusted.

4. Units – Selects between inches or millimeters.

5. Copy –Saves the current screen to the internal or external disk.

6. Clock –Sets the real time clock.

7. Alarm –Brings up the alarm menu (see 1.4.7.1 for more details).

Thickness Mode


3.14 Alarm

1. THK_ALM – Selects which thickness alarm is mode enabled: Off, Low (less than), High (greater than), or Both.

2. Lo-Thk – Sets the low value for the thickness alarm. The alarm will trip when the thickness is less than the value set.

3. Hi-Thk – Sets the high value for the thickness alarm. The alarm will trip when the thickness is greater than the value set.

4. Time – Sets the duration of triggering necessary to sound the alarm.

5. Amp-Alm – Sets the alarm mode for amplitude gate 1: Off, Greater Than, or Less Than.

6. Amp2-Alm – Sets the alarm mode for amplitude gate 2: Off, Greater Than, or Less Than.

7. Buzzer – Enables or disables the audio buzzer during alarm condition.

Thickness Mode


3.15 Setup

1. Load – Loads a previously saved setup through the file access menu.

2. Save – Saves a setup under a user selected name.

Thickness Mode


3.16 A-traces

1. A-trace1 – Enables or disables A-trace 1. This is the “full view” A-trace which determines the overall Measurement conditions.

2. A-trace2 – Enables or disables A-trace 2. This is the “enhanced view” A-trace which tracks the target echo at a selectable zoom level.

Thickness Mode


4 Thickness Mode

4.1 A Walk through using a 3/8” 5.0 MHZ Contact Tra nsducer (NDT Systems Nova Series C11 or general purpose Optima Series CHG053)

Once the effects of variables affecting thickness gaging precision are understood, the operator can quickly diagnose which variables should be adjusted. A good way of observing these effects, and to become quickly familiar with Raptor’s controls is to perform the following procedure:

1) Attach a highly damped, broadband contact transducer such as the OPTIMA CHG053 or NOVA C11 (5 MHZ, 3/8 inch element diameter) to the BNC connector on the transducer cable appropriate for the Raptor. Insert the connector in either receptacle on the top closure of Raptor.

2) Obtain a steel stepped wedge with several known thickness steps. An excellent choice, and the one upon which this procedure is based, is the OPTIMA Model TBS114. This block, made from 4340 vacuum-melted steel alloy and nickel plated, has five steps precision machined to thicknesses of 0.100, 0.200, 0.300, 0.400, 0.500 inch (2.54, 5.08, 7.62, 10.16, 12.70mm).

3) Couple the transducer to the 0.500 inch step using a drop of glycerin, light machine oil, mineral oil, or low viscosity gel-type couplant. For this familiarization exercise, it will be convenient to use a rubber band or a small weighted object that will hold the transducer in place. This trick will relieve you from having to hold the transducer in place for an extended period during familiarization.

4) Press the ON/OFF key. During this very brief period, the Raptor undergoes a host of internal diagnostic checks. Once these checks are complete, the LOGO screen appears. Press any key on the Raptor to continue to the measurement screen.

Thickness Mode


5) An A-trace will appear, along with the Main Menu items and thickness readout, the large numbers in the upper area of the A-trace. If the unit is not the correct mode, go to the MODE menu by pressing F2 and select THICKNESS mode by pressing F1. Then go to SETUP by pressing MENU/ESC twice then F7 to select SETUP menu. Press F1 to load a setup and select CONTACT 5MHZ from the setup list. The setup name should be the first in the list. Scroll up or down as necessary, then press ENTER. Note the first large back echo at the second major horizontal scale division and the thin horizontal bar at 40% full-scale (FS) amplitude. Observe that this horizontal line extends from the extreme left edge of the A-trace and terminates on the leading edge of the 1st back echo. This line, or bar, represents the thickness gate (T-gate) and shows which echo stops the gate. In this example, since the 0.500 inch step is the one being measured and the horizontal FS range is 2.50 inches, the T-gate terminates on the first echo above 40% FS amplitude, the back echo from the 0.500 inch step. Along the left-hand vertical axis, a signal will also be seen. Since the FACTORY setup defaults to initial pulse synchronization (IP SYNC), this signal is the initial pulse (IP) with its leading edge coincident with the left-hand vertical axis.

6) One other feature that should be noted is the presence of a wider shaded bar extending horizontally along the thickness gate, in this case on the MAIN A-Trace window from the left-hand axis. This bar represents the IP blocking gate (IP-BLK gate) which serves to “block” out the string of high amplitude echoes typically accompanying the IP. In its FACTORY setup default position, the IP-BLK gate is at 0.2284 inch to block out the IP echoes and thus prevent the T-gate from triggering in or on the IP. This will likely need to be adjusted depending on the specific transducer attached. Control of the IP-BLK gate is explained further in this procedure. (If an undamped or lightly damped transducer other than those recommended for this exercise is being used, it may be necessary to make an immediate adjustment of the IP-BLK gate in order to proceed. If necessary, go to Step 15, below, and perform the necessary adjustment.)

7) For the transducers and stepped wedge recommended, the thickness readout (T-readout) should be within a few thousandths of an inch from 0.500 inch plus or minus.

Thickness Mode


8) Use the front panel keypad +/- GAIN keys to increase/decrease the effective gain so that the first primary echo peak is above the threshold line, but below the top of the screen height.

9) To become familiar with the RANGE function, from the MAIN menu, press F1 to select the CALIBRATE menu, and then press F4 to select RANGE. The UP arrow key will squeeze the echoes on the A-trace to the left, that is, except for the initial pulse. If multiple back echoes are present, they will move toward the left and approach each other more closely. In our 0.500 inch steel block example, depress the DOWN arrow key until the first back echo, originally at the second vertical division of the electronic graticule moves to approximately the fourth full vertical division. The second back echo will be aligned (or nearly so) at the 8th full division. The readout value under RANGE may be close to 1.2 inch.

10) The DELAY function also has pronounced effects on the location (and LOCATION ONLY) of signals on the Atrace. Set the full-scale range using the RANGE menu selection at about the 1 inch and position the cursor at DELAY or press F3 in the CALIBRATE menu to select DELAY. Depress the UP arrow key and observe the effect. Signals move toward the left, including that of the initial pulse, which moves off-screen to the left. Note that the distance between multiple back echoes does not change as it did when range was increased. Continued depression of the UP arrow key moves echoes toward the left until they are completely delayed off-screen. If calibration has been performed for the material under test, the readout under DELAY indicates how far the display has been delayed.

11) With the RANGE at 1.00 inch, from the MAIN Menu press F2 for MODE, then press F1 for THICKNESS, then press F4 to select IP-BLK. The UP & DOWN arrow keys control the length of the blocking gate, referred to as “IP-BLK” gate, and represented by the Thick bar extending horizontally along the thickness gate line on the Atrace from the left-hand side of the screen. Its purpose is to “block” the trailing edge echoes associated with the initial pulse or any spurious signals which might interfere with what is known as the true interface. This group of echoes contains ring-down echoes from the transducer and "noise" accompanying stray reflections resulting from coupling. The "noise" is minimal when both the front surface of the transducer and the surface of the test object are smooth. This is the usual case with new, unworn transducers

Thickness Mode


and with many finely-machined test blocks or reference standards. However, actual test objects seldom have clean, smooth surfaces. They often have rough machined or mill-finished surfaces (as-cast surfaces on castings), and sometimes have corroded and/or painted surfaces. In these cases, the extent of coupling noise will be greater than that returned from test blocks. At default, the length of the blocking gate (IP-BLK gate) is about 0.200 inch equivalent in steel. With medium to broadband transducers of 2.25 MHZ or greater, the distance is usually sufficient to block IP echoes and coupling noise from standard test blocks. Note, however, that it would not be possible to measure material less than the width of the calibrated IP-BLK gate (less than ~0.200 inch at FACTORY defaults). If the total IP signal is greater, and the blocking gate must be increased, any significant echoes within the blocking gate, transducer back echoes or otherwise, will be blocked and will determine the minimum thickness that can be gaged with the correct digital thickness readout. In such cases, it may be necessary to use a different transducer or a different technique. With highly damped, broadband transducers of 5 or 10 MHZ, it should be possible to shorten the IP-BLK gate to permit IP to first back echo digital readout of 0.030 inch steel or equivalent. At this point, use the Up/Down arrow keys to change the length of the IP-BLK gate in order to observe the effects of the control.

12) Before examining the function of THICKNESS THRESHOLD (THRESH), press MENU/ESC to display the MAIN Menu. At THRESH, note that the horizontal T-gate bar is at 40%. UP or DOWN arrow keys change the threshold level of the T-gate, and the actual level of the T-gate is readout in % full-scale amplitude, variable from 0% minimum to 100% maximum. The FACTORY default amplitude of generally 40% (probe selection dependant) is a good compromise and generally effective when the first back echo amplitude is maintained between approximately 70% full-scale and to somewhat greater than saturation amplitude (greater than 100% full-scale).

4.1.1 ZERO & VELOCITY The next two functions, VEL and ZERO are adjustments necessary to "calibrate" the gage to the accurately measure the thickness of the specific material under test.

Thickness Mode


In our example, using a 0.500 inch thickness step, we have yet to perform any operations to "calibrate" the Thickness readout. Most probably the reading is close to 0.500 inch, since the FACTORY setup defaults are deliberately designed to produce nearly correct calibration for a contact transducer being used on steel having longitudinal sound velocity of 0.2330 inches/microsecond.

As a first step in becoming familiar with the VEL and ZERO functions, lets complete the calibration for thickness measurement using the step block in our example. Press the CAL key to enter the Calibration menu.

Velocity - Set the cursor at Velocity (or press F2) and adjust it to .2330 in/µs (Steel).

Zero (probe zero control position) - Using the Left/Right arrow keys, reposition it at ZERO (or press F1). Using the Up/Down arrow keys adjust the thickness reading to 0.500". When 0.500 inch [or whatever the known actual thickness of the step] is achieved in Thickness readout, the upper range calibration is complete. Note that zero may change through up to 5 or 10 counts (on the display) before the indicated thickness changes. Choosing zero roughly at the mid-point of the range needed to move from 0.499 inch to 0.501 inch. This procedure can improve thickness gaging precision.

Remove the transducer from the 0.500 inch step and couple it to the other steps on the block. If the test block has been accurately measured and the material is steel with a VELOCITY (VEL) of 0.2330 in/us, the other step measurements should be within ±0.001 inch of the actual measured values and reproducible.

If some material other than steel is used, a different procedure will be required. For a transducer of similar type as used in these procedures, reset the ZERO to approximately that of the default (.7530 µs). Depress the F2 key to position the cursor at VEL (velocity). With the transducer coupled to the thickest step, use the Up/Down arrow keys to increase/Decrease the velocity until the known thickness of the material is displayed on the thickness readout.

Now couple the transducer to the thinnest step. If thickness readout does not agree with the known thickness, press F1 to position the cursor at ZERO and use the Up/Down arrow keys to produce the known thickness on the thickness readout.

Then, again check the thickest step. If thickness readout still does not agree with known thickness, reposition the cursor at VEL (velocity) and use the Up/Down arrow keys to obtain the known thickness.

Thickness Mode


Continued adjustments between ZERO and VELOCITY will produce correct thickness readout on both the thickest and thinnest steps. At this point, the steps in between will read correctly (within the resolution, ±0.001 inch). The velocity value above the Measurement is the velocity of the material of the specific material of block under test.

A short-cut in the calibration routine for metals other than steel is to scroll the value at VEL to the nominal velocity for that material. Velocity values are tabulated in a variety of publications, including NDT Systems, Inc. OPTIMA transducer catalog.

4.2 ECHO-ECHO Setup Using 3/8" 5MHz Contact Transdu cer To examine ECHO to ECHO function, place the transducer on the 0.500 inch thickness step. Press CAL, then F4 to set RANGE to 2.00 inch with the Up/Down arrow keys. Exit Calibration with MENU ESC, then press F2 for Mode, then F1 for Thickness, then F3 for Echo. Use the Up key to select “1-2”. Echo allows the selection of a multiple echo from which the thickness measurement (Thickness gate) will begin. Up to the 3rd-multiple echo can be selected using the Up/Down arrow keys. This function is useful when using single element transducers with thin elastomeric membranes or on coated test objects. Press F5 to select the 1st ECHO BLOCKING GATE (ECHO-BLK1). Note the thick horizontal bar on the Thickness gate. Use the right arrow key to select the length of the echo blocking gate that is appropriate to block out any unwanted signals between multiple echoes in the thickness mode. The FACTORY default value is .200 inch. ECHO-BLK is actively displayed when MULT is set at 1-2 or 2-3. Look at the upper, Main Trace window. There are 2 multiple echoes in it; one at about half screen and another at about 80% across the screen. However, if you look at the Tracking (lower window) you will notice the gage is currently triggered between a single echo’s half cycle producing a reading of 0.044" which is wrong. Note the short blocking bar is about half way between. Now, look at the following image. In the Main Trace window you’ll note the ECHO-BLK gate is set just beyond the echo half cycle set. With the gate set in this manner note the Thickness Measurement bar extends to the echo set at the 80% screen position, which is the correct position. The track window now displays the echo being measured to and where the gate terminates.

For clarification regarding echo half cycles refer to the following RF based image. The one at 0.029 is triggered on successive positive half cycles. Note the position of the ECHO-BLK Gate. Then look the image displaying 0.500" and note the position of the ECHO-BLK gate. Use Polarity2 (F7) to set the polarity after the 1st echo.

Thickness Mode


For precision thickness gaging, the type of waveform used for setups has a significant effect on gaging results. Note that the RECT default is RF, meaning that the current display is of signals that are not rectified.

Appropriate Selection of Echo Half cycle

To better illustrate the effects produced by the various waveform displays, press CAL, then F4 to select RANGE. Use the DOWN arrow key to change the RANGE readout to 1.00 inch.

For this example, the display will be similar to that shown to the right:

Note that the back echoes are now displayed on a centered horizontal baseline and have both positive and negative components. This mode of display, RF, reveals all the details of the signal. If necessary to more faithfully reproduce the waveform in the figure above, it may be necessary to use the +/- GAIN keys to change the gain. Now examine the details of the back echo. The first half-cycle is negative-going, but has less relative amplitude than the next half-cycle with respect to each following half cycle (+ or -), which is positive-going. This being the case, imagine what the back echo would look like if everything below (on the negative side of) the base line were removed from the display. Vertically enlarged, that is what actually happens when +HW is selected. Selection of -HW results in the converse; only the negative-going components of the back echo signal are displayed. On the A-trace, the negative-going parts of the signal are “flipped” upright (rectified). FW represents full-wave rectification; that is, both the positive half-cycles and the flipped over negative half-cycles are displayed simultaneously.

Look at each of the responses and make a mental note of the differences. These are important differences in thickness gaging. For example, under the current test setup conditions, if FW (full-wave rectification) is selected, the lower Amplitude negative cycle appears as the first, or leading edge of the back echo. By manipulating the gain

Thickness Mode


to cause the T-gate to terminate on the negative component, then on the positive part, a significant difference in T-readout occurs.

Referring back to the Figure which shows the RF display, a good reason to select +HW over -HW or FW is because the first positive going component of the signal has greater amplitude than does the first negative, produces a “cleaner” display than FW and is less sensitive to producing Thickness readout changes as a function of gain.

There are other good reasons for offering this variety of display modes. There are instances where the more prominent half-cycle is not positive-going. In cases where the back wall is lined with another material (e.g. some elastomers), the first negative-going half-cycle is more prominent. This phenomenon has to do with the relative acoustical impedance characteristics of the two materials that make up an interface. Many liquids, elastomers, and polymers forming an intimate interface with metals produce echoes whose phase is reversed from that of the metal/air interface.

The RF display can be referred to if there is any question about which waveform should be selected. For thickness gaging metals much beyond one inch thick, it will be necessary to “expand” the RF display. If, for example, for a 2 inch thick test specimen, the full-scale range of the Raptor has been set to a long range, and the RF display is selected, there will be poor detail in the presentation of the RF.

In order to expand the RF display of the back echo under such condition, delay can be used to reposition the back echo very near the left side of the A-trace. Then, reducing full-scale range to 0.50 inch (12.7mm) reproduces the RF of the back echo similar to that of a much thinner test object.

From the MAIN Menu select Pulser (F3) and then DAMP (F2). The default value is specific to the transducer selected, but 50 Ohms is a usually good match for the type of transducer being used in this example. To observe the effect of damping changes, depress the Up/Down arrow key and note a new, higher or lower damping resistance value displayed. Also note that the IP echoes tend to extend farther at higher damping resistance. Damping changes likewise increase both the amplitude and shape of the back echo. To observe the effect of damping on the back echo, use +/- GAIN keys to control the gain (dB). With down and up adjustments as required, establish the amplitude of the first back echo at approximately 50% FS (the precise location is unimportant). Then, return the cursor to DAMP and use the Up/Down arrow key to once again increase the damping resistance. Observe that the amplitude of the back echo increases, perhaps substantially, with increased damping resistance.

Thickness Mode


While this effect can be used to advantage under some conditions, for precision, high-resolution thickness gaging, it is usually desirable to select relatively low damping resistance. With experience, through careful observation of the changing shapes of the IP and back echo, it is possible to optimize the damping for the job at hand. For now, return the damping resistance value to 50 ohms, the default value.

4.3 Procedures for Using Dual Element Transducers w ith Delay Lines. Dual element transducers combine the advantages of single element delay line transducers with the addition of a few more. The sound beam of a dual element transducer is generally directed into the test object at a small angle. The dual element transducer has two active elements mounted side-by-side with a barrier strip of sound-absorbing material between them. One element is connected to the instrument pulser and the other to the receiver. Otherwise, they are electrically isolated from one another. The elements are mounted at slight angles with respect to the barrier strip, thus forming the shape of a shallow angle roof. The transmitted longitudinal beam centerline enters the test object at the “roof angle”. The beam continues into and through the test object, reflects from the back wall, and returns at the same angle toward the receiving transducer.

A dual element transducer is always in a “listening” mode as one half is transmitting. The real benefit with a dual can be found when inspecting corroded, pitted or eroded materials. Dual element transducers have the ability to discriminate the peaks and valleys of corrosion and or pitting.

4.3.1 Key Concept The time it takes to traverse this path includes the sum of times through the transmission delay line, through the test object thickness to the back wall, from the back wall through the test object again, and through the receiving element delay line. Therefore a process called Probe Zeroing needs to be done; it cancels out the added material in the sound path, such as the internal delay lines. Also, if a probe designed for the gage is used, the instrument compensates for the non-linearity due to the V-Path.

By “ZEROing” out the constant distance paths taken by the sound beam in traversing the dual delay lines, a measurement can be made of the travel distance in the test object only.

Thickness Mode


Since the sound beam travels at a slight angle into and out of the test object, the path taken is slightly longer than in the case where the sound beam enters and exits perpendicular to the test object surface. Calibration at a specific thickness applies only for that thickness, plus or minus. While the error at other thicknesses is small, for high precision measurements, it should be taken into account. While the error can be calculated, it is usually more convenient to determine it experimentally, or to recalibrate for different ranges of expected test object thickness. This error is more pronounced between 0.40 inch and about 0.20 inch, depending on manufacturer. This point will be illustrated in the following setups. This common error is referred to as "V-Path Error", so-called because of the V-shaped path the soundbeam takes in traveling from the transmitting element to the receiving element of the transducer.

There are several considerations to dual element transducer setups:

1) If the temperatures of the test object and transducer are essentially the same and the setup is made at basically ambient conditions, the delay line ZERO procedure is relatively easy.

2) If the test object is at a substantially different temperature than the transducer, setting up for multiple echo interval measurement will be more precise. This technique is also applicable if the test object is coated or painted.

4.4 Dual Element Delay Line ZEROing Procedure for R aptor Most dual element transducers are either undamped or lightly damped. As a consequence, the setup must be carefully optimized. The first step is to decide upon which form of display rectification will best serve. In the following procedure, a 5 MHZ, 3/8 inch (9.5mm) diameter transducer (NOVA Model TG506) can be used to produce measurements in the range from 0.200 to 0.500 inch. The factory stored SETUP name in the Raptor closely matching this probe would be “Dual 5MHz ½ in.” or follow this procedure.

1. In the Pulser (F3) Menu, select DUAL (F1). Then, in the CAL Menu, change RANGE to 2.00 inch. In the RECEIVER (F4) Menu, select RECT (F1) then RF. Adjust gain to produce and maintain an echo pattern which is less-than-saturated. Set DAMP (F3) at 375 ohms or adjust to produce the sharpest, or “cleanest”, echo pattern.

Thickness Mode


2. Study this echo pattern carefully. Notice that there is a low amplitude negative-going half-cycle, then larger amplitude positive and negative half-cycles. During the optimization step above, observe that the amplitude of the first small negative-going half-cycle changes very little as a consequence of varying pulse width and amplitude. In the RECEIVER (F4) then RECT (F1) menu, alternately observe the effects of +HW and -HW rectification. While -HW (shown on the right, below) could be used, the echo half-cycle on which the T-Gate terminates varies considerable with changes in echo amplitude. At +HW, the first positive-going half-cycle is at full-scale amplitude. Since both displays were produced at the same level of gain, +HW rectification should be chosen.

3. The next step is to complete the calibration. In the MAIN then Calibrate (F1) menu (or press front panel CAL button), adjust Velocity to 0.2330. Then move to and adjust ZERO to produce the thickness readout corresponding to a known thickness (in this case, 0.500 inch). Note, when you check the measurement of the 0.200 inch step it produces ~0.205 inch. This error is due to “V-Path Error”, mentioned above. Check the thicknesses in between and note the variations.

4. With the error having been determined to be ~0.005 inch in the range from 0.200 to 0.500 inch, the “safer” way to calibrate is to establish the known thickness at the lower extreme of the measurement range. Thus, ZEROing at 0.200 inch produces the “conservative” error of 0.006 inch at the 0.500 inch step. Note the ZERO difference.

4.5 Dual Element Thru-Paint Measurements. With careful optimization and setup, multiple back echo intervals can be used for thickness measurement using dual element transducers. In the example shown below, multiple back echo intervals as far as the 4th back echo can be seen. In this case, the first back echo was set to the left-hand start of the windowed A-trace.

Go to MODE (F2), then THICKNESS (F1), then ECHO (F3) and change to 1-2.

Go to ECHO-BLK and set to a minimum point between the 1st and 2nd echo where the gage will trigger reliably on the proper second echo. As a point of reference, compare the two screens below. In the Left screen, a “standard” fingertip dual transducer is connected. Note

Thickness Mode


how the waveform extends in a decaying fashion between the 1st and 2nd echo. In this case the ECHO-BLK will need to be extended out far enough to pass the multiple echo cycles of the first echo. This will limit the low end thickness capability. In the right image, a TG560P transducer is attached. In this case the transducer is optimized to allow for thinner material measurement.

This technique can be used with many dual element transducers to measure painted or coated objects or object at elevated temperatures. With the ZEROing technique described in the preceding procedure, when the transducer delay lines contact a hot surface, they rapidly expand. Expansion changes the V-path significantly, and consequently produces sizeable errors. Using a multi-echo mode eliminates this error.

In general, multi echo measurements in a dual element mode are limited to a upper thickness range of about 3 inch, probe, material, coating and application specific as the 2nd echo tends to diminish even under ideal circumstances.

Flaw Mode


5 Flaw Mode The FLAW MODE (selected from the MODE menu or front panel direct access key FLAW MODE) contains items specific to flaw detection. When this mode is first selected, GATE1 will be displayed in the measurement screen.

5.1 Flaw-Lin In this mode, two Linear Amplitude Gates can be defined for the purposes of echo amplitude measurement and threshold triggered alarm. These Gates are defined by:

5.1.1 Start (F1) and End (F2) Establish the beginning and ending of GATE1

5.1.2 Thresh (F3) Threshold allows adjustment of the vertical threshold of GATE1 in percent from 0% to 100% in 1% increments. (This threshold is tied directly to the thickness mode threshold for ease of mode switching)

5.1.3 Alarm (F4) Alarm enters the Alarm menu. Relevant options in Alarm menu for Flaw Mode:

Time – Sets the duration of triggering necessary to sound the alarm.

Amp-Alm – Sets the alarm mode for GATE1: Off, Greater Than, or Less Than.

Flaw Mode


Amp2-Alm – Sets the alarm mode for GATE2: Off, Greater Than, or Less Than.

Buzzer – Enables or disables the audio buzzer during alarm condition.

5.1.4 GATE2 (F5) Enables a second, independent Flaw gate

5.1.5 GATE2 Start (F6), End (F7), and Thresh (F8) Allow adjustment of the beginning, ending, and threshold level of GATE2. (GATE2 threshold is independent of all others)

Flaw-Dag


6 Flaw-Dag DAG (Distance Amplitude Gating): Calculates signal amplitude as a percentage or dB difference of the DAC curve level same size reflectors peak along the curve independent of their location. An alarm can be activated when a gated signal breaks the curve. DAC (Distance Amplitude Correction): Corrects for distance/amplitude variations due to material attenuation and beam spreading. Reference echoes are brought to a standard full screen level of 80%.

Flaw-Dag


6.1 Manual Dag setup From the Main menu press F2 to get to the Mode menu then F3 to get into Flaw-Dag menu. The screen will look similar to the screen on the right. To begin setup use F5 (Add) to set the number of points on your DAG curve. The Raptor allows for a maximum of 20 points. It is suggested that Peak hold be turned on at this time by pressing F1. Peak hold will assist in setting up the points of your curve. When your first echo is correctly positioned on the screen, use F3 (X) and F4 (Y) to move the point, represented by a square on the screen, onto the peak of the echo. When X or Y is selected the Up/Down arrows are used to change the value of X or Y.

Flaw-Dag


Once the point and the peak echo match, press F2 (Pt#) to move to the next point. When your second echo is correctly positioned on the screen, use F3 (X) and F4 (Y) to move the point onto the peak of the echo. Repeat these steps for each additional point.

Flaw-Dag


At this point you have a DAG gate. Select F8 to turn on DAC all points should be at equal amplitude to the first DAG point. If any points are not equal use F8 to turn off DAC and use F2 to select the point that needs to be readjusted usually the Y needs adjusting and then turn DAC back on with F8. Again look for equal amplitude based off the highest point. Other controls on this menu are F6 Erase which removes a selected point and F7 Rst which resets the DAG setup completely.

Flaw-Dag


6.2 Auto DAG From the Main menu press F2 to get to the Mode menu then F5 to get into the Dag Setup menu. The screen will look similar to the screen on the right. To begin setup use F2 (Start) when your first echo is correctly positioned on the screen, use F3 (Auto 80%) to set the point onto the peak of the echo and set the echo to 80%. Once the point is correctly positioned press F4 (Accept Pt) if it is not correct then press F6 (Del Pt). Repeat these steps for all subsequent points up to a maximum of 20. Once all points are entered press F7 (Accept All) and then F5 (End) to complete the gate. After completing the gate press F8 (DAC) to bring the DAC on line.

Shear or Angle Mode


7 Shear or Angle Mode The following is a method for calibrating in the angle beam mode. There are several other methods possible. The following is simply a recommendation.

Setting up for shearwave calibration encompasses virtually every feature in the Raptor, from THICKNESS to FLAW, and then to the SHEAR (trig) mode. As such, we will be switching between each of these modes, adjusting the components required to fully run in a calibrated manor in SHEAR MODE.

There are elements of the calibration to be aware of as we get started. A significant one is the included, Longitudinal sound path of the wedge itself, as well as the matching layer of the transducer, both of which need to be taken into account in the ZEROing of the thickness. For this procedure we will be using a miniature IIW, Type 2 block incorporating a 1 inch and 2 inch radius path.

7.1 Setup - Equipment

1. Raptor UT Instrument

2. Mini IIW-Type 2

3. 3.5 MHz 1/2 inch Transducer NDT Model No. TAB034

4. 60 Degree ST Wedge, NDT Model TAW460

Shear or Angle Mode


5. Couplant (preferably Glycerin)

7.2 A few items to be entered before starting the C alibration:

1. Enter SHEAR MODE (F2 for Mode, F4 for Shear)

2. Set Angle (F1) to 60.0

3. Enter Matl-Thk (F2) as 2.5 inch to keep 2 inch echoes on screen and assure LEG (skip) count will be accurate. When we are finished calibrating, the Matl-Thk will be readjusted to the actual base material under test.

4. Measure the distance from the wedge index point, which is the sound entry point usually indicated with a scribe line on the wedge, from the transducer to the bottom of the wedge. In this case the SD-Offset (F3) is 0.600. The SD-Offset simply provides an automated method to subtract the wedge face distance so the user can measure (usually with a scale) from the end of the wedge to the surface above the defect.

7.3 Calibration:

5. Set Range (F4) to 5 inch in CAL menu

6. Set Raptor to Thickness (F1) in Mode (F2) menu

Shear or Angle Mode


7. Set Thresh (F1) to 60%

8. Place transducer (assembled to wedge) on IIW block and attain a set of full screen height echoes (one from the 1 inch radius and the other from the 2 inch radius) as shown below.

9. Set IP blk (F4) so the wider shadowed gate is set past the Initial Pulse. This prevents the Raptor from triggering on Transducer/wedge/pulser “front end” ring-down noise.

7.4 EBLK Adjusted

10. Set Echo (F3) to 1-2 (1st to 2nd Echo) where we will be measuring from the 1 inch to the 2 inch radius path. If the measuring gate line does not extend from the 1st to the 2nd echo as shown in the example, it is likely that the Echo Block gate requires an adjustment. The Echo Block is the short shaded gate as it is shown on the 2nd echo. It must extend past the width of the echo envelope in order to stop on the next echo. Study the images to the above.

Shear or Angle Mode


11. Exit the Thickness menu (MENU ESC) and select Flaw-Lin (F2) if needed to set the flaw gate in position (adjust Start and End to be over desired echoes).

12. Exit the Flaw-Lin menu (MENU ESC) and select Shear (F4)

13. Assure Angle, Matl-Thk and SD-Offset are as originally set.

14. Select Velocity (F5) and adjust so that PATH reads 1.000 inch as the distance from echo 1 to echo 2.

15. Exit the Shear Menu (MENU ESC) and select Thickness (F1), then set Echo (F3) to IP-1st

16. Exit (MENU ESC) and set Mode to Shear (F4)

17. Without moving probe, adjust Zero (F4) to attain a Path reading of 1.000 inch. Since we know the VELOCITY is set correctly for the material using Echo to Echo to eliminate variables in the wedge and probe, this process will adjust the excess transit time (zero) to eliminate the wedge and transducer face thickness from the total sound path travel

18. Once the ZERO is adjusted to attain 1.000 inch, slide the transducer assembly to read only the 2 inch radius. If the calibration was done properly you should be very close to the 2.000 inch Path (soundpath) +/- any variation when you moved the probe over.

Shear or Angle Mode


19. From here, you are ready to adjust Matl-Thk to the thickness of the material under test. As the material gets thinner you may note the LEG count increase and decrease as you scan indicating the skip path.

Setups


8 Setups In designing the menus for the Raptor, particular attention has been paid to simplifying the process of locating items, then prompting the operator to do something intuitive in order to change control settings.

8.1 FACTORY Setup Variables. When the Raptor is turned on by pressing the ON/OFF control, the LOGO screen is displayed automatically. When the gage is operated for the first time, or if FACTORY DEFAULT RESET is performed (hold ENTER while booting), all the control variables “default” to the Contact 5MHz profile (after that, they will display the last previous setup parameters). For many common flaw detection or thickness gaging applications, it is only necessary to “fine tune” a few variables. Some applications can be started without any adjustments. The FACTORY setup variables have values that match or nearly match a variety of the most commonly used transducers for flaw detection or thickness gaging.

From the Main menu, select Setup (F7) or press SETUP, then Load (F1) to see the list of default and user setups stored on the gage.

With Raptor’s broadband receiver and Spike pulser, it is possible to achieve high resolution, penetration, and sensitivity by using relatively highly damped, broadband transducers for thickness gaging as well as lower Q or tuned transducers, such as angle beam probes. Of course, there will be instances where reduced bandwidth transducers will be preferred and therefore the “FILTER” setting in the Receiver menu may be turned on, but a surprising number of applications can be satisfied with the FILTER in broadband mode.

Setups


Once you have “dialed-in” the settings which are most optimal for your transducer and application, you can save them all into a convenient quick-load setup. From the Main menu, select Setup (F7) or press SETUP, then Save (F2), then Save (F1) to open the keyboard dialog so that your setup can be named for reference. Once done naming, select ENTER to save, and ENTER again to confirm. Follow the loading procedures above to reload your setup at any time

Scanning


9 Scanning

9.1 New CScan Select New CScan (F1) from the SCAN menu and press ENTER. This menu selection will clear any scan information in RAM memory and reset the screen so new scan data can be acquired. If this is the first scan to be set up, then the operator needs to clarify the scanner selection before initializing this step.

9.1.1 Scan Area Definition Now the Scan Area Definition screen will appear. Use the Up/Down arrows to select, then use the Left/Right arrows or numbers to enter values. “Index” refers to the distance between data points in each axis. “Length” refers to the positive dimension to be scanned in each axis. “Points” shows how many data points will be collected in each axis. Note that the first data point is taken at zero, and the last data point taken at the length entered. Example: A 1.0 inch index and a 12.0 inch length will yield thirteen data points.

The “Data Stored Each Point” selection allows you to choose between three methods of holding data information acquired during a scan. “Lowest” means that the lowest reading in a data point will be held

Scanning


across multiple passes. “Highest” means that the highest reading in a data point will be held across multiple passes. “Center” means that the reading closest to the dimensional center in a data point will be held as aggregated over multiple passes. When all selections have been made press ENTER to proceed or MENU ESC to back up to the previous screen (this applies throughout the program).

Place the transducer at the zero reference corner by using the corresponding motor jog arrow keys to position the scanner in the proper location. Press ENTER to initialize the scan area, MENU ESC to abort to the previous screen.

When the scan area is initialized, a grey box will appear on the screen and the scale will be repositioned at the bottom or left side of the screen depending on the size and shape of the scan area.

Scanning


9.1.2 Start Scan The C-Scan pop-up window will appear; move the highlight bar to Start Scan (F1). Make sure that there is nothing that will obstruct the movement of the scanner (like cables) during the scan, and make sure that there is plenty of couplant for the transducer. If you are ready to scan press ENTER, and the motorized scan will begin. If you are in the manual mode, you can begin scanning now. You can stop a scan at any time by pressing MENU ESC. If you need to stop a scan, you may want to restart it using the Start Scan (F1) command.

Scanning


9.1.3 Move Motors Pressing ENTER at the Move selection will allow you to jog the motors to position the scanner at a particular location.

9.1.4 Home Motors Pressing ENTER at the Home Motors selection will return the scanner to its original zero position where the scan was started from. If you stop a scan in the middle of a scan, you do not have to home the motors before proceeding. Even if you have jogged the motors around a bit, you can restart a scan by going back the Start Scan selection and pressing ENTER. If the scanner is momentarily stalled, and then continues, only the data at the end of that stroke will be lost. The system will put itself back location and continue the scan without losing proper position.

Scanning


9.1.5 Speed/Strokes Using the Up/Down arrow keys, select the number of strokes the scanner will make before indexing. A minimum of one and a maximum of ten strokes are allowed. This feature is helpful when rough material, or other conditions make accuracy difficult. By stroking an additional time, the operator can have a greater confidence in the data collected in undesirable conditions.

9.1.6 Clear Scan If you want to re-scan an area you do not have to enter a new scan. You can move the highlight bar to the Clear Scan selection and press ENTER. If you have not saved the data already scanned, it will be lost! To scan an area over again choose: Home, then Clear scan, then Start scan.

9.1.7 Image Opens the Image options sub-menu

9.1.7.1 Scale Scale adjusts the Range and Offset for displaying readings along the color spectrum.

Scanning


9.1.7.2 Color bar Allows for various colorization schemes for scan data: Flip (inverts current spectrum), Spectrum(ROYGBIV), Gray (White to Black), Red (to Black), Green (to Black), and Blue (to Black).

Scanning


9.1.7.3 Zoom Zoom opens a screen for zooming in on sections of a scan to show details of a reading. Arrow keys move the zoom window. F1 changes to numeric view. F2 zooms out to full. F3 gives a full screen view of the zoomed area. F5 zooms out. F6 zooms in. F7 makes zoom window Tall/Thin. F8 makes zoom window Wide/Short. MENU/ESC exits.

Scanning


9.1.7.4 B-Scan B-scan opens a screen for viewing the B-scans intersecting at a given point of a Cscan. Arrow keys move cursor. F1 finds the lowest measurement in the scan and slews to that point. F2 finds the highest measurement in the scan and slews to that point. MENU/ESC exits.

Scanning


9.1.7.5 Histogram Opens a Statistical histogram of the measurements made in a scan. Arrow keys move the graph horizontally. F1 performs an automatic Min/Max adjustment. F2/F3 move the vertical scale up/down. ENTER sets the displayed Range and Offset into the image color scale. MENU/ESC exits without making changes to the scale.

Scanning


9.1.7.6 3D View Opens a dialog to define and render a 3D isometric representation of the current scan.

Scanning


9.1.7.7 Measure

1. Line – Calculates the angle and length of a line between two points. Also shows the thickness reading at each end

2. Rect/Ell – Calculates the area of Rectangle or ellipse as defined by two points and a given height.

3. Polygon – Calculates the area under a polygon defined by at least 3 points. F1 performs the calculation.

9.1.7.8 Units Units selects between Inches or Millimeters.

9.1.8 Close Scan This will exit C-scan mode without saving the scan data. Make sure that you have saved any collected data using Save Scan before exiting.

Scanning


9.1.9 Save Scan Once a scan is completed, you will want to save it. Select Save scan (F8). A keyboard entry menu will appear on the screen. Once you have named your scan, select Enter or press MENU ESC, then press ENTER to confirm.

Scanning


9.2 New BScan Select New BScan from the menu and press ENTER. This menu selection will clear any scan information in RAM memory and reset the screen so new scan data can be acquired. If this is the first scan to be set up, then the operator needs to clarify the scanner selection before initializing this step. The menus for the BScan mirror those of the CScan, so refer to definitions found in 8.2.

Scanning


9.3 Load Scan Open a file menu dialog from which saved scans can be loaded and manipulated. Press ENTER on a directory or file name to open it. F1 selects files stored internally. F2 selects files stored externally on the SD card. F3 copies a file from internal to external memory or vice versa. F4 deletes the selected file or directory. F5 renames a file.

9.4 Move Move opens the Move Motors Dialog to allow a scanner to be jogged into position before or after a scan. Use the Arrow keys to Jog. MENU ESC or ENTER exits.

Scanning


9.5 Scanner Use the arrow keys to move the highlight bar to the Scanner (F5) menu, and press ENTER. Move the highlight bar to the appropriate scanner selection and press ENTER. This tells the software which resolution, motor configuration, and coordinate system to use while scanning. This selection does not have to be made again unless you change the type of scanner being used. Note that there is a selection for an inverted pipe scanner. This setting is for using the P3-12 pipe scanner with the directions reversed. This is important when using the cantilever arm attachment (optional accessory for this scanner) to get close to an object on the opposite end of the scanner.

.

Scanning


9.6 Load Image Opens a file menu dialog from which saved bitmap images can be viewed. Press ENTER on a directory or file name to open it. F1 selects files stored internally. F2 selects files stored externally on the SD card. F3 copies a file from internal to external memory or vice versa. F4 deletes the selected file or directory. F5 renames a file. While viewing an image, press any key to exit.

SD Cards and Communications


10 SD Cards and Communications Screen captures, setup files and scanner plots can be retrieved from the Raptor two ways. The first is by an SD Card inserted in the SD slot on the lower left hand side of the Raptor. The second is by the USB port that is in the same area.

10.1 SD Cards The Raptor will accept any SD card that is not High capacity. The Raptor is shipped with a 2G SD Card as an included accessory. When saving screenshots or other data the user will have to select the external card in the Save menu otherwise the data will be saved in internal memory.

10.1.1 An example Screenshot A screen similar to the one at right will be presented when the IMAGE key is pressed. At this screen you can enter a Screen File name and accept the default location, which is internal memory or Press F1 to select a new location.



10.1.2 File Menu A screen similar to the one at right will be presented when the F1 key is pressed. At this screen you can manage your file saving features. In this menu F1 and F2 select where to save the file in Internal or External memory. The External memory is the SD card placed in the external SD slot.

F3 well create a new directory in the selected memory internal or external.

F4 will delete the selected file.

F5 will copy the selected file to the external memory.



10.1.3 F2 to select external memory Press F2 to select the external memory. Either press ENTER to select the root of the SD card or use the UP/Down arrows to select a directory and then press ENTER. If you have selected the Root level you will be returned to the Filename entry screen. If you have selected a subdirectory it will be noted in the path space. You will then again select the external memory space by pressing F2 again you will see the save here indication move to the external file space. Pressing ENTER will now return you to the filename entry screen.



10.1.4 Filename Entry The screen on the right shows the filename entry screen. Use the arrow keys or an external keyboard to enter a filename for the screenshot. When finished entering the filename press ENTER on the virtual keyboard or on the external keyboard. A popup screen will ask for confirmation before saving press ENTER again to continue with the save.

After the file save is complete the SD Card can be removed and read into a computer.



10.2 USB Port Communications through the USB port will be handled by a Data Transfer Program.

Appendix A Transducer Selection


11 Appendix A Transducer Selection The Raptor is a capable precision thickness gage. Virtually any broadband or general purpose transducer (application dependant) can be used with the Raptor, as can equivalent transducers manufactured by other producers.

While the commentary below pertains to applications in metals, there are numerous applications to a wide variety of engineering materials. For plastics, glasses and other more or less isotropic materials, the procedures are similar to those for metals. Major differences in testing nonmetals are in the velocity of sound and different impedance characteristics. Fiber-reinforced composite materials are characteristically anisotropic, having different acoustical properties in different directions, and often require specialized transducers and procedures for satisfactory ultrasonic testing results.

In general, however, many of the transducer selection criteria factors outlined below apply for nonmetals, but additional experimentation may be required. NDT Systems, Inc. engineers have extensive experience in ultrasonic testing of many materials and can provide assistance when called upon.

The following suggestions are by no means fully comprehensive or mandatory. Alternative approaches may produce essentially the same results. The operator should experiment to determine the best transducer for given applications or contact NDT Systems, Inc. for advice.



11.1 Thickness Gaging Applications.

11.1.1 Thickness Ranges

11.1.1.1 Single Element, Delay Line Transducers. Some highly damped, high frequency transducers of this type are capable of producing fully resolved multiple back echoes equivalent to as little as 0.005 inch (0.13mm) in steel having smooth surfaces. However, such transducers will be relatively expensive and not readily attainable.

Standard inexpensive delay line transducers, highly damped, in the frequency range of 10 to 20 MHz, will ordinarily produce good results down to approximately 0.008 inch (0.20mm). Given smooth surfaces in metals having relatively low attenuation, like wrought steel or aluminum, such transducers can be used to gage up to 0.75 inch (20mm), more or less, depending upon the length of the delay line.

To determine the practical minimum thickness resolution of a delay line transducer, it is necessary to have an array of thin shims ranging in thickness around the desired minimum to be measured. Inexpensive sets of steel shims, used as feeler gages, can be obtained from well equipped hardware stores, automotive parts houses or specialty tool suppliers. The nominal thickness is typically imprinted onto each shim, often in inches and millimeters. Available sets contain as many as 15 or 20 shims, ranging from 0.005 to 0.025 inch (0.13 to 0.64mm) thick. While we have found that the stated thickness is nominal, subject to variation up to ±0.0004 inch (0.01mm), these shims can be used to readily determine the minimum thickness that can be expected from a given transducer.



Under ideal conditions, parts having very smooth, parallel surfaces can be measured to an accuracy approaching ±0.0001 (±0.003mm). To achieve such accuracy, not only is it necessary to have an appropriate transducer, the thickness gaging instrument must have extremely stable, high speed electronic circuitry. The Raptor fulfills this requirement admirably.

11.1.1.2 Single Element, Focused Immersion Transduc ers. Some transducers of this type have been designed specifically for precision thickness gaging of metals 0.010 inch (0.25mm) thick and greater. Small diameter, high frequency, short-focused immersion transducers also can be used to measure the distance to quite small internal reflectors. This is useful, for example, in gaging remaining thickness over internal passages in turbine blades.

11.1.2 Thickness Ranging from 0.030 inch (0.76mm) U pward.

11.1.2.1 Single Element Contact Transducers Hard-Fa ced Wear Plates. Depending upon active element size and frequency, highly damped (broadband) transducers of this type can seldom be used on steel or aluminum much below 0.030 inch (0.8mm). The ultimate minimum thickness limitation must be determined experimentally.

The advantage of using this type of transducer is that much thicker sections can be gaged, and on materials that have less than smooth surfaces or are relatively attenuative. Again, some experimentation will indicate the limitations and advantages among transducers of the same type, but having different sizes, frequencies and spectral characteristics.



When trying to achieve best results on relatively thin materials, the most important considerations are frequency and spectral characteristics. Foremost is the need to use a transducer having the greatest bandwidth, all other things being equal. Such transducers have relatively large, high density masses bonded to the internal face of the active element. This mass minimizes the amount of “ringing” of the active element following excitation by a short duration, high voltage electrical pulse. This kind of high mechanical damping minimizes the length of the ultrasonic wavetrain associated with the high energy initial pulse as well as the subsequent back-wall echoes.

Also necessary to achieve best thickness resolution is to use the highest frequency consistent with external factors that affect coupling efficiency, and to take material attenuation into consideration. If a transducer is expected to produce minimum thickness resolution and be used over a broad range of thicknesses, test material attenuation may dictate a compromise. While higher frequencies produce thinner thickness resolution, attenuation is more pronounced at higher frequencies.

For relatively flat, smooth-surfaced steel or aluminum test objects, highly damped contact transducers in the frequency range from 5 to 10 MHZ generally will produce acceptable results in the thickness range from 0.022 inch (.55mm) up to 5 inches (125mm) more or less. With the Raptor, and under ideal external conditions, transducers of 5, 7.5 or 10 MHZ having active elements of 0.25 to 0.50 inch (6.4 to 12.7mm) diameter will cover the range from 0.030 to 10 inches (0.76 to 250mm) or more.

11.1.2.2 Single Element Contact Transducers with Me mbrane and Other Protective Devices.

So-called protected element transducers are used in relatively rugged applications involving rough, abrasive test object surfaces or surfaces at elevated temperatures. Usual designs of protected element



transducers include reduced internal damping, lower frequencies and larger diameters. As a result, their application typically ranges from a few tenths of an inch (10mm plus or minus) upwards.

Often used on castings, forgings and mill-finished piping, protected element transducers are infrequently used for thickness gaging; more often used for flaw detection. However, if the protective element is a relatively thin elastomer or flexible polymer, the procedures for thickness gaging are similar to those for single element contact-type transducers. For thicker wear-caps or temperature-protective delay lines, procedures are more like those for delay line transducers.

11.1.2.3 Dual Element Contact-Type Transducers. This category of transducers is frequently used in thickness gaging applications, combining some of the advantages of both single element contact and delay line models. They have two elements, each with a separate delay line, mounted side-by-side in a single fixed housing. The elements are isolated acoustically from one another by a sound-absorbing barrier between them. They are electrically isolated as well; one serves as a transmitter, the other as a receiver. The ultrasonic instrument must provide the capability of isolating the pulser and receiver, as does the Raptor.

Practical minimum thickness resolution from a dual element transducer optimized for thickness gaging is approximately 0.040 inch (1.0mm). Typical frequencies for thickness gaging applications range from 2.25 to 10 MHZ, and the elements can be semi-circular or rectangular. While again it is only possible to generalize the applications, dual elements provide a good balance among resolution, penetration and sensitivity.



11.2 Flaw Detection Applications.

11.2.1 Straight Beam Longitudinal Wave Tests. All the various types of transducers used for thickness gaging are also used for flaw detection. However, flaw detection focuses on characterizing the amplitude of echoes from small internal reflectors (flaws) as opposed to accurate measurement of the time-of-flight interval between front-wall and back-wall echoes.

In a sense, both flaw detection and thickness gaging procedures combine in most tests governed by flaw detection criteria. In most instances, once a flaw has been detected and judged to be significant, it is also required to describe its geometry, position and location within the test object, at least to the extent possible.

Usual flaw detection procedures depend upon the capabilities of the instrument/transducer combination to detect small reflectors. Occasionally, this feature of high sensitivity requires that both the transducer and instrument receiver amplifier be narrow-banded and frequency-matched to one another. To produce a narrow-banded transducer, little or no mechanical damping is applied to the back face of the active element. This results in a more highly energetic transducer, but one that vibrates or "rings down" for a short time after the excitation pulse shuts off. This continuing oscillation produces a long duration wave-train that effectively “blinds” the transducer from differentiating echoes from reflectors (flaws or back-wall) within the ring-down period. While sensitive to the detection of echoes from small, deep-lying reflectors, narrow-banded transducers are limited in their ability to resolve echoes from near-surface flaws or from the surfaces of thin-walled test objects.



Transducer frequency also has significant effects on the sensitivity to detection of small flaw echoes. As the frequency of a narrow-band transducer is increased (assuming narrow-band frequency matching in the instrument receiver), the ability of the sound beam to react to small reflectors is enhanced. However, in polycrystalline metals and multi constituent composites, internal reflections from grain boundaries or other interfaces greatly increase at high ultrasonic frequencies.

The effect manifests as a scattering of the sound beam, both reducing its ability to penetrate and decreasing the signal-to-noise ratio in reflected echoes that return to the transducer.

A further consideration in transducer selection for flaw detection is the effects of frequency and active element size on the directivity and coherence of the sound beam. The shape of the sound beam often must be taken into account. Both near-field effects and beam-spreading relate to sensitivity; unfortunately, the relationships between element frequency and size are sometimes at odds, forcing compromises with respect to sensitivity, penetration and near-surface flaw detection.

Without delving into the mathematics of beam geometry, the facts are:

1) For a given element size, higher frequencies produce less divergent beams, but increase the length of the near-field.

2) For a given frequency, smaller element sizes produce shorter near-fields, but increase beam divergence.

Since the sensitivity requirements are dictated by the particular code, standard or procedure governing specific tests, it is not possible to be very specific in recommending flaw detection transducers. However,



since a large number (if not a majority) of straight beam flaw detection ultrasonic tests are performed on metals less than 2 to 3 inches (50 to 75mm) thick, a few general statements apply:

1) Using broadband transducers will greatly enhance near-surface flaw detection capabilities and most frequently will produce adequate penetration and sensitivity - generally a better compromise in many tests than using narrow band transducers.

2) If penetration of the soundbeam is a problem, use the lowest frequency transducer that produces desired sensitivity. If near-surface resolution is not required, use a low frequency narrowband transducer.

3) If signal-to-noise sensitivity is a problem, use narrow-band transducers sensitive to small flaws yet not overly sensitive to other internal reflectors such as grain boundaries in metals.

4) When a combination of problems exists, experiment with different spectral characteristics (bandwidth) at the theoretical size and frequency otherwise indicated.

The foregoing discussion applies for immersion transducer selection as well as for the various types of contact transducers. However, with immersion transducers, another significant factor emerges; the sound beam can be focused. Within some limits, focusing can produce several advantages

B. The irregular effects of the near-field can be eliminated.



C. Beam divergence can be controlled and beam energy can be concentrated within a small cross-section of the beam. Sensitivity to detection of small flaws can he increased.

D. On parts having convex curved surfaces, focusing can be used to improve soundbeam coupling: spherical focusing is best for compound curvature, while cylindrical focusing can be used on conic and cylindrical shapes

Focusing is only effective within certain limits depending upon transducer size and frequency. For a complete discussion on the focus ranges of immersion transducers, see OPTIMA transducer catalog in the Transducer Selection section of Part 4, Immersion Transducers.

11.2.2 Angle-Beam Shear Wave Tests. Transducer selection for angle-beam tests is relatively simple. Except for a few isolated applications, there is little need for the transducer to be broad-banded. Medium-to-low damping is ordinary; some angle-beam transducers are basically undamped. However, such transducers generally perform well with broad-banded instrument receivers.

AWS transducers, specified for use when the AWS Structural Welding Code is invoked, are supplied in three element sizes, 5/8 x 5/8 inch, 5/8 x 3/4 inch, and 3/4 x 3/4 inch (15.9 x 15.9mm, 15.9 x 19.1mm, and 19.1 x 19.1mm). All are available with a nominal frequency of 2.25 MHZ, as specified by the Code. Acrylic plastic wedges are supplied to convert the longitudinal wave to refracted shear waves at incident angles of 45°, 60°, and 70°, again as required by the Code.



Similar, general-purpose, or so-called “standard” models, are available in a greater variety of sizes and with standard angle-beam wedges additionally available for 30° and 90° refracted angles. Virtually any angle can be specified for special applications.

Other types of angle-beam transducers include Quick Change and Mini models. The Quick Change models have circular element sizes of 1/4, 3/8 and 1/2 inch (6.4, 9.5 and 12.7mm) diameter and are threaded to accommodate replaceable wedges that screw onto the transducer element. No tools are required and worn wedges are discarded. Standard and AWS models also have replaceable wedges, but a small screwdriver is required to remove and replace the wedges. Mini Angle-Beam models are compact, designed for use in confined spaces, for small parts, and to permit access between closely-spaced fasteners.

For any angle-beam application it must be kept in mind that the stated refracted angle provided by the plastic wedges pertains only for a specific material. Wedges designed for use on common alloy steels will not produce the same refracted angle in aluminum, most super-alloys, many stainless steels, titanium alloys coppers etc. When purchasing wedges, the test material must he specified or a sample furnished to the supplier in order to obtain specific refracted shear-wave incident angles.

Another precaution should he observed: replaceable wedges must be acoustically coupled to the face of the transducer element. Glycerin is most often recommended although other couplants of similar consistency can be used. During use of transducers with replaceable wedges, the interface between element and wedge should be checked frequently for proper coupling. Bubbles and incompletely wetted mating surfaces will significantly affect transducer performance; usually incomplete coupling can he seen by looking through the transparent wedge material.



11.2.3 Through-Transmission Tests. The Raptor can be used for through transmission testing on test objects where access permits placement of transducers on opposing sides of the test object, with two transducers aligned in opposition. One serves as transmitter and is connected by a separate cable to the pulser output connector. The other is connected to the adjacent connector. When DUAL is selected in the Pulser menu, the Raptor's pulser and receiver are electrically isolated. With the transducers coupled to the test object and in opposition with each other, the sound beam will pass from one to the other, unless there is an intervening acoustic discontinuity in the path of the sound beam. This technique is often used on highly attenuative test materials and is particularly suited for detection of laminar-type flaws, or regions of varying composition due to porosity or other inhomogeneous variations.

Many such tests are conducted through immersion or squirter techniques. Although specialized mechanical systems may be required to maintain transducer alignment and to provide scanning or other manipulations, more-or-less standard types of immersion transducers are used.

While some experimentation may be required in order to determine the optimum combination of transmitter/receiver transducers, the appropriate models are generally available from the extensive line of NDT Systems, Inc. OPTIMA transducers.

Likewise, for contact transducer through-transmission tests, experimentation will most probably require specific combinations of transducers, generally available from the OPTIMA selections.



11.2.4 Immersion Tests. In addition to the through-transmission or squirter techniques mentioned just above, The Raptor can he used for single transducer, pulse-echo tests. Interface synchronization (SYNC, found in the PULSER menu) provides for synchronizing the A-Trace beginning from the entry echo that occurs between the liquid couplant column and the test object surface. Even if the couplant path length varies, the start of the A-trace and thickness gate are synchronized from the interface (IF) echo.

A complete assortment of immersion transducer types, sizes, frequencies, and spectral characteristics can he found in the OPTIMA transducer catalog. Accompanying each different type of transducer shown is a brief guide to the applications appropriate for that type.

11.3 Transducers for Non-Metallic Test Materials. Virtually all the techniques and applications described above can be applied to a host of non-metallic and composite materials. It is not possible to cover the numerous applications in this manual. Transducer selection for non-metals often is much more involved. However, the Raptor’s unique design can accommodate a huge variety of transducer types. For advice, contact our Transducer Applications Specialists. Often a transducer can he recommended on the basis of a description of the application. If not, it may he necessary to submit samples of the test material.



11.4 Transducers for Specialized Applications. Ultrasonic testing techniques have applications beyond those traditionally though of regarding flaw detection and thickness gaging. There are applications in material characterization, flaw analysis, extensometry, bondtesting, liquid level sensing, velocity measurement, and others in more or less limited usage. In some cases, because the application is specialized, so must be the transducers. The Raptor can be used as the basic instrument for many unusual applications, and NDT Systems can usually match either a standard OPTIMA transducer or a custom design to the requirements of the application. Raptor users are invited to contact a NDT Systems Transducer Applications Specialist for recommendations.

Appendix B Scanners


12 Appendix B Scanners NDT Systems manufactures several standard scanners for the RAPTOR and the PortaScan 007. Shown here are several of the most common scanners.

12.1 MMS2 Precision Manual Mini-Scanner affords a non-resistive fluid motion and incorporates a zero backlash embedded urethane chain minimizing the effects of dust or grit contamination. Accuracy and repeatability to 0.010 inch mechanical resolution are possible. Y-Axis shaft is removable for easy storage. Transducer gimbal is also removable and replaceable. Sizes range from a scan envelope of 6”x6” to 15”x18”

Appendix B Scanners


12.2 FlexArm 2 Precision Flexible Arm Manual Mini-Scanner affords a non-resistive fluid motion incorporating a zero backlash Flexible Y-Axis arm with embedded flat belt drive, minimizing the effects of dust or grit contamination. Accuracy and repeatability to 0.020" mechanical resolution are possible. Y-Axis shaft is removable for easy storage. Transducer gimbal is also removable and replaceable. Y Arm Length is 12 inches. X-axis is available as magnetic or non-magnetic urethane wheels.

Appendix B Scanners


12.3 String Scan Precision Flexible Arm Manual Mini-Scanner affords a pre-tensioned fluid motion incorporating a zero backlash string encoders and, when used with the RAPTOR Imaging Flaw Detector, converts triangulated motion to X-Y coordinate motion. Accuracy and repeatability to 0.040 inch mechanical resolution are possible. Probe head stores in base clamp for easy storage. Probe is removable for easy replacement. Scan envelope limited in X & Y to base plate width which is available from 10 to 24 inches and even further if desired. General use for this scanner is in the manual pre-scanning of wing skin impact damage, for instance, before full or semi-automated scanning.

Appendix B Scanners


12.4 VS1M X-Y Please note that the VS1M X-Y scanner requires a separate external motor controller (the controller will be quoted on request). The new VS1M X-Y Scanner incorporates a unique rack & pinion, “V” rail design and is driven by 2 high torque stepper motors. In this view the scanner is fitted with 3 manually operated suction cup feet (the third is hidden under the unit in the rear). This arrangement is ideal for relatively flat and smooth surfaces. Just pump the cups down and the scanner is held in almost any inclination. These feet are interchangeable with flat plate mounts or direct mount to a surface for more of a permanent test station.The transducer is mounted on a removable, spring loaded, dual ball bearing, dual gimbal arrangement thereby allowing it to follow moderate contour changes while keeping the transducer in constant contact with the surface. This scanner also incorporates our “In & Out” BNC connectors on the head of the scanner. This relieves any excess weight of a cable from pulling on the transducer itself, again assuring consistent coupling.

Appendix B Scanners


12.5 RCA-X Battery Powered Scanner The RCA-X, Battery Powered, Cantilever Arm Scanner is an innovation permitting the operator to work on a line entirely AC Power free for up to 6 hours per charge. This scanner is a controlled motion scanner connecting directly to the RAPTOR itself and a speed controlled battery pack.

Appendix B Scanners


12.6 P5-12 Please note that the P5-12 scanner requires a separate external motor controller (the controller will be quoted on request).

Above is our P5-12, stepper or servo driven, fully automated Pipe Scanner. It incorporates a set of powerful magnetic wheels to hold itself on a pipe of 4 inch diameter to flat, as well as drive itself around the pipe. The cross carriage shuttle is mounted on 4 stainless steel re-circulating ball bearings. The screw drive has zero backlash (designed to minimize any mechanical hysteresis). The transducer sits in the spring loaded shuttle below to assure consistent contact with the material under test. There are “In & Out” BNC connectors in the head of the scanner. This relieves any excess weight of a cable from pulling on the transducer itself, again assuring consistent coupling.

Appendix B Scanners


An optional cantilever arm mounts to the scanner and is driven by the shuttle through the narrow end of the scanner to approach surfaces where clearance is a problem.

Appendix C Accessories


13 Appendix C Accessories

Available accessories for the Raptor include:

1) Extra Li Ion battery PN

2) Li Ion battery conditioner/Charger PN

3) AC Adapter PN

4) SD Card 2Gigabytes PN

5) External Keyboard PN

Appendix D Specifications


14 Appendix D Specifications Display: Full 480 x 640 (VGA) Graphic (3.4"W x 4.55"H) New Technology Display, FULLY Sunlight Viewable

SplitView: (Handheld Industry First) Size as a Function of Main Trace Window Size

SplitScan: (Handheld Industry First) Display A-Trace and B or C Scan Simultaneously

AutoTrack: (Handheld Industry First) When in SplitView, Second Window Displays a Zoom View of the Main A-Trace which Tracks the Echo Being Measured

Scan Mode: A, B and C-Scan imaging native

Freeze: Screen Freeze Mode or Instant-Freeze Mode... Perfect for Spot Weld Applications

Physical: 5.75" Wide X 3" Deep X 9.5" Long - 5.6 lbs with Battery All Aluminum with Sealed and Rubberized end caps

Range: 0.112" - 500" Delay: 0 - 200" @ Full Range!

Resolution: 0.0001"/0.001 • Inch/mm

Velocity Range: 0.0490 to .9999 in/us • fully adjustable.

Calibration: Range, Delay, Velocity & Zero

Pulser / Receiver: Up to 5KHz Rep Rate, Spike and Square Wave Pulser (50v to 450v and 20 to 10,000ns)

Display Mode: RF, +HW, -HW, FW - Hollow and Filled

GAIN: 100dB, Damping - 8 levels

Frequency Range: 500Khz - 20MHz

Tuning: 0.5, 1.0, 2.5, 5 and 10MHz

Probe Select: Single / Dual Element

Peak Echo Hold: Fixed or 2 Sec Hold

Alarm: LED Thickness High, Lo or High/Lo, Amp +/- Level

Appendix D Specifications


I/O: USB 2.0 Connectivity

SD Card: Up to 4GB user removable SD Flash Card

Memory: 75MB On-Board Memory (system & storage)

Operational Modes: Single/Dual/Angle/Contact/Delay

Gates: Contact - IP-1st, 1st-2nd Permits Through-Paint, Delay/Bubbler/Immersion, IP Blocking, IF Blocking, IF-1st, 1st-2nd Echo Blk

Amplitude: 3 Gates, Track IP, IF, previous gate. Alarm POS or NEG Gating

20 Point DAG/DAC

Imaging Features: A-Scan, B-Scan - Time encoded 'B' Scan (Scrolling) Encoded B-Scan, SpreadSheet View, Pan & Zoom, 3D, Histogram

Scanners: Manual, Semi-Automated, and Fully automated scanners supported.

Power Requirements: Operates on one Li-ion Battery for up to 8 hours while imaging! Charger included

Transducers, cables and accessories are available for almost any application

Plastic carry case included

CE Approved

Manufactured in facilities meeting ISO9001 manufacturing processes

Appendix E Warranty


15 Appendix E Warranty LIMITED WARRANTY

1. WARRANTY: NDT SYSTEMS, INC. warrants that reasonable care was used in the choice of materials and the manufacture of this instrument, and that the instrument conforms to the published ratings and characteristics applicable to the instrument at the time the instrument is shipped to the Buyer. This warranty shall extend for a period of one year from the date of shipment of the instrument (FOB Seller's plant) and shall in no event extend beyond such term. The Buyer shall notify NDT SYSTEMS, INC. by registered or certified mail, return receipt requested, of any claim of discovery of such defect. Failure to notify NDT SYSTEMS, INC. within the time and in the manner specified herein shall constitute a waiver of any such claim of defect or breach of warranty. The final determination of the existence of a defect or breach of this warranty shall be made by NDT SYSTEMS, INC. This warranty shall extend to the Buyer only, and shall not be assignable or transferable to any other person.

2. DISCLAIMER OF WARRANTIES THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OTHER THAN THOSE WARRANTIES SET FORTH IN THE PARAGRAPH ENTITLED "WARRANTY" ABOVE.

The above warranty shall not apply to digital panel meters and items with a limited life, such as batteries, probes or cables, nor to any instruments which have been subjected to misuse, improper installation or repair, alteration, or use beyond the published rating of the instrument.

3. BUYER'S REMEDIES: The Buyer's sole exclusive remedy for breach of the above warranty shall be the repair or replacement of the instrument by NDT SYSTEMS, INC., free of charge. The Buyer shall return the instrument to NDT SYSTEMS, INC., transportation prepaid. NDT SYSTEMS, INC. shall promptly repair or replace the instrument and return same to Buyer, FOB Seller's Plant, collect.

Appendix E Warranty


If, for any reason, NDT SYSTEMS, INC. is unwilling to repair or replace the instrument or, because of circumstances, the exclusive remedy provided herein fails of its essential purpose, or operates to deprive either party of the substantial value of its bargain, then the Purchaser's exclusive remedy will be the return of the purchase price for the instrument. The liability of NDT SYSTEMS, INC. shall in no event be greater than the full amount of the purchase price for the instrument.

Any attempt by NDT SYSTEMS, INC. to repair or replace any instrument sold hereunder shall not constitute an admission that the instrument, or any part thereof, is defective within the meaning of the above warranty, nor that NDT SYSTEMS, INC. has any legal responsibility to make such repair or effect such replacement.

Any such attempts, if unsuccessful, shall not create any liability on the part of NDT SYSTEMS, INC. and the purchaser is limited to the remedy set forth herein.

4. LIMITATION ON LIABILITY: NDT SYSTEMS, INC. shall not, under any circumstances, be liable for direct, incidental or consequential damages for any breach of contract, breach of warranty or misrepresentations, including the negligence of NDT SYSTEMS, INC., including, but not limited to, damages resulting directly or indirectly from the use, or loss of use, of the instrument sold hereunder, or the business of the Buyer or third persons wherein the instrument is utilized.

The above warranty, and the obligations of NDT SYSTEMS, INC. hereunder, are expressly in lieu of, and the Buyer expressly waives, any other liability of NDT SYSTEMS, INC. based upon warranty, express or implied, contract, or the negligence of NDT SYSTEMS, INC., including, but not limited to, negligence in the design of the instrument or in the choice of the materials therefore, or negligence in the repair or replacement of the instrument, whether such repair or replacement is required by the terms hereof or is voluntary, upon the part of NDT SYSTEMS, INC.

Except as provided herein, no person is authorized to assume on behalf of NDT SYSTEMS, INC. any other or additional liability or responsibility in connection with the instrument. These terms and warranty are applicable to and complete acceptance of such a binding legal agreement.

NDT Systems, Inc. 5542 Buckingham Drive

Huntington Beach, CA 92649

Documents

Raptor Operator Manual - Zion NDT€¦ · Important Information First and foremost, we at NDT Systems, Inc. would like to thank you for your purchase of the Raptor. The Raptor is