Wed, 10 December, 2025
We are launching a new joint industry project (JIP) to evaluate ultrasonic array inspection techniques for coarse-grained metallic structures.
Welding is used across industry to join metallic structures, however, those with coarse-grained welds, such as those made from stainless steel or nickel-based alloys, pose significant challenges for ultrasonic testing. This is due to the large grain sizes and the anisotropic nature of these materials, which leads to scattering, beam bending and high attenuation of the ultrasonic signal, reducing the accuracy of defect detection and flaw characterisation.
These challenges mean that industries are not gaining the full benefits of ultrasonic array inspection techniques, including advanced methods such as Phased Array Ultrasonic Testing (PAUT), Full Matrix Capture (FMC)/Total Focusing Method (TFM), Phase Coherence Imaging (PCI) and Plane Wave Imaging (PWI).
These inspection techniques have become a reliable and efficient method of non-destructive testing in industrial applications, providing a precise and comprehensive approach for detecting flaws in a wide range of materials. With an enhanced Probability of Detection, reduced need for multiple probes and scans, better defect sizing and characterisation, plus higher resolution and imaging capabilities compared to conventional ultrasonic inspection methods, such techniques are desirable to a range of industries.
In order to help unlock these benefits, even with coarse-grained welds, we are launching a new joint industry project to evaluate and compare a range of advanced ultrasonic array inspection techniques to identify the most effective approaches for detecting and sizing flaws in coarse-grained metallic structures.
The project, ‘Evaluation of Ultrasonic Array Inspection Techniques for Coarse Grain Metallic Structures,’ will provide guidance on the suitability of these techniques, enabling end users to identify suitable ultrasonic testing for their applications.
The JIP will be underpinned by experimental evidence to support the justification and qualification of ultrasonic procedures and systems, including a range of industry applications for NDT in demanding industry sectors such as power generation, nuclear, defence, and oil and gas.
About the Project
The aim of this JIP is to evaluate the performance of various ultrasonic array techniques to determine their effectiveness in detecting, sizing and characterising weld flaws in coarse-grained materials. This evaluation will allow us to deliver industrial guidance validated with experimental evidence and ultrasound physical principles.
Inspection trials will be performed on a range of test samples with different geometries and a range of artificial defect types to provide a valuable insight into the capabilities and limitations of ultrasonic array techniques for inspecting coarse-grained metallic welds.
Industrial Members who choose to join this JIP will be able to request the production of / provide test samples to match their particular interests and applications. Project sponsors will also receive a report detailing the outcomes, details of recommended practice and access to test samples produced during this project for future investigations. The outcomes will improve safety standards and manufacturing efficiency during production of critical structures across a range of industry sectors.
For more information on this project and how you could unlock improved safety and reduced costs through your inspection activities, please see here:
https://www.twi-global.com/what-we-do/research-and-technology/research-programmes/joint-industry-projects/evaluation-of-ultrasonic-array-inspection-techniques-for-coarse-grain-metallic-structures