We are your reliable partner for ultrasonic testing.

Ultrasonic Testing
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We are your reliable partner for ultrasonic testing.

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  • manual and digital testing
  • on-site or in the lab
  • single or series testing
  • quality assurance method
  • phased array
  • TOFD technology

Non-Destructive

Ultrasonic Testing

Schematic representation of non-destructive ultrasonic testing of a metal component with A-scan display.

Schematic representation of ultrasonic testing

Ultrasonic testing (UT) is a non-destructive testing method used for quality assurance of sound-conducting materials. It enables the detection of internal and external defects, particularly in welds, castings, forgings, pipes, and semi-finished products.

Before testing, a coupling agent is applied to the surface of the component. A probe emitting and receiving ultrasonic waves between 0.2 and 50 MHz is then moved across the surface – manually, semi-mechanically, or fully automatically. In automated processes, signal transmission often occurs via water baths or targeted wetting.

An ultrasonic device displays the reflected waves as echo curves (amplitudes). Deviations indicate material defects. Wall thickness can also be measured precisely, making it ideal for wear assessments.

Ultrasonic testing on cast materials is carried out according to the foundry standard DIN EN ISO 12680.

As an experienced testing partner, Zeros GmbH offers manual and semi-automated ultrasonic testing – on-site at your location or in our laboratories. We also efficiently use phased array and TOFD for single inspections and series testing. Contact us for an individual offer.

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FAQ

Frequently Asked Questions

Is Ultrasonic Testing Non-Destructive?

Yes, ultrasonic testing (UT) is a non-destructive testing (NDT) method. High-frequency sound waves are introduced into the component to detect defects and inhomogeneities within the material without damaging or altering the part. After testing, the component remains fully functional, allowing 100% material inspection during manufacturing or in-service inspections. Therefore, ultrasonic testing is a standard method used in quality assurance.

What does an ultrasonic tester do?

An ultrasonic tester performs non-destructive testing on components by sending ultrasonic waves into the material using a probe. The tester moves the probe manually or automatically across the component while monitoring the device display to detect irregularities such as cracks or voids. The tester documents and evaluates the results according to applicable standards, ensuring quality control of materials and components during manufacturing or maintenance.

Which components can be tested with ultrasonic testing?

Ultrasonic testing can be used to inspect all components and materials that are transmissive to ultrasound, such as metals, plastics, and composites. The suitability depends on the acoustic impedance and sound hardness of the material. In cast and forged components, manufacturing-related inhomogeneities can be detected immediately after production. Weld seams can be tested from a wall thickness of 8 mm using conventional ultrasonic testing, and from 6 mm using phased array techniques. Zeros GmbH also has extensive experience in project-specific validations to reliably inspect components with wall thicknesses below 6 mm using phased array technology.

What is Ultrasonic Testing (UT)?

Ultrasonic testing (UT) is a non-destructive testing method used to detect defects and measure wall thickness in materials. High-frequency sound waves generated by an ultrasonic device are transmitted into a material. When these waves encounter irregularities such as cracks, inclusions, or voids in components or welds, they are reflected. The reflected signals are captured and analyzed to determine the position, size, and type of defects. As a volumetric testing method, UT allows the internal inspection of materials like metals, plastics, and composites and is widely used in quality control.

Which Ultrasonic Testing Methods Exist?

Various ultrasonic testing methods are available for non-destructive material testing. These include conventional ultrasonic testing, phased array testing, and TOFD (Time of Flight Diffraction). The best method depends on factors such as the material, manufacturing process, wall thickness, defect detection limit, and the desired documentation. While conventional UT is sufficient for many standard inspections, phased array and TOFD offer advanced options for representation and evaluation of defect indications. We are happy to advise you on which method is best suited for your testing project.

Why is ultrasonic testing used in materials testing?

Ultrasonic testing is used in materials testing because, as a non-destructive method, it enables reliable quality assurance. Compared to other volumetric testing methods such as radiographic testing, UT is often a more cost-effective and flexible solution. It can detect internal defects like cracks, inclusions, or voids early without damaging the component. UT can be used on-site, requires no complex radiation protection measures, and provides immediate, interpretable results. Additionally, ultrasonic testing allows for precise wall thickness measurements and can be applied to a wide range of materials such as metals, plastics, and composites. These advantages make UT an essential part of non-destructive testing in both manufacturing and maintenance.

Physical Principles of Ultrasonic Testing

Basics of ultrasound vibration
Wave Oscillations

Oscillations and waves are found everywhere. A simplified form of an oscillation is a pendulum. If you hang a ball on a string and move it slightly, the pendulum will swing back and forth continuously. This movement across a resting point is called an oscillation.

If the oscillation energy is consumed, for example by air resistance, it is called a damped oscillation. If it is heavily damped, it is referred to as an impulse. If the consumed energy is restored, it is called an undamped oscillation. An undamped oscillation has a constant amplitude.

Deflection / Amplitude

The deflection indicates the distance from the resting position at any given time. The maximum deflection from the resting position is called the amplitude.

Oscillation Duration / Frequency

The oscillation period T(s) is the time span in which one full oscillation cycle occurs. The frequency is derived from the oscillation period and represents the number of oscillation cycles per unit time (e.g., 4 cycles per second = 4 Hertz).

In ultrasonic material testing, frequencies in the megahertz range are commonly used. This means several million oscillations per second. In contact technique testing between 1 to 5 MHz, and in immersion technique testing up to 25 MHz.

Basics of ultrasound oscillation duration
The Wave

The wave is the spatial propagation of an oscillation. During an oscillation period T, the oscillation travels one wavelength in space. This distance is called wavelength λ. One wavelength per oscillation period T is therefore the sound velocity c.

λ = Wavelength lambda (mm)
c = Sound velocity (m/s)
f = Frequency

Formula: c = λ : T or c = λ * f

Ultrasound waves are mechanical oscillations and cannot travel in a vacuum. In metals, atoms are tightly bound. Due to these attractive forces, it is referred to as elastic coupling. Different metals have typical, material-specific sound velocities. The sound velocity is a material constant. Choosing the correct frequency can be crucial for successful ultrasonic testing. The wavelength can be used to estimate the detection limit for the smallest detectable reflector size. This detection limit is approximately half a wavelength.

Sound Velocities in
Various Materials
Material Longitudinal Wave Transverse Wave
Water 1.48 km/s
Lead 2.16 km/s 0.70 km/s
Acrylic glass 2.73 km/s 1.36 km/s
Brass 4.70 km/s 2.10 km/s
Cast iron 3.50 km/s 1.90 km/s
Copper 4.70 km/s 2.26 km/s
Steel 5.90 km/s 3.20 km/s
Titanium 6.10 km/s 3.10 km/s
Aluminum 6.40 km/s 3.10 km/s