Chapter (8): TOFD Calibration And Checks

CHAPTER (8): TOFD CALIBRATION AND CHECKS

hrstrument and equipment calibrations for TOFD are not different from instrument calibrations for
traditional pulse-echo manual UT instruments. Calibration verifications made by the operator are
done without the use of electronic measurement instruments. Essentially the parameters measured
involve connecting a probe to the instrument and assessing the display outputs. Guidance on the
normal parameter measurements can be obtained in several international standards. These include:
. ASTM E 377, Standard Practice for Evaluating Performance Characteristics of Ultrasonic Pulse-
Echo Testing Instruments and Systems without the Use of Electronic Measurement Instruments
r EN 12668-3, Non-destructive testing - Characterisation and verification of ultrasonic
examination equipment -Part 3: Combined equipment
Parameters relating to TOFD most commonly measured in these checks include:
o Time base linearity
. Amplifier gain linearity
. Probe index point
. Beam angle
Although other parameters (e.g., pulse duratioru screen height display linearity) can be assessed, they
are not usually of concern in a TOFD calibration check.

For more detailed electronic and probe parameter assessments, other standards may be used. These
include:
. ASTM E-1324, Measuring Some Electronic Characteristics of Ultrasonic Examination
Instruments
o EN 12668-1, Non-destructive testing - Characterisation and verification of ultrasonic
examination equipment - Part 1: Instruments
. EN 72668-2, Non-destructive testing - Characterisation and verification of ultrasonic
examination equipment -Part 2: Probes

8.1 INSTRUMENT CALlBRATIONS

Traditional scope displays used a cathode ray tube. This term is associated with the original analogue
instrumentation. From its earliest days, TOFD instruments have been associated with digital
technology. As such, the RF voltage displays are constructed or painted on a monitor. The old analogue
displays often suffered linearity problems. This was due to the deflector plates becoming misaligned,
often by a simple bump to the system.

Digital instruments now operate by software controlled and precise "digital clocks" and ADC
converters. This provides the underlying instrumentation that allows the computer to display voltage

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Chapter (8): TOFD Calibration And Checks

amplitude and phase information on the instrument display. Digital units are never bumped out of
alignment and minor voltage fluctuations in power supply are regulated such that the system cuts off
rather than deteriorate the time or amplitude tolerances.

In spite of the stable nature of digital instruments, there are still mandatory requirements for
assessment of time base and amplitude control linearity. TOFD depth and sizing relies on accurate
timing made along the time base. Amplitude aspects relating to gain or amplifier controls or knowing
precisely the amplitude of a signal relative to a reference is not so critical in TOFD. However,
monitoring amplitude control is an effective method of checking that the overall performance of the
instrument is stable.
In spite of the reduced demands on vertical linearity for TOFD applications, the fact remains that a
well-maintained instrument, adhering to relatively strict tolerances, will ensure repeatable results
from system to system and from one inspection to the next, when the same component is tested.
Therefore, instrument linearity checks monitoring vertical linearity, amplitude control linearity
(amplifier) and horizontal (time base) linearity are typically required in Codes regulating the
application of TOFD.

8.1.1 TrME BASE LTNEARTTY (HORTZONTAL LTNEARITY)

To assess the time base of the instrument, it is configured to operate in the pulse-echo mode (i.e. not
the T-R mode used in TOFD). The instrument is set to display an A-scan presentation. In order to
assess the horizontal linearity of the time base this is either RF or rectified. The operator selects any
compression wave probe and configures the instrument in order to display a range suitable to obtain
at least 10 multiple back reflections from a block of a knov,,n thickness. The 25mm wall thickness of
the IIW block is a convenient option for this test. The following steps can be carried out to assess the
horizontal linearity. These correspond approximately to the steps used in the international standards.
1.. Set the phased array instrument analogue-to-digital conversion rate to at least 80 MHz.
2. With the probe coupled to the block and 200 0
A^ 10.00 mm s./"
176.1
," 20.03 mm

the A-scan displaying 10 clearly defined

multiples as illustrated in Figure 8-1, the
display software is used to assess the
interval between adjacent backwall signals.
Ensure that the first multiple is at the first
indicated point on the distance scale and
the tenth multiple at the far right edge of
the distance scale. (Note: the scale
displayed need not be a simple 10 graticule
series, so the operator has to spread the
multiples across the entire horizontal
range of the display). Figure 8-1 A-scan display for horizontal linearity
3. If accurate "distance" is to be expected on the time base (i.e. the operator is using distance
instead of time increments for the time base), then the acoustic velocity of the test block should

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Chapter (8): TOFD Calibration And Checks

be predetermined using the methods similar to those described in ASTM E-494. These are
entered into the display software and the display configured to read out in distance (thickness
or half-path or true depth).
4. Using the software cursors, determine the interval between each multiple and record the
interval of the first 10 multiples. Acceptable linearity may be established by an error tolerance,
based on the analogue-to-digital conversion rate converted to a distance equivalent. E.g. at 100
MHz, each sample of the time base is 10ns. For steel at 5900m/s each sample along the time base
(10ns) in pulse echo mode represents approximately 30prm. A tolerance of + 3 timing samples
should be achievable by most analogue-to-digital systems (that is approximately +l- 0.1mm in
compression mode at 100 MHz ADC rate). Some allowance should be made for velocity
determination error (-1%). Typically the errors on the multiples should not exceed + 0.5mm for a
steel plate. A record of the results should be kept on file.

8.1..2 DISPLAY HEIGHT LINEARITY

As with the horizontal linearity of the display, the assessment of vertical linearity of the display is also
a throwback to analogue CRT displays. Even though the TOFD instrument is being addressed by a
communication line from a computer, with the computer providing the display, the requirement still
exists in some codes (e.g., the 2010 ASME Section V Article 4 Mandatory Appendix I required
assessment of screen height linearity).

To assess the display linearity, the technique for the old analogue displays is used. This compares the
ratio of amplitude between any two signals at slightly different times along the time base.
1. With the TOFD instrument connected to a probe (shear or longitudinal) and coupled to any
block that will produce two signals, like those shown in Figure 8-2, adjust the probe such that
the amplitudes of the two signals arc at 80"/o and 40% of the display screen height. Ensure that
the signals are displayed as a rectified A-scan.
2. Increase the gain, using the receiver gain 40-00 m.n 69.02 mn

adjustment, to obtain 100% full screen height

of the larger response. The height of the lower
response is recorded at this gain setting as a
percentage of full screen height. Note: for 8 bit
digitisation systems this value should be 99%
because 100% would provide a saturation
signal (in that case, assessment of true
amplitude would be impossible, as signal
amplitude beyond the 100% height would also
display a700% height).

Figure 8-2 Display height linearity

verification
3. The height of the higher response is then reduced in 10% steps to 70% of full screen height and
the height of the second response is recorded for each step.

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 Chapter (8): TOFD Calibration And Checks

4. Return the larger signal to 80% to ensure that the smaller signal has not drifted from its original
40% level due to coupling variation. Repeat the test if variation of the second signal results in a
response that is greater than 41'/" or less than 39% FSH.
5. For an acceptable tolerance, the responses from the two reflectors should bear a 2 to 7
relationship, to within +l-3% of full screen heigh! throughout the range 1.0'/" to 700% (99% if
100% is saturation) of full screen height. The results are recorded on an Instrument tinearity
Form.

8.1.3 AMPLITUDE CONTROL LINEARITY

Codes and standards now dictate that each of the pulser-receiver components of a TOFD instrument is
to be checked to determine the linearity of the instrument amplification capabilities. To check the
receiver amplifiers the following steps are taken:

1. Select any compression wave probe and configure the instrument to display a rectified A-scan
with a range of approximately 50mm equivalent in steel.
2. Adjust the instrumenf so the pulser
^^
49.91 mm R.r 00 r
aA
0.00 mm
parameters are selected for the frequency and
bandpass filter to optimise the response from
a

the probe used (e.g., for a 5 MHz probe

frequency, tuning and bandpass filtering for
the 5 MHz probe should be used).
3. Couple the probe to a suitable surface to
obtain a pulse-echo response from a block
with parallel surfaces. The back-wall echo
from the 25mm thickness of the IIW block :

provides a suitable target option.

Altematively, immersion testing can be used.
Immersion configurations tend to be less
susceptible to coupling problems. Figure 8-3 Pulse-echo A scan of IIW block
with first back-wall echo set to 40%
4. Using the A-scan display, monitor the response from the selected back-wall target. Adjust the
gain to bring the signal to 40% screen height. This is illustrated in Figure 8-3. (Note that use of
electronic gates allows a more precise assessment of the position and amplitude of the signals
being measured. The gate in Figure 8-3 is indicated by the short red bar straddling the A-scan
signal).
5. Add gain to the receiver in the following sequence, first 1dB, then 2dB, then 4dB and then 6dB.
Remove the gain added after each increment to ensure that the signal has retume d to 40%
display height. Record the actual height of the signal as a percentage of the display height using
the amplitude control linearity portion of the linearity recording form.
6. Next, adjust the signal to 100% display height, remove 6dB gain and record the actual height of
the signal as a percentage of the display height. Signal amplitudes should fall within a range of
x3'/" of the display height required in the allowed height range as identified in Table 8-1.

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 : TOFD Calibration And Checks

8-1 itude control lineari

Ind. heisht Allowed ranse

40 +1 44-46
40 +2 48-52
40 +4 62-66
40 +6 77-83
100 -6 47-53

8.2 PERFORMANCE CHARACTERISTICS OF THE PROBES

probe parameters identified by EN-583-6 for TOFD applications are somewhat application dependent-
However, there are some minimum levels of requirement to meet. These include:
. Number of probes: 2 (transmitter and receiver)
. Type: any suitable probe (based on thickness tested)
. Wave mode: usually compression wavei *re use of shear wave probes is more complex but may
be agreed upon in special cases
r Both probes shall have the same centre frequency within a tolerance of +l-20%
. Frequency based on thickness tested (see Clause 7.2)
. The pulse length of both the lateral wave and the back-wall echo shall not exceed two cycles,
measured at10% of the peak amplitude
r Pulse repetition rate shall be set such that no interference occurs between acoustical signals
caused by successive transmission pulses.
Methods to assess centre frequency and bandwidth (number of cycles in the pulse) are found in
several Standards, including ASTM E-1065.

8.2J. PROBE EXIT POINT

It has been noted. that the actual nominal angle of a TOFD probe is not critical to the performance of
the TOFD system. Tolerance of the beam refracted angle can be plus or minus 3o to 5o without a
significant impact on the results. More important to TOFD assessments will be the accurary of the exit
point. This is because the depth assessments are based on the time measured as a function of the probe
centre spacing (PCS). Since the PCS is the distance between the exit points of the probes, the exit point
positions are critical to ensuring depth accuracies. Equations provided for calculation of error
tolerances indicated that a 2mm error in exit point could result in depth estimation errors of about
0.5mm to 1mm depending on the PCS and depth assessed.

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 : TOFD Calibration And Checks

With the probe and wedge being

evaluated, connected to the TOFD
instrument and operated in pulse-echo
mode, the beam is directed at the 100mm
radius of the IIW block. Moving the probe
forward and back, near the centre of the
radius, the signal is peaked. The point on
the probe that aligns with the centre of the
radius on the IIW block indicates the exit
point. Typically this point is marked with a
scribe line from the manufacturer, but wear
may result in the actual point moving
slightly off the theoretical position. It is the
actual position of the exit point that must
be used when determining the PCS.

Alignment of the probe wedge at the exit

point indicator is illustrated in Figure 8-4. Figure 8-4 Determining exit point of an angle beam
Probe in the IIW block tssr

8.3 PERFORMANCE CHARACTERISTICS OF SCANNERS (ENCODERS)

Scanning with TOFD, with the rare exception of the timed sampling (where no encoders are used),
usually involves positional encoders. Some Codes (e.g., ASME Section V Art. 4 Appendix III) require
verification that the encoded position is accurate to within +l-7o/" ovet 500mm.
EN 583-6 also requires tolerance limits on alignment with the reference centreline of a weld. There it
states that guiding accuracy, with respect to the centre of a reference line (the centreline of a weld),
should be kept within a tolerance of x1,0o/o of the probe index point separation.

The process of encoder calibration is relatively simple and prompted by software. The operator places
the scanner at a reference start position and prepares the scan surface for the movement that will
duplicate the scan path. With the encoder activated in calibration mode, the scanner is moved along
the scan path for a given measured distance. This is typically done by marking a set distance (e.g.,
300mm) from the starting reference point. \zVhen the scanner has reached the set distance the
movement is stopped and the operator enters the distance travelled. The number of pulses generated
by the encoder is then converted into a distance equivalent. To check that the encoder calibration is
accurate, the operator would typically move the scanner back to the reference mark along the same
scan path. If accurate, the encoded distance indicated would read 0mm. A small tolerance is allowed.
The allowance for a 10% error on the scan distance is limited to a maximum of 10mm over the scan
length.

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