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USONIC 3510 / ISONIC 3510

A product from the technical leader in Phased Array and TOFD technology

 SONOTRON NDT :

Very Powerful Superior Performance Extremely Portable Smart Phased Array Ultrasonic Flaw Detector and Recorder with 2 Conventional UT and TOFD Channels

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Phased Array (PA) Modality:

  • Fully parallel 32:32 PA electronics expandable to 64:64 / 128:128 functionality
  • 2 PA probe terminals: 1 X 32:32 / 2 X 16:16 - switchable: there is no external splitter required for operating 2 PA probes simultaneously
  • Ability of work with PA probes carrying up to 64 and 128 elements
  • Independently adjustable emitting and receiving aperture with parallel firing, A/D conversion, and on-the-fly real time digital phasing
  • Phased array pulser receiver with image guided ray tracing / scan plan designer for the numerous types of simple and complex geometry welds, shafts, bolts, spindles, composite profiles, and the like
  • 8192 independently adjustable focal laws
  • Bi-polar square wave initial pulse: up to 300 Vpp / 100 dB analogue gain / 0.2...25 MHz bandpass / 16 bit 100 MHz ADC / 32 taps smoothly tunable digital filter
  • Regular and volume overlay B-Scan / Sector Scan (S-Scan) / Horizontal Plane S-Scan (CB-Scan) coverage accompanied with all-codes-compliant A-Scan based evaluation
  • Multigroup coverage composed of several cross-sectional B- and S-Scans
  • Strip Chart
  • Single group and multigroup Top (C-Scan), Side, End View imaging formed through encoded / time-based line scanning, 3D-Viewer
  • Single side / both sides weld coverage with use of one PA probe / pair of PA probes
  • TOFD Map out of a pair of PA probes
  • Top (C-Scan), Side, End View imaging formed through encoded XY- scanning, 3D-Viewer
  • Built-in automatic coupling monitor and lamination checker for wedged probes
  • Equalized cross sectional coverage sensitivity: TCG-independent gain per focal law adjustment providing pure angle gain compensation for S-Scan, etc
  • DAC, TCG
  • Dynamic Focusing
  • FMC, TFM, Back Diffraction Technique with / without and Mode Conversion
  • Processing of diffracted and mode converted signals for defects sizing and pattern recognition
  • Operating 2D-array probes
  • 100% raw data capturing
  • Automatic alarming defects / generating of editable defects list upon scanning completed
  • Advanced defects sizing and pattern recognition utilities

Conventional UT and TOFD:

  • 2 channels
  • Single / dual modes of pulsing/receiving for every channel
  • Bi-polar square wave initial pulse: up to 300 Vpp / 100 dB analogue gain / 0.2...25 MHz bandpass / 16 bit 100 MHz ADC / 32 taps smoothly tunable digital filter
  • Regular A-Scan
  • Thickness B-Scan
  • True-to-Geometry flaw detection B-Scan – straight / angle beam probes
  • CB-Scan
  • TOFD
  • Strip Chart and Stripped C-Scan
  • Parallel or sequential pulsing/receiving and A/D conversion
  • DAC, DGS, TCG
  • FFT signal analysis
  • 100% raw data capturing

General:

  • Dual Core 1.6 GHz clock 2 GB RAM 120 GB SSD W'7PRO on-board control computer
  • Intuitive User Interface
  • Single and multi-axis encoder connection
  • Comprehensive postprocessing and data reporting toolkit
  • Remote control and data capturing with use of a regualr PC with no need in special software
  • No intake air / no cooling IP 65 light rugged case
  • Sealed all-functional keyboard and mouse
  • 8.5” bright touch screen
  • Ethernet, USB, sVGA terminals


ISONIC 3510 uniquely combines PA, single- and multi-channel conventional UT, and TOFD modalities providing 100% raw data recording and imaging. Along with the intuitive user interface, portability, lightweight, and battery operation this makes it suitable for all kinds of every-day ultrasonic inspections

The PA modality is carried by the fully parallel non-multiplexed 32:32 electronics with independently adjustable emitting and receiving aperture, each may consist of 1...32 elements when operating one PA probe or 1...16 elements per probe in case of operating two PA probes simultaneously: there is no external splitter required for the simultaneous use of 2 PA probes. The 64- and 128-elements PA probes may be used with the ISONIC 3510 as well upon they are connected to the corresponding instrument’s terminals through the various miniature extenders expanding the functionality to the fully parallel 1 X 64:64, 2 X 32:32, 1 X 128:128, and 2 X 64:64 modes with no multiplexing involved (depending on the type and quantity of the extenders). The groups of phased array probe elements composing the emitting and receiving aperture may be fully or partially matching or totally separated allowing flexible managing of the incidence angles, focal distances, types of radiated and received waves including directly reflected and diffracted signals either mode converted or not

Each channel is equipped with the own pulser-receiver and A/D converter. Parallel firing, A/D conversion, and ”on-the-fly” digital phasing are performed for every possible composition and size of the emitting and receiving aperture so the implementing of each focal law is completed within a single pulsing/receiving cycle providing the maximal possible speed of material coverage

ISONIC 3510 allows using of the various types PA probes: linear and ring arrays, dual linear arrays, matrix arrays, etc

In addition to the PA electronics ISONIC 3510 carries 2 independent conventional channels for implementing of the regular UT and TOFD inspection; each channel is capable for both single and dual modes of use

The top level ultrasonic performance is achieved through firing PA, TOFD, and conventional probes with the bipolar square wave initial pulse with wide-range-tunable duration and amplitude (up to 300 Vpp). The high stability of the initial pulse amplitude within entire duration of the positive and negative half-waves, the extremely short boosted rising and falling edges and the automatic adaptive damping improve the signal to noise ratio and resolution allowing controlling of the analogue gain over the 0…100 dB range for each modality

ISONIC 3510 is a very powerful platform for the huge number of the practical PA UT applications available for the activation at any moment. Thanks to the unique True-To-Geometry Volume Overlap Coverage and Real Time Imaging the ISONIC 3510 is suitable for the high performance inspection of the simple and complex geometry welds (butt, longitudinal, fillet, lap, corner, elbow, etc) with scanning from one or both sides simultaneously (if applicable), bolts, bridge hanger pins, wind turbine and other shafts, annular rings, flanges, rails and railway axles and wheels, CRFP and GRFP composite panels and profiled stuff, and the like. The precise and easy reproducible automatic Equalizing of the Sensitivity within Entire Cross-Section / Volume of the Material is provided by the unique TCG-independent angle gain / gain per focal law compensation solution along with the DAC / TCG image normalization

Thanks to the above noted True-To-Geometry Volume Overlap Coverage and Imaging andEqualizing of the Sensitivity within Entire Cross-Section / Volume of the Material the inspection results produced by the ISONIC 3510 are easy interpretable and well acceptable by the UT Pros and non-Pros as well

ISONIC 3510 is packed into the IP 65 reinforced plastic case with no intake air or any other cooling means required. The large 800X600 pixels 8.5” bright screen provides fine resolution and visibility for all types of inspection data presentation at strong ambient light along with the optimized power consumption rate for the outdoor operation

ISONIC 3510 is fully compliant with the following codes

  • ASME Code Case 2541 – Use of Manual Phased Array Ultrasonic Examination Section V
  • ASME Code Case 2557 – Use of Manual Phased Array S-Scan Ultrasonic Examination Section V per Article 4 Section V
  • ASME Code Case 2558 – Use of Manual Phased Array E-Scan Ultrasonic Examination Section V per Article 4 Section V
  • ASTM 1961– 06 – Standard Practice for Mechanized Ultrasonic Testing of Girth Welds Using Zonal Discrimination with Focused Search Units
  • ASME Section I – Rules for Construction of Power Boilers
  • ASME Section VIII, Division 1 – Rules for Construction of Pressure Vessels
  • ASME Section VIII, Division 2 – Rules for Construction of Pressure Vessels. Alternative Rules
  • ASME Section VIII Article KE-3 – Examination of Welds and Acceptance Criteria
  • ASME Code Case 2235 Rev 9 – Use of Ultrasonic Examination in Lieu of Radiography
  • Non-Destructive Examination of Welded Joints – Ultrasonic Examination of Welded Joints. – British and European Standard BS EN 1714:1998
  • Non-Destructive Examination of Welds – Ultrasonic Examination – Characterization of Indications in Welds. – British and European Standard BS EN 1713:1998
  • Calibration and Setting-Up of the Ultrasonic Time of Flight Diffraction (TOFD) Technique for the Detection, Location and Sizing of Flaws. – British Standard BS 7706:1993
  • WI 00121377, Welding – Use Of Time-Of-Flight Diffraction Technique (TOFD) For Testing Of Welds. – European Committee for Standardization – Document # CEN/TC 121/SC 5/WG 2 N 146, issued Feb, 12, 2003
  • ASTM E 2373 – 04 – Standard Practice for Use of the Ultrasonic Time of Flight Diffraction (TOFD) Technique
  • Non-Destructive Testing – Ultrasonic Examination – Part 5: Characterization and Sizing of Discontinuities. – British and European Standard BS EN 583-5:2001
  • Non-Destructive Testing – Ultrasonic Examination – Part 2: Sensitivity and Range Setting. – British and European Standard BS EN 583-2:2001
  • Manufacture and Testing of Pressure Vessels. Non-Destructive Testing of Welded Joints. Minimum Requirement for Non-Destructive Testing Methods – Appendix 1 to AD-Merkblatt HP5/3 (Germany).– Edition July 1989

 

PA Modality

Structure: 1 X 32:32 switchable to / from 2 X 16:16  
1 X 64:64* switchable to / from 2 X 32:32*  
1 X 128:128* switchable to / from 2 X 64:64*  
* - with use of the corresponding extension terminals
Important:  there is no external splitter required in case of using 2 PA probes simultaneously
Inital Pulse: Bipolar Square Wave with Boosted Rising and Falling Edges, Guaranteed Shell Stability, and Active Damping
Transition: <7.5 ns (10-90% for rising edges / 90-10% for falling edges)
Amplitude: Smoothly tunable (12 levels) 50V - 300 Vpp into 50 Ω
Half Wave Duration: 50-600 ns controllable in 10 ns step
Emitting aperture: 1...32/64*/128*
adjustable as fully or partially matching OR mismatching with the receiving aperture
* - with use of the corresponding extension terminals
Receiving Aperture: 1...32/64*/128*
adjustable as fully or partially matching OR mismatching with the emitting aperture
* - with use of the corresponding extension terminals
Phasing - emitting and receiving: 0-100 µs with 5 ns resolution
independently controllable
Analogue Gain: 0...100 dB controllable in 0.5 dB resolution
Advanced Low Noise Design: 85 µV peak to peak input referred to 80 dB gain / 25 MHz bandwidth
Frequency Band: 0.2 - 25 MHz
A/D Conversion: 100 MHz 16 bit
Digital Filter: 32-Taps FIR band pass with controllable lower and upper frequency limits; non-linear acoustics technique supported
Superimposing of receiving aperture signals: On-the-fly, no multiplexing involved
Phasing (receiving aperture): On-the-fly 0-100 µs with 5 ns resolution
Dynamic Focusing: Supported
FMC, TFM, Back Diffraction Technique with / without and Mode Conversion: Supported
A-Scan:
  • RF
  • Rectified (Full Wave / Negative or Positive Half Wave)
DAC / TCG:
  • One Per Focal Low
  • Multi-curve
  • Slope < 20 dB/µs
  • Available for the rectified and RF A-Scans
  • Theoretical — through entering dB/mm (dB/") factor
  • Experimental — through recording echoes from several reflectors; capacity - up to 40 points
Gates: 2 Independent gates per focal law
controllable over entire time base in 0.1 mm /// 0.001" resolution
Threshold: 5-95 % of A-Scan height controllable in 1 % resolution
Phased Array Probes:
  • 1D Array (linear, circular, and the like)
  • Dual Linear Array
Number of focal laws: 8192  
independently adjustable gain / time base per focal law
Scanning and Imaging:
  • Cross-Sectional B-Scan (E-Scan) — regular and/or Volume Overlay True-To-Geometry
  • Cross-Sectional Sector Scan (S-Scan) — regular and/or Volume Overlay and True-To-Geometry
  • Multi-group image composed of several cross-sectional B- and S-Scans
  • Horizontal Plane S-Scan
  • TFM and FMC sinthetic aperture images
  • Back-diffraction image
  • Strip Chart
  • TOFD Map out of a pair of PA probes
  • Top (C-Scan), Side, End View imaging formed through encoded / time-based line scanning, 3D-Viewer
  • Top (C-Scan), Side, End View imaging formed through encoded XY- scanning, 3D-Viewer
Data Storage: 100% raw data capturing
Postrpocessing:
  • Built-in means for the comprehensive postprocessing in the instrument
  • ISONIC PA Office - freeley distributable postprocessing package for the computer running under W'XP, W'7, W'8, W'10


Conventional UT and TOFD

Number of Channels: 2
Pulsing/Receiving (for 8 or 16 conventional channels):
  • Parallel - both channels do fire, receive, digitize, and record signals simultaneously
  • Sequential — cycles of firing, receiving, digitizing, and recording signals by each channel are separated in time in a sequence loop
Initial Pulse: Bipolar Square Wave with with Boosted Rising and Falling Edges, Guaranteed Shell Stability, and Active Damping
Transition: <7.5 ns (10-90% for rising edges / 90-10% for falling edges)
Amplitude: Smoothly tunable (12 levels) 50V - 300 Vpp into 50 Ω
Half Wave Duration: 50-600 ns independently controllable in 10 ns step
Modes: Single / Dual
Analogue Gain: 0...100 dB controllable in 0.5 dB resolution
Advanced Low Noise Design: 85 µV peak to peak input referred to 80 dB gain / 25 MHz bandwidth
Frequency Band: 0.2 - 25 MHz Wide Band
A/D Conversion: 100 MHz 16 bit
Digital Filter: 32-Taps FIR band pass with controllable lower and upper frequency limits
A-Scan:
  • RF
  • Rectified (Full Wave / Negative or Positive Half Wave)
  • Signal's Spectrum (FFT Graph)
DAC / TCG:
  • Multi-curve
  • Slope < 20 dB/µs
  • Available for the rectified and RF A-Scans
  • Theoretical — through entering dB/mm (dB/") factor
  • Experimental — through recording echoes from several reflectors; capacity - up to 40 points
DGS: Standard Library for 18 probes / unlimitedly expandable
Gates: 2 Independent Gates
controllable over entire time base in 0.1 mm /// 0.001" resolution
Threshold: 5-95 % of A-Scan height controllable in 1 % resolution
HW Gates: Standard Option
Interface Echo: Standard Option
Digital Readout:
  • 27 automatic functions
  • Dual Ultrasound Velocity Measurement Mode for Multi-Layer Structures
  • Curved Surface / Thickness / Skip correction for angle beam probes
  • Ultrasound velocity and Probe Delay Auto-Calibration for all types of probes
Freeze A-Scan:
  • Freeze All
  • Freeze Peak
    Note: signal evaluation, manipulating Gates and Gain is possible for the frozen A-Scans as for live
Scanning and Imaging - Single Channel:
  • Thickness Profile B-Scan
  • True-To-Geometry Angle / Skip Corrected Cross-sectional B-Scan
  • High Resolution B-Scan
  • Horizontal Plane View CB-Scan
  • TOFD
Scanning and Imaging - Multichannel:
  • Strip Chart - strips of 4 types, namely P/E Amplitude/TOF; Map; TOFD; Coupling
  • Stripped C-Scan
Standard Length of a Single Line Scanning record: 50-20000 mm (2"-800"), automatic scrolling
Data storage: 100% raw data capturing
Postrpocessing:
  • Built-in means for the comprehensive postprocessing in the instrument
  • ISONIC Office L - postprocessing package for the computer running under W'XP, W'7, W'8, W'10


General

D195
PRF: 10...5000 Hz controllable in 1 Hz resolution
On-Board Computer CPU: Dual Core Intel Atom N2600 CPU 1.6 GHz
RAM: 2 GB
Quasi HDD: SSD Hard Drive 120 GB
Screen: Sun readable 8.5" touch screen 800 x 600
Controls: Sealed keyboard and mouse
Standard Ports:
  • 2 x USB (optionally expandable up to 8)
  • Ethernet
  • sVGA
Operating System: W'7PRO
Encoder:
  • Single Axis Incremental TTL encoder - Built-In
  • Multi-Axis (>=2) Incremental TTL Encoder - Optional
Remote Control:
  • From an external computer running under W'XP, W'7, W'8, W'10 through Ethernet
  • No special software required
  • All calibration and inspection data is stored in the control computer
Ambient Temperature:
  • -30 °C ... +60 °C (operation)
  • -50 °C ... +60 °C (storage)
Housing:
  • Rugged reinfoirced plastic case with the stainless steel carrying handle
  • IP 65
  • No air intake
  • The cooling is not required
Dimensions: 292x295x115 mm (11.50"x11.61"x4.53") - with / without battery inside
Weight:3,050 kg (6.71 lbs) — without battery
3.800 kg (8.36 lbs) — with battery

Detection of the vertical crack in the butt weld

Detection of the lack of fusion in the butt weld

Inspection of the fillet weld - detection of the crack from the flange

Inspection of the fillet weld - detection of the incomplete penetration from the web

Recording UT Data and Dual Camera Video for the Butt Weld

True-To-Geometry S-Scan of the Butt Weld along with Dual Camera Photo

GFRP plate calibration block

Inspection of the Bridge Hanger Pin (Calibration Block)

Scanning of butt weld with embedding of the process video

Inspection of the corner radius area in the bended carbon fiber profile

Inspection of the fillet weld

Inspection of the planar butt weld

PA UT Applications

Thanks to it's  unique smart, flexible, and "teachable" architecture combined with the outstanding ultrasonic performance  ISONIC 3510  has been an ideal platform for the practically unlimited number of standard and customized inspection software applications, the number of which is increasing permanetly.Each application is dedicated to the resolving of the inspection tasks related to the  certain class of parts and materials to be tested (the similar shape parts varying by the overall dimensions and the dimensions of particular segments). Since the part to be inspected is outlined the scan plan is created just in few moments providing the  True-to-Geometry Volume Corrected Coverage and imaging. This makes it possible to inspect complex geometry parts easily while  the non Sonotron NDT made phased array instruments are practically not applicable




More details about PA AUT applications.

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