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Irregular structure welds are used in numerous military industries. This paper is interested in how to utilize phased array ultrasonic testing (PAUT) to identify and locate irregular structure weld defects. In this paper, CIVA simulation results were compared with inspection results of known defects and were found to be in very good agreement. This shows the feasibility of CIVA simulations. The coupling, among process parameters, affects the amplitude drop value from the peak to the trough of defects signal response, which represents the lateral resolution of internal weld defects and affect the imaging quality directly. Thus, the proper setting of detection parameters is critical to improve the testing efficiency and the imaging quality. This paper uses the response surface methodology (RSM) to design the test and conduct a factorial test to analyze the effect of each parameter. Modelling of the parameters and the response is conducted through center composite design (CCD) to analyze the coupling among multiple parameters and the reliability of the model. In the process of PAUT, the response surface plot, contour plot and the initial design domain of process parameters were combined for weld defects to determine the optimal parameters rapidly and correctly. Besides, CIVA simulation could further verify optimized detection parameters and position in industry site. Finally, irregular structure weld defects were identified accurately with PAUT imaging.

Experimental Study on Lateral Resolution of Phased Array Ultrasonic Testing of Irregular Structure Weld Defects