Ultrasonic Immersion Testing Systems

ScanMaster provides state-of-the-art ultrasonic immersion testing systems designed for high throughput and multi-shift operation in industrial and laboratory environments. Our fully integrated systems offer various scan configurations and utilize both conventional and phased-array ultrasonic technologies to support a variety of applications – from inspecting engine discs and high-pressure turbine blades to testing bars, shafts, billets, and plates.

ScanMaster’s Automated Ultrasonic Testing (AUT) systems are trusted by all leading

ScanMaster is approved by many manufacturers for use in manufacturing facilities and aerospace maintenance, repair and overhaul organisations.

All ScanMaster immersion systems feature high-precision, multi-axis scanning frames for the inspection of complex parts and include a multi-channel ultrasonic device recognised for its exceptional performance. Combined with a comprehensive range of software modules, this versatile system series offers customers the best value for money solutions.

• Robust immersion tanks with high-precision mechanics for reliable inspection
• Clamping and centring of the rings – Precise positioning of the bearings
• Fast two-position lifting device (operated via the HMI control panel) for easy loading and unloading of bearings – Efficient loading and unloading of bearings
• Motorised rotary table chucks for automated processes – Automated rotary movements for higher productivity
• Interface for connection to a loading and unloading robot – Integration of robot systems
• Multi-transducer probe holder for increased inspection throughput – Acceleration of the inspection processe
• Fully automated inspection process without operator intervention maximises efficiency and prevents operator errors – Efficient inspection without manual intervention

• Efficient ‘teach-in’ function for programming ball and roller bearings – Simple programming of bearings
• Offline part programming by importing CAD models – Programming flexibility
• A, B and C scan data analysis tool kit, including a tool library for analysing and evaluating scan results – Comprehensive analysis tools for precise evaluations
• 3D visualisation of the warehouse model and scanning robot – Visual representation for better analysis
• Comprehensive inspection reports with standard and customised versions -Detailed inspection reports for accurate documentation

Ultrasonic testing with immersion technology (immersion) is a very efficient method for detecting small defects and irregularities in the material with a high probability of detection (POD). This inspection method enables precise dimensioning and improved detection of sub-surface defects (improved NSR – Near Surface Resolution). The test results can easily be found in test reports for components.

In immersion ultrasonic testing, the component is immersed in a test vessel with water as the coupling medium. The ultrasonic probe (transducer) is connected to a transducer manipulator (usually with two axes of rotation), which is part of a Cartesian or angular multi-axis scanner. The ultrasonic probe is then moved along a predefined path over the surface of the component, creating a network of points (pixels) where the ultrasonic data is captured.

The ultrasonic wave generated by the probe penetrates the water and enters the component.

As the ultrasonic wave passes through the component, it is reflected back to the probe by defects, flaws or inclusions in the material. The time taken for the wave to return to the probe (ToF = Time of Flight) and the corresponding amplitude can be recorded at any data point (pixel).

The data acquired during the test can be displayed (and retrieved) as an A-scan (per pixel), B-scan, C-scan and D-scan. These images can be analysed using appropriate image processing tools to provide the required information on the integrity of the component.

Ultrasonic testing with water has several advantages. Firstly, water allows better coupling than contact testing, resulting in better resolution near the surface. In addition, the use of a computer-controlled multi-axis scanner allows better and faster inspection of components with complex geometries.