Evaluation of a custom phased array transducer concept for the inspection of large-sized forged steel blocks

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Sorel Forge specialises in delivering high quality forged steel to a wide array of Canadian and international customers. In order to ensure the quality of their product, each forging is individually inspected for flaws and internal irregularities using standard pulse-echo technique. The forgings are accepted or rejected based on the result of the ultrasonic inspection. A reliable inspection technique is, therefore, paramount to reduce the number of rejected forgings. Forged steel is an anisotropic, highly attenuative material and the specimens under inspection are very large in size. The consequences of these characteristics are that the standard pulse-echo technique often fails to deliver high quality inspection results. The work done during the Engage grant enabled us to recommend a phased array inspection technique. However commercial phased array transducer cannot be used to perform the recommended inspection technique due to the size of the steel forgings. In the project funded by the Engage Plus grant, the tools developed during the Engage grant will be leveraged to evaluate and validate a custom phased array transducer adapted to the dimensions of the steel forgings manufacture by Sorel Forge. At the end of the project, Sorel Forge will receive the recommended design for a custom phased array transducer adapted to their inspection needs as well as a working prototype.