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How can you ensure ultrasonic testing results are repeatable in manufacturing?

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Ultrasonic testing (UT) is a non-destructive testing (NDT) method that uses high-frequency sound waves to detect flaws, measure thickness, and evaluate material properties in manufactured products. UT is widely used in industries such as aerospace, automotive, oil and gas, and metal fabrication. However, to ensure the reliability and accuracy of UT results, it is essential to follow some best practices that can improve the repeatability of the testing process. Repeatability refers to the ability to obtain consistent results when performing the same test under the same conditions with the same equipment and personnel. In this article, we will discuss some of the factors that affect the repeatability of UT results and how you can optimize them in your manufacturing operations.

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Cristian Murillo Villegas

Gerente General / Vice Presidente Operaciones / Creador de la Filosofia Lean Power Management, Autor de los libros…
Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
Susheelkumar Singh

Results-Driven Deputy Manager | Global Industrial Engineer | Automotive Project Management Expert

1 Equipment Calibration

One of the most important steps to ensure the repeatability of UT results is to calibrate your equipment regularly and correctly. Calibration is the process of adjusting the settings and parameters of your UT equipment to match a known reference standard. Calibration ensures that your equipment is functioning properly and that the measurements are accurate and traceable. You should calibrate your equipment before each testing session, after any changes in the equipment or environment, and according to the manufacturer's recommendations. You should also use a calibration block that is similar to the material and geometry of the test object and record the calibration data for future reference.

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Susheelkumar Singh

Results-Driven Deputy Manager | Global Industrial Engineer | Automotive Project Management Expert
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Well, ensuring ultrasonic testing results are as repeatable as your morning coffee order involves a few tricks. First off, you want to make sure your equipment is calibrated tighter than a drum solo at a rock concert – precision is key! Next, keep those testing conditions consistent, like sticking to your favorite playlist for maximum productivity. And finally, train your operators so well they could spot a flaw faster than you can say "echo!" With these steps, your ultrasonic testing results will be as reliable as your grandma's secret cookie recipe – consistently spot on!

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Carla Lima

Montadora na Volvo Group | Tecnólogo em Gest?o da Produ??o Industrial
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Calibrar equipamentos ultrass?nicos é vital para garantir a precis?o dos resultados no controle de qualidade. No contexto da inspe??o de pe?as e detec??o de falhas, a calibra??o é fundamental. Os processos de calibra??o envolvem a prepara??o minuciosa dos equipamentos, testes em blocos certificados e análise detalhada dos resultados. Ajustes s?o feitos para garantir confiabilidade e precis?o. A documenta??o completa do processo é essencial para rastreabilidade e conformidade regulatória, promovendo a confiabilidade do sistema de produ??o.

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2 Test Procedure

Another factor that affects the repeatability of UT results is the test procedure. The test procedure is the set of instructions and steps that you follow to perform the UT test on a specific object. The test procedure should be clear, detailed, and consistent for each test object and each operator. The test procedure should include information such as the equipment settings, the transducer type and position, the scanning technique and pattern, the data collection and analysis methods, and the acceptance criteria. You should follow the test procedure exactly as written and document any deviations or anomalies that may occur during the testing process.

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Carla Lima

Montadora na Volvo Group | Tecnólogo em Gest?o da Produ??o Industrial
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O segredo por trás da precis?o dos resultados na ultrassonografia (UT) está no procedimento de teste. Ele é o guia detalhado que garante a repetibilidade dos resultados, abrangendo desde as configura??es do equipamento até os critérios de aceita??o. Seguir esse procedimento à risca e documentar qualquer desvio s?o práticas essenciais para garantir a confiabilidade dos testes UT. Na busca pela excelência, cada passo importa.

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3 Operator Training

A third factor that affects the repeatability of UT results is the operator training. The operator is the person who performs the UT test and interprets the results. The operator should have the necessary skills, knowledge, and experience to conduct the UT test correctly and reliably. The operator should be trained and certified according to the relevant standards and regulations for the industry and application. The operator should also be familiar with the equipment, the test procedure, and the test object. The operator should follow the instructions carefully and avoid any errors or biases that may affect the results. You should provide regular training and evaluation for your operators to ensure their competence and performance.

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Cristian Murillo Villegas

Gerente General / Vice Presidente Operaciones / Creador de la Filosofia Lean Power Management, Autor de los libros, Lean Power Management, Reflexiones de una industria lean y Neuro - Industrias. Speaker Internacional LPM
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El operador debe tener un rol que va más allá de ser un “ brazo de la máquina “… es una persona que previene activamente cualquier restricción que pudiese presentarse !

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4 Environmental Conditions

A fourth factor that affects the repeatability of UT results is the environmental conditions. The environmental conditions are the external factors that may influence the performance of the UT equipment and the quality of the results. Some of the environmental conditions that may affect the repeatability of UT results are temperature, humidity, noise, vibration, lighting, and dust. You should monitor and control the environmental conditions as much as possible to ensure that they are within the acceptable range for your UT equipment and test object. You should also minimize any variations or fluctuations in the environmental conditions during the testing process.

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5 Test Object Preparation

A fifth factor that affects the repeatability of UT results is the test object preparation. The test object preparation is the process of preparing the object to be tested for the UT test. The test object preparation may include cleaning, degreasing, sanding, coating, or marking the object. The test object preparation should be done in a way that does not alter the material properties or introduce any defects or contaminants that may affect the results. You should follow the same test object preparation method for each test object and each test session. You should also inspect the test object before and after the test to ensure that it is in good condition and free of any damage or interference.

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6 Data Management

A sixth factor that affects the repeatability of UT results is the data management. The data management is the process of storing, organizing, and reporting the data that you collect from the UT test. The data management should be done in a way that ensures the integrity, security, and accessibility of the data. You should use a reliable and compatible data storage system that can handle the amount and format of the data. You should also use a consistent and standardized data naming and labeling system that can identify the data source, date, time, and location. You should also use a clear and comprehensive data reporting system that can present the data in a meaningful and useful way.

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Cristian Murillo Villegas

Gerente General / Vice Presidente Operaciones / Creador de la Filosofia Lean Power Management, Autor de los libros, Lean Power Management, Reflexiones de una industria lean y Neuro - Industrias. Speaker Internacional LPM
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La información es de fundamental importancia para tomar las acciones y decisiones que fundamentarán el desarrollo continuo !

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Cristian Murillo Villegas

Gerente General / Vice Presidente Operaciones / Creador de la Filosofia Lean Power Management, Autor de los libros, Lean Power Management, Reflexiones de una industria lean y Neuro - Industrias. Speaker Internacional LPM
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Desarrollo personal Resiliencia Integración Pro actividad en el actuar Control en la ejecución Capacitación sistemática Evolución conceptual

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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It’s also crucial to consider the technological advancements and future developments in UT equipment. As technology evolves, newer models of UT devices may offer improved sensitivity, resolution, and versatility, enabling more accurate and efficient inspections. Keeping abreast of these innovations can significantly enhance testing capabilities, particularly for challenging applications or materials. Additionally, integrating digital technologies for data analysis and machine learning algorithms can further refine defect detection accuracy and predictive maintenance strategies.

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How can you ensure ultrasonic testing results are repeatable in manufacturing?

1

2

3

4

5

6

7

1 Equipment Calibration

2 Test Procedure

3 Operator Training

4 Environmental Conditions

5 Test Object Preparation

6 Data Management

7 Here’s what else to consider

Manufacturing Operations

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How can you ensure ultrasonic testing results are repeatable in manufacturing?

1

2

3

4

5

6

7

1 Equipment Calibration

2 Test Procedure

3 Operator Training

4 Environmental Conditions

5 Test Object Preparation

6 Data Management

7 Here’s what else to consider

Manufacturing Operations

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