Development and Validation of Independent Dual-Focusing Transducer for Internal Inspection of Tubes

Controllable and focused ultrasonic beams in 3-D cylindrical space are essential when inspecting tubes or tubular objects. In this article, we develop an independent dual-focusing (IDF) array ultrasonic transducer composed of 64 prefocused elements and validate the feasibility of this design. Using k-Wave toolbox based on the k-space pseudospectral method, we simulate the acoustic pressure fields in the time domain and analyze beam profiles in circumferential-radial plane, axial-radial plane and 3-D space. The simulation results prove that the structure of IDF array transducer with the designed delay laws is capable of forming focused beam. A four-element aperture with 15 mm element radius shows narrow beams on both the circumferential and axial directions. On the basis of the simulation results, we fabricate a prototype transducer, test its electrical and acoustical performance, and implement internal inspection of a tube with an inner diameter of 13 mm. The echoes of four-element aperture show a higher amplitude than others, and this is consistent with the simulation. The eight longitudinal grooves and eight ring grooves of no more than 0.5 mm width are applied in inspection experiments, and the results demonstrate that the detection sensitivity of the IDF transducer can reach 0.2 mm in both the circumferential and axial directions. The results demonstrate that forming regulable and focused beam in 3-D cylindrical space is feasible using the IDF array which can be applied when inspecting tubes.