Dakota NDT ZX2 Ultrasonic Thickness Gauge Instruction Manual
- August 20, 2024
- Dakota NDT
Table of Contents
- CHAPTER ONE INTRODUCTION
- Disclaimer
- CHAPTER TWO KEYPAD, MENU, DISPLAY & CONNECTORS
- The Display
- Measuring
- Top End Cap
- Transducer Connectors
- CHAPTER THREE PRINCIPALS OF ULTRASONIC MEASUREMENT
- Suitability of materials
- Range of measurement and accuracy
- Couplant
- Temperature
- Measurement Modes
- Pulse-Echo (P-E) Mode:
- CHAPTER FOUR SELECTING THE MEASUREMENT MODE
- Which mode & transducer do I use for my application?
- CHAPTER FIVE MAKING MEASUREMENTS
- Velocity Calibration
- Material Velocity
- Basic Material Type
- Selecting a Basic Material Type
- CHAPTER SIX ADDITIONAL FEATURES
- Factory Defaults
- Factory Reset
- APPENDIX A – VELOCITY
- APPENDIX B APPLICATION NOTES
- WARRANTY INFORMATION
- Warranty Statement
- Exclusions
- Obtaining Service During Warranty Period
- After the Warranty Period
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
Dakota NDT ZX2 Ultrasonic Thickness Gauge Instruction Manual
CHAPTER ONE INTRODUCTION
The Dakota NDT model ZX2 is a basic dual element thickness gauge with the ability to locate blind surface pitting and internal defects/flaws in materials. Based on the same operating principles as SONAR, the ZX2 is capable of measuring the thickness of various materials with accuracy as high as 0.001 inches, or 0.01 millimetres.
The principle advantage of ultrasonic measurement over traditional methods is that ultrasonic measurements can be performed with access to only one side of the material being measured.
Dakota NDT maintains a customer support resource in order to assist users with questions or difficulties not covered in this manual. Customer support may be reached at any of the following:
Dakota NDT
1500 Green Hills Road, #107 Scott Valley, CA 95066
Tel : 831-431-9722
Fax : 831-431-9723
www.dakotandt.com
Disclaimer
Inherent in ultrasonic thickness measurement is the possibility that the
instrument will use the second rather than the first echo from the back
surface of the material being measured. This may result in a thickness reading
that is TWICE what it should be.
Responsibility for proper use of the instrument and recognition of this
phenomenon rest solely with the user of the instrument. Other errors may occur
from measuring coated materials where the coating is insufficiently bonded to
the material surface. Irregular and inaccurate readings may result. Again, the
user is responsible for proper use and interpretation of the measurements
acquired.
CHAPTER TWO KEYPAD, MENU, DISPLAY & CONNECTORS
**The Keypad
**
ON/OFF/ENTER Key
The ON/OFF/ENTER key powers the unit ON or OFF. Since the same key is also
used as an ENTER key, the gauge is powered off by pressing and holding down
the key until the unit powers off.
Once the gauge is initially powered on, this key will function as the ENTER
key, similar to a computer keyboard. This key will be used to select or set a
menu option.
Note: Unit will automatically power off when idle for 5 minutes. All current settings are automatically saved prior to powering off.
PRB 0 Key
The PRB 0 key is used to “zero” the ZX2 in much the same way that a mechanical
micrometer is zeroed. If the gauge is not zeroed correctly, all of the
measurements that the gauge makes may be in error by some fixed value. Refer
to page 13 for a further explanation of this important feature.
VEL Key
The VEL key is used to enter and exit the ZX2’s calibration mode. This mode
is used to adjust the sound velocity value that the ZX2 will use for a given
material type.
Enter a known velocity value for specific material type, or manually continue
adjusting the value until the ZX2 displays the correct thickness value using a
test sample or calibration block with a known thickness. Refer to page 15 for
an explanation of calibration.
LIGHT Key
The LIGHT key accesses the backlight setting of the LCD display. The backlight
has three setting options; ON, OFF, AUTO. The auto option will only illuminate
the display when the ZX2 is measuring, or receiving an echo. If either ON or
AUTO are selected, there are three brightness options, LO, MED, HI, to select
a preferred overall brightness of the display. Refer to page 18 for an
explanation on how to enable and set the brightness.
UNITS Key
The UNITS key is used to select either English or Metric units. Refer to page
18 for an explanation of how to select the units.
+/- Increment/Decrement Key’s
The +/- Keys are used to increment/decrement values, navigate menus, and
select menu options.
MATL Key
The MATL Key is used to select a common basic material type from a short list
of 9 materials and 2 programmable custom materials for calibration. Refer to
page 15 for an explanation on selecting a basic material type.
The Display
The ZX2 uses a custom glass LCD backbit low temperature display for use in a variety of climate conditions. It contains graphic icons, as well as both 7 and 14 segment display areas. Let’s take a closer look and what all these things are telling us:
Note: This display is used for multiple gauge models in the ZX & PZX series. As a result, some of the icons and segments that are illuminated during boot up, may not be applicable to your specific model, and will never be illuminated during operation. The icons and segments that will be used with the ZX2 are shown in the diagram above.
A. Edit: This icon will be displayed, and blinking, to let a user know
when they are in an edit mode to change a value or setting.
B. Large 7 segment: The thickness measurement, velocity or alpha message
will be displayed in this area.
C. Measurement Modes: This icon indicates the measurement mode. The
ZX2 operates exclusively in pulse-echo (P-E) mode only.
D. Stability/Repeatability Indicator: This is used in conjunction with
the thickness measurement as a reference for the validity of the measurement.
The ZX2 takes multiple measurements per second, and when all the vertical bars
are illuminated, it’s a reference that the same thickness value is reliably
being measured multiple times per second.
E. Battery: Indicates the amount of battery life the ZX2 has
remaining.
F. Back light : When this icon is illuminated, it indicates the backlight
is on.
G. Small 7 Segment: The material velocity, speed the sound wave travels
through a given medium/material, is displayed in this area, informing the user
what material the ZX2 is currently calibrated too. This area is also used
for alpha messages in the menu and edit modes.
H. Units : This combination of icons are illuminated in different
sequences to inform the user what measurement units are currently being
displayed in the small 7 segment area.
I. Units: This combination of icons are illuminated in different
sequences to inform the user what measurement units are currently being
displayed in the large 7 segment area.
J. Small 14 Segment: The material type is displayed in this area. If it
is set to a value of one of the materials in our material list, it will be
displayed in alpha characters indicating the material type. Otherwise it will
be set to CUTS, indicating custom material type.
K. Features: The ZX2 can be locked once calibrated, to avoid
accidentally changing the calibration. When this icon is illuminated, the
ZX2 is in lock mode. Refer to page 19 for an explanation on locking the
ZX2.
The Transducer
The Transducer is the “business end” of the ZX2. It transmits and receives ultrasonic sound waves that the ZX2 uses to calculate the thickness of the material being measured. The transducer connects to the ZX2 via the attached cable, and two coaxial connectors. When using transducers manufactured by Dakota NDT, the orientation of the dual coaxial connectors is not critical: either plug may be fitted to either socket in the ZX2.
The transducer must be used correctly in order for the ZX2 to produce accurate, reliable measurements. Below is a short description of the transducer, followed by instructions for its use.
This is a bottom view of a typical transducer. The two semicircles of the wear
face are visible, as is the barrier separating them. One of the semicircles is
responsible for conducting ultrasonic sound into the material being measured,
and the other semicircle is responsible for conducting the echoed sound back
into the transducer.
When the transducer is placed against the material being measured, it is the
area directly beneath the center of the wear face that is being measured.
This is a top view of a typical transducer. Press against the top with the thumb or index finger to hold the transducer in place. Moderate pressure is sufficient, as it is only necessary to keep the transducer stationary, and the wear face seated flat against the surface of the material being measured.
Measuring
In order for the transducer to do its job, there must be no air gaps between the wear face and the surface of the material being measured. This is accomplished with the use of a “coupling” fluid, commonly called “couplant”. This fluid serves to “couple”, or transfer, the ultrasonic sound waves from the transducer, into the material, and back again. Before attempting to make a measurement, a small amount of couplant should be applied to the surface of the material being measured. Typically, a single droplet of couplant is sufficient.
After applying couplant, press the transducer (wear face down) firmly against the area to be measured. The Stability Indicator should have six or seven bars darkened, and a number should appear in the display. If the ZX2 has been properly “zeroed” (see page 13) and set to the correct sound velocity (see page 14), the number in the display will indicate the actual thickness of the material directly beneath the transducer.
If the Stability Indicator has fewer than five bars darkened, or the numbers on the display seem erratic, first check to make sure that there is an adequate film of couplant beneath the transducer, and that the transducer is seated flat against the material. If the condition persists, it may be necessary to select a different transducer (size or frequency) for the material being measured. See page 11 for information on transducer selection.
While the transducer is in contact with the material that is being measured, the ZX2 will perform four measurements every second, updating its display as it does so.
When the transducer is removed from the surface, the display will hold the last measurement made.
Top End Cap
The top end cap is where all connections are made to the ZX2. The diagram above shows the layout and description of the connectors:
Transducer Connectors
Refer to Diagram: The transducer connectors and battery cover/probe zero disk
are located on the ZX2’s top end cap. The transducer connectors are of
type Lemo “00”.
Note: There is no polarity associated with connecting the transducer to
the ZX2, it can be plugged into the gauge in either direction.
Probe Zero Disk & Battery Cover
Refer to Diagram: The Battery cover is the large round disk shown in the
diagram.
Note: This same disk is also used as a probe zero reference disk. Simply
remove the cover when replacing the batteries (2 AA cells). When performing a
manual probe zero function, simply place the transducer on disk making firm
contact.
Important: Be sure the battery polarity is correct, which can be found on the
back label of the ZX2. Note: Rechargeable batteries can be used, however
they must be recharged outside of the unit in a standalone battery charger.
CHAPTER THREE PRINCIPALS OF ULTRASONIC MEASUREMENT
Time versus thickness relationship
Ultrasonic thickness measurements depend on measuring the length of time it
takes for sound to travel through the material being tested. The ratio of the
thickness versus the time is known as the sound velocity. In order to make
accurate measurements, a sound velocity must be determined and entered into
the instrument.
The accuracy of a thickness measurement therefore depends on having a
consistent sound velocity. Some materials are not as consistent as others and
accuracy will be marginal. For example, some cast materials are very granular
and porous and as a result have inconsistent sound velocities.
While there are many different ultrasonic techniques to measure thickness,
which will be discussed below, all of them rely on using the sound velocity to
convert from time to thickness.
Suitability of materials
Ultrasonic thickness measurements rely on passing a sound wave through the
material being measured. Not all materials are good at transmitting sound.
Ultrasonic thickness measurement is practical in a wide variety of materials
including metals, plastics, and glass. Materials that are difficult include
some cast materials, concrete, wood, fibreglass, and some rubber.
Range of measurement and accuracy
The overall measurement capabilities, based on the wide variety of materials,
is determined by the consistency of the material being measured The range of
thickness that can be measured ultrasonically depends on the material type and
surface, as well as the technique being used and the type of transducer.
The range will vary depending on the type of material being measured.
Accuracy, is determined by how consistent the sound velocity is through the sound path being measured, and is a function of the overall thickness of the material. For example, the velocity in steel is typically within 0.5% while the velocity in cast iron can vary by 4%.
Couplant
All ultrasonic applications require some medium to couple the sound from the
transducer to the test piece. Typically a high viscosity liquid is used as the
medium.
The sound frequencies used in ultrasonic thickness measurement do not travel
through air efficiently. By using a liquid couplant between the transducer and
test piece the amount of ultrasound entering the test piece is much greater.
Temperature
Temperature has an effect on sound velocity. The higher the temperature, the
slower sound travels in a material. High temperatures can also damage
transducers and present a problem for various liquid supplants.
Since the sound velocity varies with temperature it is important to calibrate
at the same temperature as the material being measured.
Normal temperature range
Most standard transducers will operate from 0 F to 250 F.
High temperature measurements
Special transducers and supplants are available for temperatures above 250 F
up to 1000 F with intermittent contact. It is necessary to cool the transducer
by submerging it in water between measurements.
Modes and temperature errors
In addition to errors caused by velocity changing with temperature, some modes
(measurement techniques) are affected more than others. For example, dual
element pulse-echo mode has larger errors due to changes in the temperature of
the transducer. However, multi-echo techniques offer temperature compensation
help to minimize these errors.
Measurement Modes
This section will cover the different measurements modes of the ZX2, the transducers required, and the reasons for using specific modes:
Pulse-Echo (P-E) Mode:
Pulse-echo mode measures from the initial pulse (sometimes referred to as an artificial zero) to the first echo (reflection). A manual zero must be performed by placing the transducer on the reference disk located on top of the ZX2, and the PRB 0 key pressed to establish a zero point for the transducer connected.
In pulse-echo mode, errors can result from surface coatings and temperature variations. Since pulse-echo only requires one reflection, it is the most sensitive mode for measuring flaw/defects when measuring heavily corroded metals.
V-Path Correction
Dual element delay line transducers have two piezoelectric elements focused
towards one another at a slight angle, mounted on a delay line. One element is
used for transmitting sound, while the other element receives the sound
reflection. The two elements and their delay lines are packaged in a single
housing but acoustically isolated from each other with an insulated sound
barrier. This allows the transducer the ability to achieve very high
sensitivity for detecting small defects. Also, the surface of the test
material does not have to be as flat in order to obtain good measurements.
Dual element delay line transducers are have a usable range of 0.025” and up,
depending on the material, frequency, and diameter.
A limitation of dual element delay-line transducers is the V shaped sound
path.
Because the sound travels from one element to another, the time versus
thickness relationship is non-linear. Therefore, a correction table in the
instruments software is used to compensate for this error.
Dual Element Transducer showing V-path of signal
Searching for small defects
Dual element delay line transducers are especially useful in searching for
small defects. As a result, this configuration is commonly used for corrosion
inspections. The dual element style transducer will find wall deterioration,
pits, cracks, and any porosity pockets during tank and pipeline inspections.
CHAPTER FOUR SELECTING THE MEASUREMENT MODE
Which mode & transducer do I use for my application?
High penetration plastics and castings
The most common mode for these types of applications is pulse-echo. Cast iron
applications require 1 – 5MHz frequencies, and cast aluminium requires a 7 –
10MHz frequency depending on the thickness. Plastics typically require lower
frequencies depending on the thickness and make-up of the material as well.
Larger diameters offer greater penetration power based on the size of the
crystal.
Corrosion & Pit Detection in steel and cast materials
Pulse-echo mode is commonly used for locating pits and defects. Typically a
5MHz transducer, or higher, will be used for these types of applications. Use
low frequencies for greater penetration and use higher frequencies for better
resolution.
Measuring Material & Coatings
The pulse-echo coating mode should be used when both material and coating
thickness are required, while still requiring the ability to detect flaws and
pits. A special coating style transducer is required for use in this mode.
There are a variety of coating transducers in various frequencies available
from Dakota.
Thru Paint & Coatings
Often times, users will be faced with applications where the material will be
coated with paint or some other type of epoxy material. Since the velocity of
the coating is approximately 3 times slower than that of steel, pulse-echo
mode will result in an error if the coating or paint is not completely
removed.
Thin materials
Pulse echo mode and a high frequency transducer is commonly used for these
types of applications. The most common transducers are the 7.5MHz and 10MHz
models with extra resolution. The higher frequencies provide greater
resolution and a lower minimum thickness rating overall.
High temperature
Special 5 MHz High temperature transducers are available for these types of
applications. Both pulse-echo and echo-echo modes will also work for these
applications. However, echo-echo mode will eliminate error caused by
temperature variations in the transducer.
Noisy Material
Materials such as titanium, stainless steel, and aluminium may have inherent
surface noise issues or mirroring effect. Higher frequency transducers 7 –
10MHz offer improved resolution to avoid erroneous measurements.
Restricted access
Measuring materials with extreme curvatures or restricted access are best
suited for higher frequencies and smaller diameter transducers.
CHAPTER FIVE MAKING MEASUREMENTS
The steps involved in making measurements are detailed in this section. The
following sections outline how to setup and prepare your ZX2 for field use.
A manual zero must always be performed. A manual probe zero is performed using
the reference disk (battery disk) attached to the top of the instrument. The
zero compensates for variations of the transducer. Once the probe zero is
completed, the sound velocity must be determined to convert the transit time
to a physical length.
The sound velocity can be selected from the material chart in the manual, or
manually adjusted using a single, or multiple, known reference point(s) until
the ZX2 correctly measuring the reference point(s). The later will result in
greater precision overall. To enter a common velocity from a table of
velocities, look up the material on the chart in the appendix of this manual.
Refer to the section below on Material Calibration for instructions on
manually adjusting the velocity using a reference point(s)/standard(s). To
determine the velocity of a single sample, refer to the Velocity Calibration
section on page 14. The ZX2 can also be calibrated by selecting a common
material type from a short list of materials. To select a common material type
to use for calibration, refer the Basic Material Type section on page 15.
Probe zero
Setting the zero point of the ZX2 is important for the same reason that
setting the zero on a mechanical micrometer is important. It must be done
prior to calibration, and should be done throughout the day to account for any
temperature changes in the probe. If the ZX2 is not zeroed correctly, all the
measurements taken may be in error by some fixed value.
The “on block” zero procedure is outlined below:
Performing a Manual Probe Zero (On Block)
Note: The probe zero disk (battery cap) is located on the top of the
gauge, and used as the zero standard.
- Apply a drop of couplant on the transducer and place the transducer in steady contact with the disk (battery cover) located at the top of the unit to obtain a measurement.
- Be sure all six repeatability/stability bars in the top left corner of the display are fully illuminated and stable, and last digit of the measurement is toggling only +/- .001” (.01mm).
- Press the key to perform the manual zero. “PRB0” will briefly be displayed on the screen, indicating the zero calculation is being performed.
Velocity Calibration
In order for the ZX2 to make accurate measurements, it must be set to the correct sound velocity of the material being measured. Different types of materials have different inherent sound velocities. For example, the velocity of sound through steel is about 0.233 inches per microsecond, versus that of aluminium, which is about 0.248 inches per microsecond. If the gauge is not set to the correct sound velocity, all of the measurements the gauge makes will be erroneous by some amount.
If the material velocity is known, it can be manually entered into the ZX2. If the exact material velocity is unknown, a common velocity can initially be entered to set the ZX2 close to the unknown target velocity, followed by multiple fine adjustments to the velocity value until the target velocity is discovered. The steps for entering/editing the velocity value are outlined below:
Material Velocity
-
With the transducer free from contact with the material, press the key to display the current velocity. The edit icon will be illuminated and flashing.
-
Use the keys to scroll the velocity to the known target value.
Note: The longer the keys are pressed and held, the faster the value will increment/decrement.
Note : Pressing the key prior to pressing the key will abort the cal routine without saving any changes. -
Press the key to set the velocity value and return to the measurement screen. The new velocity value will be shown at the top of the display.
CHECK YOUR CALIBRATION! Place the transducer back on the calibration point and verify the thickness. If the thickness is not correct, repeat the steps above.
Basic Material Type
If the material velocity is unknown, a sample thickness cannot be taken directly from the material, but the general type of material is known, selecting a basic material type from the common material (MATL) list in the ZX2 would offer a reasonable approximation of the thickness. There are 9 common materials and 2 user programmable settings available. It’s important to note that these velocities will not always be an exact representation of the material being tested. Use these values only if a close approximation is acceptable. Follow the steps below to select a basic material type:
Selecting a Basic Material Type
-
Press the key to access the material list. The edit icon will be illuminated and flashing.
-
Use the keys to scroll through the material options.
-
When the desired MATL setting is displayed, press the key to set the material velocity and return to the measurement screen.
Note : Pressing the key prior to pressing the key will abort to the measurement screen without saving any changes. -
If USR1 or USR2 were selected, the velocity edit screen will be displayed and edit icon illuminated and flashing.
-
Use the keys to scroll to the desired material velocity.
Note: The longer these keys are held, the faster the velocity value is incremented. -
When the desired velocity setting is displayed, press the key to set the material velocity and return to the measurement screen.
-
Note : Pressing the key prior to pressing the key will abort to the measurement screen without saving any changes.
CHAPTER SIX ADDITIONAL FEATURES
Units
The ZX2 will operate in both English (inches) or Metric (millimetres) units.
The procedure to select the units is outlined as below:
- Press the key to toggle inches/millimetres (IN/MM).
Light
The ZX2 uses a custom glass segmented display that is equipped with a
backlight for use in low light conditions. The options are on/off/auto, where
the auto setting only lights the display when the gauge is coupled to the
material and receiving a measurement.
The steps below outline how to toggle the options:
Back light
-
Press the key to access the backlight status options. The edit icon will be illuminated and flashing.
-
Use the keys to toggle status on/off/auto.
Note : Pressing the key prior to pressing the key will abort to the measurement screen without saving changes. -
When the desired LITE setting is displayed, press the key to set the status and edit the BRT (brightness) option.
-
Use the keys to scroll through the BRT (LO, MED, HI) options.
-
When the desired BRT setting is displayed, press the key to set the brightness and return to the measurement screen.
Lock
The lock feature was built into the ZX2 for the purpose of locking the
operators out of editing any of the gauge settings, for purposes of
consistency between operators.
When the lock feature is enabled, the gauge calibration functionality cannot
be altered, as well as any of the individual features in the gauge. The only
keys that are always unlocked are the power and probe zero keys, as these must
remain unlocked for measurement functionality.
The procedure to enable/disable the lock feature is outlined below:
- With the ZX2 powered off, press and hold down the key while powering the ZX2 on . The lock icon will be illuminated on the display.
- To unlock the ZX2 repeat step one, but hold down the key while powering the ZX2 on .
Factory Defaults
The ZX-1 can be reset to factory defaults at any time to restore the original gauge settings. This should only be used if the gauge is not functioning properly, or perhaps multiple features have been enabled and a clean start is needed.
The procedure to reset the gauge is outlined below:
Factory Reset
-
With the ZX2 powered off, press and hold down the and keys while powering the ZX2 on .
Note: Once the measurement screen is displayed the and can be released. -
Press the keys to scroll through the factory setting options.
-
Make a note of the “MEDI” & “ZERO” settings prior to performing a reset.
These values will need to be entered back in the gauge following the reset. -
Press the keys to scroll “REST” (reset).
-
Press the key to edit the reset option.
-
Press the keys to toggle YES, followed by pressing to reset the gauge.
-
Repeat the steps above to set “MEDI” & “ZERO” back to their original settings noted in step three above.
APPENDIX A – VELOCITY
Material | sound velocity in/us | sound velocity m/s | |
---|---|---|---|
Aluminum | 0.2510 | 6375 | |
Beryllium | 0.5080 | 12903 | |
Brass | 0.1730 | 4394 | |
Bronze | 0.1390 | 3531 | |
Cadmium | 0.1090 | 2769 | |
Columbia | 0.1940 | 4928 | |
Copper | 0.1830 | 4648 | |
Glass (plate) | 0.2270 | 5766 | |
Glycerine | 0.0760 | 1930 | |
Gold | 0.1280 | 3251 | |
Inconel | 0.2290 | 5817 | |
Iron | 0.2320 | 5893 | |
Cast Iron | 0.1800 | (approx) | 4572 |
Lead | 0.0850 | 2159 | |
Magnesium | 0.2300 | 5842 | |
Mercury | 0.0570 | 1448 | |
Molybdenum | 0.2460 | 6248 | |
Monte | 0.2110 | 5359 | |
Nickel | 0.2220 | 5639 | |
Nylon | 0.1060 | (approx.) | 2692 |
Platinum | 0.1560 | 3962 | |
Plexiglas | 0.1060 | 2692 | |
Polystyrene | 0.0920 | 2337 | |
PVC | 0.0940 | 2388 | |
Quartz glass | 0.2260 | 5740 | |
Rubber vulcanised | 0.0910 | 2311 | |
Silver | 0.1420 | 3607 | |
Steel (1020) | 0.2320 | 5893 | |
Steel (4340) | 0.2330 | 5918 | |
Steel Stainless” | 0.2230 | 5664 | |
Teflon | 0.0540 | 1372 | |
Tin | 0.1310 | 3327 | |
Titanium | 0.2400 | 6096 | |
Tungsten | 0.2040 | 5182 | |
Uranium | 0.1330 | 3378 | |
Water | 0.0580 | 1473 | |
Zinc | 0.1660 | 4216 | |
Zirconium | 0.1830 | 4648 |
APPENDIX B APPLICATION NOTES
Measuring pipe and tubing
When measuring a piece of pipe to determine the thickness of the pipe wall,
orientation of the transducers is important. The transducer should be oriented
so that the gap (sound barrier) in the wear face is perpendicular (at a right
angle) to the length (long axis) of the tubing, allowing both sides of the
transducer to make the same amount of contact. The transducer orientation can
either be parallel or perpendicular for large diameter piping, as it’s much
easier to ensure both sides are making similar contact.
Measuring hot surfaces
The velocity of sound through a substance is dependent on its temperature. As
materials heat up, the velocity of sound through them decreases. In most
applications with surface temperatures less than about 200 F (100 C), no
special procedures must be observed. At temperatures above this point, the
change in sound velocity of the material being measured starts to have a
noticeable effect upon ultrasonic measurement.
At such elevated temperatures, it is recommended that the user perform calibration on a sample piece of known thickness, which is at or near the temperature of the material to be measured. This will allow the ZX2 to correctly calculate the velocity of sound through the hot material.
Expansion and contraction of the transducer based on temperature, and a varying temperature gradient, will also affect the measurement in a pulse-echo (P-E) measurement mode. It is recommended that a “transducer zero” be performed often to account for the delay line changing length and adversely affecting the accuracy of the measurements.
When performing measurements on hot surfaces, it may also be necessary to use a specially constructed high-temperature transducer. These transducers are built using materials which can withstand high temperatures. Even so, it is recommended that the probe be left in contact with the surface for as short a time as needed (intermittent contact) to acquire a stable measurement.
Measuring laminated materials
Laminated materials are unique in that their density (and therefore sound-
velocity) may vary considerably from one piece to another. Some laminated
materials may even exhibit noticeable changes in sound-velocity across a
single surface. The only way to reliably measure such materials is by
performing a calibration procedure on a sample piece of known thickness.
Ideally, this sample material should be a part of the same piece being
measured, or at least from the same lamination batch. By calibrating to each
test piece individually, the effects of variation of sound-velocity will be
minimised. If the variation is relatively close, averaging the sound
velocities to minimize error is another option.
An additional important consideration when measuring laminates is that many included air gaps or pockets which will cause an early reflection of the ultrasound beam. This effect will be noticed as a sudden decrease in thickness in an otherwise regular surface. While this may impede accurate measurement of total material thickness, it does provide the user with positive indication of air gaps in the laminate.
Measuring through paint & coatings
Measuring through paints and coatings are also unique, in that the velocity of
the paint/coating will be significantly different from the actual material
being measured. A perfect example of this would be a mild steel pipe with
.025” of coating on the surface. Where the velocity of the steel pipe is .2330
in/sec, and the velocity of the paint is .0850 in/sec. If the user is
calibrated for mild steel pipe and measures through both materials, the actual
coating thickness will appear to be approximately 3 times thicker than it
actually is, as a result of the differences in velocity.
WARRANTY INFORMATION
Warranty Statement
Dakota NDT warrants the ZX2 against defects in materials and workmanship for a period of five years from receipt by the end user. Additionally, Dakota NDT warrants transducers and accessories against such defects for a period of 90 days from receipt by the end user. If Dakota NDT receives notice of such defects during the warranty period, Dakota NDT will either, at its option, repair or replace products that prove to be defective.
Should Dakota NDT be unable to repair or replace the product within a reasonable amount of time, the customer’s alternative exclusive remedy shall be refund of the purchase price upon return of the product.
Exclusions
The above warranty shall not apply to defects resulting from: improper or inadequate maintenance by the customer; unauthorised modification or misuse; or operation outside the environmental specifications for the product.
Dakota NDT makes no other warranty, either express or implied, with respect to this product. Dakota NDT specifically disclaims any implied warranties of merchant ability or fitness for a particular purpose. Some states or provinces do not allow limitations on the duration of an implied warranty, so the above limitation or exclusion may not apply to you. However, any implied warranty of merchant ability or fitness is limited to the five-year duration of this written warranty.
This warranty gives you specific legal rights, and you may also have other rights which may vary from state to state or province to province.
Obtaining Service During Warranty Period
If your hardware should fail during the warranty period, contact Dakota NDT and arrange for servicing of the product. Retain proof of purchase in order to obtain warranty service.
For products that require servicing, Dakota NDT may use one of the following methods:
- Repair the product
- Replace the product with a re-manufactured unit
- Replace the product with a product of equal or greater performance
- Refund the purchase price.
After the Warranty Period
If your hardware should fail after the warranty period, contact Dakota NDT for details of the services available, and to arrange for non-warranty service.
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>