Surreal digital illustration of sound waves revealing flaws in metal.

Beyond the Scan: New Tech Reveals Hidden Flaws in Welds and Manufacturing

Avery Sinclair in Tech & Innovation June 2025 • 3 min read.

"Explore how advanced ultrasonic techniques are revolutionizing quality control, offering clearer insights into material integrity for safer, more reliable products."

In manufacturing and engineering, ensuring the integrity of materials is paramount. Traditional methods of quality control often fall short when it comes to detecting subtle yet critical flaws within materials, particularly in welds and complex manufactured components. However, advancements in ultrasonic testing are now offering more detailed and reliable solutions.

Ultrasonic full matrix capture/total focusing method (FMC/TFM) technology has emerged as a game-changer. This technique has matured significantly, offering enhanced detection and measurement capabilities for identifying flaws in welds and additive manufacturing processes. FMC/TFM's ability to process data from multiple probe types and wave propagation modes sets it apart from conventional methods.

Complementing FMC/TFM is the advanced focusing method (AFM), an alternative technique that closely matches the focusing quality of FMC/TFM but uses fewer data acquisitions. This results in faster data acquisition speeds and smaller data files, making it an attractive option for real-time data visualization and analysis.

Unveiling the Technologies: FMC/TFM and AFM in Action

Surreal digital illustration of sound waves revealing flaws in metal.

FMC involves using standard phased-array ultrasonic probes to gather data from every possible pulse-receive element combination within the probe array. For instance, a single element in the array sends out a pulse, and the signal amplitude versus time is recorded for each receiving element. This process is repeated for all elements in the array. Following data capture, a signal processing routine, such as TFM, reconstructs the information into an image for interpretation.

AFM enhances this process by acquiring data using multiple beam angles, and then reconstructing the data. By using fewer data points, AFM achieves faster computation speeds while maintaining a high level of focusing quality. The combination of these technologies marks a significant leap forward in non-destructive evaluation.

Key Advantages of FMC/TFM and AFM:

Improved detection of flaws, both planar and volumetric.
Enhanced measurement capabilities for accurate flaw sizing.
Real-time data visualization for immediate analysis.
Adaptability to various probe types and wave propagation modes.

To put these technologies to the test, experiments were conducted using two sample types: flat carbon steel plates with intentionally implanted flaws and flat, un-welded carbon steel plates containing electrical discharge machined (EDM) notches. These samples represent common scenarios in manufacturing, enabling a comprehensive evaluation of FMC/TFM and AFM capabilities.

The Future of Quality Control

The adoption of FMC/TFM and AFM marks a significant advancement in the field of non-destructive evaluation. These technologies enable manufacturers to detect flaws with greater precision and speed, leading to improved product quality and safety. As industries continue to demand higher standards and more reliable materials, these advanced ultrasonic techniques will undoubtedly play a crucial role in shaping the future of quality control.

About this Article -

This article was crafted using a human-AI hybrid and collaborative approach. AI assisted our team with initial drafting, research insights, identifying key questions, and image generation. Our human editors guided topic selection, defined the angle, structured the content, ensured factual accuracy and relevance, refined the tone, and conducted thorough editing to deliver helpful, high-quality information.See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1063/1.5031512, Alternate LINK

Title: Fmc/Tfm Experimental Comparisons

Journal: AIP Conference Proceedings

Publisher: Author(s)

Authors: Roger Spencer, Ruth Sunderman, Evgueni Todorov

Published: 2018-01-01

Everything You Need To Know

What does FMC/TFM technology involve, and how does it enhance flaw detection?

FMC/TFM, or Full Matrix Capture/Total Focusing Method, uses standard phased-array ultrasonic probes to capture data from every possible pulse-receive element combination within the probe array. A signal processing routine, often TFM, then reconstructs this information into an image for interpretation. This detailed capture and reconstruction process allows for enhanced detection and measurement capabilities, identifying flaws in welds and additive manufacturing processes with greater precision than conventional methods. Its ability to process data from multiple probe types and wave propagation modes sets it apart.

How does AFM differ from FMC/TFM, and what advantages does it offer in non-destructive evaluation?

AFM, or Advanced Focusing Method, enhances the data acquisition process by using multiple beam angles and then reconstructing the data. Unlike FMC/TFM which captures data from all possible element combinations, AFM uses fewer data points, resulting in faster computation speeds and smaller data files. While closely matching the focusing quality of FMC/TFM, AFM is particularly advantageous for real-time data visualization and analysis due to its efficiency.

What are the main benefits of using FMC/TFM and AFM in quality control?

The key advantages of using FMC/TFM and AFM include improved detection of both planar and volumetric flaws, enhanced measurement capabilities for accurate flaw sizing, real-time data visualization for immediate analysis, and adaptability to various probe types and wave propagation modes. These advantages lead to improved product quality and safety by allowing manufacturers to detect flaws with greater precision and speed.

What types of samples were used to evaluate the effectiveness of FMC/TFM and AFM?

These techniques were tested using flat carbon steel plates with intentionally implanted flaws and flat, un-welded carbon steel plates containing electrical discharge machined (EDM) notches. These samples represented common scenarios in manufacturing, providing a comprehensive evaluation of FMC/TFM and AFM capabilities in detecting and characterizing flaws in materials.

What implications does the adoption of FMC/TFM and AFM have for the future of quality control in manufacturing?

The adoption of FMC/TFM and AFM signifies a move towards higher standards and more reliable materials in manufacturing and engineering. By enabling manufacturers to detect flaws with greater precision and speed, these technologies contribute to improved product quality and safety. As industries demand increasingly stringent quality control, advanced ultrasonic techniques like FMC/TFM and AFM will likely play a crucial role in shaping the future of quality control, ensuring safer and more reliable products across various sectors.