When an ultrasonic wave passes from one material into another at an angle, its speed changes. This change in velocity causes the sound beam to bend, or refract, according to Snell's Law.
In angle beam ultrasonic testing, a longitudinal wave generated inside the probe wedge enters the test material and changes direction as it crosses the interface. Depending on the materials and the incident angle, part of the energy continues as a longitudinal wave while another portion converts into a shear wave. This process is known as mode conversion and forms the basis of most angle beam inspections.
Mode conversion occurs whenever an ultrasonic wave crosses the boundary between two different materials at an angle. As the wave enters the test material, its energy is divided into different wave types:
For most weld inspections, the refracted shear wave is the wave of interest because it provides excellent sensitivity to common weld discontinuities.
Two important angles determine how ultrasonic waves behave as they enter the test material.
First Critical Angle: The first critical angle is reached when the refracted longitudinal wave travels along the material surface at 90°. Beyond this point, the longitudinal wave no longer propagates into the material, leaving the shear wave as the dominant inspection beam.
Second Critical Angle: The second critical angle occurs when the refracted shear wave also reaches 90°. Beyond this angle, neither refracted longitudinal nor refracted shear waves enter the material, making conventional angle beam inspection impractical.
The relationship between the incident and refracted angles is defined by Snell's Law:
| Wedge Material | Typical Longitudinal Velocity |
|---|---|
| Acrylic (Perspex) | Approximately 2,730 m/s |
| Rexolite | Approximately 2,330 m/s |
| Polystyrene | Approximately 2,350 m/s |
These materials are selected because their sound velocities allow the desired refracted shear wave angles to be produced in steel.
| Material | Longitudinal Velocity | Shear Velocity |
|---|---|---|
| Carbon Steel | ~ 5,900 m/s | ~ 3,230 m/s |
| Stainless Steel | ~ 5,700 m/s | ~ 3,100 m/s |
| Aluminium | ~ 6,320 m/s | ~ 3,130 m/s |
| Titanium | ~ 6,100 m/s | ~ 3,100 m/s |
Material properties directly influence the refracted beam angle and must be considered when selecting wedges and probes.
The region between the first and second critical angles is where most angle beam ultrasonic inspections are performed. Operating within this range provides:
This is why common probe angles such as 45°, 60°, and 70° are designed to operate within this shear wave region for steel inspections.
Snell's Law is fundamental to many ultrasonic inspection techniques, including:
Accurate angle beam inspections depend on selecting the correct wedge, probe frequency, refracted angle and material properties. While Snell's Law predicts beam behaviour mathematically, inspection performance should always be verified through calibration using approved reference blocks and in accordance with applicable standards and procedures.