Factors Affecting Ultrasonic Thickness Gauge Readings
1. Surface roughness can significantly impact the performance of an ultrasonic thickness gauge. If the surface is too rough, it may lead to poor coupling between the probe and the material, resulting in weak or no echo signals. For surfaces with rust, paint, or oxide layers—common in in-service equipment or pipes—it’s important to clean the area by sanding, grinding, or scraping to expose a smooth metallic surface. Applying a suitable coupling agent will improve contact and ensure accurate measurements.
2. The radius of curvature of the object being measured can also affect readings. When measuring small-diameter tubes, the flat face of a standard probe may only make point or line contact with the curved surface, leading to poor sound transmission. In such cases, using a small-diameter probe (less than 6mm) can provide better contact and more accurate results when measuring curved surfaces like pipes.
3. If the measurement surface is not parallel to the back wall, the ultrasonic waves may scatter upon hitting the bottom surface, making it difficult for the probe to detect the return signal. This misalignment can result in inaccurate or no readings. Ensuring that the surface is as flat and parallel as possible is essential for reliable thickness measurements.
4. Materials such as castings or austenitic stainless steels often have uneven grain structures or coarse grains, which can cause significant scattering of ultrasonic waves. This scattering leads to reduced signal strength and potential signal cancellation, resulting in no display. To address this, a low-frequency, coarse-grain specific probe (e.g., 2.5MHz) is recommended for better penetration and clearer readings.
5. Wear on the probe's contact surface can also affect accuracy. Most thickness gauges use acrylic resin probes, which can become rough over time due to prolonged use. This increased roughness reduces sensitivity and may lead to inconsistent or incorrect readings. To restore performance, gently sand the probe surface with 500-grit sandpaper to make it smooth again. If the issue persists, consider replacing the probe to maintain measurement reliability.
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