Developing flaw sizing methodology in Total Focusing Method (TFM) by EDM calibration blocks

The Total Focusing Method (TFM) represents a significant advancement in ultrasonic inspection, delivering high-resolution imaging by leveraging phased array technology combined with sophisticated data processing algorithms. This synergy enables detailed visualization of flaws in various materials, thereby improving flaw detection and characterization. Despite TFM's capabilities, the lack of a standardized methodology for flaw sizing limits its potential for flaw evaluation. This paper seeks to establish a new paradigm in flaw sizing by introducing a custom methodology specifically designed for TFM, using electrical discharge machined (EDM) calibration blocks that reflect a range of flaw shapes. The research highlights the limitations of conventional side-drilled holes (SDH) for capturing realistic flaw nuances and emphasizes the superior ability of EDM notches to simulate the complex geometries inherent in typical flaws. By investigating the influence of different TFM modes, the study provides insight into their effectiveness in improving the accuracy of flaw characterization. Our approach addresses the challenges of existing TFM practices, with EDM notches serving as an essential tool in methodological advancement. This work contributes to the continued development of best practices in TFM application, paving the way for more accurate, reliable, and versatile nondestructive testing.