21 Industrial Ave  Upper Saddle River, NJ.

07458
Tel: (201)962-7373  Fax: (201)962-8353
E-mail: info@phase2plus.com  Web Site: http://phase2plus.com

UTG-2000 Series

OPERATION MANUAL

* Precision Measuring Tools * Indexing Fixtures * Workholding Fixtures *

* Hardness Testers * Ultrasonic Thickness * Surface Finish * Coating Thickness *
 INDEX
1) GENERAL
1.1) APPLICATIONS 3
1.2) BASIC WORKING PRINCIPLE 3

2) SPECIFICATIONS 3

3) DIAGRAM Model#UTG‐2000 & 2020 4

4) MAIN FUNCTIONS 5

4.1) PREPARING FOR MEASUREMENT 5

5) SETTING PARAMETERS 5
5.1) Velocity 6
a) Velocity Setting 6
b) Velocity Measuring 6

5.2) Probe selection 6

5.3) Resolution 7

6) TESTING PROCEDURE 7

7) CALIBRATION 7

8) MEASURING THICKNESS 7

9) MAINTENANCE 8
9.1) Battery replacement 8
9.2) Storage 8

Appendix A: Decimal and Fractions to Millimeters 9

Appendix B: Millimeters to Inches 10
Appendix C: Sound Velocity in Materials 11

1. GENERAL
1.1) APPLICATIONS
The Phase II Ultrasonic Thickness Gage, Model No.UTG‐2000 & 2020 are designed for
2
measuring the thickness of metals, plastics, ceramics, glass and other ultrasonic wave
conducting materials with two parallel surfaces (top & bottom).

The UTG‐2000/2020 can be used in industrial applications to perform precise

measurements on various kinds of materials, parts and components. Additionally, it can be
used to monitor various kinds of pipes and pressure vessels for decreasing thickness due to
corrosion and/or erosion.

1.2) BASIC WORKING PRINCIPLE

The basic principle of the ultrasonic wave in a thickness measurement is similar to that of
an optical wave. The ultrasonic wave pulses are transmitted by the probe face and are
coupled to the object to be measured using a viscous fluid called “couplant” gel. These
ultrasonic pulses propagate through the measured object and reflect back to the transducer
when they encounter the back surface. The thickness of the object is determined by
precisely measuring the time the ultrasonic wave travels in the object.

2) SPECIFICATIONS
DISPLAY: FOUR DIGIT LCD DISPLAY
RESOLUTION: 0.01in / 0.1mm & 0.001” / 0.01MM
WORKING FREQUENCY: 5 MHz
MEASURING RANGE: .047in – 8.0in (1.2 ‐ 200.0 MM) (STEEL)
LOWER MEASURING LIMIT FOR PIPES: 0.8 X 0.1” or 20 X 3mm (STEEL)
MEASURING ERROR: +/‐ (1%H+0.004”) or (1%H+0.1)MM
H = actual thickness of the object to be
measured
ADJUSTING RANGE OF SOUND VELOCITY 0.039 to 0.3937in/us or (1000‐9999 M/S)
MEASUREMENT OF SOUND VELOCITY WITH
KNOWN THICKNESS VALUE:
MEASUREMENT RANGE: 37‐373 MILES/MIN (1000‐9999 M/S)
IF THICKNESS IS LESS THAN 0.8” (20mm): +/‐ 0.004”H x 100% or  1mm/H X 100%
IF THICKNESS IS GREATER THAN 0.8” (20mm)  5%
RANGE OF OPERATING TEMPERATURE: 32‐104 DEGREES F (0‐40 DEGREES C)
POWER SUPPLY: TWO AAA BATTERIES
POWER CONSUMPTION: 3 Volts at less than 20MA
Auto Power Off 2 Minutes
DIMENSIONS: 4.3 X 2.4 X 0.9IN
WEIGHT: 4.7oz

3
 7

6
5

4 2

Model UTG-2000
1. LCD Screen 2. Calibration Block
3. Increase/Change Setting/Backlight 4. Decrease/Change Setting/AutoCalibrat
5. Power On/Off 6. Menu Program/Save
7. Probe Ports

4
 7

9 8

6
5

MODEL UTG-2020
1. LCD Screen 2. Calibration Test Block
3. Increase/Change Setting/Backlight 4. Decrease/Change Setting/Auto
Calibration
5. Power On/Off 6. Menu Program/Save
7. Probe Port 8. Memory Recall (UTG-2010&2020
Only)
9. Store Data 10. RS-232/Printer Port

4) MAIN FUNCTIONS
5
 Automatic error correction capabilities
 Automatic linear compensation to improve accuracy (involves the correction of
non‐linear errors resulting from the probe).
 Up and down keys allow for quick adjustment of sound velocity and thickness, as
well as fast checking of memory unit.
 Automatic coupling icon indicates the coupling state: stable/unstable.
 Direct determination of the sound velocity according to the thickness of the
master testing block.
 Low battery indicator
Automatic instrument shut down during idle use period

4.1) PREPARING FOR MEASUREMENT

Place the probe into the probe socket of the unit, push to turn the unit on. After a few seconds,
the screen will display 0.00in, 0.000in, 0.0mm, or 0.00mm (depending on previous setting), the
sound velocity used during the last testing procedure along with the probe type and location. (See
Below)

0.000IN 0.00mm
VEL:0.230 PT-12 VEL:5920m/s PT-12

5) SETTING PARAMETERS

A) Press the button. The screen will display as follows:

Model# UTG‐2020 Model# UTG‐2010 Model# UTG‐2000

1. Measurement 1. Measurement 1. Measurement
2. Velocity 2. Velocity 2. Velocity
3. Probe Setting 3. Probe Setting 3. Probe Setting
4. Resolution 4. Resolution 4. Resolution
5. Location 5. Location 5. Default
6. Limitation 6. Default
7. Average
8. Print
9. Default
Note: 1. Measurement = Main test screen

5.1) Velocity
6
Press the button once to select 2. Velocity. Press the button to enter into the velocity
parameter. The screen will display as follows:

1. Vel. Setting
2. Vel. Measuring

a) Vel. Setting

Press the button to enter VEL SETTING. Use the button to move the cursor from

column to column. Use the button to change the number value. When the parameter has been

set, press the button to save entry.

INPUT VELOCITY
5920 m/s

b) Vel.Measuring
In the normal measurement mode, take a thickness reading on the sample to be tested. Press the

button to enter the menu mode. Press the button to move the cursor to the 2.

Velocity menu. Press the button to enter this mode. Then press the button to

move the cursor to 2. Velocity Measuring. Next press the button to enter this mode.
The screen looks similar to this.

INPUT THICKNESS
2.016in 0.2340

Press the button and the button to change the sound velocity parameter such that
the thickness number agrees with the actual thickness of the sample being measured.

Press the button to accept this velocity and exit the Velocity menu.
To measure the sound velocity of a specific material, use a testing block with a known thickness value. Similar to the measurement of the
materials thickness, use a vernier caliper or micrometer to obtain an accurate measurement of the testing block. Then couple the probe to the
testing block until a thickness value is displayed. Remove the probe and use the keypad to adjust the displayed value to match the actual
thickness of the testing block.

5.2 PROBE SELECTION

7
A) Press the button and scroll down to: 3. PROB SETTING.

Press the button to enter parameter.

Using the arrow keys, select your probe type and highlight the number. Press the button to
select and store in memory. (This gage is supplied with a PT‐12 probe)
Visible on first screen:
Visible on 2nd 1. PT-12 screen: 3. ZT-12
1.0-200 2.0-250
2. PT-06 4. GT-13
0.8-50 3.0-100
5.4 LOCATION (Memory Groups) *Models UTG‐2010 &
2020 only
 Model# UTG –2010 has a memory capacity of 2000 measurements. These can be stored in any
group from 0000 to 1999.
 Model# UTG‐2020 has a memory capacity of 4000 measurements. These can be stored in any
group from 0000 to 3999.
To choose a specific memory location, you must go to the main menu and scroll down to

#5 LOCATION. Press the button to enter location parameter. The screen will display input
location and show the four digits for entering and recording your desired memory location.

INPUT LOCATION
0001

Using the button, choose your desired numeral for the first column. Using the button,
change the column. Continue to change numerals and columns in this manner. When the desired

memory location has been chosen, press the button to save this entry.
Method of saving your measurement:
1) Take a measurement of the sample piece to be tested. As soon as the measurement is displayed

on the LCD screen, you must push the button to save the measurement in your chosen
memory location. For each time you save a measurement, the gauge will automatically store the
chosen value in the next consecutive memory location.
For instance, if you chose your first memory location to be 0560. That number will be your first
saved value. The next saved measurement value will be stored in location number 0561 and so on.
You can always change your location group at any time by following the instructions in the previous
paragraph.

3.02mm 3.02mm
VEL:5920 PT-12 LOC: 0002 VEL:5920 PT-12 LOC: 0003

Test#1 Test#2

8
5.5 MEMORY RECALL
If you need to start retrieving measurements starting from 0001, you should be in the main test

screen. Press the button and the gauge will display the measurement saved in memory

location 0001. You can press the button as many times as you need to display the saved
values in ascending order.

Example: push the button and the display will show location 0001. Push the same button
again and the display will show the saved value from location 0002, etc.

5.6 LIMITATION (Model# UTG‐2020 only)

Press the button and return to the main menu. Scroll down until you see the

6. LIMITATION. Press the button to enter the limitation parameter.

Set your lower limit by pressing the button to advance the numerals. Press the button to
change your column. Proceed to enter upper limit using the same method. When the data has been

entered to your requirements, you must press the button to save the entry. While taking
measurements, if your value is lower than the set limit, the letter “ L” will be displayed in the top
right corner of the LCD screen. If the value is greater than the set limit, the letter “H” will appear in
the top right corner of the screen.

LO. LIM. 00.00mm

UP. LIM. 99.00mm

5.7 AVERAGE (Model# UTG‐2020 only)

The mean value can be achieved by programming from 2 to 9 times.
Example: If you need to show an average after 3 tests, you would enter 3 as your average number. You
then perform 3 tests(SEE DIRECTIONS BELOW) and the gauge will then display the average of those 3
tests. If you need an average displayed after 9 tests(maximum), you should enter 9 as your average
number.

Press the button and proceed to 7.AVERAGE. Press the button to enter parameter. Using

th button, change the number form 2 to 9. Press the button to save entry.

AVERAGE TIMES

9
a) Directions for testing for averages:
1) Place the probe on your test sample. Get your measurement value.
2) Remove the probe from the test sample. Wait for 3 seconds. The gauge will “beep” and the
average number shown on the LCD screen will descend from 3 to 2.
3) Perform this procedure again. Wait for the beep and the gauge will change the average number
from 2 to 1.
4) Perform the 3rd and final test. Remove the probe from the test sample. The gauge will beep and
automatically show the average of the 3 tests you just performed.
Note: a new average time must be entered before each set to be performed.

5.8 PRINTING (Model# UTG‐2020 only)

If you want to print the stored values, you must first determine the initial location number and the
last location number to be printed.

 Press the button to enter main menu. Scroll down to the 8.PRINT.

 Press the button to enter parameter.

 The display will show a start location and an end location.

 Use the button to change the numerals

 Use the button to change the columns.

 When the data entry has been set, press the button to save this entry.
 The gauge will automatically begin displaying and printing all values stored in the entered
location numbers.

START LOC. 0000

END LOC. 0000

a) Printing to your PC (Model# UTG‐2020 only)

 Follow the instructions noted above. Instead of printing to your mini‐printer, the values will be
displayed on your PC screen.
Note: Use supplied cables to connect the gauge to the PC.

6) TESTING PROCEDURE
 Assuming all parameters have been entered, place a small drop of coupling gel (supplied) to
the surface of the sample to be tested.
NOTE: Do not apply Gel to the probe as that may result in attempted measurements with no sample touching the
probe.
 Place the probe directly on the gel spot holding steady and firm. Do not move the probe until the
measured value has been displayed. At this time, you can remove the probe from the test
sample.
Note: Coupling gel must be used to perform all ultrasonic tests.

7) CALIBRATION
Each time the probe or battery is changed, a calibration should be performed in order to guarantee
measuring accuracy. If necessary, repeat the calibration several times. Adjust the sound velocity to
2330in/us (5981m/s) (steel/iron).
 Apply the coupling gel to the testing block(see fig. 1, #6) (metallic disc on face of gage), which
is built into the unit, and couple the probe to the testing block. At this time, the screen displays
.157in(4mm),. This indicates that the calibration is over. If the screen displays something other
than .157in (4mm), you should press the button and the gauge will automatically calibrate
itself to .157in(4mm).
10
 At that time, you can begin to perform your testing.

8) MEASURING THICKNESS
Apply the coupling gel to the material to be measured and then couple the probe to the material.
This will begin the measurement, and the screen will then display the thickness of the material (see
fig.2).
NOTE: when the probe is coupled to the material, a coupling indicator will be displayed on the LCD screen. If
the coupling indicator flickers or does not appear, the coupling process is erroneous or incomplete.
Once a thickness measurement has been obtained, remove the probe. The thickness value will remain on the
LCD screen, however, the coupling indicator will disappear (see fig.3)
NOTE: Do not apply Gel to the probe as that may result in attempted measurements with no sample touching the
probe.

* AUTOMATIC SHUT‐OFF
If the UTG‐2000 remains idle for 2 minutes, the unit will automatically shut off.

* PRECAUTIONS
The surface of the probe is made of Polypropylene resin and is very sensitive to heavy scratches and rough surfaces.
Therefore, it is recommended to apply only a light to moderate amount of pressure on the probe during testing.

The temperature of the surface of the object to be measured should not exceed 140F (60C).

Keep the UTG‐2000 clean and avoid exposure to dust, iron chips, carbon particles.

10) MAINTENANCE

10.1) REPLACING THE BATTERIES

Once the low battery indicator appears on the screen, the batteries should be replaced.

Use the following procedure when replacing the batteries.

 Power unit off or wait until the unit turns off automatically.
 Open the battery compartment by pressing your thumb down on the cover and sliding it outwards.
 Remove the used batteries and insert new batteries into the compartment, paying close attention to the polarity of
the battery.

10.2) STORING THE UTG‐2000

Be sure to clean the probe and cable after each use. Grease, oil and dust will cause the cable of the probe to age and
crack.

If the unit is not to be used for a long period of time, remove the batteries to avoid battery leakage and corrosion of the
battery contacts.

Avoid storing the unit in a damp or extremely hot environment.

11
 Inch to Millimeter Conversion Table
Decimals to Millimeters Fractions to Decimals to Millimeters
Decimal mm Decimal mm Fraction Decimal mm Fraction Decimal mm
0.001 0.0254 0.500 12.7000 1/64 0.0156 0.3969 33/64 0.5156 13.0969

0.002 0.0508 0.510 12.9540 1/32 0.0312 0.7938 17/32 0.5312 13.4938
0.003 0.0762 0.520 13.2080 3/64 0.0469 1.1906 35/64 0.5469 13.8906

0.004 0.1016 0.530 13.4620

0.005 0.1270 0.540 13.7160

0.006 0.1524 0.550 13.9700 1/16 0.0625 1.5875 9/16 0.5625 14.2875

0.007 0.1778 0.560 14.2240

0.008 0.2032 0.570 14.4780 5/64 0.0781 1.9844 37/64 0.5781 14.6844

0.009 0.2286 0.580 14.7320 3/32 0.0938 2.3812 19/32 0.5938 15.0812

0.580 14.7320 7/64 0.1094 2.7781 39/64 0.6094 15.4781

0.010 0.2540 0.590 14.9860

0.020 0.5080

0.030 0.7620

0.040 1.0160 0.600 15.2400

0.050 1.2700 0.610 15.4940 1/8 0.1250 3.1750 5/8 0.6250 15.8750

0.060 1.5240 0.620 15.7480

0.070 1.7780 0.630 16.0020

0.080 2.0320 0.640 16.2560 9/64 0.1406 3.5719 41/64 0.6406 16.2719

0.090 2.2860 0.650 16.5100 5/32 0.1562 3.9688 21/32 0.6562 16.6688

0.660 16.7640 11/64 0.1719 4.3656 43/64 0.6719 17.0656

0.100 2.5400 0.670 17.0180

0.110 2.7940 0.680 17.2720

0.120 3.0480 0.690 17.5260 3/16 0.1875 4.7625 11/16 0.6875 17.4625

0.130 3.3020

0.140 3.5560

0.150 3.8100 13/64 0.2031 5.1594 45/64 0.7031 17.8594

0.160 4.0640 0.700 17.7800 7/32 0.2188 5.5562 23 8/25 0.7188 18.2562

0.170 4.3180 0.710 18.0340 15/64 0.2344 5.9531 47/64 0.7344 18.6531

0.180 4.5720 0.720 18.2880

0.190 4.8260 0.730 18.5420 1/4 0.2500 6.3500 3/4 0.7500 19.0500

0.740 18.7960

0.200 5.0800 0.750 19.0500

2.210 5.3340 0.760 19.3040 17/64 0.2656 6.7469 49/64 0.7656 19.4469

0.220 5.5880 0.770 19.5580 9/32 0.2812 7.1438 25/32 0.7812 19.8438

0.230 5.8420 0.780 19.8120 19/64 0.2969 7.5406 51/64 0.7969 20.2406

0.240 6.0690 0.790 20.0660

0.250 6.3500

0.260 6.6040

0.270 6.8580 0.800 20.3200 5/16 0.3125 7.9375 13/16 0.8125 20.6375

0.280 7.1120 0.810 20.5740 21/64 0.3281 8.3344 53/64 0.8281 21.0344

0.290 7.3660 0.820 20.8280 11/32 0.3438 8.7312 27/32 0.8438 21.4312

0.300 7.6200 0.830 21.0820 23/64 0.3594 9.1281 55/64 0.8594 21.8281

0.310 7.8740 0.840 21.3360

0.320 8.1280 0.850 21.5900 3/8 0.3850 9.5250 7/8 0.8750 22.2250

0.330 8.3820 0.860 21.8440

0.340 8.6360 0.870 22.0980 25/64 0.3906 9.9219 57/64 0.8906 22.6219

0.350 8.8900 0.880 22.3520 13/32 0.4062 10.3188 29/32 0.9062 23.0188

0.360 9.1440 0.890 22.6060 27/64 0.4219 10.7156 59/64 0.9219 23.4156

0.370 9.3980

0.380 9.6520

0.390 9.9060 0.900 22.8600

0.400 10.1600 0.910 23.1140 7/16 0.4375 11.1125 15/16 0.9375 23.8125

12
0.410 10.4140 0.920 23.3680

0.420 10.6680 0.930 23.6220

0.430 10.9220 0.940 23.8760

0.440 11.1760 0.950 24.1300 29/64 0.4531 11.5094 61/64 0.9531 24.3094

0.450 11.4300 0.960 24.3840 15/32 0.4688 11.9062 31/32 0.9688 24.6062

0.460 11.6840 0.970 24.6380 31/64 0.4844 12.3031 63/64 0.9844 25.0031

0.470 11.9380 0.980 24.8920

0.480 12.1920 0.990 25.1460

0.490 12.4460 1.000 25.4000 1/2 0.5000 12.7000 1 1.0000 25.4000

Millimeter to Inch Conversion Table

mm Decimal mm Decimal mm Decimal mm Decimal mm Decimal
0.01 0.00039 0.41 0.01614 0.81 0.03189 21 0.82677 61 2.40157
0.02 0.00079 0.42 0.01654 0.82 0.03228 22 0.86614 62 2.44094
0.03 0.00118 0.43 0.01693 0.83 0.03268 23 0.90551 63 2.48031
0.04 0.00157 0.44 0.01732 0.84 0.03307 24 0.94488 64 2.51969
0.05 0.00197 0.45 0.01772 0.85 0.03346 25 0.98425 65

0.06 0.00236 0.46 0.01811 0.86 0.03386 26 1.02362 66 2.59843

0.07 0.00276 0.47 0.01850 0.87 0.03425 27 1.06299 67 2.63780
0.08 0.00315 0.48 0.01890 0.88 0.03465 28 1.10236 68 2.67717
0.09 0.00354 0.49 0.01929 0.89 0.03504 29 1.14173 69 2.71654
0.10 0.00394 0.50 0.01969 0.90 0.03543 30 1.18110 70 2.75591

0.11 0.00433 0.51 0.02008 0.91 0.03583 31 1.22047 71 2.79528

0.12 0.00472 0.52 0.02047 0.92 0.03622 32 1.25984 72 2.83465
0.13 0.00512 0.53 0.02087 0.93 0.03661 33 1.29921 73 2.87402
0.14 0.00551 0.54 0.02126 0.94 0.03701 34 1.33858 74 2.91339
0.15 0.00591 0.55 0.02165 0.95 0.03740 35 1.37795 75 2.95276

0.16 0.00630 0.56 0.02205 0.96 0.03780 36 1.41732 76 2.99213

0.17 0.00669 0.57 0.02244 0.97 0.03819 37 1.45669 77 3.03150
0.18 0.00709 0.58 0.02283 0.98 0.03858 38 1.49606 78 3.07087
0.19 0.00748 0.59 0.02323 0.99 0.03898 39 1.53543 79 3.11024
0.20 0.00787 0.60 0.02362 1.00 0.03937 40 1.57480 80 3.14961

0.21 0.00827 0.61 0.02402 1 0.03937 41 1.61417 81 3.18898

0.22 0.00866 0.62 0.02441 2 0.07874 42 1.65354 82 3.22835
0.23 0.00906 0.63 0.02480 3 0.11811 43 1.69291 83 3.26772
0.24 0.00945 0.64 0.02520 4 0.15748 44 1.73228 84 3.30709
0.25 0.00984 0.65 0.02559 5 0.19685 45 1.77165 85 3.34646

0.26 0.01024 0.66 0.02598 6 0.23622 46 1.81102 86 3.38583

0.27 0.01063 0.67 0.02638 7 0.27559 47 1.85039 87 3.42520
0.28 0.01102 0.68 0.02677 8 0.31496 48 1.88976 88 3.46457
0.29 0.01142 0.69 0.02717 9 0.35433 49 1.92913 89 3.50394
0.30 0.01181 0.70 0.02756 10 0.39370 50 1.96850 90 3.54331

0.31 0.01220 0.71 0.02795 11 0.43307 51 2.00787 91 3.58268

0.32 0.01260 0.72 0.02835 12 0.47244 52 2.04724 92 3.62205
0.33 0.01299 0.73 0.02874 13 0.51181 53 2.08661 93 3.66142
0.34 0.01339 0.74 0.02913 14 0.55118 54 2.12598 94 3.70079
0.35 0.01378 0.75 0.02953 15 0.59055 55 2.16535 95 3.74016

0.36 0.01417 0.76 0.02992 16 0.62992 56 2.20472 96 3.77953

0.37 0.01457 0.77 0.03032 17 0.66929 57 2.24409 97 3.81890
0.38 0.01496 0.78 0.03071 18 0.70866 58 2.28346 98 3.85827

13
0.39 0.01535 0.79 0.03110 19 0.74803 59 2.32283 99 3.89764
0.40 0.01575 0.80 0.03150 20 0.78740 60 2.36220 100 3.93701

14
All velocities are approximations:
SOUND VELOCITY MEASUREMENT CHART
Material Sound Velocity
Inch/µS M/s
Air 0.013 330
Aluminum 0.250 6300
Alumina Oxide 0.390 9900
Beryllium 0.510 12900
Boron Carbide 0.430 11000
Brass 0.170 4300
Cadmium 0.110 2800
Copper 0.180 4700
Glass(crown) 0.210 5300
Glycerin 0.075 1900
Gold 0.130 3200
Ice 0.160 4000
Inconel 0.220 5700
Iron 0.230 5900
Iron (cast) 0.180 4600
Lead 0.085 2200
Magnesium 0.230 5800
Mercury 0.057 1400
Molybdenum 0.250 6300
Monel 0.210 5400
Neoprene 0.063 1600
Nickel 0.220 5600
Nylon, 6.6 0.100 2600
Oil (SAE 30) 0.067 1700
Platinum 0.130 3300
Plexiglass 0.110 1700
Polyethylene 0.070 1900
Polystyrene 0.0930 2400
Polyurethane 0.0700 1900
Quartz 0.230 5800
Rubber, Butyl 0.070 1800
Silver 0.140 3600
Steel, Mild 0.233 5900
Steel, Stainless 0.230 5800
Teflon 0.060 1400
Tin 0.130 3300
Titanium 0.240 6100
Tungsten 0.200 5200
Uranium 0.130 3400
Water 0.584 1480
Zinc 0.170 4200
 Note: To calibrate the UTG‐2000 or 2020 , you must set the velocity to 0.2330/5981M/S (Steel) as
stated in Sect. 7 Calibration, on page 7.

15
Appendix B Applications 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. If the diameter of the pipe is larger than approximately 4 inches, measurements should be made with the
transducer oriented so that the gap in the wearface is perpendicular (at right angle) to the long axis of the pipe. For
smaller pipe diameters, two measurements should be performed, one with the wearface gap perpendicular, another with
the gap parallel to the long axis of the pipe. The smaller of the two displayed values should then be taken as the
thickness at that point.

Measuring hot surfaces

The velocity of sound through a substance is dependant upon its temperature. As materials heat up, the velocity of
sound through them decreases. In most applications with surface temperatures less than about 100 , 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 a calibration procedure on a sample piece of known thickness, which is at or near
the temperature of the material to be measured. This will allow the gauge to correctly calculate the velocity of sound
through the hot material.
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 to acquire a stable
measurement. While the transducer is in contact with a hot surface, it will begin to heat up, and through thermal
expansion and other effects, may begin to adversely affect the accuracy of measurements.
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
minimized.
An additional important consideration when measuring laminates, is that any included air gaps or pockets 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.
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, fiberglass,
and some rubber.

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Couplants
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 used in ultrasonic thickness measurement does not travel
through air efficiently.
A wide variety of couplant materials may be used in ultrasonic gauging. Propylene glycol is suitable for most
applications. In difficult applications where maximum transfer of sound energy is required, glycerin is recommended.
However, on some metals glycerin can promote corrosion by means of water absorption and thus may be undesirable.
Other suitable couplants for measurements at normal temperatures may include water, various oils and greases,
gels, and silicone fluids. Measurements at elevated temperatures will require specially formulated high temperature
couplants.
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 while in standard pulse-echo mode.
This may result in a thickness reading that is TWICE what it should be. The Responsibility for proper use of the
instrument and recognition of these types of phenomenon rests solely with the user of the instrument.

3.1 Transducer Selection

The gauge is capable of performing measurements on a wide range of materials, from various metals to glass and
plastics. Different types of material, however, will require the use of different transducers. Choosing the correct
transducer for a job is critical to being able to easily perform accurate and reliable measurement. The following
paragraphs highlight the important properties of transducers, which should be considered when selecting a transducer
for a specific job.
Generally speaking, the best transducer for a job is one that sends sufficient ultrasonic energy into the material
being measured such that a strong, stable echo is received by the gauge. Several factors affect the strength of
ultrasound as it travels. These are outlined below:
Initial Signal Strength. The stronger a signal is to begin with, the stronger its return echo will be. Initial signal
strength is largely a factor of the size of the ultrasound emitter in the transducer. A large emitting area will send more
energy into the material being measured than a small emitting area. Thus, a so-called “1/2 inch” transducer will emit a
stronger signal than a “1/4 inch” transducer.
Absorption and Scattering. As ultrasound travels through any material, it is partly absorbed. If the material
through which the sound travels has any grain structure, the sound waves will experience scattering. Both of these
effects reduce the strength of the waves, and thus, the gauge’s ability to detect the returning echo. Higher frequency
ultrasound is absorbed and scattered more than ultrasound of a lower frequency. While it may seem that using a lower
frequency transducer might be better in every instance, low frequencies are less directional than high frequencies. Thus,
a higher frequency transducer would be a better choice for detecting the exact location of small pits or flaws in the
material being measured.
Geometry of the transducer. The physical constraints of the measuring environment sometimes determine a
transducer’s suitability for a given job. Some transducers may simply be too large to be used in tightly confined areas.
Also, the surface area available for contacting with the transducer may be limited, requiring the use of a transducer with
a small wearface. Measuring on a curved surface, such as an engine cylinder wall, may require the use of a transducer
with a matching curved wearface.
Temperature of the material. When it is necessary to measure on surfaces that are exceedingly hot, high
temperature transducers must be used. These transducers are built using special materials and techniques that allow
them to withstand high temperatures without damage. Additionally, care must be taken when performing a “Probe-Zero”
or “Calibration to Known Thickness” with a high temperature transducer.
Selection of the proper transducer is often a matter of tradeoffs between various characteristics. It may be
necessary to experiment with a variety of transducers in order to find one that works well for a given job.
The transducer is the “business end” of the instrument. It transmits and receives ultrasonic sound waves that the
instrument uses to calculate the thickness of the material being measured. The transducer connects to the instrument
via the attached cable, and two coaxial connectors. When using transducers, the orientation of the dual coaxial
connectors is not critical: either plug may be fitted to either socket in the instrument.

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 The transducer must be used correctly in order for the instrument to produce accurate, reliable measurements.
Below is a short description of the transducer, followed by instructions for its use.

Above Left figure is a bottom view of a typical transducer. The two semicircles of the wearface 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 wearface that
is being measured.
Right figure 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
wearface seated flat against the surface of the material being measured.

3.2 Condition and Preparation of Surfaces

In any ultrasonic measurement scenario, the shape and roughness of the test surface are of paramount
importance. Rough, uneven surfaces may limit the penetration of ultrasound through the material, and result in unstable,
and therefore unreliable, measurements. The surface being measured should be clean, and free of any small particulate
matter, rust, or scale. The presence of such obstructions will prevent the transducer from seating properly against the
surface. Often, a wire brush or scraper will be helpful in cleaning surfaces. In more extreme cases, rotary sanders or
grinding wheels may be used, though care must be taken to prevent surface gouging, which will inhibit proper
transducer coupling.
Extremely rough surfaces, such as the pebble-like finish of some cast iron, will prove most difficult to measure.
These kinds of surfaces act on the sound beam like frosted glass on light, the beam becomes diffused and scattered in
all directions.
In addition to posing obstacles to measurement, rough surfaces contribute to excessive wear of the transducer,
particularly in situations where the transducer is “scrubbed” along the surface. Transducers should be inspected on a
regular basis, for signs of uneven wear of the wearface. If the wearface is worn on one side more than another, the
sound beam penetrating the test material may no longer be perpendicular to the material surface. In this case, it will be
difficult to exactly locate tiny irregularities in the material being measured, as the focus of the sound beam no longer lies
directly beneath the transducer.

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