The ability to measure early-stage high-temperature hydrogen attack (HTHA) has been improved by the use of optimized ultrasonic array probes and techniques. First, ultrasonic modeling and simulations were performed to design a set of array probes. The data was then collected using phased array ultrasonic testing (PAUT) and full matrix capture (FMC) techniques. Damage visualization, characterization, and sizing was completed with PAUT, total focusing method (TFM), and adaptive total focusing method (ATFM) advanced algorithms. The detection and sizing capabilities were initially validated on steel calibration samples with micromachined defects and synthetic HTHA damage. Vessels with suspected HTHA damage were removed from service, inspected with multiple array techniques, and then destructively evaluated for a results comparison with metallographic images. This study concluded that the FMC/TFM/ATFM techniques and algorithms improve detectability, characterization, and sizing of early-stage HTHA damage as compared to PAUT.
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