Full-Coverage Ultrasonic Testing, Without Sampling A Structure Point By Point
What it is
Automated Ultrasonic Testing (AUT) moves an ultrasonic probe across a surface using a mechanised raster arm, rather than a technician holding a probe by hand. The arm indexes the probe back and forth in a controlled grid, so every point in the scanned area gets a reading in a known position — not just the points a technician happened to check.
This is a different kind of coverage to our single-probe B-Scan payload, which produces a continuous thickness profile along one travel path. AUT builds a full-area map (a C-scan) across a defined zone, which is why it’s the standard method for jobs like weld seam inspection and full-area corrosion mapping, where a missed spot is a missed defect.
How it works
01
Set up the scan zone
The area to be inspected, a weld seam, a vessel section, a plate, is defined before scanning begins.
02
Raster the probe
The arm moves the probe in a controlled back-and-forth grid, indexing a known distance between each pass.
03
Build the map
Readings from every point in the grid are assembled into a single, full-area picture of the scanned zone.
04
Assess against criteria
The resulting map is reviewed against acceptance criteria to identify and size any defects found.
AUT/Corrosion Mapping
Overview
HB2 and HB3 are being developed to carry a raster-arm AUT probe assembly, letting the robot capture full-area ultrasonic coverage directly rather than requiring a mechanised rig set up separately from the surface being inspected. The exact probe and arm configuration is scoped per project rather than fixed in advance.
Use case
- Weld seam inspection, pipeline girth welds, pressure vessel welds, structural welds
- Full-area corrosion mapping across plate, shell, or tank floor sections
- Fabrication quality assurance, where complete coverage is required rather than sampling
- Complementing manual spot-check UT with systematic, full-area coverage of critical zones
Benefits
01
No missed spots
Every point in the defined zone is scanned, rather than relying on a technician’s coverage or judgement of where to check.
02
Repeatable, comparable results
A fixed grid means surveys can be directly compared over time, rather than depending on where a technician happened to scan last time.
03
A reviewable area record
The output is a single map of the scanned zone, not a scattered set of individual readings to interpret afterward.
04
Reduced reliance on technique
Mechanised, controlled probe movement reduces the variability that comes from manual scanning technique, operator to operator.
05
Suited to safety-critical zones
Full coverage matters most exactly where a missed defect has the highest consequence, welds, tank floors, pressure boundaries.
06
Mounted on the same platform
Like our other payloads, AUT is designed to be carried by a climbing robot rather than a fixed rig, extending full-area coverage to vertical and overhead structures.
Full-area coverage vs. sampling
| Criteria | Manual spot-check UT | AUT (raster, full-area) |
|---|---|---|
| Coverage | Every point in the defined zone | Only the points a technician checks |
| Consistency | Fixed grid, repeatable between surveys | Depends on technician coverage and technique |
| Isolated defects | Caught wherever they fall in the zone | Only caught if a spot check happens to land on them |
| Record | A single reviewable area map | A set of individual readings, no positional map |
| Best suited to | Welds and zones where any missed defect matters | Quick checks or where full coverage isn't required |
Frequently asked questions
How is AUT different from your B-Scan payload?
B-Scan uses a single probe with a wheel encoder to build a continuous thickness profile along one travel path — a line. AUT uses a raster arm to build a full-area map across a defined zone — a grid, not a line. They answer different questions: B-Scan for a profile along a path, AUT for complete coverage of an area.
Does AUT replace radiography or other weld inspection methods?
That depends on your inspection code and acceptance criteria, which vary by industry and asset. We’re not going to make a compliance claim here, talk to us about your specific requirements and standards, and we’ll be straightforward about what AUT can and can’t do for your programme.
What does the scan resolution or grid spacing look like?
This depends on the probe and arm configuration used, which we scope per project rather than fix in advance. If you have a target resolution or an existing AUT procedure, tell us and we’ll confirm what’s achievable.
Can AUT be mounted on your climbing robot for vertical or overhead surfaces?
That’s the goal, carrying full-area AUT coverage onto vertical and overhead structures the same way we do with our other payloads. The mechanical integration is still being scoped, so the honest answer is: talk to us about your asset and we’ll tell you where things stand.
Need full-area coverage, not just a sample?
Tell us about the weld, vessel, or structure you need inspected, and we’ll be straightforward about whether AUT is the right fit and what’s achievable today.
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