An ultrasonic thickness gauge measures the thickness of materials. Invisible sound waves go through the material being tested. They then bounce off the back of the material. This creates an echo that the transducer picks up. The gauge measures how long it takes for the echo to come back. Using the speed of sound through that material, the gauge calculates its thickness.

These gauges often test metals, plastics, composites, and more. Companies use them to see how much wear, rust, or damage has happened over time. The gauges provide a fast way to check thickness without destroying the material. More advanced gauges can test big areas. They make maps showing if some parts are thinner than others. Ultrasonic thickness gauges are important for quality testing and maintenance. The following are five key things to know about these devices.

  1. Wide Range of Applications

These gauges allow operators, inspectors, and engineers to monitor thickness over time. This helps determine if corrosion or erosion is occurring. Thinner materials may indicate a problem. Thickness checks locate areas that need repair. Tests are simple, only requiring access to one side of the item. The gauges are portable and give instant digital readings. No damage or change is made to the material being measured.

In oil and gas, an ultrasonic thickness gauge allows operators to monitor pipe and vessel wall corrosion/erosion in refineries and chemical plants without taking equipment offline. The shipping and marine transport industries also rely heavily on ultrasonic gauges for assessing corrosion in ships’ hulls, fuel and water tanks, and offshore oil platforms. Power generation facilities use them to measure pipe thickness and build-up in boilers and steam lines. Aerospace companies check aluminum skin fatigue and thinning. Steel mills, metal fabrication shops, and forges apply ultrasonic thickness gauges for routine maintenance to avoid failures in tanks, pipelines, auto parts, etc. Construction groups even use them to evaluate aging in load-bearing structural steel. With the capacity to rapidly and reliably quantify thickness down to a fraction of a millimeter, ultrasonic gauges continue growing in popularity across sectors where equipment integrity is paramount.

  1. Precise Measurements  

Today’s ultrasonic thickness gauges can deliver measurement accuracy up to ±0.001 inches or ±0.01 mm. This allows for precise monitoring of thickness changes over time. The precision depends on the material, surface condition, temperature, and proper calibration. Proper coupling between the transducer and test material is also vital for reliability. Most gauges have digital displays showing exact thickness readings.

  1. Versatile Functionality

Advanced ultrasonic thickness gauges come with built-in data loggers for compiling measurement data, multiple transducer options for various materials and use cases, scan modes for easy mapping of thickness over an area, and software for further analysis. Portable flaw detectors even allow crack and defect detection using ultrasound. Rugged designs withstand harsh field use.

  1. Better Surveys with Scan Modes  

Ultrasonic thickness gauges with scan modes provide a more efficient way to conduct surveys and create thickness maps. Common scan patterns include raster scans and rotational scans. Battery-powered magnetic wheel probes automatically take measurements as they roll across steel surfaces at normal walking pace, storing thousands of readings per survey. This expands coverage and boosts productivity.

  1. Enhanced Safety and Savings

The major advantage of ultrasonic thickness gauges is enhanced safety and cost savings. Instant thickness checks minimize equipment shutdowns for internal inspections. Precise corrosion tracking optimizes maintenance scheduling, reducing failures and extending service life at the lowest possible cost. Ports and power plants can safely push boundaries on minimum allowable thicknesses. The non-destructive testing preserves structural and pipeline integrity without any unneeded resource waste.

Today’s advanced ultrasonic thickness gauges deliver fast, accurate, non-destructive measurements in the field. Their precision, versatility, expanded coverage, and role in predictive maintenance make them an essential modern tool for industry. Correct incorporation of ultrasonic thickness readings into inspection and life extension programs provides major safety and economic benefits across infrastructure and facilities.


Sumit is a Tech and Gadget freak and loves writing about Android and iOS, his favourite past time is playing video games.

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