Simulate for Better Safety

Ultrasonic Inspections

PZFlex is used in a variety of NDE applications, from modelling transducers to wave-propagation and defect interaction through test-pieces. Multi-element arrays can be simulated to generate full inspection methods, e.g. FMC, or any other arbitrary arrangements. The rapid simulation times of PZFlex have assisted industry in eliminating the need for fabricating expensive, bespoke test pieces for pioneering new inspection techniques.

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Array inspections

Create arbitrary array configurations, and input your own focal laws to fully analyse your sector scans. Direct contact, immersion, angled wedge and TRL inspections can all be accurately recreated.

Message Passing Interface

Compounding PZFlex’s unparalleled speed, MPI offers vast increases in performance for NDE simulations. Well suited to 16+ cores systems, MPI can be used to analyse billion element wave propagation simulations in a matter of hours.

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Mode conversion

When considering inspections with complex geometries accurate simulation of mode conversion is often crucial to generating realistic results. PZFlex considers the fundamental elastodynamics of the test piece to demonstrate mode conversion between all wave modes.

CAD Import

PZFlex’s ability to mesh structures in exceptional detail makes the simulation of complex structures both easy and accurate. STEP and IGES formats can be imported directly, with other formats available through optional pre-processors.

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Full Matrix Capture

Full Matrix Capture (FMC) provides a versatile way of performing a complete inspection on a component. By running multiple PZFlex Cloud simulations in parallel FMC scans can be recreated rapidly and accurately.

Defect interaction

Realistic defect geometries often produce inspection results which are difficult to interpret. By allowing complex defect structures to be meshed in fine detail, PZFlex can recreate the scattering matrix and mode conversion effects providing accurate imaging results.

Heterogeneous Material

Simulating wave propagation through heterogeneous materials presents a number of unique challenges. Wavefronts are continuously scattered, refracted and mode converted as they move through the component, resulting in highly complex behaviour which is difficult to recreate in analytical models. PZFlex combines the capability to consider all of these effects with a selection of anisotropic material models to allow even the most complex component to be captured. These capabilities continue to open up new applications from simulation of Carbon Fibre Reinforced Composites (CFRP) and dissimilar metal welds.

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Anisotropic Materials

Welds with large single crystal grains and CFRP components both exhibit anisotropic behaviour. This can cause dramatic directional dependency in inspections. PZFlex can recreate the beam distortion that can arise, allowing complex inspections to be better understood.

CFRP

Carbon Fibre Reinforced Composite (CFRP) components exhibit dramatic anisotropy and scattering effects during wave propagation, which often limits inspection frequency. PZFlex can predict how inspections will perform in these components, allowing frequency and angle to be optimised.

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Scattering

Scattering due to grain noise or laminate layers can mask critical defects. PZFlex allows you to accurately assess backscatter levels, allowing the optimum inspection frequency to be selected.

Shell Elements

Shell elements are ideal for simulating Lamb wave propagation through multilayer laminates. Isotropic and orthotropic shells are available and coupling into bulk materials is made easy, allowing very large structures to be considered.

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Arbitrary material maps

No matter how complex the component, PZFlex can capture the microstructure in high detail. Weld maps can be read in directly from simple images, or analysed in detail before importation in pre-processors.

Honeycomb structures

Aerospace components often incorporate complex structures such as multi-layer laminates or honeycomb sections. PZFlex can use shell elements in arbitrary structured meshes to recreate these components to allow subtle effects such as delamination to be simulated.

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We use PZFlex from proof of concept to final design of complex ultrasonic transducers for the NDT of nuclear reactor components. PZFlex is a very precious tool for debugging spurious echoes occurring inside the transducer, and for making our design right first time.
  • Jean-Francios Saillant, Areva
Cutting edge research requires high-quality data, produced with rapid iteration. In work where time and accuracy are paramount, PZFlex delivers. Moreover, the support staff from PZFlex were outstanding in their willingness to help and work with us to produce exactly what we needed. Finally, all of this powerful software is relatively easy to learn and use, making PZFlex a clear leader for us. We could not recommend the product highly enough.
  • Sheridan Gho, UCSF
PZFlex offers insight into complex coupled electrical-mechanical-acoustic problems, which reduces the research and development timeframe for piezoelectric based devices.
  • Jay Bennett, Director of Transducer Technology at Ultreo Inc
We have found PZFlex to be an invaluable tool to aid efficient development of complex inspections scenarios. It has many flexible features that the user can tailor to their needs and the PZFlex team always offer great support.
  • Ailidh McGilp, Senior Project Engineer at Doosan Babcock
PZFlex helps gain insight into complex multi-modal ultrasonic transducers and helps reduce cost by virtual prototyping of design. As a consequence, the overall time to market and cost of development is reduced without sacrifice on performance of ultrasonic devices.
  • Mo Zarkan, Ultrasonic Engineer at Emerson
PZFlex ultrasonic simulation software has proven to be a valuable R&D tool as we continue to develop and enhance newer touchscreen technologies. PZFlex staff have continually provided direct, prompt and helpful support.
  • Dr. Joel Kent, Scientist at Elo Touch Solutions, Inc.
PZFlex is an essential tool in our modelling of ultrasonic transducers and in their application. It allows us to better understand how the design parameters and materials affect the performance of our new transducer designs before we proceed with expensive and time consuming manufacture. By simulating applications of our ultrasound systems this allows us to tailor bespoke solutions and accelerate the delivery of our research projects.”
  • Prof. Anthony J. Mulholland, BSc, MSc, PhD, FIMA, CMath, Head of Department Department of Mathematics and Statistics, University of Strathclyde
Modeling is essential in supporting common engineering practices in the design and development of high-quality transducers. PZFlex is an easy-to-use, reliable FEM software tool that allows our design engineers to expand beyond common practices, allowing for design iteration and complete FEM verification. I would recommend PZFlex to any transducer design engineer, not only for the quality of software, but also for the exceptional technical support and customer service.
  • Kyle Morrison, President, Sonic Concepts
The PZFlex software allows us to design and analyse complex transducers for our underwater navigation and communications products in a very short time. If needed, we can easily adapt designs in PZFlex to optimise performance for different operating conditions and environments; an ability that significantly reduces our design cycle time and ensures our clients have confidence in the solutions we provide them with. The professionals at PZFlex are integral to our work, providing both troubleshooting solutions and technical advice that have made it possible to effectively use the design tool in our applications.
  • Erman Uzgur Ph.D., Senior Transducer Design and Acoustic Engineer at Sonardyne
As a small start-up company, we are very conscious of development time. During the proof of concept of our technology, PZFlex has enabled us to rapidly produce, validate and optimise the many iterations of our designs that wouldn’t otherwise be feasible with the other products available on the market. We really hit the ground running with support of the brilliant staff at PZFlex, who have continued to prove their professional and technical quality time and again. If you at all care about getting accurate results at incredible speeds, I couldn’t recommend PZFlex more!
  • Michael Weaver, Cenofex
PZFlex has given us the ability to move beyond the One Dimensional approximations traditionally used to design Tonpilz elements. It gives fantastic insight into the element design and allows optimisation of the elements and housing structures that was previously done by an experimental approach. It gives us confidence in a design much earlier in the design cycle and the transducers designed so far with PZFlex have performed very well, significantly exceeding bandwidth and power handling requirements.
  • Neil Dearing, Technical Director at Neptune Sonar Ltd
I was thrilled about the time PZFlex using to solve my ultrasonic modeling problem. It was beyond my expectation in terms of the speed and the cost-saving of the virtual prototype. What I appreciate most is the great technical support from PZFlex group. That saved me a lot of time and helped me to solve more complex problems.
  • Sheng Liu, Dev. Engineer at Olympus OSSA
PZFlex has brought the full power of finite element simulation to non-destructive testing engineers who are not numerical modelling specialists. TWI has been validating PZFlex step-by-step and it is proving to be a powerful tool for design of advanced inspection techniques.
  • Channa Nageswaran, R&D Team Manager at The Welding Institute
PZFlex has dramatically reduced our prototype design cycles, due to the orders of magnitude reduction in calculation time compared to the competing product we were using previously. In addition, the team at PZFlex have been extremely responsive, creating new calculation add-ons specifically tailored to our requirements, allowing us to model scenarios which were previously not possible. As a result, PZFlex is now a key tool in our design process and will remain so in the future, due to its continually evolving capabilities.
  • Sam Birtwell, Research Engineer at Gill Research & Development Limited
The speed and versatility of PZFlex for piezoelectric device modeling is astounding
  • David J Powell PhD, Project Manager at Sparton Electronics
Without PZFlex the interpretation of signal features and image contrast variation in the acoustic micrographs and pulse-echo signals would be highly speculative. The power of PZFlex combined with the excellent support of the very open and interested team is extremely valuable for our day-to-day work and opened up unforeseen opportunities for us.
  • Sebastian Brand, IMWS Fraunhofer
As a developer and producer of ultrasonic flow metering devices for the water industry, PZFlex has given a great boost to the development of new ultrasonic transducer for our flow meters by means of virtual prototyping. The powerful scripting language that is used by PZFlex allows an efficient implementation of the workflow from setting up and running the model up to post-processing results. Not to mention the great support that the team of PZFlex engineers provide us with.
  • Asmorom Kibrom, Nivus GmbH
We have been successful using PZFlex to dramatically reduce prototyping time. One of the great advantages I see is the ability to evaluate a range of complex concepts and select the best potential solutions for manufacture.
  • Ewan Campbell, Commercial Manager at Morgan Advanced Materials

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