Ultrasonic Immersion Tank Testing
Manual and Semi-Automated Immersion Testing for Forgings, Extrusions, and Aerospace Rings. Mitchell Laboratories performs high-accuracy immersion ultrasonic testing on parts unsuited for automated scanning, using purpose-built tanks and custom material handling systems.
Ultrasonic Immersion Tank Testing?
Ultrasonic Immersion Tank Testing is a non-destructive testing (NDT) method where components are submerged in water to enable precise transmission of high-frequency sound waves for detecting internal flaws. At Mitchell Laboratories, this method is critical for inspecting aerospace die-forgings, extrusions, and complex geometries that benefit from manual control, technician interpretation, and high-sensitivity data capture.
Advantages of Ultrasonic Immersion Tank Testing
- Ideal for Complex Geometries: Perfect for inspecting die-forgings, curved extrusions, and shapes that challenge automated systems.
- Multiple Tank Sizes Available: Accommodates parts ranging from small components to extrusions over 50 feet in length.
- Technician Comfort & Ergonomics: Compact tanks allow for efficient, high-volume inspections with optimal technician workflow.
- Semi-Automated Twin Rotator Tank: Features dual rotators for inspecting aircraft wheels, forged rings, and cylindrical parts.
- Large-Scale Super Tank: Supports long extrusions with multi-bridge assemblies and integrated material handling systems.
- High Throughput, Manual Control: Manual scanning ensures tight control over custom probe paths and multi-surface coverage.
- Flexible Data Output: Results can be delivered in printed inspection reports or Windows-compatible digital formats.
Limitations of Ultrasonic Immersion Tank Testing
- Not Suitable for In-Service Inspection
- Submersion sensitive materials may be susceptible to corrosion or require drying protocols post-inspection
- Complex geometries may limit probe accessibility and require custom fixturing
Basic Principles of Ultrasonic Immersion Tank Testing
In ultrasonic immersion testing, the part is fully submerged in water to enable consistent sound wave transmission between the transducer and material surface. Water serves as the coupling medium, eliminating the need for gels or pastes. The ultrasonic probe transmits high-frequency sound waves into the part, which reflect off internal flaws, changes in material thickness, or structural discontinuities.
At Mitchell Laboratories:
- Manual and Semi-Automated Options: Technicians perform inspections using precision-controlled probes or dual-rotator systems, depending on part geometry and inspection scope.
- Multiple Tank Sizes: Tank configurations accommodate a range of part sizes—from aerospace wheels to 50’+ extrusions.
- Repeatable, High-Resolution Scans: Water coupling provides consistent signal quality, supporting accurate flaw detection and dimensional analysis.
Common Applications
Die-Forgings & Formed Extrusions
Aircraft Wheels & Forged Rings
Small Aerospace Components
Long Aerospace Extrusions
Low-Volume, High-Sensitivity Parts
Quality Assurance & Compliance
- ISO 9001 & AS9100D Certified
Procedures meet rigorous quality standards required for aerospace and defense manufacturing. - ITAR Registered
Compliant with International Traffic in Arms Regulations for military-grade inspection protocols. - NADCAP Accreditation
Special-process NADCAP approvals at multiple facilities ensure prime contractor acceptance. - Dimensional Traceability
All inspections are documented with part-level, technician-level, and material batch-level traceability. - Qualified, Certified Personnel
Manual immersion inspections are performed by certified Level 2 technicians under Level 3 supervision. - Material Handling & Support Fixtures
From lift-assisted setups to twin rotators and full-length bridges, our infrastructure ensures part integrity and inspection repeatability. - Continuous Quality Improvement
Customer feedback, internal audits, and regular procedure reviews drive our inspection reliability.
Frequently Asked Questions
Manual immersion is best for complex or irregular parts, like forged shapes, extrusions, or aerospace wheels, that cannot be effectively inspected by a fixed bridge.
Our Super Tank was built to inspect extrusions over 50 feet long, while other tanks support a range of part sizes from small rings to large forgings.
Yes. We use a twin-rotator semi-automated tank for efficient scanning of round parts like wheels and rings.
Yes. Our large tanks support multi-bridge setups, enabling simultaneous inspections by multiple qualified technicians for faster turnaround.
Lead times are quoted on a job-by-job basis to ensure accuracy, and we’re happy to accommodate emergency or rush requests. Backed by decades of refining our expedited process under strict deadlines, we minimize turnaround without ever sacrificing quality, returning your parts quickly and reliably.