MT160

Ultrasonic Thickness Gauge

Instruction Manual
Document Number 800103
Rev A

8475 W I-25 Frontage Rd

Suite 300

Longmont, CO 80504

(303) 682-9999 (888) 386-7835 Fax (303) 682-4368

http://www.vortekinst.com
 MT160 Instruction Manual

1 Overview ..................................... 3
1.1 Product Specifications .......................................... 3
1.2 Main Functions ..................................................... 4
1.3 Measuring Principle .............................................. 4
1.4 Configuration ........................................................ 5
1.5 Operating Conditions ............................................ 5
2 Features ....................................... 6
2.1 Main Screen .......................................................... 7
2.2 Keypad Definitions ............................................... 8
3 Preparation .................................. 9
3.1 Transducer Selection ............................................. 9
3.2 Condition and Preparation of Surfaces ............... 13
4 Operation................................... 14
4.1 Power On/Off ...................................................... 14
4.2 Probe Zero ........................................................... 14
4.3 Sound Velocity Calibration ................................. 16
4.4 Making Measurements ........................................ 19
4.5 Scan mode ........................................................... 23
4.6 Changing Resolution ........................................... 25
4.7 Changing Units ................................................... 25
4.8 Memory Management ......................................... 25
4.9 Beep Mode .......................................................... 27
4.10 EL Backlight ..................................................... 28
4.11 Battery Information ........................................... 28
4.12 Auto Power Off ................................................. 28
4.13 System Reset ..................................................... 29
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 MT160 Instruction Manual

5 Servicing ................................... 29
6 Transport and Storage ............... 29
Appendix A Sound Velocities ...... 30
Appendix B App. Notes ............... 31

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 MT160 Instruction Manual

1 Overview
The model MT160 is a digital ultrasonic thickness gauge.
Based on the same operating principles as SONAR, the instrument
is capable of measuring the thickness of various materials with
accuracy as high as 0.1mm/0.01 millimeters. It is suitable for a
variety of metallic and non-metallic materials.
1.1 Product Specifications
1) Display: 4.5-digit LCD with EL backlight.
2) Measuring Range: (0.75～300) mm (in Steel)
3) Sound Velocity Range: (1000~9999) m/s
4) Resolution: MT160: 0.1mm/0.01mm
5) Accuracy: ± (0.5% Thickness + 0.04）mm, depends on
material and conditions
6) Units: Metric/Imperial unit selectable
7) Four readings per second for single point measurement, and
ten readings per second in Scan Mode.
8) Memory to store up to 20 files (up to 99 values for each file)
9) Power Source: Two “AA”, 1.5 Volt alkaline batteries.
100 hours typical operating time (EL backlight off).
10) Communication: MT160: USB serial port
11) Outline dimensions: 150mm × 74mm × 32 mm
12) Weight: 245g

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1.2 Main Functions

1) Capable of performing measurements on a wide range of
material, including: metals, plastic, ceramics, composites,
epoxies, glass and other acoustically conductive materials.
2) Transducer models are available for special applications,
including: high temperature or coarse material applications.
3) Probe-Zero function
4) Sound-Velocity-Calibration function
5) Two-Point Calibration function
6) Two operating modes: Single point and Scan mode
7) Coupling status indicator
8) Battery status indicator
9) Auto sleep and auto power off function to conserve battery
life.

1.3 Measuring Principle

The digital ultrasonic thickness gauge determines the
thickness of a part or structure by accurately measuring the time
required for a short ultrasonic pulse generated by a transducer to
travel through the thickness of the material, reflect from the back
or inside surface, and be returned to the transducer. The measured
two-way transit time is divided by two to account for the down-
and-back travel path, and then multiplied by the velocity of sound
in the material. The result is expressed in the well-known
relationship:

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vt
H=
2
Where： H－Thickness of the test piece.
v－Sound Velocity in the material.
t－The measured round-trip transit time.

1.4 Configuration
No. Item Quantity Note
Standard 1 Main body 1
Configuration 2 Transducer 1 Model: N05
3 Couplant 1
4 Instrument Case 1
Optional 5 Transducer: N02 See Table 3-1
Configuration 6 Transducer: N07
7 Transducer: HT5
Table 1-1: Product Configuration

1.5 Operating Conditions

Operating Temperature: -20℃～＋60℃;
Storage Temperature: -30℃～＋70℃
Relative Humidity: ≤ 90％；
The surrounding environment should avoid that of vibration,
strong magnetic fields, corrosive medium and heavy dust.

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2 Features

ULTRASONIC
THICKNESS GAUGE
SN:
POWER: 2 X 1.5V

MT160

Figure 1: Product Features

1 Main Body 2 Keypad 3 LCD Display 4 Transmitter

Socket 5 Receiver Socket 6 Probe Zero-Disc
7 Communication Port 8 Label 9 Battery Cover
10 Probe

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2.1 Main Screen

Figure 2: Main Screen

1. Coupling Status: Indicates the coupling status. While the

gauge is taking a measurement, the coupling status indicator
should be on. If it is not on or not stable, the gauge is having
difficulty achieving a stable measurement, and the thickness value
displayed will most likely be erroneous.
2. Unit: Current unit system. MM or IN for thickness value. M/S
or IN/μS for sound velocity.
3. Battery Information: Indicates the remaining capacity of the
battery.
4. Information Display: Displays the measured thickness value,
the sound velocity, and shows hints of current operation.

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2.2 Keypad Definitions

Turn the instrument Sound velocity

on/off calibration

Turn on/off the EL Enter

backlight
Probe-Zero operation Plus;
Turn on/off Scan
Mode
Unit switch between Minus;
Metric and Imperial Turn on/off Beep
system Mode
Data Save or Data
Delete

Figure 3: Keypad Definitions

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3 Preparation
3.1 Transducer Selection
The gauge is inherently capable of performing measurements
on a wide range of materials, from various metals to glass and
plastics. Different types of material, however, will require the use
of different transducers. Choosing the correct transducer for a job
is critical to being able to easily perform accurate and reliable
measurements. The following paragraphs highlight the important
properties of transducers, which should be considered when
selecting a transducer for a specific job.
Generally speaking, the best transducer for a job is one that
sends sufficient ultrasonic energy into the material being
measured such that a strong, stable echo is received by the gauge.
Several factors affect the strength of ultrasound as it travels. These
are outlined below:
Initial Signal Strength. The stronger a signal is to begin with,
the stronger its return echo will be. Initial signal strength is largely
a factor of the size of the ultrasound emitter in the transducer. A
large emitting area will send more energy into the material being
measured than a small emitting area. Thus, a so-called “1/2 inch”
transducer will emit a stronger signal than a “1/4 inch” transducer.
Absorption and Scattering. As ultrasound travels through any
material, it is partly absorbed. If the material through which the
sound travels has any grain structure, the sound waves will
experience scattering. Both of these effects reduce the strength of
the waves, and thus, the gauge’s ability to detect the returning

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echo. Higher frequency ultrasound is absorbed and scattered more

than ultrasound of a lower frequency. While it may seem that
using a lower frequency transducer might be better in every
instance, low frequencies are less directional than high
frequencies. Thus, a higher frequency transducer would be a better
choice for detecting the exact location of small pits or flaws in the
material being measured.
Geometry of the transducer. The physical constraints of the
measuring environment sometimes determine a transducer’s
suitability for a given job. Some transducers may simply be too
large to be used in tightly confined areas. Also, the surface area
available for contacting with the transducer may be limited,
requiring the use of a transducer with a small wear face.
Measuring on a curved surface, such as an engine cylinder wall,
may require the use of a transducer with a matching curved wear
face.
Temperature of the material. When it is necessary to measure
on surfaces that are exceedingly hot, high temperature transducers
must be used. These transducers are built using special materials
and techniques that allow them to withstand high temperatures
without damage. Additionally, care must be taken when
performing a “Probe-Zero” or “Calibration to Known Thickness”
with a high temperature transducer.
Selection of the proper transducer is often a matter of
tradeoffs between various characteristics. It may be necessary to
experiment with a variety of transducers in order to find one that
works well for a given job.
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The transducer is the “business end” of the instrument. It

transmits and receives ultrasonic sound waves that the instrument
uses to calculate the thickness of the material being measured. The
transducer connects to the instrument via the attached cable, and
two coaxial connectors. When using transducers, the orientation of
the dual coaxial connectors is not critical: either plug may be
fitted to either socket in the instrument.
The transducer must be used correctly in order for the
instrument to produce accurate, reliable measurements. Below is a
short description of the transducer, followed by instructions for its
use.

Figure 4: View of a Typical Transducer

The left image in Figure 4 is a bottom view of a typical

transducer. The two semicircles of the wear face are visible, as is
the barrier separating them. One of the semicircles is responsible
for conducting ultrasonic sound into the material being measured,
and the other semicircle is responsible for conducting the echoed
sound back into the transducer. When the transducer is placed
against the material being measured, it is the area directly beneath
the center of the wear face that is being measured.
The right image in Figure 4 is a top view of a typical
transducer. Press against the top with the thumb or index finger to
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hold the transducer in place. Moderate pressure is sufficient, as it

is only necessary to keep the transducer stationary, and the wear
face seated flat against the surface of the material being measured.

Table 3-1: Transducer Selection

Model Freq Diam Measuring Lower Description
(MHz) (mm) Range limit
N02 2.5 14 3.0mm～ 20mm For thick, highly
300.0mm（In attenuating, or
Steel） highly scattering
40mm (in Gray materials
Cast Iron
HT200)
N05 5 10 1.2mm～ Φ20mm× Normal
230.0mm（In 3.0mm Measurement
Steel）
N07 7 6 0.75mm～ Φ15mm× For thin pipe wall
80.0mm 2.0mm or small curvature
（In Steel） pipe wall
measurement
HT5 5 14 3～200mm 30mm For high
（In Steel） temperature
(lower than
300℃)
measurement.

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3.2 Condition and Preparation of Surfaces

In any ultrasonic measurement scenario, the shape and
roughness of the test surface are of paramount importance. Rough,
uneven surfaces may limit the penetration of ultrasound through
the material, and result in unstable, and therefore unreliable,
measurements. The surface being measured should be clean, and
free of any small particulate matter, rust, or scale. The presence of
such obstructions will prevent the transducer from seating
properly against the surface. Often, a wire brush or scraper will be
necessary to help clean the surface of the material. In more
extreme cases, rotary sanders or grinding wheels may be used,
though care must be taken to prevent surface gouging, which will
inhibit proper transducer coupling.
Extremely rough surfaces, such as the pebble-like finish of
some cast iron, will prove most difficult to measure. These kinds
of surfaces act on the sound beam like frosted glass on light, the
beam becomes diffused and scattered in all directions.
In addition to posing obstacles to measurement, rough
surfaces contribute to excessive wear of the transducer,
particularly in situations where the transducer is “scrubbed” along
the surface. Transducers should be inspected on a regular basis,
for signs of uneven wear of the wear face. If the wear face is worn
on one side more than another, the sound beam penetrating the test
material may no longer be perpendicular to the material surface.
In this case, it will be difficult to exactly locate tiny irregularities
in the material being measured, as the focus of the sound beam no

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longer lies directly beneath the transducer.

4 Operation
4.1 Power On/Off

The instrument is turned on by pressing the key.

Figure 5: LCD Display with Power Turned On

The gauge can be turned off by pressing the key while it

is on. The instrument has special memory that retains all of its
settings even when the power is off.

4.2 Probe Zero

The key is used to “zero” the instrument in much the
same way that a mechanical micrometer is zeroed. If the gauge is
not zeroed correctly, all the measurements that the gauge makes
may be in error by some fixed value. When the instrument is
“zeroed”, this fixed error value is measured and automatically

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corrected for in all subsequent measurements. The instrument may

be “zeroed” by performing the following procedure:
1) Plug the transducer into the instrument. Make sure that the
connectors are fully engaged. Check that the wear face of the
transducer is clean and free of any debris.
2) Press the key to activate the probe zero mode.
3) Use the key and the key to scroll to the probe model
currently being used. Be sure to set the right probe model in
the instrument, otherwise, erroneous measurements may
result.
4) Apply a single droplet of ultrasonic couplant to the face of the
metal probe-disc.
5) Press the transducer against the probe disc, making sure that
the transducer sits flat against the surface.
6) Remove the transducer from the probe disc.
At this point, the instrument has successfully calculated its
internal error factor, and will compensate for this value in any
subsequent measurements. When performing a “probe zero”, the
instrument will always use the sound velocity value of the built-in
probe-disc, even if some other velocity value has been entered for
making actual measurements. Though the instrument will
remember the last “probe zero” performed, it is generally a good
idea to perform a “probe zero” whenever the gauge is turned on,
as well as any time a different transducer is used. This will ensure
that the instrument is always correctly zeroed.
Pressing while in probe zero mode will stop current
probe zero operation and return to measurement mode.
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4.3 Sound Velocity Calibration

In order for the gauge to make accurate measurements, it
must be set to the correct sound velocity for the material being
measured. Different types of material have different inherent
sound velocities. If the gauge is not set to the correct sound
velocity, all of the measurements the gauge makes will be
erroneous by some fixed percentage. The One-Point calibration is
the simplest and most commonly used calibration procedure,
optimizing linearity over large ranges. The Two-Point calibration
allows for greater accuracy over small ranges by calculating the
probe zero and velocity.
Note: One and Two-Point calibrations must be performed on
material with the paint or coating removed. Failure to remove the
paint or coating prior to calibration will result in a multi material
velocity calculation that may be different from the actual material
velocity intended to be measured.

4.3.1 Calibration to a known thickness

Note: This procedure requires a sample piece of the specific
material to be measured, the exact thickness of which is known
(e.g. from having been measured by some other means).
1) Perform a Probe-Zero.
2) Apply couplant to the sample piece.
3) Press the transducer against the sample piece, making sure
that the transducer sits flat against the surface of the sample.
The display should show some thickness value, and the

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coupling status indicator should appear steady.

4) Having achieved a stable reading, remove the transducer. If
the displayed thickness changes from the value shown while
the transducer was coupled, repeat step 3.
5) Press the key to activate the calibration mode. The MM
(or IN) symbol should begin flashing.
6) Use the key and the key to adjust the displayed
thickness up or down, until it matches the thickness of the
sample piece.
7) Press the key again. The M/S (or IN/μS) symbols should
begin flashing. The gauge is now displaying the sound
velocity value it has calculated based on the thickness value
that was entered.
8) Press the key once again to exit the calibration mode and
return to the measurement mode. The gauge is now ready to
perform measurements.

4.3.2 Calibration to a known velocity

Note: This procedure requires that the operator know the sound
velocity of the longitudinal wave of the material to be measured.
Using the sound velocity of the transverse (shear) wave will result
in inaccurate measurements. A table of common materials and
their longitudinal wave sound velocities can be found in Appendix
A of this manual.
1) Press the key to activate the calibration mode. The MM
(or IN) symbol should begin flashing.
2) Press the key again, so that the M/S (or IN/μS) symbols
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are flashing.
3) Use the key and the key to adjust the sound velocity
value up or down, until it matches the sound velocity of the
material to be measured. You can also press the key to
switch among the predefined velocities that are most
commonly used.
4) Press the key to exit from the calibration mode. The
gauge is now ready to perform measurements.
To achieve the most accurate measurements possible, it is
generally advisable to always calibrate the gauge to a sample
piece of known thickness. Material composition (and thus, its
sound velocity) sometimes varies from lot to lot and from
manufacturer to manufacturer. Calibration to a sample of known
thickness will ensure that the gauge is set as closely as possible to
the sound velocity of the material to be measured.

4.3.3 Two Point Calibration

Note: This procedure requires that the operator has two known
thickness points on the test piece that are representative of the
range to be measured.
1) Perform a Probe-Zero.
2) Apply couplant to the sample piece.
3) Press the transducer against the sample piece, at the
first/second calibration point, making sure that the transducer
sits flat against the surface of the sample. The display should
show some (probably incorrect) thickness value, and the
coupling status indicator should appear steady.
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4) Having achieved a stable reading, remove the transducer. If

the displayed thickness changes from the value shown while
the transducer was coupled, repeat step 3.
5) Press the key. The MM (or IN) symbol should begin
flashing.
6) Use the key and the key to adjust the displayed
thickness up or down, until it matches the thickness of the
sample piece.
7) Press the key. The display will flash 1OF2. Repeat steps 3
through 6 on the first/second calibration point.
8) Press the key, so that the M/S (or IN/μS) symbols are
flashing. The gauge will now display the sound velocity value
it has calculated based on the thickness values that were
entered in step 6.
9) Press the key once more to exit the calibration mode. The
gauge is now ready to perform measurements within this
range.

4.4 Making Measurements

When the tool is displaying thickness measurements, the
display will hold the last value measured, until a new
measurement is made. See Figure 6 for a visual representation of
this behavior.
In order for the transducer to do its job, there must be no air
gaps between the wear face and the surface of the material being
measured. This is accomplished with the use of a “coupling” fluid,

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commonly called “couplant”. This fluid serves to “couple”, or

Figure 6: MT160 Prior to New Measurement

transfer, the ultrasonic sound waves from the transducer, into the
material, and back again. Before attempting to make a
measurement, a small amount of couplant should be applied to the
surface of the material being measured. Typically, a single droplet
of couplant is sufficient.
After applying couplant, press the transducer (wear face
down) firmly against the area to be measured as shown in Figure
7.

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Figure 7: Transducer Being Pressed into Couplant on Pipe

The coupling status indicator should appear, and a digit number

should populate in the display. If the instrument has been properly
“zeroed” and set to the correct sound velocity, the number in the
display will indicate the actual thickness of the material directly
beneath the transducer. See Figure 8 for an example of what to
expect on the MT160’s display when taking a measurement.

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Figure 8: Measuring Wall Thickness of a PVC Pipe

If the coupling status indicator does not appear, is not stable,

or the numbers on the display seem erratic, check to make sure
that there is an adequate film of couplant beneath the transducer,
and that the transducer is seated flat against the material. If the
condition persists, it may be necessary to select a different
transducer (size or frequency) for the material being measured.
While the transducer is in contact with the material that is
being measured, the instrument will perform four measurements
every second, updating its display as it does so. When the
transducer is removed from the surface, the display will hold the
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last measurement made.

Note：Occasionally, a small film of couplant will be drawn out
between the transducer and the surface as the transducer is
removed. When this happens, the gauge may perform a
measurement through this couplant film, resulting in a
measurement that is larger or smaller than it should be. This
phenomenon is obvious when one thickness value is observed
while the transducer is in place, and another value is observed
after the transducer is removed. In addition, measurements
through very thick paint or coatings may result in the paint or
coating being measured rather than the actual material intended.
The responsibility for proper use of the instrument, and
recognition of these types of phenomenon, rests solely with the
user of the instrument.

4.5 Scan mode

While the gauge excels at making single point measurements,
it is sometimes desirable to examine a larger region, searching for
the thinnest point. The gauge includes a feature, called Scan
Mode, which allows it to do just that.
In normal operation, the gauge performs and displays four
measurements every second, which is quite adequate for single
measurements. In Scan Mode, however, the gauge performs ten
measurements every second, and displays the readings while
scanning. While the transducer is in contact with the material
being measured, the gauge is keeping track of the lowest

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measurement it finds. The transducer may be “scrubbed” across a

surface, and any brief interruptions in the signal will be ignored.
Be sure there is always an adequate film of couplant between the
transducer and the material being measured to ensure accurate
measurements while “scrubbing”. See Figure 9 for a visual
representation of “scrubbing” and how it will draw out the
couplant being used to transfer the ultrasonic sound waves from
the transducer, into the material, and back again.

Figure 9: Drawing Out the Couplant in Scan Mode

When the transducer loses contact with the surface for more than
two seconds, the gauge will display the smallest measurement it
found. When the transducer is removed from the material being
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scanned, the gauge will display the smallest measurement it

found.
When Scan Mode is turned off, Single Point mode will be
automatically turned on. Turn Scan Mode on/off with the
following steps:
Press the key to switch the scan measurement mode on
and off. The instrument will display the status of the scan mode on
the main screen.

4.6 Changing Resolution

The MT160 has selectable display resolution, which is
0.1mm or 0.01mm.
Press down the key while turning on the gauge to switch
the resolution between “High” and “Low”.

4.7 Changing Units

While in measurement mode, press the key to switch
back and forth between imperial and metric units.

4.8 Memory Management

4.8.1 Storing a reading
There are twenty files (F00-F19) that can be used to store the
measurement values inside the gauge. At most 100 measurements
(thickness values) can be stored to each file. By simply pressing
the key after a new measurement reading appears, the
measured thickness value will be saved to the current file. It is
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added as the last record of the file. To change the destination file
to store the measured values, follow these steps:
1) Press the key to activate the data logging functions. The
instrument will display the current file name and the total
record count of the file.
2) Use the key and the key to select the desired file to
set as the current file.
3) Press the key to exit the data logging functions at any
time.

4.8.2 Clearing selected file

The user may require the contents of an entire file be
completely cleared of all measurements. This would allow the
user to start a new list of measurements starting at storage location
L00. The procedure is outlined in the following steps:
1. Press the key to activate the data logging functions. The
instrument will display the current file name and the total
record count of the file.
2. Use the key and the key to scroll to the file that will
be cleared of all measurements.

3. Press the key on the desired file. It will automatically

clear the file, and display “-DEL”.
4. Press the key, at any time, to exit the data logging
functions and return to measurement mode.

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4.8.3 Viewing/deleting stored record

This function provides the user with the ability to view/delete
a record in a desired file previously saved in memory. Follow
these steps to perform this action.
1. Press the key to activate the data logging functions. The
instrument will display the current file name and the total
record count of the file.
2. Use the key and the key to select the desired file.
3. Press the key to enter the selected file. It will display the
current record number (for example, L012) and the record
content.
4. Use the key and the key to select the desired record.
5. Press the key on the desired record. It will automatically
delete this record, and display “-DEL”.
6. Press the key to exit the data logging functions and
return to measurement mode.

4.9 Beep Mode

When the beep is set to【On】，the instrument will make a
short hoot each time a key is pressed, on each measurement, or
when the measured value exceeds the tolerance limit.
Press the key to switch the beep mode on and off. The
instrument will display the current beep mode on the main screen.

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4.10 EL Backlight
With the background light, it is convenient to work in dark
conditions. Press the key after the device has been powered
on to switch on or switch off the background light. The EL light
will consume more power so turn it on only when necessary.

4.11 Battery Information

Two AA size alkaline batteries are needed as the power
source for the instrument. After several hours of use with one set
of batteries, the battery symbol on the screen will be shown as
. The higher number of dark bars inside the battery
symbol, the more battery life remains in the instrument. The fewer
number of dark bars inside the battery symbol, the less battery life
that remains. When the battery capacity runs out, the battery
symbol will be shown as and will begin to flash. When
this occurs, the batteries will need to be replaced.
Remove the batteries when not working for long periods of
time.

4.12 Auto Power Off

The instrument features an auto power off function designed
to conserve battery life. If the tool is idle for 5 minutes, it will turn
itself off. While the voltage of the battery is too low this function
will also work.

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4.13 System Reset

Pressing down the key while powering on the instrument
will restore factory default settings. All the memory data will be
cleared during system reset. The only time this would be helpful is
if the parameters in the gauge were corrupted.

5 Servicing
If the instrument is damaged or appears to be functioning
incorrectly, please do not return it to the factory without
requesting a Return Material Authorization (RMA) number first.
To obtain an RMA number and the correct shipping address,
submit a request through VorTek Instruments, LLC website,
vortekinst.com, or contact Customer Service at:

888-386-7835 or 303-682-9999 in the USA,

When contacting Customer Service, be sure to have the meter

serial number and model code. The warranty service will begin
once the product is received.

6 Transport and Storage

1) Keep the instrument away from vibration, strong magnetic
fields, corrosive medium and dust. Store at room temperature.
2) Transportation is allowed in original packaging.

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Appendix A: Sound Velocities

Material Sound Velocity

Longitudinal Wave
in/µs m/s
Aluminum 0.250 6340-6400

Steel, common 0.233 5920

Steel, stainless 0.226 5740
Brass 0.173 4399
Copper 0.186 4720
Iron 0.233 5930
Cast Iron 0.173-0.229 4400－5820
Lead 0.094 2400
Nylon 0.105 2680
Silver 0.142 3607
Gold 0.128 3251
Zinc 0.164 4170
Titanium 0.236 5990
Tin 0.117 2960
Epoxy resin 0.100 2540
Ice 0.157 3988
Nickel 0.222 5639
Plexiglass 0.106 2692

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Polystyrene 0.092 2337

Porcelain 0.230 5842
PVC 0.094 2388
Quartz glass 0.222 5639
Rubber, vulcanized 0.091 2311
Teflon 0.056 1422
Water 0.058 1473

Appendix B: Applications Notes

Measuring pipe and tubing
When measuring a piece of pipe to determine the thickness of
the pipe wall, orientation of the transducers is important. If the
diameter of the pipe is larger than approximately 4 inches,
measurements should be made with the transducer oriented so that
the gap in the wear face is perpendicular (at a right angle) to the
long axis of the pipe. For smaller pipe diameters, two
measurements should be performed, one with the wear face gap
perpendicular, and another with the gap parallel to the long axis of
the pipe. The smaller of the two displayed values should then be
taken as the thickness at that point. See Figure 6 for a visual
representation of the perpendicular versus parallel orientation.

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Figure 10: Transducer Orientation

Measuring hot surfaces

The velocity of sound through a substance is dependant upon its
temperature. As materials heat up, the velocity of sound through
them decreases. In most applications with surface temperatures
less than 100℃, no special procedures need to be observed. At
temperatures above this point, the change in sound velocity of the
material being measured starts to have a noticeable effect upon the
ultrasonic measurement. At such elevated temperatures, it is
recommended that the user perform a calibration procedure on a
sample piece of known thickness, which is at or near the
temperature of the material to be measured. This will allow the
gauge to correctly calculate the velocity of sound through the hot
material.
When performing measurements on hot surfaces, it may also
be necessary to use a specially constructed high-temperature
transducer. These transducers are built using materials which can
withstand high temperatures. Even so, it is recommended that the

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probe be left in contact with the surface for as short a time as

needed to acquire a stable measurement. While the transducer is in
contact with a hot surface, it will begin to heat up, and through
thermal expansion and other effects, may begin to adversely affect
the accuracy of measurements.

Measuring laminated materials.

Laminated materials are unique in that their density (and
therefore sound-velocity) may vary considerably from one piece
to another. Some laminated materials may even exhibit noticeable
changes in sound-velocity across a single surface. The only way to
reliably measure such materials is by performing a calibration
procedure on a sample piece of known thickness. Ideally, this
sample material should be a part of the same piece being
measured, or at least from the same lamination batch. By
calibrating to each test piece individually, the effects of variation
of sound-velocity will be minimized.
An additional important consideration when measuring
laminates, is that any included air gaps or pockets will cause an
early reflection of the ultrasound beam. This effect will be noticed
as a sudden decrease in thickness in an otherwise regular surface.
While this may impede accurate measurement of total material
thickness, it does provide the user with positive indication of air
gaps in the laminate.

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Suitability of materials
Ultrasonic thickness measurements rely on passing a sound wave
through the material being measured. Not all materials are good at
transmitting sound. Ultrasonic thickness measurement is practical
in a wide variety of materials including metals, plastics, and glass.
Materials that are difficult include some cast materials, concrete,
wood, fiberglass, and some rubber.

Couplants
All ultrasonic applications require some medium to couple
the sound from the transducer to the test piece. Typically, a high
viscosity liquid is used as the medium as the sound wave used for
measurement does not travel through the air efficiently.
A wide variety of couplant materials may be used in
ultrasonic gauging. Propylene glycol is suitable for most
applications. In difficult applications where maximum transfer of
sound energy is required, glycerin is recommended. However, on
some metals glycerin can promote corrosion by means of water
absorption and thus may be undesirable. Other suitable couplants
for measurements at normal temperatures may include water,
various oils and greases, gels, and silicone fluids. Measurements
at elevated temperatures will require specially formulated high
temperature couplants. If the couplant that came with your MT160
runs out, contact VorTek Instruments to order a replacement
container.
Inherent in ultrasonic thickness measurement is the
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possibility that the instrument will use the second rather than the
first echo from the back surface of the material being measured
while in standard pulse-echo mode. This may result in a thickness
reading that is twice what it should be. The responsibility for
proper use of the instrument and recognition of these types of
phenomenon rests solely with the user of the instrument.

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