New techniques developed using the array transducer, to image and size the bottom-surface and near-through-wall crack-like defects in thick carbon steel components are discussed. Three studies are reported here including (a) Optimal beam steering angle for focused and unfocused inspection using phased array method for bottom-surface crack sizing. (b) A front wall correction algorithm for sizing of near-through-wall crack-like defects. (c) A small aperture technique for sizing of near-through-wall crack-like defects. A Finite Difference Time Domain (FDTD) based simulation was used to study and verify the experimental observations. The application of time domain scheme relative arrival time technique (RATT), to measure the size of the near-through wall crack-like defects for the leak before break (LBB) criterion, was also investigated and found to be insufficient. A conventional SAFT algorithm was used for improving the sizing using the small aperture technique. © 2009 Springer Science+Business Media, LLC.