Non Destructive Evaluation of Mild Steel Material

S V Ranganayakulu, R.Gowtham
Centre for Non Destructive Evaluation, Guru Nanak Institutions Technical Campus Hyderabad 501516, R.R.Dt, Andhra Pradesh, India

Abstract
This paper gives about orientation of defect present in mild steel material (welds).The defect is analyzed by non destructive methods namely ultrasonic method, magnetic particle and liquid penetrant method. First method trace out internal defect. Last two methods implies surface and subsurface defect in the mild steel material. Dimensional measurement of welds is 30*30*10(L*B*H) .Mild steel material consist of coarse grain structure and submerged arc welding. The pulse echo of ultrasonic method has been implemented in weld to trace out of defect along with DAC(Distance Amplitude Correction) .Dry penetrant method is give out surface defect and electromagnetic yoke is used along with Ferromagnetic particle give accurate surface and sub-surface defect in welds . results has been achieved that show an no defect are detected by ultrasonic methods within limits of DAC curve .similarly liquid penetrant and magnetic particle gives no defect such that mild steel material is accepted according to acceptance standards.

Keywords: Defect, Welds, Penetrant, DAC, pulse echo.

Introduction
Todays mild steel is heavily dependent on the means of fast non destructive quality inspection of the welds joints parts together. This paper will present you three non-destructive methods suitable for welds. The aim is to raise discussion on the applicability of NDT methods namely.

Ultrasonic method
Ultrasonic method is used as an NDT-Method to evaluate the integrity of welds. The principle is to employ high frequency acoustic wave to probe the inspected sample. As acoustic wave penetrates sample, the wave is attenuated or reflected by any change in the density of the material. By observing the returned signal many characteristics can be determined. Setup takes place less than an hour and scanning time varies from a few minutes to hours depending on the size of sample and desirable resolution. Advantage are that there are no health risks for environment and it is possible to define accurately where the defect is located and how big it is. On the other hand the suitability for thick object like pipes restricted. Ultrasonic testing must requires that the inspecting technicians must be very experienced in order to get reliable result.

Dye penetrant
This is suitable for detection of cracking and porosity in welded joints and surface of the welds. The principle is that the surface of the sample is coated with penetrant in which a fluorescent dye is dissolved. The penetrant is pulled into surface defects by capillary action. After a waiting period to insure that the dye has penetrated into the cracks, the excess penetrant is cleaned from the surface of the inspected part. A developed, a white powder, is sprayed over the part. This lifts the penetrant out of the defect and the dye indication can be identified the defect. Less than one hour is usually required

2|Page

as an inspection time. The method is a lot cheaper compared to radiography or ultrasonic, but can only defect external defects.

Magnetic particle
Magnetic particle method can be used for identification of surface or subsurface. The principle is that the sample is magnetized by dusting magnetic particle over it. A surface defect will form a magnetic anomaly, attracting and holding magnetic particle and thus giving a visual indication of the defect. The evaluation time is typically few minutes. The sample must be ferromagnetic and therefore this technique cannot be used on most stainless steels. This method also is a lot cheaper compared to radiography or ultrasonic, but like dye penetrant, it only can defect external defects.

Sample preparation
Surface preparation: base metal shall be from weld spatter, foreign matter, surface irregularities that might interface with the weld examination. Mild steel material (Welds) is a submerged arc welding type which consists of coarse grain structure due to annealing heat treatment is implemented. Reflector of 2 dia hole is made to the adjacent to the welds. The tolerance for hole diameter drilled is 4mm in deep.
Table 1. Material Mild -Steel Density 7850 C Trans(m/s) 3250 C long (m) 5920 Z kg/sec-mm 46.4772

Table 2. Chemical composition of the studied steel (weight %) Chemical composition (%) P S Si Cu 0.017 0.0241 0.20 0.002

C 0.04

Mn 0.193

Al 0.02

N Ti 0.0044 0.002

Sn 0.008

Table 3. Mechanical properties of the studied steel

3|Page

Hardness 43 HRB

Cupping 11.3

Yield strength 218MPA

Tensile strength 325 mpa

Ys/Ts 0.67

Elongation 45%

Experiment task:
Task-1 (Ultrasonic Method)

Basic calibration done on V1 and V2 block for normal and angle probe respectively. The material of the basic calibration block shall be of the same material as the product and same heat treatment. Ultrasonic weld inspections are typically performed using a straight beam transducer in conjunction with an angle beam transducer. A straight beam transducer, producing a longitudinal wave at normal incidence into test piece, is first used to locate any defects at HAZ area. Scanning with straight probe no defect is located. The second step in the inspection involves using an angle beam transducer to inspect the actual weld. Angle beam transducer to inspect the actual weld. Angle beam transducer uses the principle of refraction and mode conversion to produce refracted shear or longitudinal waves in the test material. During the process of scanning the surface of the material around weldment with transducer. Refracted sound wave will bounce off a reflector in the path of the sound beam. With proper angle beam techniques, echoes returned from the weld zone and weld surface may allow determining the location and type of discontinuity. With 45 degree probe of frequency 2 MHz defect are detected at 1/2V, 1V and 1V sound path according to machined displayed values. Similarly DAC curve is constructed from peak amplitude responses from reflectors of equal area at different distance in the same material. A-scan echoes are displayed at peak amplitude of each signal is marked on the flaw detector screen. Therefore, three defect are located are as follows

4|Page

DEFECT-1

There is a defect which is getting detected at 1 V sound path there defect size is less than reference reflector. SD=25.34 BP=32.38 D=1.62

SD-surface distance, BP-beam path & D-depth

5|Page

DEFECT-2

There is a defect which is getting detected at 1 V sound path there defect size is less than reference reflector. SD=34.05 BP=43.40 D=8.94

DEFECT-3

There is a defect which is getting detected at 1 V sound path there defect size is less than reference reflector.
6|Page

SD=19.86

BP=24.86

D=3.61

Task -2 (Liquid Penetrant method)

In order to perform liquid penetrant method on weld plate. The weld plate is cleaned with PMC cleaner sprayed to remove the dust and dirt. Wiped with a lint free cloth and PMC dye penetrant is sprayed near the weld area and 20 minutes dwell time is given. It is wiped off and then PMC developer is sprayed near weld area and 10 minutes dwell time is given. Finally no defect was observed on the weld plate.
Pre-cleaning is done to remove dirt, lint, scale and oil.

Inspection on HAZ area: before starting the experiment pre-cleaning is preformed on the HAZ area then pentrant is applied. Dwell time is maintained for 10 minutes. Excess penetrant is removing by lint cloth. Sequence developer is applied.

Interpretation on HAZ:
No defect is traced out on weld surface by liquid penetrant test.
Post cleaning:

After the completion and evaluation is completed as residual penetrant if any and the developer shall be removed from the surface, so that it will not interfere with the subsequent processing or service requirement.
Inspection on the whole surface area welds: No defect is observed.

Task -3(Magnetic particle method)

With this method the ferromagnetic powder is usually applied from shaker, bulb or blower and follows these steps. 1. Apply magnetized current yoke placed on the weld plate. 2. Blow powder particle over magnetized area.
7|Page

3. Blow excess powder off part. 4. Shut off magnetizing current. The powder should float to the magnetized area so that particle will be attracted to any flux leakage.

Inspection on HAZ area

No defect has been detected.

Inspection on whole surface weld surface area

No defect is detected.

Result and discussion:

According to ultrasonic testing method mild steel material consists of 3 defects were detected. These defects are crossed 50% DAC. So, the weld piece is rejected. No significant cracks, wormhole or other surface deformities were observed in the mild steel material produced by magnetic particle and liquid penetrant method.

CONCLUSION
Non-Destructive testing techniques via: ultrasonic testing, magnetic particle testing and liquid penetrant method were successfully conducted on welds produced at various parameter combinations. It can be concluded that the magnetic particle testing of the welds is not the best technique as it was found that although all the welds passed this test and appeared as defect-free welds, the ultrasonic testing technique successfully detected the defects present in the welds and can be said to be appropriate in this regard.

ACKNOWLEDGMENT
Authors are grateful to AICTE for carryout research under Research Promotion Scheme (Project no: 8023/RID/RPS-58/ (POLICY-III) (pvt)/2011-2012).
8|Page

Gratefully acknowledgements due to Dr H S Saini, Managing Director and Sardar G S Kohli, Vice Chairman, Guru Nanak Institutions, Ibrahimpatnam for cooperation and encouragement.

Reference:
1. Atlas of Some Steel Casting Flaws as shown by Non Destructive Testing, Steel Castings Research and Trade Association, Sheffield, England, 1968. 2. Recommended Procedure for the Ultrasonic Examination of Steel Castings, Steel Castings Research and Trade Association, Sheffield, England, 1971.

3. ASTM A609, Standard Specification for Longitudinal Beam Ultrasonic Inspection of Carbon & Low Alloy Steel Castings. 4. ASME Boiler & Pressure Vessel Code, Section V, T524.2, Angle Beam Examination of Steel Castings

9|Page