Академический Документы
Профессиональный Документы
Культура Документы
4 Modes of Propagation P. 18
5 Ultrasound Generation P. 22
8 Snells Law P. 29
9 Equipment P. 32
10 Calibration Blocks P. 44
11 0 Probe Scanning P. 50
13 Sensitivity Setting P. 70
14 Flaw Location P. 78
15 Presentation P. 91
Advantages:
Applicable to non-ferromagnetics
Able to test large parts with a
portable kit
Batch testing Applicable to small parts with
complex geometry
Simple, cheap easy to interpret
Sensitivity
Disadvantages:
Will only detect defects open to the Surface
Careful surface preparation required
Not applicable to porous materials
Temperature dependant
Cannot retest indefinitely
Compatibility of chemicals
Disadvantages:
Ferromagnetic materials only
Requirement to test in 2 directions
Demagnetisation may be required
Odd shaped parts difficult to test
Not suited to batch testing
Can damage the component under test
Advantages:
Sensitive to surface defects
Can detect through several layers
Can detect through surface coatings
Accurate conductivity measurements
Can be automated
Little pre-cleaning required and Portable
Disadvantages:
Very susceptible to permeability changes
Only on conductive materials
Rev 0 December 2010 Page 4
Will not detect defects parallel to surface
Not suitable for large areas and/or complex geometries
Signal interpretation required
No permanent record (unless automated)
1.4 Radiography
Radiography monitors the varying transmission of ionising radiation through a material
with the aid of photographic film or fluorescent screens to detect changes in density and
thickness. It will locate internal and surface-breaking defects.
Advantages:
Gives a permanent record, the radiograph
Detects internal flaws
Detects volumetric flaws readily
Can be used on most materials
Can check for correct assembly
Gives a direct image of flaws
Fluoroscopy can give real time imaging
Disadvantages:
There is a radiation health hazard
Can be sensitive to defect orientation and so can miss planar flaws
Has limited ability to detect fine cracks
Access is required to both sides of the object
Skilled radiographic interpretation is required
Is a relatively slow method of inspection
Has a high capital cost and running cost
Radiography
The length and plan view position can be determined. Through-thickness positioning
requires additional angulated exposures to be taken. The through-thickness dimension of
discontinuities cannot readily be determined.
With the construction of nuclear power stations, UT was developed further and was
applied to construction and maintenance work in the oil industry as well as the inspection
of the huge commercial air fleets built up since the end of the Second World War. Over
the years, UT sets have been miniaturised with the availability of transistors and display
features improved and the process has automated and computerised.
Anything that sends back sound energy to probe to cause a signal on the screen is called a
reflector. By measuring the distance from the edge of the CRT screen to the signal, we can
calculate how far down in the material the reflector lies.
Sound is made when something vibrates. You can twang a ruler on a table or flick a
stretched elastic band to verify this. The stretched surface of the rubber band or the ruler
vibrates and sets up a series of vibrations, sound waves, in the air. As the surface of the
band or ruler pushes into the air, the air molecules are forced together and a region of high
pressure forms: compression. As the surface moves back, the air molecules move apart,
forming a low pressure area, or rarefaction. As the surface vibrates, alternate
compressions are rarefactions set up in the air and travel out from the surface to form a
sound wave. The air molecules dont move with the wave - they vibrate to and fro in time
with the vibrating surface. If we plot the displacement of the particle against time it will
produce a sine wave as shown below.
The sound wave so produced travels through the air at a speed of 332m/sec, at
0C. We hear the sound when it hits a membrane in our ear and cause it to vibrate. Sound
will travel through any medium that has molecules to move, but it travels faster in more
elastic materials because the vibrations are passed on more quickly. Sound travels faster in
water or metal than it does in air as liquids and solids are more elastic than air.
2.1 Frequency
As sound is a series of vibrations, one way of measuring it is to count the number of
vibrations per second - the frequency. Frequency is measured in Hertz. One vibration in
one second is one Hertz. Two vibrations in one second is two Hertz. Ten vibrations in one
second is 10 Hertz and 1000 vibrations in one second is 1000 Hertz or one kilohertz
(kHz). One million vibrations in a second is one Megahertz (MHz).
The higher the frequency the higher the note sounds - the higher the pitch. If you twang
the ruler or the rubber band hard, the noise is louder, it has greater amplitude, but the note
remains the same. If, however, you shorten the ruler or tighten the rubber band, they
2.2 Wavelength
A wave in the sea is a vibration of energy. As the wave passes a fixed point it produces a
constant rise and fall of energy. A complete vibration is a change in energy from
maximum to minimum and back to maximum. The distance over which one complete
vibration of energy occurs is called a wavelength.
A wavelength is the distance between the highest points of energy. It varies with the speed
of sound and with the frequency. Wavelength is represented by the Greek letter lambda
(). We can work out wavelength if we know the speed and frequency of a sound wave.
Wavelength is the velocity in meters per second divided by the frequency.
Difference in db =
=
20 x 0.301 = 6.02dB
So the answer is 6 decibels and this can be tested on a CRT screen. Obtain a signal from a
backwall echo on a test block and increase or decrease the gain until the signal touches the
top of the screen. Take out 6dBs with the gain control and the signal should drop to 50%
full screen height (FSH). If it does not, the vertical linearity of the UT set is out, the signal
height is not changing in accordance with energy from the probe.
Remember that dBs are only a means of comparing signals. All UT sets are different, so a
defect may be at FSH with a gain control reading of, say 36dB on one set and be at FSH
on another set with a gain control reading of only 28dB on another set. The Gain control
allows us to set sensitivities and forms the basis of ultrasonic sizing techniques.
beam edge
dead zone
(0% Intensity)
half angle of divergence
beam centre
(((100% Intensity)
crystal
near zone
beam edge
far zone
(0% Intensity)
Seen on the CRT as an extension of the initial pulse, the dead zone is the ringing time of
the crystal and it is minimized by the damping medium behind the crystal. Flaws or other
reflectors, lying in this dead zone region of the beam will not be detected. The dead zone
can be seen at the start of the trace on the CRT displaying A scan, but only with single
crystal probes.
In this region of the beam, the sound intensity is variable owing to wave interference,
therefore, reflectors or flaws lying in this zone may appear smaller or larger than their
actual size. The signal heights displayed on the CRT are unpredictable so it is desirable to
keep the near zone length to a minimum.
Beyond the near zone the far zone exists, in this region the beam divergence occurs,
resulting in decay in sound intensity as the distance from the crystal increased. For
example just a beam of light from torch gets weaker the further it travels. The amount of
beam divergence depends upon the crystal diameter and probe frequency.
Beam divergence
Sin /2 = or
It can be seen from the above beam spread formula, that the beam divergence can be
decreased by increasing the crystal diameter or increasing the probe frequency.
Unfortunately this will extend the length of the near zone. So in probe design there is a
compromise to obtain a minimal beam spread and shorter near zone.
In the far zone of the ultrasonic beam there is no wave interference therefore the sound
intensity is predictable. The sound intensity reduces 100% in the centre to 0% at the edge
of the beam, therefore when the centre of the beam hits the reflector/flaw the amplitude of
the signal on the CRT will be at maximum. The sound intensity also decreases with
greater distance it travels.
D1 D1
D2 D2
In the far zone the amplitude of reflected sound from large and small reflectors follow
different laws.
Large Reflectors (larger than the width of the ultrasonic beam) follow the INVERSE
LAW The amplitude is inversely proportional to the distance, i.e. if the distance is
doubled then the signal amplitude is halved (i.e. reduced 6dB).
Small Reflectors Smaller than the width of the ultrasonic beam) follow the INVERSE
SQUARE LAW The amplitude is inversely proportional to the square of the distance. i.e.
if the distance is doubled then the amplitude from the second reflector is one quarter of
the amplitude of the nearer (i.e. reduced 12dB). It is shown in the above figure.
The narrower the main lobe, i.e. the smaller the half angle of the beam, the weaker and
more numerous the side lobes.
In a modern ultrasonic pulse echo flaw detector the pulse of ultrasound is created by
charging a capacitor in the circuitry then suddenly releasing this charge of electrical
energy, about 1Kv to 2Kv, in to the probe. This electrical energy is converted in to a
mechanical vibration by the piezo electric probe. The ultrasonic vibrations are formed by
the collapse of the crystal after the electrical energy removed. The behavior of the crystal,
on collapse can be linked to the behavior of a spring when it is stretched then released.
The spring will return to its former shape. This cycle of expansion and contraction is what
form ultrasonic pulse.
Maximum expansion
crystal
Original size
time
Maximum contraction
Crystal
The length of pulse is unacceptable since in order to show separate, clear reflected signals
on the CRT then the pulses must be short and sharp. To shorten the pulses the ultrasonic
crystal must be damped with backing medium which absorbs the sound energy, for
example in much same way as a shock absorber fitted to a spring on a motor vehicle
Clock Interval;
Minimum = Transit time; Practical = 5 X Transit time
4 Modes of Propagation:
Sound waves propagate due to the vibrations or oscillatory motions of particles within a
material. Within a freely vibrating medium each particle is subject to both inertial and
elastic forces. These forces cause particles to exhibit oscillatory motions.
4.1 Compression or longitudinal waves:
Probes that produce compression waves will normally have an incident and
refracted angle of, or close to, 0. These waves travel through a medium causing the
particles of the material to oscillate parallel to the direction of wave propagation and
consist of alternate compression and dilation pressure waves.
It was later discovered that by varying the thickness of crystals and subjecting them to a voltage they
could be made to vibrate at different frequencies. Frequency depends on the thickness of the piezo-
electric crystal, according to a formula:
Where;
t = Crystal thickness; V = Velocity of sound in crystal; f = Frequency
These crystals may be X-cut or Y-cut depending on which orientation they are
sliced, from the crystal material. The crystals used in ultrasonic testing are X-cut
due to the mode of vibration they produce (compressional). This means that the
crystal is sliced with its major plane (the crystal face) perpendicular to the X
axis of the crystal material.
Common couplants are: water, oil, grease, polycell, swarfega and glycerin The
selection of couplant is sometimes based on the post-test use of the material
being tested, e.g. water based couplants may cause rusting or corrosion but are
easier to clean off in preparation for painting or coating when compared to oil or
grease, which may actually protect the material from corrosion.
Viscosity of the couplant may also be a consideration, ideally rough surfaces
require a more viscous couplant to effectively fill the air gaps more
uniformly. Whatever couplant is used for calibration/setting the search
sensitivity, this must be used throughout the subsequent inspection.
The ideal acoustic impedance of Couplant should be in between the acoustic
impedance of the probe and the acoustic impedance of the test material. The ideal
thickness of the layer of couplant should be one quarter of the wavelength of
sound through it.
Ultrasonic waves are reflected by objects or interfaces placed in their path. When striking
a spectacular (mirror like) reflector the angle at which this reflection takes place is
governed by the law of reflection, which states:
8.1 Refraction:
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Snells law states that the ratio between sound speed in two materials is the same as the
ratio between the sin of the incident and refracted angles (measured for the vertical angle).
It equates the ratio of material velocities v1 and v2 to the ratio of the sines of incident and
refracted angles.
Sin I =
However, with incident angles less than 27, both compression and shear waves are
generated in the steel. This makes interpretation very confusing. To get a shear wave on its
own, the angle of incidence must be more than 27.4, called the first critical angle. This
gives a shear wave of 33 (the lowest standard angle probe manufactured is 35).
If the incident angle is above 57.14. The shear wave is replaced by a surface wave. This
angle is called the second critical angle.
Critical angles
The largest probe angle you can get from manufacturers without a special order is 80. So
shear waves on their own in steel are only possible with incident angles between 27.4 and
57.14, using a perspex wedge. This is of course worked out by the probe manufacturers
and it must be borne in mind that a probe which gives a refracted angle of 45 in steel will
give a different refracted angle in other materials.
= ; Sin 90 = 1
Sin I =
The second critical angle is the incident angle at which a shear wave is generated in the
material at 90. Use Snells law again:
= ; Sin 90 = 1
Sin I =
When sound travels in a solid material, one form of wave energy can be transformed into
another. When a longitudinal wave strikes an interface at
an angle, some of the energy can cause particle movement in the transverse direction to
start a shear (transverse) wave. This phenomenon is referred to as mode conversion and
will occur every time a wave encounters an interface between materials of different
acoustic impedance and the incident angle is not at 90o to the interface. Mode conversion
can, therefore, cause numerous spurious indications to arise during an inspection which
the inspector must eliminate.
8.4 Diffraction:
This occurs when sound waves pass the tip of a narrow reflector. Some of the
sound scatters off the tip causing waves in different directions that reinforce or
cancel out the original waves. This results in a series of high and low intensity
waves radiating out from the tips, giving the impression of sound bending around
the edges of the defect.
9.1 Probes:
The angle of a probe used in ultrasonic testing is measured from a line
drawn perpendicular to the test surface. This line is known as the normal. A 0
probe then is one which transmits sound at 90 to the test surface. Also known as
a normal probe, this probe usually transmits compressional or longitudinal
waves. A 60 angle probe would transmit sound at 60 to the normal, i.e. 30
from the surface. The most common angle probes transmit shear waves
(although angled compression probes do exist for special applications) and the
manufacturers quote the angle of the probe for use on mild steel.
Electrical Connectors
Cork Separator
Backing Medium
Crystals
Casing
Perspex Shoes
Effects of Diameter
The ultrasonic flaw detector, the UT set, sends a voltage down a coaxial cable, sometimes
called the lead to a probe. The piezo-electric crystal in the probe is hit by the voltage and
vibrates. The vibration creates an ultrasonic pulse which enters the test material. The pulse
travels through the material until it strikes a reflector and is reflected back to the probe. It
re-enters the probe, hits the crystal and vibrates it, causing it to generate a voltage. The
voltage causes a current which travels back to the flaw detector along the cable. The set
displays the time the pulse has taken through the test material and back and the strength of
the pulse as a signal on the CRT screen.
This is basically how a UT set works. It transmits energy into material via a probe and
measures the time in microseconds that the sound pulse takes to return to the probe. The
controls on the UT set are almost entirely concerned with presenting a display on the CRT
screen for the operator to interpret.
The cathode ray tube is a device for measuring very small periods of time. The CRT
displays electrical pulses on a screen in a linear time/distance relationship. That is, the
longer the distance on the screen time base, the longer the time that has been measured.
How the CRT works
A filament is heated in a vacuum tube. The heat causes the particles of the filament to
vibrate and electrons start boiling out of the surface, a process known as thermionic
emission.
A positive potential electric charge in position further down the vacuum tube and the
negatively charged electrons from the filament are attracted towards it. The electrons pass
through a negatively charged focusing ring which pushes them towards the centre of the
tube, forcing them into a fine stream. This stream of electrons hits a phosphor covered
screen at the end of the tube. The electron bombardment forces the phosphor to give out
light and a green dot appears on the screen.
The X and Y plates above, below and beside the electron stream carry potentials that
move the electron stream from side to side and up and down, moving the green dot on the
screen.
The X plates control horizontal movement and the Y plates control vertical movement.
By altering the potential of the X and Y plates, the dot can be moved on the screen.
9.3.3 The Pulse Generator:
10 Calibration Blocks:
Tolerances: Wherever practical the limits on dimensions should be 0.1
mm.
Materials: Steel blocks are made from low or medium carbon ferritic steel
killed), normalized to produce a fine grained homogenous structure throughout.
10.1.3 Resolution:
The resolution of a 0 probe can be checked by using the three different
thickness sections around the slot below the centre of the 100mm radius. Place
the probe above the slot and with a calibrated screen note the separation between
the 85, 91 and 100mm signals.
10.2.1 Calibration:
This block can be obtained in various thicknesses, although the current standards in
use for ultrasonic calibration blocks may only mention 12.5, 20 or 25 mm.
The repeat signals secured from this through thickness can be used to calibrate the
0 probe.
10.2.2 SHEAR PROBE USES:
Probe calibration: With the probe aiming towards the 25mm radius,
signals occur at; 25mm, 100mm, 175mm, 250mm, 325mm, 400mm, etc.
With the probe facing the other way, toward the 50mm radius, the signals
occur at; 50mm, 125mm, 200mm, 275mm, 350mm, 425mm, etc.
To calibrate; the radius which gives the easiest signals, within the range
selected, to align on the graticule should be selected.
Dead zone measurements, resolution and shear probe angle checks can only be
approximated on the A2/A4 blocks, Specific blocks such as the A5, A6 and
A7 should be used for more accurate reproducible results as quoted in associated
standards, i. e. BS EN 12668: Part 3.
11.1 CALIBRATION
The initial pulse or main bang is a test signal that the flaw detector creates
and has no significance for calibration. It usually lies just off to the left of a
calibrated screen.
F 1 2
F 1
CALIBRATION EXERCISES
Using the VI block:
Calibrate the timebase for:
100 mm range using the 25 mm thickness Method: Multiple BWE
200 mm range using the 25 mm thickness Method: Multiple BWE
400 mm range using the 25 mm thickness Method: Multiple BW
100 mm range using the 100 mm thickness Method: Delay technique
200 mm range using the 100 mm thickness Method: Multiple BWE
400 mm range using the 100 mm thickness Method: Multiple BWE
20 mm range using the 10 mm thickness Method: Multiple BWE
10 mm range using the 5 mm thickness Method: Multiple BWE
10 mm range using the 10 mm thickness Method: Delay technique
1000 mm range using the 200 mm thickness Method: Multiple BWE
45/3 = 15mm
11.3 SENSITIVITY
There are various methods of setting the test sensitivity these
include:
Back wall echo level method (0 probes only)
Grass level
Using a reference reflector
Using a graph or curve plotted from reference reflectors
11.3.2 Grass
The grass or grain interference method involves coupling the probe to the test
surface and increasing the gain until the reflections from the grain structure of
the material reach a pre-determined level. This is often quoted as 2 mm 3
mm in height at the maximum test depth but ideally should be referenced as a
percentage of full screen height as not all flaw detectors use the same
dimension screen The sensitivity can be adjusted by increasing or decreasing
the level or by adding or subtracting dBs to or from the gain.
11.3.3 Reference reflectors
A common method of setting sensitivity is to set a maximised signal from a
reference reflector, at target depth, to a predetermined level, for example full
screen height. The reference reflector could take the form of a known reflector,
e.g. A transverse side drilled hole, a flat bottom hole, a slot or a vee notch, or it
could be a real, or simulated, defect of known size and type.
Rev 0 December 2010 Page 57
11.3.4 Distance amplitude curve
All reflectors in the reference block are scanned before the test, their maximum echo
heights marked on the attachment scale of the display and joined by a curve, The curve
produced is called the Distance Amplitude Curve, or DAC for short. When a
discontinuity echo appears, an immediate assessment can be made whether or not the
discontinuity echo exceeds the DAC. In addition to this a determination is made, by a
corresponding gain change, to see by how many dBs an echo exceeds the curve. This
excess recording echo height (EREH) is our reproducible measure for the evaluation and
reporting of the discontinuity.
By recording the curve using reflectors in a test object comparable to the work piece, this
curve contains all the influences in the test object (distance law, sound attenuation, and
surface losses). Corresponding corrections are therefore not necessary. Regarding the
evaluation results, we must understand here that the effect of the discontinuity (geometry,
orientation and surface quality) is not taken a great deal into account the same as the DGS
method. Therefore, the result of a discontinuity evaluation with the reference block
method has the same uncertainty as the DGS method.
The preference regarding which method to use is subjective. The corresponding national
test specifications normally state the test method to be used so that the operator is not able
to make his own decision. If no data is available, the test situation should be analyzed in
order to decide which method be best used:
Firstly, it must be established whether a reference block exists which corresponds to the
test object. If yes, then the test can be carried out simply and reproducibly with the
reference block method. If no reference block is available then the DGS method can be
used, or a reference block must be subsequently produced comparable to the test object.
However, in many cases the DGS method can be used without difficulty, namely when the
test object is made of low alloy steel, has a simple geometry, a low sound attenuation and
an even surface quality. The test should be carried out with a narrow band standard probe
with a frequency between 1 MHz and 6 MHz for which there is a DGS diagram or a DGS
scale.
The new computer controlled instruments normally support the program controlled
recording of DACs. With the USD 10 the recorded DAC is automatically converted to a
horizontal line. This is known as time corrected gain (TCG).
The recording curve is therefore an horizontal line so that the evaluation can be visually
and acoustically supported using a monitor gate (flaw alarm), Fig. 70a-c. At the same
time for each echo, the excess recording echo height is displayed in dB (DBR value in the
measurement line of the USD 10) in addition to the data for discontinuity location.
Both the 6dB drop and the equalisation methods only work accurately on
large reflectors and will grossly oversize small ones. The flaw must also be
along the centre line of the plate or again sizing accuracy will be adversely
affected.
11.5.3 Maximum amplitude (max. amp) technique:
This is used to size areas of small defects, such as inclusions, or to size multi -
faceted defects, such as cracks. The technique involves moving the probe off
the defect area until the signals disappear, then slowly bringing the probe back,
watching the whole signal group, to the first position where one of the signals
maximises. The probe position is then marked as in the other methods to mark
out the edge of the defect area. This technique will pick out the last individual
inclusion of a group or the last facet of a crack giving the overall size of the defect
or area.
Frequency of checking
This check shall be carried out at least once per week.
Method
Position the probe on a calibration block to obtain a reflected signal from a small
reflector eg 1.5mm hole in the A2 block.
Adjust the gain to set this signal to 80% FSH and note the gain setting (dB).
- Increase the gain by 2dB and record the amplitude of the signal.
Tolerance
Frequency of checking
The check shall be carried out at least once per week.
Tolerance
Tolerance will depend on application but for plotting of defects it is recommended that
probe index is accurate to within 1mm.
Frequency of checking
When a probe is in continuous use, it is recommended that the check be carried out every
few hours; otherwise, a daily check is recommended.
Method
a) Place the probe in such a position as to receive a reflected signal from the selected
transverse hole in the calibration block (eg 19mm deep hole in the A5 block).
b) Maximise the signal from the hole and mark the index point of the probe on the
block.
c) Measure the distance from the marked point on the block to the edge of the block.
Knowing the position of the drilled hole will allow the beam angle to be calculated
(see below).
Note If only a rapid check is required, maximise the signal from the 50mm hole in the A2
block. The angle can then be assessed by visual interpolation between the reference
markings on the block.
Tolerance
The accuracy by the described method is 1.5.
The accuracy in this case can only be assumed to be 3.
Frequency of checking.
When a probe is in continuous use, it is recommended that the check be carried out at least
every few hours; otherwise, a daily check is recommended.
Method
a) Place the probe on the A2 calibration block and adjust its position to maximise the
signal from the 1.5mm diameter hole.
b) Adjust the gain control to set this signal to 20%FSH and note the dB setting.
c) Increase the gain until the overall system noise (electronic noise and grain structure
grass) at the same range as the target hole reached 20%FSH and note the new dB
setting.
Note 2 If it is desired to check the sensitivity as a function of range, the use of the
standard A5 block is recommended for longer ranges.
Tolerance
Tolerance will depend on application. Any deterioration in the sensitivity value will
indicate a problem with the probe or flaw detector. A low S/N ratio would be typical of a
coarse-grained material.
Frequency of checking
Unless otherwise agreed, the check shall be carried out once per probe per day.
Method
a) Calibrate the time base in millimetres to a range that is to be used in subsequent
testing.
b) Maximise the signal from the 1.5mm side-drilled hole for shear wave probes or a
BWE for compression wave probes and set its peak to 100% screen height.
c) Measure the width of the signal in millimetres at the 10% screen height position.
d) If desired, the measurement in millimetres can be converted into microseconds by
dividing it by the relevant sound velocity.
Tolerance
Tolerance will depend upon application. A long pulse duration will limit range resolution
and indicate the need for a resolution check (A resolution check is described in Clause
No.7), and a short pulse duration may indicate the flaw detector has built-in suppression
that could prevent the observation of small signals.
Method
a) Calibrate the time base to a range of 0-100mm for either the compression or the
shear wave probe.
b) Place the probe so that the axis of the beam impinges upon the 2mm step in the A7
calibration block for shear wave probes, or the 3mm step for compression wave
probes.
c) Adjust the position of the probe so that the echoes from the two targets are of the
same height and approximately half full graticule height.
d) The steps are said to be resolved when their echoes are clearly separated at half
maximum echo height or lower.
Note The 3mm step between the 9 and 3mm drilled holes in the A6 calibration block may
also be used when checking compression probes.
Frequency of checking
The check shall be carried out monthly, or when too long a pulse duration is suspected.
The purpose of sensitivity setting is to find a gain level sufficient to find a flaw and
depends on the:
a) Probe used, in particular its frequency
b) Flaw detector
c) Properties of the test material
d) Ratio of noise to BWE or flaw echo
Find a hole on the block that approximately coincides with the thickness of the material
you are testing. Double the thickness if you are examining at full skip, i.e. bouncing your
sound beam off the backwall.
Obtain a signal from the hole and turn the gain control until the signal is at FSH.
Work out transfer correction. You have now set sensitivity and can be assured that flaws
having the equivalent reflectivity of 1.5mm side-drilled holes will appear on the screen.
EN 1714 and all US specifications recommend this method. A special reference block of
the same material as the test object is usually necessary, though the curves can be
constructed from an IOW block.
Note: Should the difference in height between the largest and the smallest echoes exceed
the range of 20 to 80%FSH the line shall be split and separate curves plotted at different
gain settings. The difference in gain between the two curves shall be noted. Examine the
test material as instructed in the specifications, comparing the signals from discontinuities
to the curves on your screen. Any signal above the curve shows a reflector larger than the
reference hole. Accept or reject discontinuities as instructed in the specification you are
working to.
Advantages
A quick way of accepting or rejecting discontinuities without too much time consumed
in sizing reflectors.
Some idea can be gained of the discontinuities size in relation to reference holes.
Uniformity provided by all technicians constructing their curves from the same test
block.
Advantages
Easy to use
Uniformity assured when different technicians use the same blocks
Blocks can be made from different materials
Disadvantages
Fairly rigid system for specific applications
Large number of blocks needed for different settings
Transfer correction usually needed
Blocks for angle probes are rarely cut exactly normal to the beam. You may hear these
blocks called HITT or ALCOA blocks, after the originators.
Using noise
Work out the maximum range at which you will be examining test material. Place the
probe on the material with couplant applied. Turn up the gain until you have 2mm grass
on the screen at the maximum range. You will now have the assurance of knowing that
any discontinuity larger than the grain size will show up on the screen.
Advantages
Quick and easy
No reference block is needed
Any defect larger than the material grains will show up
No transfer correction needed
Disadvantages
No accurate sizing of the defect
Discontinuities near the surface of the test material may be hidden in the grass
Example: You are using a 5MHz 10mm diameter compression probe on 100mm steel
plate and you find a defect at 60mm depth which gives a signal at FSH with a 30dB gain
setting. What is its flat-bottomed hole equivalent? First, work out the probe near zone. It is
21mm, so the defect is at a distance of three near zones. Now get a BWE and find what
the dB reading is. Say it is 20dB when the BWE is at FSH. 100mm is five near zones.
What will it be at 60mm, three near zones? Refer to the DGS curves. If the BWE is FSH
with 20dB at 100mm, by the law of large reflectors and according to the BWE line on the
DGS curves a BWE at 60mm should reach FSH at 16dB, 4dB less than at 100mm. The
signal height from the flaw is 30dB, 14dB more than the BWE. Look down the scale 14dB
at 3 near zones from the BWE and you find that the nearest line is 0.5 of the probe
diameter. The probe diameter is 10mm so the nearest equivalent flat bottomed hole to the
flaw had a diameter of 5mm.
By similar working, a sensitivity setting can be worked out for a flat bottomed hole of a
certain diameter at a given range to a given screen height and the flaw detector gain set
accordingly.
Disadvantages
Operators must keep referring to a chart and making calculations
Attenuation must be taken into account
No account is taken of flaw orientation
Most effective on small defects
An equivalence system not a sizing system
Flaw surfaces and shapes are not ideal reflectors, therefore signal amplitudes are not the
same as a comparative flat-bottomed hole
For angle probes, plastic slides have been manufactured by Krautkramer to fit over the
CRT screen. The set is calibrated and gain setting is made by bringing the BWE or the
echo from the 1.5mm hole on the V2 block up to marks on the slide. Flat bottomed hole
equivalents for flaws can then be read straight off the slide. The DGS system is widely
used in Germany.
The nature of the surrounding material also greatly affects the detection of defects with
coarse-grain structure reducing defect detectability. A measure of detectability of a flaw
and the effect of the many factors involved is its signal-to-noise ratio (S/N). The S/N ratio
is a measure of how the signal from the defect compares to other background reflections
(categorised as noise). A S/N ratio of 3 to 1 is often required as a minimum. The absolute
noise level and the absolute strength of an echo from a small defect depends on a number
of factors:
Probe size and focal properties.
Probe frequency, bandwidth and efficiency.
Inspection path and distance (water and/or solid).
You can calculate the location of a flaw by using trigonometric formulas as shown below.
You need to know the angle of the probe and the stand-off measured from the centre of a
weld.
Depth = Cos x range
Stand-off = Sin x range A general rule of thumb used to calculate the depth of an
indication from the range on the screen is
45 probe - range is approximately 1.5 x depth
60 probe - range is exactly 2 x depth
70 probe - range is approximately 3 x depth
It is quicker and easier, however, to use a flaw location slide and a beam plot or even a
piece of clear plastic film with the probe angle drawn on it. Use the slide as follows:
Draw a cross section of the weld on the transparent outer envelope of the slide. Draw a
mirror image of the weld cross section immediately under it if the sound energy is going
to bounce off the backwall, i.e. using full skip. Use the printed datum line on the plastic
envelope as the centre of the weld and measure all stand-offs from it. Maximise the echo
from a defect and mark where the index point falls on the parent metal. Measure its
distance from the centre of the weld.
Note the defect on a sketch and note the stand-off and range of the centre of the defect.
Move the datum line on the plastic envelope to the stand-off distance. Look along the
centre of the beam plot until you come to the range shown on the screen. Make a mark on
the envelope, this represents the centre of the defect. It shows the defects position in the
weld body.
14.4 Through-transmission
Through-transmission was used in the early days of UT and is still used in plate and bar
production. A probe one side of a component transmits an ultrasonic pulse to a receptor
probe on the other side. The absence of a pulse coming to the receiver indicates a defect.
Defect
An array transducer is simply one that contains a number of separate elements in a single
housing, and phasing refers to how those elements are sequentially pulsed. A phased array
system is normally based around a specialized ultrasonic transducer that contains many
individual elements (typically from 16 to 256) that can be pulsed separately in a
programmed pattern. These transducers may be used with various types of wedges, in a
contact mode, or in immersion testing. Their shape may be square, rectangular, or round,
and test frequencies are most commonly in the range from 1 to 10 MHz.
Phased array systems pulse and receive from multiple elements of an array. These
elements are pulsed in such a way as to cause multiple beam components to combine with
each other and form a single wave front traveling in the desired direction. Similarly, the
receiver function combines the input from multiple elements into a single presentation.
Because phasing technology permits electronic beam shaping and steering, it is possible to
generate a vast number of different ultrasonic beam profiles from a single probe assembly,
and this beam steering can be dynamically programmed to create electronic scans:
1. Software control of beam angle, focal distance, and beam spot size. These
parameters can be dynamically scanned at each inspection point to optimize
incident angle and signal-to-noise for each part geometry.
2. Multiple-angle inspection can be performed with a single, small, multi-element
probe and wedge, offering either single fixed angles or a scan through a range of
angles.
3. These capabilities provide greater flexibility for inspection of complex geometries
and tests in which part geometry limits access.
4. Multiplexing across many elements allows motionless high-speed scans from a
single transducer position. More than one scan may be performed from a single
location with various inspection angles.
Advantages
Ultrasonic phased array systems can potentially be employed in almost any test where
conventional ultrasonic flaw detectors have traditionally been used. Weld inspection and
crack detection are the most important applications, and these tests are done across a wide
range of industries including aerospace, power generation, petrochemical, metal billet and
tubular goods suppliers, pipeline construction and maintenance, structural metals, and
general manufacturing. Phased arrays can also be effectively used to profile remaining
wall thickness in corrosion survey applications.
The benefits of phased array technology over conventional UT come from its ability to use
multiple elements to steer, focus and scan beams with a single transducer assembly. Beam
steering, commonly referred to sectorial scanning, can be used for mapping components at
appropriate angles. This can greatly simplify the inspection of components with complex
geometry. The small footprint of the transducer and the ability to sweep the beam without
moving the probe also aids inspection of such components in situations where there is
limited access for mechanical scanning. Sectorial scanning is also typically used for weld
inspection. The ability to test welds with multiple angles from a single probe greatly
increases the probability of detection of anomalies. Electronic focusing permits optimizing
the beam shape and size at the expected defect location, as well as further optimizing
probability of detection. The ability to focus at multiple depths also improves the ability
for sizing critical defects for volumetric inspections. Focusing can significantly improve
signal-to-noise ratio in challenging applications, and electronic scanning across many
groups of elements allows for C-Scan images to be produced very rapidly.
The potential disadvantages of phased array systems are a somewhat higher cost and a
requirement for operator training, however these costs are frequently offset by their
greater flexibility and a reduction in the time required to perform a given inspection.
Introduction
The Time-of-Flight Diffraction (TOFD) technique is rapidly gaining importance as a
stand-alone inspection technique. The TOFD technique is an advanced ultrasonic
inspection technique that fulfils a need for reliable inspections. It is a powerful technique
because it can simultaneously detect and size defects. TOFD is now routinely used in a
wide range of applications such as inspection of piping and pressure vessels.
What type of information will TOFD generally provide? A routine inspection provides the
operator with the following information:
Information on the type of defect is limited, similar to both manual and mechanised
ultrasonic inspection. This is not necessarily a problem, because from a fracture
mechanics point of view, many defects that are normally regarded as volumetric, such as
slag inclusions, may be sharp enough to be able to act as crack initiators. Also, this aspect
is compensated, to a certain extent, by the ability of TOFD to distinguish between "defects
without measurable height" and "defects with measurable height".
This, in combination with the high probability of detection (POD) and a low false call rate
(FCR), makes TOFD a valuable tool for routine NDT, in the sense of "Good
Workmanship evaluation supported by fracture mechanics considerations".Recent
developments of codes and defect acceptance standards for use with the technique support
this tendency and is resulting in a wider acceptance every year. Apart from the growing
realisation by the market that TOFD offers unique advantages, these developments are
also stimulated by the realisation of the five main topics:
Equipment improvement
Transducer performance improvement
Initiatives to establish the qualification of TOFD operators
Acceptance of TOFD in weld and vessel inspection
Implementation of new codes and standards
Like any other technique, TOFD also has its limitations. In general the technique is less
suitable for coarse grained materials such as many types of austenitic steel. Inspectability
with TOFD is usually assessed on a case-by-case basis. In addition, inspection reliability
close to the scanning surface is hampered by the presence of the lateral wave, which may
obscure defects present in this area. Specialised software algorithms can be used to
minimise this effect. Similarly, small defects located very close to the root of the weld
may sometimes be obscured by irregular-ities in the root such as mismatch.
General acceptance of the TOFD technique will only be possible if it is also properly
embedded in codes and standards. With more and more experienced gathered the potential
Two angle beam probes (usual 45) are placed as a transmitter-receiver arrangement
and are connected together ( fig ). The distance of the probes is calculated according
to the wall thickness.
Longitudinal waves are usually applied. The sound beam spread is large to maximize
the extent of the scan.
The A-scan in the above figure shows the so-called lateral wave, the back wall echoes
and between both signals other signals can possibly appear, which can occur due to
inhomogeneity. The A-Scan is not rectified in the TOFD technique.
TOFD technique is always applied with imaging methods (Figure attached above).
It is not always easy to identify a defect, but by noting its position in the weld and moving
the probe around the defect and watching the changing signal on the screen you can come
to a reasonably accurate conclusion. Knowledge of the welding process is essential, as is
knowledge of the weld preparation, weld dimensions, size of the gap and other factors.
Slag is unlikely in a TIG weld and lack of sidewall fusion is not likely in the middle of the
weld metal. Cracks are more likely in thicker welds than in thinner welds and fusion
defects are more likely in automatic welding processes than in manual. In addition the
shape, amplitude and time-spread of a reflector as represented on the screen, can give
clues as to the identity of a flaw. We talk of a Specular reflector, that is with a mirror like
face, where all the sound is reflected back to the source of energy. Providing that is, the
probe and flaw are correctly orientated. A sidewall fusion flaw is nearest to this ideal.
However, at the other extreme, porosity can be considered as a large number of small
spherical reflectors which cause the energy to reflect everywhere. Rather like the light
reflecting from a disco ball hanging from the ceiling. Porosity is a diffuse reflector. By
combining these movements and watching the movement of the signal on the screen you
can draw conclusions. Characteristics of different defects are shown in the accompanying
diagrams, with explanations adjacent.
S1 S2 S3 S4
DAC 10dB DAC +6dB DAC 6dB 9/15dB
Indications falling into the S1 category would be immediately discounted. All other
indications would then proceed to be assessed for directional reflectivity, which is defined
as the variation in echo amplitude from a discontinuity in relation to the angle at which the
Rev 0 December 2010 Page 97
ultrasonic beam is incident upon it. An spherical indication would show the same echo
amplitude over a wide range of incident angles; 45, 60 and 70for instance, and is said to
have low directional reflectivity. A large smooth planar reflector would show a great
variation in echo amplitude and would therefore be said to have high directional
reflectivity.
The next two stages of the process analyze firstly the shape of the signal as displayed on
the A scan equipment and finally the behaviour of the signal when the probe is scanned at
90 to the discontinuity, traversing.
With respect to echo dynamic patterns indications fall into one of five categories
dependant upon the changes observed in the signal on the A scan in response to probe
movement. To aid the identification of defects there are four basic probe movements:
16.1 SCANNING PATTERNS
For angle probes the scanning patterns describe the way the probe is
manipulated as well as the way it is moved. The most common patterns, referred
to in some standards and application procedures are:
Orbital scan
Where the probe is manipulated through an arc movement whilst maintaining the
beam focused on a fixed reflector. Used often to identify porosity, where the
signal can be maintained on an orbital scan.
The instruction sheet would also contain sections giving details of any relevant
safety procedures and post test procedures such as the cleaning of the test area
afterwards. It would also have the company name, a unique technical
reference number, the originator's name and signature and an authorising
signature.
Test area
The test may involve examining the whole, of a component, or just the weld and
heat affected zone, this must be specified.
Actions to be taken
When defects are found it may be required that the defects are reported, e.g.
on a diagram or as a written description, or the weld, may be accepted or rejected
based on the defects found. If defects are to be reported then the defect
information that needs reporting would be contained in this section, i.e.
Defect type, size, lateral and longitudinal position in relation to datums, etc.
Scanning method
The method of scanning the material is either a written, step by step,
instruction or technique sheet, or involves following the steps laid out in the
relevant national standard.
An example written step by step instruction, for a single vee butt weld, could
be:
Visually inspect the parent metal and weld surfaces, reporting the
surface condition and the presence of any weld cap defects.
Scan the parent metal with a 0 probe, check and report the thickness and
any defects. Where the cap is dressed flat scan the weld metal with the 0
probe for defects and record on a rough report.
Draw up full size working diagrams and cursors (plotting systems), noting
surface distances and beam paths for each angle probe on half skip and full skip
positions.
Mark the centerline of the weld and the surface distance for each probe onto
the scanning surface.
using a guide strip behind the probe, perform a critical root scan by
scanning laterally on a fixed line parallel with the weld axis, with the probe
index point at the half skip surface distance, with each probe (access
permitting). Make a note, on a rough diagram, of any suspected defective
areas of the root, as they are located with each probe. Assess each suspect
area individually to ascertain whether the area is a defect, whether the defect
is in the root, if so, what type of defect and its size and position. Record the
defects on the rough report.
Scan the weld body on full skip, with each angle probe in turn (access
permitting), by moving the probe back and forth between the half and full
skip surface distances, whilst gradually traversing the length of the weld.
Assess each signal that falls within the half skip to full skip beam path range as
it is located. Record the defects on the rough report.
Scan the weld body on half skip, with each angle probe in turn (access
permitting), by moving the probe back and forth between the half skip surface
Root Flaws
The signal from a root flaw will appear on the time base while you are scanning laterally
along a straight edge, at a fixed position from the root. Once the signal is maximised by
getting the best reflection from the flaw it can be assumed that the centre of the beam is
hitting the bottom of the flaw. Fine adjustment of the straight edge will perhaps be
necessary.
Lack of penetration
High amplitude corner signals both sides of the weld, rapidly decreasing in
amplitude on rotational scan. Plotting at plate thickness depth, the width of with no
cross-over.
Lack of
Lack of
penetration
penetration
Excess penetration
Echo amplitude between 10 and 90%, dependent on depth and probe angle.
Multi-range signal - echo falls rapidly when traversed with 70 probe, also range
increases.
Probe movement - echo falls rapidly when angle probe traversed forward.
Root concavity
Echo sharp and large, with reduced range. Often mode conversion with60 probe.
Probe movement - traverse backwards echo falls more rapidly than lack of penetration.
Measurement - use centre of beam and 20dB drop (trailing edge) for height. Not always
possible to measure height.
Gas pore
Spherical even reflector single peak echo, narrow profile, similar to drilled hole or radius
of calibration block intensity approximately 50% CRT.
Probe movement. Rotate, lateral and traverse echo falls rapidly. Orbit echo height
remains.
Measurement. Impractical to measure height and length. Report as isolated reflector.
Equate reflectivity against disc area or DGS.
GENERAL
TECHNIQUE
When searching for defects in castings you should have, as a minimum, the
following information, which is usually written on a technique or instruction sheet (see
the appendices for an example).
Equipment required.
The instruction sheet would also contain sections giving details of any relevant safety
procedures and post test procedures such as the cleaning of the test area
afterwards. It 50 would also have the company name, a unique technical
reference number, the originator's name and signature and an authorising signature.
Test area
The test may involve testing the whole of a casting, or just sections of it, this should
be specified.
When defects are found it may be required that the defects are reported, e.g. on a
diagram or as a written description, or the casting may be accepted or
rejected according to the defects found. If defects are to be reported then the
defect 70 information that needs reporting would be contained in this section, i.e. defect
type, size, lateral and longitudinal position in relation to datums etc.
This section tells us the accept/reject criteria for particular defects, i.e. what size and type
of defects to report or which defects render the casting rejectable.
Equipment
This section should give information on; the type of flaw detector, type, size and
frequency of probes, type of couplant, calibration blocks and reference blocks to use.
Sensitivity
Method of setting and level of sensitivity need to be quoted for each scan, e.g. For the 0
probe set the response from the 3 mm flat bottom hole reference reflector to 40% fsh and
scan at this level. For the angle probes; increase the gain until 2 mm to 3 mm of grass is
obtained at the full skip beam path.
Scanning method
Prepare the material surface by removing any loose sand, rust, dirt or other debris
and visually inspect for surface defects or damage.
Calibrate the screen on the flaw detector, using a 0 probe and the A2
calibration block, for a range of 0 to 200 mm.
Set the sensitivity (as quoted in the relevant section above) and apply
couplant to the test area.
Scan the designated test area, with a probe overlap between scans of at
least 20% of the probe's diameter and at a maximum probe movement rate of
150mmtsec.
When defects meeting the criteria in the "Purpose of the test" section are found,
Rev 0 December 2010 Page 111
record the relevant defect data as in the "Actions to be taken" section.
Defects larger than the ultrasonic beam, i.e. where there is no bwe present,
should be sized using the 6 dB drop or equalisation methods. Defects
that are smaller than the ultrasonic beam should be sized and positioned
using the 20 dB drop method. Multiple or multi-faceted defects should
be sized using the maximum amplitude technique.
Prepare a neat concise report giving details of the casting's identification,
test area,
equipment used, sensitivity method and settings and a drawing with the
defect details as recorded in section 5 above. Sign and date the report
and state your relevant qualifications.
Post test procedures
This would involve cleaning any remaining couplant and dirt from the test area and
covering the surface with protective coatings according to client's requirements.
DEFECTS IN CASTINGS
Inclusions
Inclusions are formed from lumps of trapped solid non-metallic material in the
casting, of various shapes, sizes, orientations and depths. In large groups of small
inclusions, the variation, in orientation and shape, has the effect of scattering the
sound beam, as it passes through. When using a 00 probe on parallel sided castings, if the
sound reaches the back wall and reflects back, then it scatters again on the return
journey, This causes a significant drop in the amplitude of the bwe, compared to a
defect free area. The amplitudes of the signals from the defects also vary because of the
differences in sizes and orientations. The signals we see from multiple inclusions are, a
cluster of signals, of various amplitudes and depth, from the defects and a low
bwe, or no bwe. The cluster of signals from the defects has a constantly
changing pattern when you move the probe across the surface. Larger inclusions
will give stronger signals dependant on the shape, size and orientation.
When alloys are added to the molten material in a cast ingot, some of them may
not mix thoroughly and get left as segregated material in the centre of the
ingot after solidification. If the acoustic impedances of the alloys and the base
metal were different enough ultrasonic reflections may occur. In steel casting they
generally have acoustic impedance that is similar to the steel, so they are not
usually found ultrasonically unless the sensitivity of the equipment is high.
A flake
This defect occurs in the casting process by the material splashing up the sides of
the mould, this defect is on but not fused to the surface. This usually leaves a visible
"flake" of material on the surface of the casting. Using a 0 probe, scanning from the
opposite side of the casting shows a signal appearing just before the bwe. On
the defect side of the casting this defect is very easily missed because it is very near the
surface and if using a single crystal probe the signals will be in the dead zone.If a
double crystal 0 probe is used, in 'B" the defect signal will be near zero on the
CRT. In both cases, if the defect is larger than the beam then the bwe will not be
present.
These are pieces of foreign material, from the inside of the mould that have
stuck to the surface of the casting and give signal responses similar to a flake if smooth or
may just scatter the beam if rough..
Cold shuts
A lack of fusion resulting from splashing (a flake), surging, interrupted pouring or the
meeting of two streams of molten metal coming from different directions. This
defect gives a good signal response ultrasonically when favourably orientated to the
beam.
Hot tears
Surface or near surface cracks in the material due to different cooling rates at
changes in section in a casting. Ultrasonic testing gives low amplitude multiple
signals from multiple cracks or may give a high amplitude "ragged" signal from
a large crack with the orientation of its major plane favourable to the beam.
Porosity
Rev 0 December 2010 Page 114
This volumetric defect gives a multiple low amplitude signal from all directions, access
permitting.
Blowholes
These are small holes in the surface of a casting caused by the gas evolving from
decomposing grease, moisture, etc. This defect is not readily found ultrasonically
because it can be confused with rough surface signals normally obtained on
some castings.
Airlocks
Air trapped in the mould during pouring can be located ultrasonically and gives
signal responses dependant on its shape, size and orientation.
When defects are found it may be required that the defects are reported or the
casting may be accepted or rejected according to the defects found. The
accept/reject criteria tell us what size and type of defects to report or which
defects render the component rejectable, The criteria can be found in a procedure, a
written instruction sheet or in a national standard.
REPORTING
A report should give details of the casting identification, test area, surface condition,
equipment used, sensitivity settings and a drawing showing the defects and details
such as; defect type, size, lateral and longitudinal positions in relation to datums,
etc.. The report should be signed and dated and there may be a requirement
to state your relevant qualifications. Alternatively, if accepting or rejecting the
casting, instead of a drawing you may be asked to give a written statement of
conformity to the relevant acceptance level, or reasons for rejection, to the standard
employed.
GENERAL
The ultrasonic testing of forgings of simple geometry, such as bar and billet, there
are few limitations, When testing general forgings, such as crankshafts, etc., then the
most limiting factor is the shape. On complex shapes, the surface curvatures may not
allow good contact or coupling, the angles of the surfaces may prevent back wall
echoes with 0 probes and some forgings, simple or complex, may be anisotropic
in grain structure (different grain sizes in different directions).
TECHNIQUE
When searching for defects in forgings you should have, as a minimum, the
following 30 information, which is usually written on a technique or instruction sheet
(see the appendices for an example).
Equipment required.
The instruction sheet would also contain sections giving details of any relevant
safety procedures and post test procedures such as the cleaning of the test area
afterwards. It would also have the company name, a unique technical reference
number, the originator's name and signature and an authorising signature.
Test area
The test may involve testing the whole, of a component, or just parts, this
must be specified.
When defects are found it may be required that the defects are reported, e.g. on a 70
diagram or as a written description, or the component, or material, may be accepted or
rejected according to the defects found. If defects are to be reported then the defect
information that needs reporting would be contained in this section, i.e. defect
type, size, lateral and longitudinal position in relation to datums, etc.
This section tells us the accept/reject criteria for particular defects, i.e. what size
and type of defects to report or which defects render the component rejectable.
Equipment
This section should give information on; the type of flaw detector, type, size and 90
frequency of probes, type of couplant, calibration blocks and reference blocks to use.
Sensitivity
Method of setting and level of sensitivity need to be quoted for each scan, e.g. Set the bwe
from the DGS block to 80% fsh and note the gain setting, Still on the DGS block, maximise
the signal from the flat bottom hole at target depth (test material thickness) and set that to
80% fsh and note the difference in dBs between the new gain setting and the previous
one. Set the bwe from the test material to 80% fsh and add the difference noted in
the first two gain settings to the present gain and scan at this level.
Scanning method
The method of scanning the material is either a written, step by step, instruction
or technique sheet, or involves following the steps laid out in the relevant
national standard. An example written step by step could be:
Prepare the material surface by removing any loose scale, rust, dirt or other
debris and visually inspect for surface defects or damage.
Calibrate the screen on the flaw detector, using a 0 probe and the A2 calibration
block for a range of 0 to 200 mm.
Set the sensitivity (as quoted in the relevant section above) and apply
couplant to the test area.
This would involve cleaning any remaining couplant and dirt from the test area
and covering the surface with protective coatings according to client's
requirements.
DEFECTS IN FORGINGS
Inclusions
Banding
When alloys are added to the molten material in a cast ingot, some of them may not mix
thoroughly and get left as segregated material in the centre of the ingot after
solidification. These segregations get elongated and reduced in section in the
rolling and forging processes, this is known as banding. If the acoustic impedances of
the alloys and the base metal were different enough ultrasonic reflections may
occur. In steel casting they generally have an acoustic impedance that is similar
to the steel, so they are not usually found ultrasonically unless the sensitivity of the
equipment is high.
A forging lap
This defect occurs in the forging process by the material folding over onto itself
and it is flattened, but not fused onto the surface. This usually leaves a visible seam on the
surface of the forging. Using a 0 probe, scanning from the opposite side of the
forging shows a signal appearing just before the bwe. On the defect side of the
Rev 0 December 2010 Page 119
forging this defect is very easily missed because it is very near the surface and
if using a single crystal probe the signals will be in the dead zone. (However,
evidence of this problem would be a total loss of back wall echo, providing the
surface area of the lap is larger than the beam).
If a double crystal 0 probe is used, for the defect near surface, the defect signal
will be near zero on the CRT. In both cases, if the defect is larger than the
beam then the bwe will not be present.
Slugs
These are pieces of foreign material that have been pressed into the surface and
give signal responses much the same as a lap.
Bursts
When defects are found it may be required that the defects are reported, or the
material or component may be accepted or rejected according to the defects
found. The accept/reject criteria tell us what size and type of defects to report
or which defects render the component rejectable. The criteria can be found in
a procedure, a written instruction sheet or in a national standard.
REPORTING
Oil 1,440
Water 1,480
The velocity in a medium depends upon the medium's density and elasticity.
Air 330 - 0 0
Water 1,480 - 1
v = Velocity (m/sec)
f = frequency (MHz)
BS EN 1712: 1997
Ultrasonic examination of welded joints Acceptance levels
BS EN 1713: 1998
Ultrasonic examination of welded joints - Characterisation of indications in welds
BS EN 583
Ultrasonic testing
Part 1: 1999:
General principles
Part 2: 2001:
Sensitivity and range setting
Part 3: 1997:
Transmission technique
Part 4: 2002:
Ultrasonic examination for imperfections perpendicular to the surface
Part 5: 2001:
Characterisation of sizing of imperfections
Part 6:
Time of flight diffraction technique as a method for detecting and sizing of
imperfections
BS EN 10160:1999
Rev 0 December 2010 Page 127
Ultrasonic testing of steel flat products of thicknesses of > 6 mm (reflection
method) (superseding BS 5996)
BS EN 10079: 1993
Definition of steel products
BS EN 12668: 2000
Verification of UT equipment: Part 3: combined equipment (superseding BS
4331 Part 1)
BS EN 12223: 2000
Non-destructive-testing - Ultrasonic examination - Specification for calibration
block no. I (superseding BS 2704)
BS EN 27963: 1992
Calibration block no. 2 for ultrasonic examination of welds (superseding BS 2704)
BS EN 12680-1: 2003
Founding ultrasonic examination Part1: Steel castings for general purposes
BS EN 4570: 1985
Fusion welding of steel castings
Part 1:
Overall performance: on-site methods.
DD 174 (obsolete)
Calibration of time of flight diffraction
The PCN (Personal Certification in Non-Destructive Testing) is an International Scheme for the
certification of NDT technicians and supervisors and meets EN473 and ISO 9712 requirements.
Level of Qualification
Level 1
The level qualifies personnel to carry out NDT operations according to written instruction under the
supervision of a Level 2 or Level 3 person. A level 1 person has demonstrated competence to:
Level 2
This level qualifies personnel to perform and direct NDT according to established or recognized
procedures and has demonstrated competence to:
Level 3
This level qualifies personnel to direct any NDT operation for which they are certificated and:
Pre-examination Requirements
Level 1 and Level 2: There are mandatory minimum pre-approval training requirements which are given in
the PCN requirements documents.
Pre-examination training courses must be validated by the British Institute of Non-Destructive Testing
and need to cover the syllabus over a designated minimum number of hours.
Documented in-house training may account for up to one third of the required training hours. The
candidate also has to demonstrate practical experience in line with the requirements of PCN.
Level 3: The candidates have two access routes available which are shown in the PCN requirements
documents. Both training and experience requirements depend upon academic background. Note: A
mature candidate route is available
Examinations
The examination consists of general theory, specific theory and practical parts dependant on level and
type of examination.
Following an examination, a results notice will be issued: this counts as evidence of PCN certification for a
period of 42 days. The certificate will follow the results notice within 21 days.
Where the candidate is unsuccessful, one retest may be allowed providing the percentage grades are not
lower than the grades required by PCN.