Ultrasonic Testing

Weld Inspection using AWS D1.1

12/18/2013

Introduction
This presentation will help students perform testing using the American Welding Society Structural Steel D1.1-2000 code and procedure. It is important to remember that this is a general training program and the procedure should be referenced for specific information. 2

What you will learn

Completing Form D-11 Determine the proper transducer(s) needed for testing a weld. Calibration using an IIW, rumpus, and DSC block. Scanning for discontinuities. Calculate size and location of a discontinuity. Accept/Reject evaluation of a discontinuity.

Form D-11
Some basic information should be completed on form D-11 prior to the inspection. This information includes the following:

Weld Identification Material Thickness Type of Weld Joint Welding Process Quality Requirements Section Number Year of AWS D1.1 Code used. Testing Date Inspected By

Step 1 Specimen Measurement

Measure the part thickness. From this thickness you will need to calculate the skip distance. The skip distance is the area where you will scan the part with the proper angle transducer. Mark the end of the skip distance from the edge of the heat affected zone (HAZ). The area in red will be used to identify the heat affected zone.

Step 2 Inspection Layout

The skip distance will equal the surface distance of the two legs. You will need to know the distance of this area in order to perform a lamination scan followed by an angle beam examination

Inspection Layout
Identifying the skip distance from the edge of the HAZ will ensure complete coverage of the weld when performing an angle beam examination.

Step 3 Lamination Scan

A lamination scan will be performed in the area where the angle beam inspection will take place. This scan is performed with a straight beam transducer.

Lamination Scan
Perform a lamination scan from face A. You will need to see at least two plate thicknesses on the display. The first backwall reflection shall be 50 to 75% full screen height.

Lamination Scan
If any area of the base metal shows a total loss of backwall reflection, or if an indication is equal or greater to the backwall reflection, the size and location and depth will be reported.

10

Lamination Scan
Move the transducer in all directions until the amplitude of the signal is reduced by 50%. Mark the center of the transducer.

11

Lamination Scan
The area can be measured and included in the report. This area should be avoided when performing an angle beam examination or an alternate scanning procedure shall be used.

12

Lamination Scan
Note the location and size of the lamination on report form D-11 or write an additional report with a drawing showing its location.

13

Step 4 Transducer Angle

Table 6.6 will list the transducer angles needed to test the weld. For material 0.60 the transducer angle used will be 70 degrees and will be tested from face A. On Form D-11 record the transducer angle and face which you will be testing from. The face is determined from Table 6.6

14

Step 5 Screen Range

Calculate the full V-path. This is determined by the material thickness and transducer angle. Choose the appropriate screen range in order to see a minimum sound path of two legs.

15

Step 6 Screen Range

Calculate the full V-path. This is determined by the material thickness and transducer angle. Choose the appropriate screen range in order to see a minimum sound path of two legs.

16

Transducer
Verify the transducer is coupled to the wedge and there are no air pockets between the two.

17

Calibration - IIW Block

All measurements are taken from where the signal breaks the baseline of the ultrasonic screen.

18

Screen Range IIW Block

Adjust the ultrasonic machine to obtain the proper screen range. With an IIW type II block shown, the backwall reflections will be located at 2 and 4.

19

Position of the signals with a 10 screen range.

Screen Range IIW Block

The position of the 2 and 4 reflections when using a 5 screen range.

20

Position of the signals with a 5 screen range.

Screen Range DSC Block

The distance and sensitivity calibration block (DSC) can be used for calibration. With the transducer placed in the position shown, the reflections will take place at 1, 5, 9, etc.

21

Position of the signals with a 10 screen range.

Screen Range DSC Block

With the transducer placed in the position shown, the reflections will take place at 1, 5, 9, etc.

22

Position of the signals with a 5.0 screen range.

Screen Range DSC Block

With the transducer placed in the position shown, the reflections will take place at 3, 7, 11, etc.

23

Position of the signals with a 10 screen range.

Screen Range DSC Block

With the transducer placed in the position shown, the reflections will take place at 3, 7, 11, etc.

24

Position of the signals with a 15 screen range.

Screen Range Rumpus Block

The miniature calibration block or rumpus block can also be used for calibration. With the transducer placed in the position shown, the reflections will take place at 1, 4, 7, 10 etc.

25

Position of the signals with a 5 screen range.

Screen Range Rumpus Block

With the transducer placed in the position shown, the reflections will take place at 1, 4, 7, 10 etc.

26

Position of the signals with a 10 screen range.

Screen Range Rumpus Block

With the transducer placed in the position shown, the reflections will take place at 2, 5, 8, etc.

27

Position of the signals with a 5 screen range.

Screen Range Rumpus Block

With the transducer placed in the position shown, the reflections will take place at 2, 5, 8, etc.

28

Position of the signals with a 10 screen range.

Step 7 Transducer Exit Point

Determine the exit point of the transducer. Peak the signal on the ultrasonic machine and verify that the index point on the plastic wedge matches the calibration block. You may use tape and a pen to mark the exit point. This will allow for easier measurements when measuring the surface distance.

29

Exit Point IIW Block

The exit point and screen range can be performed at the same time. Slide the transducer back and forth until the signal is maximized. The pictures below shows the location of the transducer when verifying the exit point using an IIW type II block.

30

Exit Point DSC Block

The exit point and screen range can be performed at the same time. Slide the transducer back and forth until the signal is maximized. The pictures below shows the location of the transducer when verifying the exit point.

31

Exit Point Rumpus Block

The exit point and screen range can be performed at the same time. Slide the transducer back and forth until the signal is maximized. The picture below shows the location of the transducer when verifying the exit point.

32

Step 8 Transducer Angle

The angle of the transducer will need to be verified. It shall be within plus or minus 2 degrees of the required angle.

33

Angle IIW Block

Slide the transducer back and forth until the signal is maximized. The picture below shows the location of the transducer when verifying the transducer angle.

34

Angle DSC Block

Slide the transducer back and forth until the signal is maximized. The picture below shows the location of the transducer when verifying the transducer angle.

35

Angle Rumpus Block

Slide the transducer back and forth until the signal is maximized. The picture below shows the location of the transducer when verifying the transducer angle.

36

Step 9 Transducer Resolution

The resolution shall be checked with the instrument controls set at normal test settings and the indications from the holes brought to midscreen height. Resolution shall be sufficient to identify the peaks of the three holes.

37

Position of the signals with a 5 screen range.

Step 10 Reference Level

The amplitude of a known size reflector will be adjusted from 50-75% full screen height. The dB will be recorded as the reference level on form D-11.

IIW block

Rumpus block DSC block

38

Reference Level IIW Block

The transducer shall be placed in the position shown and the signal amplitude from the hole will be maximized. Adjust the dB in order to obtain a signal from 50 to 75% full screen height. This will be used as the reference level b on form D-11.

39

Position of the signals with a 10 screen range.

Reference Level DSC Block

The transducer shall be placed in the position shown and the signal amplitude from the notch will be maximized. Adjust the dB in order to obtain a signal from 50 to 75% full screen height. This will be used as the reference level b on form D-11.

40

Position of the signals with a 10 screen range.

Reference Level Rumpus Block

The transducer shall be placed in the position shown and the signal amplitude from the hole will be maximized. Adjust the dB in order to obtain a signal from 50 to 75% full screen height. This will be used as the reference level b on form D-11.

41

Position of the signals with a 5 screen range.

Step 11 Reference Level

In this example the reference level b would be recorded as 42 dB. The reference screen height used is 60% FSH.

42

Step 12 Scanning Level

Scanning level is based on sound path distance and not material thickness. If table 6.2 (Statically loaded nontubular connections) are tested, the following scanning levels will be used. Sound Path (in) 0.0 to 2.5 >2.5 to 5 >5 to 10 >10 to 15 Above Zero Reference, dB 14 19 29 39

43

Scanning Level
If table 6.3 (Cyclically loaded nontubular connections) are tested, the following scanning levels will be used.

Sound Path (in) 0.0 to 2.5 >2.5 to 5 >5 to 10 >10 to 15

Above Zero Reference, dB 20 25 35 45

44

Scanning Level
This shows the screen presentation when using a scanning level 14 dB above the reference level.

45

Step 13 Initial Information Scan

Perform an initial information scan marking the location of any suspected discontinuities.

46

Weld Configuration
You can draw a diagram of the weld on the ultrasonic screen with a water based marker or grease pencil. The line is drawn at the end of the 1st, 2nd, and 3rd leg. This may help you visualize the location of the discontinuity in the weld.

47

Step 14 Surface Distance

Calculate the surface distance in order to determine if the signal is located in the weld.

48

Step 15 Discontinuity Depth

Calculate the depth in order to determine if the signal is located in the weld.

49

Step 16 Sound Path

Move the transducer in all directions in order to peak the signal from the discontinuity. Record the Sound Path on Form D-11.

50

Step 17 Sound Path

Record the Leg on Form D-11.

51

Step 18 Indication Level

Increase or decrease the dB until the screen height from the discontinuity is equal to the reference level. Record the dB under indication level (column b).

52

dB reference level - 60% FSH.

Step 19 Attenuation Factor

Subtract one inch from the sound path distance and multiply the remainder by two. This number will be rounded to the nearest whole number. If the number is less than 0.5 dB it will be lowered to the nearest whole number. If the number is 0.5 or greater, it will be increased to the nearest whole number.

In this example, the sound path is 1.9

1.9 1 = 0.9 0.9 x 2 = 1.8 Rounded to the nearest whole number - 2 53

Attenuation Factor
On Form D-11, fill out the attenuation factor. This is located under Decibels- Attenuation Factor.
In this example, the sound path is 1.0 1.0 1 = 0.0 0.0 x 2 = 0.0

If the attenuation factor is less than 0.5, the attenuation factor will be zero.
54

Step 20 Indication Rating

The indication rating is calculated by taking the Indication level minus Reference level minus Attenuation factor. A-B-C=D
The answer D is your indication rating and can be positive or negative. Write this number in column D under Decibels, Indication Rating 55

Step 21 Discontinuity Length

Maximize the signal amplitude from the discontinuity.

56

Step 22 Discontinuity Length

Slide the transducer parallel with the weld until the signal amplitude has reduced by 50%. Mark the location next to the weld aligned with the center of the transducer. Perform this procedure in both directions.

57

Discontinuity Length
Record the length on Form D-11.

58

Step 23 Discontinuity Class

From Table 6.2 or 6.3, determine the Discontinuity Severity Class. This is based on the Indication Rating and Length.
Class A (large discontinuity) Any indication in this category shall be rejected regardless of length Class B (medium discontinuity) Any indication in this category having a length greater than shall be rejected. Class C (small discontinuity) Any indication in this category having a length greater than 2 shall be rejected. Class D (minor discontinuity) Any indication in this category shall be accepted regardless of length or location in the weld.

59

Step 24 Discontinuity Evaluation

On Form D-11 under Discontinuity Evaluation list the class of the discontinuity.

60

Step 25 Accept/Reject
On Form D-11 under Remarks accept or reject the discontinuity.

61

Step 26 Distance from Y

One side of the plate or weld can be identified with a Y location point. From the edge of the weld measure to the beginning of the discontinuity. Record Distance from Y on Form D-11.

62

Distance from Y = 1.0

Distance from Y = 0.3

Step 27 Distance from X

From the center of the weld (marked in black), if the discontinuity is located opposite the Y location mark, it will be measured as a positive number. This will be recorded under Distance from X on Form D-11.

63

Distance from X = 0.2

Step 28 Distance from X

From the center of the weld (marked in black), if the discontinuity is located on the same side as the Y location mark, it will be measured as a negative number. This will be recorded under Distance from X on Form D-11.

64

Distance from X = -0.2

Step 29 Scanning Level

Return to the scanning level and locate the next discontinuity for evaluation.

65