Formed Metal Inspection of Rail wheel segment

1) Plot the full scale end view of test piece on a piece of paper as shown below.

2) Calibrate the range with an IIW V1 block; for straight beam and angle beam transducers

Set Velocity

Set Range

Zero Probe

3) Set the sensitivity for straight beam based on the back wall as shown below

Get the ref dB

4) Scan the critical area with the straight beam look for any indication that exceed the acceptable limits as
per the worksheet.

Critical areas

Scan from all

accessible surfaces

5) Once the indication (discontinuity) is found locate it and size the indication using the 6dB drop.
Maximise the signal to a “convenient” amplitude (say 80% FSH). Move the probe until the signal drop to
½ the initial amplitude (ie. 80% to 40% - 6dB drop). Mark the centre of the probe with a pencil. Move
the other direction the other drop at ½ the initial amplitude (the other 40%) and mark the centre of the
probe – see below.

40%

80%

70mm
85mm

40%
6) Drawing a DAC for the angle beam transducer. If you are doing all 3 angles you will need to do 3
DACs. Use both the top and bottom surface to construct the DAC curve as shown below. For some
angle you may only get 3 points for some you may get 4 or more.

2
1 3

4
5

1
4 5

2 3

7) Scan the critical areas for any indication (discontinuity) as shown below.

Critical areas

Scan top and bottom

surfaces, in all possible
directions
8) Scan the critical areas for any indication (discontinuity) as shown below.

When scanning not all the angles

(45o/60o/70o) will detect the
discontinuity (indication); which is 45° 70°
why you need to use all possible
angles.
45° 60°
Once the indication is found get
the stand-off distance (SO) from
the transducer index point to a
known surface such as shown on
1 2 3 4 5 6

SO
4

the right. Also. Obtain the sound

3

path or path length (PL) from the

2

screen.
1

6 5

PL
4 3 2 1

Using the plot and “slider” you can

2
2
3

locate the indication on the plot

4

Index point
3
5

as shown on the right.

D2
60° 45° D1 On the left is another example
of an indication found by a 45o
transducer.

After obtaining the surface

distance (SO) and the PL, you
can locate the indication on the
plot as shown on the left. As the
plot is a full scale drawing you
PL can measure the position of the
5

3 4

indication, say D1 – distance

3
2
2

from the top surface or D2 –

1

1 2 3 4 5 6

distance to the inside edge. You

1

can then put them into your

5 6
2
3 4
1 2

SO
report.
3

4
9) Sizing. To get the length; maximise the signal again to a “convenient” amplitude (say 80% FSH). Move the probe
side-ways (parallel to the weld axis) to the right and watch the signal drop to ½ the initial amplitude (ie. 80% to
40% - 6dB drop). Mark the centre of the probe with a pencil. Move back to the left pass the maximum amplitude
to the other drop at ½ the initial amplitude (the other 40%) and mark the centre of the probe. The distance
between the 2 pencil marks is the length.

40%

80%

40%

10) Evaluation

From step (9), say you have a signal from the indication that is above DAC; the reference level/gain is
say 40dB. Bring the signal back to DAC (ie. “touch” the DAC curve) and say that comes to 33.5dB.
So calculate the difference, X;
X = Reference gain @ DAC – Indication gain @ DAC
X = 40 – 35.5 = 4.5 dB
Then substitute into formula;

% signal amplitude to reference = 10 (x 100%)

x/20

= 10 (x 100%)
4.5/20

= 1.68 (x 100%)
≂ 170%