12th A-PCNDT 2006 – Asia-Pacific Conference on NDT, 5th – 10th Nov 2006, Auckland, New Zealand

A FLAW SIZING TECHNIQUE FOR AUSTENITIC STAINLESS STEEL

WELDS USING CREEPING WAVE PROBE
Satoru Shiroshita1, Yoshikazu Yokono2
1
Nondestructive Inspection Co.,Ltd., Osaka, Japan
2
Pony Industry Co.,Ltd, Osaka, Japan

Abstract
One of the most important subjects in nuclear power plants is sizing of flaws which are detected during In-
Service Inspection (ISI), since reliability of flaw sizing is very important to estimate the life of the structure
or pressure equipment. The most difficult matter for applying the flaw sizing techniques mentioned above is
how to identify the flaw tip signal, especially in the case of natural cracks such as stress corrosion cracking
(SCC). At present, the identification of the flaw tip signal depends on technical skill, related knowledge and
experiment of UT personnel. This paper proposes a new technique using echo locus curves on B-scan image
for flaw sizing. The technique was applied to welds test specimens with simulated SCC and advantages of
the technique were confirmed experimentally. As a result, it is clear that flaw sizing can be conducted with
higher accuracy and misjudgment or measuring error due to personnel ability can be reduced.

1. Introduction 2. Flaw sizing technique using ultrasonic

One of the most important subjects in nuclear methods
power plants is sizing of flaws which are detected
during In-Service Inspection (ISI). Although 2.1. Present concerns on current flaw sizing
ultrasonic methods have been commonly applied techniques
for detecting and sizing flaws, there still remain Tip echo technique and TOFD technique as
some difficulties when austenitic stainless steel commonly used for flaw sizing are based on flaw
welds are inspected. These difficulties caused by tip location estimated by probe position and time of
high attenuation of signal amplitude during flight. While phased array technique is based on
propagation and low SN ratio of echoes due to imaging such as B-scan and/or C-scan presentation,
ultrasound scattering at grain boundaries. it is regarded as one of the technique to obtain flaw
Anisotropy of ultrasound characteristics such as tip indication in cross sectional B-scan image in
sound velocity is also problem to be considered. accordance with JEAG4207 for flaw sizing.
Therefore, it has been said that application of
ultrasonic testing to such welds is so limited. The most difficult matter for applying these
Recently the following procedure has been techniques is to identify the signal from flaw tip.
provided to size the inner surface breaking flaws in Therefore high quality skills and much experience
the pipe welds by the Technical Recommendation of UT personnel have been required for accurate
of Japan Electric Association, JEAG 4207:2004[1]. evaluation when performing not only tip echo
technique but also TOFD and phased array
Firstly, creeping wave technique should be used to technique. It is not too much to say that to solve
confirm the existence of the inner surface breaking this problem is the best way to improve the
flaws detected by regular UT methods. Secondly, accuracy of flaw sizing in austenitic stainless steel
mode conversion technique is used to divide the welds.
size of the flaw into three categories: large, middle
and small [2]-[3]. Thirdly, the combination of tip
echo technique, TOFD technique and/or phased 2.2. Flaw sizing technique using creeping wave
array probe technique should be applied to estimate probe
the size of the flaws.
Creeping wave probe has been regarded as a
powerful tool to detect and evaluate the opposite
However, the fact is that the problems regarding
surface breaking flaw, but there remains some
UT for austenitic stainless steel welds are not being
difficulties to analyze the obtained signals in A-
solved for all of these techniques. In this paper,
scan presentation. On the other hand, not only
flaw sizing technique using echo dynamics
creeping wave technique but also tip echo
obtained by creeping wave probe is proposed in
technique using longitudinal wave and mode
order to solve these problems.
conversion technique can be carried out by a 2.2.1. Advanced sizing technique using both
creeping wave probe. In this paper, new approach longitudinal wave and shear wave
to flaw sizing using creeping wave probe is
An example of echo locus curves on B-scan image
proposed.
of opposite surface breaking flaw is shown in Fig.2
(a). Four solid lines are generated by corner
When the creeping wave probe is scanned to and
reflections and tip echoes of both longitudinal
fro on a test material as shown in Fig.1 (a), the
wave and shear wave. Two circles with its center
echoes from some specific reflectors can be
at certain probe indexes, YL2 and YS2, and with
observed continuously moving right and left on the
radius of beam path distances calculated from time
display. The feature of the echo pattern is
of flight, TL2 and TS2, respectively. The breaking
recognized in the figure showing relations between
point of flaw can be determined by intersections of
amplitude, time of flight and probe position, that is
the circles, as shown in Fig.2 (b). The location of
to say, some locus curves in B-scan image are
the flaw tip can also be determined by intersection
observed as shown Fig.1 (b). The analysis of the
of two circles obtained from probe indexes, YL1
data to estimate the size of the reflector was carried
and YS1, and time of flight, TL1 and TS1,
out by interpretation of the signals as shown in
respectively, in the same manner. If the indication
Fig.1 (c). Some sizing techniques for opposite
of shear wave is difficult to be observed due to
surface breaking flaw are followed using the
attenuation of ultrasound, the data from only
analyzing the locus curves.
longitudinal wave can be used for drawing circles
Scan Direction to locate the opposite surface breaking position and
Encorder flaw tip.
Top Surface
Probe
The discernible part of locus curve can be used for
Longitudinal Wave
Shear Wave estimating beam path distance at certain probe
Mode converted Wave
position. Accordingly, it is not necessary to obtain
maximum echo for the case of tip echo technique.
Creeping Wave Inner They can also be determined by calculation in x-y
Crack Surface coordinate.
(a) Scanning creeping wave probe and Probe Location
YS1 YS2 YL1 YL2
ultrasound propagation
Probe Location
Time of Flight

TS1
Time of Flight

TL1
TS2
TL2

(b) Echo locus curves on B-scan image (a) Echo locus curves on B-scan image
Y L2
Probe Location Y L1
S Wave (Tip Diffraction) Y S2
Y S1
Time of Flight

L Wave (Tip Diffraction)

L Wave (Corner Reflection)

Mode Converted Wave

S Wave
(Corner Reflection)
t
hF

Creeping Wave

(c) Interpretation of the signals

Figure 1: Relations between amplitude, time of
flight and probe position (b) Estimation of reflecting location
Figure 2: An example result of sizing technique
using both longitudinal wave and shear wave
2.2.2. Estimation of surface breaking location Probe Location
using creeping wave
20.0 25.0 30.0 35.0 40.0 45.0
The solid line in Fig.3 (a) shows locus curve of 15.0

Time of Flight (μsec)

creeping wave. Time of flight represented by 20.0
vertical axis shown in the figure corresponds to
total propagation time of shear wave and creeping 25.0
Creeping Wave
wave as shown in Fig.3 (b). In this case, the 30.0

refraction angle of shear wave θ S is determined as 35.0

critical angle of shear wave. This estimation has a Shear Wave
40.0
good correlation with actual flaw location
experimentally. 45.0

The shear wave signal from corner of surface (a) Calculation result
breaking flaw is sometimes observed very close to
the creeping wave signal from breaking point of Probe Location
flaw simultaneously. In many cases these two
signals are difficult to be distinguished each other

Time of Flight (μsec)

on A-scope presentation. When the probe is
moved backward away from flaw location, they
could be separated and two locus curves can be
observed as shown in Fig.4. The results obtained Creeping Wave
by calculations and experiments are shown in Fig.4
(a) and (b), respectively.
Shear Wave

Probe Location
YC2 YC3 (b) Experimental result
YC1 YC4
Figure 4: Separation of creeping wave signal
and shear wave signal on locus curves
Time of Flight

2.2.3. Categorization of flaw using mode

TC1 conversion technique
TC2
TC3 The solid line in Fig.5 (a) shows locus curve
TC4 obtained by mode conversion technique. Shear
wave propagates along the line of P1-R1 with beam
angle of θ S and longitudinal wave propagate along
(a) Echo locus curves on B-scan image the lines of R1-S1-P1 with beam angle of θL as
Y C4 shown in Fig.5 (b), since mode conversion occurs
at the position of R1. The line of R1-S 1 is extended
YC3 to Q1 so that the length between R1 and Q1 become
YC2 same as the propagation path length of longitudinal
YC1 wave. In this case beam angle of shear wave, θ S is
defined as the angle between the central axis of the
beam and normal line of test surface. A
θS perpendicular bisector of P1-Q1 corresponds to
t

reflector face. This proves that there exists a

hF

reflecting point S1 and the flaw is higher than the

depth of S1 from the back surface.

This technique can also be used for the inclined

flaw as shown in Fig.6. Inclined angle, α is
(b) Estimation of reflecting location determined by the breaking point of flaw and flaw
Figure 3: An example result of creeping wave tip location estimated by sizing technique using
technique both longitudinal wave and shear wave as
described before.
 Probe Location having several sizes ranging from small (about
YM2 YM3 10% of thickness) to large (larger than 50% of
YM1 thickness) can be evaluated accurately comparing
YM4
with the designed values of flaw height.

Test specimens with several slits of 1mm to 19mm

Time of Flight

in height were also used for the experiments.

TM1 Estimated values by this technique as a function of
TM2 actual flaw height are shown in Fig.8. As a result,
TM3 flaw size can be estimated with the average error of
TM4 -0.19mm and the standard deviation of 0.31mm.

FAR NEAR

(a) Echo locus curves on B-scan image Flaw Height: 12.7mm

18.19
mm
YM 1 UT Result: 12.6mm

Q1 P1
(a) 6” Sch160, Flaw Location: 40°
FAR NEAR
θS
θL
t

22.71
S1
hF

Flaw Height: 7.8mm

R1 UT Result: 9.9mm

(b) 8” Sch160, Flaw Location: 170°

FAR NEAR
(b) Estimation of reflecting location
Figure 5: An example result of mode conversion
32.75

technique
Flaw Height: 4.7mm
Y1 UT Result: 3.6 mm
Flaw Height: hF
Inclined Angle: α ：Scan Direction
α P1
(c) 12” SCH160, Flaw Location: 310°
Q1 Figure 7: Results of flaw reconstruction on cross
θS sectional view
θL
t
hF

20
S1
Estimated Flaw Height by UT

Average Error : 0.19 mm

R1 Standard Deviation: 0.31 mm
RMS Error : 0.36mm
15

10
Figure 6: Mode conversion technique for the
inclined flaw
5
3. Experimental investigation into
(mm)

applicability
Some experiments using test specimens with 0
10 20
0 5 15
embedded fatigue cracks are carried out to
Actual Flaw Height (mm)
demonstrate the accuracy of this technique.
Typical examples on estimating flaw size on cross Figure 8: Estimated values by UT as a function of
sectional view are shown in Fig.7. All flaws actual flaw height
 5. Experimental results for SCC in stainless
4. Instrumentation for field application steel welds
4.1. Portable X-Y scanner The procedure for sizing flaw mentioned above was
tried to apply for stainless steel pipe welds with
Portable X-Y scanner was developed to acquire the stress corrosion cracking (SCC). Test specimen
data of time domain signal and probe position as having the diameter of 609.6mm and thickness of
shown in Fig.9. The scanner having centering 35.2mm were prepared and some SCCs of different
function module can be applied ranging from height were installed. To acquire the data creeping
circumference welds of 4B piping to but welds of wave probe, 3.5MHz in frequency, 12.7mm in
flat plate. Wheels which contact to test surface crystal size and 70 degrees in refraction angle of
have grooves to avoid slipping due to couplant. longitudinal wave, was scanned to and fro on the
test surface using the above mentioned scanner
shown in Fig.9. Data analyzing software was used
to estimate the height of SCC. A typical example
of the display obtained through the experiment is
shown in Fig.10 (a). After the estimation,
metallographic observation was carried out to verify
the actual height of SCC in the test specimen. The
cross sectional observation of the specimen
corresponding to the result in Fig.10 (a) is shown in
Fig.10 (b).

Since signals of interest indicated as inclined lines

can be easily distinguished from unnecessary noise
Figure 9: Portable X-Y scanner signals indicated as horizontal lines as shown in B-
scan image of Fig.10 (a). As analyzing software
includes advanced sizing technique, mode
4.2. Data analyzing system
conversion technique and creeping wave technique,
Software for flaw reconstruction was developed to the technique to be applied can be selected by click
make it easier to apply this technique to field the tab on the display. The example of the data
inspection. The software includes calibration of shown in Fig.10 (a) was obtained by scanning the
encoder equipped with scanner and imaging of probe on the right side upper surface shown in
cross sectional view. When moving a cursor and Fig.10 (b). The data were analyzed by advanced
clicking it on the specific locus curve, location of sizing technique of longitudinal wave, since tip
reflector is pointed on cross sectional presentation. echo of shear wave cannot be identified. Two cross
marks denoted by 1) and 2) were clicked on the
indication line of inner surface breaking point and
4.3. Recommended procedure for flaw sizing the location of crack bottom could be estimated.
After the creeping wave probe is scanned to and fro Also other two cross marks denoted by 3) and 4)
to obtain echo locus curves on B-scan presentation were clicked on the tip echo line and the location of
at the objective position of welds, the following crack tip could be estimated. The sketch shown in
procedure is recommended for flaw sizing. the top of the figure illustrates the estimated crack
location on the cross sectional image. The depth of
First, location of flaw tip is estimated as the crack can be determined to be 9.3mm by
intersection of longitudinal wave and shear wave in considering all plots shown in the figure. When the
accordance with 2.2.1. If there is no shear wave probe was scanned on the left side upper surface,
signal, then intersection of only longitudinal wave the height of SCC was estimated to be 9.6mm. As
can be used. Second, location of surface breaking shown in Fig.10 (b), it can be supposed that the
point is confirmed by creeping wave technique in height of crack is 10.2mm which is corresponds to
accordance with 2.2.2. It can be estimated by the height estimated by the sizing technique
drawing or calculation using locus curve of proposed here.
creeping wave. Third, middle position of flaw is
determined by mode conversion technique in Another example is shown in Fig.11. The height of
accordance with 2.2.3. SCC was estimated to be 18.2mm by this technique
and the actual height was confirmed to be 17.0mm,
as shown in the figure.
 3)

10.2 mm
4)
1)
2)

1 mm
0 10mm

0
(a) Sizing result using creeping wave probe (b) Cross section of the test specimen
(SUS316, 600A) with SCC
Fig.10: The example of the sizing result of UT and cross section of the test specimen (1)

17.0 mm

2 mm

0 10 mm
0

(a) Sizing result using creeping wave probe (b) Cross section of the test specimen
(SUS316, 600A) with SCC
Fig.11: The example of the sizing result of UT and cross section of the test specimen (2)

Finally, the procedure of the flaw sizing technique

6. Conclusions was proposed and it has potential ability to reduce
A flaw sizing technique in austenitic stainless steel measuring error and misjudgment due to UT
welds using creeping wave probe is investigated. personnel proficiency. It is expected that the
The following results are obtained through this technique can contribute to improve the reliability
study. of flaw sizing.
(1) It was clear that not only creeping wave
7. References
technique but also tip echo technique using
longitudinal wave and mode conversion technique [1] JEAG 4207-2004, “Ultrasonic Examination for In-
can be carried out by a creeping wave probe. Service Inspection of Light Water Nuclear Power Plant
Components”, Japan Electric Association, 2004.
(2) Drawing locus curves when the probe is [2] Panametrics NDT Web Page, “Detection and Sizing
scanning to and fro is very effective to identify Techniques of I.D. Connected Cracking”.
each signal and analyze reflection signals to [3] Peter Hayward, “Detection and Sizing of Cracking from
estimate the flaw location. the Inner Surface using ID Creeping Waves”, 10th Asia-
Pacific Conference on Non-Destructive Testing,
(3) Portable X-Y scanner and software for flaw Brisbane, Australia, 2001.
sizing are developed for field inspection.