Ultrasonic Testing
Ultrasonic Testing
DEFECT LOCATION
600
LENGTH
6 dB Drop
Defect BWE
Plan View
6 dB Drop
Defect BWE
LENGTH
20 dB Drop
Defect BWE
20 dB Beam profile
10%
When the main beam is on the defect the defect signal is at it maximum
If the edge of the beam strike At this point the MAIN BEAM is
the edge of the defect, a very directly at the edge of the
small echo appears defect
Maximum Amplitude
Remember: The peak which maximised does
not have to be the tallest or the first one
Length
LACK OF
FUSION 700 700
TIP MAXIMA
AMPLITUDE
PRIMARY OBJECTIVES:
1. TO SCAN ALL FUSION FACES AT AN ANGLE
OF INCIDENCE = 00 +/- 200 (00 +/- 100 FOR
CRITICAL EXAMINATIONS).
2. TO SCAN THE ENTIRE WELD VOLUME
INCLUDING THE HEAT AFFECTED ZONE WITH
A MINIMUM OF TWO PROBE ANGLES.
3. TO SCAN FOR POSSIBLE TRANSVERSE
IMPERFECTIONS
ULTRASONIC EXAMINATION OF WELDS
600
20
2
4
450
THE 450 PROBE CAN NOT BE USED TO SCAN THE WELD ROOT
AT HALF SKIP, THEREFORE THE 700 PROBE MUST BE USED:
57 57
700 700
58
58
120 120
23 23
COVERED AT
FULL SKIP
COVERED AT HALF
COVERED AT & FULL SKIP
HALF SKIP
ULTRASONIC EXAMINATION OF WELDS
600 SCAN OF WELD VOLUME AND FUSION ZONES
80 80
23 23
COVERED AT
FULL SKIP
COVERED AT FULL
& HALF SKIP
COVERED AT
HALF SKIP
SCANNING FOR TRANSVERSE IMPERFECTIONS
PR
OB BE
E O
PR
B E PR
RO OB
P E
SCAN
RECOGNITION OF DEFECT TYPE
ORBITAL ROTATIONAL
TYPICAL ECHO DYNAMIC PATTERNS
CRACK SLAG
ORBITAL
SCAN
ROTATIONAL
SCAN
Ultrasonic Testing
• Sensitivity
• Defect sizing
• Scanning procedures
Sensitivity
• The ability of an ultrasonic system to
find the smallest specified defect at the
maximum testing range
Depends upon
• Probe and flaw detector combination
• Material properties
• Probe frequency
• Signal to noise ratio
Methods of Setting Sensitivity
• Smallest defect at maximum test range
• Back wall echo
• Disc equivalent
• Grass levels
• Notches
• Side Drilled Holes, DAC Curves
Artificial / actual defect
Part 3
Ultrasonic Inspection
• Sensitivity
• Scanning procedure
• Defect sizing
Sensitivity
• The ability of an ultrasonic system to
find the smallest specified defect at the
maximum testing range
Depends upon:
Probe and flaw detector combination
Material properties
Probe frequency
Signal to noise ratio
Methods of Setting Sensitivity
1. Parent material
2. Root inspection
3. Fusion face & HAZ inspection
4. Weld volume
5. Transverse scan
ULTRASONIC SENSITIVITY
THE SOUND PRESSURE AND INTENSITY ALONG THE
AXIS OF AN ULTRASONIC BEAM VARY WITH RANGE:
THEREFORE THE ECHO HEIGHT FROM AN IDENTICAL
REFLECTOR WILL VARY WITH RANGE.
VARIOUS METHODS ARE USED IN ULTRASONIC
TESTING IN ORDER TO COMPENSATE FOR THIS
VARIATION IN ECHO HEIGHT.
THESE METHODS ARE REFERRED TO AS “SETTING
SENSITIVITY” OR “DISTANCE AMPLITUDE
CORRECTION.”
DISTANCE AMPLITUDE CORRECTION
24 dB 30 dB 36 dB
EXAMPLE:
ECHOES
OBTAINED ON
40 mm THICK
CALIBRATION
BLOCK
40 mm 80 mm 160 mm
TRANSFER & ATTENUATION
CORRECTION: 00 PROBES
26 dB 32 dB 38 dB
EXAMPLE:
ECHOES
OBTAINED ON
30 mm THICK
COMPONENT
30 mm 60 mm 120 mm
TRANSFER & ATTENUATION
CORRECTION: 00 PROBES
TRANSFER CORRECTION BLOCK
APPROXIMATELY 4 dB AT
ALL RANGES COMPONENT
50
EXAMPLE:
IF THE RESULTS ARE
PLOTTED ON LOG -
LINEAR PAPER THEY
WILL FORM
40
DECIBELS
STRAIGHT PARLLEL
LINES PROVIDED
THAT THERE IS NO
ATTENUATION
DIFFERENCE
30
IF AN ATTENUATION
DIFFERENCE
OCCURS THEN THE
RESULTANT LINES
20
WILL NO LONGER BE
10 100 1000 PARALLEL.
RANGE / mm
TRANSFER & ATTENUATION CORRECTION:
SHEAR WAVE PROBES
0
0
10
10
20
20
BWE
30
30
8 mm
6 mm
40
40
dB
dB
4 mm
50
50
3 mm
2 mm
60
60
1.5 mm
70
70
80
80
0 50 100 150 200
Range / mm
DGS
THE BASIC PRINCIPLE OF DGS IS THAT BY
COMPARING THE ECHO HEIGHT FROM A FLAW WITH
THE ECHO HEIGHT FROM A KNOWN REFLECTOR
(USUALLY A BACKWALL ECHO) AT THE SAME RANGE
THE FLAW CAN BE CATEGORISED AS BEING
EQUIVALENT TO A FLAT BOTTOMED HOLE REFLECTOR
OF A GIVEN SIZE AT THE SAME RANGE.
ALTHOUGH, WHEN USING DGS, IT IS USUAL TO TALK
ABOUT A FLAW AS BEING AN “X” mm FLAT
BOTTOMED HOLE EQUIVALENT THIS IS NOT A DIRECT
MEASURE OF THE SIZE OF THE FLAW.
EQUIPMENT CHECKS
TIMEBASE LINEARITY
2.0 4.0 6.0 8.0 10.0 2.0 3.7 5.85 7.9 10.0
ACCEPTABLE NOT ACCEPTABLE
EQUIPMENT CHECKS
AMPLIFIER LINEARITY
+14 dB
NOISE
SIGNAL
1.5 s @
ho mm
2.5 tres
le
mm
cen
BS 2704 A5 BLOCK
BS 2704 A2 BLOCK
100, 85 & 91 mm Dimensions
EQUIPMENT CHECKS
RESOLUTION
DEAD ZONE
450
450 450 S
D
D
USING THE A5 BLOCK
(MORE ACCURATE METHOD)
EQUIPMENT CHECKS
BEAM ANGLE
700 600
450
450 450 S
D
D
USING THE A5 BLOCK (MORE ACCURATE METHOD)
NOTE: The probe exit point can be marked either
before or during this operation.
20 dB BEAM PROFILE
(VERTICAL PLANE)
X Y
FULLY
SYMMETRICAL
TWO LINES OF
SYMMETRY
Single Shear Twin Shear
SINGLE LINE
OF SYMMETRY
0
0
-4
-4
-8
-8
dB
dB
-12
-12
-16
-16
2 MHz 10 dia.
-20
-20
4 MHz 25 dia.
-24
-24
-2 -1 0 1 2 -2 -1 0 1 2
CRYSTAL DIAMETERS CRYSTAL DIAMETERS
DEFECT LOCATION
IN FUSION WELDS
450
R
S
S = STAND OFF DISTANCE FROM ANY CONVENIENT DATUM
POINT
40
450
450
BACK
40
GOUGE
COVERAGE
OF WELD
100 VOLUME
(approx.)
00 00
ULTRASONIC
EXAMINATION OF
WELDS COVERAGE
OF FUSION
FACES
450
450
450
450
COVERAGE
OF WELD
VOLUME
SCANNING FOR TRANSVERSE IMPERFECTIONS
0
45
SCANNING FOR TRANSVERSE IMPERFECTIONS
THESE DEFECTS CAN BE DIFFERENTIATED BETWEEN
BY OBSERVING THE ECHO DYNAMIC BEHAVIOUR IN
LENGTH AND DEPTH SCANS:
PLANAR
POINT THREADLIKE (NEAR NORMAL INCIDENCE)
DEPTH
SCAN
LENGTH
SCAN