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Ultrasonic Testing

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Yaregal Solomon
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37 views22 pages

Ultrasonic Testing

Uploaded by

Yaregal Solomon
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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ULTRASONIC INPECTION

BASICS AND ITS


APPLICATION
Piezoelectric Transducers

The conversion of electrical pulses to mechanical vibrations and the


conversion of returned mechanical vibrations back into electrical energy is
the basis for ultrasonic testing. The active element is the heart of the
transducer as it converts the electrical energy to acoustic energy, and vice
versa. The active element is basically a piece of polarized material (i.e. some
parts of the molecule are positively charged, while other parts of the
molecule are negatively charged) with electrodes attached to two of its
opposite faces. When an electric field is applied across the material, the
polarized molecules will align themselves with the electric field, resulting in
induced dipoles within the molecular or crystal structure of the material. This
alignment of molecules will cause the material to change dimensions. This
phenomenon is known as electrostriction. In addition, a permanently-
polarized material such as quartz (SiO2) or barium titanate (BaTiO3) will
produce an electric field when the material changes dimensions as a result of
an imposed mechanical force. This phenomenon is known as the
piezoelectric effect.
Piezoelectric Effect

Sound wave
with
frequency f

U(f)
Short pulse
( < 1 µs )

An alternating voltage generates crystal oscillations at the frequency f


Spectrum of sound
Frequency range Hz Description Example

0 - 20 Infrasound Earth quake

20 - 20.000 Audible sound Speech, music

> 20.000 Ultrasound Bat, Quartz crystal


Basic Principles of Sound (cont.)
Ultrasonic waves are very similar to light waves in
that they can be reflected, refracted, and
focused.
Reflection and refraction occurs when sound
waves interact with interfaces of differing
acoustic properties.
In solid materials, the vibration energy can be
split into different wave modes when the wave
encounters an interface at an angle other than
90 degrees.
Ultrasonic reflections from the presence of
discontinuities or geometric features enables
detection and location.
The velocity of sound in a given material is
constant and can only be altered by a change in
the mode of energy.
Behaviour of sound at an interface

Medium 1 Medium 2

Incoming wave Transmitted wave

Reflected wave

Interface
High frequency sound waves are introduced into a material and
they are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can
visualize a cross section of the specimen showing the depth of
features that reflect sound.

initial
pulse

back surface
echo
crack
echo

crack
0 2 4 6 8 10 plate

Oscilloscope, or
flaw detector
RF signal (short)

100 ns
Block diagram: Ultrasonic Instrument
Test Techniques
Ultrasonic testing is a very versatile inspection method, and
inspections can be accomplished in a number of different ways.

Ultrasonic inspection techniques are commonly divided into


three primary classifications.
Pulse-echo and Through Transmission
(Relates to whether reflected or transmitted energy is used)
Normal Beam and Angle Beam
(Relates to the angle that the sound energy enters the test article)
Contact and Immersion
(Relates to the method of coupling the transducer to the test article)
Test Techniques - Pulse-Echo
• In pulse-echo testing, a transducer sends out a pulse of energy
and the same or a second transducer listens for reflected energy
(an echo).
• Reflections occur due to the presence of discontinuities and the
surfaces of the test article.
• The amount of reflected sound energy is displayed versus time,
f

which provides the inspector information about the size and the
location of features that reflect the sound.

initial
pulse
back surface
echo

crack
echo
crack
plate
0 2 4 6 8 10
UT Instrument Screen
Test Techniques – Through-Transmission

1
• Two transducers located on opposing 1
sides of the test specimen are used. One T R
transducer acts as a transmitter, the
other as a receiver.
• Discontinuities in the sound path will
result in a partial or total loss of sound
R
being transmitted and be indicated by a T

decrease in the received signal


amplitude. 2

• Through transmission is useful in


detecting discontinuities that are not
good reflectors, and when signal
strength is weak. It does not provide 11
depth information.

0 2 4 6 8 10
Test Techniques – Normal and Angle Beam
• In normal beam testing, the sound beam is
introduced into the test article at 90 degree to
the surface.
• In angle beam testing, the sound beam is
introduced into the test article at some angle
other than 90.
• The choice between normal and angle beam
inspection usually depends on two
considerations:
- The orientation of the feature of
interest – the sound should be
directed to produce the largest
reflection from the feature.
- Obstructions on the surface of the
part that must be worked around.
Weld inspection

a = s sinß
F
a' = a - x ß = probe angle

s s = sound path
a = surface distance
d' = s cosß a‘ = reduced surface distance
d‘ = virtual depth
0 20 40 60 80 100 d = actual depth
d = 2T - t' T = material thickness

a
x a'

ß d
Lack of fusion
Work piece with welding s
Test Techniques – Contact Vs Immersion
• To get useful levels of sound energy into a material, the air
between the transducer and the test article must be removed.
This is referred to as coupling.
• In contact testing (shown on the previous slides) a couplant
such as water, oil or a gel is applied between the transducer
and the part.
• In immersion testing, the part and the transducer are place in a
water bath. This arrangement allows better movement of the
transducer while maintaining consistent coupling.
• With immersion testing, an echo from the front surface of the
part is seen in the signal but otherwise signal interpretation is
the same for the two techniques.
1 2
IP 1 IP 2 IP = Initial Pulse
FWE FWE FWE = Front Wall
Echo
BWE BWE DE = Defect Echo
DE BWE = Back Wall
Echo

Defect 0 2 4 6 8 10 0 2 4 6 8 10
Common Application of UT

Inspection of Raw Products

Inspection Following Secondary


Processing

In-Services Damage Inspection


Inspection of Raw Products
Forgings,
Castings,
Extrusions,
etc.
Inspection Following Inspection For
Secondary Processing In-Service Damage
Machining Cracking
Welding
Corrosion
Grinding
Heat treating Erosion/Wear
Plating Heat Damage
etc. etc.
Inspection Applications

Some of the applications for which ultrasonic testing may be


employed include:
• Flaw detection (cracks, inclusions, porosity, etc.)
• Erosion & corrosion thickness gauging
• Assessment of bond integrity in adhesively joined and brazed
components
• Estimation of void content in composites and plastics
• Measurement of case hardening depth in steels
• Estimation of grain size in metals

On the following slides are examples of some common applications


of ultrasonic inspection.
Flaw Detection in Welds
• One of the most widely used
methods of inspecting
weldments is ultrasonic
inspection.
• Full penetration groove
welds lend themselves
readily to angle beam shear
wave examination.
Power Plant Inspection
Storage Tank Inspection
Pressure Vessel Inspection
Aircraft Inspection
Jet Engine Inspection
Rail Inspection
Bridge Inspection
Pipeline Inspection
Advantage of Ultrasonic Testing

• Sensitive to both surface and subsurface discontinuities.


• Depth of penetration for flaw detection or measurement is
superior to other methods.
• Only single-sided access is needed when pulse-echo technique is
used.
• High accuracy in determining reflector position and estimating
size and shape.
• Minimal part preparation required.
• Electronic equipment provides instantaneous results.
• Detailed images can be produced with automated systems.
• Has other uses such as thickness measurements, in addition to
flaw detection.
Limitations of Ultrasonic Testing
• Surface must be accessible to transmit ultrasound.
• Skill and training is more extensive than with some other methods.
• Normally requires a coupling medium to promote transfer of sound
energy into test specimen.
• Materials that are rough, irregular in shape, very small,
exceptionally thin or not homogeneous are difficult to inspect.
• Cast iron and other coarse grained materials are difficult to inspect
due to low sound transmission and high signal noise.
• Linear defects oriented parallel to the sound beam may go
undetected.
• Reference standards are required for both equipment calibration,
and characterization of flaws.

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