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Part 4
DEFECT LOCATION
DEFECT LOCATION IN ULTRASONIC
TESTING IS BASED UPON THE PREMISE
THAT A MAXIMISED ECHO RESPONSE CAN
ONLY COME FROM A REFLECTOR WHICH IS
LYING ON THE BEAM AXIS.
THIS PREMISE CAN BE ASSUMED BECAUSE
THE GREATEST SOUND INTENSITY OR
PRESSURE IS CONCENTRATED IN A SMALL
VOLUME AROUND THE BEAM AXIS.
600
2.
3.
4.
5.
2.
3.
6 dB DROP
1.
2.
3.
Sizing Methods
6 dB Drop
For sizing large planar reflectors only
Signal / echo reduced to half the height
Example:
100% to 50%
80% to 40%
70% to 35%
20% to 10%
6 dB DROP
LENGTH
6 dB Drop
Defect
BWE
Plan View
6 dB Drop
Defect
Plan View
6 dB Drop
Defect
BWE
Equalization Technique
The equalization technique can ONLY be used
BWE
Defect
if the defect is halfway the thickness
20 dB DROP
1.
2.
3.
4.
20 dB DROP
LENGTH
20 dB Drop
20 dB Beam profile
Defect
BWE
10%
When the main beam is on the defect the defect signal is at it maximum
If the probe is moved and the signal is observed until it is reduced to
10% (20dB Drop), the edge of the beam is on the edge of the defect
Repeat the above at the other side of the defect
Using the pre-constructed Beam profile and a plotting card, the
defect maybe sized
MAXIMUM AMPLITUDE
1.
2.
4.
3.
MAXIMUM AMPLITUDE
1.
2.
Sizing Method
Maximum Amplitude Technique
For sizing multifaceted defect eg. crack
Not very accurate
Small probe movement
Maximum Amplitude
Maximum Amplitude
Maximum Amplitude
Remember: The peak which maximised does
not have to be the tallest or the first one
Length
MAXIMUM AMPLITUDE
MAXIMUM AMPLITUDE
LACK OF
FUSION
700
700
AMPLITUDE
TIP MAXIMA
PRIMARY OBJECTIVES:
1.
2.
3.
20
600
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
700
700
23
700
COVERED AT
FULL SKIP
COVERED AT
HALF SKIP
COVERED AT HALF
& FULL SKIP
700
80
23
600
23
600
600
COVERED AT
FULL SKIP
COVERED AT FULL
& HALF SKIP
COVERED AT
HALF SKIP
600
PR
OB
B
RO
O
PR
PR
SCAN
BE
OB
ORBITAL
ROTATIONAL
CRACK
ORBITAL
SCAN
ROTATIONAL
SCAN
SLAG
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
Ultrasonic Inspection
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
Parent material
Root inspection
Fusion face & HAZ inspection
Weld volume
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.
BACKWALL REFLECTIONS
2.
3.
4.
5.
SURFACE NOTCHES
6.
DAC
BS EN 583-2
The DAC reference block shall be either:
1) a general purpose block of uniform low
attenuation and specified surface finish, and
having a thickness within 10% of the test object;
Or
2) a block of the same acoustic properties,
surface finish, shape and curvature as the test
object.
TRANSFER LOSSES
AS ULTRASOUND PASSES FROM THE PROBE INTO THE
MATERIAL THERE IS ALWAYS A LOSS OF ENERGY.
THE AMOUNT OF ENERGY LOST FOR THE SAME
MATERIAL WILL BE LESS IF THE SURFACE IS
PERFECTLY SMOOTH AND FLAT AND MORE IF IT IS
NOT.
UT OF WELDS IS OFTEN CARRIED OUT FROM AS
ROLLED, CURVED OR CORRODED SURFACES.
IF THE SURFACE OF THE CALIBRATION BLOCK
DIFFERS FROM THAT OF THE COMPONENT THEN THE
DIFFERENCE IN TRANSFER EFFICIENCY HAS TO BE
COMPENSATED FOR.
ATTENUATION
AS ULTRASOUND PASSES THROUGH ANY MATERIAL
ENERGY WILL BE LOST DUE TO SCATTERING AND
ABSORPTION OF THE SOUND ENERGY. THIS LOSS OF
ENERGY IS TERMED ATTENUATION.
IN THE ULTRASONIC TESTING OF TYPICAL
ENGINEERING ALLOYS THE PRIMARY CAUSE OF
ATTENUATION IS SCATTERING.
WHEN THE GRAIN SIZE OF A MATERIAL EXCEEDS
HALF OF THE WAVELENGTH OF THE SOUND HIGH
ATTENUATION WILL ALWAYS BE EXPERIENCED.
ATTENUATION
THE GRAIN SIZE IN ANY GIVEN METAL
COMPONENT DEPENDS ON:
1.
2.
3.
HEAT TREATMENT
Transfer &
Attenuation
loss
METHODS OF COMPENSATING FOR TRANSFER AND
ATTENUATION LOSS DIFFERENCES FOR 00
COMPRESSION PROBES AND FOR SHEAR WAVE
PROBES. THESE ARE BASED ON OBTAINING SIMILAR
ECHO RESPONSES ON BOTH THE CALIBRATION
BLOCK AND ON THE COMPONENT.
24 dB
30 dB
36 dB
EXAMPLE:
ECHOES
OBTAINED ON
40 mm THICK
CALIBRATION
BLOCK
40 mm
80 mm
160 mm
26 dB
32 dB
38 dB
EXAMPLE:
ECHOES
OBTAINED ON
30 mm THICK
COMPONENT
30 mm
60 mm
120 mm
TRANSFER CORRECTION
APPROXIMATELY 4 dB AT
ALL RANGES
EXAMPLE:
30
40
20
DECIBELS
50
COMPONENT
10
100
RANGE / mm
1000
IF AN ATTENUATION
DIFFERENCE
OCCURS THEN THE
RESULTANT LINES
WILL NO LONGER BE
PARALLEL.
450
ONE SKIP
RECEIVE
450
TRANSMIT
RECEIVE
450
450
TWO SKIPS
SURFACE NOTCHES
PROVIDED TO ASSIST
WITH THE
INTERPRETATION OF
SURFACE BREAKING
INDICATIONS
100
150
200
0
30
40
50
60
60
2 mm
50
3 mm
1.5 mm
70
70
50
100
Range / mm
150
200
80
80
dB
4 mm
dB
40
6 mm
30
8 mm
20
20
10
10
BWE
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
ACCEPTABLE
8.0 10.0
2.0 3.7
5.85 7.9
NOT ACCEPTABLE
10.0
EQUIPMENT CHECKS
AMPLIFIER LINEARITY
INDICATION SET
AT (%FSH)
dB CONTROL
CHANGE (dB)
ACCEPTABLE
LIMITS FOR
RESULTANT ECHO
HEIGHT
(BS 3923)
ACCEPTABLE
LIMITS FOR
RESULTANT ECHO
HEIGHT
(ASME V)
80%
-6 dB
36-45%
32-48%
80%
-12 dB
18-22%
16-24%
80%
-24 dB
visible
N/A
40%
+6 dB
71-90%
64-96%
20%
+12 dB
71-90%
64-96%
(+/- 1 dB)
(+/- 2 dB)
EQUIPMENT CHECKS
SIGNAL TO NOISE RATIO
+14 dB
NOISE
SIGNAL
RESOLUTION
BS 2704 A7 BLOCK:
2, 3, 4 & (5) mm Steps
1.5 mm
holes @
4 mm
centres
mm
1.5 s @
le
ho mm
2.5 tres
cen
BS 2704 A5 BLOCK
BS 2704 A2 BLOCK
100, 85 & 91 mm Dimensions
EQUIPMENT CHECKS
RESOLUTION
EQUIPMENT CHECKS
DEAD ZONE
EQUIPMENT CHECKS
DEAD ZONE
EQUIPMENT CHECKS
EXIT POINT
450
EXIT POINT
450
S
D
450
EQUIPMENT CHECKS
BEAM ANGLE
700
600
350
450
600
450
QUICK CHECK: USE THE SCALES
PROVIDED ON THE A2 BLOCK.
BEAM ANGLE
450
S
D
450
20 dB BEAM PROFILE
(VERTICAL PLANE)
450
S
D
450450 450
20 dB BEAM PROFILE
(HORIZONTAL PLANE)
X Y
0 Single Compression
0 Twin Compression
FULLY
SYMMETRICAL
TWO LINES OF
SYMMETRY
Single Shear
Twin Shear
SINGLE LINE
OF SYMMETRY
0-6 dB
6-12 dB
12-20 dB
-16
-12
dB
-12
-2
-1
25 dia.
-24
4 MHz
10 dia.
-20
-16
-20
2 MHz
-24
dB
-8
-8
-4
-4
CRYSTAL DIAMETERS
-2
-1
CRYSTAL DIAMETERS
DEFECT LOCATION
IN FUSION WELDS
450
S
S = STAND OFF DISTANCE FROM ANY CONVENIENT DATUM
POINT
R=
ULTRASONIC
EXAMINATION OF
WELDS
40
450
BACK
GOUGE
40
450
ULTRASONIC
EXAMINATION OF
WELDS
COVERAGE
OF FUSION
FACES
COVERAGE
OF WELD
VOLUME
100
(approx.)
00
00
ULTRASONIC
EXAMINATION OF
WELDS
COVERAGE
OF FUSION
FACES
450
450
450
450
COVERAGE
OF WELD
VOLUME
45
THREADLIKE
PLANAR
(NEAR NORMAL INCIDENCE)
DEPTH
SCAN
LENGTH
SCAN