Documente Academic
Documente Profesional
Documente Cultură
93/
Commission of the European Communities
Final Report
September 1989
EUR 12431 EN
Final Report
Authors:
R.A. Murgatroyd, P.J. Highmore, T. Bann
UKAEA, RNL, Risley - United Kingdom, Atomic Energy Authority
Risley Power Development Laboratory, Risley, Warrington, Cheshire, WA3 6AT
S.F. Burch, A.T. Ramsey
UKAEA, AERE, Harwell - United Kingdom Atomic Energy Authority
Atomic Energy Research Establishment, Harwell, Didcot, Oxfordshire, OX 11 ORA
September 1989
I CL
A EUR 12431 EN
Published by the
COMMISSION OF THE EUROPEAN COMMUNITIES
Directorate-General
Telecommunications, Information Industries and Innovation
Batiment Jean Monnet
LUXEMBOURG
LEGAL NOTICE
Neither the Commission of the European Communities nor any person
acting on behalf of the Commission is responsible for the use which might
be made of the following information.
CONTENTS
PAGE
1.
INTRODUCTION
2.
3
3
3.
6.
10
7.
8.
11
10. REFERENCES
12
11. ACKNOWLEDGEMENT
12
TABLES
13
FIGURES
19
1. INTRODUCTION
Studies on the effect of flaw characteristics and selected inspection parameters on the
detection and sizing of flaws in ferritic steel blocks have been performed by the
United Kingdom Atomic Energy Authority (UKAEA) as part of a larger Commission
of the European Communities (CEC) Parametric Study programme. The techniques included in the UKAEA studies were the 45 tandem and the time-of-flight diffraction
(TOFD) techniques.
The purpose of the work was to acquire reliable experimental data that could be used
both to test and verify theoretical models and to contribute to the resolution of
anomalies encountered in PISC round-robin inspection exercises. To this end, the data
were gathered in a format compatible with that of the theoretical predictions and
scanning parameters were employed that would test the theoretical models over a range
of inspection conditions.
For the studies, eighteen test blocks were fabricated by Ispra in which a range of flaw
types were inserted covering flaw shape, size, roughness and orientation. Thirteen of
these were selected for the UKAEA programme on the basis of their relevance to the
validation of theoretical models and their value to flaw characterisation studies.
The work involved in the programme was shared between Risley Nuclear Laboratories
(RNL) and AERE Harwell, with the teams inspecting to similar procedures. The first
series of test blocks and probes for use with the tandem technique was received in June
1986 and commissioning of scanning and data gathering equipment commenced. This
part of the programme was completed early in 1987. Two test plates suitable for use
with the TOFD technique were received in May 1987 and the experimental scanning
received high priority in the UKAEA to enable the plates to be despatched to
Association Vincotte at the end of May 1987, in accord with the overall programme.
This final report describes the programme, data gathering procedures and the results of
the studies.
The equipment used for recording the ultrasonic data digitally was similar to that
described by Carter and Slesenger [a]. The ultrasonic electronics were standard Harwell
units mounted in a CAMAC crate. A LeCroy (type 2256) 20 MHz waveform digitiser
was used to digitise the unrectified (RF) ultrasonic signals. For each waveform, 1024
successive samples were stored to an accuracy of 8 bits, giving digital data for a continuous period of 51.2 us. The initial time delay on the first digitised sample was adjusted to 165 us, so that the signals of interest were centred in the digitised section of
the waveforms.
The operation of these units was controlled by an LSI 11/23 computer, which was also
used to average 64 independent waveforms from each scan position, thus reducing
random electrical and acoustic noise. After completion of each linear scan the digitised
RF waveform data were stored on computer disc in a single file, known as a B-scan.
The B-scan files recorded on the LSI 11/23 data collection computer were transferred
to a VAX 11/750 minicomputer linked to International Imaging Systems display devices
for subsequent processing and analysis.
To facilitate comparison with theoretical predictions, the variation of peak signal
amplitude with transducer position was derived from the B-scan data using the following method. The pulse envelopes of the digitised RF waveforms were first computed
using the analytic signal method [s], using fast Fourier transforms to calculate the
necessary Hilbert transforms. This enabled the peak signal amplitude to be derived accurately for each transducer position, thus avoiding any under-estimates caused by the
20 MHz digitization.
The peak signal strengths from the calibration scans were then derived. The maximum
difference between the calibration signal strengths obtained before and after the defect
scans was only 0.1 dB. The averages of the very similar calibration signal strengths
were then used to express the defect signal amplitudes in dB relative to the peak signal
from the standard 6 mm diameter calibration reflector.
4.2
The amplitudes obtained for 0 skew and tilt scans on the re-entrant 25 mm flatbottomed hole (block 2-0-9) and the 25 mm shrink-fit (block 40-8) defect agree
to better than 0.1 dB (Table 3). Differences exist in the data obtained for these
reflectors for other tilt and skew conditions but the trends observed are similar.
This is illustrated in Figures 16 and 17 for 0 and 15 skew angles respectively.
5.2
Skew has a pronounced effect on signal amplitude. The results for the re-entrant
FBH in Block 2-0-9, Figure 18, shows in excess of a 40 dB decrease in peak
signal amplitude on the flaw centreline as the skew angle increases from 0 to
15. A similar decrease occurs for the strip flaws. This is due to the loss of much
of the specular reflection as the beam skews with respect to the flaw. As the
tandem system scans parallel to the flaw in the skewed orientation, peaks appear
at the position of the flaw edges which are in excess of 30 dB below the
maximum centreline value. The peaks at the flaw edge are attributed to edge
diffracted waves. It is conceivable that this phenomenon could lead to incorrect
flaw characterisation and sizing with amplitude-based techniques.
5.3
Amplitude peaks are not observed for the strip flaws since transverse scanning
was not included in the studies. However, it is anticipated that the behaviour
would be similar at the edge of the flaws.
5.4
The studies on the strip-flaws (Table 4) included flaws with either rough or
smooth crack faces, and a significant difference in behaviour occurred between
the two types (Figure 19). The peak amplitude for the smooth flaws decreased by
over 40 dB along the flaw centreline as skew increased from 0 to 15. Flaw tilt
further decreased the signal. A combination of 15 skew and 15 tilt resulted in a
55 dB decrease in amplitude for scans along the flaw centreline.
5.5
"Rough" flaws, as defined in the sample studied, are less affected by skew than
are smooth flaws.
5.6
A noteworthy feature of the results is that the signal amplitude from "rough"
flaws exceeds that from smooth flaws for skew angles above 5 to 10, for the
conditions studied.
5.7
The effect of tilt along the centreline of the flaw is less pronounced than that of
skew for the strip flaws (Figure 20) and decreases with increasing flaw skew.
5.8
The results for the 25 x 125 mm smooth strip flaws (Figure 21) show similar
trends for tilt and skew to those of the smaller strip flaws.
10
The scans performed on the lower defect (Figures 31a and b) show a signal at a depth
of 139 mm which is assumed to be from the upper edge of the composite defect (see
Table 8). Very weak signals appear at depths of 162 and 170 mm. A signal appears at a
depth of 180 mm on the skewed scans and corresponds to the bottom of a 41 mm high
defect whose top is at 139 mm. This presumably does not appear on the scan performed at zero skew due to shadowing by the lowermost "10 mm" disc.
Also on the two deeper sets of scans appear the mode-converted shear waves from the
bottom of the upper defect.
The TOFD results for Block 20-20 were fully consistent with both the upper and lower
multiple defects being 40 mm diameter discs saparated from (by 10 mm in the xdirection) and shadowing 10mm discs.
Regarding the upper or near-surface defect, the "40 mm" and uppermost "10 mm" discs
were detected and sized as 39.7 mm and 10.2 mm respectively. The "40 mm" disc was
located at a mean depth of 33.3 mm and the "10 mm" disc was found to have a mean
depth of 20.4 mm. The depth measurement of the bottom of the "10 mm" disc was
achieved by studying the mode-converted signals, as the direct diffracted compression
signal was shadowed by the "40 mm" disc. No obvious signals were observed from the
other two "10 mm" discs in this composite defect. The lower defect was seen to contain
a 41 mm high vertical feature at a mean depth of 160.5 mm, but no unambiguous
signals were observed from the smaller defects in this cluster.
We would suggest that for a full evaluation of this defect, scans using pulse-echo and
tandem techniques in conjunction with TOFD be employed.
The TOFD technique detected and located accurately the top and bottom of the
flaws accessible to the technique. Agreement with block fabrication data was
better than 2 mm.
9.2
Performance was limited by two inspection conditions. The first was where some
of the smaller flaws were obscured by larger ones, as seen in Block 20-20. This
would not necessarily occur with other techniques using single probes, such as
conventional pulse-echo. This indicates that whilst TOFD is a valuable sizing
technique, other diverse techniques should be included in an inspection for
reliable flaw characterisation. The second arose when defect edges lay close to a
surface making discrimination from the lateral wave difficult with standard
TOFD techniques. Further study on this aspect is planned by the UKAEA.
11
9.3
The limited data obtained at a skew angle of 15 indicates the relative insensitivity of the TOFD technique to flaw skew. In view of this it is considered that
further studies should be performed on the Ispra test blocks over a wider range
of skew and on other flaw types.
10. REFERENCES
[l]
Special Meeting of Parametric Studies Effect of the Defect Characteristics. Association Vincotte, February '86. 173/40-97/86/SC/rm.
[2]
[3]
11. ACKNOWLEDGEMENT
The valuable assistance of A.J. Plevin and N. Bealing in the experimental measurements
is acknowledged.
12
FLAW PARAMETERS
TEST BLOCK
IDENTITY
SIZE
(mil)
DEPTH
(mm)
2-0-9
40-8
is 25
0 25
82.5
82.5
FBH, Re-entrant
FBH, shrink-fit
20-14
20-16
20-18
25 x 125
25 x 125
25 x 125
82.5
82.5
82.5
Strip, DW
Strip, DW
Strip, DW
20-2
20-4
20-6
20-8
20-10
20-12
10
10
10
10
10
10
55
55
55
55
55
55
Strip,
Strip,
Strip,
Strip,
Strip,
Strip,
x
x
x
x
x
x
50
50
50
50
50
50
TILT
TYPE
DW
DW
DW
DW
DW
DW
SURFACE
SKEW
RASTER
0, 5, 10, 15"
0, 5, 10, 15
Circular flaws
0
7
10
0, 15
o, 15
0, 15
Centre
Centre
Centre
0*
0
7
7
15
15
0, 15"
0, is0
0. is
0, is-
Centre
Centre
Centre
Centre
Centre
Centre
o. is"
0, 15
TEST BLOCK
IDENTITY
20-20
20-24
COMMENTS
FLAW PARAMETERS
SIZE
(mm)
DEPTH
(imO
TYPE
TILT
SURFACE
3 - 18
25
37.5
15.5
Composite, DW
Composite, DW
0
0
S
R,S
COMMENTS
Composite flaw
Near surface, sharp-edged flaw
TABLE 3 -
Results of TANDEM inspection of Test Blocks EDC 2-0-9 and 40-8: peak flaw signal amplitude
relative to 6 mm diameter FBH reference reflector.
Flaws: 26 mm dia, 82.5 mm deep (Table 1).
SKEW ANGLE
(De,jrees)
0
0
0
14
Y+AXIS OFFSET
(mm)
EDC-40-8
0
+ 12
+ 24
21
12
- 11
21
14
- 13
0
+ 12
+ 24
0
-
2
8
7
- 12
- 24
- 17
3
5
- 13
- 15
- 11
- 13
- 12
+
+
+
+
+
+
+
+
+
+
10
10
10
10
10
+
+
-
+
+
+
+
+
15
15
15
0
+ 12
+ 24
- 11
- 22
- 28
- 15
- 22
16
15
- 12
- 24
- 12
- 27
- 18
- 3
5
5
6
5
0
12
24
12
24
3
5
2
- 14
- 7
- 21
- 21
- 28
TABLE 4 - Results of TANDEM inspection of strip flaws: peak flaw signal amplitude relative to 6 mm FBH
reference reflector.
TEST BLOCK
IDENTITY
FLAW PARAMETERS
SIZE
(mm)
DEPTH
TYPE
(mm)
TILT
(deg.)
SCAN
MAX AMP
SURFACE
SKEW
(deg.)
(dB)
20-2
20-2
10x50
55
Strip, DW
0
16
+ 2.7
- 22.7
20-4
20-4
10x60
65
Strip, DW
0
15
+ 1S.S
- 29.1
20-6
20-6
10x50
55
Strip, DW
0
15
+ 0.6
- 36.5
20-8
20-8
10x50
65
Strip, DW
0
15
- 7.6
- 15.8
20-10
20-10
10x50
55
Strip, DW
15
0
15
- 41.0
20-12
20-12
10x50
55
Strip, DW
15
0
16
13.6
- 23.6
20-14
20-14
25 x 125
82.6
Strip, DW
0
15
- 18.0
- 27.0
20-16
20-16
25 x 125
82.5
Strip, DW
0
16
- 4.0
- 37.0
20-18
20-18
25 x 125
82.5
Strip, DW
10
0
15
- CO
- 34.0
8.2
FLAW
FLAW TIP
AS DEEPLY-BURIED FLAW
TOP
Not resolved
165.0
BOTTOM
30.0 + 1.0
Not resolved
TOP
Not resolved
166.6 + 1.5
BOTTOM
28.0 + 0.5
Not resolved
15
x/mm
COMMENT
INFERRED DEPTH
(mm)
SIGNAL No.
ARRIVAL TIME
(psec)
1.10
c/c from C
13.4
1.40
- 10
c/c from A
15.3
1.85
4.50
- 3 to 5
c reflected off 40 mm
defect on to B, c to R
5.90
- 14
c to C, s to A, c to R
6.35
c to B, diffracted to 40 mm
defect, reflected to 10 mm,
c to R (all compression)
10
7.65
13
8.05
- 22
8.70
- 27
c to B, c t 40 mm defect,
e to A, diffracted shear
wave to R
9.35
- 12
c to B, s to 40 mm defect,
reflection to 10 mm defect,
mode conversion to c to R
c to B, s to 40 mm defect,
c to 10 mm defect, c to R
c
s
= compression wave
= shear wave
A
B
C
16
25.5
SIGNAL No.
ARRIVAL TIME
x/mm
COMMENT
( V"<0
INFERRED DEPTH
(mm)
63.1
59
62.8
16.40
82
53.0
16.3
(cross-over point
11
4.65
- 12
7.56
11-32
9.10
11-34
12.10
16-30
13.76
13-26
15.35
8
9
10
18.8
86
11
18.1
111
= compression wave
= shear wave
,1
<J,
SIGNAL No.
ARRIVAL TIME
(usee)
x/mm
COMMENT
2.8
- 14 to 29
7.4
46 to 74
15.9
- 13 to + 7
INFERRED DEPTH
(mm)
65.6
138.7
40 mm defect
4
14.6
144
52.8
40 mm defect
c
s
18
14.6
18.1
17.7
22.7
9
10
= compression wave
= shear wave
147
62.8
170
174
13
170
20.9
162
25.2
10
180
L
W
T
D
X
Figure 1 -
REF-2
2-0-9
40-8
459.5
2C0
193.5
82.5
50
449.5
299
192.5
82.5
30
600
299.5
194
82.5
30
3J'
PLUG
END-FACE
REFLECTOR
Figure 2 -
18
>
Of ENTRANT HOLE
RE
19
PLAN VIEW
centreline
scan only
-X-*
Figure 3 -
PLAN VIEW
Figure 4 -
20
and
YrOmm
>
<
_i
UJ
a.
100.0
Figure 5 -
110.0
120.0
130.0
Y-0mm
40.0
50.0
60.0
70.0
80.0
90.0
100.0
110.0
120.0
130 0
X Imml
Figure 6 -
10
PISC - E D C - 2 0 - 2
81-1192-EDC-20-2
10 SO
WEIGHT ~ 350 Kg
ALL DIMENSIONS IN MM
C=M
at
at
CD
CM
195,5
757,3
MATERIAL
CLADDING
NONE
22
20
95,
-28.0
14.0
fdB)
(dB)
(dB)
-30.0
12.0
10.0
4.0
2.0
-20.0
-34.0
-36.0
8.0
6.0
/\
-32.0
2o.o r
-2.0
-38.0
/'
-40.0
,1
60.0
-42.0
-44.0
(mm)
100.0
1
140.0
A
A
,1mm)
-20.0
10.0
12.0
14.0
(mm)
60.0
20.0
100.0
16.0
140.0
18.0
Figure 10 -
Figure 9 -
340
-8.0
-40.0
(dB)
36.0
(dB)
-10.0
38.0
140.0
6.0
-46.0
. -.
100.0
2D
-20.0
20.0
4.0
/V
8.0
Figure 8I
(dB)
2.0
40.0
-14.0
42.0
-16.0
44.0
-18.0
46.0
-20.0
41.0
-22.0
50.0
-24.0
-42.0
-12.0
/
/
-46.0
\
\
-48.0
-50.0
n
Jr
A^
-44.0
-52.0
52.0 f-
-20.0
-26.0
1
20.0
60.0
100.0
(mm)
140.0
Figure 11
ynamic plot Block 6, Smooth, 7* tilt. 15* skew.
M
GO
-20.0
-54.0
1
20.0
_i
. _
60.0
i
100.0
( mm
140.0
Figure 12 Echo-dynamic plot Block 10, Smooth, 15* tilt, 0' skew.
-20.0
20.0
J _
60.0
100.0
(mm)
140.0
-21
-+
-12
12
Y-OFFSET
( mm )
24
i
X E0C 2 - 0 - 9
E0C 4 0 - 8
-10-
400
60.0
PEAK SIGNAL
-to-- AMPLITUDE
(dB)
Figure 14
Smooth defects 0 deg. skew; Echodynamic when scanning parallel to the
defect.
Figure 16 Comparison of Blocks EDC 2-0-9 and 40-8 for 0* skew, 0* tilt.
PEAK SIGNAL
AMPLITUDE
dB)
10.0,
-60.0
EDC
EDC
2-0-9
40-8
60 0
Y-OFFSET
( mm )
-5-10-
Figure IS
Rough defects 0 deg. skew; Echodynamic when scanning parallel to the
defect.
-15--
Figure 17 Comparison of Blocks EDC 2-0-9 and 40-8 for 15 skew, 0 tilt.
AMPLITUDE
IdB)
0*
TILT
Figure 20 - Variation in peak signal amplitude with tilt for 10 x 50 mm strip flaws .
PEAK
AMPLITUDE
(dB )
SH00TH
ROUGH
AMPLITUDE
IdB)
HAW
FLAW
to
SKEW
ANGLE
10
" ^v^
ROUGH , 7 * TILT
ROUGH , TILT
ROUGH , 1 S * TILT
-11 -
TILT
ANGLE
SKE
SHOOTH , 0 * TILT
-10
SMOOTH . V TILT
SMOOTH , 15* TILT
"**.
-JO
oi
Figure 19 - Variation in peak s ignal amplitude with skew for 10 x 50 mm strip flaws .
,Jt
I S ' SKEW
Figure 21 - Variation of amplitude from 25 x 125 mm s mooth s trip flaw with tilt and
skew.
81-1192-EDC-20-20
WEIGHT ~
350Kg
20 -95
ALL DIMENSIONS IN MM
- co v
en
35
35
195,9
756,6
MATERIAL
CLADDING
NONE
Figure 22 -
26
10
SCAN TYPE
Rx PROBE
FLAW
Tx PROBE
1*
0SKEW
XY SCAN
TOP VIEW
SCAN DIRECTION
0SKEW
YX SCAN
TOP VIEW
15SKEW
XY SCAN
TOP VIEW
15SKEW
YX SCAN
TOP VIEW
BEAM PATHS
SIDE VIEW
Figure 23 -
00
TRANSVERSE
Y=0
TRANSVERSE
.
LONGITUDINALS I
in f
10mm
DEFECT
---J-o
_e
LONGITUDINAL
40 mm
DEFECT
710mm
x=o
Figure 24 -
[ e = ANGLE OF SKEW]
(a) XY SCAN
XY SCAN!
(b)'YX'SCAN
F 170
a.
a
-60 -40-20
20 40 60
X"POSITION (MM)
-40-20
20 40
Y POSITION (MM)
Figure 25
-150
-110
"
-70
-30
30
70
X "POSITION'(MM)'
Figure 26
no
lso
CO
=n 170
a.
UJ
a
UJ
-60 -40-20
20 40 60
X~P0SITi0N~(MM)
Figure 27 -
-150 -110
-70
-3D
30
70
110
X~ POSITION" (MM)
150
Figure 28a -
Figure 28b -
31
<,
t = 1.A0M S
@^K
zS>
<h
t = 4.50 Ms
t = 1.85 MS
<?
< ^
zg>
Z>
<,
t = 9.3Ms
KEY
COMPRESSION WAVE
SHEAR WAVE
Figure 29 32
to
Figure 30 -
Figure 31a -
Figure 30b -
Figure 31b -
Studies on the effect of flaw characteristics and selected inspection parameters on the
detection and sizing of flaws in ferritic steel blocks have been performed by the United
Kingdom Atomic Energy Authority (UKAEA) as part of a larger Commission of the European Communities (CEC) Parametric Study programme. The techniques included in the
UKAEA studies were the 45 tandem and the time-of-flight diffraction (TOFD) techniques.
The purpose of the work was to acquire reliable experimental data that could be used
both to test and verify theoretical models and to contribute to the resolution of anomalies encountered in PISC round-robin inspection exercises. To this end, the data were
gathered in a format compatible with that of the theoretical predictions and scanning
parameters were employed that would test the theoretical models over a range of inspection conditions.
For the studies, eighteen test blocks were fabricated by Ispra in which a range of flaw
types were inserted covering flaw shape, size, roughness and orientation. Thirteen of
these were selected for the UKAEA programme on the basis of their relevance to the
validation of theoretical models and their value to flaw characterisation studies.
The work involved in the programme was shared between Risley Nuclear Laboratories
(RNL) and AERE Harwell, with the teams inspecting two similar procedures. The first
series of test blocks and probes for use with the tandem technique was received in
June 1986 and commissioning of scanning and data gathering equipment commenced.
This part of the programme was completed early in 1987. Two test plates suitable for
use with the TOFD technique were received in May 1987 and the experimental scanning received high priority in the UKAEA to enable the plates to be despatched to Association Vingotte at the end of May 1987, in accord with the overall programme.
This final report describes the programme, data gathering procedures and the results
of the studies.
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