BRITISH STANDARD BS 4124 : 1991 Methods for Ultrasonic detection of imperfections in steel forgings ah BENEBS 4124: 1991 ‘This British Standard, having been prepared under the direction of the Iron and Stee! Standards Policy Committee, \was published under the authority of the Board of BSI find comes into effect on 28 February 1001 ©BSI 1991 First published as BS $124 Part 1, February 10967 Second edition as BS 4124, Sune 1987 Third edition February 1991 ‘The following BSI references relate to the work on this standard Commitee reference ISM/73 Draft for comment 8942487 DX ISBN 0 580 191877 Committees responsible for this British Standard ‘The preparation of this British Standard was entrusted by the Iron and Stee! Standards Policy Committee (ISM/-) to Technical Committee ISM/73, upon which the following bodies were represented: Associated Offices Technical Committee BEAMA Ltd. British Compressed Air Society British Forging Industry Association British Gas ple British Shipbuilders British Steel Industry Electricity Supply Industry in England and Wales Engineering Equipment and Materials Users Association High Pressure Pipework Consultative Committee Process Plant Association Seamless Steel Tube Association Welding Institute Coopted experts ‘The following body was also represented in the drafting of this standard, through subcommittees and panels: British Valve Manufacturers Association Ltd. Amendments issued since publication ‘Amd. No. Date ‘Text affectedBS 4124 : 1991 a Contents Page Committees responsible Inside front cover Foreword 2 ‘Methods — 0 Introduction 3 1 Scope 3 2 Definitions 3 3 Principle 3 4 Equipment 4 5 Surface condition 4 6 Requirements for testing 5 7 Procedures for the assessment of imperfections 8 8 Test report 9 Appendices eee A Flaw recording levels and defect acceptance criteria 10 B__ Information to be provided by the purchaser and details for agreement between contracting parties 10 € Technique or procedure sheet 10 D__ Probe frequency iL E__ Preparation and use of reference blocks and reference reflectors i F Compensation for material attenuation, curvature and surface finish 12 G __ Notes for guidance on the DGS diagram 13, Tbe 1 Gain compensation for difference in material attenuation between a reference block and the component under test ea Figures 1 Curvature corrections 13 2 Universal DGS diagram for normal (0°) probes 4 3 Typical DGS diagram for shear wave probe of 2 MHz, 20:mm x 22 mm erystal size Ww 4 Typical DGS diagram forshear wave probe of4 Mil 8mm 8mm 5 Measurement of shear wave attenuation 20 6 _ Measurement of shear wave transfer loss 20BS 4124: 1991 Foreword This new edition of this British Standard has been prepared under the direction of the Iron and Steel Standards Policy Committee. It replaces BS 4124 : 1987 which is withdrawn. This edition introduces technical changes to bring the standard up to date but does not reflect a full review of the standard, which will be undertaken in due course. Notes for guidance on the distance gain size (DGS) diagram have been included in this edition in a new appendix G, Reference to the withdrawn BS 3923 ; Part 3 has been deleted, Since 1967, when BS 4124 : Part 1 was first published, ultrasonic testing techniques have undergone considerable development. The use of assessment methods by which flaw detections are related to artificial defects in test blocks (e.g. flat-bottomed holes, horizontal holes and notches), for comparison and evaluation purposes, has seen widespread acceptance. In addition, the distance gain size (DGS) diagram technique of expressing flaw indications in terms of dise reflectors has found many applications and this technique therefore is included in this standard, The possibility also of introducing acceptance levels in this revision was carefully considered, but it was decided that, because of the large number of variable factors, e.g. size of component, application, desired standard of integrity, stress levels and fracture toughness properties of many types of steels used, it was not feasible to produce acceptance levels that would meet the requirements of all parties, Consequently, it will be necessary for acceptance levels to be agreed between the parties concerned when they are not specified in the appropriate product standards. An objective in this standard has been to enable its users to draw up appropriate procedures to cover their own specific requirements. Attention is drawn to the last paragraph of clause 1, from which it will be evident that it is necessary that, when reference to this standard is made in an enquiry or order, requirements. governing the procedures to be adopted and acceptance levels to be met are clarified between the contracting parties, It is important to recognize that non-destructive testing methods are generally complementary to one another and therefore should be considered collectively in relationship to testing as a whole, so that the most suitable methods are employed and the extent of the inspection is compatible with the ultimate application of the product. Compliance with a British Standard does not of itself confer immunity from legal obligations.BS 4124 : 1991 ee Methods 0 Introduction Ultrasonic testing involves the reflection of a high frequency beam of sound by internal imperfections in a piece of material and is complementary to ‘magnetic particle and dye penetrant testing. It is capable of examining much greater thicknesses of ‘material than is possible with X-ray and gamma ray techniques and is generally a much more sensitive and versatile method The ultrasonic testing technique selected in any particular circumstance is governed by the degree of confidence required that all significant imperfections in specific parts of the material under test can be detected. No ultrasonic test can give a completely unequivocal answer. Experience and the degree of confidence sought determine how detailed an examination is required and these factors will normally be taken into account in a technique sheet detailing the types of probe(s), scanning coverage, ete. to be used. This standard is predominantly intended for the ‘examination of machined forgings after completion of the final heat treatment. The inspection techniques are governed by the geometry of the forging under test. If the ultrasonic coverage is restricted by the geometry of the component in its final heat treated and/or finish machined condition, then the principal test is eonducted at an intermediate stage of machining or production when the component presents a simple geometric form. NOTE 1. It may only be possible to obtain a limited test result on forgings examined at invermesiate stages of heat treatment ‘where structural refinement has not occurred. NOTE 2. There i a possblty of the introduction of defects during subsequent eat treatment. NOTE 3. Knowledge of the method of manufacture of the ‘component assists in the correct interpretation ofthe rests of ‘the examination NOTE 4, Special consideration should be ven to zones affected by changes of setion and radi. ‘The minimum extent of scanning coverage is described in 6.6; the precise degree of testing may be agreed between the parties concerned depending upon, for example, whether the test is a final examination of an important component, whether it is desired to detect extremely small imperfections, or whether the test is designed to indicate if a component is suitable for further processing having been shown to be free from significant imperfections in certain areas. 1 Scope This British Standard describes four methods for the ultrasonic testing of ferritic and austenitic steel forgings using A-scope pulse echo ultrasonic equipment, under surface contact and manual operation conditions, for the detection of imperfections. It gives descriptions of equipment and its use including methods of setting the test sensitivity and of assessing the size of imperfections. Although the techniques described are applicable to both ferritic and austenitic materials, the test may be limited on austenitic steels since they may possess a coarse grain size that cannot be refined by heat treatment (see note 1 in appendix D). It is important for users of this British Standard to recognize that all the requirements to be met for compliance are specified in the main body of the standard and that, in certain instances, these are minimum requirements only. Several additional aspects, however, are referred to as the subject of agreement between the contracting parties or to definition by the purchaser. For these, it is essential that the purchaser establishes clearly at the outset, with the agreement of the supplier, the precise nature and extent of his requirements, Information and guidance in these matters are given in appendices A, B and C, NOTE. The titles of the publications referred to inthis standard are listed on the inside back cover 2 Definitions For the purposes of this British Standard, the definitions given in BS 3683 : Part 4 apply, together with the following. 2.1 imperfections Discontinuities that cause ultrasonic indications. 2.2 flaws Imperfections ‘detected’ at the testing sensitivity that, when evaluated, meet the agreed acceptance criteria, 2.3 defects Imperfections ‘detected’ at the testing sensitivity that, when evaluated, do not meet the agreed acceptance criteria, 3 Principle 3.1 General An ultrasonic beam, transmitted through the forging from a surface contact probe, is reflected by internal imperfections. Detection of the reflection enables the depth, location and size of an imperfection to be established and thereby permits the imperfection to be assessed as either a flaw or a defect. ‘The four techniques for the detection and assessment of imperfections described in this, standard are listed in 8.2 to 3.5. 3.2 20 dB drop technique ‘The relatively sudden fall in the intensity of the acoustic energy near to the perimeter of the ultrasonic beam permits a beam profile to be plotted. From the profile, the ~20 dB contour, relative to the axial intensity of the beam, is known at any depth, By means of the ~20 dB contour, the edge of an imperfection can be related to the position of the probe on the surface of the forging,BS 4124: 1991 The 20 dB drop technique is suitable for the detection and assessment of imperfections in rectangular forgings. It may also be used to assess the longitudinal dimension of an imperfection in a cylindrical forging, but may assess the circumferential dimension of an imperfection incorrectly. ‘The 20 dB drop technique is an appropriate technique for assessing imperfections less than the probe crystal size and having a dimension, in the test direction of probe movement, greater than 5 mm. ‘The 20 dB drop technique has the advantage that results are independent of attenuation. 3.8 6 dB drop technique When half the ultrasonic beam strikes an imperfection and the other half passes it, the echo amplitude is reduced by 6 dB from the maximum echo amplitude obtainable. This fact enables the periphery of an imperfection to be established with respect to the beam axis at the depth of the imperfection, ‘The 6 dB drop technique is also suitable for the detection and assessment of imperfections in rectangular forgings and for assessing the longitudinal dimension of an imperfection in a cylindrical forging. However, like the 20 dB technique (see 3.2), it may assess incorrectly the circumferential dimension of an imperfection in a cylindrical forging. ‘The 6 AB drop technique is suitable for assessing the size of an imperfection that is near to, or larger than, the probe crystal dimension. ‘The 6 dB drop technique has the advantage that the results are independent of attenuation. 3.4 Distance amplitude technique using reference blocks The response from an imperfection is compared with that from known reflectors, at known depths ina test block, enabling the location and size of the imperfection to be assessed, ‘The distance amplitude technique is suitable for the detection and assessment of imperfections in forgings of most shapes and sizes, It is an appropriate technique for assessing imperfections smaller than the probe crystal diameter in forgings where the beam path length can be conveniently reproduced in reference blocks 3.5 Distance gain size (DGS) technique ‘The distance gain size (DGS) technique is similar in principle to the distance amplitude technique using, reference blocks (see 3.4) without the need for reference test blocks. A DGS diagram such as shown in figure 2 indicates, by means of a number of distance-amplitude curves for various ideal dise reflectors, the relationship of the intensity of the sound reflection from different diameter reflectors at varying distances to the back wall echo (see 7.5). The diagram is related to attenuation free material ‘The DGS technique is suitable for the assessment of imperfections in forgings of all shapes and sizes, It is suitable for assessing the size of an imperfection of dimensions up to that of the probe crystal, the size being described in terms of an equivalent ideal dise shaped reflector. 4 Equipment ‘The ultrasonic testing equipment shall be capable of working at test frequencies within the range 0.5 MHz to 6 MHz and shall feature an A-scope presentation. The trace shall be well defined and associated with permanent graticule scale markings for both depth range and echo amplitude. NOTE. The probe type and probe frequency are subject to lagreement between the contracting partes and should be stated ‘on the technique or procedure sheet (see appendix C, item (A), For guidance concerning probe frequency, see appendix D. 5 Surface condition 5.1 General The minimum requirements for the test surface condition shall be as specified in 8.2 and 5.3. NOTE. If the purchaser requires special surface finish, this shouldbe stated on the enquiry, order or drawing (see B.2(0) And on a technique oF procedure sheet (see B.24) and Appendix (a). 5.2 Unmachined forgings ‘The test surface of unmachined forgings shall be clean and free from loose scale, to ensure that acoustic coupling is maintained, NOTE 1. Ibis generally impracticable to carryout a comprehensive examination on unmachined forgnys. Therefore, ‘while unmachined forgings may be subjected to-a preliminary examination, its ustally necessary forthe final examination to bre earied out between machining stages, NOTE 2 It may be necessary forthe contracting parties to agree to shot blasting, or surface grinding to metalic nines of in agreed array of longitudinal citcumferential paths. 5.3 Machined for The surfaces of machined forgings to be scanned shall be machined to a surface finish of 6.3 yam Ry or better, as assessed by the method given in BS 1134: Part 1 NOTE 1. A surface finish having en appearance resembling that ‘of a gramophone reeor, i.e. with regula, sharp ridged srooves, ‘nay eause spurious indications NOTE 2. Surface tears should be avnided,BS 4124 : 1991 6 Requirements for testing 6.1 General ‘The inspection procedures shall be carried out in accordance with the details given in 6.2 to 6.7 and clause 7. NOTE. Its essential that personnel conducting ultrasonic testing be trained personnel who have proved their competence {0 perform the examination. If the purchaser requires that the ‘operator has an agreed, minim level of competence, this ‘should be stated (see B.2(a). 6.2 Coupling medium Interpose a coupling medium between the probe and forging to allow efficient transmission of ultrasound. The same medium shall be used for the calibration of the equipment and for the examination of forgings. NOTE. Suitable coupling media are ol, grease, glycerol and water cellulose paste 6.3 Procedures for checking and calibrating the equipment 6.3.1 General Check the equipment and calibrate it in accordance with the procedures given in 6.8.2 to 6.3.7. 6.3.2 Linearity of time base Check the linearity of the time base at least once weekly and formally record the results. The procedure for calibration and the deviation tolerances shall be as given in 5.1, 5.2 and 5.3 of BS 4331 : Part 1 : 1978. 6.3.3 Calibration of time base Calibrate the time base on each of the following occasion (a) at the beginning of a working perio (b) whenever the probe is changed; (c) after any period during which the power to the equipment has been switched off; (d) after a change of testing range. Perform the calibration either as deseribed in 6.1 and 6.2 of BS 4331 : Part 1 : 1978 or, when geometry permits, by using a suitable measured section of the forging under test. The calibration tolerance shall be as given in 6.3 of BS 4331 Part 1: 1978. 6.3.4 Linearity of equipment gain Check the linearity of the equipment gain at least once weekly and formally record the results. The procedure for calibration and the deviation tolerance shall be as given in 7.1, 7.2 and 7.3 of BS 4331 : Part 1 : 1978. 6.3.5 Sensitivity and signal-to-noise ratio Check the sensitivity and signal-to-noise ratio at least once per day for each probe to be employed for testing, using the method described in 10.1 and 10.2 of BS 4331 : Part 1: 1978, The calibration tolerance shall be as given in 10.3 of BS 4331 ; Part 1 : 1978, 6.3.6 Resolution The ultrasonic instrument/probe shall be capable of clearly resolving adjacent targets when their separation in depth along the beam axis is equal to, or less than twice the wavelength. Resolution shall be checked monthly in accordance with 14.2 of BS 4331 : Part 8 : 1974 6.3.7 Probe dead zone Measure the dead zone of each test probe monthly, by the method described in 9.2.1 of BS 4331 Part 3 : 1974. Any dead zone deviation which would adversely affect the examination of the forging shall be cause for withdrawal of the probe 6.4 Probe characteristics 6.4.1 Establish the probe characteristics given in (a) to (c) only where imperfections are to be located accurately or assessments are to be carried out in accordance with 7.2 and 7.3, (a) Probe index and beam angle. Determine the probe index and beam angle for shear wave probes using the methods described in clauses 4 and 5 of BS 4331 : Part 3: 1974. (b) Beam alignment. Determine the beam alignment (squint) for shear wave and compression wave probes using the method described in clause 13 of BS 4331 : Part 3 : 1974. (©) Beam profile. Establish the beam profile for compression wave and shear wave probes where measurements or assessments are to be carried ‘out by probe movement in accordance with the 20 dB drop technique described in 7.2. The ‘method described in clause 6 and A.2.1 of BS 4331 : Part 3 : 1974 shall be used. 6.4.2. Establish the probe characteristics given in (a) and (b) where imperfections are to be evaluated by the distance gain size (DGS) technique described in 7. (a) Near field, Measure the near field by the method described in clause 10 of BS 4331 Part 3 : 1974, (b) Dominant frequency, Where the dominant, frequency of the probe is not certified by the manufacturer, measure the dominant frequency before the probe is put into service using the procedure given in clause 7 of BS 4331 : Part 3 1974, 6.5 Scanning speed and scanning index 6.5.1 Scanning speed The scanning speed shall not exceed 150 min/s. 6.5.2 Scanning index The scanning index (i.e. the crystal path overlap/overiay) shall be at least 10 % of the scanning crystal diameter/dimension, If the purchaser reburies a specific scanning index or \ speed within the provisions specified in 6.5:1 and 6.5.2 should be stated on the enquiry, order or drawing (see B.2(e)) and on the technique ar procedure appendix C, item(s).BS 4124: 1991 6.6 Scanning coverage NOTE. See notes | and 2to 6.2 concerning limitations due to surface condition om unimachined forgings 6.6.1 General ‘The minimum scanning coverage shall be in accordance with 6.6.2 to 6.6.7. NOTE 1. Ifthe purchaser requires extra scanning, this should be ‘stated clearly on the enquiry, onder or drawing (see B.24f) ar on ‘a technique or procedure sheet (see appendix €, item (). NOTE 2. For complex forgings and small diameter forgings it may be necessary to develop and agree special techniques ineluding the use of contoured probes. Where possible, examination Should take place at the stage of manufacture which presents ‘the simplest geometrical outline NOTE 3. 1 circumferential angle tests ate specitied the depth ‘examined is limited. The axis of 35° probe ean cover up to a Mlepth of 0.215 = the diameter of the component. ‘The factors for 45°, 60° and 70 probes are 0.146, 0.057 and 0.090 respectively. This applies to eth soll ancl hollow elinders. NOTE 4, In the case of both cylindrical and rectangular forgings (ee 6.6.2 and 6.6.8) which are to be bored, Ie soften desirable to carry out the ultrasonic examination while the forging i sll, si 6.6.2 Cylindrical forgings longitudinally forged 6.6.2.1 Solid Examine solid forgings over a minimum angle of 180° round their periphery, along their entire length, using a compression wave probe(s) with a 0° angle of incidence. 6.6.2.2 Bored Examine bored forgings over 360° round their periphery, along their entire length, using a compression wave probe(s) with a 0° angle of incidence 6.6.2.3 Solid and bored Where practicable, also examine both solid and bored forgings in a longitudinal direction, using either compression or angle probes, as appropriate to forging geometry. 6.6.3 Rectangular forgings, longitudinally forged 6.6.3.1 Solid Examine solid forgings from at least three mutually adjacent faces over their complete surface using a compression wave probe(s) with a 0° angle of incidence. 6.6.8.2 Bored Examine bored forgings from all six faces over their entire surface, using a compression wave probe(s) with a 0° angle of incidence. 6.6.4 Multi-sided forgings Examine multi-sided forgings from all faces, using a compression wave probe(s) with a 0° angle of incidenee. 6.6.5 Upset forgings In cases where the final forging involves an upsetting operation, examine the forging through the thickness using a compression wave probe(s). Where practicable, carry out compression wave examination round a minimum of 180° of the periphery of unbored forgings and 360° of bored forgings. Use angle probes where the shape of the forging prevents a comprehensive examination with compression wave probes. In such instances, carry out scanning with angle probes, from the same face in both a radial and tangential direction. 6.6.6 Hollow forgings Examine hollow forgings over 360° round their periphery, along their entire length, using a compression wave probes) with a 0° angle of incidence. Where practicable, also examine hollow forgings in a longitudinal direction, using either compression or angle probes, as appropriate to forging geometry, 6.6.7 Near surface examination of forgings When near surface examination of the forging is applied, it shall include the use of combined crystal probes over the appropriate surfaces. NOTE, This standard does not specify a requirement that near srface examination be applied. Ifthe purehaser requires i, this ‘Should be stated on the enquiry or order and on a technique oF proceedure sheet (see B.2, item (g) and appendix C) 6.7 Procedures for setting the test sensiti 6.7.1 General ‘The method of setting the test sensitivity shall be selected from one of the three techniques described in 6.7.2 to 6.7.4 and shall satisfy the appropriate procedure requirements, NOTE, All three techniques are applicable to both compression and shear wave examinations; however, distance gain sige (DGS) technique (6-7-4) is more complex when applied to shear wave ry 6.7.2 Grain interference technique Set the test sensitivity with the probe in contact with the surface of the forging under test. Adjust ‘the equipment gain until the grain interference level at the portion of the beam path under consideration reaches the required amplitude. NOTE, If no value is specifically aygeed between the contracting parties, the amplitude should be between 2 mm at 3 mm 6.7.3 Reference reflector technique NOTE 1. Re holes for compress rence reflectors, which are usually a-bottomed n waves ad transverse holes oF notches for shear waves, are employed in establishing the test sensitivity (ee 7.8). NOTE 2. The type and ste of reference reflector and the reference echo amplitude to be obtained atthe reference depth {or the purpose of establishing test sensitivity should be stich a8 to meet the requited acceptance enteria as agreed between the eontractng parties (see A:2)BS 4124: 1991 6.7.3.1 Produce a reference test block containing 6.7.3.4 Make any necessary correction for the the reference reflector(s) in accordance with reduction in test sensitivity which occurs when the appendix E and determine the material attenuation probe is transferred from a flat to @ curved entry of the block. surface and for variations in surface finish using NOTE, Guidance om compensation for materi attenuation the procedures given in F-2 faven in appendix F NOTE, F.2 alo refers to several coniton in whieh agreement ne ye Gn special proces ot roqutrements wl ted be ae reference block, obtain an echo fom the reference "ke"® erate, ig so or er reflector and adjust the echo amplitude to the ee alee ae Tate 6.7.4 Distance gain size (DGS) technigque : NOTE. The sie ofthe de ro, the erence depth and 6.7.3.8 Properly compensate the equipment reference amplitude forthe purpose of estashing test setting obtained for any difference in excess of sensitivity should be such as to 2 dB in the attenuation between the reference test teria as agreed between the block and the same or equivalent thickness of the forging under test using the values given in table 1 (see 7.4 and F.1). neet the required acceptance snracting partes (see A.2) ‘Table 1. Gain compensation for difference in material attenuation between a reference block and | the component under test Distance to | Compensation for state material attenuation difference (@B/mm) : | refiector”” | calculated on the basis of dstance to reflector %2}, [0.0028 | 0.0050 | 0.0075 | 0.0100 [0.0125 | 0.0150 | 0.020 | 0.025 | 0.030 [0.040 | 0.050 mm aw fas fas fas [as fas fap [ap lap jan [ap 125 a ie | fo lo a | 25 nit frit frit [nt [nts nt [ra f2 fafa 50 en ee ie 75 fa eee ee sae one ea 100 ea se eo eee 125 Pe een 150 nl [2 ose ee es 200 init 2} ee eee toe laa ioe lo 250 [nl (3 4 5 8 10 [is [15 [20 300 a eo 6 o |2 [1 re |e loo | ooo et au ae oe | eee 2 [2s fas | 0 eee fe fio ae aie fo] oe ue ele [rs le eo Iti ar tanga of degen ase, 1? MEMS sof couse enery esting fm he rate of he NOTE 2 The compensation i applied a postive or negative value depending on whether the component attenuation is higher or Ibwer than tat ofthe reference bck NOTE 3 The material attenuation dtference values (mm) stated inthis able ar onthe bass ofthe oa dstance traveled by Thera, he ewe tance to reflector NOTE 4, Whee high steno vale ota this table, mayb necessary to employ subsiiary DAC as described in 7BS 4124: 1991 6.7.4.1 Apply the technique as described in 6.7.4.2 to 6.7.4.5, using either the universal DGS diagram given in figure 2 or a DGS diagram for use with a specific type of probe. 6.7.4.2 From the DGS diagram, determine the difference in decibels between the appropriate dise reflector curve at the reference reflector depth and the back wall echo curve at the thickness under test, 6.7.4.3 On the component under test, obtain a back wall echo and adjust the gain to bring the echo amplitude to the reference amplitude (see note to 6.7.4). Increase the gain by the number of, decibels prviously determined in 6.7.4.2. This is the test sensitivity for non-attenuative materials, 6.7.4.4 When the attenuation of the forging under test exceeds 2 dB, properly compensate the gain, as determined in 6.7.4.3, by reducing the gain by the number of decibels due to material attenuation between the reference reflector position and the back wall. NOTE, Notes for guidance on the DGS diagram are given in appendix G 6.7.4.5 Apply compensation in accordance with F.2 if the back reflecting surface of the ‘component is convex, 7 Procedures for the assessment of imperfections 7.1 General ‘The technique selected for the assessment of imperfections shall follow the procedures described in 7.2, 7.8, 7.4 or 7.5, as appropriate, NOTE. A number of techniques may be used to assess either the dimensions ofthe imperfection or equivalent reflecting area Although those deserved in 7.2 to 7.3 allow certain freedom of choice, the selection ofa suitable technique is governed by the shape of the component, the sizeof the imperfection and its position in the material If the purchaser requires the selection ‘fa particular technique, this should be stated on the enquiry. onder or drawing (see A. and B.2(c) 7.2 20 dB drop technique 7.2.1 Determine the probe/beam alignment in accordance with 6.4.1(b) and the 20 dB beam profile prepared in accordance with 6.4.1(c), 7.2.2 When an imperfection is located, pass the probe over it to ascertain its approximate size. Locate the probe over the imperfection such that the maximum reflection amplitude is obtained. Adjust the gain of the flaw detector such that this reflection amplitude is between 20 ‘% and 80 % full sereen height, Note the height of the reflector. 7.2.3. Adjust the calibrated gain control to increase the amplification by 20 dB and move the probe outwards from the imperfection until the imperfection echo falls to the height noted in 7.2.2, Establish the boundary of the imperfection at this position by reference to the beam profile (see 7.2.1) which gives the beam width relative to the probe axis at the same depth as the imperfection. 7.2.4 Follow this procedure for a sufficient number of positions around the periphery of the imperfection to establish its extent. NOTE. The beam profile ean vary in different planes relative to the probe, particulary in the ease of combined double probes with a separator. Ibis important to assess the imperfection dimensions with the probe correctly orientated in relation to its measured profile 7.3 6 dB drop technique 7.3.1 Determine the probe/beam alignment in accordance with 6.4.1(b) so that the position of the beam axis is known at any depth. 7.3.2 When an imperfection is located, pass the probe over it to ascertain roughly its size. Locate the probe over the imperfection such that the maximum reflection amplitude is obtained. Adjust the gain of the flaw detector such that this reflection amplitude is between 20 % and 80 % full screen height. Note the height of the reflection, 7.3.3 Adjust the calibrated gain control to increase the amplification by 6 dB and move the probe outwards from the imperfection until the iperfection echo falls to the height noted in 7.3.2. Establish the boundary of the iperfection at this position by reference to the beam axis (see 7.3.1) at the depth of the imperfection 7.3.4 Follow this procedure for sufficient positions around the periphery of an imperfection to establish it extent. 7.4 Distance amplitude technique using reference blocks 7.4.1 Prepare reference blocks in accordance with appendix E, containing an appropriate number of reference reflectors (see note 1) at suitable beam path lengths. For compression waves use reference reflectors comprising flat-bottomed holes drilled in the block perpendicular to the entry surface whilst, for shear waves, use notches or holes transverse to the ultrasonic beam. NOTE 1. The size and nature of the reference reflectors should be such as to meet the required aeceptance criteria as agreed betsveen the contracting parties (see A.2 and B.2(d)) NOTE 2. Procedures for the manufacture and use of reference blocks are given in appendices E and F 7.4.2. Establish the sensitivity on the block by setting the echo amplitude from the most responsive reflector to approximately 80 % full screen height. Mark the echo height at this beam path length on the oscilloscope screen and record the equipment gain.7.4.3. For compression waves, move the probe over each reference reflector in turn and mark the amplitude of each respective reflector echo at the established test sensitivity on the sereen at the appropriate beam path length. When each reflector echo amplitude has been marked, construct a distance-amplitude curve (DAC) on the screen by joining the marked positions. Record the equipment gain at which the DAC was constructed. 7.4.4 At any beam path distance do not use the DAC below 20 ‘% full screen height. If the amplitude falls below this level, increase the reference sensitivity by 6 dB or increments thereof, to establish a new DAC for the appropriate beam paths. Record this new equipment gain. 7.4.5 Transfer the probe to the component under test and adjust the equipment gain for any surface curvature and/or attenuation differences between the test block and component. Make the attenuation adjustment with respect to the path length to the indication under assessment (see table 1 and appendix F), NOTE 1. Contracting partes may agree 10 use w higher test sensitivity than the level estas in 7.4 [NOTE 2, The recording level for imperfections at an amplitude Ielow tha established in 74 may’ De agreed Between the contracting partes 7.5 Distance gain size (DGS) technique 7.5.1 This technique uses a DGS diagram as described in 3.5 and shown in appendix G. 7.5.2 In the universal DGS diagram, the units for distance are expressed in near zones and the disc size to crystal diameter expressed as a ratio, Use the values of near field and dominant frequency as determined in 6.4.2(a) and 6.4.2(b) to calculate the effective crystal diameter. 7.5.3. Establish the sensitivity for the test as in 6.7.4. In normal practice, use the back wall in an imperfection free region of the component as the reference reflector, Note the reading of the calibrated gain control and the distance to the reflector. Measure all imperfection echo amplitudes relative to the reference reflector echo amplitude. 7.5.4 When an imperfection has been located, bring its echo amplitude to the reference level using the calibrated gain control, Note the new reading of the gain and the distance to the imperfection, 7.5.5 Where applicable, correct the measured values of gain for attenuation and, if required, surface curvature (see 6.7.4.4, 6.7.4.5 and appendix F). Determine the difference in gain between the reference echo and the imperfection echo using the corrected values, 7.5.6 If a DGS diagram for a specific probe is being used, relate the gain difference in decibels and the path length to the indication in millimetres to the DGS diagram and obtain the equivalent dise reflector diameter in millimetres, 7.5.7 If the universal DGS diagram is used, express the path length to the indication in terms of probe near zones and at the intercept with the gain difference in decibels. Read off a value for S, ‘The equivalent disc reflector diameter is § x (effective crystal diameter), NOTE 1. The accurate assessment of the ind ‘conducted in the probe near zone [NOTE 2. For guidance on the use of the DGS diagram, see appendix G. NOTE: 2. A universal DGS diagram for shear wave probes is not avallable NOTE 4. The effective erystal diameter can be calculated if frequency of the crystal and the near zone distance are known, for It may be obtained from the probe manufacturer, 8 Test report ‘The test report shall state the results of the ultrasonic examination and shall also include the following information: (a) a description and identity of the component; (b) the date of the test; (©) the stage of manufacture at which the test was carried out; (@) a statement of compliance with the written technique or procedure sheet if one is required or, if it is not required, the following: (1) a description of the equipment used; (2) the technique and test sensitivity; (8) the couplant used; (4) the surface finish of the forging; (c) the name of the company conducting the test; (8) the name and appropriate qualifications of the person performing the tests and his signature if required (see B.2(k)); (8) the signature of the person responsible on behalf of the company conducting the test.BS 4124: 1991 Appendices Appendix A. Flaw recording levels and defect acceptance criteria A.1 General It is important that the flaw recording levels and defect acceptance criteria be agreed between the contracting parties and stated in accordance with A.2.2, A.2.8 and A.2.4, on the enquiry, drawing or order or on the technique or procedure sheet (see appendix C, items (k) and (1). Agreement on these matters will need to take account of the requirements of the application and to be specified in relation to the assessment technique employed (see third paragraph of foreword, and clause 7) A.2 Statement of acceptance criteria A.2.1 The criteria for acceptance should be stated in accordance with A.2.2, A.2.3 and A.2.4, on the enquiry, drawing or order (see B.2(i)) or should be agreed between the contracting parties, bearing in mind the requirements of the application. A.2.2 Where the 20 dB drop or 6 dB drop techniques are employed, the agreed criteria should be stated in terms of the area of the imperfection or its major dimension falling within the limitations for these techniques (see 3.2 and 8.3), A.2.3 Where the distance amplitude, reference block, technique is employed, the type and size of i.e. flat-bottomed holes, transverse holes 's, should be specified A.24 Where the DGS technique is employed, the disc reflector diameter should be specified. Appendix B. Information to be provided by the purchaser and details for agreement between contracting parties B.1 General This appendix lists the information which it is essential that the purchaser provide with an enquiry, drawing or order. When an order is placed, it is essential that the contracting parties agree to all relevant details, taking into account the requirements of the application, In the absence of information or agreement, the supplier, in order to comply with this British Standard, is bound only to meet the requirements specified definitively in the clauses in the mai body of the standard and users are reminded that, in certain instances, these are minimum requirements only (see clause 1), 10 B.2 Information to be provided ‘The purchaser should state at least the following information on the enquiry, drawing or order. (a) Whether or not a minimum operator qualification is required (see note to 6.1). (b) Whether or not a specific method of setting the test sensitivity is to be used (see 6.7) (c) Whether or not a specific imperfection assessment technique is to be used (see clause 7). (@) Whether or not special calibration test blocks are required and, if so, the number, size and type of reference reflectors (see 6.7 and clause 7) (e) Whether or not a specific scanning speed and/or scanning index is required (see 6.5.1 and 6.5.2), (f) The extent of scanning coverage required (see note 1 to 6.6.1), (g) Whether or not near surface examination is, required (see note to 6.6.7), (h) Whether or not a written technique or procedure sheet is required (see clause 8), whether or not it is to be submitted for approval and, if so, whether or not it is to be agreed before manufacture is commenced. NOTE, The information tobe inched in the technique or procedure sheet Is given in appendix C. () Whether or not specific acceptance criteria are to be met (see A.2.1), ) Whether or not there is any recording size or level of imperfections to be reported on the appropriate test certificate (sce clause 8 and appendix A) and whether a plot or record of the imperfections relative to datum points is required. (k) Whether or not the signature of the operator is required on the test report (see clause &(f)). (@) Whether or not a special surface finish is required (see note to 5.1) NOTE. The purchaser is responsible for informing the supplier of the requirements of any third party, Appendix C. Technique or procedure sheet Where a technique or procedure sheet is required (see B.2(h)), it is essential that the following information be included: (a) reference to all relevant documents, standards and operator qualifications, as appropriate; (b) type of equipment to be used; (c) calibration of the equipment; (a) type of probe(s) and the test frequency(ies) to be used (see clause 4 and appendix D);(e) type of couplant; (f) manufacturing stage(s) at which ultrasonic testing is to be carried out; (g) surface condition and finish (see clause 5); (h) scanning speed (see 6.5.1) and scanning \dex (see 6.5.2); (i) scanning coverage (relative to type of forging, direction of test and type of probe) (see 6.6); G) test sensitivity and technique (see 6.7); (k) imperfection assessment: techniques and recording levels (see clause 7 and appendix A); (D acceptance levels (see A.2); (m) format of test reports (see B.2(j). Appendix D. Probe frequency ‘The flaw recording or acceptance level required in a particular examination influences the choice of frequency. However, the beam path length, together with the material structure, may limit the test frequency which can be used. If this does not permit the required test level to be achieved (see appendix C, item (d)), the contracting parties should agree on alternative standards or on corrective action to be taken, e.g. additional heat treatment, Asa guide, the following are recommended frequencies for various conditions of test. Recommendations 1 ME compression wave Purpose Deep penetration (e.g, longitudinal tests on shafts) Coarse structure (e.g. austenitic steels) Average conditions 1 MHz to 2 MHz compression wave 2 MHz to 2.5 MHz compression wave 4 MHz to 5 MHz compression wave High resolution NOTE 1. The testing techniques described in this standard can be used for forgings in all steet grades. t should be appreciated, however, that forgings may be encountered, e.8, austenitic rade, in which the metallurgical structure is such that the level of penetration, detection and sizing of defects are degraded, even with the use of low frequency probes, The Inability to test forgings ofthis nature atthe prescribed test levels may not constitute a reason for rejection and the use of alternative NDT methods should be considered. NOTE 2. Provision may be made in any agreed procedure for shear wave examinations tobe conducted. When equal resolution is desirable the shear wave test should be conducted at approximately half the frequency of the compression wave tests, which will ensure that the wavelengths ofthe two modes are similar, BS 4124: 1991 Appendix E. Preparation and use of reference blocks and reference reflectors E.1 Reference blocks E.1.1 The material used for the preparation of reference blocks shall be taken either from the same material as that under test or from material of the same class, i.e. ferritie or austenitic NOTE. In this context ferrtic covers all non-austenitic steels E.1.2. The dimensions of the block shall be chosen to allow for adequate separation between individual reflector echoes from side walls and other external boundaries or internal surfaces. E.1.3. The only surfaces of a reference block that require to be machined shall be the ultrasonic entry surface and those from which a reference reflector is machined or which are intended to reflect a back wall echo. NOTE 1. The recommended finish ofthese surfaces is 3.2 yan Ry 10 6.3 yi Ra. NOTE 2. For some special purposes it may be necessary to reproduce the curvature and/or surface inish of the test block ‘on the reference block, in order to provide an essential Similarity of acoustic coupling and transmission. E.1.4 In the case of rectangular blocks, the relevant surfaces as described in E.1.3 shall be flat and parallel or perpendicular to each other to within a tolerance of 30° E.2 Reference reflectors E.2.1 Flat-bottomed holes E.2.1.1 The holes shall be drilled in the back face of the block and shall be within a tolerance of + 1.0 mm of the nominal depth required and perpendicular to the sound entry face within a tolerance of 30’. ‘The actual depths shall be measured and recorded. NOTE, Due to limitations in driling deep holes it may be necessary to machine the back surface of the block to form a sultable number of parallel steps at appropriate distances from the sound entry surfaces, E.2.1.2. The bottom of each hole shall be made by drilling with a carefully prepared flat-bottomed drill or cutter. [NOTE, Discrepancies in perpendicular or incomplete fattening of a hole will result in a reduction of the reflected echo amplitude compared to a perfectly formed hole ofthe same diameter and a consequent overassessment of the size of a particular flaw. E.2.2 Holes transverse to the ultrasonic beam (side drilled holes) E.2.2.1 The holes shall be drilled from a side adjacent to and perpendicular to the sound entry face. They shall be drilled perpendicular to the side face within a tolerance of 30’ NOTE, Iti recommended that, where practicable the holes are riled completely through the block.BS 4124: 1991 ——_——————— E.2.2.2 The length of the holes and where applicable the width of the block shall exceed the 20 dB beam profile of the probe at the maximum, beam path distance. NOTE. Discrepancies in the orientation of & hole will result in & reduction of the reflected echo amplitude with results as dlesenbed in E212, E.2.3 Notches transverse to the ultrasonic beam E.2.3.1 The notch shall be machined to the specified length and depth. The latter may be expressed as a percentage of the section thickness under test ‘The width of the notch shall not exceed twice the depth. NOTE 1. The recommended form of a notch f rectangular in section and is prstuced sing an end miler enter or by leetrical discharge machining [NOTE 2, Atypical note, for example, may have alent of 50/mm, inching end radi, and 2 depth of 5% ofthe section ‘ickness, E.2.3.2 The tolerance on the depth shall be 5 % of the specified notch depth but not less than £ 0.2 mm. The tolerances on the overall length of the notch shall be £ 1.0 mm. Appendix F. Compensation for material attenuation, curvature and surface finish F.1 Guidance on compensation for material attenuation When compensating for material attenuation using the DGS diagram with compression and shear wave probes, reference should be made to appendix G for guidance. NOTE, Material atenuation (the acouste attenuation ofthe ‘material refers hereto the diferent inherent acoustic ttenaton characteristics of the materials Involved, nd the acoustic loses die to distance, ie. diverence losses Compensation for material attenuation when using shear wave probes as described in appendix G ‘complex and a more practical solution is to use reference blocks with the same attenuation properties as the component under test. When plotting distance amplitude curves using reference blocks having a different attenuation factor (positive or negative) from that of the component under test it should be remembered that correction for attenuation is directly proportional to beam path Iength (see table 1). This is illustrated by the following example. The total material attenuation over the full thickness of ‘a component under test is 6 dB greater than that of the reference block of equal thickness on which the distance amplitude curve was obtained R If the sensitivity were increased by 6 dB when. testing the component to correct the plotted curve at or near the back wall, then at half depth the correction would be 3 dB in excess. The reverse would apply if the attenuation of the block was 6 dB greater than the component. It is therefore necessary to apply corrections with respect to depth in accordance with table 1 F.2 Procedures for compensation for curvature and surface finish F.2.1 General ‘The procedures for making corrections for curvature and for surface finish shall be as stated in F2.2 and F.2.3 respectively. F.2.2 Curvature corrections F.2.2.1 Make curvature corrections where necessary when transferring from flat to both convex and concave sound entry surfaces and for transfer from flat to convex sound reflecting surfaces and for combinations of both. F.2.2.2 If correction is required for the transfer from a flat sound entry surface to a component having a convex sound entry surface, use the following procedure. Obtain a back wall echo from the reference block at a height of 70 % to 80 % full screen height and mark the amplitude on the oscilloscope screen. At the same sensitivity setting, apply the probe to the ‘component under test and increase the gain until the back wall echo reaches the amplitude previously marked. If the attenuation of the component block and the reference block are the same, the increase in gain required is the curvature correction. Increase the test or assessment sensitivity by this value if the section thickness and attenuation values of the test block and specimen are the same. Where attenuation differences occur, make allowances as detailed in F.1 NOTE. 1. Several curvature corrections may be required for a forging having a numberof diameters. NOTE 2, If the DGS technique is being used, and differences in curvature and variation in thickness are involved, compensation Stout be made using the methods described for this technique in appendix G F.2.2.3 If correction is required for a transfer from a reference block having a flat sound entry surface to a component having a concave sound entry surface, the procedure will need to be agreed between the contracting parties and stated in the technique or procedure sheet (see appendix C). F.2.2.4 When testing from small radius convex or concave sound entry surfaces, agreement between the contracting parties may be necessary on special procedures involving the use of suitable contoured test blocks and probes; such agreed procedures will need to be stated in the technique or procedure sheet (see appendix C).Surface contact Correction for curved back wall (ratio re) Figure 1. Curvature corrections probe 6 ‘TM | {Bore surtace e i = 1- F Os ae mail 6 N | Be ™ | | P>— ott + Ht Fi | dor 002 005 01 as 10 so 10.0 | le F.2.2.5 Calculate the compensation for a ‘component having a convex reflecting surface from figure 1, F.2.2.6 Compensation for a component having a concave reflecting surface is normally only required under special circumstances and, where necessary, should be included in a technique or procedure sheet (see appendix C), F.2.3 Correction for surface finish NOTE. In the correction for sound entry surface curvature, the surface finish is automatically compensated and ont flat sound ‘entry surfaces of diferent finish require consideration, F.2.3.1 Apply compensation for differences in surface finish in a similar manner to that for curved sound entry surface correction (given in F.2.2) as follows. F.2.3.2 Obtain the gain difference between the back wall echoes from the reference block and the component under test. This gain difference is due to a combined effect of material attenuation, surface finish and path difference. F.2.3.3. Measure the attenuation on both reference block and component and calculate for path differences. Modify the overall gain difference (in dB) obtained in F.2.3.2 by the result. Any difference (in dB) in excess of attenuation is, therefore the result of surface finish, Appendix G. Notes for guidance on the DGS diagram G.1 Normal probes (see figure 2) G.1.1 General ‘The DGS diagram for single crystal normal probes was drawn by plotting amplitude in decibels from a series of disc-shaped reflectors with increasing distance from the probe in water. The loss due to water attenuation was allowed for in each case and therefore the graph shows the reflection conditions for any material, assuming no attenuation. The distance is given in near fields and is on a log base. If the near field length Nis not known for the probe in use it may be calculated from the formula De Vee X wavelength where D is the crystal diameter. ‘The backwall echo line indicates the maximum reflection from a large reflector with increasing distance from the probe, which becomes a straight line after three near field lengths. This confirms the radiation law for large reflectors in the far field, i.e. the amplitude is inversely proportional to the distance, so that if the distance is doubled the 1BBS 4124: 1991 001 06080209 05 on 0€ ap 09. os on oe oz s saqoad (,0) pwutiou 405 urease SOC TesIEATUA “Zz amNR LE z oreosocov0sa 7 ED ZO t t { Ss NS Ni i 4amplitude is halved (a 6 dB reduction). This law provides a simple method of measuring attenuation. Ifa difference of more than 6 dB is measured, then this will be due to attenuation in the material, leaving a simple calculation for the attenuation factor. ‘The DGS technique should not be relied upon for accurate assessment of reflectors within one near field length from the scanning surface. More accurate results may be obtained within this depth range by use of the Distance Amplitude Curve (DAC) technique. Example 1 Forging thickness 30 mm, Probe frequency 4 MHz Probe diameter 10 mm Near field length 17 mm The second back echo at 60 mm distance is greater than 3N (51 mm); therefore, the second and fourth echoes are on the 6 dB slope. ‘Suppose the difference in echo amplitude ‘measured between second and fourth echo is 10 dB. Total beam path between second and fourth echo is 120 mm. Therefore, the attenuation of the material at 4 MHz is (10 = 6)/120 = 180 dBimm or 33 dB/m, Alternatively, back echoes in the near field may be used. Any difference between their amplitudes in excess of what is shown in figure 2 indicates the amount of attenuation over the total distance travelled between the two echoes, NOTE. The attenuation factor 1/30 dBitmm means that the sound is attentated by 1.30 dB for every millimetre of sound path travelled, bearing in mind thar the sound in reflection Aechnique has to travel there and ack, Since the flaw detector calibration is always for the distance in front of the probe and not the total distance travelled, it may be more convenient to express the factor in the same way, i.e, 66 dB/m, It is important to indicate in which form the factor is being used ‘The lines below the back echo line show the amplitude of reflectors which are smaller than the beam width. These values are shown in relation to the crystal diameter and, for small reflectors within the near field, the nodes and anti-nodes of sensitivity are clearly indicated. They do not arise with a large reflector since all the incident energy is totally reflected. Well into the far field all these lines indicate that reflections from small reflectors follow the inverse square law, so that if the distance is doubled then the amplitude is reduced by a factor of 4 (i.e. by 12 dB). BS 4124 : 1991 The term ‘small reflectors’ is related to the beam width and not to the crystal diameter, since reflectors greater than the probe diameter behave as small reflectors when far enough away to be encompassed within the spreading beam width. This is shown in figure 2 by the lines with $ values, of 1 and 2 times the crystal diameter, G.1.2 Setting the sensitivity In order to use figure 2 to determine the sensitivity setting, the operator first needs to know the smallest dise-shaped flaw or equivalent reflector size that has to be detected and, secondly, at what amplitude it should be recorded. The following testing example illustrates the method, Example 2 Forging thickness 260 mm. Probe frequency 4 MHz Probe diameter 25 mm. Near field length (N) 104 mm Smallest flaw to be detected equivalent to flaw 5 mm diameter (0.28). Defect echo height 40 % Pull Screen Height (FSH) The first backwall echo will be at a distance of 2.5 near fields. It can be seen from figure 2 that close to the scanning surface a 0.28 flaw will give an echo approximately 24 dB below the backwall echo, Near to the backwall of the specimen such a flaw will be only 22 dB below, but at the worst position, 0.5 distance (52 mm), it wil below, In order to produce a flaw echo height of 40 sH at the worst position (27 dB below), the backwall echo height has first to be set at 40 % FSH and then increased by 27 dB. This ensures that all flaws that have to be detected will give signals equal to or greater than 40 % FSH irrespective of attenuation, It is obvious when the minimum recording level is drawn on the figure that reflections from certain depths could give echoes greater than that level and yet still be acceptable. To determine therefore whether or not the echo is greater or less than the minimum size, or in fact to determine its actual ‘equivalent flaw size, the gain should be reduced by the decibel difference between the 0.28 line and the recording level at the defect depth. 40 % FSH is then the minimum recording level at that distance. This example assumes no attenuation in the material at the frequency in use, although by taking the back wall echo as a reference any. attenuation present would only make the sensitivity too high rather than too low.BS 4124: 1991 ——————————— If the attenuation has been measured it may turn out to be insignificant, e.g. 1/200 dB/mm (5 dB/m), in view of the thickness involved. If the attenuation is significant, however, as shown in Example 1 (1/30 dB/mm) then this should be taken into account as follows. Draw in the attenuation line as shown. In this case, since the backwall echo has been taken as the reference reflector, the allowance for attenuation is greater the nearer the reflector is to the scanning surface. ‘The difference at the scanning surface in this ease is 17.3 dB, i.e. 260 mm x 2 x 1/30, Assuming now that a flaw 19 dB greater than the recording level has been found at a depth of 0.3N, two corrections should be made to the gain: 4 dB for the difference between the 0.25 line and the recording level and 15 dB for the difference between the recording level and the attenuation line, i.e. the total correction to be made is a reduction in echo height of 19 dB, after which a decision as to whether a flaw is rejectable is directly related to the recording level of 40 ‘% FSH, If it is necessary to determine the equivalent flaw size for the flaw echo at 0.3N, its amplitude (in dB) above 40 '% FSH should be measured and reduced by the decibel difference between the recording level and the attenuation line. For example: Flaw depth 62 mm, i.e, 0.6N Echo height above recording level 24 dB Decibel difference between recording level and attenuation line 13 dB Final echo height above recording level 24 dB ~ 13 4B = 11 dB, ie. on 0.38 line From figure 2, 0.3 x crystal diameter = 0.3 x 25 mm’= 7.5 mm ‘Therefore the equivalent flaw diameter is 7.5 mm. NOTE 1. In the example use the hackwall echo happened to be at 2.5N buc it could have been 1) 4N of 5.54 oF any other valve, depending on the material thickness and the probe near field length. Furthermore, the S values and the distance values in neat felts eould bath be given directly in millimetres once the probe crystal diameter and near feld length are known, S diagram shown in figure 2 is based on the radiation laws [ei essential, therefore, that the amplifier and probe characteristics in use should not give results conflicting fom those shown inthe diagram, In other ‘words, the flaw detector and prob: combination sould be ‘entirely compatible with the DGS diagram in use G.2 Shear wave probes (see figures 3 and 4) .2.1 General ‘The DGS diagram for shear wave probes is essentially the same as for normal probes, except that distance is measured from the probe index and therefore most of the near field is fortunately lost in the probe. The horizontal axis as before gives the distance along the beam path; corresponding ‘equivalent surface distances are shown for the different shear wave probes. Note that in the two DGS diagrams shown in figures 3 and 4 the probe 16 size is stated and therefore the equivalent flat- bottomed hole sizes and the horizontal axis have been calibrated directly in millimetres, In order to use these diagrams to determine the sensitivity setting the operator first needs to know the smallest dise-shaped flaw or equivalent reflector size that has to be detected, and secondly at what amplitude it is to be recorded. 1p set the sensitivity for testing with a shear wave probe, however, is more complex than using a simple normal probe. Because there is no backwall echo to use as a standard reference, a separate reference echo has to be used, such as the 100 mm radius of the A2 calibration block (see BS 2704). ‘This means that an allowance has to be made for the different surface conditions (transfer loss) between the test block and the forging, the different attenuation factors between the two materials and also the difference in distance between the 100 mm radius reflector and the farthest defect distance in the material, ‘The procedure to arrive at the correet gain setting to ensure that the smallest defect to be detected throughout the scanning distance will at least give an echo at the appropriate screen height, taking into account the factors mentioned above, is as, follows: (a) measure attenuation of material (see @.2.2); (b) measure transfer loss between A2 test block and plate (see G.2.8); (©) read difference in decibels between back echo from 100 mm radius on A2 block to minimum defect size at worst position on DGS diagram, which should be available for the probe in use; (@) set back echo from 100 mm radius to 10 ‘% FSH, plus difference in decibels from (c), plus transfer loss from (b), plus difference in attenuation from 100 mm radius on A2 block to ‘maximum testing distance in plate. Example 3 Probe frequency 4 MHz, 8 mm x 9 mm crystal Smallest defect to be detected equivalent to 2 mm diameter disc-shaped flaw Maximum defect distance 150 mm. ‘Transfer loss 4 dB Attenuation of A2 block 40 dB/m beam front of probe Attenuation of plate 80 dB/m beam path in front of probe ‘The setting required to bring a 2 mm diameter equivalent flaw to the record level at the worst distance (150 mm) would be an echo from the A2 block 100 mm radius to 2 divisions, plus 30 dB from (c), plus 4 dB from (b), plus 8 dB difference in attenuation from 100 mm radius on A2 block to maximum testing distance in plate, i.e. an A2 back echo to 2 divisions plus 42 dB, hin‘ays [easszo wut zz x unUr OZ “ZHW Z JO aqord davm avoys 10} uNBABEIP SHA TOIdAY, “g aMS4q [ww) agoud jo aBpa yuosy wosy arDjsns Buoy aauDjsip mI eoou 000s 002 oct 00s ooz ome 0 TT ot TTT T ].00 00d 000s ove 100s ooz oor Tot Un TTT 209 000s o00z 0001 aos 0oz 01 __as T Tt T Poot TPT at (wu) jvied votssiua wo.y yiod wood = 000s oz ont 00s ove oot ag en ot - + + co i 3 a = Fos. 05/8 Soy on 's 0€ oz oz o oF 7BS 4124: 1991 azys TeysAu un G x URW g ‘ZHTIN F Jo oqord oxvm sways L0J urBABEIp SO TAAL, “pansy (wu) aqoad jo a6pa yuo. wosy a204:ns Guo} asuD{s:p MDI 00 oot 00s, oz. 0s 0 ° (ea TIT T T ol oz oot os ozo ° T TT T 1 T 209 ooz oor 0s. oz 0 TOT THOTT TT TT TITY 3? (wu) quod voyssiwe wos yd woag =g 002 00 00s 002 oot os, oz o c= 09 a 0s tap) vol onaUy=D" on 09 (wUw)-DIp 2124 pawoyjoq—sO} JuaTDAIND3 = 5] aN FENOLLWANSLUV— “I 4¢ 0 TaA31 SNIGUOISN 0€ 02With this sensitivity, the minimum equivalent flaw size to be recorded will at least reach 40 % FSH wherever it appears throughout the scanning distance. It is possible, as with the normal probe test, that echoes in excess of 40 % FSH could be acceptable, To determine whether or not this is so, and at the same time to evaluate the equivalent flaw size for any such echo, proceed as follows: (2) draw on the diagram the attenuation curve as shown; (2) locate the defect depth on the diagram in distance and amplitude above the record level; (3) reduce the defect position by the difference in decibels between the record level and the attenuation line. Example 4 Defect echo 50 mm beam path from sereen Echo height 34 dB greater than record level of 40% FSH Record level to attenuation line 8 dB Therefore, new position on diagram is 34 ~ 8 ='26 dB above record level and hence equivalent flaw size is 4 mm diameter. G.2.2 Measurement of shear wave attenuation ‘The shear wave attenuation of the forging may be measured as follows: (a) use one pro of the same angle and frequency as will be used for the test and calibrate the screen for beam path; (b) use two probes, separate transmitter and receiver, and locate as shown in figure 5 so that signal A.BI appears at 50 mm and signal A.B2 at 100 mm on the screen; (c) measure difference between through transmission signal height A.BI and A.B2; (q) Subtract the difference in decibels indicated on the DGS diagram, the remainder being attenuation over half skip distance on the sereen or 100 mm of beam path, Example 5 Probes of 4 MHz, 8 mm x 9 mm crystal size % skip distance 50 mm Signal height A.B2 54 dB Signal height A.BI 44 0B Difference 10 4B Difference according to DGS diagram 5 dB (50 mm to 100 mm) Therefore, attenuation is, (10 dB ~ 5 dB) 50 mm ~ 1/10 dBimm of beam path on screen. G.2.8 Measurement of shear wave transfer loss ‘The shear wave transfer loss between the A2 block and the forging under test can be measured as follows: {@) use one probe of the same angle and frequency as will be used for the test and calibrate the screen for beam path; (b) use two probes, separate transmitter and Feceiver, and locate as shown in figure 6; (©) measure difference between through transmission signal height of A2 block and forging; (@) subtract the difference indicated on the DGS iagram, the remainder being shear wave transfer loss, Example 6 Probes of 4 MHz, 8 mm x 9 mm crystal size ‘Through transmission signal (14 skip on 68 dB screen) forging Through transmission signal (14 skip on 56 dB. sereen) A2 block Difference 12 dB Difference according to DGS diagram, 3 dB (50 mm to 80 mm) Attenuation difference according to attenuation curve for A2 block at (0 mm and attenuation curve for plate at 80 mm, 5 dB ‘Therefore, transfer loss is 12 dB - 3dB ~ 5dB = 4 4B. 19BS 4124: 1991 \ Type A2 block (BS 2704) Bp Forging “e Figure 6. Measurement of shear wave transfer loss 20BS 4124 : 1991 Publication(s) referred to BS 1134 BS 2704 BS 3683 BS 4331 Assessment of surface texture Part 1 Methods and instrumentation Specification for calibration blocks for use in ultrasonic flaw detection Glossary of terms used in non-destruetive testing Part 4 Ultrasonic flaw detection Methods for assessing the performance characteristics of ultrasonic flaw detection equipment Part 1 Overall performance: on-site methods Part 3 Guidance on the in-service monitoring of probes (excluding immersion probes)BS 4124 : 1991 BSI 2 Park Street London WIA 28S BSI Linford Wood Milton Keynes MK14 6LE. ——————_—————— BSI — British Standards Institution BSI is the independent national body responsible for preparing British Standards. It presents the UK view on standards in Europe and at the international level. It is incorporated by Royal Charter. 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