Phased Array Flaw Characterization

The following is a basic guideline to flaw characterization utilizing signal response relationships commonly found when performing a
butt weld examination. Flaw signals are typically characterized by their shape, appearance, and by their location. The shape of
the indications signal response will allow for the indication (in the A-scan) to be characterized as a volumetric or planar flaw. The
appearance (in the S-scan) will allow for the indication to be further classified if feasible. The location of the indication (in the S-
scan) allows the operator to use their welding and materials knowledge and experience to recognize that certain flaws exist in certain
areas of the weld. Using these three aids together a technician can characterize a flaw, although it is still difficult to differentiate
between most volumetric flaws. On thin wall materials (less than 4.0mm) it is simply a go / no-go interpretation. This is due to the
difficulty locating and sizing a flaw within a thin material thickness. On thicker components the level of characterization will increase.
A thicker component makes it easier to recognize the exact relative location of the flaw in the weld volume and characterize the
defect.

A figure of a typical S-Scan image can be seen on page 4 with the weld material outlined and regions of interest (Zones) identified.

Flaw Location (S-scan) Shape (A-scan) Appearance (S-scan) Comment

Lack of Zone #2 on bevel A sharp indication with Appear as a tight indication Indication shall
Sidewall Fusion edge closest to probe very little length on time line located at the fusion zone with generally appear on the
only response a measurable height. Length is closest probe only due to
measured by utilizing encoder flaw orientation. Heights
position measurements in the can be measured
weld direction. utilizing cursors on S-
Scan.
Porosity Zone #2 in weldment A broad indication with a Appear as a broad indication Indication shall appear
(Volumetric) region wide length along time line within weldment in which on one or both probes
response height cannot be measured. depending on flaw
Length is not measurable due orientation. Single
to probe aperture. porosity indications shall
be classified as
volumetric only.
Cluster PorosityZone #2 in weldment Broad indications spread Appear as numerous broad Indications shall appear
region out along time line response indications when scanned on one or both probes
Gammatec Flaw Characterisation Document (F12/07GAM)
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 along its length. Length is
measured by utilizing encoder
position measurements in the
weld direction.
Slag Zone #2 in weldment A broad indication with Appear as a broad indication
region multiple spikes along its time located at the fusion zone or
line response within weldment with a
measurable height. Length is
measured by utilizing encoder
position measurements in the
weld direction.
Tungsten Zone #2 in weldment A broad indication with a Appear as a broad indication
Inclusion region wide length along time line within weldment in which
(Volumetric) response height cannot be measured.
Length is not measurable due
to probe aperture.
Incomplete Zone #1, #2 and #3 A generally sharp Appear as sharp well defined
Penetration indication that may have indications on the higher
minor length along the time angles in Zone #1, #2 and on
line response the lower angles in Zone #3.
Indications shall appear on
both search units on either side
of the weld. Length is
measured by utilizing encoder
position measurements in the
weld direction.
Gammatec Flaw Characterisation Document (F12/07GAM)
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depending on flaw
orientations.
Indication shall appear
on one or both probes
depending on flaw
orientation.
Indication shall appear
on one or both probes
depending on flaw
orientation. Tungsten
Inclusions shall be
classified as
volumetric only.
Indications shall appear
on both search units on
either side of the weld.
Indications present in
Zone #1 and #2 are
generally used to
measure flaw height.
Crack Zone #1, #2 and #3 An indication with multiple
tight peaks within the signal
response along the time line.
This is a result of sound
reflecting from the multiple
faces along a cracks height.
Appear as numerous Cracking can be found at
interlinking indications any location within the
along a measurable height. The weldment and heat
numerous indications are a affected zone.
result of sound reflection from
a cracks multiple faces. Length
is measured by utilizing
encoder position
measurements in the weld
direction.

External Zone #2 at the toe of A generally broad indication Generally appears as a faint A visual examination
Undercut the weld along the time line response. and broad indication at the will confirm external
O.D. toe of a weld. Indication undercut indications.
will usually only appear on the Undercut responses will
search unit closest to that side generally not break
of the weld. DAC.

Internal Zone #1 and #3 at the A generally broad indication Generally appear as faint and Undercut responses will
Undercut internal toe of the along the time line response broad indications in Zones #1 generally not break
root pass and #2 at the internal toe of the DAC. Indications that
root pass. Indications will break DAC in this region
usually appear on the search are generally a result of
unit closest to that side of the non-fusion at the root
weld. weld pass.

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 The above figure
depicts the three regions of interest on an S- scan image when performing a butt weld examination.

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