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Abstract: The article presents issues concerning the formation of root geome-
try indications in conventional ultrasonic tests and in the Phased Array tests. In
addition, the article describes the manner enabling the verification of sources
of indications allowing their proper classification both in classical and Phased
Array tests. The article contains results of T-joint-related tests performed us-
ing the Phased Array technique and depicting the scale of geometry indications
when testing welded joints. The article is addressed to NDT personnel perform-
ing ultrasonic tests.
doi: 10.17729/ebis.2017.2/6
mgr inż. Rafał Kaczmarek (MSc Eng.) – Częstochowa University of Technology, Welding Department
Fig. 3 Classification of an indication originating from geometry in the Phased Array technique
based on the image obtained from both sides of the weld axis. The presence of the indication
behind the weld (reference) axis both from position A and A' demonstrates that the indication
originates from geometry
It should be emphasized that the condition wards the lower values of beam trajectory and
enabling the obtainment of the proper position might be mistakenly interpreted as an indica-
of the impulse in the above-presented scheme tion of a welding imperfection such as the lack of
is the precise identification of distance P from penetration or a root concavity (Fig. 4b). The ul-
the weld axis, which, in turn, requires the ac- trasonic beam entering the material has a certain
curate determination of joint thickness t, beam width significantly increasing (because of diver-
insertion angle α and probe centre x. Even small gence) along with the beam path length. The an-
errors in the identification of any of the above- gle of divergence is inversely proportional to the
named values may result in the shifting of the frequency and the size of the transducer. As a re-
impulse towards lower beam path values and, sult, the positioning of the probe at point B will
consequently, in the wrong classification of not enable the proper classification of the indica-
a geometry indication as that originating from tion as the echo of the weld root originates from
the lack of penetration or a root concavity. the side edge of the beam and not from its axis.
No. 2/2017 BIULETYN INSTYTUTU SPAWALNICTWA 47
If the distance between the probe and the indication of the weld root occurs not when
weld axis is longer than P, the impulse moves the probe is in position A, but B or C (Fig. 4),
towards the higher values of beam trajectory particularly where the root shape orientation is
(Fig. 4c). The situation is analogous to that de- the most favourable in relation to an angle cor-
scribed above, only that the echo of the root responding to the edge of the ultrasonic beam
originates from the edge of the ultrasonic beam and not its nominal angle. As can be seen, the
demonstrating a refraction angle greater than echo envelope maximum position should not
probe nominal angle α. As values read out of be treated as the decisive criterion when qual-
the flaw detector gate are projected onto the ifying an indication as that of geometry.
beam axis, they also, in the case under consid- In practice, the situation where the axis of
eration, may lead to an error. The above-named the weld face is shifted in relation to the axis
error will be the greater, the lower the frequen- of the weld root occurs quite frequently, par-
cy and the smaller the size of the probe trans- ticularly as regards joints made using a simple
ducer and, thus, the greater the width and the run, were adding another run on the edge of
angle of beam divergence. The above-presented the weld face moves the weld face axis by dis-
error is frequently made by UT controllers un- tance z in relation to the weld root axis (Fig. 5).
critically accepting and recording (in a related In the above-named situation, the use of the
report) the values of a shortened projection and above-presented procedure requires the setting
of a depth (read out using the flaw detector). of the probe positioned in relation to the weld
In the above-named case (Fig. 4c), the values face axis at distance y = P – z and y’ = P + z for
read out of the flaw detector gate would imply probe positions A and A’ respectively. It is only
the presence of a discontinuity before the weld then that geometry indications will appear in
axis, at a depth considerably above the surface the expected area, i.e. directly after the first half
of the opposite sheet.
As can be seen, the precise set-
ting of the probe in accordance with
the provided scheme is crucially im-
portant as regards the proper inter-
pretation of a reason behind a given
indication. Other manners used
when recognising indications of ge-
ometry are encumbered with signif-
icant errors. It should be noted that
the use of the echo envelope max-
imum position, i.e. the maximum
amplitude obtained when the probe
is moved from position B to C, does
not always result in the proper clas-
sification of an indication. This is so
because the amplitude of echo de-
pends on numerous factors, includ-
ing the shape and orientation of the Fig. 4. Exemplary situations where probes are not aligned in relation to
the axis of the weld during the classification of indications and possi-
reflector. For this reason, very of- ble outcomes. The red marker indicates the position of the indication
ten the highest amplitude of the read out of the gate flaw detector whereas the green arrow indicates the
actual reflector, i.e. the weld root
Fig. 5. Proper manner of setting the probes when classify- Fig. 6. Exemplary indication of a lack of penetration in the
ing indications where the axis of the weld face and that of root of the single-sided weld
the weld root of are not aligned
Fig. 7. Exemplary indication of an incomplete fusion in the Fig. 8. Exemplary indication of a crack in the weld root
weld root against the background of geometry indications against the background of geometry indications
The above-presented results of the Phased Array making of special specimens of welded joints
tests demonstrated that significant percentage enabling the acquisition of skills necessary to
of indications obtained in echo method-based distinguish between relevant indications and
ultrasonic tests might come from the geometric geometry indications. The above-named spec-
features of welded joints subjected to tests. The imens with known discontinuities, tested us-
analysis presented in the article only focused ing various NDT methods, could be particularly
on indications generated as a result of the di- useful when testing joints having complicat-
rect reflection from the weld root as the afore- ed geometry (butt joints with a backing strip,
said indications are most popular and usually T-joints, nozzle branch connections, etc.).
characterised by the highest amplitude. How- Another method enabling the reduction of
ever, quite frequently, indications obtained in the content of false indications in ultrasonic
tests are geometry indications reflected from tests consists in the replacement of convention-
the weld face, often accompanied by the trans- al ultrasonic tests with the TOFD and Phased
formation of a transverse wave into a longitudi- Array techniques. If the appropriate spacing
nal wave. The considerable number of geometry of the probes is maintained, the TOFD tests are
indications significantly impedes the perfor- least likely to generate false indications. How-
mance of conventional ultrasonic tests and the ever, as regards joints of the most critical im-
proper recognition of indications generated by portance, it is necessary to cover TOFD silent
actual discontinuities, hence the high value of zones with an additional test in order to detect
above-presented false coverage ratio in relation small discontinuities (if any) in the weld face
to manual ultrasonic tests. For this reason, it is and root areas [5, 6].
necessary to become skilled at distinguishing In comparison with the conventional ultra-
between relevant indications and joint-related sonic method, the Phased Array tests enable
geometry indications. This article might come the more efficient distinction of geometry in-
particularly helpful for persons beginning to dications, particularly in cases of encoded tests
work as ultrasonic test controllers. performed simultaneously using two PA groups
Very good preparation for the assessment of on both weld sides. All geometry indications
indications in a given type of a joint involves the can be then easily distinguished in B-scans as
drawing of the joint with the detailed analysis of well as can be systematically verified in test re-
the ultrasonic beam trajectory and the assess- sults concerning the second PA group. In ad-
ment of potential beam reflection areas. Anoth- dition, because of the possibility of accessing
er suggestion worth considering includes the all recorded A-scans constituting scans in the
52 BIULETYN INSTYTUTU SPAWALNICTWA No. 2/2017
Phased Array technique, the correctness of the [4] ISO/DIS 19285:2016 Non-destructive testing
classification of indications can be repeatedly of welds – Phased Array technique (PA) – Ac-
verified after the completion of tests. Therefore, ceptance criteria
the development of volumetric non-destructive [5] Kaczmarek R., Kaczmarek K., Słania J.,
tests in laboratories performing tests of welded Krawczyk R.: Performing of ultrasonic in-
joints appears to be the right direction. spection using TOFD technique in terms of the
requirements of related standards. Biuletyn
References Instytutu Spawalnictwa, 2016, no. 4, pp 47-56
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Automated Phased Array Technology twa, 2016, no. 5, pp. 135-140
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