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MODULE 3
SYLLABUS
Ultrasonic Testing (UT): principle, types of waves, frequency, velocity,
wavelength, reflection, divergence, attenuation, mode conversion in
ultrasonic UT testing methods - contact testing and immersion testing,
normal beam and straight beam testing, angle beam testing, dual crystal
probe,
ultrasonic
testing
techniques
resonance
testing,
through
WHAT IS ULTRASONIC
TESTING?
Ultrasonic testing is one of the NDT methods to find out the condition of
elastic materials by means of injecting mechanical vibrations into the
materials.
This method is capable of detecting surface, subsurface and internal
discontinuities on materials
Sounds below approximately 16 Hz are below the limit of human hearing
and are called subsonic vibrations, and sounds above approximately
20,000 Hz are too high to be heard and are called ultrasonic vibrations.
Between those two values, is the audible range.
Sreerag V, Asst. Prof.
ULTRASONIC TESTINGPRINCIPLE
GENERAL
Ultrasonic waves are send
through the material by means of transducers
If there is any discontinuity in the path of the propagation, the material
would change or modify the waves that can be viewed in the form of
indication , through a testing system.
It is based on the fact that solid materials are good conductors of sound
waves. Whereby the waves are not only reflected at the interfaces but
also by internal flaws.
Obeys the laws of optics
Sreerag V, Asst. Prof.
Where,
Properties
Easily generated
Travels Through all media
Highest velocity compared to other types of waves.
First explained by Lord Rayleigh. Hence these waves are also called as Rayleigh
waves.
Surface wave velocity is given by ,
Properties
Less attenuation compared to other two waves.
Maximum depth of penetration is one wave length beneath the surface.
Travels along flat or curved surfaces of relatively thick solid specimens.
For propagation material should be free from oil, grease and loose scales.
It wont exist in solid immersed in liquid.
Sreerag V, Asst. Prof.
IMPORTANT TERMS
TIME PERIOD, T
WAVE LENGTH ,
Distance between two neighboring points having the same phase
REFLECTION
At an interface, a proportion of the sound may be transmitted to the next medium and the remainder reflected back
to the first medium
Where, Z is the acoustic impedance and is given by
Sreerag V, Asst. Prof.
IMPORTANT TERMS
ATTENUATION
IMPORTANT TERMS
MODE CONVERSION
IMPORTANT TERMS
Couplants
Water
Kerosene
Oil
Grease
Wallpaper paste
ULTRASONIC TESTING
METHODS
Contact testing
Immersion testing
Normal beam testing
Straight beam testing
Angle beam testing
Dual crystal probe
CONTACT TESTING
In contact testing (shown on the previous slides)
a couplant such as water, oil or a gel is applied
between the transducer and the part.
IMMERSION TESTING
In immersion testing, the part and the transducer are place in a water
bath. This arrangement allows better movement of the transducer while
maintaining consistent coupling.
With immersion testing, an echo from the front surface of the part is seen
in the signal but otherwise signal interpretation is the same for the two
techniques.
ULTRASONIC TESTING
TECHNIQUE
Resonance testing
Pulse echo testing
Through transmission testing
RESONANCE TESTING
TECHNIQUE
Each component has its own resonant frequencies (eg : ringing of bell, wine
glass)
The tones of the ringing depends on size, material of the component.
Earlier people have been inspecting materials by hitting them with a hammer
and listening to them.
Computers and modern electronics enabled us to take the human element out
of the inspection process.
It operates by exciting the component with a sine wave.
It then sweeps all of the individual frequencies through the required test
range.
It improves the detectability of inspection compared to the old hammer
Sreerag V, Asst. Prof.
DEPARTMENT OF MECHANICAL ENGINEERING
method.
PULSE-ECHO TESTING
TECHNIQUE
0
Sreerag V, Asst. Prof.
crack
4
10
plate
DEPARTMENT OF MECHANICAL ENGINEERING
THROUGH TRANSMISSION
TESTING TECHNIQUE
Two transducers located on opposing sides of the test specimen are used.
One transducer acts as a transmitter, the other as a receiver.
Discontinuities in the sound path will result in a partial or total loss of
sound being transmitted and be indicated by a decrease in the received
signal amplitude.
Through transmission is useful in detecting discontinuities that are not
good reflectors, and when signal strength is weak. It does not provide
depth information.
TRANSDUCERS
Production and detection of ultrasonic waves for inspection
Transducers are kept inside device known as search units or probes
Active element piezo-electric crystal
Pressure applied electric charge is generated
Electric charge is applied crystal mechanically deforms
Crystals used
Quartz
Lithium sulphate
Polarised ceramics
CONSTRUCTION OF
ULTRASONIC TRANSDUCER
Transducer contain piezo-electric crystals, thickness varies with frequency
Mechanical damping by loading transducer with heavy damping slug
Damping slug tungsten powder mixed into an epoxy resin
Crystal, damping slug and electrical contacts are mounted inside suitable housing
Basic consideration in probe design
DUAL ELEMENT
TRANSDUCER (DUAL PROBE)
Two single transducers are mounted, one act as transmitter and the
other as receiver
Can be kept side by side for direct testing and stacked or tandem
for angle testing
Used to get good near surface resolution with straight beam
scanning
Two crystal elements are used, both slightly inclined towards each
other, and are stuck to relatively long delay path
Constructed for a particular material thickness and using on other
materials wouldnt get us correct result
For thin objects high roof angle
Sreerag V, Asst. Prof.
DUAL ELEMENT
TRANSDUCER (DUAL PROBE)
Skip
distance: In angle beam testing, the distance along the test surface
from sound entrant point to the point at which the sound returns to the same
surface. It can be considered the top surface distance of a complete vee
path of sound in the test material.
Vee path: The angle beam path in materials starting at the search-unit
examination surface, through the material to the reflecting surface,
continuing to the examination surface in front of the search unit, and
reflecting back along the same path to the search unit. The path is usually
shaped like the letter V.
Vee path
Sreerag V, Asst. Prof.
IMMERSION TESTING
TRANSDUCERS (FOCUSED
PROBES)
Used to achieve near surface resolution
No wear plates or water proofing
Suitably ground acoustical lens are attached to
the immersion probes for focusing sound beam
Other frontal members are added to the
transducer like wear plates for added protection
Frontal units are shaped to direct ultrasound
perpendicular to the surface at all points on
curved surface and radii are known are contour
correction lenses
Sreerag V, Asst. Prof.
ADVANTAGES OF FOCUSED
PROBES
Attached lens increase sensitivity, resolution and reduce metal
noise and effect due to surface roughness
Cylindrical focused transducer focuses the beam to a long narrow
beam making it possible to detect very fine defects
Spherically focused transducers focuses beam to a point, making
the point of maximum intensity move towards transducer, but
shortens the range.
REFERENCE BLOCKS
A- SCAN
Represents the material condition through which the sound beam is
passing.
Doesnt yield information regarding spatial distribution.
B- SCAN
Displays a crossectional view of the Workpiece
Arrival of Pulse V/S Transducer position
C- SCAN
Displays a plan view of the Workpiece
Uses Raster scan technique.