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Fig 1:
The sizing methods using advanced techniques such as inside diameter (ID ) or outside diameter (OD)
creeping waves, bi-modal and refracted compression waves may be considered to be more accurate than the
traditional sizing methods. Using any of the sizing methods requires reflectors of a known length and
height, equipment of known performance and personnel suitably trained and qualified.
Fig 2:
The I.D. creeping wave probe is essentially a sub surface wave that runs along the inside surface of the
material being scanned. The creeping wave is produced, refer FIG 2 above, by using a probe that generates
a 30 shear wave, a 70 refracted compression (longitudinal) wave and a second 70 refracted compression
wave.
The probes used in this paper to produce creep waves were a WSY70-2 and a WSY70-4 single element
transducers. The probes of this design were developed in the 70's to inspect stainless steel welds and to
detect under cladding cracks in the nuclear, petrochemical and pulp and paper industries. Additionally a
45 shear wave probe and Bi-modal probes were also used. The above probes can be used to find and give
reliable initial information on the depth (height) of a crack as follows:
The 30 shear wave hits the inside diameter (ID) or back wall of the specimen and mode converts into a
70 compression wave which in turn strikes the crack and then is reflected back to the probe. This route
gives the term used for these types of probes i.e. '30-70-70'(essentially a 31.5 shear wave). When the
reflected signal is returned to the probe it indicates as seen on the CRT that the reflector is half or greater
than the material thickness. (refer FIG 3)
When the shear wave hits the ID or back wall it also generates a creeping wave that runs along the inside
surface of the material until it strikes the reflector. It then runs up the reflector and gives a diffracted signal
from the tip of the reflector which in turn is detected by the probe and is shown on the CRT. This type of
signal indicates that the reflector is related to the ID. (refer FIG 3)
Fig 3:
Note: The above, FIG 3, shows the typical types of CRT presentation when all three of the signal responses
discussed above are shown on the CRT. The standing wave between 5 and 15 is not shown.
Prior to testing the effectiveness of this method of sizing the ultrasonic flaw detector was set up as
discussed below.
The initial calibration was done using a block of similar material and thickness with notches running from
the ID of 20%, 40%, 60% and 80%. The ID creeping wave and 30 - 70 - 70 signals were set to
approximately 40 and 50 on the CRT with the amplitude of the latter being adjusted to give a suitable
evaluation setting. This adjustment was necessary to control the base line noise level to around 5%.
The calibration method used permits the operator to classify the reflector as shallow, mid wall or higher.
Following this initial calibration the reflector heights of the test block were checked.
Results of trial blocks.
The test blocks, carbon steel 25mm thick, had induced cracks of varying heights, all of which were surface
braking on the ID (back wall). The blocks were scanned using the 30 - 70 - 70 probe and then evaluated for
height using a standard shear wave probe 45 and a twin crystal Bi-Modal probe. The results were recorded
as shown below and are reported in percentages of material thickness.
sample
A
B
C
D
45Tip Diffraction
40%
50%
32%
35%
Bi-Modal
50%
54%
49%
40%
Actual
55%
61%
43%
39%
E
F
G
H
I
J
35%
40%
7%
40%
45%
15%
48%
44%
ND
61%
52%
ND
52%
48%
9%
65%
52%
15%
Table 1:
The above results were evaluated using the conventional pulse echo 'A scan' presentation and also using
radio frequency (RF) presentation. The amplitude of the creeping wave signal relies upon the refracted
angle of the probe used. The greater the refracted angle the less gain is required, refracted compression
waves above 55will produce an ID creeping wave.
Results
From the above results the creeping wave can be used to size vertical planar reflectors emanating from the
ID with an accuracy of better than 15%. If the material being scanned is divided into zones, the following
criteria may be used:
Use the ID creeping wave method to place the reflector height in the lower third, middle third and upper
third of the material. This operation is very important if the preferred sizing method is to be applied.
Use the tip diffraction method to find vertical planar reflectors from 10% to;55% of the material thickness.
This is done using a 45 shear wave probe.
Use the bi-modal method to find vertical planar reflectors in the range of 20% to 80% of the material
thickness.
Use the refracted compression wave for planar reflector greater than 50% of the material thickness.
When the reflector is not vertical the amplitude of the creeping wave reduces.