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Ultrasonic Setting-Blocks PDF
Ultrasonic Setting-Blocks PDF
Sec V.
hole
location
1/4, 1/2, 3/4T
discontinuity type
relative sensitivity
Planar
Highest
Linear
Intermediate
Spherical [ cluster ]
Intermediate
Spherical [ isolated ]
Lowest
[ assuming favorable orientation ]
Effective
angles
4340 Steel
347,Aust Stainless
Aluminum
Inconel
Titanium, 105A
60
56
57
54
57
-------------------------------------------------------------------3240
3090
3130
3020
3120
45
42
43.5
41
43
70
64
65
61
65
Flaw Calculations :
Distance to reflector from
The probe exit point :
Beam path X Sin A
Depth of reflector from the
scanning surface level :
In Leg 1
[ before reflection from the
undersurface ]
beam path X Cos A
In Leg 2
[ after reflection from the
Undersurface ]
2 Thickness - ( Beam path X Cos A )
A is effective Angle of the Probe.
0
Angle
80
70
60
45
---------------------------------------------Sin A
.98 .94
.86
.7
Cos A
.17 .34
.5
.7
Tan A 5.67 2.74 1.73 1.0
Sec A 5.88 2.94 2.0 1.4
[ Sec A = 1 / Cos A ]
Locating discontinuities :
Ultrasound beam is a diverging cone with maximum sensitivity along its axis. Consequently, a flaw will produce a
signal even when the beam axis does not pass directly through it. It is therefore necessary to shift the probe till the
flaw signal becomes maximum. The flaw is then on the axis of the beam. The angle marked on the probe is the
angle of this beam axis for steel testing. The location of the flaw is then calculated by recording the sound travel
path displayed on the CRT screen and using trigonometric relations.
The CRT screen is to be marked at half skip and full skip beam paths [ Thickness X Sec A, 2 X Thickness X Sec A ]
to separate Leg 1 and Leg 2 region.
The defects in a test part usually produce a clearly defined echo envelope [ rise and fall of the echo signal ]. Such
indications should be analyzed thoroughly.
Weld flaw signals :
Single Pore : produces low amplitude narrow based sharp echo. When the probe is orbited around the pore, the echo
is maintained with small amplitude variations. They can only be detected as points.
Porosity cluster : Produces low amplitude broad based indications with many peaks. When the probe is orbited around
the cluster, the echoes will be held with amplitude and range variations.
Isolated Slag : produces forked and broad based echo. When the probe is orbited, the echo is maintained with some
amplitude variation and retains the forked shape.
Slag lines : echo falls rapidly when the probe is rotated or orbited and held when moved lateral to the weld.
Cracks and bonding flaws along the weld seam : produce a sharply defined large echo when beamed at right angles.
Due to multi - faceted nature of an open crack, the echo will have multiple peaks and wide envelope.
DAC Plot.
Mat
Dist
1 / 8
1/4
1/2
3/4
1.5
3.0
6.0
FBH
dia
5 X 1 / 64
5
5
5
5
3, 5 , 8
5,8
Notches :
For evaluating incomplete penetration in welds or discontinuities
forming a corner, such as a surface crack or weld undercut,
machined surface notches may be employed for sensitivity
calibration and size comparison, since they more nearly represent
the actual discontinuity. A Vee shaped notch is an useful reference
for evaluating side wall lack of fusion in vee welds. Square
notches are useful for evaluating Lack of penetration.
Reflection amplitude from Vee, square and U shaped notches of
comparable dimensions may vary widely depending on the angle,
frequency and vibrational mode of the interrogating sound beam.
These notches are best produced by Electric Discharge Machining
[ spark eroded ] process.
The notches are usually at least one inch long [ min two times
the probe crystal width is recommended ], with a depth
[ d ] of 2 to 10 % of thickness of the part for weld inspection.
The width [ w ] of the cut is usually 1/16". For base material
examination of tubular products, axial and circumferential notches of
the required dimensions on the outside and the inside surfaces, in
a calibration block made from the product being examined is used.
For plates, 3% of thickness depth notch is recommended.
[ always refer applicable test procedure for notch details ]
Sound beam path in curved part :
While testing curved parts, increase in beam path due to part
curvature must be considered.
Two similar angle probes can be used to find the beam path
to hit the undersurface of a curved part. Using a calibrated
range, the equipment is set to dual probe mode. The probes
are positioned on the part, facing each other, and at
approximately one skip distance apart. Keeping one probe fixed,
the other probe is moved to produce a maximized signal. The
distance indicated on the CRT is the effective beam path for
the angle probe in use to hit the under surface of the part.
The maximum incident sound beam angle, [ grazing incidence ]
which can still hit the undersurface [ irradiation depth ] of a
curved part can be found from the relation ;
Probe angle A = Inv Sin [1- ( 2 t / D )]
where, t is wall thickness and D is outside diameter of pipe.
Depth of irradiation can be calculated from ;
Irradiation depth = Irradiation factor X Diameter
Irradiation factor :
.5 [ 1 - sin A ]
35
0.213
45
0.146
60
0.067
70
0.030
Piezo-electric effect :
Piezo electric effect is a phenomenon, whereby electric charges
appear on the surfaces of certain solid materials, when it is
subjected to mechanical stress or pressure.
Conversely, when a piezoelectric crystal is placed in an electric
field, the crystal exhibits deformation, i.e. the dimensions of the
crystal change. When the direction of the applied electric field is
reversed, the direction of the deformation is also reversed. This is
called the reverse piezoelectric effect.
If, instead of DC field, an alternating field is applied, the crystal
will vibrate at the frequency of the AC field. If this driving
frequency corresponds with the frequency where the thickness of
the crystal represents half a wavelength, [ Crystal thk = / 2,
wave length in crystal ] the amplitude of the vibration will be
much greater. This is the crystals fundamental resonance frequency.
The crystal will also have frequencies of large amplitude whenever
the thickness of the crystal is equal to an odd multiple of half a
wavelength. The largest amplitude occurs only at fundamental
frequency and as the harmonic number increases the amplitude of
vibration decreases.
The ability of a material to exhibit piezoelectric effect is due to its
atomic structure. An unstressed piezoelectric crystal will have equal
distances between its positive and negative charges. As stress is
applied, deformation occurs which changes this distance
relationship. This change in distance between atoms results in
polarization of the crystal. Detectable electrical charges appear on
the surfaces. As the applied stress is relived, the positive and
negative charges attract each other and the crystal comes back to
its unstressed condition.
In some crystalline materials piezoelectricity occurs naturally, such
as crystals of quartz or tourmaline. In some ceramic materials,
piezoelectricity can be induced artificially by reorienting their crystal
domains. This is performed by slowly cooling the material from
curie temperature under intense electric field. This is known as
polling. These materials are known as polarized ceramics and are
widely used for the construction of ultrasonic probes for their good
efficiency of ultrasound generation with lower voltage.
Polarized ceramic crystals of Barium Titanate and Lead Zirconate
Titanate [ PZT ] are most common for the construction of standard
probes. Barium Titanates are produced by baking together barium
0
carbonate and titanium dioxide at 1250 C. The crystals are
0
subjected to an intense 2kV / mm electric field at 140 C [ the curie
point ] and allowed to cool. The crystals become polarized, and
after loosing 50% activity in 24 hours become fairly constant. These
crystals suffer from aging and are not suitable for testing at high
temperature.
Solid solution of lead zirconate and lead titanate [ or PZT ] offers
good overall performance. This has a much higher curie point [ 320
0
to 350 C ] and its piezoelectric properties can be tailored to out perform barium titanate. Lead zirconate titanate is commercially
available with many added minor constituents, which are not
disclosed by the manufactures.
Lithium Niobate, Lithium Sulphate, Lead Meta Niobate, Lead
Titanate, Quartz are some of the other active elements in probes
and are utilized for their specific properties.
Sound field :
The ultrasound intensity along the beam is not
uniform but varies due to the size of the source
that gives rise to interference effects. The face
of the crystal does not vibrate uniformly under
the influence of the triggering electrical pulse.
The crystal acts as a mosaic of large number
of tiny individual crystals, each vibrating in the
same direction but slightly out of phase with its
neighbors. Each element in the mosaic acts like
a point source and radiates a spherical wave,
outward from the plane of the crystal face. As
these spherical waves with different phases
encounter one another in the region near the
crystal face, interference effect sets up a series
of maximum and minimum intensity locations.
This interference zone ends at the last
maximum, at a distance N from the crystal and
is known as the near field [ Fresnel zone ] of the
sound beam. The location of the last maximum
is the natural focus of the transducer and the
sound field converges to half the source size at
this location. Because of this intensity variations,
echo amplitude from a constant reflector in the
near zone will vary and it can be extremely
difficult to accurately evaluate the size of the
reflector.
Testing in the near zone is limited to :
Thickness measurements, Detection of defects and Sizing of
large defects only.
Intensity variations [ interference ] in the near zone is lesser
for rectangular shaped crystals.
The near field distance depends on the size and frequency of
the transducer and the effective wave length in the test
material. Near field for a circular element with a single operating
frequency in a single medium is,
2
N = D / 4
D is element size and is effective wavelength.
At distance greater than N, known as the far field of the
ultrasonic beam [ Fraunhoper zone ], there are no interference
effects. In this zone the sound field diverge in the shape of a
cone and the sound pressure is inversely proportional to
distance and follows an exponential decay curve.
Half angle of divergence [ to the boundary of sound field ],
- / 2 = Sin 1.22 / D
In the far zone the signal from a large reflector [ larger than
the beam cross section at that distance ] follows the inverse
proportional law. After a distance of three near zones from the
crystal, a double distant echo from a large reflector will cause
the echo intensity to reduce by 6 dB. The signal from a small
reflector causes greater directional change and a smaller amount
of the reflected energy reaches the probe. The signal amplitude
decreases to one fourth when the distance is doubled [ - 12 dB ]
Beam spread decreases with increase in frequency and Crystal
size. Consideration of beam spread is important when measuring
the size of a discontinuity and inspecting for flaws near a
sidewall or corner or small round parts, where the diverging
beam may produce spurious echoes.
The near field and far field effects also occur when ultrasonic
waves are reflected from an interface.
Transfer Correction :
If the reference block used for setting up the
test sensitivity is not fabricated from the material
to be tested, the sound attenuation characteristic
of the block material may be different from that
of the test material. The differences in surface
conditions will also change sound attenuation.
A correction for test sensitivity is required to
compensate for the differences between the
reference blocks and the test specimen for
surface roughness, contact area and internal
sound attenuation. This is known as transfer
correction and must be considered while using a
DAC curve for flaw evaluation.
Ultrasonic wave :
Ultrasound is transmission of energy through an elastic medium,
by means of vibrations of the particles. The vibrating particles
transfers some of the vibrational [ mechanical ] energy on to
neighboring particles and force them to vibrate. The energy thus
propagates through particles. Because of this, sound cannot
propagate in vacuum.
Sound generated above 20,000 Hz is called ultrasound. Ultrasound
propagates more easily through solids than through liquids or
gasses. Ultrasound with frequencies of 1 MHz and above is
directional, has short wavelength, and gets reflected from small
discontinuities in materials. This property makes ultrasound useful
for detecting and locating defects in materials.
Wave length : Ultrasonic vibrations travel in the form of waves. The
distance, measured along the line of propagation, between two wave
surfaces in which the phase differs by one complete period is
wavelength. It is not the material's particles that moves through the
thickness, it is the vibrational [ mechanical ] energy that is
transferred from one particle to another.
Frequency : The number of wave lengths [ vibration cycles of a
particle ] completed in one second is frequency.
Unit of frequency is Hertz [ Hz ]
1000 Hz is equal to 1 KHz, 1000 KHz is 1 MHz.
If a 2 megahertz probe is used for an inspection, that means the
parts particles will vibrate 2000000 times per second. Ultrasound
travels in Steel, 5960000 mm in 1 second, i. e. 2000000 waves will
occupy 5960000 mm. So wave length in this case is 2.98 mm.
Frequency depends on the probe and does not change with test
material.
Cycle : The particles are displaced, first in the forward direction
and then in the opposite direction. These two displacements equal
one cycle.
Period : The time required to complete a full cycle of vibration of a
particle is period.
Period is one second divided by frequency. [ T = 1 / F ]
Velocity : Velocity is the speed of energy transfer between two
points. The distance of propagation of the wave [ energy ] in one
second is the velocity of the wave. Velocity of ultrasound in a
perfectly elastic material at a given temperature and pressure is
constant. Velocity depends on the density, elasticity and rigidity of
the test material.
IIW block :
for calibration of
test ranges,
probe and flaw
detectors
performance
check.
Ultrasound propagates by
means of the oscillatory
motion of the atomic or
molecular particles in the
medium.
Ultrasound wave modes :
All material substances are composed of atoms, which may be
forced into vibrational motion about their equilibrium positions.
When the particles are displaced from their equilibrium positions
by any applied force, internal stress acts to restore the particles
to their original positions. Because of this inter-atomic forces
between adjacent particles, a displacement at one point induces
displacement at neighboring points and so on, thus propagating
a stress - strain wave. The actual displacement of matter that
occur in ultrasonic wave is very small.
The amplitude, mode of vibration and the velocity of the wave
differ in solids, liquids and gasses because of the large
differences in the mean distances between particles in these
form of matters. These differences influence the forces of
attraction between particles and the elastic behavior of the
materials. In air, sound travels by compressions and rarefactions
of the air molecules in the direction of sound propagation and
generate longitudinal wave. In solids, the molecules can support
vibrations in other directions, hence, a number of different types
of sound wave modes are possible.
Longitudinal or Compressoinal wave is generated when the
external applied force produces vibration of the particles in the
direction of the wave propagation. The wave produces alternate
zones of compressions and rarefactions. Longitudinal wave can
propagate by simply pushing the particles of the medium and
hence can be generated in gasses, liquids and solids. Because
of its easy generation and detection, longitudinal wave is most
widely used in ultrasonic testing. Almost all of the ultrasonic
energy used for material testing is generated in this mode and
is then converted to other wave modes for different testing
applications. Straight beam examination utilize these waves.
Shear waves can have the vibration at any angle with respect
to the direction of wave propagation and can therefore be
polarized. Shear wave is commonly described as a wave with
particle vibration perpendicular to wave propagation. These waves
propagate with a velocity which is about 55 % of longitudinal
waves. Shear waves will not propagate in liquids and gasses
since these mediums do not support shear forces. Shear wave
has shorter wavelength, can detect smaller flaws and has higher
attenuation compared to equivalent longitudinal wave. Angle
beam examination mostly utilize shear waves.
Surface waves propagate along the surface of a metal with an
elliptical particle motion. To sustain the waves, the medium above
the metal surface must be gas or a very thin layer of liquid
couplant. The waves propagate along the test surface through a
thickness of only one wavelength. At one wavelength deep, the
wave energy drops to only 4 %. The waves have a velocity of
approximately 92 % of equivalent shear wave.
Surface wave follows curved surfaces and gets reflected from
sharp corners, surface and very near surface discontinuities.
Surface wave has low attenuation and high sensitivity for
detection of surface defects.
Lamb wave or plate waves are produced by an angulated
compression wave launched into a thin plate [ few wavelengths
thick ]. Lamb waves are zig zag reflected longitudinal and
transverse waves, but bounded by the sheet or plate surfaces
Welding defects :
Crack : Cracks are rupture of metal caused by severe heat and stress.
Crack can occur anywhere in the weld metal, heat affected zone and
in the base metal. Longitudinal cracks propagate along the weld length.
Transverse cracks are perpendicular to the weld seam. Crater cracks
form at the weld surface and radiate out in many directions [ visible at
surface ]. Base metal cracks may be in any orientation to the weld.
Tight crack produces small indication or no indication at all. Opened
cracks usually produce recognizable high amplitude broad based
indication with wide signal envelope.
Lack of penetration : Incomplete filling and not bridging the gap of the
weld root opening. Weld metal does not extend entirely through the
joint thickness. For welding from one side, this discontinuity is open to
the surface. Produces high amplitude sharp indication from the corner
of the root face, detectable from both the sides of the weld. Plotting
does not cross over the root centerline. Cross over indicates probability
of root lack of fusion or root undercut.
Lack of fusion / Cold lap : Failure of the weld metal to fuse along the
edges of the base metal [ bevel ] or lack of bond between adjacent
weld passes [ an area of the parent metal or already solidified weld
metal does not get melted to fuse with the weld metal ]. Usually caused
by improper heat or poorly prepared weld surfaces. Lack of fusion may
have slag associated with it. Produces high amplitude sharp indication,
0
only when intercepted at 90 , usually detectable from one side of the
weld only. When slag is present, the defect is detectable from both
the sides of the weld.
Slag / Inclusions : Entrapment of foreign material in the weld metal. Slag
may be small irregular fragments or elongated. Slag lines follow the
direction of welding and will be located along the weld groove edge or
between passes following a valley left by weld passes. Produces
forked, broad based, lower height indication, Usually detectable from both
the sides of the weld.
Porosity : Porosity occurs when gasses in the molten weld metal fails
to escape before solidification of the weld material. Occurs anywhere
within the weld. Isolated pore is a single spherical gas pocket.
Scattered porosity is random distribution of single pores. Cluster
porosity is a group of pores. Wormhole is an elongated
[ tunneling ] pore. Hollow bead is an elongated gas pocket that tunnels
down the root pass in the direction of welding.
Single pore produces a narrow base sharp small amplitude indication.
Single and dispersed / scattered pores are difficult to detect.
Cluster will produce broad base indication with multiple peaks.
Root concavity : The root of the weld is fused but the center of the
root weld pass is below the surface of the adjacent base material. This
defect occurs on joints that are welded from one side only, where
excessive melting of the underside occurs. This discontinuity is open to
the surface. Detectable as low amplitude signal from both the sides of
the weld. Plotting short of plate thickness with no crossover. Difficult to
0
detect if wide and shallow. [ a 45 probe is preferred ]
Undercut : Undercut is a groove cut along the edge of the weld,
caused by excessive melting of base material and left unfilled by the
weld metal. Undercut forms on any or all the four edges of the weld. It
is open to the surface. Produces sharp indication at half or full skip
0
beam path, amplitude depends on depth of cut [ 45 probe preferred ].
May produce twin peaked signal due to beam spread hitting both the
defect and the root bead. Plots short of plate thickness with no cross
over.
Excess Penetration : Excess metal accumulation at root, occurs mostly
after root repair. Low amplitude signal from the root bead, detectable
from both the sides, distinguishing feature is ringing of the falling edge
of the signal. Beam path just longer than half skip beam path. Plots
deeper than plate thickness level with cross over.
Misalignment with / without penetration : Misalignment of the members is
visible at the surface. Produces high amplitude root signal detectable
from the member which is lower in height. Scanning from the other
member does not produce any indication.
Backing Bar : The inherent gap between the backing bar and the base
material and the edges of a narrow backing strip produce indications.
Other defects : Irregular weld surface, Excessive capping, Under fill,
Irregular root penetration, Burn through, Tungsten [ GTAW ],
Tan 80 0
Tan 70 0
Tan 60 0
Tan 45 0
Cos 80 0
Cos 70 0
Cos 60 0
Cos 45 -
5.67
2.74
1.73
1.0
0.17
0.34
0.50
0.70
SF
80 0
70 0
60 0
45 -
5.75
2.94
2.0
1.41