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Course Outline For Ultrasonic Testing in Accordance With AWS D1.1 and ASME V
Course Outline For Ultrasonic Testing in Accordance With AWS D1.1 and ASME V
Angle Beam
General Information
References:................................................................................................................................................... 2
Math Review ................................................................................................................................................. 2
Trigonometry ................................................................................................................................. 2
Physical Measurements............................................................................................................. 13
Calculate Distances................................................................................................................... 13
Mark Surface Distances on Plate Adjacent to Weld................................................................. 13
Weld Profile/Sound Path Transparency.................................................................................... 13
Basic Angle Beam Calibration .................................................................................................................... 14
Sweep Distance:........................................................................................................................ 14
Sensitivity ................................................................................................................................. 14
APPENDIX A: AWS D1.1............................................................................................................................ 16
APPENDIX B: ASME V ............................................................................................................................... 17
Quiz Questions:............................................................................................................................................. 1
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Angle Beam
General Information
References:
ASME V Article 4 & 5
AWS D1.1 Section 6 & Annexes
ASTM E164
Math Review
Trigonometry
SP = T/cos0: 1st leg Sound Path
SP = 2 x (T/cos0): Full V Sound Path
SD = SP x sin0: Surface Distance
T = SP x cos0: 1st Leg Depth
T = 2 x (T [SP x cos0]): 2nd Leg Depth
T = (SP x cos0) (2 x T): 3rd Leg Depth
SD Full V
SP 2nd leg
SP 1st leg
T
SP 3rd leg
Near Field:
2
N= D x F
(4 x V)
Keep velocity in microseconds to cancel out frequency exponents. Near field
calculations are important when dimensioning flaws because they can mask tip
diffraction signals.
Beam Spread
SIN0 = 1.22 ( / D)
The sin value for angle beam spread equals 1.22 x wavelength divided by
diameter. Its a sin value so you need to do a sin-1 function to convert it back into a
degree value. Beam spread plots may be required and they should always be
supported by a Near Field and Beam Spread calculations. The 1.22 constant plots
the theoretical beam edge. 1.09 constant for 12 dB.
Circumferential Scanning Formula
SIN01 = (ID/OD) x SIN02
Angle Beam General
K2 Technologies Rev 1 05/01/04
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Angle Beam
General Information
Calculates the required refracted angle (01) to produce desired refracted angle (02)
at the inside diameter of the component. Enter the desired angle of refraction at ID
for SIN02; SIN01 is the wedge angle required to achieve the desired angle.
SIN02 = SIN01 / (ID/OD)
To determine angle of refraction at ID for a known wedge angle.
dB equation
dB = 20 x log(Amp%2 / Amp%1)
Used to determine the db difference between two amplitudes.
Wavelength:
= V/F
Longitudinal
Velocity
Shear
Velocity
Air
0.013
0.33
0.0004
Aluminum
0.25
6.3
0.12
3.1
17
Alumina Oxide
0.39
9.9
0.23
5.8
32
Beryllium
0.51
12.9
0.35
8.9
23
Boron Carbide
0.43
11
26.4
Brass
0.17
4.3
0.08
36.7
Cadmium
0.11
2.8
0.059
1.5
24
Copper
0.18
4.7
0.089
2.3
41.6
Glass (crown)
0.21
5.3
0.12
18.9
Glycerin
0.075
1.9
2.42
Gold
0.13
3.2
0.047
1.2
62.6
Ice
0.16
0.08
3.5
Inconel
0.22
5.7
0.12
47.2
Acoustic
Impedance
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Angle Beam
General Information
Iron
0.23
5.9
0.13
3.2
45.4
Iron (cast)
0.18
4.6
0.1
2.6
33.2
Lucite
0.106
2.7
0.05
1.26
3.16
Lead
0.085
2.2
0.03
0.7
24.6
Magnesium
0.23
5.8
0.12
10
Mercury
0.057
1.4
19.6
Molybdenum
0.25
6.3
0.13
3.4
64.2
Monel
0.21
5.4
0.11
2.7
47.6
Neoprene
0.063
1.6
2.1
Nickel
0.22
5.6
0.12
49.5
Nylon, 6-6
0.1
2.6
0.043
1.1
2.9
0.067
1.7
1.5
Platinum
0.13
3.3
0.067
1.7
69.8
Plexiglass
0.11
2.7
0.043
1.1
3.1
Polyethylene
0.07
1.9
0.02
0.5
1.7
Polystyrene
0.093
2.4
0.04
1.1
2.5
Polyurethane
0.07
1.9
1.9
Quartz
0.23
5.8
0.087
2.2
15.2
Rubber, Butyl
0.07
1.8
Silver
0.14
3.6
0.06
1.6
38
Steel, mild
0.23
5.9
0.13
3.2
46
Steel, stainless
0.23
5.8
0.12
3.1
45.4
Teflon
0.06
1.4
Tin
0.13
3.3
0.07
1.7
24.2
0.24
0.2
0.13
0.0584
6.1
5.2
3.4
1.48
0.12
0.11
0.08
-
3.1
2.9
2
-
27.3
101
63
1.48
Titanium
Tungsten
Uranium
Water
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Angle Beam
General Information
General Discussion of Ultrasonic Sizing of Flaws
A full volumetric weld inspection consists of propagating ultrasound throughout the entire weld
metal volume and heat affected zone (HAZ) in a cross pattern; i.e., each angle used is propagated
from both sides to achieve the cross pattern using the 1st and 2nd legs as diagramed below. If
access is limited to only one side of the weld then a 2nd and 3rd leg exam is performed to achieve
the same cross pattern. Whenever possible, use the first leg of sound path in all weld
examinations.
The ASME Section V, Articles 4 and 5 and AWS D1.1 Annex K codes require flaw
dimensioning using decibel (dB) drop sizing methods; e.g., a 50% amplitude drop. It has been
demonstrated that when the flaw is
50% drop 50% drop
50% drop
50% drop
less than the beam spread, the dB
drop sizing method tends to
dimension the beam profile instead
of the actual flaw size, thereby
over sizing the flaw. This
becomes even more pronounced
Flaws
when plotting flaws using an angle
beam; often the flaws plot into the
base metal when they shouldnt, or
they dont plot to the exact same
position from each side of the
weld when they should. The
Flaw dimension
Element dimension
diagram on the right shows the
transducer dimensioning the flaws
via the 50% amplitude drop. The
flaw on the left gets oversized
because its smaller than the beam
profile. The flaw on the left is
accurately sized because its
Figure 3. Flaw Dimensioning, 6dB Drop Method
dimension is larger than the beam
profile.
In addition, it is recognized that other techniques different than the nominal 45o, 60o & 70o shear
wave examinations may be required verify and dimension planar flaws. This is a good reason
why codes specify a scanning sensitivity that is above the reference level. Flaw
Angle Beam General
K2 Technologies Rev 1 05/01/04
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Angle Beam
General Information
characterization and sizing methods such as ID Creeping Waves, Tip Diffraction, Bi-Modal, and
Refracted Longitudinal Waves have demonstrated a higher degree of accuracy for sizing the
depth of planar flaws in pipe, plate and vessel components welds, in lieu of the Amplitude
Comparison or dB Drop Techniques. Tip Diffraction is the only advanced technique discussed
in this curriculum.
Interpreting Signals
Rise and Fall Time
The signal rise time is related to how fast the signal peaks as the transducer is moved toward
a reflector, and how fast it falls when the transducer is moved away from it. As shown
below, the rise and fall time of signals is drastically affected by the angle of the sound beam.
70o
60o
45o
In the above diagram the beam profile is dimensioned instead of the SDH. This can lead to
over sizing flaws as well as underestimating flaw depth. This problem alleviates itself once
the flaw size is equal to or larger then the beam profile. Discontinuities with a through wall
dimension greater than the beam profile dimension will have a longer rise/fall time and be
more accurately dimensioned. Geometry
indications from a weld cap or weld root
exhibit a slow rise/fall time and have a
broad base signal with multiple peaks.
Peaks
Sound that is reflected back to the
transducer at different or varying time of
flight (TOF) indicates a multifaceted
reflector surface and creates multiple peaks
on the signal. In most cases the
multifaceted surface is also irregular to
Angle Beam General
K2 Technologies Rev 1 05/01/04
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Angle Beam
General Information
normal incidence, such as the face of a crack that follows grain boundaries or porosity, both
of which cause sound to be dispersed and lowers signal amplitude. Indications that reflect
sound back at the same TOF do not exhibit multiple peaks. Lower dB to view and interpret
the signal peak
Signal Base
The signal base is related to amplification and to the amount of time, or more
specifically, the difference in TOF from when the first energy is returned from the flaw
to when the last energy is returned; transducer position is static. As shown, a radius
reflector widens the signal base compared to a normal incidence reflector, which is the
narrowest. An irregular surface also causes signal base to increase. A sharp signal has a
narrow base.
Of the nominal angles, the 70o shear wave mode is nearest to normal incidence to a
subsurface vertical weld centerline crack and will return the most energy.
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Angle Beam
General Information
Tip Diffracted
The radial wave pattern that emanates from a long crack tip is reliably detectable only in the
far field and requires a good signal to noise ratio. Better results obtained with a highly
damped 45o or 60o shear wave. Interpretation of RF A-scan display better for low amplitude
signals.
.
These signals are important, due to their vertical orientation these types of planar indications are
difficult to detect. The technician needs to acknowledge their critical nature and further
investigate with other angles.
Transmit Receive
This signal only appears when it reflects from
a planar flaw and is received on a second
transducer. A transmit/receive technique can
be employed to further investigate a planar
discontinuity. Through transmission is an
amplitude attenuation test.
The operator should determine if the weld exhibits a root geometry that will reflect sound
back to the transducer. The sound path should calculate to a thickness equal to or slightly
greater than weld plate thickness. The surface distance from each side of the weld should
not plot exactly to the same point or to the weld centerline. This signal should be closely
interpreted during inspection, so that other root indications coming up just in front of, or
on the front flank of this signal, may be noted and interpreted also.
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Angle Beam
General Information
SD plot overlaps
2. Excessive Root:
Excessive Root is similar to the Root Geometry noted in Figure 9 above. Excessive root
bead will have sharper sides due to excess weld metal melting through. Signals will vary
more in amplitude and exhibit a greater TOF than normal root geometry.
3. Longitudinal Crack (weld metal or HAZ):
Best detected with a 45o angle due to corner trap at ID. Signal will appear sharp with fast
rise time. The 60o angle will provide approximately the return amplitude of the 45o
angle. If the crack follows grain boundaries and exhibits a multifaceted face the signal
may exhibit a multiple peak and return less sound than a notch in a reference block.
Crack indications should plot to same point from each side of weld.
SD plots to same point above crack
Transducer needs to be aligned parallel to weld direction and skewed 30o to propagate
sound in towards the weld root to detect short transverse root cracks. The skewed sound
beam will cause some sound to reflect off small transverse cracks and away from
transducer, reducing the returned amplitude.
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Angle Beam
General Information
Weld Cap
Figure 11. Rotation of transducer for detection of transverse flaws.
A tight root fit up during welding, or poor arc penetration, can make this indication
difficult to distinguish from a centerline root crack. Signal characteristics from IP should
exhibit a single peak because the sound beam is reflecting from a uniform surface.
Surface distance will not plot to exact same point. Depth
will be equal to or less than plate thickness.
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Angle Beam
General Information
Suck Back will plot similar to incomplete penetration. Due to the concaved (rounded)
geometry of suck back the signal may not be as sharp, nor have as much amplitue, as that
of a centerline root crack or incomplete penetration.
Midwall Indications (subsurface)
1. Lack of fusion on bevel face:
The sound beam needs to strike lack of fusion at or near normal incidence, therefore lack
of fusion exhibits greater amplitude on the 2nd leg when scanning from same side of weld
as indication, or 1st leg when on opposite side of weld; unless weld thickness is great
enough the weld cap usually creates an obstacle and the 3rd leg is required when on the
opposite side of the weld joint. A 60o angle is best suited for LOF on a 30o weld joint
bevel and a 70o angle is best suited for LOF on a 22.5o weld joint bevel because they are
nearest the normal incidence of 90o.
Second leg on opposite side
of weld reflects off LOF
A slag line can generally be detected from both sides of the weld. Signal characteristics
may include multiple peaks and a broad base.
2. Porosity
The operator should determine if the weld exhibits a weld cap geometry that will reflect
sound back to the transducer. This is a broad based signal with multiple peaks and is
generally maintained over full length of weld. Adjust amplitude to reference level and
try dampening signal with finger. The sound path should calculate to a full V path or
slightly greater. The surface distance should plot to the opposite side of weld cap. This
signal should be closely interpreted during examination, so that other indications coming
up just in front of, or on the front flank of this signal, may be noted and interpreted also.
Angle Beam General
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Angle Beam
General Information
2. Longitudinal Cracks (weld metal or HAZ)
Longitudinal Cracks are best detected at the end of the 2nd leg of the 45o angle. Shallow
toe cracks are easy to miss when weld cap geometry exists.
3. Transverse Cracks (weld metal or HAZ)
Transducer needs to be aligned parallel to weld direction. The end of the second leg of a
45o angle is best suited for this indication.
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Angle Beam
General Information
Pre Inspection Requirements
It is recommended that these pre inspection requirements be performed prior to calibrating
equipment and examining welds. The results of these measurements may be used to select
the best angle or determine a better technique.
Physical Measurements
1. Measure Weld Thickness (adjacent plate).
2. Measure weld cap width.
3. Measure transducer offset (distance from sound exit point to front of wedge).
4. Add 2 and 3 above, this is the closest surface distance to the weld centerline the
transducer can be positioned.
Calculate Distances
1. Sound Path (SP) for 1st leg or V path.
2. Surface Distance (SD) for 1st leg or path.
3. If SD for V path is less than number 4 above then you CANNOT reach the weld root
on the first leg SP with the angle being used, you will have to use the third leg to get root
coverage or change to a higher angle.
4. Surface Distance (SD) for full V path.
5. Surface Distance (SD) for 1 V path.
Mark Surface Distances on Plate Adjacent to Weld
1. Parallel to the weld mark a 1st leg X line on the plate that is equal to a V Surface
Distance from the weld centerline; when the transducer exit point is on this line the end
of the 1st leg of Sound Path will be at the weld root.
2. Parallel to the weld mark a 2nd leg X line on the plate that is equal to a Full V Surface
Distance from the weld centerline; when the transducer exit point is on this line the end
of the 2nd leg of Sound Path will be at the centerline of the weld cap.
3. Parallel to the weld mark a 3rd leg X line on the plate that is equal to a 1 V Surface
Distance from the weld centerline; when the transducer exit point is on this line the end
of the 1st leg of Sound Path will be at the weld root.
Weld Profile/Sound Path Transparency
The Weld Profile/Sound Path Transparency is a useful tool to help the operator visualize
sound paths within a complex weld joint and to easily and quickly characterize a flaw; it also
serves as a useful tool to diagram to welders or clients where rejects or other discontinuities
are located.
1. Using graph paper draw a cross section of the weld joint.
If weld thickness is much less than one inch the weld joint should be drawn on a 2:1
scale.
Mark the weld centerline and in each direction mark reticules at about 0.2
increments with cumulative distance at major reticules. Reference drawings or use
other means to obtain correct bevel angle(s) of weld joints.
Angle Beam General
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Angle Beam
General Information
Make sure enough base plate exists to support the number of V paths you will use
when examining the weld.
2. On a different graph paper draw, to the same scale, the sound path at the angle(s) and V
paths to be used in examining the weld.
3. Mark the sound path distance at the end of each leg, then mark reticules along each sound
path leg at about 0.2 increments.
4. Copy the weld cross section onto a transparency. You can now take the sound paths and
slide them through the weld to easily visualize weld joint location and surface distance to
discontinuities.
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Angle Beam
General Information
2"
1"
1"
4"
1
"
4"
9"
4"
Figure 17. Plot the next two reflectors
1"
3"
1"
5"
In the above diagrams the dashed sound path is not at an angle that can be received from the
transducer element, only the solid sound path lines are at the correct angle to create a signal. The
distance between signals is equal to the sum of both radiuses.
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Angle Beam
General Information
APPENDIX A: AWS D1.1
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Angle Beam
General Information
APPENDIX B: ASME V
Page 17 of 17
Angle Beam
General Information
Quiz Questions:
NAME:_________________________________________
1. To obtain full volume weld metal examination on a .580 thickness which of the
following scenarios is the most appropriate; i.e., provides the cross pattern with the least
amount of sound path?
a. A 1st leg 70o exam from both sides of the weld
b. A 2nd and 3rd leg 45o exam from both sides of the weld
c. A 3rd and 4th leg 60o exam from both sides of the weld
d. A 2nd and 3rd leg 52o exam from both sides of the weld.
2. What is the surface distance in 1. a. above?
a. 1.96
b. .62
c. 2.0
d. none of the above
3. A beam profile larger than the reflector may dimension the reflector as being
a. Oversized
b. Undersized
c. Correct size
d. +/-.10%
4. The amplitude reflected from a crack should be
a. Equal to lack of fusion of similar size
b. Less than when sound is reflected at less than normal incidence
c. Maximum when sound is reflected at normal incidence
d. Equal to the incident angle amplitude
5. What is the near field length of a .375 diameter, 7.5 MHz transducer propagating a
longitudinal wave mode in steel?
(show your work)
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Angle Beam
General Information
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Angle Beam
General Information
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