NDT Training Program ULTRASONIC METHOD ® ASNT Continuing Education a In Nondestructive Testing The American Society for Nondestructive TestingUltrasonic Method NDT Training Program Students Guide Boe. Table of Contents Page P: pil Lessong7pes oeseetasneeen ii Worksheet Quiz. Introduction... Related Reading utline.. Lesson 1 Quiz. Lesson 8.. Quiz. Lesson 2, Lesson 9. 1 Worksheet # 1 Quiz... 1 Worksheet Lesson 10........ Worksheet Worksheet #1..... Worksheet Worksheet #1... Quiz... Lesson 4... Worksheet Lesson 11...... Worksheet Worksheet Quiz. Worksheet Quiz.. Quiz... Lesson 5... Lesson 12... ion Worksheet Worksheet #1 Worksheet #1. Quiz. Quiz... Quiz 16 Quiz Continued.. Lesson 13, 16: Lesson 6... 7 Quiz. 172 Worksheet . Worksheet # Quiz. Lesson 14,, ) Quiz.vay Lesson] SIC APPLICATIONS OF ULTRASONICS. "RASONICS iS A VERSATILE INSPECTION TECHNIQUE, IT iS USED TO TEST a \ETY OF BOTH METALLIC AND NONMETALLIC PRODUCTS SUCH AS WELDS, ZINGS, CASTINGS, SHEET, TUBING, PLASTICS AND CERAMICS. ASONICS HAS AN ADVANTAGE OF DETECTING SUBSURFACE D!SCONT! ?S WITH ACCESS TO ONLY ONE SIDE CF THE SPECIMEN SJECTIVE OF ULTRASONIC TESTING IS TO ENSURE PRODUCT RELIABIL- MEANS OF: ITAINING INFORMATION RELATED TO DISCONTINUITIES CLOSING THE NATURE OF THE DISCONTINUITY WITHOUT IMPAIRING . USEFULNESS OF THE PART. . we ARATING ACCEPTABLE AND UNACCEPTABLE MATERIALS IN AC. DANCE WITH PREDETERMINED STANDARDS, AND CERTIFICATION TANT THAT THE TECHNICIAN AND SUPERVISOR BE QUALIFIED IN SONIC METHOD BEFORE THE TECHNIQUE IS USED AND TEST RE- JATED. \N SOCIETY FOR NONDESTRUCTIVE TESTING RECOMMENDS THE DOCUMENT “RECOMMENDED PRACTICE NO, SNT-TC-1A.” NT PROVIDES THE EMPLOYER WITH THE NECESSARY GUIDE- PERLY QUALIFY AND CERTIFY THE NOT TECHNICIAN IN ALL 4 THIS DOCUMENT THE EMPLOYER MUST ESTABLISH A “WRIT- VHICH DESCRIBES IN DETAIL HOW THE TECHNICIAN WILL BE ED AND CERTIFIED. ctive DVISED TO STUDY THE CURRENT EDITION OF SNT-TC-1A TO. Ul =COMMENDED INITIAL NUMBER OF HOURS OF CLASSROOM MONTHS OF EXPERIENCE NECESSARY TO BE CERTIFIED AS STING TECHNICIAN. strUT Lecture Guide Lesson 1 CERTIFICATION OF NOT PERSONNEL IS THE RESPONSIBILITY OF THE EMPLOYER AND IS USUALLY AT THREE LEVELS. FIC CALIBRATIONS, SPECIFIC TESTS, AND SPECIFIC EVALUATIGNS ACCORDING TO WRITTEN INSTRUCTIONS. LEVEL i! SET UP AND CALIBRATE EQUIPMENT AND INTERPRET AND EVALU- TE RESULTS WITH RESPECT TO CODES, STANDARDS AND SPECIFI CATIONS. MUST. BE ABLE TO PREPARE WRITTEN INSTRUCTIONS AND REPORT TEST RESULTS. LEVEL III RESPONSIBLE FOR ESTABLISHING HNIQUES, INTERPRETING CODES, AND DESIGNATING THE TEST METHOD AND TECHNIQUE TO BE USED. MUST HAVE A PRACTICAL BACKGROUND IN THE TECH. GE NOLOGY AND BE FAMILIAR WITH O7| COMMONLY USED METH ODS OF NOT. THE SNT-TC-1A DOCUMENT RECOMMENDS THAT LEVEL | AND Il NDT TECHNI CIANS BE EXAMINED IN THE FOLLOWING AREAS A. GENERAL EXAMINATION B. SPECIFIC EXAMINATION C. PRACTICAL EXAMINATIONUT Lecture Guide Lesson 1 ASNT PROVIDES A SERVICE TO THE INDUSTRY BY PROVIDING LEVEL Ill EXAMI. NATIONS IN THE BASIC AND METHOD AREAS. BECAUSE OF THE INDIVIDUAL REQUIREMENTS OF THE MANY INDUSTRICS USING NDT, THE SPECIFIC EXAMI. NATION IS STILL THE RESPONSIBILITY OF THE EMPLOYER. THE FOLLOWING FLOW CHART INDICATES THE PATHS THAT CAN BE TAKEN TO. BE CERTIFIED ACCORDING TO THE SNT-TC-1A DOCUMENT. ASNT CERTIFICATION WITHOUT EXAMINATION® : Bae ar sacar EXAMINATION BY THE EMPL EXAMINATION BY OUTS EMPLOYER WAIVES EXAMINATION “Comtiicate issued to vu +" This documentation as ecommenged A paragrishs S833 83.4 aac! the SNT-TE-1A. 1980 ection,Key Name UI LESSON 1 quiz The selection of one test method over another is usually the decision of the Level! technician pertorming the test ASNT provides a service for examining Level |, 11 and Itt p sonal in the General an Specific areas. . Tne fesponsibillly of Issuing a ceriificate to tne NOT technician Is always retained t the employer in compliance with the SNT-TC-1A document Hie SNT-TC-1A document Is to be used as a recommended guideline, the “Weltten, Practica” must be submitted to ASNT for approva pais SNT-TC-1A guidatines are followad, the Level ill technician shoulé have a Kpowledge ol other commonly used methods of NOT even thougn cecilllenian is Aeeced only In the ultrasonic area, the nt Ltechniclan perlorming an ultrasonic test Is permitted® to accept or reject or Lancia ee thal weltlen instructions or procedures are given to him by @ Level "I or Level til, “Wn accordance with SNT-TC-1A) TO.gOmPY with the guidsiinas of SNT-TC-14, ali three levels of technicians must take cortices, P*astleat” and “Specific test if examinations are used to deternine certification Je June 1980 Edition of SNT-TC-14 permits the employer to walve an examination for Level Ili personnel provided that documentation 's on tlle showing the technician's qualitications. wad Sesential that every employer thal uses the SNT-TC-14 document establish a “Written Practice.” UU an employer does not have a Level Ill in his company, the services of an outside agency may be retained 10 perform these functions An advantage of ultrasonics Is that it reveals in only one side of the part being inspectea nal discontinuities with access te Ultrasonic inspection techniques can be used without Impaiting the future usefulness of the material. 12 possible pointsay Lesson 2 ULTRASONIC PRINCIPLES IN ULTRASONIC TESTING WE USE SOMETHING CALLED “ULTRASONIC VIBRA- TIONS.” WE MUST KNOW TWO FACTS ABOUT A VIBRATION: 1. A VIBRATION IS A BACK AND FORTH MOVEMENT. 2. A VIBRATION IS ENERGY IN MOTION. A DEPRESSION OF A SURFACE FROM ITS NORMAL POSITION IS CALLED A DISPLACEMENT. - = RUBBER BALL VIBRATIONS PASS THROUGH A SOLID MATERIAL AS A SUCCESSION OF PARTI- CLE DISPLACEMENTS. THIS CAN BE VISUALIZED AS SHOWN BELOW: Ah LIb THE STRUCTURE OF A MATERIAL IS ACTUALLY MANY SMALL PARTICLES OR GROUPS OF ATOMS. THESE PARTICLES HAVE NORMAL OR REST POSITIONS, AND CAN BE DIS- PLACED FROM THESE POSITIONS BY SOME FORCE. WHEN THE FORCE IS REMOVED, THE PARTICLES WILL TEND TO RETURN TO THEIR ORIGINAL POSI- TIONS.UT Lecture Guide: Lesson 2 ENERGY IS TRANSMITTED THROUGH A SOLID MATERIAL BY A SERIES or ¢ SMALL MATERIAL DISPLACEMENTS WITHIN THE MATERIAL. TRANSMISSION OF ULTRASONIC VIBRATIONS THROUGH A MATERIAL IS i} QTED TO THE ELASTIC PROPERTIES OF THE MATERIAL, '" fOU TAP A METAL SURFACE, THE SURFACE MOVES INWARD, CAUSING A DIC @UACEMENT. AS PLATE stRuCK enna a WITH HAKMER support viEwA VIEW 8 “INO THE METAL IS ELASTIC THE SURFACE WILL TEND TO MOVE BACK TO ITS DRIGINAL (REST) POSITION. THE SURFACE WILL ALSO MOVE THROUGH THE UMIGINAL POSITION AND MOVE TO A MAXIMUM DISTANCE IN THE OPPOSITE DIRECTION "Ul", COMPLETE SEQUENCE OF MOVEMENTS IS DEFINED AS A CYCLE, DIRECTION OF : x ae sans . : a L ae HE TIME REQUIRED FOR SOMETHING TO MOVE THROUGH ONE COMPLETE CY- CLE IS CALLED THE PERIOD. EXAMPLE: IF THE SWINGING BALL ABOVE MOVES OVER PATH ABCDE IN ONE SECOND, THEN THE PERIOD OF THE CYCLE !S ONE SECOND.UT Lecture Guide Lesson ¢ THE NUMBER OF CYCLES IN A GIVEN PERIOD OF TIME IS CALLED THE FRE. QUENCY. EXAMPLE: IF THE EALL SWINGS THROUGH THREE COMPLETE CYCLES IN _ NE SECOND, THEN THE FREQUENCY IS 3 CPS (CYCLES PER SEc. OND). IF YOU STRIKE A DRUM, IT HAS A FREQUENCY THAT IS LOW, APPROXIMATELY 50 CPS. THE TOP NOTE ON THE PIANO HAS A HIGHER FREQUENCY, APPROXIMATELY 4300 CPS. THE UNIT OF FREQUENCY USED TO DENOTE ONE CYCLE PER SECOND IS HEATZ (ABBREVIATED Hz). ONE CYCLE PER SECOND (CPS) IS EQUAL TO ONE HERTZ (Hz); 2 CPS = 2 Hz, ETC. SOUND TRAVELS IN METAL AS WELL AS IN AIR. SOUND 1S A VIBRATION AND HAS A RANGE OF FREQUENCIES. MAN CAN ONLY HEAR VIBRATIONS (SOUND) UP TO ABOUT 20,000 Hz, HOWEVER, SOUND FROM AN ULTRASONIC TESTING UNIT 1S ABOUT 5,000,000 Hz. (6 MEGAHERTZ). VIBRATIONS ABOVE THE HUMAN HEARING RANGE ARE CALLED ULTRASONIC VIBRATIONS, THE TWO TERMS, SOUND AND VIBRATIONS, AS WE WILL USE THEM WILL MEAN THE SAME THING. THE BEST WAY TO DEFINE SOUND IS TO SAY THAT IT IS A VIBRATION THAT TRANSMITS ENERGY BY A SERIES OF SMALL MATERIAL DISPLACEMENTS.UT Lecture Guide Lesson 2 ULTRASONIC TESTING IS THE PROCESS OF APPLYING ULTRASONIC SOUND TO A SPECIMEN AND DETERMINING ITS SOUNDNESS, THICKNESS, OR SOME PHYSICAL PROPERTY. THE ENERGY IS ORIGINATED IN SOMET! ING CALLED 4 “TRANSDUCER” WHICH CAUSES MATERIAL DISPLACEMENT W:THIN THE SPECIMEN. : A TRANSDUCER IS A DEVICE THAT CONVERTS ENERGY FROM ONE FoRM To ANOTHER, EXAMPLE: ELECTRICAL ENERGY TO MECHANICAL, OR MECHANICAL To ELECTRICAL, A SPEAKER IN A RADIO CONVERTS ELECTRICAL ENERGY To 4 BACK AND FORTH MECHANICAL MOVEMENT. VIEW “A OW ILLUSTRATES THE “PIEZOELECTRIC EFFECT.” ELECTRICAL ENERGY Is App, THROUGH TWO WIRES CONNECTED TO A CRYSTAL, Caus ING THE CRYSTAL TO VIBRATE, THE TERMS CRYSTAL AND TRANSDUCER ARE USED INTERCHANGEABLY IN THIS LESSON, - NST shan 7 | ELECTRICAL EvERGY | werarion souwo— wine view a view e ELECTRICAL ENERGY CAUSES A PIEZOELECTRIC CRYSTAL TO EXPAND AND CONTRACT, FORMING MECHANICAL VIBRATIONS. TRawsoucen, Nore SOUND IS REFLECTED WITHIN SPECIMEN-ANO RETURNS TO TRANSOUCERUT Lecture Gi Loss ENERGY TRANSMITTED BY A TRANSDUCER CAN BE EITHER PULSED OR CON. TINUOUS. PULSED ULTRASOUND IS DEFINED AS SHORT GROUPS OF TRANSMITTED VIBRATIONS BEFORE AND AFTER WHICH THE TRANSE!7ER CAN ACTAS A RECEIVER. STEEL, WATER AND OIL WILL TRANSMIT ULTRASOUND VERY WELL, BUT AIR . PRESENTS A PROBLEM. rRansoucer ook i Mo - oe on. AIR IS A POOR TRANSMITTER OF ULTRASOUND BECAUSE THE PARTICLE DEN. SITY IS SO LOW THAT IT IS DIFFICULT TO TRANSMIT SOUND. ENERGY FROM t PARTICLE TO PARTICLE. THAT IS WHY WE PUT OIL OR GREASE BETWEEN THE TRANSDUCER AND THE SPECIMEN. i THE PARTICLE DENSITY OF A MATERIAL HELPS DETERMINE THE VELOCITY OF SOUND. THE VELOCITY OF SOUND WILL CHANGE AS 'T MOVES FROM ONE MEDIUM TO ANOTHER AS SHOWN BELOW. THE ELASTICITY OF THE MATERIAL IS ALSO A FACTOR. Sobol s ld a 0.33 KM/SEC 1.48 KM/SEC 5.9 KM/SEC = AIR WATER STEEL © =~ t VISUALIZE THAT THE BALLS SHOWN ABOVE REPRESENT THE INTERNAL STRUCTURE OF AIR, WATER AND. STEEL. THE IMPULSE MOVING THROUGH THE ROW OF BALLS CAN BE COMPARED TOA PULSE OF ULTRASONIC SOUND.UT Lecture Guice Lesson 2 A PRACTICAL” EXAMPLE OF THE VELOCITY OF SOUND’ IN DIFFERENT MATERIALS IS SHOWN BELOW. IT WILL TAKE LONGER FOR THE SOUND TO TRAVEL THROUGH THE WATER HAN THROUGH THE STEEL. THE SOUND VELOCITY iN STEEL IS APPROXIM LY FOUR TIMES GREATER THAN IN WATER A WAVELENGTH IS CONSIDERED TO 8E THE DISTANCE BETWEEN TWO SUC. CESSIVE DISPLACEMENTS, TRANSDUCER WAVELENGTH—1 = | ft» | gy af } THE WAVELENGTH CAN ALSO BE DEFINED AS THE DISTANCE A WAVE TRAVELS DURING ONE COMPLETE CYCLE. “Tt MY bpp © 8 © ® ae VIEW B THE SYMBOL !S USED TO REPRESENT A WAVELENGTH AND IS CALLED “LAMBDA”. -cy UT Lecture Guide Lesson 2 THE ILLUSTRATION BELOW SHOWS 4 TRANSDUCER VIBRATING AT A FIXED FREQUENCY (f} AND TRANSMITTING SOUND WAVES INTO THE SPECIMEN. ‘TRANSDUCER, ai eee “Hr fob td SOUND WAVES —— THESE SOUND WAVES MOVE AT A FIXED VELOCITY (v) THROUGH THE SPECIMEN. _ THE WAVELENGTH CAN BE CHANGED IF THE FREQUENCY OF THE TRANSDUCER VIBRATION CHANGES. VELociT) Noe! WAVELENGTH = —YELOCITY _ f FREQUENCY EXAMPLE: YOU CAN SHORTEN THE WAVELENGTH BY INCREASING THE FREQUENCY, WAVELENGTH IS A RATIO OF A FIXED VALUE (VELOCITY) DIVIDED BY A VARIABLE (FREQUENCY). IN PRACTICAL SITUATIONS, THE SMALLEST DISCONTINUITY YOU CAN FIND WITH ULTRASONIC TESTING IS ABOUT 1/2 LAMBDA (WAVELENGTH). THEREFORE, TO DETECT SMALLER DEFECTS, YOU WILL NEED TRANSDUCERS THAT PRODUCE HIGHER FREQUENCIES. EXAMPLE: WHAT WOULD BE THE SMALLEST DISCONTINUITY THAT YOU COULD FIND IN A STEEL SPECIMEN-WITH A VELOCITY OF 6KM/SEC USING A TRANSDUCER WITH A FREQUENCY OF 3 MEGAHERTZ (MHz). ok ° s . a = BAI OMISEC > siLLIMETERS 3 MHz IF THE SMALLEST DEFECT DETECTABLE IS 1/2 LAMBDA, THEN ‘THE ANSWER IS 1 MILLIMETER OR 0.040 INCHES.C®% & Name UT LESSON 2 WORKSHEET ‘The distance between two displacements fs called the WAVELENGTH. This Is the distance a wave advancss while a particle makes one comelete cycle. The symbol used to represent a wavelength" ) "is called LAMBDA. The wavelength Is a ratio of a fIxed value (VELOCITY) divided by a variable (FREQUENCY). VELOCITY ¥ FREQUENCY t WAVELENGTH = For the purpose of this exercise, consider that tne smallest discontinully detectable us pulse echo testing Is one half lambda 1. What is the smailest detect you can detect with a 2 MH? probe inspecting a steel speci men with a velocity of 6.0 x 10° cm/sec? (answer in inches) (1 mm equals 040") = 3 millimeters ciettct oe my 4080" «CE B. Cc D. 2069 O cay, car pit zkel 2! What is the smallest detect you could detect if you increased the probe frequency to £ MHz? (answer In inches) 2m Mme fers = ba x oye” = Core * 3. What probe below would detect the smallest delect if men with a velocity of 5.9 x 10° cmisec? What is the smaiiest each of the below would detect? 2047 2.5 MHz 9-223 5.0 MHz : 0.011 10.0 MHz 4. With everything else equal, would a wavelength be longer in water or in steel? Sound moves Fastat in greet, THEgeroe? Lomgen MMUE LER you were inspecting a steel speci (answer in inches) 5. With ever . To understand our definition of ultrasonics, a steei ball Is considered to be mare elas! Relative to ultrasonic testing, alr is considered a good conductor and for this reasor ultrasound will carry long distances In alr. . Particle density of a materia! has a direct relationship to the velocity cf sound In tha material. Tha symbol used to represent a wavelength Is called “Shepda.”" thing else eq. tia wavelongth in water would be shorter than a wavelengt In steel. than a lead ball. . Man can hear sounds up to approximately 5,000,900 Hz. . Vibrations pass through a solid material as a series of particie displacemenis. The velocity of sound is slower in steel than In water. The number of cycles In a given period of time !s called the frequency. For the purposes of this lesson, 1/2 the wavelength Is considered to be the smallest dt continultyhat can be detected with ultrasonics. It the longitudinal velocity In aluminum is 6.5 x 10 m/sec and you are using a 2.5 Mr probe, what is the smailest discontinuity you can detect? (3 pts), The ability of a transducer to convert mechanical energy to electrical and electric energy to mechanical is due to the eltect: The distance that an ultrasonic pulse travels while a particle makes one complete cyc Is called mos 7Lesson 3 ULTRASONIC EQUIPMENT CRT MARKER a TIMER purser | ——[ secenen 4 Gare foe] buts ANSEICES 1 circuit [seneRaTom aoe ciRculT Hi sweer cimeuit 7! awsoucen— | | SUPPLY OISCONTINUI Ty Lee J + BACK REFLECTION THE ULTRASONIC PULSE ECHO INSTRUMENT GENERATES HIGH VOLTAGE @ ELECTRICAL PULSES OF SHORT DURATION. THESE PULSES ARE APPLIED TO THE TRANSDUCER WHICH CONVERTS THEM INTO MECHANICAL VIBRATIONS. THAT ARE APPLIED TO THE MATERIAL BEING INSPECTED. A.LARGE PERCENTAGE OF THE SOUND IS REFLECTED FROM THE FRONT SURFACE OF THE TEST PART BACK TO THE TRANSDUCER, THE REMAINDER, 1S REFLECTED BY THE BACK SURFACE OR DISCONTINUITIES, THE SOUND REFLECTED BACK TO THE TRANSDUCER IS CONVERTED BACK TO ELECTRICAL PULSES, WHICH ARE AMPLIFIED AND DISPLAYED ON THE CATHGDE RAY TUBE (CRT) AS VERTICAL-PULSES. THE A-SCAN DISPLAY INDICATES THE DEPTH AND THE AMPLITUDE OF THE SOUND REFLECTIONS FROM A DISCONTINUITY, THE AMPLITUDE IS A RELATIVE MEASURE OF THE AMOUNT OF REFLECTED ENERGY.THE An yy Biscowrmury "un system woBray UT Lecture Gute lesson 3 PULSF-ECKO IS THE MOST WIDELY USED ULTRASONIC SYSTEM. SHORT EVENLY TIMED PULSES OF ULTRASONIC WAVES ARE TRANSMITTED INTO THE MATERIAL BEING TESTED. THESE PULSES REFLECT FROM DISCONTINUITIES IN THEIR PATH, OR FROM ANY BOUNDARY THAT THEY STRIKE THE RECEIVED REFLECTIONS ARE THEN DISPLAYED ON A CATHODE RAY TUBE (CAT). THE SAME TRANSDUCER CAN BE USED TO. TRANSMIT AND RECEIVE, @ = tHRovcy TRANSMISSION REQUIRES THE USE OF TWO TRANSDUCERS, ONE FOR SENDING AND THE OTHER FOR RECEIVING, EITHER SHORT PULSES OR CONTINUOUS WAVES ARE TRANSMITTED INTO THE MATERIAL. THE QUALITY OF THE MATERIAL BEING TESTED IS MEASURED IN TERMS OF ENERGY LOST BY A SOUND BEAM AS [T TRAVELS THROUGH THE MATERIAL. THERE ARE TWO TEST METHODS NORMALLY USED IN ULTRASONIC TESTING Cy “CONTACT TESTING” - WHERE T, TRANSDUCER IS COUPLED TO THE ~~ MATERIAL THROUGH A THIN LAYER OF COUPLANT, “IMMERSION TESTING” - BOTH THE MATERIAL AND THE TRANSDUCER ARE IMMERSED IN A TANK OF COUPLANT (USUALLY WATER)TH UT Lecture Guide Lesson 3 TO DETERMINE THE LOCATION OF DISCONTINUITIES WITHIN A TEST PART, THE CRT HORIZONTAL DISPLAY IS DIVIDED INTO CONVENIENT INCREMENTS SUCH AS CENTIMETERS, INCHES, ETC. 7 | I + bos | AT A GIVEN SENSITIVITY (GAIN) SETTING, THE AMPLITUDE OF THE PIP IS DETERMINED BY THE STRENGTH OF THE SIGNAL GENERATED BY THE REFLECTED SOUND WAVE, THUS, THE CRT DISPLAYS TWO TYPES OF INFORMATION: 1. DISTANCE (TIME) OF THE DISCONTINUITY FROM THE TRANSDUCER 2. RELATIVE MAGNITUDE OF THE REFLECTED ENERGY FOCUS AND ASTIGMATISM CONTROLS - ADJUST THE SHARPNESS OF THE DIS- PLAYED SIGNALS. EF SENSITIVITY OR GAIN CONTROLS - DETERMINE THE AMOUNT OF AMPLIFICA- "TION THE SIGNALS FROM THE DISCONTINUITY RECEIVED, INCREASING THE SENSITIVITY (GAIN) INCREASES THE AMPLITUDE OF THE PIPS ON THE CRT SCREEN. 22UT Lecture Guide Lesson 3 ) TWO CONTROLS, THE “SWEEP LENGTH" AND “SWEEP DELAY" REGULATE HOW MUCH OF THE TEST PART IS DISPLAYED AT ONE TIME ON THE CRT, AND WHAT PORTION OF THE PART IS DISPLAYED. THE SWEEP LENGTH (MATERIAL CONTACL) EXPANDS OR COMPRESSES THE DISPLAY ON THE CRT AS SHOWN BELOW: ae be 0 Fr. 2 +} EXPANDED SWEEP COMPRESSED SWEEP view A views THE SWEEP DELAY CONTROL ALLOWS ONE TO MOVE THE VIEWING SCREEN ALONG THE DEPTH OF THE TEST PART. IN IMMERSION TESTING, THE SWEEP DELAY CAN BE USED TO REMOVE THE INITIAL PULSE FROM THE CRT. A-=INITIAL PULSE 8 FRONT SURFACE PIP C= 1ST BACK SURFACE REFLECTION PIP- EL UT Lecture Guide Lesson 3 “PULSE REPETITION RATE” CONTROL. REGULATES HOW OFTEN THE PULSE IS APPLIED. PULSE RATES VARY FROM 50 TO 1200 PULSES PER SECOND oR MORE. WHEN THE SWEEP is LONG, THE PULSE RATE MUST BE LOWER TO AiLow ENOUGH TIME FOR THE SWEEP. TO BE DISPLAYED BEFORE ANOTHER PULSE IS TRANSMITTED. . IN SOME INSTRUMENTS THE PULSE RATE IS ADJUSTED AUTOMATICALLY, INCREASING THE PULSE LENGTH INCREASES THE AMOUNT OF SOUND ENERGY APPLIED TO THE TEST PART, BUT DECREASES THE RESOLVING POWER OF THE EQUIPMENT. THE “PULSE ENERGY” MUST BE INCREASED TO OBTAIN DEEP PENETRATION COARSE GRAINED MATERIALS. THE “REJECT CONTROL” on “SUPPRESSICN CONTROL” iS USED To ELIMI. NATE OR REDUCE “GRASS” OR VERY Low AMPLITUDE PIPS ALONG T) OF THE SWEEP LINE. THIS CONTROL MAY AFFECT THE VERTICAL LINE OF THE PRESENTATION. A“FLAW ALARM" OR “GATING CIRCUIT” IS U TO ESTABLISH ZONES ALONG THE SWEEP LINE WITHIN WHICH PIPS OF PREDETERMINED AMPLITUDE WILL ACTIVATE EIT! AN ALARM OR A RECORDING SYSTEM, ARITY ALARM AMPLITUDE START OF GATE: END OF GATE view A views 24 €UI Lecture Guide Losson 3 D “DISTANCEIAMPLITUDE CONTROL" - iN ULTRASONIC TESTING THE AMPLITUDE OF THE PIP FROM A DISCONTINUITY OF A GIVEN SIZE DECREASES AS THE DEPTH INCREASES. TO COMPENSATE FOR THIS “ATTENUATION,” AN ELEC. TRONIC CONTROL HAS BEEN ADDED TO MANY ULTRASONIC UNITS. SOME GF THE COMMON NAMES FOR THIS CONTROL ARE: DAC - DISTANCE AMPLITUDE CORRECTION TCG - TIME CORRECTED GAIN STC - SENSITIVITY TIME CONTROL THIS CONTROL IS VERY USEFUL WHEN USED iN CONJUNCTION WITH THE FLAW ALARM AND WITH RECORDING SYSTEMS.Name UT LESSON 3 WORKSHEET #1 A. AS shows Uslow, many ultiasonic units nave £0 divisions along the base line of the CAT By using the simple formuta below, we can make the distance across the screen cistance we wish from about 5 inches to over 106 inches, ‘The formula used to find the vaiue of each division on the screen below screen eseni any Range x2 Increment/Division 98. 100 EXAMPLE: If you wanted the entire screen to represent 10”, we would find that by using the for- mula that, each division on the base line represents 0.2°. Incibiv = 0X2 aU 300 700 0.2" 8. After you have selected a suitable screen ran, match the pulses on the CAT to @ known thi later lessons. ge itis then possibie to use the sweep controls and ickness calibration block. This will be discussed in C. Many Ultrasonic units have 100 divisions across the base line instead of 50. In divide the range by 100 to find the increment per division, . D. On the next page fill in the CRT screens as instructed. this case simply arUT LESSON 3 WORKSHEET #1 On the CRT screens below. draw In the left adge of the first back reflection and al Ivast one multiple Of the back echo as It would appear using a normal beam transducer on & properly calibrated unit. i i i} i coon ot t SCREEN RANGE - 1 inch CREEN RANGE - 25° PART THICKNESS - 0.49" ow. PART THICKNESS - 4 g 7 i T 5 6 7 3 T 3 i ‘ I ; | ! | : | ' | | / | : | ta | | I L 4 ab Lt af : eae Be eee = Pate Tj i ai i 1 i | oe Mf the above CAT Is calibrated to a If the above CRT Is calibrated to a 7" range, what Is the distance to 2.5° range, what is the distance to the pulse? gre the pulse? rz | Fange, where would the pips for EACH SQUARE REPRESENTS 1/4* the two discontinuities and.back echoes 31 an appear as shown is Fig. 17Name__**“ J UT LESSON 3 auiz —E_ 1. with “through Transmission, en increase In ampiliude incl possible discontinuity —E_ 2. the "Puise Echo" system uses a continuous wave and the echo. ; : T's. Both contact testing and Immersion testing require the use of a coupling medium. LL. « typically, ne “gain” control will determine the emourt of amplification for a suspected presence of a arate transducer receives discontinulty Indication, F’_ 5. Sweep length and awaep delay are two names for the same contro FF" 6 The sweep length control is offen used to sweep the inna! pulse off the CRT In immer. slon testing —D_ 7 in tne A-scan presesitation used In contact testing, the height of the vertical deflection (lp) on the CAT represents A. velocity B. elapsed time ©. distance D. signal amplitude —E_ 6. the “aistance amplitude correction conto! has the ability to a the screen range when a thicker part la inspected 2.2L 6, On ne CRT A” below, craw in the pulse I! a normal beam transducer were used to show & 9° deep continulty using a 15" screen range. How many divisions irom the wos aps) 10. On the CRT "B" below. what is the distance to the pulse I! 8 2.5 screen range were be Ing ussd for the inspaction? — @ pie) jomatically Increase ; 165" oe z 3 « 5 0 1 z 7 4 3 A_| | | i B | ! r | : | + : o 4 i ‘0 sbi t =a t r : ipo i =t_= \4 + ae = x. £ 3 FT hit it TAF Gj z i re . |i Ty 1 as eet 7 isnt Dweteawy Ax AL 7 (oe maison ce 14 possible points 33Lesson 4 MODES OF ULTRASONIC WAVE TRAVEL VELOCITY CAN OC DEFINED AS THE DISTANCE A WAVE WILL PROPAGATE THROUGH A MEDIUM IN A GIVEN UNIT OF TIME, USUALLY A SECOND, THE WAVE SPEED REMAINS CONSTANT THROUGH A GIVEN MEDIUM. TRANSDUCER STEEL SS on. couoc sr pot « TS LISTED BELOW IS A TABLE OF IMPEDANCE, VELOCITY AND DENSITY VALUES, 4 THIS INFORMATION WILL BE USEFUL LATER IN THIS LESSON FOR PERFORM- ING BASIC ULTRASONIC CALCULATIONS. ACOUSTIC __ SOUND. mPEance vevocity DENSIT mareriaL | crawcm?-secr_| vcwsecr | ccramvem IR 0.000033 x10 | 0.35 x 10° 0.001 WATER 0.143 x 108 2.49 x 105 1.00 ALUMINUM 1.72 x 108 6.35 x 108 an Steet 4.56 x 10° 5.85 x 10% 78 ULTRASONIC WAVES ARE REFLECTED WHE! A DIFFERENT ACOUSTICAL IMPEDANCE, AN INTERFACE iS THE COMMON BOUNDAI PHASES, SUCH AS ALUMINUM.TO-STEEL 35 N THEY ENCOUNTER A MEDIUM OF THE “SURFACE” AT WHICH THIS REFLECTION OCCURS IS CALLED AN “INTERFACE.” RY BETWEEN TWO MATERIALS OR OR WATER-TO-STEEL.UT Lecture Guice lessen 4 SEAM CF ENERGY APPROACHING AN INTERFACE IS REFERRED TO AS AN “INCIDENT WAVE.” THE ANGLE AT WHICH THE WAVE STRIKES THE INTERFACE IS KNOWN AS THE “ANGLE OF INCIDENCE” AS SHOWN BELOW. | macinary PERPENDICULAR UNE nreseace x ANGULAR INCIDENCE INCIDENT WAVE, THE INCIDENT WAVE IS SAID TO HAVE NORMAL INCIDENCE WHEN ITS DIREC. TION OF PROPAGATION IS PERPENDICULAR TO AN INTERFACE. AS SHOWN BELOW THE ANGLE OF INCIDENCE IS ZERO. | IMCIDENT WAVE Ie NORMAL INCIDENCE SOME OF THE WAVE ENERGY STRIKING AN INTERFACE WILL BE TRANSMITTED THROUGH THE INTERFACE, AND SOME WILL BE REFLECTED AT THE ANGLE OF INCIDENCE, THE AMOUNT OF REFLECTION DEPENDS ON THE ACOUSTIC IMPEDANCE RATIO BETWEEN THE TWO MEDIA INVOLVED. THIS REFLECTANCE FACTOR WILL BE DISCUSSED IN DETAIL IN THE NEXT LESSON.UT Lecture Guide Lesson 4 THE ANGLE OF REFLECTION ar AN INTERFACE OR BOUNDARY ALWays EQUALS THE ANGLE OF INCIDENCE. ANGLE “A" = ANGLE “B" NORMAL INCIDENCE ante \ i enters ANGLE OF REFLECTION TRAWSOUCER = OUPLANT — . |__— INCIDENT Wave INTERFACE GR BOUNDARY. —~\ REFLECTED Wave IMASINARY LIKE ULTRASONIC VIBRATIONS TRAVEL IN MANY MODES, AND THE MOST COMMON ARE: 1. LONGITUDINAL (COMPRESSION) 2. SHEAR (TRANSVERSE) 7 3. SURFACE (RAYLEIGH) 4. PLATE (LAMB) EACH WAVE MODE HAS A SPECIFIC FUNCTION IN ULTRASONIC INSPECTION AND IT IS IMPORTANT THAT EACH BE UNDERSTOCGD COMPLETELY.UT Lecture Guide Lesson 4 LONGITUDINAL (COMPRESSIONAL) WAVES HAVE PARTICLE VIBRATIONS IN A, BACK AND FORTH MOTION IN THE DIRECTION OF WAVE PROPAGATION. CONSIDER THAT ALL MATERIALS ARZ MADE UP OF ATOMS LINED UP IN STRAIGHT LINES TO FORM A LATTICE STRUCTURE. WHEN STRIKING THE SIDE OF THE LATTICE, A CHAIN REACTION OF PARTIC: MOVEMENT !S STARTED CAUSING THE LONGITUDINAL WAVE. Va [Tae = renee | RECTION OF PROPAGATION PARTICLE MOTION eet LonciTuowas waves SHEAR (TRANSVERSE) WAVES HAVE PARTICLE VIBRATIONS PERPENDICULAR TO THE DIRECTION OF WAVE MOTION SHEAR WAVES WILL NOT TRAVEL THROUGH LIQUIDS OR GASSES, IN SOME MATERIALS, THE VELOCITY OF 4 SHEAR WAVE IS ABOUT 4/2 THAT OF LONGITUDINAL WAVES. THEREFORE, THE WAVELENGTH IS SHORTER ‘ABOUT 1/2), PERMITTING SMALLER DISCONTINUITIES TO BE LOCATED. MEDIUM Ht DIRECTION OF PROPAGATION ohahiclede Le elbedat (SHEAR WAVES)UT Lecture Guice Lesson 4 D MODE CONVERSION TAKES PLACE WHEN A SOUND BEAM HITS AN INTERFACE BETWEEN TWO DIFFERENT MEDIA AT AN ANGLE OTHER THAN 90 DEGREES, MODE CONVERSION IN THE CASE PRESENTED BELOW PRODUCES Two REFLECTED BEAMS: ONE BEAM CONSISTS OF LONGITUDINAL WAVES. THE OTHER BEAM CONSISTS OF SHEAR WAVES. . TRANSDUCER / GREASE COUPLANT INCIDENT Bam (LONGITUDINAL WAVES) REFLECTED BEAM (LONGITUDINAL Waves} REFLECTED SEAM (SHEAR Waves) THE ULTRASONIC ANGLE BEAM TRANSDUCER USES THE FOLLOWING EXAM- PLE, THE “REFRACTED” SHEAR WAVES ARE USEFUL IN MANY INSPECTION TECHNIQUES. THE “ANGLE OF REFRACTION” IS THE FRACTED BEAM AS IT ENTERS THE SEC( PERPENDICULAR TO THE INTERFACE. ANGLE FORMED BETWEEN A RE- OND MEDIUM AND A LINE DRAWN NORMAL INCIDENCE, INCIDENT BEAM (LONGITUDINAL) INTERPRE * ‘ANGLE OF REFRACTION (LONGITUDINAL) REFRACTED BEAM (LONGITUDINAL WAVES) REFRACTED BEAM (SHEAR WAVES) ANGLE OF REFRACTION (SHEAR) 39SNELL’S LAW CAN B TWEEN MEDIA FOR BOTH Q SIND, | vy SINS, wg es # THE FOLLOWING EXAMPLE A LONGITUDINAL WAV! E USE! E PASSING THROUGH A UT Lecture Guide Lesson 4 TO DETERMINE ANGULAR D RELATIONSHIPS BE. LONGITUDINAL AND SHEAR WAVES, ANGLE OF INCIDENCE VELOCITY IN FIRST MEDIUM ANGLE OF. REFRACTION VELOCITY IN SECOND MEDIUM CALCULATES THE ou no ANGLE OF REFRACTION, FOR WATER-TO-STEEL INTERFACE. 10 DEGREES = ANGLE OF INCIDENCE @) 2-49 KMISEC = LONGITUDINAL VELOCITY IN WATER (A) 5.85 KMISEC = LONGITUDINAL VELOCITY IN STEEL ,) sind v, sia eV, Ma Vo(sin 4,) sin ¢, «2 | FINST MEDIUM (wat ‘SECOND MEDIUM (57UT Lecture Guide Lesson 4 ) AS THE ANGLE OF INCIDENCE INCREASES, THE ANGLE OF REFRACTION IN- CREASES. WHEN THE REFRACTION ANGLE OF A LONGITUDINAL WAVE REACHES ¢0 DEGREES, THE WAVE EMERGES FROM iHE SECOND MEDIUM AND TRAVELS PARALLEL TO THE INTERFACE OR SURFACE. | THIS IS CALLED ITS FIRST OR-LOWER “CRITICAL ANGLE” ABOVE APPROXI- MATELY 26 DEGREES WITH A PLASTIC-TO-STEEL INTERFACE, ONLY SHEAR WAVES ARE GENERATED IN THE PART. ANGLE cee i PLASTIC STEEL | ur I ' REFRACTED SHEAR Wave IF THE ANGLE OF INCIDENCE IS INCREASED PAST THE FIRST CRITICAL ANGLE, ONLY A SHEAR WAVE IS GENERATED IN THE PART. WHEN THE ANGLE OF RE. FRACTION FOR THE SHEAR WAVE iS SO DEGREES, THEN WE HAVE REACHED THE UPPER OR SECOND CRITICAL ANGLE WHICH PRODUCES SURFACE WAVES, AS SHOWN BELOW, THERE IS THEN TOTAL REFLECTION FOR BOTH LONGI- TUDINAL AND SHEAR WAVES, WITH A PLASTIC-TO-STEEL INTERFACE, THIS HAPPENS AT APPROXIMATELY 58.DEGREES. - REFLECTED LONGITUDINAL wo REFRACTED SHEAR one (SURFACE WAVE) atUT Lecture Guide Lesson 4 WHEN THE INCIDENT BEAM IS AT iTS SECOND CRITICAL ANGLE, A THIRD TYPE OF WAVE'IS DEVELOPED, CALLED A RAYLEIGH OR SURFACE WAVE. AS SHOWN BELOW, THE WAVE TRAVELS WITH AN ELLIPTICAL PARTICLE MO- TION, SURFACE WAVES ARE USEFUL IN DETECTING SURFACE CRACKS, BUT ONLY PENETRATE ABOUT ONE WAVELENGTH. ma ) PARTICLE MOTION sr SURFACE Waves. as SuRFACE AS SHOWN BELOW, SURFACE WAVES HAVE THE ABILITY TO FOLLOW THE SURFACE CONTOUR AS LONG AS THE CONTOUR D NOT SHARPLY CHANGE. HOWEVER, THE SURFACE WAVE CAN BE ALMOST COMPLETELY ABSORBED BY EXCESS COUPLANT OR BY TOUCHING YOUR FINGER TO THE SURFACE OF THE PART AHEAD OF THE TRANSDUCER, TRANSDUCER LZ iseontiuity TEST SPECIMENUT Lecture Guide Lesson a ATE WAVES OR LAMB WAVES HAVE THE ABILITY TO PROPAGATE THROUGH N PLATES IN A VARIETY OF WAVE MODES DEPENDING ON PLATE THICK. ©SS, TRANSDUCER FREQUENCY AND INCIDENT ANGLE. PLATE WAVES ARE GENERATED BY USING LONGITUDINAL WAVES WHICH CEVELOP EITHER SYMMETRICAL OR ASYMMETRICAL WAVES AS SHOWN, Low, : LATE WAVES OCCUPY THE ENTIRE THICKNESS OF THE PART. WITHOUT SATURATING” THE PART, THE WAVE CANNOT EXIST. ’ ty s PaRTiCLe _} morion PARTICLE \ J MOTION SYMMETRICAL ASYMMETRICAL PLATE waves 10 GENERATE PLATE WAVES, YOU ADJUST THE INCIDENT ANGLE TO THE OINT THAT MAXIMUM REFLECTIONS ARE OBSERVED ON THE CRT SCREEN | HOM A KNOWN REFLECTOR. 1 IS NOT POSSIBLE TO GENERATE SHEAR OR SURFACE WAVES ON MATERIALS (HINNER THAN ONE-HALF WAVELENGTH. THEREFORE, PLATE WAVES ARE USEFUL AS SHOWN BELOW. - : Ni ‘TRANSDUCER HOLLOW EXTRUSIONKey Name. UT LESSON 4 WORKSHEET #1 A. Using Snell's Law and the attached Sine tabie, calculate the following refrac ion in the sketch below. LUCITE (long. velocity 2.73 x 105 cm/sec) STEEL 1 ( long. velocity 5.9 x 10° cm/sec) (shear velocity 3.23 x 105 cm/sec) Find the retracted longitudinal wave Il the incigent angie d, is 25 degrees, (SHOW WORK) (2 pts) 2422 “$k yaa # - ‘Ze. 222. Find the retracted shear wave angle If the incident angle is 45 degrees, «SHOW WORK) ,(2 pts) eke) xe 373 x x 33 278 £223. Ityou wanted a shear wave to travel into ine stest at 70 degrees, what would the incident angie through the lucite be? (SHOW WORK) (2 pts) oe 278 7379 323 119, = 18°, is it possible to have a refracted longitudinal wave? W yes, what is it? (SHOW WORK) (2 pts) If no, why not? a noonny 209 - 1 ) ~4e_S. 119, = 96% sit possible to have a retracted longitudinal wave?” If yes, what is it? (SHOW WORK) If no. why not? ! pce eet, retical angle; 4 10 possible points aUT LESSON 4 D ourz T__ 1. An “ultrasonic beam” travels through @ medium as waves of kound energy. 2. Normal incidence Is when the Incident beam Is parallel to the Interfac F 3, The retraction of an incident beam al an interface Is equal to lls angie of reflection, T_ 4. Particte vibration in a longitudinal wave Is in the direction of wave propagation, F__ 5, Shear wave velocity Is approximately twice the velocity of longitudinal waves, 1 6. Mode conversion occurs when & sound beam strikes an interface between two media of —L eaten different velocities at an engie. 7. The bending of an incident beam as It passes through an interface Is called retraction, 8. Longitudinal waves will propagate through both tolids and liquids. 8. Both plate waves and surtace waves can follow the part contour, Sin p. V, Shear velocity In steel = 3.23 x 10" cmisec le Long. velocity In steel = 5.85 x 10 cmisec @ Sin 8, Vz Long. velocity In water = 1.49 x 10" cmisec Long. velocity In lucite = 2.73 x 10 m/sec USING THE ABOVE INFORMATION, SOLVE THE FOLLOWING PROBLEMS. INDICATE THE APPROXIMATE ANGLES ON THE SKETCH AND LABEL EACH, 10. If you wanted a shear wave to travel Into steel! at 60 degrees, what would be the incident angle on the lucite wedge? (SHOW WORK) (3 pis) a IS ° 3 273 See 3.7% = | 5 ° es +e 5 y= 47 i . What would be the refracted longitudinal wave If the angie of incidenca to see! intertace is 12 degrees?” (SHOW WORK) (9 pts) through a water Pg 2o1g _ 14 ® x 7 x 7 eS 49 15 possible points