Ultrasonic Testing

Weld Inspection using AWS D1.1

1 1/4/2015
Introduction
This presentation will help
students perform testing
using the American
Welding Society Structural
Steel D1.1-2000 code and
procedure.

It is important to
remember that this is a
general training program
and the procedure should
be referenced for specific
information.

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What you will learn
 Completing Form D-11
 Determine the proper transducer(s) needed for
testing a weld.
 Calibration using an IIW, rumpus, and DSC
block.
 Scanning for discontinuities.
 Calculate size and location of a discontinuity.
 Accept/Reject evaluation of a discontinuity.

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Form D-11
Some basic information should be completed on form D-11 prior
to the inspection. This information includes the following:

 Weld Identification
 Material Thickness
 Type of Weld Joint
 Welding Process
 Quality Requirements
 Section Number
 Year of AWS D1.1 Code used.
 Testing Date
 Inspected By
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Step 1 – Specimen Measurement
Measure the part thickness. From this thickness you will need to
calculate the skip distance. The skip distance is the area where you
will scan the part with the proper angle transducer. Mark the end of
the skip distance from the edge of the heat affected zone (HAZ).
The area in red will be used to identify the heat affected zone.

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Step 2 – Inspection Layout
The skip distance will equal the surface distance of the
two legs. You will need to know the distance of this area
in order to perform a lamination scan followed by an
angle beam examination

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Inspection Layout
Identifying the skip distance from the edge of the
HAZ will ensure complete coverage of the weld
when performing an angle beam examination.

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Step 3 – Lamination Scan
A lamination scan will be performed in the area
where the angle beam inspection will take place.
This scan is performed with a straight beam
transducer.

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Lamination Scan
Perform a lamination scan from face “A”. You will need
to see at least two plate thicknesses on the display. The
first backwall reflection shall be 50 to 75% full screen
height.

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Lamination Scan
If any area of the base metal shows a total loss of
backwall reflection, or if an indication is equal or greater
to the backwall reflection, the size and location and
depth will be reported.

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 Lamination Scan
Move the transducer in all directions until the
amplitude of the signal is reduced by 50%. Mark the
center of the transducer.

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Lamination Scan
The area can be measured and included in the report. This
area should be avoided when performing an angle beam
examination or an alternate scanning procedure shall be
used.

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Lamination Scan
Note the location and size of the lamination on report
form D-11 or write an additional report with a drawing
showing its location.

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Step 4 – Transducer Angle
Table 6.6 will list the transducer angles needed to test the weld.
For material 0.60” the transducer angle used will be 70 degrees
and will be tested from face “A”. On Form D-11 record the
transducer angle and face which you will be testing from. The
face is determined from Table 6.6

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Step 5 – Screen Range
Calculate the full V-path. This is determined by the
material thickness and transducer angle. Choose the
appropriate screen range in order to see a minimum
sound path of two legs.

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Step 6 – Screen Range
Calculate the full V-path. This is determined by the
material thickness and transducer angle. Choose the
appropriate screen range in order to see a minimum
sound path of two legs.

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Transducer
Verify the transducer is coupled to the wedge
and there are no air pockets between the two.

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Calibration - IIW Block
All measurements are taken from where the signal
breaks the baseline of the ultrasonic screen.

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Screen Range – IIW Block
Adjust the ultrasonic machine to obtain the proper
screen range. With an IIW type II block shown, the
backwall reflections will be located at 2” and 4”.

Position of the signals

with a 10” screen range.
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Screen Range – IIW Block
The position of the 2” and 4” reflections when using a
5” screen range.

Position of the signals

20 with a 5” screen range.
Screen Range – DSC Block
The distance and sensitivity calibration block (DSC) can be
used for calibration. With the transducer placed in the position
shown, the reflections will take place at 1”, 5”, 9”, etc.

Position of the signals

with a 10” screen range.
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Screen Range – DSC Block
With the transducer placed in the position shown, the
reflections will take place at 1”, 5”, 9”, etc.

Position of the signals

with a 5.0” screen range.
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Screen Range – DSC Block
With the transducer placed in the position shown, the
reflections will take place at 3”, 7”, 11”, etc.

Position of the signals

23 with a 10” screen range.
Screen Range – DSC Block
With the transducer placed in the position shown, the
reflections will take place at 3”, 7”, 11”, etc.

Position of the signals

with a 15” screen range.
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Screen Range – Rumpus Block
The miniature calibration block or rumpus block can also be
used for calibration. With the transducer placed in the position
shown, the reflections will take place at 1”, 4”, 7”, 10” etc.

Position of the signals

25 with a 5” screen range.
Screen Range – Rumpus Block
With the transducer placed in the position shown, the
reflections will take place at 1”, 4”, 7”, 10” etc.

Position of the signals

26 with a 10” screen range.
Screen Range – Rumpus Block
With the transducer placed in the position shown, the
reflections will take place at 2”, 5”, 8”, etc.

Position of the signals

27 with a 5” screen range.
Screen Range – Rumpus Block
With the transducer placed in the position shown, the
reflections will take place at 2”, 5”, 8”, etc.

Position of the signals

28 with a 10” screen range.
Step 7 – Transducer Exit Point
Determine the exit point of the transducer. Peak the signal on
the ultrasonic machine and verify that the index point on the
plastic wedge matches the calibration block. You may use tape
and a pen to mark the exit point. This will allow for easier
measurements when measuring the surface distance.

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Exit Point – IIW Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The pictures below shows the location of the
transducer when verifying the exit point using an IIW type II
block.

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Exit Point – DSC Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The pictures below shows the location of the
transducer when verifying the exit point.

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Exit Point – Rumpus Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of the
transducer when verifying the exit point.

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Step 8 – Transducer Angle
The angle of the transducer will need to be verified. It
shall be within plus or minus 2 degrees of the required
angle.

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Angle – IIW Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.

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Angle – DSC Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.

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Angle – Rumpus Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.

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Step 9 – Transducer Resolution
The resolution shall be checked with the instrument controls set at normal
test settings and the indications from the holes brought to midscreen height.
Resolution shall be sufficient to identify the peaks of the three holes.

Position of the signals

37 with a 5” screen range.
Step 10 – Reference Level
The amplitude of a known size reflector will be
adjusted from 50-75% full screen height. The dB will
be recorded as the reference level on form D-11.

IIW block Rumpus block

DSC block
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Reference Level – IIW Block
The transducer shall be placed in the position shown and the signal
amplitude from the hole will be maximized. Adjust the dB in order to obtain a
signal from 50 to 75% full screen height. This will be used as the reference
level “b” on form D-11.

Position of the signals

39 with a 10” screen range.
Reference Level – DSC Block
The transducer shall be placed in the position shown and the
signal amplitude from the notch will be maximized. Adjust the
dB in order to obtain a signal from 50 to 75% full screen height.
This will be used as the reference level “b” on form D-11.

Position of the signals

40 with a 10” screen range.
Reference Level – Rumpus Block
The transducer shall be placed in the position shown and the
signal amplitude from the hole will be maximized. Adjust the dB
in order to obtain a signal from 50 to 75% full screen height.
This will be used as the reference level “b” on form D-11.

Position of the signals

41 with a 5” screen range.
Step 11 – Reference Level
In this example the reference level “b” would be
recorded as 42 dB. The reference screen height used
is 60% FSH.

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Step 12 – Scanning Level
Scanning level is based on sound path distance and not
material thickness. If table 6.2 (Statically loaded nontubular
connections) are tested, the following scanning levels will be
used.
Above Zero
Sound Path (in) Reference, dB
0.0” to 2.5” 14
>2.5” to 5” 19
>5” to 10” 29
>10” to 15” 39

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Scanning Level
If table 6.3 (Cyclically loaded nontubular connections) are
tested, the following scanning levels will be used.

Above Zero
Sound Path (in) Reference, dB
0.0” to 2.5” 20
>2.5” to 5” 25
>5” to 10” 35
>10” to 15” 45

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Scanning Level
This shows the screen presentation when using a
scanning level 14 dB above the reference level.

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Step 13 – Initial Information Scan
Perform an initial information scan marking the
location of any suspected discontinuities.

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Weld Configuration
You can draw a diagram of the weld on the ultrasonic screen
with a water based marker or grease pencil. The line is drawn
at the end of the 1st, 2nd, and 3rd leg. This may help you
visualize the location of the discontinuity in the weld.

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Step 14 – Surface Distance
Calculate the surface distance in order to determine if
the signal is located in the weld.

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Step 15 – Discontinuity Depth
Calculate the depth in order to determine if the signal
is located in the weld.

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Step 16 – Sound Path
Move the transducer in all directions in order to peak
the signal from the discontinuity. Record the “Sound
Path” on Form D-11.

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Step 17 – Sound Path
Record the “Leg” on Form D-11.

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Step 18 – Indication Level
Increase or decrease the dB until the screen height from the
discontinuity is equal to the reference level. Record the dB
under indication level (column b).

dB reference level - 60% FSH.

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Step 19 – Attenuation Factor
Subtract one inch from the sound path distance and multiply the
remainder by two. This number will be rounded to the nearest
whole number. If the number is less than 0.5 dB it will be
lowered to the nearest whole number. If the number is 0.5 or
greater, it will be increased to the nearest whole number.

In this example, the sound

path is 1.9”

1.9” – 1 = 0.9
0.9 x 2 = 1.8

Rounded to the nearest

whole number - 2
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Attenuation Factor
On Form D-11, fill out the attenuation factor. This is
located under “Decibels- Attenuation Factor.

In this example, the sound

path is 1.0”

1.0 – 1 = 0.0
0.0 x 2 = 0.0

If the attenuation factor is

less than 0.5, the
attenuation factor will be
zero.
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Step 20 – Indication Rating
The indication rating is calculated by taking the
“Indication level” minus “Reference level” minus
“Attenuation factor”. A-B-C=D

The answer “D” is

your indication rating
and can be positive or
negative. Write this
number in column “D”
under “Decibels”,
Indication Rating”

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Step 21 – Discontinuity Length
Maximize the signal amplitude from the discontinuity.

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Step 22 – Discontinuity Length
Slide the transducer parallel with the weld until the
signal amplitude has reduced by 50%. Mark the
location next to the weld aligned with the center of the
transducer. Perform this procedure in both directions.

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Discontinuity Length
Record the length on Form D-11.

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Step 23 – Discontinuity Class
From Table 6.2 or 6.3, determine the Discontinuity
Severity Class. This is based on the Indication Rating
and Length.
Class A (large discontinuity)
Any indication in this category shall be rejected regardless of length

Class B (medium discontinuity)

Any indication in this category having a length greater than ¾” shall be rejected.

Class C (small discontinuity)

Any indication in this category having a length greater than 2” shall be rejected.

Class D (minor discontinuity)

Any indication in this category shall be accepted regardless of length or location in
the weld.

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Step 24 – Discontinuity Evaluation
On Form D-11 under “Discontinuity Evaluation” list the
class of the discontinuity.

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Step 25 – Accept/Reject
On Form D-11 under “Remarks” accept or reject the
discontinuity.

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Step 26 – Distance from “Y”
One side of the plate or weld can be identified with a “Y”
location point. From the edge of the weld measure to the
beginning of the discontinuity. Record “Distance from “Y” on
Form D-11.

Distance from “Y” = 1.0” Distance from “Y” = 0.3”

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Step 27 – Distance from “X”
From the center of the weld (marked in black), if the
discontinuity is located opposite the “Y” location mark, it will be
measured as a positive number. This will be recorded under
“Distance from X” on Form D-11.

Distance from X = 0.2”

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Step 28 – Distance from “X”
From the center of the weld (marked in black), if the
discontinuity is located on the same side as the “Y” location
mark, it will be measured as a negative number. This will be
recorded under “Distance from X” on Form D-11.

64 Distance from X = -0.2”

Step 29 – Scanning Level
Return to the scanning level and locate the next
discontinuity for evaluation.

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