PNNL - 162AER - Cast SS - Crack Sizing

MARCH 23, 2004
162AER001
Qualification of the Future

Technical report
Preface
This document reports all the major results obtained in the project ”qualification of the
Future”. The project was coordinated by Trueflaw Ltd. and funded by Trueflaw Ltd. (Fin-
land), Teollisuuden Voima Oy (Finland), Fortum Nuclear Services Ltd. (Finland), Pacific
Northwest National Laboratory (USA) and Technology Development Agency Finland
(Tekes). Their financial support is gratefully acknowledged.
Objective of the project was to show the applicability of Trueflaw flaw manufacturing
technology to challenging materials and components used in the nuclear industry. All used
materials and components were provided by the project participants and were selected to
be as representative as possible.
Trueflaw flaw manufacturing technology enables production of realistic artificial flaws
directly into wide range of materials and components. Realistic flaws are used in NDE
training and qualification to simulate real, service-induced flaws.
Flaws produced with the Trueflaw method are natural flaws without any additional dis-
turbances in the material. Thus the NDE response from these flaws is very close to those
obtained from service-induced flaws. Trueflaw production technology allows control of
flaw location, orientation and size. Results published in this report show how flexibly
natural flaws can be produced in different materials and components.
The representatives of the participating companies, Dr. Steven Doctor from Pacific
Northwest National Laboratories, Mr. Kari Hukkanen from Teollisuuden Voima Oy and
Mr. Raimo Paussu from Fortum Nuclear Services Ltd. gave valuable support and techni-
cal advice during the project and commented on this report. Their support is gratefully
acknowledged.
Furthermore, the project was carried out in strong cooperation with VTT Industrial
Systems (Finland) and Helsinki University of Technology (Finland). The authors wish to
express their gratitude to these organizations and their representatives, Mr. Jorma Pitkänen
(VTT) and professor Hannu Hänninen (HUT).
Iikka Virkkunen Mika Kemppainen

Managing Director Technology Director
Trueflaw Ltd. Trueflaw Ltd.
2
Contents
Preface 2
1. QUALIFICATION OF THE FUTURE 4
2. AIM OF THE PROJECT 5
3. TASKS 5
3.1 PNNL, Pacific Northwest National Laboratory (PNNL) 5
3.2 Fortum Nuclear Services Ltd. (FNS) 5
3.3 Teollisuuden Voima Oy (TVO) 5
3.4 Other 5
3.5 Production details 5
4. RESULTS 6
4.1 Pacific Northwest National Laboratory (PNNL) 6
4.2 Fortum Nuclear Services Ltd. (FNS) 7
4.3 Teollisuuden Voima Oy (TVO) 9
4.4 Other 10
5. CONCLUSIONS 13
Contact information 14
3
1. QUALIFICATION OF THE FUTURE
The project “qualification of the Future” was coordi- were Helsinki University of Technology and VTT In-
nated by Trueflaw Ltd. and funded by the participants and dustrial Systems, respectively.
Technology Development Agency Finland (Tekes). Originally the planned duration of the project was one
Participating companies were Trueflaw Ltd. (Finland), year, but was later extended by one month. The actual
Teollisuuden Voima Oy (Finland), Fortum Nuclear project duration was 1.10.2002-31.10.2003.
Services Ltd. (Finland) and Pacific Northwest National The management group gathered three times during
Laboratory (USA). the project. Meeting minutes of all three meetings were
Trueflaw’s main motivation for the project was to prove made and delivered to project participants. Meeting dates
the capabilities of the new technology and to obtain and places were:
references in challenging nuclear industry applications. 1) 12.2.2003 Trueflaw Ltd, Espoo Finland
Participation motivation for Pacific Northwest National 2) 9.6.2003 Fortum Nuclear Services, Vantaa, Finland
Laboratories was to gain information and experience of 3) 6.10.2003 Pacific Northwest National Laboratory,
the artificial flaw manufacturing method to be able to Richland, WA, USA
evaluate its potentials. Participation motivation for both Table 1 shows the work schedule including all tasks per-
TVO and Fortum Nuclear Services was to support the formed during the project. Officially the project started
development of the new artificial flaw manufacturing 1.10.2002, but the practical work was fully started after
method and increase the knowledge of the potentials the funding was confirmed by Tekes in the beginning
of the new technology. of year 2003.
Two major subcontractors provided the equipment ca-
pacity and nondestructive examinations needed. These
Table 1 Project tasks and schedule.
Qualification of the Future

Project timetable - ok, work done -management group meeting
- under construction - planned NDT reporting by VTT
- planned work a - NDT/basic inspection
2002 2003
Action Oct Nov Dec Jan Feb Mar Apr May June July Aug Sep Oct
Management group meeting
Specimens from ABB to Trueflaw
PT by Trueflaw
Research Plan
Research plan
Research Plan
Design+manufact. of fixtures etc.
UT of specimens a
Crack manufacturing
Specimens from TVO to Trueflaw
PT, UT, ET a a
Crack manufacturing
Specimens from FNS to Trueflaw 2
PT, UT, ET, destructive a1 1 2 2 2 1 2
Specimen shipping to TVO 2
Crack manufacturing 2 2 2
PT, UT, ET
Specimen shipping to PNNL 2
Final reporting
Final reporting
Final reporting
Specimen shipping to FNS
NDT report/VTT 1 -> 2 ->
NDT report/VTT -> ->
NDT report/VTT ->
4
2. AIM OF THE PROJECT
The aim of the project was to show the applicability of Furthermore, the aim was to show that the method can
Trueflaw artificial flaw manufacturing method to different, be used to ready-made full-size mock-ups. Such mock-ups
challenging nuclear power industry austenitic materials were a real size core spray nozzle safe-end from BWR
and one ferritic material in a specific case. Challenging type NPP (TVO) and a T-joint of primary pipe from a
austenitic materials were large grain cast austenitic stain- PWR type NPP (FNS).
less steel (PNNL) and Inconel 600 (TVO). The ferritic Test materials and specimens were provided by the
material used was a “St 52” carbon steel in dissimilar project participants.
metal weld construction (FNS).
3. TASKS
The original work plan of the project is included in plan was to produce two flaws in the specimen. The
the Appendix 1. Different participant-specific tasks are first flaw was to be produced in the heat affected zone
shortly presented in the following. of the butt weld between austenitic stainless steel (AISI
316) and Inconel 600 within the AISI 316 material. The
3.1 PNNL, Pacific Northwest National
second flaw was to be produced in the heat affected zone
Laboratory (PNNL) of the buttering weld between Inconel 600 and carbon
Pacific Northwest National Laboratory provided large steel (A508) within the Inconel 600 material. Intended
grain cast austenitic stainless steel specimens for the depths of both flaws were 5 mm and lengths 15 mm
project. There were five specimens, three of them included (aspect ratios 1:3).
previously made thermal fatigue cracks (made by PNNL),
one was a calibration specimen with EDM-notches and 3.4 Other
one a blank specimen. All specimens were sections of During the project there were some second priority
a primary pipe butt weld, consisting of equiaxed and interests to show the applicability of the method to two
dendritic materials welded together. narrow gap GTAW welded austenitic stainless steel speci-
The aim was to produce one flaw in the equiaxed side ments. Flaws were produced in the heat affected zone of
of the weld in the blank specimen, close to the fusion welds. This work was performed as Trueflaw Ltd interest
line. The crack size to be produced was 25% of the wall with specimens owned by Trueflaw Ltd.
thickness (thickness 60 mm) hence being 17 mm deep and Additionally, an interest rose to study the effect of ther-
34 mm long (aspect ratio 1:2). Plan was to compare the mal fatigue loading on the obtained ultrasonic response
NDE response of the flaw produced during the project from ready-made flaws. These studies were performed
to responses of those produced previously by PNNL. with several flaws in different specimens. During the
studies the crack behavior was monitored in-situ using
3.2 Fortum Nuclear Services Ltd. (FNS) thermal loading. Monitoring was performed with dif-
There were two flaw production tasks for Fortum ferent ultrasonic probes and techniques and a digital
Nuclear Services. These were production of a flaw in video camera.
the ferritic material of a dissimilar metal weld speci- The aim of these studies was to understand the crack
men and production of a flaw in a massive (420 kg) real behavior under different thermal loading cycles, the ef-
size ready-made primary circuit pipe nozzle mock-up. fect of loading on the residual crack opening and ultra-
In both cases the flaws were to be produced in the in- sonic response from different parts of the crack during
ner diameter of the specimen, in the heat affected zone dynamic loading. The surface opening behavior was
(HAZ) of the weld. recorded by video camera. The ultrasonic data obtained
The flaw location in the dissimilar metal weld was in revealed the behavior both in surface and subsurface
the ferritic steel within the heat affected zone (HAZ) of parts of the crack.
the buttering weld. Only indicative size specifications
were given for the intended flaw in the dissimilar metal 3.5 Production details
weld. The location of the intended flaw in the massive, The applied flaw manufacturing method utilizes ther-
real-size mock-up was in the HAZ of the pipe weld- mal fatigue damage mechanism. Local thermal fatigue
ment between the austenitic stainless steel pipe and the loading is applied by high frequency induction heating
nozzle. The specified length of this flaw was 15-16 mm and water or air spray cooling. Applied flaw production
and depth 7-8 mm. tolerances were ±2 mm for length and ±1 mm for depth
in all cases.
3.3 Teollisuuden Voima Oy (TVO)
Teollisuuden Voima Oy provided a ready-made core
spray nozzle safe-end mock-up for the project. The
5
4. RESULTS
Participant-specific results are presented in this chapter. the surface opening so, that the final maximum surface
opening is 200 µm. The lower part of the Figure 2 shows
4.1 Pacific Northwest National Laboratory
the dye penetrant indication after thermal fatigue load-
(PNNL) ing versus in-situ UT studies. In addition to increased
The type of specimen used in these tests is shown in maximum opening (as seen in the middle of the crack),
the Figure 1. The butt weld is visible in the specimen. the figure clearly shows contrary behavior of flaw tips
The equiaxed material is to the left side and dendritic and branches, showing weaker dye penetrant indication.
material to the right side of the weld. This indicates, that while the loading in the middle of the
A single flaw was produced in the specimen, in the flaw has increased the opening, the stabilizing stresses
equiaxed side of the weld. The dye penetrant indication have closed the flaw extremities.
of the ready-made flaw is shown in the upper part of Flaw sizing with ultrasonic testing of the produced
the Figure 2. The flaw depth is 16 mm and the length flaw was subcontracted to VTT Industrial Systems. Their
33 mm, hence meeting the specified production toler- report of nondestructive inspection results is attached as
ances. The maximum surface opening of the flaw was Appendix 2. The specimen was nondestructively tested
85 µm before performing dynamical thermal fatigue also by PNNL. This report is attached as Appendix 3.
loading versus in-situ ultrasonic testing studies. The The specimen will be used for NDT studies by PNNL
applied loading cycles of those studies clearly changed and presumably won’t be destructively tested.
Figure 1. Blank cast, large grain austenitic stainless steel specimen provided by PNNL.
Figure 2. Dye penetrant indications of the ready-made flaw a) before and b) after thermal fatigue loading versus in-situ ultrasonic
measurement studies.
6
4.2 Fortum Nuclear Services Ltd. (FNS)
A flaw was produced in the dissimilar metal weld speci- tion of a flaw in ferritic material, there remained a need to
men provided by FNS. The specimen was made of carbon develop the method to meet the challenges of controlled
steel and austenitic stainless steel with a buttering weld as flaw growth and further development is needed to find
shown in the Figure 3. The produced flaw was the first the optimum parameters.
ever made in the carbon steel with the Trueflaw method. The second FNS task was to show the capability of the
Hence, there were several trials needed to find suitable Trueflaw method in producing a flaw in a massive, real-
manufacturing parameters. As a result, a single flaw was size mock-up of primary circuit pipe nozzle (Figure 5).
produced in the heat affected zone of the buttering weld The primary pipe is made of Russian type Ti-stabilized
in the carbon steel as shown in the Figure 4. The flaw austenitic stainless steel 08X18H12T and the nozzle is
length was 7.5 mm and depth 2-3 mm, depth determined made of western type Ti-stabilized austenitic stainless
by ultrasonic testing. Despite the success of the produc- steel W1.4541.
Figure 3. Drawing of the dissimilar metal weld specimen and construction of the buttering weld between austenitic (right side) and ferritic
(left side) pipes.
Figure 4. Flaw produced in the heat affected zone of the dissimilar metal weld. Ferritic material is in the upper part of the figure. The
produced flaw has grown in the ferritic material, in the heat affected zone near the buttering weld.
7
A flaw was produced in the pipe to nozzle joint, in the
inner surface of the nozzle as shown in Figure 6. The
flaw location was chosen by the representative of FNS
to be 33-38 mm from the primary pipe inner surface and
in the circumferential location of 225° (measured from
the 0°-position specified by FNS). Figure 7 shows the
dye penetrant indication of the ready-made flaw in the
heat affected zone of the pipe to nozzle weld. The flaw
length is 15.5 mm and depth 7.7 mm. Flaw is located in
the primary pipe side of the weld 35-38 mm from the
inner surface of the primary pipe. The right end of the
flaw touches the fusion line while left end is about three
millimeters away from the fusion line in the HAZ.
Figure 5. Massive (420 kg), real size primary circuit pipe nozzle
mock-up. Diameter and wall thickness for the primary
pipe were 570 mm x 36 mm, and for the nozzle 313 mm
x 52 mm, respectively.
Figure 6. Flaw located in the pipe to nozzle joint in the inner surface of the nozzle.
Figure 7. Dye penetrant indication of the produced flaw in the heat affected zone of the pipe to nozzle weld.
8
Flaws produced for FNS were only briefly nondestruc- artificial defects in the specimen and only limited space
tively tested and there is no NDE report available. The for intended flaws. Figure 9 shows the drawing of the
specimen will be used in procedure qualification and later specimen and locations for two intended flaws.
in personnel training. Two flaws were produced in the core spray nozzle, the
4.3 Teollisuuden Voima Oy (TVO) first one in the heat affected zone of the austenitic stain-
The TVO tasks included both a new material applica- less steel and the second one in the heat affected zone
tion, Inconel 600, and performance demonstration of of the Inconel 600.
the capability of producing flaws in a realistic, full size The aimed location for the first flaw was 5-10 mm from
core spray nozzle safe-end mock-up. The flaws were to the weld center line (WCL). The dye penetrant indication
be made in the inner diameter of the specimen shown of the first flaw in austenitic stainless steel is shown in
in Figure 8. The flaw locations and orientations were Figure 10. Flaw length is 15.5 mm and depth 5 mm and
selected according to instruction given by the repre- it is located about 6 mm from the WCL.
sentative of TVO. There were several previously made
Figure 8. Real size core spray nozzle safe-end mock-up with three different ultrasonic probes used for thermal fatigue loading versus
ultrasonic response studies.
Figure 9. Drawing of the specimen and flaw locations.
9
The second flaw was produced in the heat affected zone The nondestructive inspection report is attached as Ap-
of the Inconel 600. Figure 11 shows the dye penetrant pendix 4. The specimen will be used for NDT training
indication of the flaw. The flaw length is 14.2 mm and and won’t be destructively tested.
depth 5 mm. The figure shows also a small, less than 1 4.4 Other
mm deep secondary indication in the corner of a shoulder Narrow Gap GTAW Welds
visible in the lower part of the figure. The initiation of A Trueflaw interest was to show the applicability of
the secondary flaw was caused by the stress rising effect the method to narrow gap GTAW-welded specimens.
of the shoulder. Without vicinity of such a stress riser, These specimens were made of AISI 304 and AISI 316
there would have been no secondary indication. The type austenitic stainless steels and provided by Trueflaw
secondary indication does not affect the performance Ltd.
of ultrasonic testing, as it is located about 7 mm away
from the actual flaw.
Figure 10. Dye penetrant indication of the flaw in the heat affected zone of the AISI316.
Figure 11. Dye penetrant indication of the flaw in the heat affected zone of the Inconel 600.
10
Figure 12 shows dye penetrant indication of a single flaw weld root, near the right end of the flaw, was caused by
produced in the heat affected zone of narrow gap weld locally unhomogeneous material. Loading of the adjacent
on the inner diameter of AISI 316 austenitic stainless material caused high enough stresses to break the weak
steel pipe section. The weld material is AISI 316 austenitic material in the centre line of the weld root.
stainless steel as well. Wall thickness of the pipe was 20 Figure 13 shows the specimen and dye penetrant indi-
mm and diameter 320 mm. The figure also shows some cation of a flaw produced in the heat affected zone of
smaller, secondary indications both in the base material narrow gap GTAW weld on the outer diameter of AISI
and weld root. Indications in the base material near the left 304 austenitic stainless steel pipe section. The weld mate-
end of the flaw were caused by erroneous initial produc- rial is AISI 308LSi austenitic stainless steel. Wall thickness
tion parameters and local changes in the microstructure of the pipe was 14 mm and diameter 168 mm.
of the heat affected zone. The maximum depths of these The nondestructive inspection report of both GTAW
indications are 1-2 mm. One secondary indication in the specimens is attached as Appendix 5.
Figure 12. Produced flaw in the heat affected zone of narrow gap GTAW weld. Base material AISI 316, weld material AISI 316.
Figure 13. Produced flaw in the heat affected zone of narrow gap GTAW weld. Base material AISI 304, weld material AISI 308LSi.
11
Studies of thermal loading vs. UT response
During the project, an interest arose to study the
changes of ultrasonic response from the flaw during
thermal fatigue dynamic loading of ready-made flaws.
These studies were conducted by in-situ measurements
with different flaws and specimens, several ultrasonic
probes and techniques. Studies were begun with a plate
specimen with previously made large (length 20 mm,
depth 7.5 mm) thermal fatigue flaw in it. As an example,
Figure 14 shows two different probe fixtures used in
these studies. Totally, there were 16 different probes, two
different data collection modes (RF+Log), 21 different
thermal fatigue cycles and three different probe fixtures
used. Hence, there were 63 different series of loading Figure 15. Specimen and ready-made flaw used in the thermal
cycles and in all 420 loading cycles applied. fatigue loading versus ultrasonic response studies of
cast austenitic stainless steel.
Figure 16. Core spray nozzle specimen and ready-made flaws

used in the thermal fatigue loading versus ultrasonic
response studies of AISI316 and Inconel 600.
Figure 14. Two different probe fixtures used in thermal fatigue
loading versus ultrasonic response studies of a plate
specimen.
Good results obtained with the plate sample encour- presented in two different conferences. Three of them
aged us to perform similar studies with real specimens (Appendices 6-8) were given in the 30th annual Review
available in the project. Studies were performed with of Progress in Quantitative Nondestructive Evaluation
the large grain cast austenitic stainless steel specimen (QNDE) Conference, held in Greenbay, Wisconsin 28.7.
and the core spray nozzle mock-up shown in the Figure - 1.8.2003. One paper (Appendix 9) was given in the
15 and Figure 16, respectively. Studies were performed Vessel Penetration Inspection, Crack Growth and Repair
with realistic flaws produced in these specimens during Conference, sponsored by USNRC and Argonne National
the project. Laboratory, held in Gaithersburg, Washington D.C. 29.9.
Results of studies of thermal fatigue loading versus ultra- - 2.10.2003 (proceedings to be published in 2004).
sonic response obtained from different parts of flaws were
published during the project as four conference papers
12
5. CONCLUSIONS
There were two main goals in the project: the first was the participants gave positive feedback on the project.
to demonstrate the performance of the Trueflaw method Comments given by the participants are enclosed as Ap-
to challenging nuclear materials and constructions and the pendices 10-12. The blank feedback commentary form
second was to acquire representative references for the provided by Trueflaw is enclosed as Appendix 13.
new technology. The Trueflaw method had not before The main technical results obtained proved that the
been used for all of materials and constructions provided technology is applicable to large grain cast austenitic
by the project participants. It was understood in the plan- stainless steel (CCSS-material), Ni-based Inconel 600-al-
ning stage of the project, that implementation of most loy and real size components (pressure vessel core spray
planned tasks would need situation specific assessment. nozzle and massive primary pipe nozzle). In addition,
This came true and many technical challenges were met knowledge has substantially increased in the control of
during the implementation. Hence, task specific plans the loading cycle, repeatability of the flaw manufacturing
had to be altered in order to reach the aims set. Despite and understanding of the ultrasonic response obtained
the challenging aims, remarkable results were achieved from produced flaws in the as produced condition and
during the short duration of the project. All major aims under dynamical loading.
set in the beginning of the projects were fulfilled. All of
13
APPENDIX 1
WORK PLAN FOR PNNL
In the research project "Qualification of the future" Trueflaw Ltd. produces
thermal fatigue cracks, that are representative and usable as a qualification
defect, in a blank specimen provided by PNNL. The blank specimen (B501)
consists of two pipe sections welded together; one of the sections has equiaxed
microstructure and the other one dendritic microstructure. Pipe sections are butt-
welded and there is a counterbore in the welded area. During the project
produced crack will be compared to thermal fatigue cracks previously made by
PNNL in other similar pieces. The crack location is not critical because the base
metal has large grain size and most of the insonification is controlled by the base
metal scattering properties. The crack depth is chosen to compare cracking by
the two different cracking processes (PNNL vs. Trueflaw). The crack size is
larger than the grain size and suitable for producing a representative UT signal.!
A crack will be produced in the counterbore region near the weld, in the
equiaxed material. The aimed crack length is 34 mm and depth 17 mm - 25% of
the wall thickness. The maximum attainable depth of a fatigue crack is half of its
surface length. Crack is located in the vicinity of the weld centerline. The crack
depth 25% of the wall thickness is in the range of where the probability of
detecting is high and UT provides useful structural integrity information on the
CSS component.
PNNL also provide other specimens. These specimens include previous made
thermal fatigue cracks and a calibration standard. Specimens will be tested with
different NDT methods and compared to crack produced during the project.
Specimens are:
- B515 with a thermal fatigue crack that is 32 mm long and 17 mm deep
- B504 with a thermal fatigue crack that is 61.5 mm long and 28 mm deep
- B519 with a thermal fatigue crack that is 57 mm long and also 28 mm deep
- B505 a calibration standard with side drilled holes and 10% end milled
notches
- B501 a blank with no cracks (to be used for crack production during the
project)
According to penetrant tests, all present cracks are in the equiaxed side of welds.
The distance between cracks and weld could not be accurately measured, but
cracks seemed to be inside 3-4 mm range from the weld centerline. Cracks in
sample B515 and B504 gave clear indication on dye penetrant testing, but only
very weak indication was obtained from sample B519. Furthermore, the
indication in B519 is separated in two sections. PNNL manufactured these
cracks by introducing a small, 1 to 1.5 mm starter notch and applying a thermal
loading. After the crack was grown to final size, the starter notch was ground
out in such a way that the cracked region blends with the surrounding material.!
1(3)
Work plan:
Action Time-table Situation
Specimens from ABB to Trueflaw 12/02 Ok
PT by Trueflaw 01/03 Ok
Research plan 01/03 Under constr.
Design+manufact. of fixtures etc. 02/03 Plan
UT of specimens 02/03 Plan
Crack manufacturing 03-05/03 Plan
PT, UT, ET 06-07/03 Plan
Specimen shipping to PNNL 07/03 Plan
Final reporting 08-09/03 Plan
2(3)
WORK PLAN FOR FNS AND TVO
In the project “Qualification of the Future” Trueflaw produces
representative thermal fatigue cracks in specimens given by Fortum Nuclear
Services Oy (FNS) and Teollisuuden Voima Oy (TVO). Suitable specimens
are selected so, that they serve the NDT qualification development of FNS
and TVO and they represent new developments for Trueflaw.
After the project FNS and TVO will have specimens with realistic cracks to
be used for NDT training and qualification purposes.
FNS will provide the project with two types of specimens. These are a full-
scale mock-up T-joint of primary circuit pipe from VVER 440 type NPP
(sample YA 004, ca 200 kg) and dissimilar weld specimen. In addition to
Trueflaw cracks, FNS will produce other defects with its own methods in the
specimens. FNS has capabilities to produce both mechanical fatigue and
solidification cracks.
Crack will be produced in the inner surface of the T-joint near the weld
fusion line. Dimensions and location of the crack will be selected later. The
specimen will be used as training sample after the project and will not be
destructively tested. All the information of the sample can be published.
FNS will manufacture a new dissimilar metal butt-welded pipe specimen for
the project. Specimen consists of two pipes: ferritic st52 pipe and austenitic
stainless steel TP316L pipe. Outer diameter of pipes is 160 mm and inner
132 mm. Filler metal for the butter weld will be AWS A/SFA5.4: E309 MO-
17 and for the weld AWS A/SFA5.4: E316L-17. Accurate crack dimensions
and location will be determined later. Both Trueflaw and FNS will produce
flaws in the specimen, which will finally be destructively tested.
TVO has a ready-made reactor safe-end mock-up consisting of nozzle, safe-
end and pipe parts. The nozzle is made of ferritic steel A508, the safe-end of
Inconel 600 and the pipe of AISI 304L type austenitic stainless steel. A crack
will be produced in the heat affected zone of the weld, parallel to the weld.
The size of the intended crack is about 15 x 5 mm (length x depth).
Production of two cracks is planned: one in the nozzle/safe-end joint and
the other one in the safe-end/pipe joint. Specimen has been used for open
trials and all the information can be published. More information about the
sample can be found in the Masters thesis of Kalle Maukonen (in Finnish).
Specimen will remain as training sample for mechanized inspections and
will not be destructively tested.
3(3)
APPENDIX 2
RESEARCH REPORT NO TUO77-032705 11.7.2003
Inspection of austenitic castings

Customer: Trueflaw Ltd
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
VTT INDUSTRIAL SYSTEMS

1 (11)
Public Registered in VTT

publications register JURE
Confidential X
Internal use only
Title
Customer or financing body and order date/No. Research report No.
Trueflaw Ltd. TUO77-032705
Project Project No.
TUPÄ-03 G3SU00202
Author(s) No. of pages/appendices
Jorma Pitkänen 11 p + app. 7 p
Keywords
ultrasonic inspection, castings, dye penetrant testing
Summary
In this report the inspection of austenitic castings is reported . These castings contained
several flaws, which were inspected with dye penetrant and ultrasonic testing. In these
inspections the lengths of defects were determined with dye penetrant testing and the
heights of cracks were estimated with 1 MHz TRL-probe. The estimated sizes for cracks
were between 11 - 32 mm and the lengths of cracks varied from 28 mm to 67 mm.
The ultrasonic inspection was extreme difficult, because of the grain structure of the base
material and also the weld material. The only probe, which gave reflections from the
calibration block reflectors was 1 MHz TRL-probe focussed to 80 mm sound path. The
measured results from the 5 different specimen are shown in this report.
Date 11 July, 2003
Rauno Rintamaa Jorma Pitkänen

Research Manager Research Scientist Checked
Distribution (customers and VTT):
VTT 1 (Jorma Pitkänen); Trueflaw 1 (Mika Kemppainen); PNNL 1 (Steven Doctor)
TVO 1 (Kari Hukkanen); Fortum 1 (Raimo Paussu)
The use of the name of VTT in advertising, or publication of this report in part is allowed only by written
permission from VTT.

Kemistintie 3, Espoo Tel. +358 9 4561 name.surname@vtt.fi
P.O. Box 1704, FIN-02044 VTT Fax +358 9 456 7002, www.vtt.fi/tuo
FINLAND +358 9 456 5875 Business ID 0244679-4
Appendix 1 2(11)
1/ 3 RESEARCH REPORT No: TUO77-032705
Foreword
Espoo 11th July 2003
This study is carried out in co-operation with Trueflaw Ltd in the project of Future
Qualification and the author is thanking every partner from their valuable information to
inspected components
Author
Appendix 1 3(11)
Table of contents
1 Introduction ................................................................................................... 4
2 Goal ................................................................................................................ 4
3 Restrictions of the study .............................................................................. 4
4 Methods ......................................................................................................... 4
5 Results ........................................................................................................... 6
6 Discussion ................................................................................................... 10
7 Conclusions................................................................................................. 10
References ............................................................................................................. 11
Appendix 1 4(11)
1 Introduction
The surface flaws in pipings can produce a leak if they can grow to the critical size. In some
cases the piping material is extremely difficult to inspect with any NDT-method. Even
radiography in thick walled cast material components can be at the limit of the resolution. The
cracks must be in the same direction as the X-ray beam, otherwise they are difficult to detect.
In this study ultrasonic inspection and dye penetrant testing were used for detection and sizing
of defects in austenitic casting material. These materials are extreme difficult materials for
ultrasonic testing because of the very coarse grained stucture of cast austenitic steel.
2 Goal
The goal of this inspection was to determine the sizes and lengths of the various cracks in the
PNNL test specimen. The main emphasis was to determine the size of the new crack
manufactured by the Trueflaw method.
3 Restrictions of the study

The coarse grained material caused limitations for probes suitable in the inspection. The used
technique had following limitations.
Low frequency - 1 MHz - low spatial resolution

Large piezo crystals - difficult to keep proper contact in
inspection
Longitudinal wave mode -low corner echo reflectivity
Transmitter-receiver -probe - limited focus thickness
Because of these limitations the real inspection repeatability and accuracy is decreased not
only because of the grain size and orientation.
4 Methods
Four test specimen having a crack were inspected and one specimen (B505) was used as a
calibration block, figure 1. Specimen B505 contains side-drill holes in different depths ( 15,
30 and 45 mm) and notches at the opposite surface relative to inspection surface. The total
thicknesses of the cast specimens were 60 mm.
The specimens were inspected first with colour dye penetrant method. The results are given in
the table and are shown from the inspection protocol pictures in appendix 1. The ultrasonic
inspections were carried out with 1 MHz TRL probe shown in figure 2. The calibration for
Appendix 1 5(11)
rough sizing is shown in figure 3. The simple echo curve from side-drill holes and notch was
used as shown in figure 3.
Figure 1 The used cast austenitic steel specimen: B501, B519, B504, B515 and B505
Figure 2 TRL Ultrasonic 1 MHz probe
The echoes were recorded and sized down to noise level. The noise level varied from one
position to other in one test specimen. As the ultrasonic equipment Sumiad V 3.34 was used.
The detected A-scan indications were stored on the hard disk. The evaluation was performed
according to the calibration curve from specimen B505.
Appendix 1 6(11)
A B
C
Figure 3 Calibration curve (A) to specimen B505 side drill holes (C) and a notch at the
opposite surface (B)
5 Results
Each stored A-scan from the test specimen is shown in figures 4 -14 and results form dye
pentrant testing and the result of the ultrasonic inspection is shown in the table 1
Figure 4 505B Side-drill holes and notch from direction D.

Appendix 1 7(11)
Figure 5 Notch echo in the specimen 505B in the side D
Figure 6 Crack corner in the specimen 501B from side E.
Figure 7 Crack upper end in the specimen 501B from side E

Appendix 1 8(11)
Figure 8 Crack corner in the specimen 504B from side D
Figure 9 Crack upper end in the specimen 504B from side D

Appendix 1 9(11)

Appendix 1 10(11)
In table 1 is summarised the result of ultrasonic and dye penetrant testing ( appendicies 1 and
2).
Table 1 The result table of dye penetrant testing and ultrasonic inspection from different
specimen
Specimen Reflectors Depth Specimen depth length
505 B Side-Drill hole1 15 mm 501B 17 mm 34 mm
505 B Side-Drill hole2 30 mm 504B 28 mm 61,5 mm
505 B Side-Drill hole3 45 mm 515B 17 mm 32 mm
505 B Notch 60 mm 519B 28 mm 57 mm
VTT Measurement
Specimen Reflectors Crack Depth Crack Length Remarks
501 B Crack 16 mm 32 mm A-scan picture not from the deepest spot
504 B Crack 32 mm 67 mm
515 B Crack 18 mm 28 mm
519 B Crack 11 mm 52 mm On the surface tight crack
6 Discussion and conclusions

The test specimens were difficult to inspect. The echoes from defects (cracks) were not easily
distinguished from the grain noise echoes (=material noise). The indications of the grain noise
from the weld and base material were similar level than defect indication. The probability to
accurately to detect a defect and to size it is less than in normal austenitic pipe inspection.
To evaluate a defect training with the real data (real component) is needed, because the
indications were not easy detected because of 2 reasons:
- Rough grain structure was changing the sound path direction
The large contact surface of the probe made the inspection very
variable because of large contact area
The detected indications could not be in every case to as large as it should, because of those 2
reasons (in the specimen 519B it should be a a deeper crack, but it could not be measured. So
the material is not totally for this inspection
Appendix 1 11(11)
References
Becker F. L., Doctor S. R., Heasler P. G., Morris C. J., Pitman S. G., Selby G. P. & Simonen
F. A., 1980
Integration of NDE Reliability and fracture mechanics, PNNL Laboratory, NUREG/CR-1696
PNL-3469 Vol 1. 170p + appendices 54p
Bates D. J., Doctor S. R., Heasler P. G.& Burck E., 1987

Stainless steel round robin test centrifugally cast stainless steel screening phase, Programm
for inspection of steel components PISC, JRC Ispra, 70p + appendices 192 p
Appendix 1 1(4)
RESEARCH REPORT No: TUO77-032705
Appendix 1 2(4)
Picture 1. Test specimen B519. Several linear indications both sides and center of the weld.
The length of the longest indication was 28 mm.
Appendix 1 3(4)
Picture 2. Test specimen B504. Strong linear indication and netlike indication both sides of
the weld. The length of the longest indication was 67 mm.
Appendix 1 4(4)
Picture 3. Test specimen B515. Two linear indications. Radial indication on the middle of the
weld and one axial indication. The length of the longest indication was 28 mm.
Appendix 2 1(3)
Appendix 2 2(3)
Picture 1. Test specimen B501. One crack like linear indication. The length of the indication
was 32 mm.
Appendix 2 3(3)
Picture 2. Close-up from indication in test block no B501.

APPENDIX 3
Preliminary Results of CSS Studies
Presented by
Steven Doctor
at
ASME Section XI Code Meeting
December 8-9, 2003
Orlando, Florida
Objective
Work funded by the NRC on JCN Y6604 with

Debbie Jackson as program manager
Work performed in cooperation with the
Westinghouse Owners Group (WOG) and EPRI
NDE Center in providing access to fifteen WOG
samples
Studies being performed to assess NDE
technologies as to their effectiveness in reliably
inspecting coarse grained materials such as cast
stainless steel, far side inspection of austenitic
stainless steel, etc.
Present work focused on ID inspection of CSS
1
Comments on Samples
PNNL samples have ID conditions that do not

hinder inspections
ID conditions of WOG specimens are described as
not easy but not worst case conditions
Specimens were made from all types and
combinations of material with SS cladding, Inconel
buttering,SS and Inconel welds, Static CSS and
Centrifugally CSS, and wrought austenitic SS
All roots machined smooth and flat
Samples
Fifteen Westinghouse Owner’s Group specimens

Five PNNL samples that were used also in PISC III
program
2
ID Phased Array and TOFD
Phased arrays not optimized for the ID

Major problem was the limited access because of
ID geometry and the transducer foot print
But where ID was not a problem could detect ID
surface breaking cracks – For WOG specimens 7
of 11 detected
Length sizing could be performed
No tip signals detected
ID TOFD Lateral Wave Obstruction Results
Not optimized because set up with 3.5 MHz

frequency
Could not traverse the counter bore transition
region
Counter bore flats not wide enough for transducers
to straddle the weld
Tight, planar and smooth flaws were harder to
detect whereas, branched and open cracks were
easier to detect
3
ID Eddy Current Inspection Results
Probe type Zetec Z0000857-1

! Coil diameter 0.12 inches
! Plus point coil design
Instrument Zetec MIZ-27 SI
Frequencies 100 kHz, 250 kHz, 500 kHz
Cracks have phase angles of about 90 degrees or
270 degrees
Used C-scans of magnitude and C-scans of phase
Demagnatizing improved images 50% of the time
PNNL Sample TFC
4
PNNL Sample TFC
WOG Sample MFC
10
5
WOG Sample MFC
11
WOG Sample MFC
12
6
WOG Sample MFC – Phase Plot
13
WOG Sample MFC

Normal left side – Demagnetized right side
14
7
WOG Sample MFC
Normal left side – Demagnitized right side
15
PNNL Sample TFC -Trueflaw

-Trueflaw
16
8
ID ET Length Sizing Results
Used loss of signal for length sizing

! 16 of 19 were undersized
! RMSE of 0.368 inches
Noise signals that would be confused with crack
signals having high amplitude and correct phase
! Eleven would be miss called cracks
! Average length of 0.3715 inches
! Range from 0.122 to 0.766 inches
17
Conclusions
ET was very effective in that all of the cracks were

detected
Both magnitude and phase angle images were
useful in detecting the cracks
Demagnitizing the inspection zones was useful 50%
of the time
Further studies need to be conducted to address
closure weld conditions
Circumferential cracks longer than about 0.5
inches should be reliably detected.
Axial cracks in welds will be challenging but should
be reliably detected in DMWs
18
9
APPENDIX 4
RESEARCH REPORT NO. TUO77-033229 22.10.2003
Defect characterisation in corespray nozzle

by ultrasonic measurements
Customer: Trueflaw Ltd.

RESEARCH REPORT No. TUO77-033229 1(1)
Requested by Trueflaw, Mika Kemppainen, P.O. Box 540, FIN-02151 Espoo
Order Trueflaw No. 29403001
Handled by Research Scientist Jorma Pitkänen, P.O. Box 1704,

FIN-02044 VTT, Finland, e-mail: jorma.pitkanen@vtt.fi
Defect characterisation in corespray nozzle 323/2 by ultrasonic

measurements
Tested Object Corespray nozzle 323/2 made from Aisi316 and Inconel 600 and Inconel
weld material, shown in appendix 1. Two cracks made by Trueflaw locations
shown in appendix 1 were measured by ultrasonic testing.
Summary of ultrasonic testing
The measured sizes for controlled produced crack made by Trueflaw in

Inconel weld, which wallthickness was 10 mm, was determined using 70°
shear wave composite ultrasonic probe (4MHz). The length was measured to
be 14 mm and height 6 mm according to appendix 2. Indication was a crack
like indication. The amplitude received from the reflector along the length
varied clearly, which can be a sign of tortouos path of the reflector, which is
normal characteristics for cracks.

Inconel weld, which wallthickness was 23 mm, was determined using 41°
shear wave ultrasonic probe (1,5 MHz). The length was measured to be 18
mm and height 6 mm according to appendix 3. The behaviour of the reflector
was similar than in case where wallthickness was 10 mm. In this case in
appendix 3 is also seen a smaller crack, which is in 5 mm distance from the
larger crack. The height of that small crack is less than 1 mm. The accurate
size of that crack is not determined.
The used ultrasonic equipment was Sumiad V3.34. The results were analysed
by the Masera NT.
Espoo, 22 October 2003
Research Manager Rauno Rintamaa
Research Scientist Jorma Pitkänen
APPENDICES 3 copies
DISTRIBUTION Customer, 4 copies, VTT Industrial Systems, 1 copy

Kemistintie 3, Espoo Tel. +358 9 4561 name.surname@vtt.fi
P.O. Box 1704, FIN-02044 VTT Fax +358 9 456 7002, www.vtt.fi/tuo
FINLAND +358 9 456 5875 Business ID 0244679-4
RESEARCH REPORT No. TUO77-033229
Appendix 1 1 (1)
Figure 1. The drawing of the corespray nozzle with planned flaw locations in the component
The use of the name of VTT in advertising, or the publication of this report in part
is allowed only by written permission from VTT.
Appendix 2 1 (1)
Figure 1. The ultrasonic inspection of the inconel weld between Aisi 316 and Inconel 600 materials.
Figure. 2 The ultrasonic inspection result of the measurement
Appendix 3 1 (1)
Figure 1. The ultrasonic inspection of the inconel weld between Ferritic and Inconel 600 materials.
Figure 2. The ultrasonic inspection result of the measurement
APPENDIX 5
RESEARCH REPORT NO. TUO77-033230 23.10.2003
Defect characterisation in austenitic

specimen by ultrasonic measurements
Customer: Trueflaw Ltd.

1 (1)
Requested by Trueflaw, Mika Kemppainen, P.O. Box 540, FIN-02151 Espoo
Order Trueflaw No. 29403001
Handled by Research Scientist Jorma Pitkänen, P.O. Box 1704,

FIN-02044 VTT, Finland, e-mail: jorma.pitkanen@vtt.fi
Defect characterisation in austenitic specimen by ultrasonic measurements
Tested Object Two austenitic samples Tvo 2/97 and Tvo 4 (Austenitic specimen) were
inspected by ultrasonic testing. In appendix 1 is shown Tvo 4 and in appendix
2 Tvo 97/2.
Summary of ultrasonic testing
The measured sizes for controlled produced crack made by Trueflaw in TVO
2/97 specimen, which wallthickness was 14 mm, was determined using
different ultrasonic probes and the results are shown in the table 1 (appendix
2). The length was measured to be 3 mm and height 1.5 mm according to
appendix 2. Indication was a crack like indication. The crack tip indication
varied with different probes not showing clearly same size for the reflector.
The measured length of the indication is short thus comparison - Is the
reflector acting like a crack? - is not possible to determine with the used
ultrasonic technique. The measurements was carried out with manual
ultrasonic equipment USN 52

austenitic specimen, which wallthickness was 20 mm, was determined using
65°L shear wave ultrasonic probe (5 MHz). The length was measured to be
22 mm and height 9.5 mm according to appendix 1. The behaviour of the
reflector was a crack like behaviour. The amplitude varied along the length of
the reflector and it looks like the crack face is changing towards to sound
field. The crack tip signal is not clearly seen. The measurements was carried
out with SAFT-equipment.
Espoo, 23 October 2003
Research Manager Rauno Rintamaa
Research Scientist Jorma Pitkänen
APPENDICES 2
DISTRIBUTION Customer, 4 copies, VTT Industrial Systems, 1 copy
Appendix 1 1 (1)
Figure 1. TVO 4 Specimen, Narrow gap weld, Reflector: controlled produced thermal fatigue crack.
Figure 2. TVO 4 Specimen, SAFT-measurement with 65°L 5 MHz probe, reflector face is drawn in to
the B-scan.
Appendix 2 1 (1)
Reflector
Figure 1. Ultrasonic inspection was carried out to specimen Tvo 2/97.
Table 1. The ultrasonic inspection result of the measurement.
Probe Notch depth C1 / [dB] C2 / [dB] Lenght Opposite side as reflector=O

(-6 dB) Same side as reflector =S
WSY60-2 2 -5.5 (58.5) 53 O
4 +1 (52) 53 O
6 +6 (47) 53 O
20 +8 (46) 54 O
Estimation Crack (<2 mm) -7.5 (63) 55.5 3 mm O
T55-4 2 mm-Tip O
Adept 1 mm- Tip O
TRL-5 2 mm - Tip 3 mm S
Result 1.5 mm 3 mm
height length
APPENDIX 6
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1279
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1228
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1230
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1231
APPENDIX 8
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1582
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1586
APPENDIX 9
PRODUCTION OF REALISTIC ARTIFICIAL FLAW IN INCONEL 600 SAFE-END
Mika Kemppainen, Trueflaw Ltd., Espoo Finland

Iikka Virkkunen, Trueflaw Ltd., Espoo Finland
Jorma Pitkänen, VTT Industrial Systems, Espoo, Finland
Kari Hukkanen, TVO Oy, Olkiluoto, Finland
Hannu Hänninen, Helsinki University of Technology, Espoo, Finland
The importance of NDT qualification has received significant attention

during the recent years. Recent findings of cracks in Inconel 600 in
different NPP components have also increased interest in the reliability of
in-service inspections of this material. This, in turn, sets challenge for
manufacturing of representative qualification specimens and flaws. A new,
advanced flaw production technique has become available. The technique
enables production of realistic cracks to ready-made mock-ups without
implanting or welding.
This paper describes the advanced crack production technique and its
application to Inconel 600. A realistic, controlled crack was produced to a
core spray nozzle safe-end mock-up. The technique produces true fatigue
cracks, which are representative of most real, service-induced cracks. The
technique is applicable to any shape or size of component and results only
in an intended crack without unwanted disturbances. The technique allows
production of a single or separate cracks as well as different combinations
of them.
In addition to the controlled crack production, the paper introduces studies
of the effects of different thermal fatigue loading cycles on the ultrasonic
response obtained from the crack in Inconel 600. Results of the study show
the effect of different thermal fatigue loading cycles on the obtained
ultrasonic response during dynamic loading of the artificially produced
crack. Control of crack growth and relationship between loading
parameters and ultrasonic response are discussed.
Introduction
The last decade has brought new challenges for the nondestructive testing in the nuclear power
field. Several through-the-wall leakages in components and structures that have not been covered
by in-service inspection programs have gathered attention of the whole nuclear community. One
of current concerns is the primary water stress corrosion cracking of Inconel 600 alloy and its
weld metals in the pressure vessel head and bottom penetration nozzles. This type of degradation
and crack growth was not originally considered in components in question.
The NDE qualification procedures are still under development all over the world. This
includes development of better flaw production techniques producing representative flaws. There
are certain factors that have to be taken into account when a flaw is used as a reflector for
ultrasonic inspection. The ultrasonic response is affected by different crack characteristics, among
others, location, orientation and size of a crack1, the opening of a crack and crack tip2,3,4, the
remaining residual stresses in the material5,6, fracture surface roughness7,4, crack tip plastic zone8
and filling of the crack with water9. These characteristics of cracks affect propagation, reflection,
diffraction, transmission, attenuation and diffusion of ultrasonic energy9,10.
Wüstenberg et al.11 mentioned, that if the main interaction of a flaw used in qualification is
based on the crack tip diffraction, the only possibility would be use of service-induced flaws as
cut outs from real components and weld implant them to qualification mock-ups. This was based
on the fact that there was no flaw production technique capable of producing realistic cracks or
flaws which represent sufficient weak crack tip diffraction. Hence, there is a need to develop a
flaw manufacturing technique that is capable of producing realistic flaws representative from all
typical characteristics point of view.
A novel artificial flaw production technique and its applicability for Inconel 600 is introduced
in this paper. The technique is used to produce a realistic crack in a core spray nozzle mock-up
component of a BWR-type nuclear power plant. Furthermore, the ultrasonic response of the crack
under dynamical thermal loading was studied in order to understand the relationship between
ultrasonic response and different crack opening conditions.
Materials and Methods
The flaw production technique is based on thermal fatigue loading. Loading is applied by high
frequency induction heating and water or air spray cooling. Produced flaws are representative of
real, service-induced fatigue flaws in metallographic sense and hence they are supposed to be
representative also in terms of NDE response. The technique allows production of realistic flaws
with controlled location, orientation and size. Characteristics of flaws produced with the
technique are introduced in more detail in references 12,13,14. The technique is applicable to
different materials and virtually any shape or size of a sample. The only requirement for the crack
production is that the intended location must be accessible.
Sample
This paper introduces flaw production to a full-size core spray nozzle, safe-end mock-up
(BWR-type nuclear power plant). Figure 1 shows the nozzle consisting of three different
materials: A508 carbon steel, Inconel 600 and AISI 316 type austenitic stainless steel. There is a
buttering and a joint weld between the carbon steel (with cladding on the inner surface) and
Inconel 600 safe-end, and a butt weld between Inconel 600 safe-end and AISI 316 austenitic
stainless steel pipe. Both welds were made with Inconel 182 filler material with Inconel 82 root
pass. After welding the working allowances were machined away. The finishing machining
removed the root pass so, that the welds of the ready-made mock-up are Inconel 182.
Figure 1 Core spray nozzle mock-up with Inconel 600 safe-end.

Figure 2 shows the drawing of the nozzle mock-up and the intended location of the flaw
production. The intended location is in Inconel 600 in the HAZ of the buttering weld. The wall
thickness of the Inconel 600 safe-end in the intended location is 23 mm. Nozzle was received as
ready-made and no machining or welding was allowed. Flaw was to be produced to the inner
surface in as-received condition of the nozzle. The specimen was nondestructively tested after
flaw production and no destructive tests were performed.
Figure 2 Drawing of the core spray nozzle and location of the produced crack in Inconel 600
safe-end in the heat affected zone of the buttering weld.
NDT set-up
A pulse-echo shear wave probe (41°, 1.5 MHz) was used when performing the inspection of
the nozzle after crack production. The same probe was used during the studies of the relationship
between ultrasonic response and crack loading. These studies were performed with a ready-made
crack. The probe was attached on the outside surface of the mock-up and the surface breaking
crack in the inner surface was monitored through the wall, in front of the weld. Ultrasonic signals
were gathered in-situ during continued thermal fatigue cycling of the crack. Details about the
NDT measurement system are given in reference15.
Applied loads
In order to study the effect of different loadings, two different thermal fatigue loading cycles
were applied. Temperature curves of applied cycles are shown in Figure 3 as measured from the
sample surface. The first cycle (B1) had high heating rate and short cooling time with heating and
cooling times of 10 and 15 s, respectively. The second cycle (B2) had lower heating rate and
longer cooling time with heating and cooling times 20 and 25 s, respectively. Water spray cooling
was applied for both cycles. The first cycle reached higher temperature than the second cycle. In
order to see the effect of the stabilised cycles, B1 loading was applied as 20 and B2 as 16
successive cycles.
Figure 3 Two different temperature loading cycles used in the studies.
FEM-analysis
Applied cycles were analysed by finite element modeling (FEM) giving results of temperature
and strain distributions through the material thickness during dynamical loading. Used finite
element model is presented in more detail in reference16.
Results
A realistic crack was produced in the inner surface of the nozzle. Figure 4 shows the dye
penetrant indication of the produced single crack in Inconel 600 safe-end in the heat affected zone
of the buttering weld. The weld is located in the upper part and Inconel 600 base material in the
lower part of the figure. The length of the crack is 14.2 mm and the depth is 5 mm, thus being
about 22% through the wall. The maximum surface opening of the crack varies locally between
30 – 45 µm. In the figure, there is also a very small (less than 1 mm deep) secondary indication in
the corner of the shoulder visible in the lower part of the figure. The initiation of the secondary
crack was caused by the stress rising effect of the shoulder. Without vicinity ofsuch a stress riser,
there would have been no secondary cracking. The secondary indication does not affect the
performance of ultrasonic testing as it is located about 7 mm away from the actual crack.
Figure 4 Dye penetrant indication of the produced realistic crack in Inconel 600 safe-end in
the heat affected zone of the buttering weld.
The size of the crack was controlled by process control during the production and confirmed
by ultrasonic testing. The obtained signal from the crack at room temperature is shown in Figure
5. The reflections from crack opening corner and subsurface parts of the crack are visible in the
figure. The ultrasonic inspection sized the crack to be 18 mm long and 6 mm deep. The measured
length by ultrasonic testing is clearly bigger than the actual value as seen from Figure 4. Also the
measured depth differs from the given process value, but it lies inside the production tolerances
(±1 mm).
Figure 5 A-scan obtained from the crack at room temperature (41°, 1.5 MHz, shear wave
probe).
The studies of ultrasonic response versus dynamical thermal loading resulted in a large amount
of ultrasonic data. Figure 6 shows the ultrasonic signal obtained from the crack in the end of
cooling and heating phases of cycle B2. The figure clearly shows the differences between
different crack opening states. Results shown in the figure have been obtained in the turning
points of surface temperature cycles.
Figure 6 A-scans from the crack in the end of cooling and in the end of heating of thermal
fatigue loading cycle. Differences in ultrasonic response are related to the crack
opening and closing behaviour.
Results of finite element modeling gave temperature and strain distributions through the wall
thickness. Figures 7 and 8 show solved strain distributions for analysed cycles B1 and B2,
respectively. Nozzle ID is in the left side and OD on the right side of both figures. The results
clearly show the difference between the faster and slower loading rates.
Figure 7 Strain distribution for loading cycle B1. Nozzle ID on the left and OD on the right
side of the figure.
Figure 8 Strain distribution for loading cycle B2. Nozzle ID on the left and OD on the right
side of the figure.
The obtained ultrasonic signal amplitudes from corner reflection and crack tip varied during
the loading. These variations are related to the opening behaviour of the different parts of the
crack. Figures 9 and 10 show the combined results of strain variations from modeling and
measured changes of ultrasonic amplitudes from corner reflection and crack tip for cycles B1 and
B2, respectively.
Figure 9 Combined results of strain and ultrasonic amplitude variations from crack corner and
tip caused by loading cycle B1.
Figure 10 Combined results of strain and ultrasonic amplitude variations from crack corner and
tip caused by loading cycle B2.
Discussion
The results show that a realistic crack was produced in the heat affected zone of the buttering
weld in Inconel 600 safe-end, as intended. The flaw location and size were accurately controlled.
The dye penetrant indication shows a single, tortuous crack, which has a natural propagation in
the heat affected zone of the buttering weld. The crack is narrow and its opening varies in
different parts of the crack.
The ultrasonic response is determined to be a crack-like indication. Similarly, the amplitudes

from corner, face and crack tip are representative and set realistic challenge for the inspection.
Ultrasonically the produced crack represents a difficult reflector caused by its realistic
characteristics. The realistic crack causes unhomogeneous reflections affecting the detection. The
tight crack tip and small crack tip radius make the sizing of the crack challenging.
It was shown that the technique is applicable to ready-made mock-up without causing any
alterations to the component. The results show, that the technique fulfills the important factors to
be taken into account when performance demonstration is designed and an artificial flaw is used
as a reflector. These factors include correspondence of reflector dimensions and dynamic range of
echo amplitude, representativeness of position, orientation, fracture surface roughness and
reproducibility of the artificial reflector both metallografically and echodynamically1,11.
The results of ultrasonic response versus thermal fatigue loading show how different parts of
the crack are opening and closing at different time moments. For example, the corner amplitude
decreased during heating and increased during cooling. While the crack tip amplitude increased
during heating and decreased during cooling. That is, crack tip amplitude changes were opposite
to the corner amplitude.
Amplitude decrease is caused by crack closure and increase by opening of the crack. It is
known that the surface breaking part of the crack is closed during heating and opened during
cooling as described, e.g., in reference17. However, the ultrasonic results of the crack tip
amplitude show, that the tip is openend during heating and closed during cooling. This is caused
by temperature cycling inducing stress gradients in the specimen. During heating the surface layer
of the material is heated up and experiencing increased compressive stresses. At the same time,
subsurface parts of the crack are at lower temperature and may be under tensile stress. The
increase of crack tip amplitude during heating clearly indicate that the crack tip is opened, i.e.
under tensile stress.
The finite element modeling, however, shows different results for the strain variations in the
depth of the crack. For both analysed cycles the model shows decreasing strains during heating
and increasing strains during cooling at the crack tip. This is explained by the fact that the model
was made for solid material and does not take into account the flaw in the material.
Conclusions
The novel artificial flaw production technique is available for different materials including
Inconel 600. The technique is applicable to full size mock-ups with challenging multi-material
structures. Flaw production does not cause any unwanted alterations and is applied to ready-
made, finished surfaces. The produced flaws are realistic thermal fatigue cracks. Cracks are
tortuous, tight, narrow and have a small crack tip radius. Hence, the reflection properties of
produced cracks are realistic.
Flaws produced with the new technique can be used in NDE training and qualification
purposes. The accurate positioning, control of crack size and reproducibility offer an opportunity
to have realistic reflectors in testing, training or qualification specimens. The production process
does not set any requirements for the specimen and, hence, also specimens with existing flaws
can be used.
Acknowledgements
This work was performed in a research and development project funded by Technology
Agency Finland (Tekes), Trueflaw Ltd., Pacific Northwest National Laboratory (PNNL, USA),
TVO Oy and Fortum Nuclear Services Ltd. The participants are acknowledged for giving the
funding, delivery of test materials and technical support.
References
1. G. Waites, C. and Whittle, J., 1998. The Status of Performance Demonstration and
Evaluation Developments. Insight, 40 (12), December, pp. 810-813.
2. Ahmed, S.R. and Saka, M., 1998. A Sensitive Ultrasonic Approach to NDE of Tightly
Closed Small Cracks. Journal of Pressure Vessel Technology, Transactions of the ASME,
120, November, pp. 384-392 .
4. Wirdelius, H. and Österberg, E., 2000. Study of Defect Characteristics Essential for NDT
Testing Methods ET, UT and RT. SKI Project Number 98267, SKI Report 00:42, October,
Sweden. 50 p.
3. Yoneyama, H., Senoo, M., Miharada, H. and Uesugi, N., 2000. Comparison of Echo Heights
between Fatigue Crack and EDM Notch. Proceedings of 2nd International Conference on
NDE in Relation to Structural Integrity for Nuclear and Pressurized Components, 24-26
May, New Orleans, Louisiana, U.S.A. 8 p.
5. Gauthier, V., 1998. Thermal Fatigue Cracking of Safety Injection System Pipes Non
Destructive Testing Inspections Feedback. Proceedings of NEA/CSNI Specialists' Meeting
on: Experiences with Thermal Fatigue in LWR Piping Caused by Mixing and Stratification,
8-10 June, Paris, France. pp. 436-453.
6. Iida, K., Takumi, K. and Naruse, A., 1988. Influence of Stress Condition on Flaw
Detectability and Sizing Accuracy by Ultrasonic Inspection. The Ninth International
Conference on Nondestructive Evaluation in the Nuclear Industry, 25-28 April, Tokyo,
Japan. pp. 563-567.
7. Ogilvy, J.A., 1989. Model for the Ultrasonic Inspection of Rough Defects. Ultrasonics, 27,
pp. 69-79.
8. Saka, M., Fukuda, Y., 1991. NDT of Closed Cracks by Ultrasonic Propagation along the
Crack Surface. NDT&E International, 24 (4), pp. 191-194.
9. Becker, F.L., Doctor, S.R., Heasler, P.G., Morris, C.J., Pitman, S.G., Selby, G.P. and
Simonen, F.A., 1981. Integration of NDE Reliability and Fracture Mechanics - Phase I
Report. NUREG/CR-1696 PNL-3469, 1. 170 p.
10. Ibrahim, S.I. and Whittaker, V.N., 1981. The Influence of Crack Topography and
Compressive Stresses on the Ultrasonic Detection of Fatigue Cracks in Submerged Arc
Welds. British Journal of NDT, September, pp. 233-240.
11. Wüstenberg, H. and Erhard, A., 1994. Problems with Artificial Test Reflectors at the
Performance Demonstration of Ultrasonic Inspections. Proceedings of 6th European
Conference on Non Destructive Testing, Nice, pp. 741-746.
12. Kemppainen, M., Virkkunen, I, Pitkänen, J., Paussu, R. and Hänninen, H., 2002. Realistic
Cracks for In-Service Inspection Qualification Mock-ups. Proceedings of the 8th European
Conference on Non-destructive Testing, Barcelona, Spain.
13. Kemppainen, M., Virkkunen, I, Pitkänen, J., Paussu, R. and Hänninen, H., 2002.
Comparison of Realistic Artificial Cracks and In-service Cracks. Proceedings of the 8th
European Conference on Non-destructive Testing, Barcelona, Spain.
14. Kemppainen, M., Virkkunen, I, Pitkänen, J., Paussu, R. and Hänninen, H., 2003. Advanced
Flaw Production Method for In-service Inspection Qualification Mock-ups. Journal of
Nuclear Engineering and Design, 224, pp. 105-117.
15. Pitkänen, J., Kemppainen, M., Virkkunen, I., and Hänninen, H., 2003. Ultrasonic Study of
Crack under a Dynamic Thermal Load. Proceedings of Review of Progress in Quantitative
Nondestructive Evaluation QNDE, Melville, New York. To be published.
16. Virkkunen, I., Kemppainen, M., Pitkänen, J. and Hänninen, H., 2003. Effect of Thermal
Stresses along Crack Surface on Ultrasonic Response. Proceedings of Review of Progress in
Quantitative Nondestructive Evaluation QNDE, Melville, New York. To be published.
17. Kemppainen, M., Virkkunen, I., Pitkänen, J. and Hänninen, H., 2003. Advanced Flaw
Manufacturing and Crack Growth Control. Proceedings of Review of Progress in
Quantitative Nondestructive Evaluation QNDE, Melville, New York. To be published.
APPENDIX 10
PARTICIPANT COMMENTARY / EVALUATION OF THE PROJECT:
“QUALIFICATION OF THE FUTURE”
PARTICIPANT IDENTIFICATION AND CASE
- Fortum Nuclear Services Ltd.

- Raimo Paussu
- Case: Massive austenitic stainless steel T-joint weld (nozzle-to-pipe)
- Case: Dissimilar butt weld (ferrite pipe with buttering-to-austenitic pipe)
BACKGROUND
- Thermal fatigue cracks are needed as realistic cracks for optimization and
qualification of NDE inspection systems (technique, personnel and
equipment).
- Producing of thermal fatigue cracks gives an added value for Fortum

when fabricating own test blocks with other types of cracks.
- This technique is perhaps the only possible way to producing cracks for
eddy current examination (without causing disturbing noise into surface).
- The possibility to produce thermal fatigue cracks into massive test blocks
was not earlier demonstrated.
- The possibility to produce thermal fatigue cracks into dissimilar weld was
not yet tried at all.
PROJECT
- Single thermal fatigue crack was produced into specified position and
orientation into massive test block without problems in the process.
- New case of dissimilar weld faced difficulties in crack initiation into

specified position and in control of crack growth. The target position for
crack was the boundary of ferrite pipe and buttering.
Similar crack initiation problems (position) were also faced by Fortum in

producing mechanical fatigue cracks into the same test block.
EVALUATION OF THE WORK
- Producing single thermal fatigue crack into massive test block was a
success. This will encourage the future crack production of massive test
blocks and weld joints made of austenitic stainless steel.
- Dissimilar weld is very difficult task for UT examination. There is a

common need for relevant test blocks with realistic cracks for the
optimization and qualification of inspection systems for dissimilar welds.
Dissimilar weld is very different and difficult new case and real challenge
for the new crack production technology. Ferrite material and different
boundaries in the weld joint cause the problems for the process. More
actions are needed for this difficult case in the future.
- Overall evaluation of the project: Really good benefit has got with very
limited financing. More research work is carried out than planned.
The project has given new information from crack behavior and UT
response, and also given possibilities to understand the relationship of
crack stress status versus UT response.
FUTURE WORK
- Possibility to manipulate and control the crack opening should be

examined in more detailed
o applications for parametric studies for UT and ET
(detection of tight cracks)
o applications for qualification of VT
(visual examination with eye, optical devices and video cameras).
- Possibility to manipulate and control the crack tip and crack face stress
status should be examined in more detailed
o applications for parametric studies - UT and ET responses from
crack (tip, face and opening) in different stress status
- Further actions for crack production of dissimilar weld and ferrite

materials are recommended as actual application.
APPENDIX 11
PARTICIPANT COMMENTARY/EVALUATION OF THE PROJECT:

- Pacific Northwest National Laboratory (PNNL)
- Steven R. Doctor
- Large grain cast austenitic stainless steel (CCSS) primary pipe section
BACKGROUND
The interest in this work was based on experience of putting thermal fatigue cracks
into a variety of materials for use in laboratory parametric studies and inspection
assessments via round robin studies. Thermal fatigue cracks produced at PNNL were
grown by heating the entire specimen and then spraying with water the area where the
crack was to be grown. This works acceptably for small specimens but if one is dealing
with full scale components then, it becomes impractical to heat up the entire component.
Thermal fatigue cracks are tight and they simulate challenging cracks from an NDE
perspective. The interest was in comparing thermal fatigue cracks produced using rf
induction heating with those that PNNL has grown.
The goal was to assess the new thermal fatigue method of growing cracks in
controlled manner in various materials and to make a comparison of these thermal fatigue
cracks with cracks produced by other processes.
PROJECT
The program was very successful because a number of cracks were produced in
various materials and their acoustic response was compared with that of cracks produced
by other techniques in similar material.
I thought that the project was very successful and accomplished the goals that it set.
I also was provided one of the cracks for conducting my own independent assessment of
a thermal fatigue crack in centrifugally cast stainless steel material. I have done this from
the inside diameter (ID) of the specimen but have not conducted the studies from the
outside diameter (OD).
This new technique is very attractive because it provides for the first time a means
to place challenging thermal fatigue cracks in full sized components, This means that a
component from a cancelled plant can be used for studies with cracks being introduced
without the problems associated with other implanting procedures. The cracks that are
created would be acceptable to use for performance demonstration activities such as those
required by ASME Section XI Appendix VIII Code.
I would have been surprised if the technology had not worked. Thermal fatigue
cracking does occur inservice and the only difference here is that it is a controlled process
to produce a crack at specific location with desired size.
I would rate this project very high. On a scale of 0 to 100 I would give this project
a 95.
FUTURE WORK
For coarse grained material, I think that there should be some destructive testing
conducted to validate the crack depth. With large components, it will be easier to take
the thermal fatigue equipment to the component and thus, developing a field deployable
system would be useful.
I think the areas where this technology can be used would include the fabrication of
training specimens, development of test specimens for laboratory studies and for use in
performance demonstration tests.
PWSCC cracks are being simulated by a number of processes that includes efforts
to close or tighten the flaw so that it has similar acoustic properties to real PWSCC. This
does simulate some of the flaw properties but not all of them. I think that these thermal
fatigue cracks may be a better simulation of PWSCC but work would need to be
conducted to prove this position.
This process will have to compete versus other cracking processes. The less
expensively it can be performed the larger the potential market that it will have.
APPENDIX 12
Organisaatio Asiakirjan nimi Asiakirjatunnus
Inspection EVALUATION
Voimaantulopvm Sivu(t)
1 (1)
Laatija(t)/Pvm Tarkastaja(t)/Pvm Hyväksyjä(t)/Pvm Ark n:o
Kari Hukkanen
25.2.2004
ITVO COMMENTARY/EVALUATION OF THE PROJECT: “QUALIFICATION OF

THE FUTURE”

- Name of the organization is Teollisuuden Voima Oy (TVO)
- Name of the representative is Kari Hukkanen
- Case TVO was making of two cracks in the heat affected zone (HAZ) of the
Reactor Pressure Vessel (RPV) safe-end welds (RPV/safe-end/pipe) mock-up
test piece
BACKGROUND
- RPV safe-end is Alloy 600 and it is welded to the RPV nozzle by Inconel 182
filler material. Afterwards has been discovered the reactor bi-metal weld
material disposed to the sensibilisation of stress corrosion.
PROJECT
- The project achieved the aims set in the beginning of the project very well,
because of defect type, -orientation and -size were inside in the definition line.

- The project was successful. It was important to detect how was a behavior of the
crack size and - orientation in Alloy 600 blended weld material
- The outcome of the project was that it support for example OL3 (new nuclear
unit in Olkiluoto) in the future coming test - and qualification pieces defect
manufacturing possibilities by same engineering
- The project was performed by skilled specialists on time schedule
FUTURE WORK
- Future work should be participating to the test specimen defect manufacturing in
many projects of qualification work in Finland and abroad
VANHENTUNEET ASIAKIRJAT
Asiakirjatunnus Laatija(t)/Pvm Asiakirjatunnus Laatija(t)/Pvm
APPENDIX 13
PARTICIPANT COMMENTARY/EVALUATION OF THE PROJECT:

- Name of the organization
- Name of the representative
- Case
BACKGROUND
- Why was the participant primarily interested in the project
- Aims set in the beginning of the project (if applicable)
PROJECT
- How well did the project achieve the aims set in the beginning of the
project? Please discuss possible deviations from the aims set.

- Was the project successful/unsuccessful?
- What was the outcome from the project – what did the participating
organization get from the project, does it support its other activities and
future prospects
- Lessons learned about the new technology
- Overall evaluation of the project
FUTURE WORK
- Possible ideas and/or suggestions for future work
- Areas of application for the new technology
- Areas or applications where the new technology would give an added
value for present know-how, technology or economics/security
Trueflaw Ltd. http://www.trueflaw.com
PO Box 540 , Tekniikantie 21 E-mail: trueflaw@trueflaw.com
FIN-02151 Espoo, FINLAND Fax: +358 9 455 3117

PNNL - 162AER - Cast SS - Crack Sizing

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MARCH 23, 2004

Qualification of the Future

Iikka Virkkunen Mika Kemppainen

Table 1 Project tasks and schedule.

Qualification of the Future

Figure 9. Drawing of the specimen and flaw locations.

Figure 16. Core spray nozzle specimen and ready-made flaws

Specimens from ABB to Trueflaw 12/02 Ok

Research plan 01/03 Under constr.

Design+manufact. of fixtures etc. 02/03 Plan

UT of specimens 02/03 Plan

Crack manufacturing 03-05/03 Plan

PT, UT, ET 06-07/03 Plan

Specimen shipping to PNNL 07/03 Plan

Final reporting 08-09/03 Plan

Inspection of austenitic castings

VTT TECHNICAL RESEARCH CENTRE OF FINLAND

VTT INDUSTRIAL SYSTEMS

Public Registered in VTT

Date 11 July, 2003

Rauno Rintamaa Jorma Pitkänen

VTT TECHNICAL RESEARCH CENTRE OF FINLAND

Espoo 11th July 2003

3 Restrictions of the study .............................................................................. 4

Inspection of austenitic castings

3 Restrictions of the study

Low frequency - 1 MHz - low spatial resolution

Figure 2 TRL Ultrasonic 1 MHz probe

Figure 4 505B Side-drill holes and notch from direction D.

Figure 5 Notch echo in the specimen 505B in the side D

Figure 6 Crack corner in the specimen 501B from side E.

Figure 7 Crack upper end in the specimen 501B from side E

Figure 8 Crack corner in the specimen 504B from side D

Figure 9 Crack upper end in the specimen 504B from side D

Figure 10 Crack upper end in the specimen 504B from side D

Figure 11 Crack corner in the specimen 515B from side D

Figure 12 Crack upper end in the specimen 515B from side D

Figure 13 Crack corner in the specimen 519B from side D

Figure 14 Crack upper end in the specimen 519B from side D

6 Discussion and conclusions

Bates D. J., Doctor S. R., Heasler P. G.& Burck E., 1987

Picture 2. Close-up from indication in test block no B501.

Work funded by the NRC on JCN Y6604 with

PNNL samples have ID conditions that do not

Fifteen Westinghouse Owner’s Group specimens

Phased arrays not optimized for the ID

ID TOFD Lateral Wave Obstruction Results

Not optimized because set up with 3.5 MHz

Probe type Zetec Z0000857-1

PNNL Sample TFC

WOG Sample MFC

WOG Sample MFC

WOG Sample MFC

PNNL Sample TFC -Trueflaw

Used loss of signal for length sizing

ET was very effective in that all of the cracks were

Defect characterisation in corespray nozzle

VTT TECHNICAL RESEARCH CENTRE OF FINLAND

Requested by Trueflaw, Mika Kemppainen, P.O. Box 540, FIN-02151 Espoo

Order Trueflaw No. 29403001

Handled by Research Scientist Jorma Pitkänen, P.O. Box 1704,

Defect characterisation in corespray nozzle 323/2 by ultrasonic

Summary of ultrasonic testing