Detection and Sizing Techniques for ID Connected Cracking

by Russ Minkwitz
This application note provides a brief summary of advanced detection and sizing techniques for
the evaluation of flaws connected to the inner surface of pipes, beams, and other metallic test
material, using the Panametrics-NDT CDS-4T and CDS-7T wedges. In general, these techniques
have found application for the detection, characterization and sizing of intergranular or
transgranular stress corrosion cracks and fatigue-type cracks whether inherent, processing or
service induced.
Background
Once a suspected Inside Diameter (ID) connected crack has been detected, then by general code
or regulatory mandates it must be qualified. This initial process usually involves the use of the
same 1.5, 2.25, or 5 MHz shear wave angle beam transducer that was used in the detection
phases. Further evaluation of signal amplitude, rise and fall time, echo dynamic and pulse
duration, will hopefully help determine if the suspect signal is from ID geometry, counterbore,
root, or if it is an actual flaw.
Another method that can be used for the qualification process involves the use of a single
element creeping wave transducer. This technique continues to grow in popularity because of
simplicity and because it can provide both detection and preliminary sizing information about the
suspected flaw.
The Single Element Creeping Wave Technique

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The single element angle beam assemblies used in the ID creeping wave technique are designed
to create a 70 degree refracted longitudinal wave in the material of interest. As a result of the
incident angle used in creating this 70 degree L-wave wave, other wave modes are created.
These different modes all interact to create a unique echo pattern which will vary depending
upon how far into the material the defect has propagated. The behavior of each of these
components can be broken down into the following three categories:

Direct Longitudinal Wave: This is the 70 degree refracted longitudinal wave, which, after a
quick and easy calibration procedure, should only appear when a crack is very deep.
Shear Wave (30-70-70): Along with the 70 degree longitudinal wave, a 30 degree shear wave is
generated. The 30 degree shear wave will hit the back surface of the test piece and some of the
wave energy will be reflected as a 70 degree longitudinal signal. The "mode-converted" 70
degree wave will strike the reflector face and then propagate back to the transducer. This round
trip signal is also known as a "30-70-70" signal to denote the angle of each portion of the
triangular soundpath. This signal is present for mid-wall and deep cracks.
ID Creeping Wave: This wave mode is essentially a subsurface longitudinal wave which
propagates along the inner surface of the test piece. The ID Creeping wave signal can be
considered a "marker" as its presence provides strong evidence that an ID connected flaw may
exist.

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Calibration Using the Creeping Wave Angle Beam Assembly
The relative ease of implementing the creeping wave technique can be attributed to the fact that
calibration and signal evaluation are heavily based upon the simple concept of pattern

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recognition. In general, signals created by the three wave modes will either be present or absent
from the A-Scan display depending upon the nature and geometry of the reflector.
Calibration involves positioning echoes from two of the three waves; the ID Creeping wave and
the 30-70-70 signal. It is recommended that calibration be carried out on a calibration block that
is the same thickness as the material to be examined. In order to approximate the cracks that will
be inspected, a series of notches should be cut into the block. Typically, notch depth will range
from 20% to 80% through wall. The side of the block can be used for the calibration as it will
produce indications from all three wave modes. The difference in the arrival times of each of the
signals will be the same in the reference block and test material when they are of equal thickness.
To calibrate, the 30-70-70 signal from the side of the block will be positioned at the fourth screen
division of the flaw detector screen while the ID Creeping wave signal is positioned at the fifth
screen division.

Once this relationship has been established, the detection and signal discrimination process using
the creeping wave transducer, may begin. Because of the relatively high level of energy
contained in the creeping wave package, and the fact that it travels relatively close to the inner
surface, it is extremely sensitive to ID connected cracks. However, because it is not a true
surface wave and does not follow surface geometry, it will be less sensitive to reflectors such as
weld roots which provide strong indications when shear wave transducers are used. For this
reason, the inspector can re-evaluate what had originally been characterized as a flaw, as well as
scan the test material for additional suspected ID-connected indications.
The creeping wave transducer will also allow the user to obtain preliminary sizing information
because each of the wave modes will appear only under certain conditions. The relative depth of
a reflector will dictate which signals are received from the transducer.
The A-scan in Figure 1 shows an ID creeping wave signal only. This would indicate the presence
of a shallow defect.

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The A-scan in Figure 2 shows both an ID creeping wave signal and a 30-70-70 round trip signal.
This indicates the presence of a mid-wall defect.

The A-scan in Figure 3 shows all three signals. The ID creeping wave, the 30-70-70 round trip
signal, and the direct longitudinal wave signal are all present. This indicates the presence of a
deep crack.

As with any ultrasonic NDT technique, there are limitations. The signals from the three wave
modes can have different amplitude relationships depending upon transducer frequency,
damping characteristics, element size, and the thickness of the material to be examined.
Furthermore, the type of metal examined or actual OD surface geometries may change the

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incident angle thus changing the echo amplitude relationship. It is for these reasons that use of an
appropriate calibration block is recommended for this technique.
This potential variability is also the reason that this technique is referred to as a qualitative
approach. The echo relationships do give a very good indication as to the approximate depth of a
flaw, but further sizing techniques must be used to verify the depth of the reflector.
Sizing Techniques
(a) Use of the Sizing Flow Chart
The results that are obtained using the ID Creeping wave technique can be summarized in a
sizing flow chart. This flow chart can be used to direct the inspector to the correct technique to
use during the sizing phase of inspection.

(b) Tip Diffraction Technique

This method is used for sizing shallow cracks ranging from approximately 5% to 35% through
wall. In this method the arrival time of the signal from the tip of the crack is used to determine
crack depth. To simplify this process the instrument is calibrated so that each screen division
corresponds to a particular flaw depth. Typically each of the first five screen divisions are chosen
to represent 20% of the material thickness. So, a 20% through wall crack will produce a signal at
the 4th screen division, a 40% through wall crack will produce a signal at the 3rd screen division
etc. Also noted during this technique is the separation of the tip signal from the corner reflection.
The information obtained from this separation allows the operator to make a final and accurate
determination of crack depth. An example of an A-Scan from a 20% through wall defect is
shown in Figure 4.

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In order to provide good resolution of the signal from the crack tip, a highly-damped 5 MHz, 45
or 60 degree shear wave transducer is typically used. Since the signal from the crack tip can be
relatively weak, the flaw detector should have an RF display. Such a display makes it easier to
see the crack tip signals when the signal-to-noise ratio is poor, as shown in Figure 5.

(c) Bi-Modal Technique

This method is used for sizing cracks ranging in depth from 30% to 70% through wall. A 3 MHz
dual element-tandem transducer is typically used. This probe transmits a 50 degree refracted

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longitudinal wave and the corresponding shear wave from the front crystal and receives the wave
modes from the rear crystal.

The calibration and use of this transducer is essentially a combination of the tip diffraction and
creeping wave techniques. As with the tip diffraction technique, the flaw detector is calibrated so
that the signal from the tip of the crack arrives at a particular screen division. As also done with
this diffraction technique, the separation of the different modes are recorded and used during the
evaluation/sizing process.

(d) High-Angle Longitudinal Wave Technique

The final quantitative sizing technique is used for sizing cracks ranging in depth from
approximately 60% to 95% through wall. This method again uses signal arrival time from the
crack tip as an indication of crack depth. The signals from cracks located close to the surface are
calibrated to the first few graticules while the deeper indications are calibrated to the higher
numbered graticules. It should be noted that these indications show the amount of good material
that is remaining in test samples, not the actual depth of the crack. We recommend dual element
high angle longitudinal wave transducers to incorporate this technique. OD creeping wave
transducers are useful for detecting cracks that propagate almost completely through wall.

Conclusion
The most important aspect of these techniques is their simplicity. Once the behavior of the sound
beam is understood the process of detection and sizing ID connected defects becomes one of
calibration and pattern recognition. In addition, the sizing techniques are inherently more
accurate because they are based on the arrival time of echoes, whereas traditional techniques that
utilize signal amplitude are subject to a great deal of variability due to coupling conditions. The
effects of these variables are reduced or eliminated with transit time based techniques.