NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai,

T.N., India

A Comparative Study of PAUT and TOFD responses with the changes in

microstructure of various materials - A Step towards reliable detection
Dharmveer SINGH, Abhishek BANERJEE, Sumit DAS
More info about this article: http://www.ndt.net/?id=22312

GE Power India Limited, Durgapur – 713206, West Bengal, India

E-mail: dharmveer.singh@ge.com, abhishek.banerjee1@ge.com

Abstract

The ever-changing market and evolving power sector poses a constant need for cost reduction and reducing
atmospheric emissions. This has led to a worldwide impetus to improve the power plant efficiency thereby reducing
emissions and improving cost effectiveness. This necessitate the requirement for materials with improved elevated
temperature and high strength properties. These new and critical materials need the reliable NDE techniques which
can provide more accurate flaw detection.
Among all non-destructive examination methods, Advanced Ultrasonic examinations (PAUT and TOFD) are some
of the most reliable volumetric examinations along with conventional Ultrasonic Examination for the most used and
advance materials. The change in microstructures of the materials affect acoustic properties of the material, resulting
in change of attenuation, scattering, SNR etc. Heat treatment and mechanical work (cold or hot) modifies the
microstructure of the material. This provides a correlation between heat treatment, mechanical work and responses
from ultrasonic examination
Ultrasonic testing suffers from some inherent drawbacks which can be correlated with the microstructure of the
materials. Microstructural variations can cause varied ultrasonic response because of changes in attenuation,
velocity, scattering, SNR. Further, it is well known that prior heat treatment and mechanical working also plays a
key role in modifying microstructure of the material. Hence a correlation is often derived between the heat treatment
and variation in ultrasonic response.
The intent of this paper is to present the unique study of the variations in the ultrasonic responses with respect to the
changes in microstructure of various material used in industry. Specimen was heat treated at different heat treatment
cycles and this study was carried out to find the correlation between microstructural changes and acoustic response
of the material. Further investigation was done to improve the detectability from PAUT and TOFD.

Keywords
UT (Ultrasonic Testing), PAUT (Phased Array Ultrasonic Testing), NDT (Non-Destructive Testing), SNR (Signal to
Noise Ratio)

1. Introduction

The prime objective of NDT is to detect and characterize flaws in a component to assure that the
component meets the required quality standards and hence fit for its intended service. There are
several NDT techniques which are used for volumetric examination like RT (Radiographic
Testing), UT (Ultrasonic Testing), PAUT (Phased Array Ultrasonic testing), TOFD (Time of
Flight Diffraction). However, application of PAUT, TOFD or a combination of both is
increasingly being used in volumetric examination owing to its benefits of versatility, cost
effectiveness and sensitivity in detection of subtle defects [1-2]. We know that among many
other factors, material microstructure plays a very significant role in affecting the performance of
ultrasonic systems. It is also a very well-established fact that the material microstructure can be
altered greatly with different heat treatments cycles. Hence there is close interplay of factors like
heat treatment, material microstructure and performance of PAUT, TOFD testing.
Polycrystalline materials with grain structure will cause attenuation and backscatter which will

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

significantly alter the ultrasonic response of the system. Grain boundary which the interface
between two adjacent grains exists in polycrystalline metals and will cause scattering of the
propagating ultrasonic wave which causes attenuation as well as noise echo. Sometimes even the
noise echoes can be strong enough to mask defect echoes from small indications [3].
Hence a better understanding of factors like heat treatment, subsequent microstructural changes
and how it effects the performance of testing is of paramount interest to NDT personnel. It is the
goal of this work to understand experimentally, the effects of different heat treatments upon the
microstructure of the material and its interaction with PAUT and TOFDs response of the system.
This study can help to understand the interaction of the factors which in turn can help to design
better inspection system [4].

2. Experimental Study
A plain low carbon steel plate was identified for the study as specimen for this work. To start
with, sample was prepared and analyzed with OES (Optical Emission Spectroscopy) to confirm
the grade of the material. Artificial discontinuities were simulated by inserting SDHs through
machining to get PAUT and TOFD responses. Various heat treatment cycles were attempted to
create the changes in the microstructure and obtain a grain size variation. After each heat
treatment, a detailed metallurgical and acoustic study with several changes in parameters of
PAUT and TOFD was carried out in the plate to understand the correlation of these parameters
with changes in microstructure and possibilities of optimization of the ultrasonic response.

2.1 Material:
Material selected for this study was plain low carbon steel plate (ASTM Number SA516 Gr 70)
which is supplied in as rolled condition. Great weldability, numerous applications in structural
and power sector were the main reason to select this material.

2.2 Chemical Composition Determination by Optical Emission Spectroscopy (OES)

OES confirms the material grade of SA 516 Gr. 70 after analyzing the chemical composition
from a standard square sample of dimension 30 x 30 mm as given in Table-1

Element Percentage (%) Element Percentage (%)

C 0.234 Mo 0.0076
Si 0.216 Ni 0.015
Mn 1.289 Cu 0.041
P 0.022 Al 0.042
S 0.019 As 0.0061
Cr 0.021 B 0.00042
Co 0.0055 Ti 0.0020
Nb 0.0023 V 0.0018
Sb 0.0040 W 0.014
Sn 0.0013 Zr 0.0012
Table 1. Chemical Composition of SA516 Gr 70 Determined by OES

2.3 Sample Preparation for Ultrasonic Study

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

SDHs of 1.5 mm diameter at ½ T and ¼ T at plate of dimension (290x145x25mm) was used as

artificial reflectors for ultrasonic study to provide more versatility and the same reflection for
different beam angles (T = Thickness of the plate). A detailed schematic view is presented as
below:

1/4 T 25 mm
PAUT/TOFD
PROBE
1/2 T

SDH

145 mm
290mmm

Fig.1.Schematic View of Sample

2.4 Heat Treatment

The plate was exposed to multiple heat treatment cycles at different stages to produce
microstructural variation in the sample. Heat Treatment was performed by resistance coil heating
and the sample was insulated sufficiently on both sides to prevent heat loss and sharp
temperature gradient. Calibrated thermocouples and temperature recorders were used to monitor
the heat treatment parameters. Inside and outside surface thermocouples were attached to the
sample by means of capacitor discharge method. Sufficient care was taken so that the sample
was cooled under insulated condition to maintain extremely slow cooling rate.
Annealing heat treatment was used since it causes changes in microstructure and corresponding
mechanical properties of the material by three processes which takes place at different stages of
annealing: recovery, recrystallization and grain growth. In the first heat treatment cycle, sub
critical annealing performed and for the subsequent two more cycles, full annealing was
performed with increase in the holding time. The annealing conditions as shown in Table 2.
Heat Treatment Cycle Type of Heat Treatment Annealing Soaking Time (min)
temperature (ºC)
HT-1 Process / Subcritical 650 ±10 180
Annealing
HT-2 Full Annealing 950 ±10 185
HT-3 Full Annealing 950 ±10 370
Table 2. Annealing conditions used for heat treatment

185 HT-2
HT-1 950

Rate of cooling:
180 40-50(°C/hr)
650
Temperature (° C)
Temperature (° C)

Rate of cooling:
20-30(°C/hr)

Rate of heating: Rate of heating:

80-90(°C/hr) 80-90(°C/hr)

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Time (min) Time (min)
 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

HT-3
370
950
Rate of cooling:
Temperature (° C) 40-50(°C/hr)

Rate of heating:
80-90(°C/hr)

Time (min)

Fig.2 Annealing regimes used for heat treatment of the sample

2.5 Microstructural Investigation and Hardness Survey

Samples were cut and prepared for microstructural investigation and hardness survey for as
rolled condition and after each annealing treatment.

2.5.1 Sample Preparation

Samples in the longitudinal and transverse directions were cut from the plate using a band saw
machine and then the samples were polished using emery papers of different grit, starting with
coarse and then finer grit was used. Final polishing was done in a wheel polishing machine using
diamond suspension as abrasive. The sample was then etched using 2% Nital (98% Ethyl alcohol
+ 2% Nitric Acid).

2.5.2 Microstructural Study

Samples were studied using an optical microscope at 200X magnification. The results of
microstructural investigations are presented below:

a. As rolled condition

Fig. 3 Longitudinal Direction (200X)

Fig. 4 Transverse Direction (200X)

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NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

b. After Heat Treatment -1 (HT-1)

Fig. 5 Longitudinal Direction (200X) Fig. 6 Transverse Direction (200X)

c. After Heat Treatment -2 (HT-2)

d. After Heat Treatment -3 (HT-3)

Fig. 7 Longitudinal Direction (200X) Fig. 8 Transverse Direction (200X)

d. After Heat Treatment -3 (HT-3)

Fig. 9 Longitudinal Direction (200X) Fig. 10 Transverse Direction (200X)

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

As rolled sample shows banded microstructure with alternating bands of ferrite and pearlite
aligned parallel to the rolling direction (Fig. 3 & Fig. 4). After the first heat treatment cycle
which was performed below lower critical temperature there was minor increase in the grain
size, however the banded microstructure was still evident (Fig. 5 & Fig. 6). After the full
annealing heat treatment performed above Upper Critical Temperature, an increase in grain size
was observed and there was homogenization of the banded structure as evident from
microstructure in the transverse direction (Fig. 7 & Fig. 8). In the third heat treatment cycle, full
annealing was performed with increase in soaking time from the second heat treatment cycle,
this resulted in more homogenization of the structure, since it’s a diffusion based process
complete homogenization may take extremely long annealing time, partial homogenization was
noticed (Fig 8 & Fig 10) at the second and third heat treatment cycle which was performed
above Upper Critical Temperature.

2.5.3 Grain size measurement and Hardness Survey

Grain size measurement was performed as per ASTM E-112 in the longitudinal and transverse
direction using image analyzer, in the as rolled state and after each annealing treatment.
Hardness measurement was also done at each stage using Vickers’s hardness testing machine.
Grain Size measurement and hardness was measured consecutively for three times and average
was reported. The results are shown as below:

Longitudinal Transverse 152 151

150
ASTM Grain Size Number(G)

10,1
10,05 10 148
9,89
146 145 145
Hardness (Hv10)

144
9,54 9,49 144
9,4 9,44
142

140
As rolled HT-1 HT-2 HT-3 As rolled HT-1 HT-2 HT-3

Sample Condition Sample Condition

Fig. 11 Grain Size variation with Heat Treatment Fig 12 Hardness variation with Heat Treatment

As evident from Fig. 11 the ASTM Grain Size Number (G) reduced subsequently after annealing
heat treatment. The reason behind this reduction in G is the corresponding grain growth that
resulted from annealing treatment. The major increase in grain size happened in HT-2 i.e. after
full annealing treatment performed above the Upper Critical Temperature. However, there was
not much of a change noticed in grain size after the soaking time was increased in annealing
treatment (after HT-4).
The sudden drop in the hardness value (Fig. 12) after the first sub critical annealing (HT-1) can
be attributed to the recovery process that happens during annealing which reduces the dislocation
density in the material. However, there was no major change in the hardness values after HT-2 &
HT-3. The results obtained after hardness and grain size survey are in conformance with the
microstructural changes than happened due to the annealing treatments given to the sample.

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

2.6 Ultrasonic Study

2.6.1 Attenuation Study
A calibrated Vernier Caliper was used to measure the thickness of the block and attenuation
study was performed using backwall echo patterns of longitudinal wave obtained using phased
array probe of 4MHz and Ultrasonic Testing machine Omniscan MX2. Attenuation study was
performed in as rolled condition and after performing each heat treatment. Decrease in
ultrasound intensity with distance i.e. attenuation is expressed in decibels per unit length and can
be found by the following relation:
20
=
2 −
Where Am and An = amplitudes of mth and nth back reflections (n>m), and T is the thickness [5].
In this study, the first and the second backwall reflection was used to calculate the attenuation
coefficient. The variation of attenuation coefficient in the as rolled condition and different stages
after heat treatment is presented in the below (Fig. 13)

As Rolled HT-1 HT-2 HT-3

0,108
Attenuation (dB/mm)

0,106
0,104
0,102
0,1
0,098
0,096
0,094
0,092
Fig. 13 Variation in attenuation coefficient with heat treatment

The attenuation that takes place in the material is having two components, absorption and
scattering. Energy loss due to absorption is a combined effect of mechanisms like dislocation
damping, hysteresis losses, thermos elastic effects, etc. Loss due to scattering is predominantly
dependent upon ratio of grain size and wavelength. Attenuation in the material is strongly
influenced by the microstructure of the material and the same has been studies in this work. It is
established that heat treatment plays an important role to modify the microstructure which causes
a change in the attenuation within the material. The parameters playing a role may include grain
size, grain boundaries, the relative amounts of phases, the layer thickness of the pearlite [6-7].
As illustrated in Fig. 13, attenuation was found to increase with heat treatment which can be
attributed to the factor of increase in grain size due to heat treatment. However, there was a
minor decrease in attenuation coefficient noticed after the final heat treatment which can be due
to partial removal of banding structure and the onset of homogenization of the structure, however
this needs to be investigated in detail in future work to study the effect of homogenization on
attenuation within the material.

2.6.2 PAUT and TOFD testing and evaluation

The purpose of the study was to investigate the changes in response of PAUT and TOFD due to
heat treatment and study the possibilities of overcoming the challenges of higher noise and lower
SNR due to microstructural changes. To have a better understanding of all these factors and their

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

interdependence, multiple scans were performed with variation in beam path, indication depth
(SDH at different depths), frequency, filter, averaging. The same number of scans were repeated
for both PAUT and TOFD after each heat treatment to understand the effect of microstructural
changes upon PAUT and TOFD response and to get the optimum response with changes in UT
parameters.

2.6.2.1 PAUT and TOFD setup

Omniscan MX2 machine was used to perform the testing and Cutting Oil was used as a coolant
medium in all the scans. Manual encoded scans were recorded and the data evaluation was done
using Tomoview Software. To minimize the possibilities of variation in manual scan same set of
data was recorded multiple times and once uniform results were obtained the same was used for
analysis. Scanning setup is as per attached Fig. 14

Fig.14 PAUT and TOFD Scanning

Scanning variables can be well understood from the attached details (Table 3, Table4):

Probe
Angle Index Probe Frequency Wedge Angle PCS
Probe Frequency Wedge Scan
(Deg) Half Full
Skip Skip C543-
5 MHz
ST1-
60 Deg 57.74
5L64A12/ 5MHz/ SA12- SM 60L-IHC
45 Linear +26 -5 C543- ST1-
2.25L64A12 2.25MHz N55S 5 MHz 70 Deg 91.58
5L64A12/ 5MHz/ SA12- SM 70L-IHC
55 Linear +14 -24
2.25L64A12 2.25MHz N55S C563- ST1-
5L64A12/ 5MHz/ SA12- 10 MHz 60 Deg 57.74
60 Linear +14 -34 SM 60L-IHC
2.25L64A12 2.25MHz N55S
5L64A12/ 5MHz/ SA12- 40 to C563- ST1-
Sectorial +22 -8 10 MHz 70 Deg 91.58
2.25L64A12 2.25MHz N55S 67 SM 70L-IHC

Table 3. PAUT scanning parameters Table 4. TOFD scanning parameters

Scanning was performed as per attached scan plans:

Fig. 15. PAUT sample scan plan

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

Fig. 16. TOFD sample scan plan

2.6.2.2 Signal to Noise Ratio (SNR):

60 30
40 20

SNR
SNR

Filter 2
20 10
Filter 5
0 0
As HT-1 HT-2 HT-3 Filter 4
Rolled

Fig 17 Variation in SNR with heat treatment for ½ T SDH Fig 18 Variation in SNR with heat treatment for ½ T SDH
(2MHz, 45 °) (2MHz, 60 °)

2.7 Experimental Result

Noise levels at different heat-treated stages were compared. Impacts of averaging and filtering
were analyzed for finding the way to improve SNR. Following results were observed
a. Attenuation increased from as rolled stage up to HT2 while it decreased from HT2 to
HT3.
b. Noise level of PAUT and TOFD signals was increased from as rolled to HT1 while then
it shown decremental effect from HT1 to HT2 and finally very less change from HT2 to
HT3.
c. Amplitude of the reflected signal shows the same trend. It increased from as rolled stage
to HT1 and then decreased from HT1 to HT2 while very less change from HT2 to HT3.
d. The variation in SNR is studied with the responses from the reflections from ½ T SDH
with respect to the noise level. Variations in PAUT is described by Fig. 17 and Fig. 18
while variations in SNR in TOFD will be an extended work.
e. Averaging and filtering has crucial role to play in improving detectability.

2.8 Scope of future work

a. Change in orientation of grains in both longitudinal and transverse directions and their
impact on the signals for TOFD and PAUT with more details.
b. Effect of heat treatment in modifying the banded structure of the rolled steel plate can be
investigated in more details through SEM and TEM analysis.
c. Analysis of SNR of TOFD and PAUT with different heat treatment cycles

3. Conclusion

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 NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

192 scans of PAUT and 112 scans of TOFD at a specimen with different heat-treated conditions
provided great amount of information. Changes in grain size were noticed in subsequent heat
treatment cycles. This results in more noise level in the indications of PAUT and TOFD of the
same specimen compared to the indication observed at as rolled condition

a 5 X 60 b 10 X 70 c 5 X 70
Averaging Averaging Filter
30 40 10
Noise Level

Noise Level

Noise Level
20 4 4
20 5 4
10 8 8
0 0 As… 0 7

As…
As…

16 16
HT-1
HT-2
HT-3

HT-1
HT-2
HT-3
HT-1
HT-2
HT-3

d 10 X 60 e Noise - 2MHz, 45 f
Amp - 1/2 SDH - 5
Filter Deg, FS MHz, FS
20 6 100
Noise Level

Noise Level

Indication Level
4 2 5
10 10 50
2 5 8
0 7 0 0
As…

As…
As…

4 4
HT-1
HT-2
HT-3

HT-1
HT-2
HT-3
HT-1
HT-2
HT-3

Fig. 19. a, b, c, d are the responses for TOFD where N is Frequency in MHz and M is angle in
(N x M) format. e. represents noise level for PAUT and f. represents amplitude for all heat
treatments

This is far evident and as expected. When specimen was heat treated above upper critical
temperature, even though grain size increases, onset of homogenization of the banded structure
was also noticed. The probable reason for reduction in noise level and attenuation of PAUT and
TOFD after HT2 may be due increase in homogeneity of the structure and it can be an extended
scope of this work.
The selection of appropriate filtering and averaging is the key for improving SNR which reduces
due to increase in grain size in due course of different heat treatment cycles.

4. Acknowledgment
We sincerely thank Supriyo Roy, Supervisor – Metallurgical Laboratory, and Subhendu Saha,
Engineer - Metallurgical Laboratory for carrying out the spectroscopy and metallography of the
samples.

5. Reference
1. Characterization of Material Properties by Ultrasonics, P.P. Nanekar and B. K. Shah
2. Future of Volumetric Examination in Power Sector – Phased Array Ultrasonic Testing
(PAUT) and Time of Flight Diffraction(TOFD), Dharmveer Singh, Abhishek Banerjee

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NDE 2017 Conference & Exhibition of the Indian Society for NDT (ISNT), 14-16 December 2017, Chennai, T.N., India

3. Effects of material microstructure and surface geometry on ultrasonic scattering and flaw
detection , Yanming Guo
4. Analysis of relation between Ultrasonic Testing and Microstructure : A Step Towards
Highly Reliable Fault Detection , A Khaira , S Srivastav, A Suhane
5. Ultrasonic Attenuation and Velocity in Steel Standard Reference Blocks , M.G.S. Ali ,
N.Z. Elsayed, Ahmed M. Eid

6. Modelling of Microstructural Banding during Transformations in Steel, Dipl.-Ing. Eric A.

Jägle

7. Ultrasonic characterisation of hot-rolled and heat-treated plain carbon steels , C H Gür

and Y Keleş

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