Se) Cutech Arabia LLC Ultrasonic Testing (UT) LEVEL-Il Training Course Prepared by Dr. Samir Saad General Manager Cutech Arabia LLCAZ About the Author Experience: 17 Years (Oil and Gas) Skills & Expertise + Welding and Welding Inspection + Non-Destructive Testing + Material Technology + In Service & On-stream Inspection + Corrosion and Management + Asset Integrity Management DrSamir Saad Education Certification MSS. and Ph.D. degrees in Welding Engineering Technology. Bachelor of Mechanical Engineering. Professional Certification ‘ASME Authorized Inspector (A), Boland Pressure Vessel [ASNT NDT LEVEL Min 11 methods, ASNT 10: 190002, 41. Visual and Optical Testing (VT). "7. Magnetic fx leakage Testing (MEL), 2. Radiographic Testing (FN, 8. inferred thermal testing (IR), 3. Utresonic Testing (UT). 9. Leak Testing (LD, 4. Liquid Penetrant Testog (PT), 10. Acoustic Emission Testing (AE) 5. Magnetic Testing (MM), 11. Newton Radiography (NA) 6. Electromagnetic Tesing (ET), ‘AWS-CWEng, -Costiiod Welding Engineer, ID NO. 17010086. AWS-CWE - Cerfied Welding Educator, ID NO, 1902001€. ‘ANS-CWI - Certied Welding Inspector, 1D NO. 19021321. ‘ANS-CWS ~ Certied Welding Superasor, ID NO. 20030008, [AWS-CWSR - Cored Welding Sales Representative, 1D NO. 2003000R {ESWIP 3.22 - Senior Welting Inspector Personal, ID NO.74305, [BGAS-CSWIP-Painting Inspocior Grade 2-8GAS, 10:529730 ‘API 610- Pressure Vessel Inspector ID NO_ 35376, [API 870. Process Piping Inspector ID NO. 38328 ‘API 683. aboveground storage tank inspector ID NO. 96171 ‘APL RP 880 -Risk-Basod Inspection professional ID NO. 52784 ‘APLRP 671- Corrosion and Materials Profesional ID NO. 56359 ‘API 936 - Rofractory Personnol, 1D NO. 94784 [APIST7 = Welding Inspection and Metalurgy, 10 NO, 94785 [API SIFE-Source Inspector:Finad Equipment, ID NO. 95780 Lead auditor according to 180 9001:2018 from IRCChapter Qualification and Certification we Requirements oe y ! Dr.Samir Saad3XThe following documents outline personnel qualification and certification requirements: 1. ASNT Recommended Practice No. SNT-TC-1A. 2. ANSI/ASNT CP-189: Standard for Qualification and Certification of Nondestructive Personnel. 3. ACCP: ASNT Central Certification Program. 4. NAS 410, National Aerospace Standard Certification and Qualification of Nondestructive Testing Personnel. Dr.Semir Saadi Training and Qualification Process: Certification of NDT personnel is the responsibility of the employer A person who is in the process of training and qualification is considered a trainee. Three Basic Levels of Qualification LEVEL | —is qualified to perform specific calibrations, specific tests, and specific evaluations. The NDT Level I should receive the necessary instruction and supervision from a certified NDT Level 1! or Ii individual. LEVEL I — is qualified to set up and calibrate equipment and to interpret and evaluate results with respect to codes, standards and specifications. LEVEL Ill — must be capable and responsible for establishing techniques, interpreting codes, and designating the test method and technique to be used. The NDT Level Ill, in the methods in which certified, should be capable of training and examining NDT Level | and Il personnel for certification in those methods. 20 Dr.Semir Saadi* Qualification Requirements: 1. Organized training (required class hours). |. Required testing (general, specific, practical). . Education (depends on written practice). . Experience (documented hours). . Physical attributes to perform examinations (vision acuity and color contrast test performed annually). XL Certification + Certification is a written testimony that an individual has met all the qualifications of a company’s written practice. Dr.Semir SaadChapter 2 Introduction to NDT woe oe y Dr.Samir SaadDr.Semir Saad— fo | Surface Surface/sub-surface and Volumetric 1Nisual Testing(VT) 1.Radiography Testing(RT) 2.Magnetic Particle Testing (MT) 2.Ultrasonic Testing(UT) (surface and near surface , applied on only ferromagnetic material) 3. Penetrant Testing (PT) (any defects open to surface) 4. Eddy Current (ET) ( surface and near surface) Dr.Semir SaadVT Vv il is the most extensively used NDE method for welds. The oldest and most widely used inspection techniques The eyes of inspector are the only ‘equipment’ used for the inspection Applicable to virtually any material at an \Tis commonly performed on castings, forgings, and welds and it is performed after machining processes as well. It includes either the direct or indirect observation of the exposed surfaces of the weld and base metal. Dr.Semir Saad¥¥ Direct visual examination > is conducted when access is sufficient to place the eye within 6 in. through 24 in. (150 mm through 600 mm) of the surface to be examined and at an angle not less than 30 degrees to the surface as illustrated in Figure Mirrors may be used to improve the angle of vision 7267020 Dr.Semir SaadMI. lists requirements for visual examination. + Codes and specifications may list compliance with these requirements as mandatory. + 2) A written procedure is required for examinations. * b) The minimum amount of information thatis to be included in the written procedure. + c) Demonstration of the adequacy of the inspection procedure. * d) Personnel are required to demonstrate annually completion of a J-1 Jaeger-type eye vision test. * €) Direct visual examination requires access to permit the eye to be within 6 in. through 24 in. (150 mm through 600 mm) of the surface, at an angle not less than 30 degrees. + f) The minimum required illumination of the part under examination, * g) Indirect visual examination permits the use of remote visual examination and devices be employed. + h) Evaluation of indicationsin terms of the acceptance standards of the referencingcode. Dr.Semir SaadOptical Aids Optical aids used in visual inspection 34 Adequate Illumination: include the following. Ambient Light Meters Lighting the inspection surface ilumination is of extreme importance. Adequate ilumination levels should be established in order to ensure and effective visual inspection. snail _ Illumination meters for the Standards such as ASME Section V Article 9 measurement of ambient specty lighting levels of 100 foot-candles (white) light in foot-candles (1000 lux) at the examination surface or lux. Dr.Samir SaadQ Effective program of visual inspection + It has been proven that EFFECTIVE program of visual inspection will discover vast majority of the defects which would be found later using expensive NDE methods “This only possible when the VT is accomplished: > BEFORE, DURING and AFTER welding > Bya trained and qualified inspector (that’s why AWS developed the CWI program) > PropertoolsQ Why VT is very cost effective: Relative simplicity It is least expensive inspection method Minimal amount of equipment required Minimize the repair time and cost; > Itallows for detection and correction of many discontinuities before weld completion Application of VT *% Before welding “ During welding _s& After welding‘Sequence of Welding and Inspection Operations Prior to Welding During Welding After Welding Material Identification — Chemical analysis — Mechanical properties Base Metal Conditions — Freedom from internal and surface discontinuities — Flatness, straightness, — Edge Shape — Dimensional accuracy — Cleanliness Root opening — Alignment — Backing — Tack welds Special Assembly/Fabrication Practice — Adequacy and accuracy of jigging, bracing, or fixturing — Application and accuracy of pre-stressing or precambering Preheat and interpass temperatures — Controls, — Measurement methods Filler Metal — Identification — Control — Handling Root Pass — Contour — Soundness Root preparation prior to welding second side Cleaning between passes Appearance or passes (sometimes in comparison with workmanship. standard) In-process NDE as required or specified ‘Conformance to approved welding procedure Postheat treatment requirements Acceptance inspection Method of cleaning for inspection Nondestructive examination — Visual examination — Surface contour and finish of welds — Conformity of welds with drawings — Magnetic particle — Liquid penetrant examination — Radiographic examination — Ultrasonic examination — Proof testing — Other suitable methods Destructive testing — Chemical — Mechanical — Metallographie Marking for acceptance or rejection Repairs Inspection after repair32 Optical Aids corners if necessary. > — Optical aids used in visual inspection include the following. b) Mirrors | ¥ valuable to the inspector allowing them to look inside piping, threaded and bored holes, inside castings and around Dr.Semir Saad32 Optical Aids > — Optical aids used in visual inspection include the following. ¢) Magnifiers Y helpful in bringing out smalll details and defects. : ~ ‘ Dr.Semir SaadVisual Inspection Tools Optical aids used in visual inspection include the following. widely used for examining tubes, a deep hole, long bores, and pipe bends, having internal surfaces not accessible to direct viewing metal. Dr.Semir SaadWeld Examination Devices Typical inspection tools for weld inspection include the following. a) Inspector's kit contains some of the basic tools needed to perform an adequate visual examination of a weld during all stages of welding {Before welding ,During welding and After welding} Itincludes as the following:- 1. G inch Ruler 1 inch Micrometer Metric Dial Caliper Paimgren Gage Undercut Gage Fillet Weld Gages Dr.SamtirSaadWeld Examination Devices > Typical inspection tools for weld inspection include the following. b) Bridge cam gauge VY “can be used to determine the weld preparation angle prior to welding. This tool can also be used to measure excess weld metal (reinforcement), depth of undercut or pitting, fillet weld throat size or weld leg length a - Lae and misalignment (high-low). NEWETWED TOA ANGLEOFPREMNATON— MSMLOWENT woereut Excess WELD METAL PUT LEM Dr.Semir Saad¥£ Weld Examination Devices Typical inspection tools for weld inspection include the following Bridge Fillet weld gauge-The types of fillet weld gauges include. 1) Adjustable fillet weld gauge—measures wold sizes for fit-ups with 45 degree members and welds with unequal weld leg lengths. The weld filet gauge —2 quick golno-go gauge used to measure the filet weld leg length. Gauges normally come in sets with weld leg sizes from 1/8 in. (3 mm) to 4 in. f (25.4 mm). a weld filet gauge being used to determine it the crown has acceptable concavity or convexity Dr.Semir Saad3 Weld Examination Devices Typical inspection tools for weld inspection include the following. ¢) Digital pyrometer or temperature sensitive crayons {measures preheat and interpass temperatures. == [saa [a Sa) =>) Dr.Semir SaadQ Penetrant examination is a sensitive method of detecting and locating discontinuities, provided the discontinuities are clear and open to the surface. Q Method = The method employs a penetrating liquid dye which is applied to the properly cleaned surface to be examined and which enters the discontinuity. * After a suitable dwell time. the excess penetrantis removed from the surface and the part is dried. * A developers then applied which acts as a blotter. drawing the penetrant out of the discontinuity. = The penetrant, drawn from an opening on the surface. indicates the presence and location _,of a discontinuity 7Deen ais Apply Penetrant Cleanthen apply Developer ResultQ basic classifications of the penetrant method “There are two basic classifications of the penetrant method, both using a similar principle. * One usesa visible dye and the other uses a fluorescent dye which is only visible with exposure to ultraviolet light. Visible penetrantis usually red in color to provide a contrast against the white developer background. Normal white lightis usually sufficient to view the discontinuities. Fluorescent penetrants provide a greenish yellow indication against a dark background when viewed in a darkened area under a black (ultraviolet) light source. The fluorescent method is more sensitive due to the fact that the human conn eye CaN more easily discern a fluorescent indication.PT Types Ovisible dye OFluorescent dye OThree removal systems: > Solvent > Water > Emulsifiable Solvent removal , Visible dye typeQ These Are the Medias by Which They Can Keep Permanent Records. “+ Sketches “Photographs Lift off tapesQ Advantages and Disadvantages Advantages Disadvantages 1) Low operator skill level 1) Highly clean metal 2) All materials (Non Porous) 2) Open Surface flaws only 3) Low cost method 3) Somewhat slow 4) Simple equipmentQ Application = Magnetic particle inspection may be applied to detect surface and near surface defects in ferromagnetic materials only . Q Method Clean area to be tested Apply contrast paint Apply magnetism to the component Apply ferromagnetic ink to the component during magnetising Interpret the test area Post clean and demagnetise (if required)O Method Contrast paint Magnet & Ink Result Se AQ Magnetic Field Orientation and Flaw Detectability » Ifthe magnetic field is parallel to the defect, the field will see little disruption and no flux leakage field will be produced. a (_= » An orientation of 45 to 90 degrees between the magnetic field and the defect is necessary to form an indication.Q Circumferential Magnetization BXTERNAL, > Circular magnetic fields are produced by he 1) passing current through the part 2) A headshot on a wet horizontal test unit an 2 CURRENT 3) Prods 4)Central conductorsQ longitudinal Magnetization > alongitudinal magnetic fields are produced by, 1) Permanent magnets and Electromagnetic yokes 2) Coils & Solenoids ‘cuRRENT,Question = 2? From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the imaaes below? Cracks at 90° toline force will show Cracks at parallel to line force will not showQuestion 2+ From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the CURRENT (> (COR DC) MAGNETIC LINES SP FORCE Longitudinal (along the axis)Question i? From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the images below? um cChaa _ Sassy ‘CURRENT Longitudinal (along the axis) Transverse (perpendicular the axis)QO Magnetic Particles * ferromagnetic iron oxides “Dry or wet * Types “Color dyed “Fluorescent OMT Equipment “AC / DC bench units “AC yokes “AC / DC yokes “AC / DC prods “AC/DC coilsQ These Are the Medias by Which They Can Keep Permanent Records. “+ Sketches “Photographs Lift off tapesO Magnetic Particles Advantages Disadvantages 1) Low operator skill level 1) Fe Magnetic metal only 2) Rapid 2) De-magnetize may be required 3) Relatively cheap 3) Can cause arc strikes # 4) Portable 4) Poor with thick coatings # When using the straight current prod techniqueQ Overview of Radiographic Testing X or Gamma radiation is imposed upon a test object Radiation is transmitted to varying degrees dependent upon the density of the material through which it is travelling Thinner areas and low density materials show as darker areas on the radiograph Thicker areas and High density materials show as lighter areas on a radiograph Applicable to metals, non-metals and compositesLoad film Exposure to Radiation —_ Interpret Graph k Radioactive source Developed Graph 1Ql Film cassette ‘Latent image on the filmLIGHTEST DARKEST O Areas of high radiation transmission, or low absorption, appear as dark areas on the developed film. O Areas of low radiation transmission, or high absorption, appearas light areas on the developed film.Radiographic Testing High dense discontinuity Low dense discontinuity Darker region ‘on radiographLIGHTEST Metal Densities Grams/cubic centimeter Aluminum —= 2.70 Steel 7.87 Copper 8.96 Lead 11.34 Tungsten 19.30Flaw OrientationRadiographic Testing Flaw Orientation o° 10° 20°Radiographic Techniques Single Wall Single Image Panoramic IQI’s are placed on the film side Source inside film outside (single exposure)Radiographic Techniques Double Wall Single Image (DWSI) IQI’s are placed on the film side Source outside film outside (multiple exposure) This technique is intended for pipe diameters over 100mmRadiographic Techniques Double Wall Double Image (DWDI) IQI's are placed on the source or film side Source outside film outside (multiple exposure) A minimum of two exposures This technique is intended for pipe diameters less than oOmmRadiographic Techniques Double Wall Double Image (DW!) Elliptical RadiographRadiographic Testing Radiographic Sensitivity ( 2% thickness test object) \ Hole type IQ! Wire type IQIRadiographic Sensitivity OPlacement of IQI Hole Type IQ!‘Advantages Disadvantages 1) A permanent record 1) High operator skill 2) Most materials 2) Difficult interpretation 3) Little surface preparation 3) Requires access to both sides 4) Flaw orientation 5) Safety requirements*Main Features: Surface and sub-surface detection This detection method uses high frequency sound waves, typically above 2MHz to pass through a material A probe is used which contains a piezo-electric crystal to transmit and receive ultrasonic pulses and display the signals on a cathode ray tube or digital display. a piezo-electric crystal “Refers to materials which can convert electrical energy to mechanical energy and vice versa.” For ultrasound to enter a material ,a couplant must be introduced between the probe and specimenApply Couplant — Sound wave Result* CRT display | Signal rebounded from Lack of fusionUltrasonic Testing! Digital UTSet, Pulse echo signals Ascan Display Compression probe checking the material ThicknessThicknessQO Longitudinal (straight beam)-Compression Probe defect Back wall “* Thickness measurement eden initialpulse echo echo “Lamination check Compression Probe CRT DisplayQ Shear (angle beam) Probe Weld check initial pulse. defect echo. CRT Display Full. Skip.UT Advantages A true volumetric test One side access UT Limitations * Highly skilled operator * Smooth surfaces * Groove welds > 1/4” thick Very accurate Deep penetration - 200” Critical flaws found Equipment fully portableEddy Current Testing “Based on the principle of eddy currents being formed in conductive materials in the presence of an AC coil and changes in those eddy currents by material changes.” Induced Eddy CurrentsET application Flaw detection Metal thickness Coating thickness Metal hardness Heat treatmentET Advantages ET Limitations No contact required with part Highly skilled operator No couplant required “Too sensitive” Readily Automated Shallow penetration - 3/16” Applicable to all metals Calibration standards required Requires surface cleanliness Magnetic materials more difficultChapter 3 Introduction to manual ultrasonic oe y ! Dr.Samir SaadUT application i. Thickness measurement: corrosion, erosion, bore hole eccentricity, process control ii. Flaw detection: voids, cracks, inclusions, piping, laminations, disbond, bursts, flakes, rate of crack growth iii. Material properties: grain size, structure, elastic constants, nodularity in cast ironDigital ee UT Set, signals Ascan Display Compression probe checking the material ThicknessThicknessNon-destructive Testing Ohiresoiie = The distance of sound traveled can be displayed on the Flaw Detector > The screen can be calibrated to give accurate readings of the distance co Signal from the backwall Bottom / Backwall Dr.Semir Saad[ Basic Principles of Ultrasonic Testing ) <¢ Thickness / depth measuremen The closer the reflector to the surface, the signal will be more to the left of the screen 2 ‘The thickness is read from the screen ‘The THINNER the material the less distance the sound travel Dr.Semir Saadst Basic Principles of Ultrasonic Testing > The presence of a Defect in the material shows up on the screen of the flaw detector with a less distance than the bottom of the material. 2p. The BWE signal i. Defect signalQ Shear (angle beam) Probe Weld check initial pulse. defect echo % Skip CRT Display Initial pulse. defect echo. CRT Display Full. Skip.3£ what is Sound ? >» Amechanical vibration 34 what is Ultrasonic? > Very High Frequency sound — above 20 KHz (20,000 cps) Dr.Semir SaadXf Acoustic Spectrum Sonic / Audible <== Human 16Hz - 20kHz Ultrasonic > 20kHz = 20,000Hz 10 100 1K 10K 100K 1M 10M 100m -_ — Ultrasonic Testing 0.5MHz - 50MHz Ultrasonic : Sound with frequency above 20 KHzQ Properties of a sound wave >» Sound cannottravel in vacuum > — Sound energy to be transmitted / transferred from one particle to another Atomic structures gas liquid solid + medium dosiy + high density + medium bonding forces * sttong bonding forces Dr.Semir Saad + low density + weak bonding forcesi Piezo-Electric Effect When exposed to an alternating current crystal expands and contracts Converting electrical energy into mechanical and Vic versa. Sound wave with frequency f Crystal (Quartz) Fy U(f) Dr.Samir Saadi Piezo-Electric Effect * Reception of ultrasonic waves > —Asound wave hitting a piezoelectric crystal, induces crystal vibration which then causes electrical voltages at the crystal surfaces. > Converting mechanical into electrical energy and Vic versa Electrical energy Piezoelectrical crystal Ultrasonic wave <_ <_ \ D Pups [ yw Dr.Semir Saadi Piezo-Electric Effect * Reception of ultrasonic waves > —Asound wave hitting a piezoelectric crystal, induces crystal vibration which then causes electrical voltages at the crystal surfaces. > Converting mechanical into electrical energy and Vic versa Electrical energy Piezoelectrical crystal Ultrasonic wave <_ i — Nn Dr.Semir Saad<< Properties of Piezo-Electric Materials Crystal material | “Advantages ‘Limitations ‘Stable. Poor piezo electric Quartz Good wear resistance properties [PSoetansmiters) Lithium sulphate Best received and asl¥ | sonable in water est transmitier and good piezo electric properties May be preformed 10 focus beam Good ‘clectrie properties Lead Zirconate Titanate | Good transmitter and all | po. stvering Lion properties Barium Titanate ‘Temperature critical Lead Zirconate polarized Dr.Semir SaadXt velocity The velocity of sound in a particular material is CONSTANT It is the product of DENSITY and ELASTICITY of the material + It will NOT change if frequency changes + Only the wavelength changes Examples: V Compression in steel: 5960m/s V Compression in water: 1470m/s V Compression in air 330 m/s 5MHz a WATER Dr.Semir Saadxt Sound travelling through a material * - Sound velocity mainly depends on the density and E-modulus of the material. Compression waves Steel 5960m/sec Water 1470m/sec Air 344m/see Copper _—-4700m/sec Air > 330 mis Water > 1480mis ST 5920 m/s OS TS 3250 m/s Shear waves Steel Water Air Copper + Due to the different type of oscillation, transverse waves travel at lower speeds. Dr.Semir SaadXf Sound travelling through a material + Acoustic Velocities, Densities and Acoustic Impedance of common Material Steel Aluminum Plexiglass ‘Water Quartz Dr.Semir SaadFrequency > Frequency is Number of cycles per second 1 second 1 second 1 second 1 cycle per 1 second 3 cycle per 1 second 18 cycle per 4 = 1 Hertz =3 Hertz second = 18 Hertz The higher the frequency the smaller the wavelength Dr.Samir SaadFrequency > Frequency is Number of cycles per second >1Hz 1 cycle per second >1Kilohertz = 1 KHz = 1000Hz = 1000 000Hz >1Megahertz = 1 MHz 20KHz = 20 000 Hz 5MHz = 5 000 000 Hz Dr.Semir SaadFrequency Test frequency for various product forms Forged/rolled materials G.e., sheet, plate, bar, and forgings) Drawn/extruded materials (i.e., pipe, tube, bar and rod) Welds ‘Composites/ceramics 10-50 MHz Dr.Semir SaadWavelength > Wavelength is the distance required to complete a cycle. > Sound waves are the vibration of particles in solids, liquids or gases. » Particles vibrate about a mean position. wavelength Displacement The distance taken to complete one cycle e ( r One cycle Dr.Samir SaadWavelength Wavelength Velocity Frequency Dr.Semir Saad< Wavelength + The higher the frequency the smaller the wavelength “ The smaller the wavelength the higher the sensitivity > Sensitivity is The smallest detectable flaw by the system or technique Dr.Semir Saad6 Wavelength Q Wavelength is a function of frequency and velocity. Therefore: Vv =— or f =V or — f a 7 Va TA f Example :- Compute the wavelength of ultrasonic energy in steel at 5MHz compression wave probe A= 5,900,000 “11 5,000,000 Dr.Semir Saad mm“ In UT, the smallest detectable flaw is 2 1 (half the wavelength). > Half wavelength formula for detectability :- Maximum Wavelength . Diameter of FBH or defect yo ga High Frequency Transducer mamm> Low wavelength mmi> Good detectability Dr.Semir Saad1) What is the velocity difference in steel compared with in water? 4times 2) Ifthe frequency remain constant, in what material does sound has the highest velocity, steel, water, or air? Steel 3) Ifthe frequency remain constant, in what material does sound has the shortest wavelength, steel, water, or air? Air Remember the formula ABvIE Dr.Semir Saad4) Which probe has the smallest wavelength? 5) Which probe has the longest wavelength? 1MHz 5MHz 10 MHz 25 MHz LONGEST SMALLEST rABVIF Ft a} FH at Dr.Samir Saad7) Compute the wavelength of ultrasonic energy in lead at 1MHz.(V=2.1 Kmisec) V f v 1MHz compression wave probe in lead a=*1=2.1mm Dr.Semir Saad8) Which of the following compressional probe has the highest sensitivity? > 1 MHz » 2 MHz > 5 MHz >» 10 MHz Dr.Semir Saad9) Calculate the maximum wavelength for detecting a 2mm diameter flaw in steel. A ex. = 2d A wax= 2X2= 4mm Dr.Semir Saad10)What Would be the frequency of transducer used to detect 2mm diameter flaw in steel. A Max. — =2 d A uex.= 2X2= 4mm f=V =5.85Km/4mm = 1.46 MHz Dr.Semir SaadChapter 4 Sound Waveforms woe oe y Dr.Samir Saadx Compression / Longitudinal » Vibration in the parallel /same direction of propagation » Travel in solids, liquids and gases a Particle vibration tt 1 tigtot tt t trvit Propagationx Shear / Transverse » Vibration at right angles / perpendicular to direction of propagation » Travel in solids only » Velocity =~ 1/2 compression (same material) a Asian = Assn Particle vibration 7 “7 4; 4 «PropagationFrequency (F) Compression (2) — Shear (A) * 0.5MHz ° 11.8 * 65 1 MHz * 59 * 3.2 2MHz * 2.95 16 4MHz * 1.48 * 08 6MHZ * 0.98 * 0.54 The smaller the wavelength the better the sensitivity and Good detectabilityx Surface Wave / Rayleigh wave > Elliptical vibration >Penetrate only one wavelength (A) deep so, its used to detect surface cracks. » Surface waves only propagate in solid bodies. > Easily dampened by heavy grease or wet finger > Follows curves but reflected by sharp corners or " cracks =0.9V, V curface shearSt Lamb / Plate Wave > Produced by the manipulation of surface waves and others >it Can not propagate neither shear nor Surface waves in parts thinner than wavelength (A) deep so , Plate Wave used mainly to test very thin materials / plates >Velocity varies with plate thickness and frequencies “Tw SHEET on PLATE [one cTION OFPROPAGATION parricue ¢_} woriow SEE ‘SYMMETRICAL ASYMMETRICAL, PLATE WAVES.Chapter 3 Reflection and Transmission we — iin y Dr.Samir SaadBehaviour at an interface “Behaviour at an interface » As soon as a sound waye comes to a change in material characteri: eg. the surface of a workpiece, or an internal inclusion, wave propagation will change too: rr Incoming wave Transmitted wave a Interfaceit Reflection and Transmission » We use sound waves in flaw detection because they will reflect when they encounter a sudden change in acoustic impedance in material. > When sound wave strikes an interface, some energy of sound wave will be transmitted at point of incidence and some energy will be reflected. > The amount of energy reflected will depend upon the acoustic impedance ratio of the two mediums. * > Acoustic Impedance’ is a material property and is defined as a product of Z= pl sound velocity and density of the material.KX Acoustic Impedance » Acoustic Impedance’ is a material property and is defined as a product of sound velocity and density of the material. Z = PY Where :- Z1_= Impedance of material through which sound travelling Z= acoustic impedance. V = velocity of sound wave. p= density of medium. i =(B-ZYy.. Se Reflection Energy (RE) = (1 — Ze J 100% Transmission Energy (TE)=(100-RE) 77 tpedance of material sound striks at the interfaceKX Acoustic Impedance ACOUSTI O D IMPEDANCE VELOCITY DENSITY MATERIAL, (GRAM/CM® - SEC) cemysec) _|_(GRAM/cM’ AIR 0.000033 x 10° | 0,33x 10> WATER 0.149 x 10° 1,49 x 10% ALUMINUM 1,72 x 10° 6.35 x 10> STEEL 4.56 x 10° 5.85 x 10° > The greater the acoustic impedance difference, the greater the percentage of reflection1) Calculate the reflected energy and transmitted energy in Steel - Perspex where Z of Perspex is 320 and Z of steel is 4560 ? ; a-(224) 100% Z,+Z, % RE = {(4560-320) / 4560+320f} Re=87% TE= 100-RE Te=100-87 TE=13% Dr.Semir Saadif Reflection and Transmission: [Steel — Perspex (plexiglas )] Incoming wave Transmitted wave Reflected wave2) Calculate the reflected energy and transmitted energy in Steel - water where Z of water is 149 and Z of steel is 4560 ? n-(2% % RE = {(4560-149) / 4560+149}} RE = 87.74 %= 88 % TE= 100-RE TE=100-88 % TE=12% Dr.Semir Saad Angle of Incidence = Angle of ReflectionXf Law of refraction » Inclined incidence (not at 900 ) Incident Transmitted > The sound is refracted due to differences in sound velocity in the two DIFFERENT materialsXf Refraction * Only occurs when: » The incident angle is other than 0° » The Two Materials has different VELOCITIES Wate Steel Wate Stéel Steel | Steel RefractedXf Refraction + Only occurs when: » The incident angle is other than 0° » The Two Materials has different VELOCITIES 65" RefractedIncident Material 1 Material 2 Refracted Sine I _ V in Material 1 Sine RV in Material 21) Ultrasonic energy is transmitted into steel at incident angle of 20- degrees.what is the angle of the refracted shear wave within the material? Vs=5960 m/sec. Vperspex=2730 msec. Sine I _ V in Perspex Sine RV in Steel Sine 20 _ 2730 Sine R 5960. R=48.3 Perspex Dr.Semir Saad2) Ultrasonic energy is transmitted into steel at incident angle of 15- degrees.what is the angle of the refracted shear wave within the material? Vs=5960 m/sec. Vperspex=2730 m/sec. Sine I _ V in Perspex Sine RV in Steel Sine 15 Sine R R=344 Perspex = 5960 Dr.Semir SaadWhen an incident beam of sound approaches an interface of two different materials: REFRACTION occurs Perspex There may be more than one waveform transmitted into the second material, example: Comprpngiea aagSORT” C___ changes into another waveform: MODE s CHANGErst critical angle Cc if the angle of Incidents increased the angle of refraction also increases Up toa point where the ‘Compression Wave is at ‘90° from the Normal Perspex © 90° This happens at the FIRST CRITICAL ANGLE3) 1st Critical Angle Calculation Sine 1 _ 2730 Sine 90 5960. Sin90 =1 2730 ~ 5960 SinI = 0.458 I =27.26 Perspex Sinl Dr.Semir Saadxt First critical angle | at this time called First Critical Angle and equal 27.4° for Perspex to Steel and equal to 15° for Water to Steel. Compression wave refracted at 90 degrees Ss4) Calculate the 1st critical angle for a perspex/copper interface? V Comp copper : 4700m/sec & V Comp perspex : 2730m/sec Sine I _ V in Perspex Sine RV in Copper Perspex Sine I 2730 Sine 90 4700 Copper 1=35.5 Dr.Semir SaadX2nd Critical Angle C lat this time called 2"¢ Critical Angle and equal 57 for Perspex to Steel and equal to 27° for Water to Steel. S (Surface Wave) Shear wave refracted at 90 degrees Shear wave becomes a surface waveSine 1 _ 2730 Sine 90 3240 Sin90 =1 Perspex 2730 Sink = s mm 3240 SinI = 0.8425 L=574 Dr.Semir Saad( Refraction and mode conversion at non-perpendicular } Xf Refraction and mode conversion at non-perpendicular boundaries RELATIVE AMPLITUDE OF WAVE MODES C7... INCIDENT ANGLE 1st Critical 2nd Critical ‘Angle ‘Angle