Formed Metal Inspection of Aluminum Extrusion

1) Plot the full scale end view of test piece on a piece of paper as shown below.

2) Calibrate the range with a ASTM D-A block (XXXX-X-0025); for straight beam transducer
100

80

Set Velocity 
60

Set Range  40

20
Zero Probe 
0 20 40 60 80 100

3) Using a set of ASTM D-A blocks, construct a DAC curve, as shown below
C
Get the ref dB
100

80 A B

60

A
B
40

C
20

0 20 40 60 80 100
4) Scan the specified areas with the straight beam look for any indication that exceed the acceptable
limits as per the worksheet. Mark the suspect areas on the edge as shown below for further
investigation.

Mark the suspect 
areas for further 
investigation 

5) Once the indication (discontinuity) is found, locate it and size the indication using the 6dB drop.
Maximise the signal to a “convenient” amplitude (say 80% FSH). Move the probe until the signal drop to
½ the initial amplitude (ie. 80% to 40% - 6dB drop). Mark the centre of the probe with a pencil. Move
the other direction the other drop at ½ the initial amplitude (the other 40%) and mark the centre of the
probe – see below.

40%

80%

40%
6) Evaluation

From step (5), get the indication (signal) amplitude or if it exceeds reference level/gain/DAC, bring it
down to reference (ie. “touch” the DAC curve). Calculate the difference, X;
X = Reference gain @ DAC – Indication gain @ DAC
Eg. X = 40 – 30.5 = 9.5 dB
Then substitute into formula;
x/20
% signal amplitude to reference = 10 (x 100%)
9.5/20
= 10 (x 100%)
= 2.985 (x 100%)
≂ 300%