Ultrasonic Testing (UT) LEVEL-II Training Course Prepared by Dr. Samir Saad General Manager Cutech Arabia LLCa 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 (Al), Bois and Pressure Vessel [ASNT NDT LEVEL Min 11 methods, ASNT 10: 190002 41. Visual and Optical Testing (VT), "7, Magnetic fx leskage Testing (WFL), 2. Radiographic Testing. (FN, 8 inferred thermal testing (IR), 3. Utresonic Testing (UT). 8. Leak Testing (LD, 4. Liquid Ponotrant Testing (PT), 10. Acoust Emission Testing (AE) 5. Magnetic Testing (MM), 11. Neutron Radiography (NA) 6. Electromagnetic Tesing (EM), ‘AWIS-CWEng, -Cortiied Welling Engineer, ID NO. 17010086. AWS-CWE - Certied Welling Educator, ID NO, 1902001E. ‘ANS-CWI- Certied Welding Inspector, 1D NO. 19021321. ‘ANS-CWS ~ Certied Welding Superasor, ID NO. 20030008, [AWS-CWSR - Cortiiod Welding Sales Representative, ID NO. 2003000R {CSWIP 3.22 - Senior Welting Inspector Personal, ID NO.74305, [BGAS-CEWIP-Painting Inspoctor Grade 2-8GAS, 10:529730 ‘API 610- Pressure Vessel Inspector ID NO_ 38376, ‘APL 870- Process Piping Inspector ID NO. 38328 [API @83- aboveground storage tank inspector ID NO. 26171 [API RP 880 -Risk-Basod Inspection professional ID NO. 82784 ‘APLRP 6T1- Corrosion and Materials Profesional ID NO. 56350 ‘API 896 - Rofractory Personnel, ID NO. 9478 [API S77 = Welding Inspection and Metallurgy, 10 NO, 94785 [API SIFE-Source Inspector:Finad Equipment, ID.NO. 95780 Lead auditor according to 180 9001:2018 from IRCChapter-1 Qualification and Certification we Requirements = / 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.Samir 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 | should receive the necessary instruction and supervision from a certified NDT Level I! 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 III — 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 II personnel for certification in those methods. a Dr.Samir Saadit 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). Xf Certification “Certification is a written testimony that an individual has met all the qualifications of a company’s written practice. 72672020 Dr.Samir Saadac Chapter 2 Introduction to NDT. we < z Dr.Samir SaadDr.Samir Saad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.Samir Saad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 \VTis commonly performed on castings, forgings, and welds and itis performed after machining processes as well. Itincludes either the direct or indirect observation of the exposed surfaces of the weld and base metal Dr.Samir Saad$f 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 notlless than 30 degrees to the surface as illustrated in Figure Mirrors may be used to improve the angle of vision. 5726/2020 Dr.Samir Saad( vt + Codes and specifications may list compliance with these requirementsas mandatory. me requirements listed in this article in * a) A written procedure is required for examinations. '* b) The minimum amount of information thatis to be included in the y written procedure. 2 + c) Demonstration of the adequacy of the inspection procedure. lists += d) Personnel are required to demonstrate annually completion of aJ-1 Jaeger-type eye vision test. requirements Peay eee Recerca eemenecetet teen ieee ete within 6 in, through 24 in. (150 mm through 600 mm) of the surface, at for visual 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. ‘examination and devices be employed. ‘+ h) Evaluation of indicationsin terms of the acceptance standards of the referencingcode. (0 Dr.Samir SaadSagres of stewing ln wie and stright stresta to remain lang In wet weather the wheel of heavy cariags plowed them int setae in ey water te dt wa enane te wih | Falnthetonatitants wed smud whe arching teOptical Aids Optical aids used in visual inspection

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 ote Application of VT * Before welding % During welding _.. 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, dimensional accuracy Joint Condition — Edge Shape — Dimensional accuracy — Cleanliness — Root opening — Alignment — Backing — Tack welds Special Assembly/Pabrication 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3 Optical Aids > b) Optical aids used in visual inspection include the following. Mirrors valuable to the inspector allowing them to look inside piping, threaded and bored holes, inside castings and around corners if necessary. Dr.Samir Saad Ws3 Optical Aids > — Optical aids used in visual inspection include the following. c) Magnifiers Y helpful in bringing out smalll details anddefects. a Dr.Semir Saad( Visual Inspection Tools } > — Optical aids used in visual inspection include the following. ¥ — widely used for examining tubes, adeep hole, long bores, and pipe bends, having internal surfaces not accessible to direct viewing metal.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:- 6 inch Ruler 4 inch Micrometer Metric Dial Caliper Palmgren Gage Undercut Gage Fillet Weld Gages Dr.SamtinSaadWeld Examination Devices > — Typical inspection tools for weld inspection include the following. b) Bridge cam gauge 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 . 4 ei and misalignment (high-low). NEWETWEDTOAT—AMGLEOEPREMNATON— MMLOWENT Excess WeLO METAL Furr ues ume Dr.Samir SaadX% Weld Examination Devices > Typical inspection tools for weld inspection include the following C) Bridge Fillet weld gauge-The types of fillet weld gauges include. 1) Adjustable fillet weld gauge—measures weld sizes for fit-ups with 45 degree members and welds With unequal weld leg lengths The weld fillet gauge —a quick go/no-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 1 in. (25.4 mm). a weld fillet gauge being used to determine if the crown has acceptable concavity or convexity Dr.Samir Saad£ Weld Examination Devices Typical inspection tools for weld inspection include the following. ¢) Digital pyrometer or temperature sensitive crayons. {measures preheat and interpass temperatures, == [saa [Esa Saas) Sa) Dr.Samir SaadQ Penetrant examination isa 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 eof @ discontinuityBrirey o = = 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 ssan0 @ye Can more easily discern a fluorescentindication.Ovisible dye OFluorescent dye OThree removal systems: >» Solvent > Water > Emulsifiable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)QO Method Contrast paint Magnet & Ink ResultQO 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. S » An orientation of 45 to 90 degrees between the magnetic field and the defect is necessary to form an indication.Q Circumferential Magnetization EXTERNAL, > Circular magnetic fields are produced.by 7 ELD 1) passing current through the part 2) A headshot on a wet horizontal test unit an —_ CURRENT 3) Prods 4)Central conductorsQ longitudinal Magnetization > alongitudinal magnetic fields are produced by, 1) Permanent magnets and Electromagnetic yokes 2) Coils & SolenoidsQuestion = 2 From the previous slide regarding the optimum test sensitivity, which kinds of defect are easily found in the imaaes below? ERE Dnce 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 G) (AC oR Boy est MAGNETIC LINES SPP SRcE Longitudinal (along the axis)Question i? From the previous slide regarding the optimum test sensi , which kinds of defect are easily found in the i images below? ‘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QO 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 are 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 Radioactive source Developed Graph 1Q1 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.High dense discontinuity Low dense discontinuity Film Lighter region on radiograph Darker region ‘on radiographLIGHTEST DARKEST 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 J f- Fanilagreplilt Sensitivity ‘ 2% thickness test object). \ J Wire type QI d : JRadiographic Sensitivity O Placement of IQI Hole Type IQ! Wire Type IQIAdvantages Disadvantages 1) A permanent record 1) High operator skill 2) Most materials 2) Difficultinterpretation 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 UT Set, Pulse echo signals Ascan Display Compression probe checking the material ThicknessThicknessQ Longitudinal (straight beam)-Compression Probe “ Thickness measurement a defect Back wall initialpulse echo echo “Lamination check( Ultrasonic Testing J Q Shear (angle beam) Probe Weld check initial pulse. defect echo CRT Display initial pulse. defect echo. 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 rg k a tneasaaiesET application Flaw detection Metal thickness Coating thickness Metal hardness Heat treatmentET Advantages No contact required with part No couplant required Readily Automated Applicable to all metals ET Limitations Highly skilled operator “Too sensitive” Shallow penetration - 3/16” Calibration standards required Requires surface cleanliness Magnetic materials more difficult~~ a Chapter 3>_ Introduction tomanual ultrasonic & 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| Basic Principles of Ultrasonic Testing, | f ~ Digital UT Set, Pulse echo signals Ascan Display Compression probe checking the material ThicknessThickness Nai i —#Non-destructive Testing Ulifasonic Examination<% Basic Principles of Ultrasonic Testing > The distance of sound traveled can be displayed on the Flaw Detector > The screen can be calibrated to give accurate readings of the distance K Signal from the backwall Bottom / Backwall Dr.Samir Saad| Basic Principles of Ultrasonic Testing, | St 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.Samir Saad<% 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. , oS The BWE signal ‘a : Defect signalQ Shear (angle beam) Probe “+ Weld check initial pulse- defect echo. CRT Display initial pulse. Full Skip.3£ what is Sound ? Amechanical vibration x What is Ultrasonic? > Very High Frequency sound — above 20 KHz (20,000 cps) Dr.Samir 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 liquid solid SS + medium density + high density + medium bonding forces * sttong bonding forces Dr.Samir Saad + low a) + weak bonding forcesi Piezo-Electric Effect When exposed to an alternating current crystal expands and contracts Converting electrical energy into mechanical and Vie 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 electricalenergy and Vic versa Electrical energy Piezoelectrical crystal Ultrasonic wave —[- iv 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 electricalenergy and Vic versa Electrical energy Piezoelectrical crystal Ultrasonic wave <_ | — a\ nw V Dr.Samir Saad<< Properties of Piezo-Electric Materials Crystal material Advantages. Limitations ‘Stable Poor piezo electric Good wear resistance properties Best received and casily damped Best transmitter and good piezo electric properties May be preformed to focus beam Good electric properties Lead Zirconate Titanate | Good transmitter and all | po. stvering round properties Quartz Lithium sulphate Soluble in water Barium Titanate ‘Temperature critical Lead Zirconate polarized Dr.Samir SaadXt velocity The velocity of sound in a particular material is CONSTAND ‘> It is the product of DENSITY and ELASTICITY of the material 4 It will NOT change if frequency changes > Only the wavelandiichimages “> Examples: V Compression in steel 5960m/s V Compression in water: 1470m/s VCompressionin air 330.n/s Dr.Samir SaadXE 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/see Air 344m/see Copper ——-4700m/sec Air > 330 mis Water se 1480 mis SO TS 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.Samir SaadXf Sound travelling through a material ‘+ Acoustic Velocities, Densities and Acoustic Impedance of common Material Steel Aluminum Plexiglass ‘Water Dr.Samir 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 > 1 Kilohertz = 1KHz = 1000Hz > 1 Megahertz 1MHz =1000000Hz 20KHz = 20 000 Hz SMHz = 5 000 000 Hz Dr.Samir SaadFrequency Test frequency for various product forms Forged/rolled materials G.e., sheet, plate, bar, and forgings) Draw n/extruded materials (i-e., pipe, tube, bar and rod) Welds Composites/ceramics 10-50 MHz Dr.Samir 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 One cycle Dr.Samir SaadXt Wavelength Wavelength Velocity Frequency Dr.Samir Saad Sensitivity is The smallest detectable flaw by the system or technique Dr.Samir Saadx Wavelength Q Wavelength is a function of frequency and velocity. Therefore: V =— or f =V or — f a 7 Va TA f Example :- Compute the wavelength of ultrasonic energy in steel at SMHz compression wave probe qe 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 Ne gat High Frequency Transducer mmm> Low wavelength mmi> Good detectability Dr.Samir 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 ASvIF Dr.Samir Saad4) Which probe has the smallest wavelength? 5) Which probe has the longest wavelength? 1MHz 5MHz 10 MHz 25 MHz LONGEST SMALLEST ABvIit Ft ay Fe at Dr.Samir Saad7) Compute the wavelength of ultrasonic energy in lead at 1MHz.(V=2.1 Kmisec) A=— f v 1MHz compression wave probe in lead A= =2.4mm Dr.Samir Saad8) Which of the following compressional probe has the highest sensitivity? > 1 MHz >» 2 MHz > 5 MHz > 10 MHz Dr.Samir Saad9) Calculate the maximum wavelength for detecting a 2mm diameter flaw in steel. A ax.= 2d A wax = 2X2= 4mm Dr.Samir Saad10)What Would be the frequency of transducer used to detect 2mm diameter flaw in steel. AQ mox.= 2 d A nex. = 2X2= 4mm f =V =5.85Km/4mm = 1.46 MHz Dr.Samir Saad> Chapter’ ~ Sound Waveforms be < z Dr.Samir Saad52g Compression / Longitudinal » Vibration in the parallel /same direction. of propagation » Travel in solids, liquids and gases Particle vibrationXf Shear / Transverse » Vibration at right angles / perpendicular to direction of propagation » Travel in solids only > Velocity = 1/2 compression (same material) WF crear = EV tenet Hain oe Praia Particle vibration x “7 oy 4Frequency (F) Compression (A) Shear (A) * 0.5MHz ° 11.8 * 65 1 MHz ° 59 * 82 2MHz * 2.95 16 4MHz * 1.48 * 08 6MHZ + 0.98 * 0.54 The smaller the wavelength the better the sensitivity and Good detectabilityXf 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 surface cracks _— = 0.9V 5, year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 fomEcTiON OF PROPAGATION parricue ¢_} woriow == SSS EB = ‘SYMMETRICAL ASYMMETRICAL, PLATE WAVES.> Chapter5s = Reflection and Transmission < z Dr.Samir Saad|. Behaviour at.an interface...) As soon as a sound wave comes to a change in material characteristics ,e.g. the surface of a workpiece, or an internal inclusion, wave propagation will change Incoming wave Transmitted wave —— ss Reflected wave 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.i Acoustic Impedance » Acoustic Impedance’ is a material property and is defined as a product of sound velocity and density of the material. Z = pr Z1= Impedance of material through which sound travelling Where :- Z = acoustic impedance. V = velocity of sound wave. p= density of medium Reflection Energy ( RE) = (4-2) ~100% Transmission Energy (TE)=(100-RE) 7% impedance of material sound striks at the interfacei Acoustic Impedance ACOUSTI OUND IMPEDANCE VELOCITY DENSIT MATERIAL, (GRAM/CM? - SEC) tcw/secr _|_(GRAM/CM’ AIR 0.000033 x 10° | 0,33 x 10° WATER 0.149 x 10° 1,49 x 10% ‘ALUMINUM 1,72 x10 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) 18ou, ZrZy % RE = {(4560-320) / 4560+320f} Re = 87% TE= 100-RE Te=100-87 TE=13% Dr.Samir Saad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 ? x100% % RE = {(4560-149) / 4560+149}} RE = 87.74 %= 88 % TE= 100-RE TE=100-88 % TE=12% Dr.Samir 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 Steel RefractedXf Refraction * Only occurs when: > The incident angle is other than 0° » The Two Materials has different VELOCITIESIncident Material 1 Material 2 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 m/sec. Sine I _ V in Perspex Sine R V in Steel Sine 20 _ 2730 Sine R 5960 R= 48.3 Perspex Dr.Samir 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.Samir 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: Comping AagSOT C___ changes into another waveform: MODE s CHANGEx First critical angle Cc if the angle of Incidents increased the angle of refraction also increases Up to a point where the Compression Wave is at Perspex go>trom the Normal © 90° This happens at the FIRST CRITICAL ANGLE &3) 1st Critical Angle Calculation Sine _ 2730 Sine 90 5960 Sin90 =1 2730 ~ 5960 SinI = 0.458 1 =27.26 Sinl Dr.Samir Saadx 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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.Samir SaadXtand 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5) 2nd Critical Angle Calculation Sine I y 2730 Sine 90 3240 Sin90 =1 Perspex 2730 Sink = x mm 3240 SinI = 0.8425 1=574 Dr.Samir SaadXf Refraction and mode conversion at non-perpendicular boundaries RELATIVE AMPLITUDE OF WAVE MODES Longitudinal INCIDENT ANGLE 1st Critical 2nd Critical ‘Angle ‘AngieBeyond the 24. Critical Angle: All waves are reflected out of the material NO wave in the material. Before the 1*. Critical Angle: There are both Compression and ‘Shear wave inthe second terial mated the FIRST CRITICAL ANGLE ‘Compression wave refracted at 90° ‘Shear wave at 33 degrees in the ‘material Between the 1*. And 2". Critical Angle: Only SHEAR wave in the material. Compression is reflected out of the material. At the 2"4 Critical Angle: Shear is refracted to 90° and become SURFACE wave» Standard angle probes between 1st and 2nd.critical angles (45,60,70) > Stated angle is refracted angle in steel > No angle probe under 35, and more than 80: to avoid being 2 waves in the same material. One Defect Two Echoes a s~ Chapter ~~ Probes Dr.Samir Saad Cutting Perpendicular to X-axis Produce longitudinal waves. » Cutting Perpendicular to Y-axis Produce shear waves. zOThe frequency of the probe depends on the THICKNESS of the crystal OFormula for frequency: Fr=V/2t Where Fr = the Fundamental frequency V = the velocity in the crystal t = the thickness of the crystal Q Fundamental frequency is the frequency of the material ( crystal ) where at that frequency the material will vibrate. OThe Thinner the crystal the Higher the frequency1) Which of the followings has the Thinnest crystal ? . 1 MHz Compression probe . 5 MHz Compression probe - 10 MHz Shear probe . 25 MHz Shear probe D. 25 MHz Shear Probe 672672020 Dr.Samir Saad<{Probe Design 1. case: consist of metal housing That contains all the following parts. 2. Backing Material: Provide damping of the transducer Oscillations (made of epoxy, rubber or Plastics). ti 3.Electrodes: Are primarily silver or gold deposited ia on the piezo- Electric element. 4.Crystal (piezo Electric element) ol 5. Wear face: Thin layer made of Lucite, Ceramic or eine late. Quartz wear plate.( Types.of Probe ) J SLTypes of Probe according to the refracted wave introduced A. Compression Probe (Normal ayer Probe). 1) single probe: In normal beam testing, the sound beam is Introduced into the test article at 90 degree to the surface. generally used for thicker materials Electrical connector s Damping Transducer( Types.of Probe ) long, rectangular active area, usually made from a “mosaic” of crystals, for rapid scanning of large surfaces. > Agrouping of a number of crystal in one transducer with all contact surface in the same plane ,and vibrating in phase with each other to act as a singletransducer.SLTypes of Probe according to the refracted wave introduced B. Angle Probe > Angle beam transducers incorporate wedges to introduce a refracted shear wave into a material. » The incident wedge angle is used with the material velocity to determine the desired refracted shear wave according to Snell’s Law » Transducers can use fixed or variable wedge angles. » Common application is in weld examination.C. Pitch-catch probe * Pitch-Catch: any technique using separate transmitting and receiving crystals “can be in the same housing or separate housings * for example: 1) dual element 2) through transmission 3) tandem angle beamC. Pitch-catch probe scoune 1) dual element (Normal “0° Probe) mee SV wcoe consist of a matched pair of angle beam probes. Dual Element transducer advantages: preferred for thickness gauging of materials with corroded/eroded back surface good for inspecting thinner materials because dead zone is off the left side of the display Dual Element transducer limitations: doubling/tripling: very thin material could read out as 2 or 3 times actual thickness cross-over: very thick material will not return an echo to the receiving crystal cross-talk echo: sound leakage from transmit to receive sides of probe assembly cause a misleading signalitch-catch probe 2) tandem angle beam » Its acts as duel crystal technique but with separate two transducers. Transmitter Transducer —_ Receiver TransducerTyp2s._of Probe C. Pitch-catch probe ™% 3) Through transmission f Transmitting and receiving probes ‘on opposite sides of the specimen Presence of defect indicated by reduction in transmission signal Through transmission is useful in detecting discontinuities that are not good reflectors, and when signal strength is weak. Itdoes not provide depth informationD. Transducer array ( phased arrays)probe “Transducer array: a series of transducers, sequentially pulsed » steering of arrayed transducers allows manipulation of the ultrasonic beam. Immersion: for use ina liquid environment “* Immersion transducers are designed to transmit sound whereby the transducer and test specimen are immersed in a liquid coupling medium (usually water). > Immersion transducers doesn’t need protective layer. > Immersion transducers are manufactured with planar, cylindrical or spherical acoustic lenses (focusing lens). athanniges Of Focussing Lens Increasing The intensity. Greater width of length (for spherical lens) greater sensitivity. Used with rough surfaces.E. Immersion: for use in a liquid environment 1) Focused transducers >» Focused transducers have a concave surface used to improve near surface resolution, lateral resolution, and localized defect sensitivity 2) Concave transducers » Concave transducers are used to focus sound. Immersion: for use in a liquid environment 2) Concave transducers » Concave transducers are used to focus sound >» However, sound striking a convex surface diverges, while sound striking a concave surface converges SS Convex Surtace Bitect Concave Surface Etteot a convex surface diverges a concave surface convergesXCo-axial cable *Co-axial cable is used to provide shielding from electromagnetic induction. * Probe is connected to co-axial cable and co-axial cable is connected to instrument by means of connectors. Widely used connectors are Lemo, BNC, microdot etc. Types of ConnectorsThe Capability Of rans Propagation of Ultrasound, ‘Sound Intensity & Attenuation & Dr.Samir Saad only defects having a suitably orientated reflecting surface can be detected by pulse echo methods!! i e The lower the velocity the bigger the near zone1- What is the near zone length of a 5SMHz compression probe with a crystal diameter of 10mm in steel? D°f 4V _ 107 x 5,000 ,000 ~ 4x 5,920 ,000 = 21.1mm Near Zone Dr.Samir Saad( Practice problem } 2- Which of the above probes has the longest Near Zone ? ~ 7» Inthe far zone sound pulses spread out as they move away from the crystal = 0.14396 Angle = 8.27 a 2 Dr.Samir Saad2- For a 2MHz shear wave probe of crystal diameter 14mm the theoretical angle of divergence to 20dB edge of the beam when used on steel is approximately? 0 _ KV. = aS = 1008 x 3.30 Km _/s 14 x2 MHz = 0.127 2 9293 2 Dr.Samir SaadThe decibel is a logarithmic base unit used to compare sound intensities. “Amplitude ratios in decibels a = AntiLog, (aB/20) 1 A dB= 20 EO 11- Two signals at 20% and 40% FSH. What is the difference between them in dB’s? A, dB=20L0g,y rt 1 40 AaB =20L0g ,, DD 20L08..1)2 dB = 20x0.3010 dB=6dB Dr.Samir Saad2- Two signals at 10% and 100% FSH. What is the difference between them in dB’s? Ai aa 2a 1 aB=20Log \, ~ = 20Log.,,10 aB=20x1 dB=6dB Dr.Samir Saad3- If the amplitude of one signal 20% FSH and a second signal at the same range is 14 dB higher What is the amplitude of second signal? fs = AntiLog ,,(dB/ 20) 1 Ho — sntiog (14/20) 1 H, = 20xdntiLog (14/20) H, = 100% 672672020 Dr.Samir Saad we Play: & 3 Dr.Samir SaadX The Horizontal axis : Represents time base / beam path length / distance / depth The Vertical axis : Represent the amount of sound energy returned to the crystalX Using Transducers With Frequency between (1 to 5 MHZ) © To get useful levels of sound energy into material, the air between the transducerand the test article must be removed. This'is referred to as coupling. In contact testing a couplant suchas oil, grease or a gel is applied between the transducer Gontact Feineaticer Couplant supX A transducer sends outa pulse of energy and the same or a second transducer listens for reflected energy (an echo). » Reflections occur due to the presence of discontinuities and the surfaces of the test article. » The amount of reflected sound energy is displayed versus time, which provides the inspector information about the size and the location of features that reflect the sound, defect Back wall Initialpuise “echo echo CRT Display> Digital display showing signal generated from sound reflecting off b > Digital display showing the presence of a reflector mi , with lower amplitude back surface reflector. > The pulse-echo technique allows testing when access to only one side of the material is possible, and it allows the location of reflectors to be precisely determinedX» There are two crystals One act as a Transmitter and the other as a receiver. >» There are may be side by side or may be stacked.Types of Scanning A. Contact Testing Method (The Tandem Technique) > The tandem method employed 2 probe on the same side , with each other spaced ata predetermined length > One transmitting signal the other set to received signal if reflected from a defect. > The distance between the probe depends on the probe angle, material thickness and the depth of expected defects. > The techniques are used to find for defects at predetermined depth such as in the root of double V weld. > The presentation could be a A-Scan display. Transmitter Transducer _ Receiver Transducer{ Ultrasonic Basic Testing Methods ) ii Types of Scanning A, Contact Testing Method (Through-Transmission Techniques) svanemiting and nf (Le a ear. of the specimen Presence of defect indicated by reduction in transmission signal Through transmission is useful in detecting discontinuities that are not good reflectors, and when signal strength is. weak. It does not provide depth information> Digital display showing recei nd through material thickness. Raa en ie due to presence of a inuity in the sound field.it Types of Scanning B. Immersion Testing Method » Using Transducers With Frequency between (10 to 25 MHZ) > In immersion testing, the part and the transducer are place in a water bath. This arrangement allows better movement of the transducer while maintaining consistent coupling With immersion testing, an echo from the front surface of the part is seen in the signal. Water path not less than ¥ Steel Thickness (e.g. for 100mm steel the water gap shall be >25mm) Immersion testing Water CouplantUltrasonic Basic Testing Methods. eof . 42 Types of Scanning B. Immersion Testing Method psy-la¢ Surface1- The 6”’ thick A.S.S ,5MHz,3/4’’ diameter probe, approximate water path to inspect full thick of plate? AG” B3” e155” D. None of the above C.1.5°" 672672020 Dr.Samir SaadChapter 10_ Instrumentation » be < z Dr.Samir SaadD-meters or digital thickness gauge instruments provide the user with a digital (numeric) readout. They are designed primarily for corrosion/erosion inspection applications. Some instruments provide the user with both a digital readout and a display of the signal. A distinct pi ae of these units is that they allow the user to evaluate the signal to ensure that the digital measurements are of the desired features.( lastrumentation Flaw detectors are instruments designed primarily for the inspection of components for defects. However, the signal can be evaluated to obtain other information such as material thickness values. Both analog and digital display. Offer the user options of gatin horizontal sweep and amplitude threshold.Chapter® nN Calibration Blocks be & : Dr.Samir Saada ars The user must "calibrate" the system, which includes the equipment settings, the transducer, and the test setup, to validate that the desired level of precision and accuracy are achieved. standards also help the inspector to estimate the size of flaws. In a pulse-echo type setup, signal strength depends on both the size of the flaw and the distance between the flaw and the transducer. By comparing the signal from the reference standard to that received from the actual flaw, the inspector can estimate the flaw size. The type of standard used is dependent on the application and the form and shape of the object being evaluated( Calibration Block J 1) V1-Block » Used for setting metal-distance and sensitivity settings, determining the sound exit point. and refracted angle of angle beam transducers, and evaluating depth resolution of normal beam inspection setups.2) V2-Block > block is much smaller and lighter than the IW block but performs many of the same functions. > The miniature angle-beam block can be used to check the beam angle and exit point of the transducer. The block can also be used to make metal-distance and sensitivity calibrations for both angle and normal-beam inspection setups.The miniature resolution block is used to evaluate the near-surface resolution and sensitivity of a normal-beam setup It can be used to calibrate high-resolution thickness gages over the range of 0.015 inches (0.381 mm) to 0.125 inches (3.175 mm).4) Step and Tapered Calibration Wedges, > Step wedges are typically manufactured with four or five steps but custom wedge can be obtained with any number of steps > Tapered wedges have a constant taper over the desired thickness range 26/2020 esa Saad5) Distance/Sensitivity (DS) Block The DS test block is a calibration standard used to check the horizontal linearity and the dB accuracy per requirements of AWS and (AASHTO )American Association of State Highway and Transportation Officials.6) Distance/Area-Amplitude Blocks > Distance/area amplitude correction blocks typically are purchased as a ten-block set. > Sets are commonly sold in 4340 Vacuum melt Steel, 7075-T6 Aluminum, and Type 304 Corrosion Resistant Steel. > Sets can also be purchased in titanium. >Each block contains a single flat-bottomed, plugged hole. The hole sizes and metal path distances are as follows: 3/64" at 3" 5/64" at 1/8", 1/4", 1/2", 3/4", 11/2", 3", and 6" 8/64" at 3" and 6"Chapter 12 Angle and Normal Beam Inspection Applications and gaye Methods oe Dr.Samir Saad“+ Normal Beam Inspection Applications >Thickness measurements > lamination check IP = Initial pulse F=Flaw BE = Backwall echo> Applications clude f routinely utilized in the petrochemical and utility industries to determing various n.[ Normal Bean Inspection Applications J + Flaw Detection - laminations » Contact, pulse-echo inspection for laminations on 36” rolled beam. Signal showing multiple back surface echoes in an unflawed area. Additional echoes indicate laminations in the memberSI DIMENSIONS (mm)Calibration Of Compression (Normal) Probe Using V1 (IW) BLOCK 1) Range (Time Base). Set the probe at position B. By sweep length control can set the echo signal at the end of the tenth box. Thus, the width of CRT 100 mm representative of ten boxes. To Make Sure the Probe is placed in position A,Will appear four pulses to represent the distance between every 2 consecutive pulse 25 mm“ Calibration Of Compression (Normal) Probe Ke v1 cw) BLOCK 1) Range (Time Base). ii) For ranges of 200 mm and above, = The probe is placed at position B orc. The screen appearance shows multiple echo signals at intervals each equivalent to a range of 100 mm in steel. The equipmentis "then adjusted to make the signals correspond with suitable divisions, e.g. for a range of 200 mm full width, 2 echo signals will be presented after the initial pulse as shown in Figure .‘ Calibration Of Compression (Normal) Probe Using V1 (IIW) BLOCK 2) Dead Zone. + Set the probe in position D. + Move the probe forward and backward to obtain the maximum echo signal on CRT at 5 mm after the initial pulse. Thus, the UT device has the ability to feature & detect discontinuity of 5 mm or more. But that pulse Echo not clear, confused or inside under the initial pulse at 5 mm and so the UT device does not have the estimated feature & detect discontinuity less [—]rosmon‘+ Calibration Of Compression (Normal) Probe Using V1 (IIW) BLOCK 3) Resolution. = Set the probe in position E . = The Probe shall clearly resolve all three distances at 85mm, 91mm & 100mm. Good resolution fh Bad resolution POSITION E‘+ Calibration Of Compression (Normal) Probe Using V1 (IIW) BLOCK 4) Sensitivity. = Set the probe in position E . = Move the probe forward and backward to obtain the maximum echo signal on CRT at 15mm after the initial pulse on CRT increase or degrease the echo to reach 80% FSH POSITION F( Angle Beam Inspection Applications ) + Angle Beam Inspection Applications Q Flaw Detection in Welds > One of the most widely used methods of inspecting weldments is ultrasonic inspection. »Full penetration groove welds lend themselves readily to angle beam shear wave examination1) Exit Point (Index Point). = Set the probe in position A. = Move the probe forward and backward to obtain the maximum echo signal on CRT. = Record of the mark on the probe is identical to the focal point on the block; this mark is the actual point of exit waves. USING THE A? BLOCK+ Calibration Of Compression (Normal) Probe Using V1 block 1) Exit Point (Index Point). * Asecond method to obtain the Exit Point (Index Point). = Move the probe forward and backward to obtain the maximum echo signal on CRT. kalba > X=X-Value =Index Point > a’=distance front edge of probe x=100-a’“+ Calibration Of Compression (Normal) Probe Using V1 block a Probe Angle (Wedge Angle). Depending on angle of probe ,we select the position of probe on the block test ,for example if the angle of probe is 60. Set the probe in position b. Move the probe forward and backward to obtain the maximum echo signal on CRT. Then compare the exit point mark (which had been identified previously) to marks angles recorded on the test block . Record the angle (59,60,61..,ect) and write in the report and we will use this angle in the calculations later. eal 4-2 mm (0.080 in.) eat oan f ozsmmaingr Qian, 3.2 mm~ oizsin) sam (4 in ger 200 mam (4 in. dR 168 mun. (6.6) orsaniv seas MP Find Index/Range/Resolution+ Calibration Of Compression (Normal) Probe Using V1 block 2) Probe Angle (Wedge Angle). » Asecond method to obtain the Probe Angle (Wedge Angle). peewee A= (a’ +x)-35 Tan @= (A/30)+ Calibration Of Compression (Normal) Probe Using V1 block 3) Range (Time Base) = Set the probe in position A. = Move the probe forward and backward to obtain the maximum echo signal on CRT. by sweep length control adjust the echo signal to correspond with the 100 mm, as shown in Figure Below. iz.+ Calibration Of Compression (Normal) Probe Using V1 block 4) Sensitivity. * Set the probe in position C. Move the probe forward and backward to obtain the maximum echo signal on CRT increase or degrease the echo to reach 80% FSH... > Note: the hole at a depth of 15 mm.if you use the probe angle 60 , distance between the exit point and hole should be the 30 mm L=Beam Bath=Sound Bath =Screen Reading L=15 /cos @ L=15/ cos 60=30 mm“+ Calibration Of shear (angle) Probe Using V2 BLOCK 1) Exit Point (Index Point).. = Set the probe in position A. = Move the probe forward and backward to obtain the maximum echo signal on CRT. = Record of the mark on the probe. is identical to the focal point on the block; this mark is the actual point of exit waves“+ Calibration Of shear (angle) Probe Using V2 BLOCK 2) Probe Angle (Wedge Angle). Depending on angle of probe ,we select the position of probe on the block test ,for example if the angle of probe is70. Set the probe in position b. Move the probe forward and backward to obtain the maximum echo signal on CRT. Then compare the exit point mark (which had been identified previously) to marks angles recorded on the test block . Record the angle (69,70,71...,etc.) and write in the report and we will use this angle in the calculations later.“+ Calibration Of shear (angle) Probe Using V2 BLOCK 3) Range (Time Base). = Set the probe in position A. = Move the probe forward and backward to obtain the maximum echo signal on CRT. by sweep length control adjust the echo signal to correspond with the 100 mm or 125 mm, as shown in Figure Below.“+ Calibration Of shear (angle) Probe Using V2 BLOCK 3) Range (Time Base).“+ Calibration Of shear (angle) Probe Using V2 BLOCK 4) Sensitivity. = Set the probe in position B. = Move the probe forward and backward to obtain the maximum echo signal on CRT increase or deqrease the echo to reach 80% FSH. Note : the hole at a depth of 8 mm. if you use the probe angle 70 , distance between the exit point and hole should be the 23 mm L=Beam Bath=Sound Bath =Screen t Reading L=8 /cos @ spejn0 L=8/ cos 60=23 mm‘+ Distance Amplitude Correction (DAC) = Acoustic signals from the same reflecting surface will have different amplitudes at different distances from the transducer. = Distance amplitude correction (DAC) provides a means of establishing a graphic reference level sensitivity as a function of sweep distance on the A-scan display. (ee STs, S|Distance Amplitude Correction (DAC) A. Non-piping calibration blocks in according with ASME V Te Sal ore 726/tzo ttm deersion. esa Saad% Distance Amplitude Correction (DAC) B. piping calibration blocks in according with ASME V = For examinations in materials where the examination surface diameter is equal to or less than 20 in. (500 mm), a curved block shall be used. SSN psn, Arc lensth Cladaing Gt presents Mi + Notes shall be located no closer than er 2 In. C25 mim), whichever greater, t© any block edoe orto ater notees% Distance Amplitude Correction (DAC) B. piping calibration blocks in according with ASME V = Asingle curved basic calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter.1- an 8 in (200 mm) diameter block may be used to calibrate for examinations on surfaces in the range of curvature ???? from 7.2 in. to 12 in. (180 mm to 300 mm) in diameter. Dr.Samir Saad‘Distance Amplitude Correction (DAC) ‘A. Non-piping calibration blocks in according with ASME VDistance Amplitude Correction (DAC) . Non-piping calibration blocks in according with ASME V A L=Beam Bath=Sound Bath =Screen Reading -L1=0.25T /cos © -L2=0.5T/cos 6 -L3=0.75T /cos © -L4=T cos 6 + 0.25T /cos ©Transfer Correction (Attenuation and surface correction) > Place two similar angle beam search units on the Piassiteragn aecnven calibration block or mock-up to be used in the j ) seman position shown below. using through transmission methods, maximize the indication obtained and obtain a dB value of the, indication Transfer the same two search units to the part to 8 be examined, orient in the same direction in which * scanning will be performed, and obtain a dB value of indications as explained above from the least eae three locations. ree The difference in dB between the calibration block or mock-up and the average of that obtained from the part to be examined should be recorded and cam aue aaa Pant used to adjust the standard sensitivity. enonChapter 1 Select a probe angle and frequenc for inspection , Scanning and 7 Interpretation oe Dr.Samir Saad++ Common practice to Select a probe angle and frequency for inspection > UT of groove welds and HAZs between the thicknesses of [8 mm and 200 mm] Ultrasonic probe frequencies ‘Thickness range, “Transverse wave probe frequency | Longitudinal wave probe frequency inmm in MHz in Mhz Sst g i105 iss 1<40 Biot tos a0 <1 = 100 2 2105 ‘Table | Weld ground on both sides Table I Weld not ground Plate thickness, mm Favourable probe angle Plate thickness, mm | Favourable probe angle 5-15 70° 15-30 45° 60", 70° 5-20 70 30-60 45%, 60° (70°) 20-40 45%, 60°, 70° coer 60 45°, 60" over 40 45°, 60° (70°)» Before being to scanning shall be draw of joint and obtain the half skip (H.S), (root sound path) and full skip (F.S) & (cap sound path). > This is used in the following formulas: + H.S=T x Tane + F.S=2 x Tan e + 0.5 Cap width + S.P Root = T/Cos @ + S.P Cap=2x T/Cose> Calculation the skip distance and V-path SKIP DISTANCE ——— >> 0, = Refracted Angle T = Material Thickness Skip Distance = 27x TanO, esa Saad> Calculation the surface distance and depth of defect 26/2020 Surface Distance On = Angle of Refraction T = Material Thickness Surface Distance = Sin@,x Sound Path Depth (1 Leg) = Cos@gx Sound Path Depth from (2"# leg)=2T-cos Q,.x sound path1. Assingle Vee, butt weld in a 3 in. plate is being examined using a 60-degree shear wave. An indication on the CRT appears at a sound path distance of 9 in. At the same time the exit point of the transducer is 7.8 i from the centerline of the weld. This suggests the reflector could be (a) Acrackin the mear side HAZ. Lack of fusion at the weld/base material interface. (©) Inadequate penetration at the toe of the weld. An undercut condition on the far side of the weld. Aslag inclusion in the center of the weld. 1. Sound path (1) T/Cos R=3/Cos 60= 6” and sound of indication at 9" so indication at the 24 leg. 2. Depth of indication =21-8.P* Cos R=2*3-(9*Cos 60) =1.5" 3. the exit point of the transducer is 7.8 in. from the centerline of the weld and depth {s in middle ofweld. So the defect my be round indication. Answer: © Aslag inclusion in the center of the weld. Dr.Samir Saad2-A single Vee, butt weld in a 3 in. plate is being examined using a 60-degree shear wave. An indication on the CRT appears at a sound path distance of 6 in, At the same time the exit point of the transducer is 5.2 in. from the centerline of the weld. strong indication is received indicating a probablereflectorin the the weld. (a) Rootarea of. (>) Crown area of. (© Midseetion of. (@) Base metal adjacentto. (©) _Backingstrip beneath. 1. Sound path (1!) T/Cos R-8/Cos 60-6” and sound of indication at 5.2” so indication at the 1™ leg. 2. Depth ofindication =S.P* Cos R= (6*Cos 60) =3 3. the exit point of the transducer Is8.2 °. from the centreline of the weld and depth isin root of weld. 4. Answer: @ —-Rootarea of. Dr.Samir Saad> Movements of Transducer to scan Longitudinal or Transverse discontinuities> Planar Discontinuity Characteristics iit, ‘Ample drdps of sanity as the search unt position is changed ‘fom normal nadent angle wn the acorn. “Ampltude drops slighty attest movement Sper an eaeloe t movenan nga te Shwe decoy> Discontinuity Height Dimension> Discontinuity Length Dimension ‘Move search unit to end & unit Indication drops to 1/2 of height ‘roar the end. Mark sea lace {gjacont to search unit Center beam relerence mar Move agaren unit ton G a ination tangth (Oise diatance between Both marks. t \— WELDMENT REFERENCE MARK LL = Tota! engin of aisconuinuty Discontinuity location along the wold is from the weldment reference mark| Interpretation And Evaluation Of Defects | > Interpretation And Evaluation Of Defects According To ASME Code. * From ASME Code acceptance criteria Q Where indications are interpreted to be cracks, lack of fusion, or incomplete penetration, they are unacceptable regardless of discontinuity or signal amplitude. Q All indications which produce a response Smaller than 20% of the reference level , they are acceptable regardless of the length of discontinuity rear| Interpretation And Evaluation Of Defects | > Interpretation And Evaluation Of Defects According To ASME Code. “+ From ASME Code acceptance criteria Q Allindications which produce a response greater than 80% of the reference level , they are acceptable regardless of the length of discontinuity Ped5 Interpretation And Evaluation Of Defects According To ASME Code. \ ¢ From ASME Code acceptance criteria Cee CAP RT Icy Up to Reject 19 mm ys From 19 mm Reject To 57 mm 19mm —_For-tover Reject 57 mmChapter14 Discontinuity characteristics a & Dr.Samir SaadPredetermined team [at ont otoTese TET