ULTRASONIC TESTING OF 125MM APFSDS/T

PENETRATOR
 NON DESTRUCTIVE TESTING- OVERVIEW
• Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials, components
or assemblies for discontinuities, or differences in characteristics without destroying the serviceability
of the part or system. It is used to monitor the quality of the:
(a) Raw materials that are used in the construction of the product.
(b) Fabrication processes that are used to manufacture the product.
(c) Finished product before it is put into service.

• Use of NDT during all stages of manufacturing results in the following benefits
(a) It increases the safety and reliability of the product during operation.
(b) It decreases the cost of the product by reducing scrap and conserving materials, labor & energy.
(c) It enhances the reputation of the manufacturer as producer of quality goods.
(d) It enables design of new products.
NDT METHODS

• Visual Inspection

• Liquid Penetrant Testing

• Magnetic Particle Testing

• Eddy Current Testing

• Radiographic Testing

• Ultrasonic testing
ULTRASONIC TESTING (UT)
• Ultrasonic inspection is a non-destructive method by which high
frequency sound waves are introduced into the object being inspected.

• The intensity of sound waves is either measured after reflection (pulse

echo) at interfaces (or flaw) or is measured at the opposite surface of
the specimen (pulse transmission).

• The reflected beam is detected and analyzed to define the presence

and location of flaws.

• Ultrasonic testing has a higher penetrating power than radiography and

can detect flaws deep in the test object (up to about 7 meters of steel).

• It is quite sensitive to small flaws and allows the precise determination

of the location and size of the flaws.
ULTRASONIC TESTING (UT)
Advantages
(a) It has high sensitivity which
permits detection of minute defects;
(b) It has high penetrating power
which allows examination of
extremely thick sections;
(c) It has a high accuracy of
measurement of flaw position and
size;
(d) It has fast response that enables
rapid and automatic inspection;
(e) It needs access to only one
surface of the specimen.
Limitations
(a) Unfavorable geometry of the test
object causes problems during
inspection;
(b) Inspection of materials having
coarse grain microstructure is difficult;
(c) It requires the use of a couplant
and smooth surface;
(d) Defect orientation affects defect
detectability;
(e) Reference standards and
calibration are required;
5
WHY ULTRASONIC FLAW DETECTOR (USOINC 8)
• T.A Penetrator being used in APFSDS/T are manufactured using Powder Metallurgy Technique.
• Voids, porosities, cavities, cracks can occur inside Penetrator material i.e Rods during
subsequent processing of Powders:
(a) Filling of moulds for pressing
(b) Heat Treatment of Pressed Rods
(c) Swaging of T.A Rods
• Inspection of every part of each Penetrator is integral to attain utmost quality/reliability of Ammo.
• Two NDT Techniques can be used for defects detection.
(a) R.T
(b) U.T
• R.T has its limitation regarding T.A material due to high absorption of Radiations.
• U.T is most widely used technique for inspection of T.A material being cost effective as well.
• Presently, U.T of T.A Rods is being carried out as per specifications in TOT;
(a) Rod is rotated along its axis and probes passes travels axially from one corner to another
enabling inspection of every millimeter of Rod.
Existing Set Up
• As the basic U.T equipment has provision of 8 Nos channels, therefore, two sets of probes are
employed to check 02 Nos Rods simultaneously.

• Indications of defects beyond the present conditions are displayed in different colors on screen of
an external PC.

• Type / Location of defects is stored in memory of external PC.

FLAT BOTTOM HOLES

• Reference standard blocks /rods are required for calibration of UT equipment as per international
standards.
• Flat bottom holes are drilled over reference standards to calibrate the machine according to
requirement.
• These holes are drilled as per specified values given in International standards.
• Presently, reference standard having FBHs of 1.2mm & 1.5mm is being used for Ultrasonic Flaw
Detector (USONIC 8).

• ASTM Standard E1158 (Standard guidelines to prepare reference block)

– Rod ᴓ ≥ 1” Required FBH is 5/64” or greater (1.98mm).

– Rod ᴓ < 1” Required FBH is 2/64” to 5/64” (0.79mm to 1.98mm).

9
DETECTING THE FLAWS BELOW 1.2MM

• UFD (USONIC 8) already has ability to detect defects below 1.2mm provided the following:
(a) Artificial defects in reference rod of desired size.
(b) Modification in the software for representation of defect on External PC

BOTTLENECKS

• POF has no facility to drill the hole(FBH) below 1.2mm. As efforts were made for same purpose
in 2014-15.

• To detect defect below than 1.2mm in Tungsten Alloy material, we have to amplify the return
signal strength to that extent which causes unnecessary noise signals.
THANKS
11 11