 NON DESTRUCTIVE TESTING

 Flaw Detection
 Flaw Localization
 Type of Flaw Determination
 Flaw Dimension Estimation
 Flaw Detection

Face AV = Front wall echo (FWE)

Face AR = Back wall echo (BWE)

d1 = Dimension of first flaw

d2 = Dimension of second flaw

CRT Display
 Flaw Localization

•The transducer is scanning until the maximum echo is obtained

- The flaw is exactly below the transducer
• If the flaw is not perpendicular to beam wave direction :
- The flaw can not be detected by using straight beam probe
- The flaw can only be detected by using angle beam probe
• The transducer position
must be changed for
obtaining an echo

• If the flaw is
perpendicular to the
object surface
- Use two transducers
 Type of Flaw Determination
• Planar flaw (cracks) more dangerous
• Volume flaw (voids, inclusions)  less dangerous
• Change transducer orientation 10o and observe the echo
 Flaw Dimension Estimation
• Amplitude Analysis
- 6 db Drop Method
- Comparison Method
- DGS Method
• Time Analysis
- TOFD Method
• Frequency Analysis
- Ultrasonic Spectroscopy
 6 dB Drop Method
- Flaw dimension > transducer diameter
 Comparison Method
- Flaw dimension < transducer diameter
- Using block references with flat bottom hole (FBH)
- Flaw dimension is estimated by amplitude comparison
- If the amplitude of flaw echo equal to the amplitude of FBH
Flaw dimension  diameter of FBH
 Distance Gain Scale (DGS) Method
- D is distance of the flaw
- A is amplitude of the echo
- G is the ratio between flaw dimension and transducer diameter

DGS graphic for far field

DGS graphic for near field
 Time of Flight Diffraction (TOFD) Method
- Measure the time propagation of
diffraction waves from the crack tips

1 2
d V 2t1  4S 2
2
1 2
2a  V 2t 2  4 S 2  d
2

V = Wave velocity

d = Crack depth

2S = Transducer distance

2a = Crack dimension

t1, t2 = Time propagation of diffracted waves

TOFD method for oblique crack
• Using tandem transducer
• Measure time propagation for two positions of transducer
• Calculate the position of the crack tips
• Estimate the crack depth and orientation
Problem No. 1
A surface crack is detected in a steel material. For estimating its dimension (h) and orientation (),
a tandem system is used which consists of one transducer as transmitting transducer (T) and two
transducers (R1 and R2) as receiving transducer. These transducer are transversal transducers with
wave velocity of VT. The distances between them are a, b and c as shown at figure below. The time
propagation from T to R1 is t1 whereas the time propagation from T to R 2 is t2.
a). Express the crack dimension and orientation as function of the wave velocity V T
the distances (a, b and c) and the time propagation (t 1 and t2).
b). Calculate h and , if VT = 3230 m/s, a = 40 mm, b = 60 mm, c = 110
c mm,
t1 = 32.275 s and t2 = 47.554 s.
a b
T R1 R2


x y
h z

Steel
 c

a b
T R1 R2


x y
h z

Steel

x  h 2  a 2  2ah cos  y  h 2  b 2  2bh cos  z  h 2  c 2  2ch cos 

x  y  VT t1  f  h 2  a 2  2ah cos   h 2  b 2  2bh cos  h cos   q
f  h 2  a 2  2aq  h 2  b 2  2bq  h 2  b 2  2bq  f  h 2  a 2  2aq
h 2  b 2  2bq  f 2  h 2  a 2  2aq  2f h 2  a 2  2aq
2 2 f 2  a 2  b 2  ( 2a  2 b ) q
h  a  2aq   Dq  E h 2  a 2  2aq  D 2q 2  2DEq  E 2
2f
h 2  D 2 q 2  (2DE  2a )q  (E 2  a 2 )  h 2  D 2 q 2  Fq  G (*)
x  h 2  a 2  2ah cos  y  h 2  b 2  2bh cos  z  h 2  c 2  2ch cos 
x  y  VT t1  f  h 2  a 2  2ah cos   h 2  b 2  2bh cos  h cos   q
f  h 2  a 2  2aq  h 2  b 2  2bq  h 2  b 2  2bq  f  h 2  a 2  2aq
h 2  b 2  2bq  f 2  h 2  a 2  2aq  2f h 2  a 2  2aq
2 2 f 2  a 2  b 2  ( 2a  2 b ) q
h  a  2aq   Dq  E h 2  a 2  2aq  D 2q 2  2DEq  E 2
2f
h 2  D 2 q 2  (2DE  2a )q  (E 2  a 2 )  h 2  D 2 q 2  Fq  G (*)
x  h 2  a 2  2ah cos  y  h 2  b 2  2bh cos  z  h 2  c 2  2ch cos 
x  z  VT t 2  g  h 2  a 2  2ah cos   h 2  c 2  2ch cos  h cos   q
g  h 2  a 2  2aq  h 2  c 2  2cq  h 2  c 2  2cq  g  h 2  a 2  2aq
h 2  c 2  2cq  g 2  h 2  a 2  2aq  2f h 2  a 2  2aq
2 2 f 2  a 2  c 2  ( 2a  2c)q
h  a  2aq   Hq  I h 2  a 2  2aq  H 2 q 2  2HIq  I 2
2g
h 2  H 2 q 2  (2HI  2a )q  (I 2  a 2 )  h 2  H 2 q 2  Jq  K (**)
D 2 q 2  Fq  G  H 2 q 2  Jq  K  ( D 2  H 2 )q 2  ( F  J )q  (G  K )  0

2  B  B 2  4 AC q
Aq  Bq  C  0  q  h  H 2 q 2  Jq  K    cos1  
2A h
 c

a b
T R1 R2


x y
h z

Steel

x  h 2  a 2  2ah cos  y  h 2  b 2  2bh cos  z  h 2  c 2  2ch cos 

x  z  VT t 2  g  h 2  a 2  2ah cos   h 2  c 2  2ch cos  h cos   q
g  h 2  a 2  2aq  h 2  c 2  2cq  h 2  c 2  2cq  g  h 2  a 2  2aq
h 2  c 2  2cq  g 2  h 2  a 2  2aq  2f h 2  a 2  2aq
2 2 f 2  a 2  c 2  ( 2a  2c ) q
h  a  2aq   Hq  I h 2  a 2  2aq  H 2 q 2  2HIq  I 2
2g
h 2  H 2 q 2  (2HI  2a )q  (I 2  a 2 )  h 2  H 2 q 2  Jq  K (**)
 2 2 f 2  a 2  b 2  ( 2a  2 b ) q
h  a  2aq   Dq  E h 2  a 2  2aq  D 2q 2  2DEq  E 2
2f
h 2  D 2 q 2  (2DE  2a )q  (E 2  a 2 )  h 2  D 2 q 2  Fq  G (*)

2 2 f 2  a 2  c 2  ( 2a  2c)q
h  a  2aq   Hq  I h 2  a 2  2aq  H 2 q 2  2HIq  I 2
2g
h 2  H 2 q 2  (2HI  2a )q  (I 2  a 2 )  h 2  H 2 q 2  Jq  K (**)

D 2 q 2  Fq  G  H 2 q 2 DJqq  Fq
K  G
 H q( D 2  K 2 2( D  H )q  ( F  J )q  (G  K )  0
 H )q  ( F  J )q  (G  K )  0
2 2 2 2 2 2 2
 Jq
 B  B 2  4 AC
Aq 2  Bq  C  0 2 q 
 B  B  4AC 2 A
Aq 2  Bq  C  0  q 2 2 q
h  H q  Jq 2KA    cos 1  
h
q
h  H 2 q 2  Jq  K    cos 1  
h
Assignment No. 1
An oblique crack is detected inside an aluminum material. For estimating its dimension (h) and
orientation (), three transversal transducer with wave velocity of 3100 m/s are used. When these
transducers are located at (0, 50), (80,50) and (100, 50) the time propagation measured are :
t1(T-R1) = 20.9 S, t2(T-R1) = 24.6 S
t 1(T-R2) = 21.8 S, t 2(T-R2) = 26.1 S.
a). Design a computer program using MatLab for estimating the crack dimension and orientation.
b). Calculate h and  using the computer program.

T(0,50) R1(80,50) R2(100,50)

O(0,0)