Ultrasonic testing of welds.

UT is now a primary means of NDE . Of the

big five NDE methods, only UT and RT can
reveal flaws which are substantially
subsurface:
Because the propagation of US is essentially a
mechanical phenomenon, it is especially suited
to determining characteristics of Engg.
Materials.The major NDE applications
includes:flaw detection thickness
measurement, and metallurgical
characterization
The principal advantages are:
1. Its ability to penetrate to greater depths.
2. Its ability to test from one surface
3. Its sensitivity to detect minute flaws
4. Its comparative accuracy in determining
flaw size and location
5. Its electronic operation for rapid and
automated inspection.The principal
disadvantages are:
6. Technicians’ considerable native ability,
training, experience,and motivation,
7. Good coupling, surface roughness,
Ultrasonic testing of welds.
Selection of Probe angle: Based on grove
angle.
Probe angle  = 90- /2 where  is the grove
angle.
Common practice of selection of
angle:

1. Based on grove angle

2. As per AWS 0-30 mm thick 70 degree
3. 30-40 mm “” 60 “”
4. > 40 mm “”” 45 “”
5. Finally as per approved procedure
 Selection of Frequency:
1. Depends on job thickness and beam path
2. Surface roughness, & grain size
3. Size of discontinuity sought.
4. In practice the following is the most suited
frequency range: 2.25 to 4.0 M.Hz
5. 2.25 M.Hz is the most ideal as it detects the
discontinuities comparable to calibration
standard, without producing very fine
indications which are of not interest for
acceptance or rejection,greater
penetration,good S/N ratio.
 The Procedure
1. Study the weld details- process, edge ppn,
backing strip, grove angle,
2. Remove all loose scales, loose paints,
spatter,
3. Scan the entire surface intended for angle
beam probe’s travel up to the weld with
normal beam for possible lamination and
other gross discontinuities.
4. Study the procedure for UT inspection.
Selection of equipment scanning
range:
1. Calculate the HSD & FSD and HBP & FBP
HSD (OA) =t tan : FSD(OB) = 2t tan ;
HBP(AO’) = t/cos  and FBP(BA’O)=
2t/cos
2. Set the range to approx. to 1.25 times of
FBP= 1.25 BA’O
B A O

A’ O’
Defect sizing & reference blocks
In UT the relative size of the defect is
compared with a known artificial flaw or
reflector.There are many methods of sizing in
practice, and the common most methods are
DGS SCALES, AND a reference block with a
SDH hole.
DGS STANDS FOR DISTANCE, GAIN, & SIZE
ASME BPV CODE AND API, AWS THE SIZE IS
ESTIMATED WITH SDH
ASME REFERENCE BLOCKS
FOR WELD DEFECT SIZING A DAC CURVE
IS DRAWN WITH A KNOWN SIZE OF
SDH. THE SAME HOLE SERVES AS A
REFERENCE REFLECTOR AT DIFFERENT
PATH SHOWING REDUCED AMPLITUDE
AT INCREASED BEAM PATH.
DAC CURVE.
ON A CRT SCREEN
SCANNING TECHNIQUES.
SIN  = ID/OD
THE  THE LIMITING ANGLE
SHALL NOT EXCEED THE
CALCULATED VALUE, BUT
CAN BE LESS.
 


r


Full skip = 2R sin-1{Wt sin /2r}/180

Wt = full path length=2R sin (-)/sin
And sin = R sin /r
R,r outer & inner radii,    included angles
Weld scanning for tubular
products, off-shore plat form
structures.

T H
S
ZONES
T= TOE,S= SIDE, H=HEEL PROBE IS
TRAVERSED ESSENTIALLY
 SPECIAL TECHNIQUES;
TANDEM TECHNIQUE;(ONE BEHIND THE
OTHER) to detect vertical cracks.
y x O
d
t

The distance between the probes =oy-ox

= 2 tan  (t-d).
Pitch and catch technique-to
detect transverse crack

R
 TOFD-DIFFRACTION AT THE
END OF CRACK TIPS.
DIFFRACTION-BENDING OF WAVES OVER
AN OBSTACLE (SAY THE CRACK) WITH IN
THE MEDIUM. TOFD TO LOCATE CRACK
TIPS.
 SIZING THE DEFECTS FOR
ACCEPTANCE/REJECTION.
ACCEPTANCE CODES SUCH AS ASME, API,
AWS,DIN, BS SPECIFY THE SIZE OF EACH
DISCONTINUITY CONSIDERING THE TYPE
OF LOADING/STRESS DIRECTION ETC.
SO THERE IS NO COMMON ACCEPTANCE
CODE FOR ALL THE ENGG. PRODUCTS.
IN UT ACTUAL SIZE CAN NEVER BE ESTIMATED.
BUT THE ESTIMATED SIZE IS SMALLER THAN
THE ACTUAL SIZE.
BECAUSE: 1. DEFECTS’ REFLECTING CHARACTERISTICS
DO NOT MATCH WITH THE REFERENCE ARTIFICIAL
REFLECTORS.
THE PERCENTAGE OF REFLECTED INTENSITY IS HIGHER
FOR REFERENCE REFLECTOR – SMOOTH MACHINE MADE
SURFACE, STEEL-AIR INTERFACE,NORMAL INCIDENCE OF
US WAVES.
DEFECT-ROUGH IRREGULAR SURFACE, NOT STEEL AIR
INTERFACE ,PERFECT NORMAL INCIDENCE CAN NEVER BE
ACHIEVED BECAUSE OF ORIENTATION.
 Interpretation of test results;
The percentage of energy reflected back to the
transducer depends on:
1. The acoustic impedance mismatch
2. The orientation of discontinuity w.r.t to the
direction of US beam
3. The surface profile of the discontinuity-
smooth and plane, irregular or curved
4. The size of the discontinuity.
Ultrasonic testing of off-shore
platform structures: RP 2X
OFF-SHORE STRUCTURES REQUIRE EXTENSIVE USE OF
T,K,Y TUBULAR MEMBER INTERSECTIONS. US IS THE BEST
MTHOD TO INSPECT THE WELDED AREA.
RT IS THE MOST SENSITIVE TO THREE DIMENSIONAL
DISONTINUITIES SUCH AS INCLUSIONS, POROSITY.
CRACKS, LOF, ARE LESS RELIABLY DETECTED ESPECIALLY
WHEN ORIENTED A FEW DEGREES ASKEW OF THE
RADIATION BEAM.
AS THE THICKNESS OF THE WELD INCREASES, THE
QUALITYOF THE DISCONTINUITY IMAGE DECREASES DUE
TO RADIATION QUALITY, SCATTERING EFFECTS, ETC.,
TKY TRANSPARENCY SHEETS.
 UT ON TUBULAR PRODUCTS:
API RP2-X
WELD PROFILES:
 RP-2X TRANSFER LOSS
CORRECTION.
REFERENCE BLOCKA B D
C

0
0
 TRANSFER LOSS -CONTD.
ON THE JOB SURFACE;

A A ON REFERENCE BLK
BB ON JOB
A
THE DIFF. IN dB is transfer
Loss in fig. B A
B
 Ultrasonic reject criteria API RP2X
LEVEL A – WORKMANSHIP QUALITY-NOT
INHERENTLY RELATED TO THE
COMPONENTS’S FITNESS FOR PURPOSE- BUT
BASED ON THE QUALTIY OF WELD THAT
WELDER SHOULD BE ABLE TO ACHIEVE.
LEVEL C- EXPERIENCED BASED FITNESS FOR
PURPOSE QUALITY-BASED UPON
GENERALIZED CONSIDERATION OF FATIGUE,
BRITTLE FRCTURE, & TENSILE INSTABILITY
MODES OF FAILURE –SEE API RP2A
CONTD…
LEVEL F
SPECIFIC “FITNESS FOR PURPOSE” QUALITY
BASED UPON SPECIFIC ANALYSIS OF
FATIGUE, BRITTLE FRACTURE, TENSILE
INSTABILITY AND ANY OTHER POTENTIAL
FAILURE MODES.