Top Banner

of 158

Twi Ut Notes

Jul 07, 2018

Download

Documents

kyihan
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
  • 8/19/2019 Twi Ut Notes

    1/158

  • 8/19/2019 Twi Ut Notes

    2/158

    Course Layout

    • Duration : 9.5 Days (Mon – Fri)• Start : 8:30 am

    • Coffee Break : 10:00 – 10:30 am

    • Lunch : 12:30 – 1:30 pm• Tea Break : 3:00 – 3:30 pm

    • Day End : 5:00 pm

    • Course Objective: To train and prepare participants to obtainrequired skill and knowledge in Ultrasonic Testing and to meet theexamination schemes requirements.

  • 8/19/2019 Twi Ut Notes

    3/158

    NDT

    Most common NDT methods:

    Penetrant Testing (PT)

    Magnetic Particle Testing (MT)

    Eddy Current Testing (ET)

    Radiographic Testing (RT)

    Ultrasonic Testing (UT)

    Mainly used for

    surface testing

    Mainly used for

    Internal Testing

  • 8/19/2019 Twi Ut Notes

    4/158

    NDT

    • Which method is the best ?Depends on many factors and conditions

  • 8/19/2019 Twi Ut Notes

    5/158

    Basic Principles of Ultrasonic Testing

    • To understand and appreciate thecapability and limitation of UT

  • 8/19/2019 Twi Ut Notes

    6/158

    Basic Principles of Ultrasonic Testing

    Sound is transmitted in the material to be tested

    The sound reflected back to the probe is

    displayed on

    the Flaw Detector

  • 8/19/2019 Twi Ut Notes

    7/158

  • 8/19/2019 Twi Ut Notes

    8/158

    Basic Principles of Ultrasonic TestingThe 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

    The BWE signal

    Defect signal

    Defect

  • 8/19/2019 Twi Ut Notes

    9/158

    The depth of the defect can be read with reference to

    the marker on the screen

    0 10 20 30 40 50 60

    60 mm

  • 8/19/2019 Twi Ut Notes

    10/158

    Thickness / depth measurement

    A

    A

    B

    B

    C

    C

    The THINNER  the material the

    less distance the sound travel

    The closer the reflector to

    the surface, the signal will

    be more to the left of the

    screen

    The thickness is read from the screen

    684630

  • 8/19/2019 Twi Ut Notes

    11/158

    Ultrasonic Testing

    Principles of Sound

  • 8/19/2019 Twi Ut Notes

    12/158

    Sound• Wavelength :

    The distance required to complete a cycle•   Measured in Meter or mm

    • Frequency :

    The number of cycles per unit time

    •   Measured in Hertz (Hz) or Cycles per second (cps)

    • Velocity :

    How quick the sound travels

    Distance per unit time•   Measured in meter / second (m / sec)

  • 8/19/2019 Twi Ut Notes

    13/158

    Properties of a sound wave

    • Sound cannot travel in

    vacuum• Sound energy to be

    transmitted / transferredfrom one particle to

    another

    SOLID LIQUID GAS

  • 8/19/2019 Twi Ut Notes

    14/158

    Velocity

    •  The velocity of sound in a particular material is CONSTANT

    •  It is the product of DENSITY and ELASTICITY of the material

    •  It will NOT change if frequency changes

    •  Only the wavelength changes

    •  Examples:

    V Compression in steel : 5960 m/sV Compression in water : 1470 m/s

    V Compression in air : 330 m/s

    STEEL WATER AIR

    5 M Hz

  • 8/19/2019 Twi Ut Notes

    15/158

    Velocity

    4 times

    What is the velocity difference in steel compared with in water?

    If the frequency remain constant, in what material does sound

    has the highest velocity, steel, water, or air?

    Steel

    If the frequency remain constant, in what material does sound

    has the shortest wavelength, steel, water, or air?

    Air

    Remember the formula

      = v / f 

  • 8/19/2019 Twi Ut Notes

    16/158

    DRUM BEATLow Frequency Sound

    40 Hz

    Glass

    High Frequency

    5 K Hz

    ULTRASONIC TESTING

    Very High Frequency

    5 M Hz

  • 8/19/2019 Twi Ut Notes

    17/158

    Ultrasonic

    • Sound : mechanical vibration

    What is Ultrasonic?

    Very High Frequency sound – above 20 KHz

    20,000 cps

  • 8/19/2019 Twi Ut Notes

    18/158

     coustic Spectrum

    0 10 100 1K 10K 100K 1M 10M 100m

    Sonic / Audible

    Human

    16Hz ‐ 20kHz

    Ultrasonic> 20kHz = 20,000Hz

    Ultrasonic Testing

    0.5MHz ‐ 50MHz

    Ultrasonic : Sound with frequency above 20 KHz

  • 8/19/2019 Twi Ut Notes

    19/158

    Frequency

    • Frequency : Number of cycles persecond

    1 second

    1 cycle per 1 second = 1Hertz

    18 cycle per 1 second =18 Hertz

    3 cycle per 1 second = 3Hertz

    1 second 1 second

    THE HIGHER THE FREQUENCY THE SMALLER THE WAVELENGTH

  • 8/19/2019 Twi Ut Notes

    20/158

    Frequency

    • 1 Hz = 1 cycle per second• 1 Kilohertz = 1 KHz = 1000Hz

    • 1 Megahertz = 1 MHz = 1000 000Hz

    20 KHz =   20 000 Hz

    5 M Hz =   5 000 000 Hz

  • 8/19/2019 Twi Ut Notes

    21/158

    Sound waves are the vibration of particles in solids, liquids or

    gases.

    Particles vibrate about a mean position.

    One cycle

    Displacement

    The distance

    taken to

    complete one

    cyclewavelength

     

    wavelength

    Wavelength

    Wavelength is the distance required to complete a cycle.

  • 8/19/2019 Twi Ut Notes

    22/158

     f 

    V  

    Velocity

    Frequency

    Wavelength

  • 8/19/2019 Twi Ut Notes

    23/158

    Frequency & Wavelength

    1 M Hz 5 M Hz 10 M Hz 25 M Hz

    Which probe has the smallest wavelength?

    SMALLESTLONGEST

    Which probe has the longest wavelength?

     

    = v / f 

    FF

  • 8/19/2019 Twi Ut Notes

    24/158

    Wavelength is a function of frequency and velocity.

    5MHz compression wave

    probe in steel

    mm18.1000,000,5000,900,5  

    Therefore:

     f V     V 

      f or or V    f   

  • 8/19/2019 Twi Ut Notes

    25/158

    • Which of the following compressional probe has thehighest sensitivity?

    • 1 MHz

    • 2 MHz

    • 5 MHz

    • 10 MHz

    10 MHz

  • 8/19/2019 Twi Ut Notes

    26/158

  • 8/19/2019 Twi Ut Notes

    27/158

    The Sound Beam

    • Dead Zone• Near Zone or Fresnel Zone

    • Far Zone or Fraunhofer Zone

  • 8/19/2019 Twi Ut Notes

    28/158

    The Sound Beam

    NZ   FZ

    Distance

    Intensity

    varies

    Exponential Decay

    MainBeam

  • 8/19/2019 Twi Ut Notes

    29/158

    Main Lobe

    Side Lobes

    Near

    Zone

    Main Beam

    The main beam or the centrebeam has the highest intensity of

    sound energy

    Any reflector hit by the main beam

    will reflect the high amount of

    energy

    The side lobes has multi

    minute main beams

    Two identical defects may give

    different amplitudes of signals

  • 8/19/2019 Twi Ut Notes

    30/158

    Sound Beam

    Near Zone

    • Thicknessmeasurement

    • Detection of defects

    • Sizing of large defectsonly

    Far Zone

    • Thicknessmeasurement

    • Defect detection

    • Sizing of all defects

    Near zone length as small as possible

  • 8/19/2019 Twi Ut Notes

    31/158

    Near Zone

     f  D

     f V 

     D

    4 Near Zone

    4 Near Zone

    2

    2

     

     

  • 8/19/2019 Twi Ut Notes

    32/158

    Near Zone

    • What is the near zone length of a 5MHz compressionprobe with a crystal diameter of 10mm in steel?

    mm

     f  D

    1.21000,920,54

    000,000,510

    4 Near Zone

    2

    2

  • 8/19/2019 Twi Ut Notes

    33/158

    Near Zone

    • The bigger the diameter the bigger the near zone

    • The higher the frequency the bigger the near zone

    • The lower the velocity the bigger the near zone

    Should large diameter crystal probes have a high or

    low frequency?

     f  D D

    4

     

    4

     Near Zone22

     

  • 8/19/2019 Twi Ut Notes

    34/158

    1 M Hz 5 M Hz

    1 M Hz

    5 M Hz

    Which of the above probes has the longest Near Zone ?

  • 8/19/2019 Twi Ut Notes

    35/158

    Near Zone

    • The bigger the diameter the bigger the near zone

    • The higher the frequency the bigger the near zone

    • The lower the velocity the bigger the near zone

    Should large diameter crystal probes have a high or

    low frequency?

     f  D D

    4

     

    4

     Near Zone22

     

  • 8/19/2019 Twi Ut Notes

    36/158

    Beam Spread

    • In the far zone sound pulses spread out as theymove away from the crystal

     Df 

    KV 

     D

    Sine or2

      

    /2

  • 8/19/2019 Twi Ut Notes

    37/158

    Beam Spread

     Df 

    KV 

     D

    Sine or2

      

    Edge,K=1.22

    20dB,K=1.08

    6dB,K=0.56

    Beam axis or

    Main Beam

  • 8/19/2019 Twi Ut Notes

    38/158

    Beam Spread

    • The bigger the diameter the smaller the beamspread

    • The higher the frequency the smaller the beamspread

     Df 

    KV 

     D

    Sine or2

      

    Which has the larger beam spread, a compression or a

    shear wave probe?

  • 8/19/2019 Twi Ut Notes

    39/158

    Beam Spread

    • What is the beam spread of a 10mm,5MHzcompression wave probe in steel?

    o

     Df 

    KV Sine

    35.7 1278.0

    105000

    592008.12

     

  • 8/19/2019 Twi Ut Notes

    40/158

    1 M Hz 5 M Hz

    1 M Hz

    5 M Hz

    Which of the above probes has the Largest Beam Spread ?

  • 8/19/2019 Twi Ut Notes

    41/158

    Beam Spread

    • The bigger the diameter the smaller the beamspread

    • The higher the frequency the smaller the beamspread

     Df 

    KV 

     D

    Sine or2

      

    Which has the larger beam spread, a compression or a

    shear wave probe?

  • 8/19/2019 Twi Ut Notes

    42/158

    Testing close to side walls

  • 8/19/2019 Twi Ut Notes

    43/158

    Ultrasonic Testing techniques

    • Pulse Echo

    • Through Transmission

    • Transmission with Reflection

  • 8/19/2019 Twi Ut Notes

    44/158

    Pulse Echo Technique

    • Single probe sends and receives

    sound• Gives an indication of defect

    depth and dimensions

    • Not fail safe

  • 8/19/2019 Twi Ut Notes

    45/158

    Defect Position

    No indication from defect A (wrong orientation)

    AB

    B

  • 8/19/2019 Twi Ut Notes

    46/158

  • 8/19/2019 Twi Ut Notes

    47/158

    Through Transmission Technique

    Advantages• Less attenuation

    • No probe ringing

    • No dead zone• Orientation does not

    matter

    Disadvantages• Defect not located

    • Defect can’t beidentified

    • Vertical defects don’tshow

    • Must be automated

    • Need access to bothsurfaces

  • 8/19/2019 Twi Ut Notes

    48/158

    Transmission with Reflection

    RT

    Also known as:

    Tandem Technique or

    Pitch and Catch Technique

  • 8/19/2019 Twi Ut Notes

    49/158

  • 8/19/2019 Twi Ut Notes

    50/158

    Pulse Length

    • The longer the pulse, the more penetrating thesound

    • The shorter the pulse the better the sensitivityand resolution

    Short pulse, 1 or 2 cycles Long pulse 12 cycles

  • 8/19/2019 Twi Ut Notes

    51/158

    Ideal Pulse Length

    5 cycles for weld testing

  • 8/19/2019 Twi Ut Notes

    52/158

    The Sound Beam

    • Dead Zone

    • Near Zone or Fresnel Zone

    • Far Zone or Fraunhofer Zone

  • 8/19/2019 Twi Ut Notes

    53/158

  • 8/19/2019 Twi Ut Notes

    54/158

    Main Lobe

    Side Lobes

    NearZone

    Main Beam

    The main beam or the centre

    beam has the highest intensity ofsound energy

    Any reflector hit by the main beam

    will reflect the high amount of

    energy

    The side lobes has multiminute main beams

    Two identical defects may give

    different amplitudes of signals

  • 8/19/2019 Twi Ut Notes

    55/158

    Sound Beam

    Near Zone

    • Thicknessmeasurement

    • Detection of defects

    • Sizing of large defectsonly

    Far Zone

    • Thicknessmeasurement

    • Defect detection

    • Sizing of all defects

    Near zone length as small as possible

  • 8/19/2019 Twi Ut Notes

    56/158

  • 8/19/2019 Twi Ut Notes

    57/158

  • 8/19/2019 Twi Ut Notes

    58/158

    Near Zone

    • The bigger the diameter the bigger the near zone

    • The higher the frequency the bigger the near zone

    • The lower the velocity the bigger the near zone

    Should large diameter crystal probes have a high or

    low frequency?

     f  D D

    4 Near Zone

    22

     

  • 8/19/2019 Twi Ut Notes

    59/158

    1 M Hz 5 M Hz

    1 M Hz

    5 M Hz

    Which of the above probes has the longest Near Zone ?

  • 8/19/2019 Twi Ut Notes

    60/158

    Near Zone

    • The bigger the diameter the bigger the near zone

    • The higher the frequency the bigger the near zone

    • The lower the velocity the bigger the near zone

    Should large diameter crystal probes have a high or

    low frequency?

     f  D D

    4 Near Zone

    22

     

  • 8/19/2019 Twi Ut Notes

    61/158

    Beam Spread

    • In the far zone sound pulses spread out as theymove away from the crystal

     Df 

    KV 

     D

    Sine or2

      

    /2

  • 8/19/2019 Twi Ut Notes

    62/158

    Beam Spread

     Df 

    KV 

     D

    Sine or2

      

    Edge,K=1.22

    20dB,K=1.08

    6dB,K=0.56

    Beam axis or

    Main Beam

  • 8/19/2019 Twi Ut Notes

    63/158

  • 8/19/2019 Twi Ut Notes

    64/158

  • 8/19/2019 Twi Ut Notes

    65/158

    1 M Hz 5 M Hz

    1 M Hz

    5 M Hz

    Which of the above probes has the Largest Beam Spread ?

  • 8/19/2019 Twi Ut Notes

    66/158

  • 8/19/2019 Twi Ut Notes

    67/158

    Testing close to side walls

  • 8/19/2019 Twi Ut Notes

    68/158

    Sound at an Interface

    • Sound will be either transmitted across orreflected back

    Reflected

    Transmitted

    InterfaceHow much is reflected andtransmitted depends upon the

    relative acoustic impedance of the

    2 materials

  • 8/19/2019 Twi Ut Notes

    69/158

  • 8/19/2019 Twi Ut Notes

    70/158

    Law of Reflection

    • Angle of Incidence = Angle of Reflection

    60o 60o

  • 8/19/2019 Twi Ut Notes

    71/158

    Inclined incidence(not at 90

    o

    )

    Incident

    Transmitted

    The sound is refracted due to differences in sound

    velocity in the 2 DIFFERENT materials

  • 8/19/2019 Twi Ut Notes

    72/158

    REFR CTION

    • Only occurs when:

    The incident angle is other than 0°

    Water

    Steel

    Steel

    Steel

    Water

    Steel

    30°

    Refracted

  • 8/19/2019 Twi Ut Notes

    73/158

    REFR CTION

    • Only occurs when:

    The incident angle is other than 0°

    Steel

    Steel

    Water

    Steel

    30°

    Refracted

    The Two Materials has different VELOCITIES

    No Refraction

    30°

    30°

    65°

  • 8/19/2019 Twi Ut Notes

    74/158

    Snell’s Law

    I

    R

    Material 1

    Material 2

    2Materialin1Material

      VelinVel

     RSine I Sine

    Incident

    Refracted

    Normal

  • 8/19/2019 Twi Ut Notes

    75/158

    Snell’s Law

    Perspex 

    Steel 

    20

    48.3

    2Materialin

    1Material

      Vel

    inVel

     RSine

     I Sine

    5960

    2730

    48.3

    20

    Sine

    Sine

    4580.04580.0  

  • 8/19/2019 Twi Ut Notes

    76/158

    Snell’s Law

    Perspex 

    Steel 

    15

    34.4

    2Materialin

    1Material

      Vel

    inVel

     RSine

     I Sine

    5960

    2730

    15

    Sine

    Sine

    2730

    596015SinSinR  

    565.0SinR4.34 R

  • 8/19/2019 Twi Ut Notes

    77/158

    Snell’s Law

    Perspex 

    Steel 

    20

    S

    48.3

    24

  • 8/19/2019 Twi Ut Notes

    78/158

    Snell’s Law

    Perspex 

    Steel 

    S

    C C

    CC

    S

    When an incident beam of sound

    approaches an interface of two different

    materials:   REFRACTION occurs

    There may be more than one waveform

    transmitted into the second material,example: Compression and Shear

    When a waveform changes into

    another waveform: MODE

    CHANGE

  • 8/19/2019 Twi Ut Notes

    79/158

    Snell’s Law

    Perspex 

    Steel 

    C

    C

    S

    If the angle of Incident is

    increased the angle of

    refraction also increases

    Up to a point where the

    Compression Wave is at 90°

    from the Normal

    90°   This happens at the

    FIRST CRITICAL ANGLE

  • 8/19/2019 Twi Ut Notes

    80/158

    1st Critical ngle

    27.4

    S

    33

    C  Compression wave refracted at 90

    degrees

  • 8/19/2019 Twi Ut Notes

    81/158

    2nd Critical ngle

    S (Surface Wave)

    90

    Shear wave refracted at 90 degrees

    57 

    Shear wave becomes a surface wave

  • 8/19/2019 Twi Ut Notes

    82/158

    1st Critical Angle CalculationC 

    Perspex 

    Steel 

    5960

    2730

    90

    I

    Sine

    Sine

    59602730SinI 

    458.0SinI 

    26.27 I 

    S

    190   Sin

    27.2

  • 8/19/2019 Twi Ut Notes

    83/158

    Before the 1st. Critical Angle: There are

  • 8/19/2019 Twi Ut Notes

    84/158

    1st.

    2nd.

    33°

    90°

    both Compression and Shear wave inthe second material

    S C

    At the FIRST CRITICAL ANGLE Compression

    wave refracted at 90°

    Shear wave at 33 degrees in the material

    Between the 1st. And 2nd.

    Critical Angle: Only SHEAR

    wave in the material.

    Compression is reflected out of

    the material.

    C

    At the 2nd. Critical Angle: Shear is

    refracted to 90° and become

    SURFACE wave

    Beyond the 2nd. Critical

    Angle: All waves are

    reflected out of thematerial. NO wave in the

    material.

  • 8/19/2019 Twi Ut Notes

    85/158

  • 8/19/2019 Twi Ut Notes

    86/158

    Summary• 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.

    C

    S

    C S

    One Defect Two Echoes

  • 8/19/2019 Twi Ut Notes

    87/158

    Snell’s Law

    • Calculate the 1st critical angle for aperspex/copper interface

    • V Comp perspex : 2730m/sec

    • V Comp copper : 4700m/sec

    5.355808.04700

    2730SinI 

  • 8/19/2019 Twi Ut Notes

    88/158

    Sound Generation

    • Hammers (Wheel tapers)

    •  Magnetostrictive• Lasers

    • Piezo‐electric

    magnetostrictive

  • 8/19/2019 Twi Ut Notes

    89/158

    Piezo‐Electric Effect

    • When exposed to an alternating current a crystalexpands and contracts

    • Converting electrical energy into mechanical

    ‐ + + ‐ ‐ +

    Pi El t i M t i l

  • 8/19/2019 Twi Ut Notes

    90/158

    Piezo‐Electric MaterialsQUARTZ

    •  Resistant to wear

    •   Insoluble in water•  Resists ageing

    •   Inefficient converter ofenergy

    •  Needs a relatively highvoltage

    Very rarely used nowadays

    LITHIUM SULPHATE

    •  Efficient receiver

    •  Low electrical impedance•  Operates on low voltage

    •  Water soluble

    •  Low mechanical strength

    •  Useable only up to 30ºC

    Used mainly in medical 

  • 8/19/2019 Twi Ut Notes

    91/158

    Polarized Crystals

    • Powders heated tohigh temperatures

    • Pressed into shape

    • Cooled in very strong

    electrical fields

    Examples

    • Barium titanate (Ba Ti O3)

    • Lead metaniobate(Pb Nb O6)

    • Lead zirconate titanate (Pb TiO3 or Pb Zr O3)

    Most of the probes for conventional usage use

    PZT : Lead Zirconate Titanate

  • 8/19/2019 Twi Ut Notes

    92/158

    Probes

    Z

  • 8/19/2019 Twi Ut Notes

    93/158

    Probes• The most important part of theprobe is the crystal

    • The crystal are cut to a particular

    way and thickness to give theintended properties

    • Most of the conventional crystalare X – cut to produce

    Compression wave

    X

    XX

    Y

    Probes

  • 8/19/2019 Twi Ut Notes

    94/158

    • The frequency of the probe depends on theTHICKNESS of the crystal

    • Formula for frequency:

    Ff = V / 2tWhere Ff = the Fundamental frequency 

    V = the velocity in the crystal 

    t = the thickness of the crystal 

    Fundamental frequency is the frequency of the material ( crystal ) whereat that frequency the material will vibrate.

  • 8/19/2019 Twi Ut Notes

    95/158

    Probes

    •   The Thinner the crystal the Higher the frequency

    •  Which of the followings has the Thinnest crystal ?

    1 MHz Compression probe

    5 MHz Compression probe

    10 MHz Shear probe

    25 MHz Shear probe

    25 MHz Shear

    Probe

  • 8/19/2019 Twi Ut Notes

    96/158

    Probe Design

    • Compression Probe•   Normal probe

    •   0°

    Damping

    Transducer

    Electrical

    connectors

    Housing

  • 8/19/2019 Twi Ut Notes

    97/158

    Probe Design

    • Shear Probe•  Angle probe

    Damping

    Transducer

    Perspex wedge

    Backing medium

    Probe Shoe

  • 8/19/2019 Twi Ut Notes

    98/158

    Probe Design

    Twin Crystal

    Advantages

    • Can be focused

    • Measure thin plate• Near surface resolution

    Disadvantages

    • Difficult to use on

    curved surfaces

    • Sizing small defects

    • Signal amplitude /focal spot length

    Transmitter Receiver

    Focusing

    lensSeparator /

    Insulator

  • 8/19/2019 Twi Ut Notes

    99/158

    Sound Intensity

    Comparing the intensity of 2 signals

    1

    0

    1

    0

    P

    P

     I 

     I 

    Electrical power proportional to thesquare of the voltage produced

    21

    2

    0

    1

    0

    )(

    )(

    P

    P

    21

    2

    0

    1

    0

    )(

    )(

     I 

     I Hence

    Sound Intensity

  • 8/19/2019 Twi Ut Notes

    100/158

    Sound Intensity

    2

    1

    2

    0

    1

    0

    )(

    )(

     I 

     I    Will lead to large ratios

    2

    1

    20

    10..

    1

    010..

    )(

    )(

    V  Log

     I 

     I  Log   Therefore

    dBV V  Log

     I  I  Log

    1

    010..

    1

    010.. 20

     BELV 

    V  Log

     I 

     I  Log

    1

    010..

    1

    010.. 2

    2 signals at 20% and 40% FSH.

  • 8/19/2019 Twi Ut Notes

    101/158

    1

    010..20 H  H  LogdB

    2 signals at 20% and 40% FSH.What is the difference between them in dB’s?

    2..2020

    4020 1010..   Log LogdB  

    3010.020dB

    dBdB 6

    2 signals at 10% and 100% FSH.

  • 8/19/2019 Twi Ut Notes

    102/158

    1

    010..20 H  H  LogdB

    2 signals at 10% and 100% FSH.What is the difference between them in dB’s?

    10..2010

    10020 1010..   Log LogdB  

    120dB

    dBdB 20

  • 8/19/2019 Twi Ut Notes

    103/158

    mplitude ratios in decibels

    • 2 : 1 = 6bB

    • 4 : 1 = 12dB• 5 : 1 = 14dB

    • 10 : 1 = 20dB

    • 100 : 1 = 40dB

    Automated Inspections

  • 8/19/2019 Twi Ut Notes

    104/158

    Automated Inspections

    • Pulse Echo

    • Through Transmission

    • Transmission with Reflection

    • Contact scanning

    • Gap scanning

    • Immersion testing

  • 8/19/2019 Twi Ut Notes

    105/158

    Gap Scanning

    • Probe held a fixed distance abovethe surface (1 or 2mm)

    • Couplant is fed into the gap

    Immersion Testing

    C t i l d i t fill d t k

  • 8/19/2019 Twi Ut Notes

    106/158

    • Component is placed in a water filled tank

    • Item is scanned with a probe at a fixed distanceabove the surface

    Immersion Testing

  • 8/19/2019 Twi Ut Notes

    107/158

    Water path

    distance

    Water path distance

    Front surface Back surface

    Defect

    Ultrasonic Testing

  • 8/19/2019 Twi Ut Notes

    108/158

    • Sensitivity

    • Defect sizing

    • Scanning procedures

    Sensitivity

  • 8/19/2019 Twi Ut Notes

    109/158

    • The ability of an ultrasonic system to find thesmallest specified defect at the maximum testing

    range

    Depends upon

    • Probe and flaw detector combination

    • Material properties

    • Probe frequency• Signal to noise ratio

    Methods of Setting Sensitivity

  • 8/19/2019 Twi Ut Notes

    110/158

    • Smallest defect at maximum test range

    • Back wall echo

    • Disc equivalent

    • Grass levels

    • Notches• Side Drilled Holes, DAC Curves

    rtificial / actual defect

  • 8/19/2019 Twi Ut Notes

    111/158

    Example: The defect echo is set to

    FSH (Full Screen Height)

    Sizing Methods

    6 dB Drop

  • 8/19/2019 Twi Ut Notes

    112/158

    p

    • For sizing large planar reflectors only

    • Signal / echo reduced to half the height

    • Example:100% to 50%

    80% to 40%

    70% to 35%

    20% to 10%

    Centre of probe marked representing the edge of defect.

    6 dB Drop

  • 8/19/2019 Twi Ut Notes

    113/158

    BWEDefect

    The back wall echo reduced as some part of the

    beam now striking the defect

    The echo of the defect has NOT yet maximise as

    the whole beam Not yet striking the defectPlan View

    6 dB Drop

  • 8/19/2019 Twi Ut Notes

    114/158

    Plan View

    Now the whole beam is on the defect

    Defect

    Back wall echo is now may be reduced or

    disappeared

    6 dB Drop

  • 8/19/2019 Twi Ut Notes

    115/158

    BWEDefect

    Plan View

    The probe is moved back until the echo is

    reduced by half of it’s original height

    At this point the probe centre beam is directly

    on the edge of the defect

    The probe is then removed and the centre is

    marked, and repeat to size the whole defect

    Sizing Method

  • 8/19/2019 Twi Ut Notes

    116/158

    • Maximum Amplitude Technique

    For sizing multifaceted defect – eg. crack

    Not very accurate

    Small probe movement

    Maximum mplitude

  • 8/19/2019 Twi Ut Notes

    117/158

    The whole probe beam is on the on the

    defect

    At this point, multipoint of the defect reflect

    the sound to the probe

    The echo (signal) show as a few peaks

    Multifaceted defect : crack

    Maximum mplitude

  • 8/19/2019 Twi Ut Notes

    118/158

    Multifaceted defect : crack

    The probe is moved out of the

    defect, the signal disappeared

    If the edge of the beam strike the

    edge of the defect, a very small

    echo appears

    If the probe is moved into the defect,the signals height increase

    At this point the MAIN BEAM is

    directly at the edge of the defect

    One of the peak maximised

    Maximum mplitude

    Remember: The peak which maximised does not

    have to be the tallest or the first one

  • 8/19/2019 Twi Ut Notes

    119/158

    The probe is to be moved to the other endof the defect

    The signals will flactuate as the beam hits the

    different faces of the defects

    The probe is moved back into the defect and

    to observe a peak of the signal maximises

    Mark the point under thecentre of the probe

    which indicates the edge

    of the defect

    The length of the defect is

    measured

    Length

    Equalization Technique

    BWEDefect

    The equalization technique can ONLY be used if the

    defect is halfway the thickness

  • 8/19/2019 Twi Ut Notes

    120/158

    At this point the whole beam is on theback wall

    BWE

    At this point the whole beam is on

    the defect

    The BWE is at it maximum

    The Defect echo is at it

    maximum

    Defect

    At the edge of the defect, half of

    the beam is on the defect, and

    another half is on the back wall

    The defect echo is at equal

    height as the back wall

    The point is marked as the edge of defect

    20 dB Drop

    Defect BWE

  • 8/19/2019 Twi Ut Notes

    121/158

    Defect BWE

    When the main beam is on the defect the defect signal is at it maximum

    If the probe is moved and the signal is observed until it is reduced to 10%

    (20dB Drop), the edge of the beam is on the edge of the defect

    10%

    Using the pre‐constructed Beam profile and a plotting card, the defect

    maybe sized

    Repeat the above at the other side of the defect

    20 dB Beam profile

  • 8/19/2019 Twi Ut Notes

    122/158

    Product Technology

    Welding

    A Weld : Definitions• A union between A ti d f t

  • 8/19/2019 Twi Ut Notes

    123/158

     A union betweenpieces of metal at facesrendered plastic orliquid by heat,pressureor both.

    BS 499

    • A continuous defectsurrounded by parent

    materialNASA

    Welds• An ideal weld must give a strong bond between

    materials with the interfaces disappearing

  • 8/19/2019 Twi Ut Notes

    124/158

    To achieve this

    • Smooth,flat or matching surfaces

    • Surfaces shall be free from contaminants

    • Metals shall be free from impurities

    • Metals shall have identical crystalline structures

    Welding• A union between pieces of metal at faces

  • 8/19/2019 Twi Ut Notes

    125/158

    rendered plastic or liquid by heat,pressure or

    both.

    BS 499

    • Ultrasonics• Electron beam

    • Friction

    • Electric resistance

    • Electric arc

    Possible energy sources

    Electric Arc Welding

  • 8/19/2019 Twi Ut Notes

    126/158

    Power

    supply

    Work piece

    Electrode

    Clamp(Earth)

    Electric Arc Welding• Electric discharge produced between cathode and anode by

    a potential difference (40 to 60 volts)

  • 8/19/2019 Twi Ut Notes

    127/158

    • Discharge ionises air and produces ‐ve electrons and +ve

    ions

    • Electrons impact upon anode, ions upon cathode

    • Impact of particles converts kinetic energy to heat (7000

    o

    C)and light

    • Amperage controls number of ions and electrons, Voltagecontrols their velocity

    Electric Arc WeldingArc Welding Processes

    • Manual metal arc

  • 8/19/2019 Twi Ut Notes

    128/158

     Manual metal arc

    • Tungsten Inert Gas

    • Metal Inert Gas

    • Submerged Arc

    Differences between them

    • Methods of shielding the arc

    • Consumable or Non-consumable electrode

    • Degree of automation

    Zones in Fusion Welds

    F i Z

  • 8/19/2019 Twi Ut Notes

    129/158

    • Fusion Zone

    Zones in Fusion Welds

    • F sion Zone

  • 8/19/2019 Twi Ut Notes

    130/158

    • Fusion Zone

    • Heat Affected Zone

    Zones in Fusion Welds

    • Fusion Zone

  • 8/19/2019 Twi Ut Notes

    131/158

    • Fusion Zone

    • Heat Affected Zone

    • Parent Material or Base Metal

  • 8/19/2019 Twi Ut Notes

    132/158

    Manual Metal Arc (MMA)

    Consumable

    electrode

  • 8/19/2019 Twi Ut Notes

    133/158

    Flux coating

    Core wire

    Arc

    Evolved gas

    shield

    Parent metal

    Slag

    Weld metal

    Manual Metal Arc Welding

  • 8/19/2019 Twi Ut Notes

    134/158

    • Shielding provided by

    decomposition of fluxcovering

    • Electrode consumable

    • Manual process

    Welder controls

    • Arc length

    • Angle of electrode

    • Speed of travel

    • Amperage settings

    Tungsten Inert Gas (TIG)Gas nozzle

  • 8/19/2019 Twi Ut Notes

    135/158

    Non‐consumable

    tungsten

    electrode

    Arc

    Parent metal

    Weld metal

    Gas shield

    Filler wire

    Metal Inert Gas (MIG)Gas nozzle   Reel feed

  • 8/19/2019 Twi Ut Notes

    136/158

    Consumableelectrode(filler wire)

    Arc

    Parent metal

    Weld metal

    Gas shield

    Submerged Arc Reel feed

  • 8/19/2019 Twi Ut Notes

    137/158

    Consumableelectrode

    Flux feed

    Flux

    retrieval

    Parent metal

    Weld metal

    Slag

    Electroslag

    Filler wire

  • 8/19/2019 Twi Ut Notes

    138/158

    Molten flux

    Weld metal

    Water cooled

    copper shoes

    Welding Defects

    4 Crack Types

    Cracks

  • 8/19/2019 Twi Ut Notes

    139/158

    yp

    • Solidification cracks

    • Hydrogen induced cracks

    • Lamellar tearing

    • Reheat cracks

    Welding Defects

    l ifi d b h

    Cracks

  • 8/19/2019 Twi Ut Notes

    140/158

    Classified by Shape

    • Longitudinal• Transverse

    • Branched

    • Chevron

    Classified by Position

    • HAZ

    • Centreline

    • Crater 

    • Fusion zone

    • Parent metal

    Welding Defects

    Cracks

  • 8/19/2019 Twi Ut Notes

    141/158

    Solidification

    • Occurs during weld solidification process

    • Steels with high sulphur content (low ductility atelevated temperature)

    • Requires high tensile stress• Occur longitudinally down centre of weld

    • eg Crater cracking

    Welding Defects

    Hydrogen Induced 

    bl d h d

    Cracks

  • 8/19/2019 Twi Ut Notes

    142/158

    • Requires susceptible grain structure, stress and hydrogen

    • Hydrogen enters via welding arc

    • Hydrogen source ‐ atmosphere or contamination ofpreparation or electrode

    • Moisture diffuses out into parent metal on cooling• Most likely in HAZ

    Welding Defects

    Lamellar Tearing

    Cracks

  • 8/19/2019 Twi Ut Notes

    143/158

    • Step like appearance

    • Occurs in parent material or HAZ

    • Only in rolled direction of the parent material

    • Associated with restrained joints subjected to through

    thickness stresses on corners, tees and fillets• Requires high sulphur or non‐metallic inclusions

    Welding Defects

    Re‐Heat Cracking

    Cracks

  • 8/19/2019 Twi Ut Notes

    144/158

    • Occurs mainly in HAZ of low alloy steels during post weld

    heat treatment or service at elevated temperatures• Occurs in areas of high stress and existing defects

    • Prevented by toe grinding, elimination of poor profilematerial selection and controlled post weld heattreatment

    Welding Defects• Incomplete root penetration

  • 8/19/2019 Twi Ut Notes

    145/158

    Causes

    •   Too large or small a root gap

    •   Arc too long

    •   Wrong polarity

    •   Electrode too large for joint preparation

    •   Incorrect electrode angle

    •   Too fast a speed of travel for current

    Welding Defects

    • Root concavity 

  • 8/19/2019 Twi Ut Notes

    146/158

    Causes

    • Root gap too large

    • Insufficient arc energy

    • Excessive back purge (TIG)

    Welding Defects

    • Lack of fusion

  • 8/19/2019 Twi Ut Notes

    147/158

    Causes• Contaminated weld preparation

    • Amperage too low

    • Amperage too high (welder increases speed of

    travel)

  • 8/19/2019 Twi Ut Notes

    148/158

    Welding Defects

    • Incompletely Filled Groove

  • 8/19/2019 Twi Ut Notes

    149/158

    Causes

    • Insufficient weld metal deposited

    • Improper welding technique

    Welding Defects

    • Gas pores / Porosity 

  • 8/19/2019 Twi Ut Notes

    150/158

    Causes

    • Excessive moisture in flux or preparation

    • Contaminated preparation

    • Low welding current

    • Arc length too long

    • Damaged electrode flux

    • Removal of gas shield

  • 8/19/2019 Twi Ut Notes

    151/158

  • 8/19/2019 Twi Ut Notes

    152/158

  • 8/19/2019 Twi Ut Notes

    153/158

    Welding Defects

    • Arc Strikes

    Causes

    •  Spatter 

    Causes

  • 8/19/2019 Twi Ut Notes

    154/158

    • Electrode straying ontoparent metal

    • Electrode holder with

    poor insulation

    • Poor contact of earth

    clamp

    • Excessive arc energy• Excessive arc length

    • Damp electrodes

    • Arc blow

    Nature and Origin of Defects

  • 8/19/2019 Twi Ut Notes

    155/158

    • Inherent

    • Processing

    • In Service

    Heat Induced Defects

    • Heat treatment cracks

  • 8/19/2019 Twi Ut Notes

    156/158

    • Grinding cracks

    • Friction induced cracks

    In Service Cracks

    • Fatigue cracks

    Cyclic stress

    Fatique

  • 8/19/2019 Twi Ut Notes

    157/158

    g

    • Stress corrosion cracks

    • Hydrogen induced cracks

    Hydrogen

    crack

    Product Technology

    Steel Production

    Wrought ProductionCasting Welding

  • 8/19/2019 Twi Ut Notes

    158/158

    Wrought Production

    Extrusion

    Forging

    Rolling

    Casting Welding

    Defects Inherent

    Processing

    Service

    Heat Treatment