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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.
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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
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NDT
• Which method is the best ?Depends on many factors and conditions
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Basic Principles of Ultrasonic Testing
• To understand and appreciate thecapability and limitation of UT
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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
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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
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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
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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
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Ultrasonic Testing
Principles of Sound
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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)
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Properties of a sound wave
• Sound cannot travel in
vacuum• Sound energy to be
transmitted / transferredfrom one particle to
another
SOLID LIQUID GAS
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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
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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
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DRUM BEATLow Frequency Sound
40 Hz
Glass
High Frequency
5 K Hz
ULTRASONIC TESTING
Very High Frequency
5 M Hz
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Ultrasonic
• Sound : mechanical vibration
What is Ultrasonic?
Very High Frequency sound – above 20 KHz
20,000 cps
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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
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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
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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
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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.
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f
V
Velocity
Frequency
Wavelength
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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
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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
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• Which of the following compressional probe has thehighest sensitivity?
• 1 MHz
• 2 MHz
• 5 MHz
• 10 MHz
10 MHz
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The Sound Beam
• Dead Zone• Near Zone or Fresnel Zone
• Far Zone or Fraunhofer Zone
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The Sound Beam
NZ FZ
Distance
Intensity
varies
Exponential Decay
MainBeam
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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
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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
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Near Zone
V
f D
f V
D
4 Near Zone
4 Near Zone
2
2
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Near Zone
• What is the near zone length of a 5MHz compressionprobe with a crystal diameter of 10mm in steel?
mm
V
f D
1.21000,920,54
000,000,510
4 Near Zone
2
2
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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?
V
f D D
4
4
Near Zone22
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1 M Hz 5 M Hz
1 M Hz
5 M Hz
Which of the above probes has the longest Near Zone ?
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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?
V
f D D
4
4
Near Zone22
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Beam Spread
• In the far zone sound pulses spread out as theymove away from the crystal
Df
KV
D
K
Sine or2
/2
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Beam Spread
Df
KV
D
K
Sine or2
Edge,K=1.22
20dB,K=1.08
6dB,K=0.56
Beam axis or
Main Beam
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Beam Spread
• The bigger the diameter the smaller the beamspread
• The higher the frequency the smaller the beamspread
Df
KV
D
K
Sine or2
Which has the larger beam spread, a compression or a
shear wave probe?
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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
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1 M Hz 5 M Hz
1 M Hz
5 M Hz
Which of the above probes has the Largest Beam Spread ?
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Beam Spread
• The bigger the diameter the smaller the beamspread
• The higher the frequency the smaller the beamspread
Df
KV
D
K
Sine or2
Which has the larger beam spread, a compression or a
shear wave probe?
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Testing close to side walls
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Ultrasonic Testing techniques
• Pulse Echo
• Through Transmission
• Transmission with Reflection
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Pulse Echo Technique
• Single probe sends and receives
sound• Gives an indication of defect
depth and dimensions
• Not fail safe
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Defect Position
No indication from defect A (wrong orientation)
AB
B
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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
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Transmission with Reflection
RT
Also known as:
Tandem Technique or
Pitch and Catch Technique
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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
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Ideal Pulse Length
5 cycles for weld testing
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The Sound Beam
• Dead Zone
• Near Zone or Fresnel Zone
• Far Zone or Fraunhofer Zone
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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
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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
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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?
V
f D D
4
4 Near Zone
22
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1 M Hz 5 M Hz
1 M Hz
5 M Hz
Which of the above probes has the longest Near Zone ?
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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?
V
f D D
4
4 Near Zone
22
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Beam Spread
• In the far zone sound pulses spread out as theymove away from the crystal
Df
KV
D
K
Sine or2
/2
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Beam Spread
Df
KV
D
K
Sine or2
Edge,K=1.22
20dB,K=1.08
6dB,K=0.56
Beam axis or
Main Beam
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1 M Hz 5 M Hz
1 M Hz
5 M Hz
Which of the above probes has the Largest Beam Spread ?
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Testing close to side walls
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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
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Law of Reflection
• Angle of Incidence = Angle of Reflection
60o 60o
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Inclined incidence(not at 90
o
)
Incident
Transmitted
The sound is refracted due to differences in sound
velocity in the 2 DIFFERENT materials
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REFR CTION
• Only occurs when:
The incident angle is other than 0°
Water
Steel
Steel
Steel
Water
Steel
30°
Refracted
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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°
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Snell’s Law
I
R
Material 1
Material 2
2Materialin1Material
VelinVel
RSine I Sine
Incident
Refracted
Normal
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Snell’s Law
C
Perspex
Steel
C
20
48.3
2Materialin
1Material
Vel
inVel
RSine
I Sine
5960
2730
48.3
20
Sine
Sine
4580.04580.0
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Snell’s Law
C
Perspex
Steel
C
15
34.4
2Materialin
1Material
Vel
inVel
RSine
I Sine
5960
2730
R
15
Sine
Sine
2730
596015SinSinR
565.0SinR4.34 R
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Snell’s Law
C
Perspex
Steel
C
20
S
48.3
24
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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
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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
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1st Critical ngle
C
27.4
S
33
C Compression wave refracted at 90
degrees
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2nd Critical ngle
C
S (Surface Wave)
90
C
Shear wave refracted at 90 degrees
57
Shear wave becomes a surface wave
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1st Critical Angle CalculationC
Perspex
Steel
C
5960
2730
90
I
Sine
Sine
59602730SinI
458.0SinI
26.27 I
S
190 Sin
27.2
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Before the 1st. Critical Angle: There are
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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.
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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
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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
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Sound Generation
• Hammers (Wheel tapers)
• Magnetostrictive• Lasers
• Piezo‐electric
magnetostrictive
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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
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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
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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
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Probes
Z
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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
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• 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.
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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
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Probe Design
• Compression Probe• Normal probe
• 0°
Damping
Transducer
Electrical
connectors
Housing
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Probe Design
• Shear Probe• Angle probe
Damping
Transducer
Perspex wedge
Backing medium
Probe Shoe
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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
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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
)(
)(
V
V
P
P
21
2
0
1
0
)(
)(
V
V
I
I Hence
Sound Intensity
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Sound Intensity
2
1
2
0
1
0
)(
)(
V
V
I
I Will lead to large ratios
2
1
20
10..
1
010..
)(
)(
V
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.
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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.
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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
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mplitude ratios in decibels
• 2 : 1 = 6bB
• 4 : 1 = 12dB• 5 : 1 = 14dB
• 10 : 1 = 20dB
• 100 : 1 = 40dB
Automated Inspections
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Automated Inspections
• Pulse Echo
• Through Transmission
• Transmission with Reflection
• Contact scanning
• Gap scanning
• Immersion testing
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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
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• Component is placed in a water filled tank
• Item is scanned with a probe at a fixed distanceabove the surface
Immersion Testing
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Water path
distance
Water path distance
Front surface Back surface
Defect
Ultrasonic Testing
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• Sensitivity
• Defect sizing
• Scanning procedures
Sensitivity
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• 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
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• Smallest defect at maximum test range
• Back wall echo
• Disc equivalent
• Grass levels
• Notches• Side Drilled Holes, DAC Curves
rtificial / actual defect
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Example: The defect echo is set to
FSH (Full Screen Height)
Sizing Methods
6 dB Drop
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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
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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
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Plan View
Now the whole beam is on the defect
Defect
Back wall echo is now may be reduced or
disappeared
6 dB Drop
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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
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• Maximum Amplitude Technique
For sizing multifaceted defect – eg. crack
Not very accurate
Small probe movement
Maximum mplitude
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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
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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
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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
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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
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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
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Product Technology
Welding
A Weld : Definitions• A union between A ti d f t
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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
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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
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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
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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)
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• 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
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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
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• Fusion Zone
Zones in Fusion Welds
• F sion Zone
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• Fusion Zone
• Heat Affected Zone
Zones in Fusion Welds
• Fusion Zone
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• Fusion Zone
• Heat Affected Zone
• Parent Material or Base Metal
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Manual Metal Arc (MMA)
Consumable
electrode
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Flux coating
Core wire
Arc
Evolved gas
shield
Parent metal
Slag
Weld metal
Manual Metal Arc Welding
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• 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
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Non‐consumable
tungsten
electrode
Arc
Parent metal
Weld metal
Gas shield
Filler wire
Metal Inert Gas (MIG)Gas nozzle Reel feed
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Consumableelectrode(filler wire)
Arc
Parent metal
Weld metal
Gas shield
Submerged Arc Reel feed
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Consumableelectrode
Flux feed
Flux
retrieval
Parent metal
Weld metal
Slag
Electroslag
Filler wire
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Molten flux
Weld metal
Water cooled
copper shoes
Welding Defects
4 Crack Types
Cracks
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yp
• Solidification cracks
• Hydrogen induced cracks
• Lamellar tearing
• Reheat cracks
Welding Defects
l ifi d b h
Cracks
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Classified by Shape
• Longitudinal• Transverse
• Branched
• Chevron
Classified by Position
• HAZ
• Centreline
• Crater
• Fusion zone
• Parent metal
Welding Defects
Cracks
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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
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• 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
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• 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
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• 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
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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
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Causes
• Root gap too large
• Insufficient arc energy
• Excessive back purge (TIG)
Welding Defects
• Lack of fusion
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Causes• Contaminated weld preparation
• Amperage too low
• Amperage too high (welder increases speed of
travel)
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Welding Defects
• Incompletely Filled Groove
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Causes
• Insufficient weld metal deposited
• Improper welding technique
Welding Defects
• Gas pores / Porosity
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Causes
• Excessive moisture in flux or preparation
• Contaminated preparation
• Low welding current
• Arc length too long
• Damaged electrode flux
• Removal of gas shield
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Welding Defects
• Arc Strikes
Causes
• Spatter
Causes
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• 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
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• Inherent
• Processing
• In Service
Heat Induced Defects
• Heat treatment cracks
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• Grinding cracks
• Friction induced cracks
In Service Cracks
• Fatigue cracks
Cyclic stress
Fatique
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g
• Stress corrosion cracks
• Hydrogen induced cracks
Hydrogen
crack
Product Technology
Steel Production
Wrought ProductionCasting Welding
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Wrought Production
Extrusion
Forging
Rolling
Casting Welding
Defects Inherent
Processing
Service
Heat Treatment