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    Ue Evaluation & Interpretation

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    VaraGoud
    Ultrasonic examination provides information on discontinuities that is important for engineering design calculations, including probability of detection, discontinuity location and orientation, crack growth monitoring, and material behavior. Precise evaluation of discontinuity size is difficult, as ultrasonic testing can only interpret echo patterns rather than directly measure discontinuity size. Discontinuity evaluation depends on factors like echo amplitude, scanning to determine boundaries, and comparing to reference standards. Characterization of discontinuity type considers echo signal shape and amplitude.

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    Ue Evaluation & Interpretation

    Uploaded by

    VaraGoud
    79 views39 pages
    Ultrasonic examination provides information on discontinuities that is important for engineering design calculations, including probability of detection, discontinuity location and orientation, crack growth monitoring, and material behavior. Precise evaluation of discontinuity size is difficult, as ultrasonic testing can only interpret echo patterns rather than directly measure discontinuity size. Discontinuity evaluation depends on factors like echo amplitude, scanning to determine boundaries, and comparing to reference standards. Characterization of discontinuity type considers echo signal shape and amplitude.

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    Ultrasonic examination provides information on discontinuities that is important for engineering design calculations, including probability of detection, discontinuity location and orientation, crack growth monitoring, and material behavior. Precise evaluation of discontinuity size is difficult, as ultrasonic testing can only interpret echo patterns rather than directly measure discontinuity size. Discontinuity evaluation depends on factors like echo amplitude, scanning to determine boundaries, and comparing to reference standards. Characterization of discontinuity type considers echo signal shape and amplitude.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    79 views39 pages

    Ue Evaluation & Interpretation

    Uploaded by

    VaraGoud
    Ultrasonic examination provides information on discontinuities that is important for engineering design calculations, including probability of detection, discontinuity location and orientation, crack growth monitoring, and material behavior. Precise evaluation of discontinuity size is difficult, as ultrasonic testing can only interpret echo patterns rather than directly measure discontinuity size. Discontinuity evaluation depends on factors like echo amplitude, scanning to determine boundaries, and comparing to reference standards. Characterization of discontinuity type considers echo signal shape and amplitude.

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    Evaluation & Interpretation

    Ultrasonic examination
    R.SUBBARATNAM
    RETD., HEAD, QA&NDT SECTION,
    QUALITY ASSURANCE DIVISION
    IGCAR, KALPAKKAM
    Subbu_10@yahoo.com

    The Requirements
    Present day construction requires precise sizing,
    location and orientation of the discontinuities
    Designers applies their various calculations /
    factors like

    Probability of detection (POD)


    Discontinuity location and orientation
    Crack initiation and their growth and monitoring
    Assessment of critical flaw size for fracture mechanics
    Behavior of Low weight high strength materials at dif.
    conditions
    Corrosion and its effects and monitoring

    Ultrasonic examination provides information on


    the above factors

    EVALUATION
    A discontinuity is best evaluated when its size
    (extension) is known.
    The operator's wants to know the "real / actual reflector
    size".
    However, only the echo can be interpreted, which is
    based on the reflected sound coming from the
    discontinuity.
    It is very often difficult and in some cases even
    impossible, to reliably assert the size of the reflector.
    In fact, the echo pattern and height plays the decisive
    part when evaluating discontinuities.
    Discontinuities can be differentiated or categorized as
    larger or smaller than the beam size

    Evaluation of larger discontinuities


    In ultrasonic evaluation it is possible to assess the true reflector size as
    long as the discontinuity is large compared to the diameter of the
    sound field.
    The discontinuity reflects the complete energy back.
    By scanning the boundaries of the discontinuity, reliable information can
    be obtained about its extension from the signal height of the
    discontinuity echo.
    The probe position on the test object at which the echo drops by
    exactly half (-6dB) indicates that the discontinuity is only being hit by
    half the sound beam.
    This means that the acoustic axis is exactly / nearly on the boundary of
    the discontinuity. The probe position is marked and the operator
    determines further boundary points until a contour of the discontinuity is
    formed by joining the marked points together.

    Evaluation of small discontinuities


    A reflector which is completely contained within the sound
    beam is regarded as a small reflector.
    If such a reflector is evaluated by scanning, then it is not
    the size of the reflector which is obtained as a result, but
    the diameter / size of the sound beam.
    Therefore, the scanning method described earlier is not
    practical in this case.
    It can be noted that that the height of a reflected echo will
    become greater, the larger the sound beam area which
    covers / interact the reflector.
    This feasible behaviour can be used on small reflectors:
    their echo heights increase with their areas and
    corresponding reflection.

    The sound reflection of the reflector boundary becomes


    more exact for smaller the diameter of the sound beam is
    at the reflector position.
    Therefore, if the reflector extension is to be exactly
    measured, it is recommended that a probe be selected
    which has its focal point / near zone at the same distance
    as the reflector.
    TR probes are especially suited which have a horse-shoe
    shaped sound beam with a small diameter (1 - 5 mm) at
    their most sensitive depth range.

    The echo heights are proportional to their area or The


    echo heights are proportional to the square of their
    diameter
    Under optimal conditions, e.g. with flat bottom holes and
    at equal depths, this law can be confirmed. Example:
    The flat-bottom hole with a diameter of 2 mm has an
    echo which is 4 times that of a 1 mm flat-bottom hole
    because the area has quadrupled.
    However, if the echoes from two drill holes at different
    depths are compared then an additional distance
    dependence of the echo heights is established.
    (attenuation)

    With accurate tests using flat-bottom holes at different


    depths a simple law can be found, at least in the far field
    of the applied sound beam.
    This does not normally apply to the near-field of the
    sound beam. Here, the test results show that the echo
    heights within the focus reach their highest amplitude
    and are reduced again at shorter distances

    In practise this almost never occurs which means that the true size
    of a discontinuity is normally larger than the equivalent reflector
    size.
    A law for this cannot be derived because the echo height is strongly
    dependent on the characteristics of the discontinuity, this means its
    geometry, orientation to the sound beam and the surface quality.
    For example, a pore (spherically shaped gas inclusion) with a
    diameter of 2 mm has an equivalent reflector size of 1 mm; an
    angled flat reflector gives, according to orientation, a result of ERS
    (equivalent reflector size) 0 (not detectable).
    Scanning the discontinuity from different directions, assessing the
    echo shape and the behaviour of the display when moving the probe
    (echo dynamics) are just a few techniques which can be
    successfully applied to get best result.
    This uncertainty in the evaluation of the discontinuity is however
    neutralized when other possibilities and high end techniques in
    ultrasonic testing are used to inspect detected discontinuities closer.

    DAC / DGS method


    The above uncertainties in evaluation can be reduced
    when there is a so called reference block, which is
    made of the same material with acoustic similarities
    as the object to be tested and which also contains real /
    artificial reflectors whose echoes can be directly
    compared to the discontinuity echoes from the test
    object.
    The application of the reference block method is, in
    practise, made in two different ways: Comparison of
    echo Amplitudes and Distance amplitude curve
    Comparison of echo amplitude method is not generally
    used, as the discontinuity type, location and
    orientation are different with the real discontinuities

    The advantages of the reference block


    method with a DAC are:
    that it is no longer necessary to compare each
    discontinuity echo with the corresponding
    reference echo from the reference block but to
    directly make the evaluation with the DAC.
    that the recording of a DAC for certain
    applications is only required once because the
    curve is documented on a transparency or in the
    memory of a modern ultrasonic test instrument.
    The reflectors location and position is
    important with respect to the acceptance of
    specimen examined

    Area amplitude Base different size same location

    Distance amplitude Base Same size at different location

    DAC Eqpt With out NZ

    DAC - Manual
    DAC Eqpt With NZ

    DGS / AVG

    Discontinuity Orientation
    Discontinuities are differently oriented according to the
    manufacturing processes.
    Operator should know the approximate discontinuity
    orientation and has to send the ultrasonic beam normal
    to the discontinuity orientation to the extent possible.
    He should know the feasibility of approaching the
    discontinuity through the ultrasonic beam and bring out
    the maximum information.

    Volumetric discontinuity Normal & Angle

    Selection of proper beam direction


    to get more information

    Normal beam does not provides information


    angle beam provides the information

    Not proper

    Selection of proper angle

    Proper

    Better but leads


    to confusion
    depth indicated
    more

    Best method Tandom

    Lower freq provides


    better results
    Application of different technique

    Possibility of identification
    Near surface discontinuities
    use high frq./ T-R better near
    surface resolution

    Not identified

    Sound attenuation
    In addition to the laws which establish the behaviour of disk
    shaped reflectors within the sound beam of a probe (distance
    and size laws) another effect can be observed: sound
    attenuation.
    The sound attenuation is caused by the structure of the test
    object.
    Mostly the material structure can be divided in to three Fine,
    Medium and Coarse
    Fine grain structure More absorption Ex: Forging
    Medium Grain easy for exam Ex: Steel, Aluminium
    Coarse Grain More Noise Ex: Casting, Aus SS Weld
    Attenuation is also strongly dependent on the frequency and
    the wave mode of the applied probe. Only when these effects
    are known signal can be considered for the discontinuity
    evaluation.
    Lower frequency and longitudinal mode are ideal for
    highly attenuating material examination

    Ultrasonic Examination
    Casting Restricted / Difficult due to Coarse grain
    Forging Widely used as the fine grain exists Long. &
    Angle beam used

    Semi finished products Billets, Rods

    Rolled Products
    Plates both contact & immersion - Long. & Angle ,
    Pipes & Tubes Immersion - Long. & Angle

    Welding Usually Angle

    UE OF WELD - EXAMINATION

    Flaw Sizing
     Flaw Location
     Flaw Length
    S
    t

    Stand Off (S) = P sin


    Depth (d)

    Probe Travel

    = P cos
    Amplitude

    d
    t

    Length

    SIGNAL ANALYSIS

    CONSIDERATION
    AMPLITUDE WRT DAC
    >20%(relevent), >50% (record), >100% (not
    acceptable)

    SIZING
    LENGTH
    - 6 / 12 dB METHOD

    DISCONTINUITY POSITION
    ORIENTATION
    DISCONTINUITY ACCEPTANCE

    Flaw Characterization
     Scanning technique Probe movement to determine the
    discontinuitys Location, Length and Orientation
     Ultrasonic Signal gives the information about the
    discontinuitys Characterisation / Type
    Sharp High Ampl. Signal Planar type of discontinuity
    Wide Low Ampl. Signal Volumetric Type of discontinuity

    Discontinuity Representation

    Planar
    Crack, LP, LF

    Volumetric
    Slag, Incln.

    Volumetric
    Porosity

    Very Sharp,
    High Amplitude

    Wide, Medium
    Amplitude.

    Sharp, High Amplitude,


    Vanishes when probe
    rotated / moved

    REPORTING
    

    BASIC / SCANNING DETAILS

    DISCONTINUITY
    TYPE
    SIZE LENGTH
    POSITION LOCATION, DEPTH

    ACCEPTANCE - CODE / SPCN / PROC

    CONDUCTED BY

    REPORTED BY

    STD FORMAT

    Ultrasonic test report


    Weld test Specimen No. 1 Parent material: ST 52
    Weld type: V Weld preparation: 30Welding method: Covered electrode
    Added material: unknown Test volume: Weld + HAZ
    Test surface: 1,2 (see drawing) Test surface condition: evenly rough
    Weld thickness: 25 mm Weld width 32 mm Weld length 200 mm
    Reference points: see drawing
    Misc.: Evaluation with DGS scale
    Test instrument: USK 7 D Calibration range: 200 mm
    Sensitivity setting: ERS 3 + 6 dB Corrections: + 14 dB transfer loss
    Probe: MWB 70 4E Frequency: 4 MHz Angle of incidence: 70
    Scanning position: drawing Standard Calibration V2 Reference block: R25C
    Couplant: ZG 5 Pre-test: nothing found
    Test class: Recording threshold: ERS 3
    Indications recorded:
    No. Sec. l max d Dir dB Findings / remarks
    1
    1
    30 21 2 +18 Root crack
    2
    1
    32 23 1 + 6 Root crack
    3
    1 166 21 2 + 6 Root crack
    4
    1 163 22 1 + 2 Root crack
    5
    1 126 19 1 - 8 Pore/small inclusion near edge
    6
    1 50 22 6 - 6 Transverse crack

    Thick weld coverage to 1


    skip

    Turbine Shaft
    Area of interest
    Fur tree Root

    Weld with Single side Approach


    1 to 1 skip
    Where to approach

    Nozzle weld coverage

    How to approach

    What I am getting

    How I am getting the signal


    S/N RATIO

    How I am
    presenting

    Latest Techniques provide more details less scanning time

    ANY
    ?

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