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MANUFACTURED

DISCONTINUITIES
or REAL FLAWS
-
NDE APPLICATIONS
AND
CHARACTERISTICS
What Are Real Flaws ?

  Manufactured Discontinuities or Real Flaws are


intentionally created and placed defects in critical
areas, such as weld joints, base materials, parts, etc .

  Their intent is to replicate the NDE response of the


actual defect
Two Fundamental Approaches

  Induced – Actual Creation of the flaw in a


controlled environment where its extents can be
accurately measured

  Manufactured – Manufacturing of an indication


that will produce the expected NDE response
Three Types of Real Flaws
  Weld or Base Material Defects

  Fatigue Cracks

  Alternative Flaws
Real Flaw Type 1 -
Weld/Base Material Defects
Weld defects occur during the welding process.
Some Examples of weld defects:

  Slag or Tungsten Inclusion


  Lack of Fusion

  Incomplete Penetration

  Porosity
Real Flaw Type 1 –
Weld/Base Material Defects

Base Material defects are present in the base material


of machined parts, vessels, structures, or in the raw
material itself

  Lamination
  Single Gas Pores

  Cracking
Real Flaw Type 2 -
Fatigue Cracks

These cracks are a result of cyclic fatiguing or


loading

  Thermal Fatigue

  Mechanical Fatigue
Real Flaw Type 3 -
Alternative Flaws

  Intended to minimize base metal disturbance

  Combination of traditional flaw manufacturing with


machining and PWHT

  Limited customer base currently


REAL FLAWS –
NDE APPLICATIONS
Who uses Real Flaws ?

Some industries or groups currently benefitting from


their use are:
  Commercial Nuclear Power

  Petrochemical

  Nuclear Navy

  Aerospace

  Training & Education


Who uses Real Flaws ?

Some codes currently being serviced by these flaws


are:
  AWS D1.1 & D1.8

  ASME Sec V, VII, XI

  ASME BPVC CASE 2235

  API-UT-1 & RP 2X
The Future
  New Materials

  New Defect Types

  Tighter Tolerances

  New Markets
REAL FLAWS –
NDE CHARACTERISTICS
A36 CS Plate, 12 x12 x 0.75 T
A-Scan UT Calibration

PLATE BOTTOM

PLATE TOP
Phased Array Calibration
CURRENT ANGLE

SECTOR SCAN
40° - 70°

PLATE BOTTOM

A-SCAN (53°)
Lack of Fusion

Incompletely fused area in the weld. Typically


between the weld and base material or in
between weld beads or passes.
Lack of Fusion(Mid-Wall)

Expected UT Response –

  Location – Approximately 1.8 or 5.3 screen


divisions(conventional)
  Signal – Crack-like, well-defined

  Consistent signal as probe is skewed or moved


axially
Lack of Fusion(Mid-Wall)

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TOP
Lack of Fusion(Mid-Wall)
Probe Skewed Left 15° Probe Skewed Right 15°

GATE
Lack of Fusion(Mid-Wall)

LACK OF FUSION

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Slag Inclusion

Non-metallic byproduct of the welding process,


which becomes trapped in the weld
Slag Inclusion

Expected UT Response –

  Location – Anywhere in weld volume


  Signal – Broad, multi-peaked, singular

entity
  Primarily amplitude change is seen

with axial movement or skewing of probe


Slag Inclusion

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TOP
Slag Inclusion
Probe Skewed Left 15° Probe Skewed Right 15°
Slag Inclusion

SLAG INCLUSION

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Porosity

Entrapped gas in solidified metal. It can be


clustered or linear(wormhole).
Porosity(Cluster)

Expected UT Response –

  Location – Any position through the volume of


the weld
  Signal – Broader signal with multiple peaks and

multiple ring cycles


  Axial movement or skewing of probe show a

consistent indication response


Porosity(Cluster)

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TOP
Porosity(Cluster)
Probe Skewed Left 15° Probe Skewed Right 15°
Porosity(Cluster)

POROSITY

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Incomplete Penetration

Area where the weld does not fully penetrate


through the thickness of the weld joint..
Incomplete Penetration

Expected UT Response –

  Location – Weld centerline, at or near 3.5 screen


divisions
  Signal – Clean, sharp, well-defined
Incomplete Penetration

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TOP
TIP SIGNAL
Incomplete Penetration

TIP SIGNAL

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INCOMPLETE
PENETRATION
Fatigue Crack – HAZ Area

Base material crack located a short distance from


the weld fusion line, in the HAZ(Heat-Affected
Zone)
Fatigue Crack – HAZ Area

Expected UT Response –
  Location – At or near 3.5 screen divisions
  Signal – Single indication with multiple ring
cycles, sometimes accompanied by pre & post-
cursor indications
  Axial probe movement results in increase &
decrease of signal, but no character changes
  Skewing of probe may show amplitude changes
in signal
Fatigue Crack – HAZ Area

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TOP
Fatigue Crack – HAZ Area
Probe Skewed Left 15° Probe Skewed Right 15°
Fatigue Crack – HAZ Area

HAZ CRACK

A-SCAN

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Fatigue Crack – Toe Area

Base material crack located at the toe of the weld


crown, running parallel to the weld
Fatigue Crack – Toe Area

Expected UT Response –

  Location – At or near 7th screen division


  Signal – Similar response to HAZ crack, with

location being the differentiating factor


Fatigue Crack – Toe Area

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TOP
Fatigue Crack – Toe Area
Probe Skewed Left 15° Probe Skewed Right 15°
Fatigue Crack – Toe Area
TOE CRACK

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THANK YOU!

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