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NDT
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NDT
NON-DESTRUCTIVE TESTING
Examination of materials and components in
such a way that allows material to be
examinated without changing or destroying
their usefulness
NDT
Most common NDT methods:
Penetrant Testing (PT)
Magnetic Particle Testing (MT)
NDT
Which NDT method is
the best ?
Depends on many
factors and conditions
Ultrasonic Inspection
Sub-surface detection
This detection method uses high frequency sound
waves, typically above 2MHz to pass through a material
A probe is used which contains a piezo electric crystal to
transmit and receive ultrasonic pulses and display the
signals on a cathode ray tube or digital display
The actual display relates to the time taken for the
ultrasonic pulses to travel the distance to the interface
and back
An interface could be the back of a plate material or a
defect
For ultrasound to enter a material a couplant must be
introduced between the probe and specimen
Ultrasonic Inspection
Pulse echo
signals
A scan Display
Compression probe
UT Set, Digital
Ultrasonic Inspection
defect
echo
initial pulse
Back wall
echo
Material Thk
defect
Compression Probe
10
20
30
40
CRT Display
50
Bottom / Backwall
Defect
10
20
30
40
50
60
60 mm
30
46
68
C
B
A
Ultrasonic Inspection
A Scan
Display
Angle Probe
UT Set
Ultrasonic Inspection
initial pulse
defect echo
Surface distance
defect
sound path
0
Angle Probe
10
20
30
40
CRT Display
50
Ultrasonic Inspection
Advantages
Disadvantages
contaminate
No permanent record
Ultrasonic Testing
Principles of Sound
What is Sound ?
A mechanical vibration
The vibrations create Pressure Waves
Sound travels faster in more elastic
materials
Number of pressure waves per second is
the Frequency
Speed of travel is the Sound velocity
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)
Wavelength
Velocity
f
Frequency
Sound Waves
One cycle
SOLID
LIQUID
GAS
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/s
V Compression in water : 1470 m/s
V Compression in air : 330 m/s
5 M Hz
STEEL
WATER
AIR
Shear waves
Steel5960m/sec
Steel3245m/sec
Water 1470m/sec
Water NA
Air
Air
344m/sec
Copper 4700m/sec
NA
Copper 2330m/sec
Ultrasonic
Sound : mechanical vibration
What is Ultrasonic?
Very High Frequency sound above 20 KHz
20,000 cps
Acoustic Spectrum
Sonic / Audible
Human
16Hz - 20kHz
10
100
1K
Ultrasonic
> 20kHz = 20,000Hz
Frequency
Frequency : Number of cycles per
second
1 second
1 cycle per 1 second =
1 Hertz
1 second
3 cycle per 1 second =
3 Hertz
1 second
18 cycle per 1 second
= 18 Hertz
Pg 21
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
ULTRASONIC TESTING
Very High Frequency
5 M Hz
Glass
High Frequency
5 K Hz
DRUM BEAT
Low Frequency Sound
40 Hz
f
5MHz compression
wave probe in steel
5,900,000
1.18mm
5,000,000
Frequency
1 M Hz
LONGEST
5 M Hz
10 M Hz
25 M Hz
SMALLEST
=v/f
10 MHz
Sound Waveforms
Sound travels in different waveforms in
different conditions
Compression wave
Shear wave
Surface wave
Lamb wave
Compression / Longitudinal
Vibration and propagation in the same
direction / parallel
Travel in solids, liquids and gases
Particle vibration
Propagation
Shear / Transverse
Vibration at right angles / perpendicular to
direction of propagation
Travel in solids only
Velocity 1/2 compression (same material)
Particle vibration
Propagation
Compression v Shear
Frequency
0.5MHz
1 MHz
2MHz
4MHz
6MHZ
Compression
11.8
5.9
2.95
1.48
0.98
Shear
6.5
3.2
1.6
0.8
0.54
Shear waves
Steel5960m/sec
Steel3245m/sec
Water 1470m/sec
Water NA
Air
Air
344m/sec
Copper 4700m/sec
NA
Copper 2330m/sec
Surface Wave
Elliptical vibration
Velocity 8% less than shear
Penetrate one wavelength deep
SYMETRIC
ASSYMETRIC
Sound Beam
Near Zone
Thickness
measurement
Detection of defects
Sizing of large
defects only
Far Zone
Thickness
measurement
Defect detection
Sizing of all defects
N=
FZ
Main
Beam
Intensity
varies
Exponential Decay
Distance
Near
Zone
Side Lobes
Main Beam
Near Zone
2
D
Near Zone
4
V
D f
Near Zone
4V
Near Zone
What is the near zone length of a 5MHz
compression probe with a crystal diameter
of 10mm in steel?
2
D f
Near Zone
4V
2
10 5,000,000
4 5,920,000
21.1mm
Near Zone
2
D
Near Zone
4
D f
4V
5 M Hz
5 M Hz
Beam Spread
In the far zone sound pulses spread out
as they move away from the crystal
/2
K
KV
Sine
or
2 D
Df
Beam Spread
K
KV
Sine
or
2 D
Df
Edge,K=1.22
20dB,K=1.08
6dB,K=0.56
Beam axis
or Main Beam
Beam Spread
What is the beam spread of a 10mm,5MHz
compression wave probe in steel?
KV
Sine
2
Df
1.08 5920
5000 10
o
0.1278
7.35
5 M Hz
5 M Hz
Beam Spread
K
KV
Sine
or
2 D
Df
The bigger the diameter the smaller the
beam spread
The higher the frequency the smaller
the beam spread
Which has the larger beam spread, a compression
or a shear wave probe?
Ultrasonic Pulse
A short pulse of electricity is applied to a
piezo-electric crystal
The crystal begins to vibration
increases to maximum amplitude and
then decays
Maximum
10% of
Maximum
Pulse length
Pulse Length
Pulse Length
The longer the pulse, the more
penetrating the sound
The shorter the pulse the better the
sensitivity and resolution
Pulse Length
Resolution
RESOLUTION in Pulse Echo Testing is the ability
to separate echoes from two or more closely
spaced reflectors.
RESOLUTION is strongly affected by Pulse
Length:
Short Pulse Length - GOOD RESOLUTION
Long Pulse Length - POOR RESOLUTION
RESOLUTION is an extremely important property
in WELD TESTING because the ability to
separate ROOT GEOMETRY echoes from ROOT
CRACK or LACK OF ROOT FUSION echoes largely
determines the effectiveness of Pulse Echo UT
in the testing of single sided welds.
Resolution
90%
> 6dB
10%
Good resolution
Resolution
90%
< 6dB
50%
Poor resolution
Beam Spread
Attenuation
Made up of
absorption and
scatter
Scatter
The bigger the grain
size the worse the
problem
The higher the
frequency of the
probe the worse the
problem
1 MHz
5 MHz
Beam Spread
The sound beam
spread out and the
intensity decreases
80%
80%
40%
37%
20%
ZERO ATTENUATION
15%
ATTENUATION 0.02 dB/mm
Sound at an Interface
Sound will be either transmitted across
or reflected back
Reflected
Interface
Transmitted
Acoustic Impedance
Definition
The Resistance to the
passage of sound
within a material
Measured in
kg / m2 x sec
Formula
Z V
= Density , V = Velocity
% Sound Reflected at an
Interface
2
Z1 Z 2
100 % reflected
Z1 Z 2
% Sound Reflected + % Sound Transmitted = 100%
Therefore
% Sound Transmitted = 100% - % Sound Reflected
46.7 1.48
100
%
reflected
46.7 1.48
2
45.22
48.18 100 % reflected
Air
Steel
Steel
Air
Large Acoustic Impedance
Ratio
Aluminum
Steel
Steel
Steel
No Acoustic Impedance
Difference
Interface Behaviour
Similarly:
At an Steel - Air interface 99.96% of
the incident sound is reflected
At a Steel - Perspex interface 75.99%
of the incident sound is reflected
Sound Intensity
H0
dB 20 Log..10
H1
40
dB 20 Log..10 20 Log..102
20
dB 20 0.3010
dB 6dB
H0
dB 20 Log..10
H1
100
dB 20 Log..10
20 Log..1010
10
dB 20 1
dB 20dB
2:1=
4:1=
5:1=
10 : 1
100 : 1
6bB
12dB
14dB
= 20dB
= 40dB