NON DESTRUCTIVE TESTING

NDT TESTING OF MATERIAL WITHOUT DISTROYING IT

USED WORLD WIDE TO

- DETECT THE PRESENCE OF CRACK OR OTHER DISCONTINUITY

- DETECT MINUTE CHANGES IN SURFACE FINISH

- MEASURE THE THICKNESS OF MATERIALS & COATING

- DETERMINE OTHER CHARACTERISTICS OF INDUSTRIAL PRODUCT

 NON DESTRUCTIVE TESTING

TYPICAL NONDESTRUCTIVE TEST METHODS WHICH CAN BE REQUIRED AT

FIELD ARE

1. ULTRASONIC TEST 6. VIBRATION ANALYSES

2. RADIOGRAPHY 7. COATING THICKNESS TEST

3. MAGNETIC PARTICLE TEST 8. HARDNESS TEST

4. LIQUID PENETRANT TEST 9. LEAK DETECTION

5. EDDY CURRENT TEST

 NON DESTRUCTIVE TESTING
REASONS FOR USE OF NONDESTRUCTIVE TESTS

- TO ENSURE PRODUCT RELIABILITY

- TO PREVENT ACCIDENTS & SAVE HUMAN LIFE

- TO ENSURE CUSTOMER SATISFACTION AND TO MAINTAIN

THE MANUFACTURER’S “GOOD NAME”

- TO AID IN BETTER PRODUCT DESIGN

- TO CONTROL MANUFACTURING PROCESSES

- TO LOWER MANUFACTURING COSTS

- TO MAINTAIN A UNIFORM QUALITY LEVEL

 NON DESTRUCTIVE TESTING
DEFINITIONS

TERMINOLOGY DEFINITION
DISCONTINUITY A BREAK OR INTERRUPTION IN THE
NORMAL PHYSICAL STRUCTURE OF
AN ARTICLE

DEFECT A CONDITION WHICH WILL

INTERFERE WITH THE SAFE OR
SATISFACTORY SERVICE OF THE
PARTICULAR PART IN QUESTION
 NON DESTRUCTIVE TESTING
METHODS USED FOR DETECTION OF DISCONTINUITIES

DISCONTINUITY DETECTED BY
INTERNAL • ULTRASONIC TEST
DISCONTINUIIES
• RADIOGRAPHIC TEST

SURFACE OR • MPI
SUBSURFACE
• LPI
DISCONTINUITIES
• UT WITH SURFACE PROBES
• EDDY CURRENT
 DISCONTINUITIES IN FERROMAGNETIC MATERIALS

DISCONTINUITIES OCCURS DURING

INHERENT DISCONTINUITIES • INITIAL MELTING & REFINING PROCESSES

• SOLIDIFICATION FROM MOLTEN STATE A BREAK

OR INTERRUPTION IN THE NORMAL PHYSICAL
STRUCTURE OF AN ARTICLE

PRIMARY PROCESSING • STEEL INGOT WORKED DOWN TO SHAPE SUCH

AS BILLETS & SLABS
DISCONTINUITIES
• HOT AND COLD WORKING TO PRODUCE SHAPES
SUCH AS PLATES,BARS,ROD,WIRE,TUBING AND
PIPE

SECONDARY PROCESSING • FORMING, MACHINING,WELDING & HEAT

TREATMENT
DISCONTINUITIES

SERVICE DISCONTINUITIES • SERVICE / OPERATION

 INHERENT DISCONTINUITIES

DISCONTINUITY LOCATION CAUSE

COLD SHUT SURFACE OR THE MEETING OF TWO

SUBSURFACE STREAMS OF LIQUID METAL
THAT DO NOT FUSE TOGETHER

PIPE SUBSURFACE AN ABSENCE OF MOLTEN

METAL DURING FINAL
SOLIDIFICATION PROCESS

HOT TEARS SURFACE RESTRAIN FROM CORE OR

MOLD DURING SOLIDIFICATION
PROCESS

POROSITY SURFACE OR ETRAPPED GASES DURING

SUBSURFACE SOLIDIFICATION

INCLUSIONS SURFACE OR CONTAMINANTS INTRODUCED

SUBSURFACE DURING THE CASTING
PROCESS

SEGREGATION SURFACE OR LOCALIZED DIFFERENCE IN

SUBSURFACE MATERIAL COMPOSITION
 PRIMARY PROCESSING DISCONTINUITIES

DISCONTINUITY LOCATION CAUSE

SEAMS SURFACE ELONGATION OF UNFUSED SURFACE

DISCONTINUITIES IN ROLLED PRODUCTS

LAMINATIONS SUBSURFACE ELONGATION OF INHERENT

DISCONTINUITIES DURING THE ROLLING
PROCESS

STRINGERS SUBSURFACE -DO-

CUPPING SUBSURFACE INTERNAL STRESSES DURING COLD

DRAWING

COOLING CRACKS SURFACE UNEVEN COOLING OF COLD DRAWN

PRODUCTS

LAPS SURFACE MATERIAL FOLDED OVER & COMPRESSED

BURSTS SURFACE OR FORMING PROCESSES AT EXCESSIVE

TEMPERATURE

HYDROGEN FLAKES SUBSURFACE AN ABUNDANCE OF HYDROGEN DURING

THE FORMING PROCESS
 SECONDARY PROCESSING DISCONTINUITIES

DISCONTINUITY LOCATION CAUSE

GRINDING CRACKS SURFACE LOCALIZED OVERHEATING OF THE

MATERIAL DUE TO IMPROPER GRINDING
PROCEDURES

HEAT TREATING CRACKS SURFACE UNEVEN HEATING OR COOLING

QUENCH CRACKS SURFACE SUDDEN COOLING FROM ELEVATED

TEMPERATURES

PICKLING CRACKS SURFACE RESIDUAL STRESSES BEING RELIEVED

MACHINING TEARS SURFACE IMPROPER MACHINING PRACTICES

PLATING CRACKS SURFACE RESIDUAL STRESSES BEING RELIEVED

 SERVICE INDUCED DISCONTINUITIES

DISCONTINUITY LOCATION CAUSE

FATIGUE SURFACE CYCLICALLY APPLIED STRESS

CREEP SURFACE OR MATERIAL SUBJECTED TO ELEVATED

SUBSURFACE TEMPERATURES AND STRESS BELOW
YIELD POINT

STRESS CORROSION SURFACE COMBINED EFFECT OF A STATIC TENSILE

LOAD & A CORROSIVE ENVIRONMENT

HYDROGEN CRACKING SURFACE OR COMBINED EFFECT OF APPLIED TENSILE

OR RESIDUAL STRESS AND HYDROGEN
ENCIRCLED ENVIRONMENT
 ULTRASONIC TESTING

PRINCIPLES OF ULTRASONIC TESTING

TECHNIQUES

EQUIPMENT AND PROBES

INTERPRETATION

LIMITATIONS
 ULTRASONIC WAVES

ULTRASONIC WAVES ARE

• MECHANICAL VIBRATIONS

• FREQUENCY OF VIBRATION IS BEYOND THE AUDIBILITY

RANGE OF HUMAN EAR (20 Hz - 20KHz)
•
• FREQUENCY RANGE (20 KHz - 50 MHz)

• TRAVELS IN MOST OF METAL WITHOUT SERIOUS LOSS OF

ENERGY

• EXCEPTIONS - BRASS, COPPER, URANIUM, CAST IRON,

AUSTENITIC STEEL
 ULTRASONIC WAVES
PROPERTIES OF ULTRASONIC WAVES

• CAN TRAVEL LONG DISTANCE IN SOLID MATERIALS

• TRAVEL IN WELL DEFINED BEAM

• VELOCITY IS CONSTANT IN HOMOGENOUS MATERIALS

• WAVES ARE REFLECTED/REFRACTED WHERE ELASTIC &

PHYSICAL PROPERTIES CHANGE
 ULTRASONIC WAVES

EXAMINATION BY ULTRASONIC WAVES

• CAPABLE OF VERY HIGH SENSITIVITY

• POROSITY, BLOW HOLES, CRACK, INCLUSIONS LIE IN THE

PATH OF AN ULTRASONIC BEAM PRODUCE STRONG
REFLECTION
 ULTRASONIC WAVES
WAVE PROPAGATION CHARACTERISTICS
ON THE BASIS OF PARTICLE DISPLACEMENT IN THE MEDIUM,
ULTRASONIC WAVES ARE CLASSIFIED AS

LONGITUDINAL WAVES
MEDIUM

DIRECTION OF PROPAGATION

PARTICLE MOTION

SHEAR WAVES OR TRANSVERSE WAVES

MEDIUM

DIRECTION OF PROPAGATION

PARTICLE MOTION
 ULTRASONIC WAVES
WAVE PROPAGATION CHARACTERISTICS

SURFACE WAVES OR RAYLEIGH WAVES

MEDIUM SURFACE
DIRECTION OF PROPAGATION

PARTICLE MOTION
 TRANSMISSION, REFLECTION & MODE CONVERSION OF
LONGITUDINAL WAVES AT AN INTERFACE

INCIDENT LONGITUDINAL WAVE REFLECTED SHEAR WAVE

VELOCITY = VL 3 VELOCITY = VS

1
1 REFLECTED LONGITUDINAL WAVE
VELOCITY = VL

MEDIUM - 1 INTERFACE

TRANSMITTED LONGITUDINAL WAVE

MEDIUM - 2 4 VELOCITY = CL

2

TRANSMITTED SHEAR WAVE

VELOCITY = CS

SNELL’S LAW
VL = VS = CL = CS

Sin1 Sin3 Sin4 Sin2

 PRINCIPLE OF ULTRASONIC TESTING

BACK WALL ECHO

AMPLITUDE

DISCONTINUITY
INDICATION
INITIAL PULSE
HORIZONTAL
SWEEP

TRANSDUCER

MATERIAL DISCONTINIUITY REFLECTION FROM BACK WALL REFLECTION

DICONTINUITY
 ULTRASONIC DISPLAYS
A - SCAN DISPLAY
A - SCAN IS A TIME VERSUS AMPLITUDE DISPLAY WHICH REVEALS A DISCONTINUITY
USING A ‘PIP’ ON A CRT

BACK WALL ECHO

AMPLITUDE INITIAL PULSE DISCONTINUITY

INDICATION
HORIZONTAL
TRANSDUCER SWEEP

MATERIAL DISCONTINIUITY REFLECTION BACK WALL

FROM REFLECTION
DICONTINUITY

RELATIVE FLAW SIZE CAN BE OBTAINED BY COMPARING THE HEIGHT OF

ECHO FROM AN ACTUAL FLAW AND ONE ARTIFICIALLY
PRODUCED OF KNOWN PARAMETER

DISTANCE OF DISCONTINUITY CAN BE READ ON HORIZONTAL TRACE OF CRT

FROM TEST SURFACE
 ULTRASONIC DISPLAYS

B - SCAN DISPLAY CROSS SECTIONAL VIEW OF THE MATERIAL SHOWING

DEPTH AND WIDTH OF THE DISCONTINUITY
PROBE TRAVEL

FRONT SURFACE

PROBE POSITIONS
DISCONTINUITIES
BACK SURFACE
FRONT SURFACE

THICKNESS OF
TEST MATERIAL

BACK SURFACE
B SCAN PRESENTATION
 ULTRASONIC DISPLAYS

C - SCAN DISPLAY  GIVES PLAN VIEW OF THE TEST SPECIMEN

 SHOWS THE SHAPE AND LOCATION OF THE DEFECT
 IT WILL NOT GIVE DEPTH OF THE DEFECT
PROBE TRAVEL

FRONT SURFACE

DISCONTINUITIES
BACK SURFACE

C SCAN PRESENTATION
 ULTRASONIC TRANSDUCER

A DEVICE THAT CONVERTS ENERGY FROM ONE FORM TO ANOTHER

PIEZOELECTRIC REVERSIBLE
MOST WIDELY USED

ELECTROMAGNETIC REVERSIBLE
CAN BE USED FOR METAL
TESTING WITH OUT CONTACT

ELECTROSTATIC REVERSIBLE
LOW FREQUENCY APPLICATION

MAGNETORESTRICTIVE REVERSIBLE
LOW FREQUENCY
CONTACT - NECESSARY

LASER NOT REVERSIBLE

NO MATERIAL CONTACT
 ULTRASONIC TRANSDUCER
PIEZOELECTRIC EFFECT
A B
 
+ + + + + + + + + + + + - - - - - - - - - - - -

- - - - - - - - - - - - + + + + + + + + + + + +

 
D C
Ē Ē

COMPRESSIONS AND EXPANSIONS OF A PIEZOELECTRICTRANSDUCER

A EFFECT OF TENSILE STRESS ‘’
B EFFECT OF COMPRESSIVE STRESS ‘’
C EXPANSION CAUSED BY APPLICATION OF ELECTRIC FIELD ‘E’
D CONTRACTION CAUSED BY REVERSAL OF ‘E’
 PIEZOELECTRIC MATERIAL

QUARTZ EXCELLENT STABILITY

WEAR RESISTANT
LEAST EFFICIENT GENERATOR OF ACOUSTIC

CERAMIC MOST EFFICIENT GENERATOR OF ACOUSTIC

LOW MECHANICAL STRENGTH
USABLE UPTO 3000 C

LITHIUM SULPHATE INTERMEDIATE GENERATOR

FRAGILE
SOLUBLE IN WATER
LIMITED UPTO 740 C
 METHODS OF ULTRASONIC TESTING OF MATERIALS
1. RESONANCE METHOD
• MAINLY USED FOR THICKNESS MEASUREMENT
• CONTINUOUS LONG WAVES ARE USED
• STATIONARY WAVES ARE SET UP IN THE MATERIAL

THICKNESS d = 0.5*V/fe
fe = f n+1 - fn

THICKNESS = 0.5  WAVELENGTH

THICKNESS = 1  WAVELENGTH

LAMINATIONS CAN BE DETECTED BY THIS METHOD

 METHODS OF ULTRASONIC TESTING OF MATERIALS
2. THROUGH TRANSMISSION METHOD
INTENSITY OF ULTRASOUND IS MEASURED AFTER IT HAS PASSED THROUGH
THE TEST PIECE

TRANSMITTING PROBE RECEIVING PROBE

INTENSITY METER

HIGH FREQUENCY 0
GENERATOR AMPLIFIER 100%
INTENSITY

AMPLIFIER

25% intensity due to partial energy

being received because of the discontinuity
DISCONTINUITY

ADVANTAGES • CAPABILITY OF TESTING THICKER TEST SPECIMENS

• DEFECTS VERY NEAR TO THE SURFACE CAN BE DETECTED

• DEFECT LOCATION IS NOT POSSIBLE.

LIMITATIONS
• BOTH SIDES SHOULD BE ACCESSIBLE.
 METHODS OF ULTRASONIC TESTING OF MATERIALS

3. PULSE ECHO METHOD

AMPLIFIER

RECEIVER

HIGH FREQUENCY
GENERATOR

TRANSMITTER

PULSE ECHO METHOD

CONTACT TESTING IMMERSION TESTING

NORMAL ANGLE T.R. NORMAL ANGLE

PROBE PROBE PROBE PROBE PROBE

0.5 TO 6 MHz COMMONLY USED FREQUENCY FOR CONTACT TESTING

10 TO 25 MHz IMMERSION TESTING

 CONTACT TESTING

SIDE - 1 SIDE - 2

SIDE - 3 SIDE - 4
DOUBLE “V” BUTT JOINT
SCANNING FROM ALL FOUR SIDES

ADVANTAGES IT IS PORTABLE.

SYSTEM DOES NOT REQUIRE LARGE

AMOUNT OF ACCESSORIES
 IMMERSION TESTING
TRANSDUCER FRONT SURFACE
INITIAL PULSE REFLECTION FROM
FRONT SURFACE

DISCONTINUITY
WATER
BACK
REFLECTION

BACK SURFACE DISCONTINUITY

WATER PATH TEST PIECE PATH

“x” “y”

MOST COMMONLY USED COUPLANT WATER

MORE SENSITIVE, AS HIGHER FREQUENCY PROBES CAN BE USED
HOWEVER REQUIRES LARGE NUMBER OF ACCESSORIES
 ULTRASONIC FLAW DETECTOR
4a 5 13 13a 13b 8 3
4 3a

14

100
80
20
40

60
0
3 2

40
1

20
0
0 2 4 6 8 10
8a
2
6
1b 17 7
1a
FRONT VIEW
CONNECTOR SOCKETS (1a & 1b) SUPPRESSION CONTROL(5)
ON/OFF SWITCH (2) DELAY CONTROL(6)
TEST RANGE CONTROL (3 & 3A) FOCUS(7)
GAIN CONTROL (4 & 4a)
MONITOR GATE START & WIDTH CONTROL (8 & 8A)
 CALIBERATION BLOCKS
1. IIW ‘V1’ BLOCK
35
2
200
15

6
400 500 600
1.5  HOLE
100

55

91
50  HOLE

600 700 750

30

25
5

100
10 FOCAL POINT
300

25
1.5

THICKNESS OF THE PERSPEX INSERT PERSPEX 2

EQUIVALENT TO 50 MM STEEL INSERT
 CALIBERATION BLOCKS
1. IIW ‘V2’ BLOCK
75

12.5

25 50

ANGLE BEAM PROBE

FOCAL POINT

20 450 600

1.5  HOLE
MINIATURE ANGLE BEAM BLOCK
CONSTRUCTION OF PROBES
 CHARACTERISTIC OF ULTRASONIC PROBES

SENSITIVITY
• ABILITY OF THE PROBE TO DETECT SMALLEST DISCONTINUITY
• MEASURED BY THE AMPLITUDE OF ITS RESPONSE TO ENERGY
REFLECTED FROM A STANDARD DISCONTINUITY
100

100
PROBE NO. - 1 PROBE NO. - 2
80

80
60

60
40
40
20

20
0
0

0 2 4 6 8 10 0 2 4 6 8 10

FLAT BOTTOM HOLE FLAT BOTTOM HOLE

SAME REFLECTOR, SAME DISTANCE & GAIN SETTING PROBE N0 - 2 IS MORE SENSITIVE

HIGHER THE FREQUENCY, MORE THE SENSITIVITY

 CHARACTERISTIC OF ULTRASONIC PROBES

RESOLUTION
ABILITY TO SEPARATE ECHOES FROM TWO OR MORE DISCONTINUITIES LOCATED
CLOSE TOGETHER IN DEPTH

100

100
80

80
60

60
40

40
20
20
0

0
0 2 4 6 8 10 0 2 4 6 8 10

GOOD RESOLUTION POOR RESOLUTION

HIGHER THE FREQUENCY, BETTER WILL BE RESOLUTION

 CHARACTERISTICS OF ULTRASONIC PROBE
DEAD ZONE ZONE IN WHICH NO DEFECTS CAN BE DETECTEDWIDTH OF INITIAL
PULSE COVERED IS CALLED DEAD ZONE DISTANCE

DISTANCE TRAVELLED INITIAL ECHO DEFECT DEFECT

BY PULSE IN “x” SEC. ECHO ECHO

100
80
60
D

40
20
DISTANCE TRAVELLED
BY PULSE IN “T” SEC.

0
0 2 4 6 8 10

DEFECT
INDICATION

T TIME FOR WHICH PULSE IS APPLIED BY INSTRUMENT

x TIME TAKEN BY CRYSTAL TIME TO STOP VIBRATION (BECAUSE OF INERTIA)

D DISTANCE TRAVELLED BY SOUND WAVE DURING (T + x) SEC.

ORDER OF FEW mm

USE SHORT PULSE, HIGH DAMPING TO REDUCE ‘D’

 CALIBERATION OF ULTRASONIC EQUIPEMENT

GENERAL RULES

• MINIMUM TWO REFERENCE POINTS ARE NECESSARY

• FIRST REFERENCE ALWAYS CONTROLLED WITH THE HELP OF

DELAY CONTROL KNOB

• SECOND REFERENCE POINT ALWAYS CONTROLLED WITH THE HELP

OF RANGE CONTROL KNOB
INITIAL ECHO 1ST BACK WALL ECHO
(BWE)
IIW “V1” BLOCK

100
80
60
40
20
0

0 2 4 6 8 10
 CALIBERATION OF ULTRASONIC EQUIPEMENT
RANGE CALIBERATION BY NORMAL PROBE
INITIAL ECHO 1ST BACK WALL ECHO
(BWE)

100
IIW “V1” BLOCK

80
60
40
20
0
0 2 4 6 8 10

2ND
1ST BWE BWE INITIAL ECHO 1ST BWE

2ND
100
100

BWE
80
80

INITIAL ECHO
60
60

40
40

20
20

0
0

0 2 4 6 8 10 0 2 4 6 8 10
 APPLICATIONS OF ULTRASONIC TESTING

1. TESTING OF LAMINATION IN PLATES

INITIAL ECHO 1ST BWE 2ND BWE
FROM DEFECT FROM DEFECT
INITIAL ECHO 1ST BWE 2ND BWE
3RD BWE
FROM DEFECT
100

100
80

80
60

60
40

40
20

20
0

0
0 2 4 6 8 10 0 2 4 6 8 10

NO DEFECT DEFECT INDICATION

4TH BWE
FROM DEFECT
PLATE LAMINATION IN THE PLATE
 APPLICATIONS OF ULTRASONIC TESTING

2. BOND TESTING
INITIAL ECHO 1ST BWE 2ND BWE
FIRST ECHO
FROM DEFECT FROM DEFECT
INITIAL ECHO 100 FROM INTERFACE 1ST BWE

100
80

80
60

60
40

40
20

20
0

0
0 2 4 6 8 10 0 2 4 6 8 10

NO DEFECT DEFECT INDICATION

INTERFACE
DEFECT IN BONDING
AT INTERFACE CALLED “DISBONDING”

BEARING
CASTING PORTION

BABBIT METAL
 INTERPRETATION OF ULTRASONIC FLAW - ECHO INDICATIONS

1. PLANAR FLAW (CRACK, LACK OF FUSION)

SHARP INDICATION WHEN BEAM IS STRIKING r TO IT.

CONSIDERABLE DIFFERENCE WHEN ANGLE OF APPROACH
IN ECHO HEIGHT CHANGED

INDICATION FROM
PLANAR FLAW
INITIAL ECHO BWE
INITIAL ECHO BWE
1 100

100
80
80

60
60

40
40

2
20

20
0
0

0 2 4 6 8 10 0 2 4 6 8 10

PLANAR FLAW SCREEN PRESENTATION SCREEN PRESENTATION

WHEN PROBE IS AT 1 WHEN PROBE IS AT 2
 INTERPRETATION OF ULTRASONIC FLAW - ECHO INDICATIONS

2. SPHERICAL FLAW (POROSITY)

• REFLECT ONLY A SMALL AMOUNT OF SOUND

• ECHO HEIGHT SMALL
• ECHO HEIGHT REMAINS UNCHANGED WHEN ANGLE OF
APPROACH IS CHANGED

INDICATION FROM
SPHERICAL FLAW
1 INITIAL ECHO BWE

100
80
4

60
2

40
20
0 0 2 4 6 8 10

3
SPHERICALFLAW SCREEN PRESENTATION
WHEN PROBE IS AT 1 OR 2 OR 3 OR 4
 WELD TESTING - INTERPRETATION OF ULTRASONIC INDICATIONS

1. LACK OF PENETRATION
INDICATION FROM CORNER
INITIAL ECHO

100
ANGLE PROBE WELD

80
60
1 2

40
20
0
0 2 4 6 8 10

SCREEN PRESENTATION
LACK OF PENETRATION WHEN PROBE IS AT 1 OR 2

• SHARP ECHO FROM BOTH SIDES OF WELD

• INDICATION REMAINS AT THE SAME POSITION WHEN PROBE IS

MOVED ALONG THE LENGTH
 WELD TESTING - INTERPRETATION OF ULTRASONIC INDICATIONS

2. EXCESS PENETRATION
INDICATION FROM
INITIAL ECHO EXCESS PENETRATION

100
ANGLE PROBE WELD

80
60
1 2

40
20
0
0 2 4 6 8 10

SCREEN PRESENTATION WHEN PROBE

EXCESS PENETRATION IS AT 1

ECHO MAY BE ABSENT WHEN PROBE

AT 2 DEPENDING ON SURFACE
CONTOUR

• SHARP ECHO DEPENDS ON SHAPE OF ROOT SURFACE

 WELD TESTING - INTERPRETATION OF ULTRASONIC INDICATIONS

3. MISMATCH
INDICATION FROM
INITIAL ECHO MISMATCH

100
ANGLE PROBE WELD

80
60
1 2

40
20
0
0 2 4 6 8 10

SCREEN PRESENTATION WHEN PROBE

IS AT 2

MISMATCH ECHO MAY BE ABSENT WHEN PROBE

AT 1 DEPENDING ON SURFACE
CONTOUR

• STRONG ECHO INDICATION WHEN SCANNED FROM LOWER SIDE OF

THE WELD

• NO INDICATION FROM OTHER SIDE

 WELD TESTING - INTERPRETATION OF ULTRASONIC INDICATIONS

4. ROOT CONCAVITY
INDICATION FROM
INITIAL ECHO ROOT CONCAVITY

100
ANGLE PROBE WELD

80
60
1 2

40
20
0
0 2 4 6 8 10

SCREEN PRESENTATION WHEN PROBE

IS AT 1 OR 2
ROOT CONCAVITY
ULTRASONIC TESTING DURING OVERHAUL OF POWER PLANT UNITS

- UT OF TURBINE ROTOR

- UT OF TURBINE & PUMPS JOURNAL & THRUST BEARING

- UT OF FANS SHAFT

- UT OF PUMPS SHAFT

- UT OF REPAIR WELDS IN HIGH PRESSURE LINES

- UT OF VALVE SPINDLES

- BOILER TUBE THICKNESS SURVEY USING

ULTRASONIC THICKNESS MEASURING INSTRUMENT
 SELECTION OF TEST FREQUENCIES

TEST PARPMETERS RECOMMENDED

FREQUENCY RANGE
CAST IRON & COARSE GRAIN MATERIALS 0.5 MHz

REFINED GRAIN STEELS, 2.25 TO 5.0 MHz

SMALL DISCONTINUITIES,
(BURST,FLAKING,PIPE)
LARGE FORGINGS

SMALL FORGINGS 5.0 - 10.0 MHz

MICROSCOPIC DEFECTS, 10.0 MHz

FATIGUE CRACKS ETC.

 SELECTION OF PROBES

TYPE OF PROBE SIZE APPLICATION / ADVANTAGE

NORMAL BEAM LARGE USED FOR THICKER SECTION

PROBE DIAMETER
MAXIMUM BEAM COVERAGE
D MINIMUM NUMBER OF
SCANNING PASSES
LOW BEAM SPREAD

SMALL LESS THICK SECTION

DIAMETER
D BEAM SPREAD IS MORE
DESIRABLE FOR RANDOMLY
ORIENTED FLAW
 SELECTION OF PROBES

TYPE OF SIZE APPLICATION / ADVANTAGE

PROBE
ANGLE BEAM MINIATURE (8*9) FOR DEFECTS AT ANGLE TO
PROBE TEST SURFACE
FLAW DETECTABILITY IS
BETTER, AS SHEAR WAVES ARE
USED
T. R. PROBE 10 MM DIAMETER MUST BE USED FOR LOW
THICKNESS PLATES (5 - 20 mm)
TO DETECT NEAR SURFACE
DEFECT
 D
D

DISTANCE TRAVELLED
BY PULSE IN “x” SEC.

D
DISTANCE TRAVELLED
BY PULSE IN “T” SEC.
 ULTRASONIC TESTING

ADVANTAGES

- ABILITY TO TEST MATERIAL WITH ACCESS ONLY

ON ONE SIDE

- GREATER PENETRATION POWER

- RESULTS ARE KNOWN IMMEDIATELY

- NO HEALTH HAZARD LIKE RADIOGRAPHY

 ULTRASONIC TESTING

LIMITATIONS
- REQUIRES LOT OF SKILL

- PROPERLY TRAINED, QUALIFIED & EXPERIENCED OPERATOR IS

NEEDED

- CAN BE USED ONLY FOR THOSE MATERIAL IN WHICH

ULTRASOUND CAN BE TRANSMITTED

- VERY THIN SHEETS, COARSE GRAIN MATERIAL ARE DIFFICULT

TO TEST

- GEOMETRY OF THE OBJECT & GRAIN STRUCTURE CAN MAKE

TESTING DIFFICULT

- ORIENTATION OF THE DEFECT, SIZE, NATURE & DISTRIBUTION

CAN AFFECT THE DETECTABILITY