ULTRASONIC COURSE

LEVEL I & II
ISSUED BY : GANZORY

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 Introduction
 This course to be familiar with the
different scanning techniques of UT
 To be familiar with different UT systems
 To analysis the different defects
 To be ready for examination acc.
SNT –TC – 1A

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 UT COURSE
 1ST day
 Applications, training, and principles
 2nd day
 Equipment control, wave propagation ,
transducers
 3rd day
 Beam spread , attenuation Scanning techniques,
 4th day
 Scanning techniques , contact & immersion
 5th day
 Interpretation of defects
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 UT COURSE
 6th day
 Standard reference blocks, calibration
 7th day
 Practical Training on ut calibration
 8th day
 Classification of discontinuities ,
 9th day
 Aut and its applications
 10th day
 Examination

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 Introduction to manual ultrasonic
Why use ultrasonic for nondestructive
material testing?

 Ultrasonic frequency ( 0.5MHZ TO 25MHZ )

 Both radiography and ultrasonic tests are
the most frequently for test internal flaws
 Ultrasonic can discover volumetric defect
 Planner defects can easily discover more
than radiography

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 General guide
 High frequency : less beam spread
 Greater sensitivity
 Greater resolution
 Greater attenuation
 Pour penetration
 Low frequency : deeper penetration
 Less attenuation
 Greater beam spread
 Less sensitivity
 Less resolution
 Usually desirable to test at the lowest frequency that will locate
specified minimum sizes and types of discontinuity consistently
 Small grain size steels 2.25 to 5 mhz
 Microscopic inclusion 10mhz
 Medium carbon steel castings 1 to 5mhz
 Small forgings 5 to 10 mhz
 Large forgings 2.25 to 5mhz
 High carbon steel 500khz
 Cast iron less than 500khz
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 Ultrasonic waves

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wave propagation

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wave
propagation

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wave
propagation

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 2. Ultrasonic testing tasks
 Detection of reflectors

 Location of reflectors

 Evaluation of reflectors

 Diagnosis of reflectors (reflector

type, orientation, etc.)
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 Angle testing contact type

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 3. Detection of discontinuities

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 The famous contact probes

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 Detection of discontinuities

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 Detection of discontinuities

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 Detection of discontinuities

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 Detection of discontinuities
Angle reflection effect

Fig. 10a Tandem testing: upper zone F

Fig. 10c Tandem testing: lower zone F

Fig. 10b Tandem testing: center zone

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 Amplifier
 The gain difference ∆v = 20 log A2/A1
 ∆v = gain difference
 A1 = echo amplitude 1
 A2 = echo amplitude 2
 a) Large voltage ratios can be given in small figures, e.g.
 1000 : 1 = 60 dB
 1000000 : 1 = 120 dB
 b) A reversal of the voltage ratios only requires a change of the sign , e.g.
 10000 : 1 = 80 dB
 1 : 10000 = -80 dB
 c) A multiplication of the voltage ratio corresponds to a simple addition of a dB
value ,
 e.g.
 Gain factor 2 + 6 dB
 Gain factor 10 + 20 dB
 Gain factor 100 + 40 dB

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 4. Method of testing and instrument technology

Fig. 12 The principle of Fig. 13 Block diagram:

time of flight measurement Pulse Echo Method

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 EQUIPMENT & LAMINATION

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Fig. 16a Initial pulse = Start Fig. 16b after 10 ms

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 Fig. 17a Beam spot at the 4th scale Fig. 17b Beam spot at the 8th scale Fig. 18 Backwall echo at the 8th
graduation graduation scale graduation

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 Fig. 19a Straight-beam probe: initial Fig. 19b Angle-beam probe: initial
pulse delay pulse delay

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 Fig. 20 Test object with Fig. 21a Discontinuity in Fig. 21b Discontinuity near
discontinuity, display with front of the backwall the surface
flaw echo

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 Fig. 23 Shadowing of the
Fig. 22 A non-detectable Fig. 24 Echo sequence of a
back-wall echo by a larger
near-to-surface discontinuity near-to-surface discontinuity
near-to-surface reflector
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 Fig. 25 Dead zone: display, test object
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 Fig. 27 Longitudinal wave

Fig. 29 Transverse wave

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 4.4 Refraction and mode conversion

a = angle of incidence
b = angle of refraction
c 1 = sound velocity in medium 1
c 2 = sound velocity in medium 2

Fig. 30a Refraction and reflection Fig. 30b Refraction and reflection
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Fig. 32a Refraction: 1st critical Fig. 32b Refraction: transverse
angle wave under 45°
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 Fig. 32c Refraction: Fig. 32d Total Fig. 33 Usable range
2nd critical angle, reflection for angle-beam
surface wave probes in steel

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 Fig. 36 TR probe on the test object: CRT with Fig. 37 TR probe on the test object:
backwall echo discontinuity echo in the cross-talk echo

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 Thickness measurement

s = sound path [mm]

c = sound velocity [km/s] Fig. 38 Wall thickness
t = transit time [ms] measurement with a digital
thickness gauge in practice

1st Echo = t,
2nd Echo = 2t,
3rd Echo = 3t, etc.

Fig. 39 USK 7: Backwall echo

sequence with a straight-beam probe
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 Thickness measurements
Echo-No Sound path si Scale factor k Skalen-position Ti
i [mm] [mm/scale grad.] [scale grad.]

1 25 10 2.5

2 50 10 5.0

3 75 10 7.5

4 100 10 10.0
Fig. 40 Calibration range: 0-10mm

si = sound path of umpteenth echoes

Ti = scale position of the umpteenth echo
k= scale factor
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 5.1.3 Calibration with an angle-beam probe

Fig. 48 Different probe angels at V1 block

Fig. 47a WB 60-2E on Calibration Block 1

Fig. 49a Sound path in the V1 block without angle reflection

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47b MWB 45-4E on Calibration Block 2 Fig. 49b Sound path in the V1 block with
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angle reflection.
 Fig. 50 Range: 250 mm with a WB 60-2 Fig. 51a Path of a sound wave in a V2
on V1 block block, radius 50 mm

Fig. 51b Path of a sound wave in a V2 Fig. 52 Range: 100 mm calibrated on V2,
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block, radius 25 mm radius 25 mm.
 Fig. 54b Reduced surface distances and x-
Fig. 54a The flaw triangle
value

Fig. 56b The real reflector depth after sound

Fig. 56a The apparent depth
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 6. Evaluation of discontinuities

Fig. 58b Top view with reflector for

Fig. 57 A large reflector in the sound beam
extension.
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 6.2 Evaluation of small discontinuities: The DGS method

Fig. 59 Reflectors with different areas and

their echoes
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The echo heights are proportional to
their area or The echo heights are
proportional to the square of their
diameter.

The echo heights reduce to the

square of their distance
Fig. 60 Reflectors at different depths
and their echoes

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 Fig. 61 Distance amplitude curve of a Fig. 62 Evaluation of a discontinuity
2 mm - disk reflector (F) using evaluation curves.

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 6.4.1 Comparison of echo amplitudes

Fig. 65 Test object with a Fig. 66 Reference block: Fig. 67 References block:
flaw: echo at 80% reference echo at 30%. reference echo to reference
(reference height) height
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 6.4.2 Distance amplitude curve

Fig. 69 DAC of the reference echoes (top) and Fig. 68 Reference block wiht side drilled
with time corrected gain (bottom). holes and resulting echoes
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 Introduction to scanning models


A SCAN

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 SCANNING TYPES

B SCAN

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 SCANNING TYPES

C SCAN

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 SCANNING TYPES

D SCAN
TOFD

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 SCANNING TYPES

P- SCAN

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 Time of Flight Diffraction Technique (TOFD)

 The following main principles

describe TOFD:

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TOFD INTERPRETATION
 Time of Flight Diffraction Technique (TOFD)

1 = transmitted wave
2 = reflected wave
3 = through transmitted wave
4 = diffracted wave at upper crack tip
5 = diffracted wave at lower crack tip

1- lateral wave
2 - diffraction signal at upper crack tip
3 - diffraction signal at lower crack tip
4- back wall reflection

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 Time of Flight Diffraction Technique (TOFD)

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 Time of Flight Diffraction Technique (TOFD)

TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 TOFD INTERPRETATION

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 INDEX POINT CHECK

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 ANGLE PROBE CHECK

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 TIME BASE CALIBRATION USING ZERO PROBE

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 TIME BASE CALIBRATION USING ANGLE PROBE

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 Time base calibration using V2 block

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 PROBE CALIBRATION

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 CALIBRATION WITHOUT REFERANCE BLOCKS

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 SKIP DISTANCE CALCULATION

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 CALIBRATION REQUIRED ACC. TO BS

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 Distance Amplitude Correction (D.A.C.) Curves

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 IMMERSION TEST

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fig 37 Several techniques and applications for wheel-type search units, (a) Typical setup for a
wheel-type 9' - search unit. (b) Straight-beam inspection with beam entering the test piece
perpendicular to the surface. (c) Angle-beam inspection with beam entering the test piece at
45° to the surface. Beam can also be directed forward or to the side at 90° to the direction of
wheel rotation, (d) Use of two transducers to cross and angle the beams to the sides and
forward cross-eyed Lamb unit

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 IMMERSION TEST

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Wheel probe application

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Ut for extruded mandrel

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 (b) Oscilloscope display for correct oil level

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 (c) Oscilloscope display for incorrect oil level
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Setup for determining
the position of a piston
in a hydraulic oil
accumulator by use of
two contact search units
utilizing a through
transmission
arrangement

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 SLAG INCLUSION ECHO

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 LAMINATION

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 PROCEDURE QUALIFICATION AND APPROVAL
API RP 2X 1996
1. Type of weld configurations and surface temperature
range to be examined.
2. Acceptance criteria for each type of weld.
3. Type of ultrasonic instrumentation (manufacturer, model,
and serial number).
4. Use of electronic gates, suppression, alarms,
5. Equipment calibration and frequency.
6. Equipment standardization and frequency.
7. Length of coaxial cable.
8. Transducer frequency, size and shape, beam angle, and
type of wedge on angle beam probes.
9. Surface preparation.
10. Couplant.
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 11. Base metal examination.
12. Transfer correction.
13. Scanning sensitivity.
14. Scanning pattern.
15. Triangulation methods for determining
effective beam angle, indexing of root area,
and ßaw location.
16. Method of discontinuity length determination.
17. Method of discontinuity width determination.
18. Reporting and retention.

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 Horizontal linearity

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 T-532 Screen Height Linearity
 The ultrasonic instrument shall provide linear
vertical presentation within +5% of the full screen
height for 20% to 80% of the calibrated screen
height [base line to maximum calibrated screen
point(s)].
 of each period of extended use (or every 3
months,whichever is less).

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 T-533 Amplitude Control Linearity ( ref. ASME
5)
 The ultrasonic instrument shall utilize an amplitude
control accurate over its useful range to +20% of
the nominal amplitude ratio, to allow measurement
of indications beyond the linear range of the
vertical display on the screen.
 shall be performed at the beginning of each period
of extended use (or every 3 months, whichever is
less).

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