WELDS IN THIN MATERIALS:

UDC 620. 179. 1

ULTRASONIC EXAMINATION
Key words: NDT, welding, testing
TABLE OF CONTENTS
1 INTRODUCTION
1.1 Scope
1.2 Reporting level
1.3 Acceptance criteria
1.4 Extent of examination
1.5 References
1.6 Definitions
2 APPLICATION
2.1 General
2.2 Required information
3 PERSONNEL
4 SURFACE PREPARATION
5 COUPLANT
6 PERIODIC CHECK OF EQUIPMENT
6.1 General
6.2 Periodic quality checks
6.3 Periodic checks during operation
2
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
7 DESCRIPTION OF EQUIPMENT 3
7.1 Ultrasonic apparatus 3
7.2 Probes 3
7.2.1 General 3
7.2.2 Aluminium 3
7.2.3 Carbon steel 4
7.2.4 Austenitic steel 4
7.3 Calibration blocks 4
7.4 Reference blocks 4
7.5 Control blocks 5
8 PROCEDURE FOR EXAMINATION OF WELDS 5
8.1 General 5
8.2 Calibration of probes 5
8.3 Adjustment of time base 5
8.4 Sensitivity setting 6
8.5 Examination of parent metal 6
8.6 Examination routines 8
9 REPORTING 8-9
Published by NORDTEST Tekniikantie 12, FIN-02150 ESPOO, FINLAND Phone +358 9 455 4600 Fax +358 9 455 4272
ISSN 0283-720X Proj. 864-89 www.nordtest.org
NORDTEST METHOD NT NDT 013 2
1 INTRODUCTION
1.1 Scope
This Nordtest method specifies procedures for weld examin-
ation in thin materials by manually operated ultrasonics. The
method is limited to ordinary carbon steel, aluminium alloys
and austenitic steel with commonly accepted qualities for
conventional ultrasonic testing. The thickness range covered
is from 7 mm down to 3 mm, i.e. below the ranges covered by
ordinary procedures for ultrasonic weld examination which
often apply a lower limit of around 8 mm.
1.2 Reporting level
This Nordtest method does not specify reporting level.
1.3 Acceptance criteria
This Nordtest method does not specify acceptance criteria.
Reference is to be made to relevant codes or other documents
specifying such criteria.
1.4 Extent of examination
This Nordtest method does not specify the extent of examin-
ation in terms of areas to be examined, examination coverage
(percentage of total test specimen surface) or examination
intervals.
1.5 References
For common ultrasonic practices, reference is to be made to
relevant parts of DOC IIS/IIW -527-76 Handbook on the
Ultrasonic Examination of Welds. The International Institute
of Welding.
1.6 Definitions
Probe stand-off
The probe stand-off is the gap between the probe shoe
and the test object surface.
TR (twin crystal) probe
A transmitter-receiver (TR) probe has two crystals, one
for transmitting the sound and the other for receiving, and
is often also referred to as a twin crystal probe. The TR
arrangement can be either straight beam probes or angle
beam probes.
Probe log
A collection of probe data sheets and calibration data for
the probes used in the examination.
2 APPLICATION
2.1 General
Whenever an ultrasonic examination is specified to be per-
formed according to this document, the applications are re-
stricted to:
Weld examination.
Ordinary carbon steel, austenitic steel, aluminium alloys
and materials of comparable ultrasonic properties.
Material thicknesses in the range of 3 mm to 7 mm.
Surface curvature (external radius) exceeding 50 mm.
Surface temperature up to 60 C.
2.2 Required information
Reference to this document only is insufficient in order to
specify a proper ultrasonic examination. At least the following
additional information has to be given:
(i) Reporting level.
(ii) Extent of examination, i.e. areas to be
ing configuration and dimensions.
examined includ-
In addition the following information may be given:
(iii) Acceptance criteria.
(iv) Precautions in case unacceptable weld defects are
found.
3 PERSONNEL
The personnel responsible for performing ultrasonic examin-
ation of welds in thin plates according to this document shall
be examined and certified according to level 2 of the NORD-
TEST certification scheme or equivalent. Moreover, the per-
sonnel concerned shall:
(i) Be familiar with the possibilities and the limitations of this
special thin material method used to detect and size weld
defects.
(ii ) The personnel should also keep themselves informed
about developments in using ultrasonics in thin materi-
als.
(iii) Be specifically trained in the practical testing of welds in
the actual thickness range.
Whenever necessary, the personnel in question should be
submitted to qualification tests to prove their proficiency.
4 SURFACE PREPARATION
For examination of welds in thin plates the weld must be
prepared flush, i.e. weld cap and root must align with the base
material. This alignment must be good, since any remaining
material below the plate level may contain sharp edges caus-
ing more serious disturbances than the original weld.
NORDTEST METHOD NT NDT 013 3
Generally the condition of the surface that will be in contact
with the probe shall be such that satisfactory coupling between
the probe and the workpiece can be maintained, providing
satisfactory conditions for the transmission of the ultrasonic
waves. Surfaces where scanning will be performed must also
allow for free movement of the probe.
The surface roughness should not exceed 6 m rms.
For aluminium the grinding requirement may impose specific
requirements on the grinding equipment to avoid corrosion
problems. Aluminium surfaces should be metallically clean.
5 COUPLANT
A couplant such as water, oil, grease or a commercial ultra-
sonic couplant shall be used in accordance with common
practices (IIW doc. 527-76, Section 4.3).
A probe holder with a 0.05 to 0.1 mm probe stand-off may be
used with micro miniature probes when using liquid couplant,
to ensure stable coupling, less probe wear, more easy probe
handling and correct probe angle.
6 PERIODIC CHECK OF EQUIPMENT
6.1 General
Whenever personnel discovers irregularities in equipment per-
formance, or the equipment has been exposed to rough treat-
ment which could influence the equipment performance, a
quality check is required. Documents of quality checks shall
be available.
6.2 Periodic quality checks
The ultrasonic apparatus, probes and cables shall be checked
at intervals not exceeding 6 months. The check shall ensure
that all the operating modes function satisfactory.
6.3 Periodic checks during operation
In order to ensure that the ultrasonic equipment is properly
calibrated at any time during examination, the operator shall
perform checks at regular intervals as outlined below:
- Ultrasonic apparatus
At approximately
performed:
two-hourly intervals, the following shall be
* check of time-base range or display range using blocks
manufactured for the purpose.
* check of sensitivity.
- Angle beam probes
The angle probes shall be checked frequently and always
before and after a specific ultrasonic examination.
If wear has caused an angular deviation of more 2
from the nominal value, the probe shall be replaced. When
replacing a probe, all calibration, adjustment of time-base and
sensitivity setting shall be repeated.
- Straight beam probes
The straight beam probes shall be checked frequently and
always before and after a specific ultrasonic examination.
Echo amplitude and number of echoes (if applicable) from a
calibration/reference block can be used in the check pro-
cedure.
7 DESCRIPTION OF EQUIPMENT
7.1 Ultrasonic apparatus
An oscilloscope type ultrasonic flaw detector (A-scan display
or similar) covering at least the frequency range of 4-12 MHz
shall be used.
The apparatus must be able to work in single as well as twin
crystal modes.
It must be possible to adjust the time base of the apparatus
down to a range of 10 mm corresponding to full screen width.
It must be possible to draw a reference curve directly on the
screen.
7.2 Probes
7.2.1 General
Single crystal probes should be chosen so that sound paths
exceed 60 % of the near field length.
Twin crystal probes should be chosen so that the sound path
is typically 50-200 % of focal distance.
High frequencies, 4-10 MHz, should be used for good sensi-
tivity. The highest frequency probes are needed for the
smallest plate thicknesses.
The probe angle should be in the range of 60 to 80. The
advantage of using different probe angles may be less for thin
plate examination because the ultrasonic beam may fill the
inspection volume. This will depend on plate thickness, probe
frequency and probe crystal size. For high frequency micro
miniature probes this effect will be less pronounced.
7.2.2 Aluminium
Ultrasonic probes with the following characteristics shall be
used:
(i) Micro miniature angle beam probes or TR probes,
- Frequency in the range of 4-10 MHz
- A probe angle of approximately 70 should be used.
The probe angle in aluminium will depend on the type
of alloy and treatment of the material. The nominal
probe angle will normally be given for steel, and the
actual probe angle has to be established by cali-
bration as described in Clause 8.2.
- Transversal wave mode.
NORDTEST METHOD NT NDT013 4
(ii) Straight beam TR probes,
- Frequency in the range of 10 MHz
Focus at 50-200 % of nominal thickness.
7.2.3 Carbon steel
Ultrasonic probes with the following characteristics shall be
used:
(i) Micro miniature angle beam probes or TR probes,
- Frequency in the range of 4-10 MHz
- Beam angle of 70
(ii) Straight beam TR probes,
- Frequency in the range of 4-10 MHz
- Focus at 50-200 % of nominal thickness.
7.2.4 Austenitic steel
Ultrasonic probes with the following characteristics shall be
used:
(i) Micro miniature angle beam probes or TR probes,
- Frequency in the range of 4-10 MHz
- Beam angle of 70
- Twin crystal probe
- Transverse wave mode, since the lower attenuation
of longitudinal waves gives no advantage for the short
7.3 Calibration blocks
The following calibration blocks shall be applied:
( i ) The IIW Calibration Block No. 2, the V2 block, shall be
used for determination of probe index point, as described
in the examination procedure 8.2.
( i i ) A calibration and reference block shall be used for deter-
mination of probe angle and for adjustment of time base.
The block shall be made of the same material or a
material with the same ultrasonic properties as the test
object. The calibration/reference block is described
below and is shown in Figure 7.1.
7.4 Reference blocks
A reference block shall be made of the same material or a
material with the same ultrasonic properties as the test object.
The dimensions of the reference block shall be:
Thickness (T) Same as the test object.
Length (L) Minimum 70 mm.
Width (W) Minimum 40 mm.
A cylindrical bore hole of 1.0 mm diameter and two notches of
1.0 mm depth and max. 0.2 mm width, with lengths equal to
half the reference block width, shall be positioned as shown in
Figure 7.1.
(i) The notches shall be used to determine probe angle.
(ii) The time base should be calibrated using the cylindrical
path lengths in thin plates. bore hole as reflector.
W/2
Notches shall have rounded ends (side milling cutter)
1 mm bore hole of max 20 mm length
Figure 7.1. Calibration and reference block with side drilled hole and notches.
NORDTEST METHOD NT NDT 013 5
(iii) Sensitivity setting shall be performed with the cylindrical
bore hole of 1 mm diameter. The construction of the
reference curve should be carried out as recommended
by DOC IIS/IIW - 527-76.
7.5 Control blocks
It is recommended, but non-mandatory, to have control blocks
with real defects for the purpose of increased detection re-
liability. The control block shall have the same material quality,
thickness, surface geometry and surface condition as the body
to be examined.
8 PROCEDURE FOR EXAMINATION OF WELDS
8.1 General
The ultrasonic weld examination shall be performed according
to commonly accepted practice, as described in DOC IIS/IIW-
527-76. The temperature of the calibration and reference block
shall be the same as that of the surface of the test object within
10 C.
8.2 Calibration of probes
( i ) The IIW Calibration Block No. 2, the V2 Block, shall be
used for initial determination of index point. See Fig. 8.1.
INDEX POINT
The echo is maximized against the 25 mm or 50 mm
diameter surface and the position of the index point is
positioned directly below the reference mark on the
calibration block. The index point should be marked on
the probe and the result should be reported in the probe
log.
( i i ) The calibration of the angle of refraction shall be per-
formed directly on the reference block by mechanically
measuring the plate thickness and horizontal distance
from the index point of the probe to the position of the
notches, and then calculating the angle. The calibration
procedure is described in Figure 8.2. At least one of the
indicated positions should be used, and the angle of
refraction then calculated from the following formula:
a = arctg(d/T)
(iii) If the probe wedge has been adapted to test body
curvature, the probe index and angle of refraction shall
be determined by using a reference block of curvature
similar to that of the test object.
8.3 Adjustment of time base
On both planar and curved contact surfaces, the cylindrical
bore hole in the reference block should be used for adjustment
of time base.
The echoes against the cylindrical bore hole should be
maximized in at least two of the positions A, B, C and D in
Figure 8.3, and the time base of the apparatus should be
adjusted so that the full length of the minimum scanning area
is within the screen.
Figure 8.1. Calibration of index point using the V2 block. Figure 8.2. Calibration of probe angle.
Figure 8.3. Calibration of time base.
NORDTEST METHOD NT NDT 013 6
Figure 8.4. Calculation of sound path s and horizontal distance d from the probe to a cylindrical bore hole.
The sound path s and the horizontal distance d from the first
probe position A to the reflector can be calculated by the
following formulas, when the plate thickness T, the probe angle
a and the radius R (0.5 mm) of the cylindrical bore hole are
known (see Figure 8.4):
s = (T/2)/cos(a) - R
d = (T/2)tg(a) - R sin(a)
The position A is approximately 1/4 skip distance from the bore
hole and the positions B, C and D correspond to 3/4, 5/4 and
7/4 skip distances, or N*(1/4) skip distances, where N is 1, 3,
5 and 7. A table of horizontal distances and sound paths
corresponding to the probe positions A, B, C and D should be
made and the probe positions for these skip distances should
be marked with a felt tip pen on the surface of the reference
block. The formulas for these positions will be
s = N(T/2)/cos(a) - R
d = N(T/2)tg(a) - R sin(a)
An example of such a table is given below, for T = 4 mm, a =
Probe ID
Probe angle
Date
Operator
Probe position A, B, C, D,
1/4 skip 3/4 skip 5/4 skip 7/4 skip
Sound path,
s [mm] 5.3 17.0 28. 7 40. 4
Horizontal distance
d [mm] 5.0 16.0 27. 0 38. 0
8.4 Sensitivity setting
The sensitivity setting shall be performed and a reference
curve shall be established by using the 1 mm diameter bore
hole in the reference block described in Fig. 7.1. The procedure
is shown in Figures 8.5 to 8.8.
The sound path from the position corresponding to the first
point on the reference curve to the cylindrical bore hole should
be not less than 60 % of the near field length of the probe.
Probe positions A(1), B(3) and C(5) shall be used for estab-
lishing the reference curve if the sound path from the probe in
position A(1) to the reflector is more than 0.6 times (60 %) the
near field length of the probe. Otherwise probe positions A(3),
B(5) and C(7) shall be used.
The echo height from the first position should be maximized
and the gain adjusted so that the echo height is 80 % of the
full screen height.
With constant gain setting echo heights from the other probe
positions shall be maximized and the maximum echo positions
should be marked on the instrument screen.
A smooth curve should be drawn through the established echo
height positions and is to be plotted on the instrument screen.
The two curves at 50 % and 20 % of the reference curve should
also be established and plotted on the instrument screen.
For aluminium, reporting level and acceptance criteria often
require the use of a higher sensitivity, because lack of fusion
defects in aluminium are often partly transparent to ultrasound.
The required sensitivity levels must be established individually.
8.5 Examination of parent metal
Parent metal should be checked for lamination type defects in
the scanning area by using a straight beam TR probe with a
focal distance comparable to (50 to 200 % of) the material
t hi ckness.
70:
NORDTEST METHOD NT NDT 013 7
Figure 8.5. Probe positions for establishing reference curve, numbers in parentheses are number of quarter
skip distances.
100 % t
75 %
\
\
\
\
\
\ REFERENCE CURVE
A(1) B(3) C(5)
Figure 8.6. Reference curve corresponding to above probe
positions, numbers in parentheses correspond to number of
quarter skip distances.
Figure 8.7. Probe positions for establishing reference curve, numbers in parentheses correspond to number
of quarter skip distances.
100 % t
75 %
!
\
\
\
\
\
\ REFERENCE CURVE
Figure 8.8. Reference curve corresponding to above probe
positions, numbers in parentheses correspond to number of
quarter skip distances.
NORDTEST METHOD NT NDT 013 8
MINIMUM SCANNING AREA
Figure 8.9. Minimum scanning area for probes with short near field length.
I MINIMUM SCANNING AREA
I
i
I
I
s = 10 mm
Figure 8.10. Minimum scanning area using a probe with relatively long near field length.
MACHINED FLUSH
I
WELD LONGITUDINAL AXIS \
reflector position near the center of the plate, and the most far
away probe position corresponds to a reflector position near
the top (Figure 8.9) or bottom (Figure 8.10) surface of the
plate with a distance S, minimum 10 mm, from the weld
groove.
The distances from the probe positions to the weld corre-
sponding to the minimum scanning area should be established
by using the notches of the reference block. The scanning area
should then be marked on the surface of the test object.
Scanning for detection of transverse cracks should be per-
formed by moving the probe in the direction of the longitudinal
axis of the weld on the machined surface directly below the
weld, as shown in Figure 8.11.
Figure 8.11. Scanning for transverse cracks.
9 REPORTING
8.6 Examination routines
The centre of the weld should be marked on the surface. The
minimum scanning area is indicated in Figure 8.9 for probes
with short near field lengths, with reference curves established
according to Figures 8.5 and 8.6. For probes with longer near
field lengths, with reference curves established according to
Figures 8.7 and 8.8, the minimum scanning area is indicated
in Figure 8.10. The closest probe position corresponds to a
The results from the weld examination shall be given in a report
which should include all the necessary information required to:
(i) Take decisions on acceptance.
(ii) Facilitate repair or other remedial actions on unaccept-
able structures.
(iii) Enable measurements to be repeated in order to check
measurement reliability.
NORDTEST METHOD NT NDT 013 9
The test report shall therefore include the following informa-
tion:
(9) Description of calibration block and report on calibration
data
(1) Job identification
(2) Test object identification, drawings and dimensions
(3) Date, time and place of the examination
(4) Ambient conditions of the examination
(5) Name and signature of the operator
(6) Relevant material characteristics
(7) Surface condition and geometry
(8) Data related to equipment, eg. manufacturer, serial no.,
equipment type, probe description
(10) Description of reference blocks and report on reference
data
(11) Data concerning the results from the examination.
(12) Additional data which may concern limitations of the
examination because of surface geometry, coating thick-
ness or others.
(13) Specific requirements agreed upon by the parties in-
volved
(14) Drawings of affected areas, if required.