CALIBRATION

R.SUBBARATNAM
RETD., HEAD, QA & NDT
QUALITY ASSURANCE DIVISION
IGCAR, KALPAKKAM
SUBBU_10@YAHOO.COM

CALIBRATION
To have consistent results at any time of
examination.
Calibration of the system includes the calibration
of equipment instrumentation and the calibration
of probe/s.
Calibrations of equipment instrumentation are
as follows:
screen height, gain (amplitude), sweep or range
five factors to be checked in the equipment probe
combination or system
Vertical linearity, Horizontal linearity, Dead zone, Sensitivity
and Maximum power.
Exit point & Angle in angle beam transducer

Calibration of Vertical / Screen Height Linearity

The signal amplitude is dependent on the Gain setting.
The signal from the standard reflectors and the signal
amplitude from defect are kept at required height by adjusting
the Instrument Gain - called as reference gain.
Hence, gain affects the amplitude in turn will affect the
sensitivity of the examination.
Vertical / Screen Height linearity is the measure of the
uniformity of the signal amplitude on the screen.
This is other way of checking the instruments screen linearity.
The vertical linearity is checked by adjusting the gain in steps
of 2 / 6 dB (by adding or subtracting the gain) from a
reference level and noting the amplitude heights.
The variation shall not be more than or less than 5% of the
required height.
Also the vertical linearity is measured between 20% to 80%,
as the amplitude will not be linear below and above the
above-specified values.

Calibration of Amplitude Linearity

The amplitude linearity is the check of the instruments the gain
control or the amplifier.
The amplitude linearity is checked using the amplitude from a
standard reflector and adjusting it by adjusting the gain control and
noting the signal amplitude on the screen.
The variation shall not vary more than 1% of the required value.

Original limit
(setting) (%FSH)

Change in Gain
control (dB)

Indication Values
(%FSH)

80%

-6

32 48 %

80%

-12

16 24 %

40%

+6

64 96 %

20%

+12

64 96 %

Calibration of Horizontal Linearity

Horizontal linearity is the measure of uniformity of the
sweep speed of the instrument.
The instrument shall be linear with in the dynamic ranges
of the sweep ranges.
This is one way of checking the equipments timer
circuitry.
Getting the position of multiple echoes from standard
calibration blocks checks the horizontal linearity.
Any variation in the echo position indicates the nonlinearity.

Dead Zone
Dead zone is the zone occupied by the initial pulse / pip
on the time base.
This is affecting the resolution of the examination.
This is mostly dependent on the frequency of the
transducer selected. Higher the frequency lesser the
dead zone.
Usually the dead zone is specified in mm.
This is measured by the reflected signal from the 1/16
hole of IIW calibration block for longitudinal / normal
beam probe.

Calibration of transducers
Calibration of transducers is also important.
But it always accompanied along with the equipments
calibration.
This is most important for the transmitter receiver (T-R)
and angle beam probes.
In the case of transmitter receiver probes the working
length (focal point) is to be known before engaging the
probe.
In the case of angle beam probe the exit angle and the
exit point are the important features.

Calibration Blocks
IIW V1 and Miniature V2 Blocks
The following are checked using V1 block:
Time base / horizontal linearity using longitudinal beam
Vertical / Screen Height and Amplitude Linearity using
longitudinal beam
Calibration of transducer for their exit point and angle
Resolution of the system
Dead Zone up to 5 / 10 mm
Maximum power of the system using the Perspex block
Exit angle and angle of examination

In the case of V2 block except the dead zone and the

maximum power others can be evaluated.

Area amplitude block

The area amplitude blocks are used for checking the
amplitude linearity.
A series of blocks containing different diameter flat
bottom holes at same depth are used.
These are used for area / amplitude response and also
used for calibrating the sensitivity of the system.

Distance amplitude blocks (B-Blocks)

The distance amplitude blocks are having single
diameter flat bottom hole at increasing beam
path distances.
These blocks are used for establishing the
distance amplitude response characteristics of
the system in the test material.

Calibration of sensitivity
Sensitivity of the UE system is to detect the smallest
discontinuity.
It depends on the following factors / parameters

Orientation of the discontinuity

Depth of the discontinuity
Type and surface condition of discontinuity
Geometry and surface condition of the specimen
Specimen Grain structure
Transducer type and its frequency
Beam orientation with respect to the discontinuity
Sensitivity requirement for the testing
Couplant
Type of Equipment and its capability

Out of the above, it may be any one or combination of

two or more, which will affect the sensitivity

Orientation and depth of the discontinuity &

Type and surface condition of discontinuity
Orientation of the discontinuity will be varying according to the type
of manufacturing and type of discontinuity.
The personnel shall know the basics and history of the discontinuity.
Ultrasonic beam shall be directed at normal to discontinuity to the
maximum possible, to get better sensitivity.
The signal from the discontinuity at different depth depends on the
attenuation of the material being tested.
Discontinuity can be classified as planar or volumetric.
If the discontinuity is a planar a high amplitude sharp signal is
received, if the beam is directed in proper orientation.
Where as, a volumetric discontinuity gives wide and comparatively
low amplitude signal.
If the surface of the discontinuity is plain / smooth then a better
signal is received than a wavy surface of the discontinuity.

Geometry and surface condition of the specimen

The geometry of the specimen can be classified as regular flat,
curved or special.
In the case of regular flat geometry examination is easier.
In the case of curved geometry the transducer makes only line
contact or less area contact.
the energy transmission is less and hence the sensitivity.
attaching a shoe on the transducer is normally used in contact testing.
this has the problem of variation in the angle of examination and the
energy transmission due to additional introduction of shoe material.
it is to be dealt carefully, to get the maximum sensitivity.

The surface condition of the specimen affects the sensitivity.

One is the variation of energy transmission and the other of
increasing width of initial signal.
Second factor affects the near surface resolution.
If the surface is very rough the angle of examination is affected, in
the case of angle beam examination.

Specimen Grain structure

Important feature in sensitivity.

grain structure - one shall know about the attenuation of sound energy in
the materials.
attenuation consists of two parts - absorption and scattering.
absorption implies the energy loss due to absorption.
scattering is the energy reflected at the grain boundary and hence, more
noise.
attenuation is measured as dB per length of energy travel in the medium
(dB/m). attenuation is compared with the signal from the reflector to the
noise level as signal to noise ratio (S/N Ratio).
A higher signal to noise ratio (S/N) indicates higher sensitivity.
specimen can be divided in to four categories with respect to the specimen
grain size for ultrasonic examination.
Very fine, fine, medium and large or coarse grain structure.
fine grain and medium grain materials are easy for ultrasonic examination.
very fine and coarse grain materials are difficult to examine or in some
cases can not be examined.
very fine grain structure material will absorb more energy. A good example
for this is loss of back wall echo while examining fine grain forging.
large or coarse grain structure, the grain boundary reflects the energy and
hence, more noise is resulted. This will result in very low signal to noise
ratio, affecting the sensitivity. A good example for the same is the
examination of thick austenitic stainless steel weld.

Transducer type and selection of frequency

Many transducers are used for the examination
according to the type of discontinuity expected.
The transducers are available with various sizes.
One should know the effect of the transducers.
Higher the size more energy and its transmission. But
more near zone and less beam divergence. Vice versa
for the lower size transducer.
Similarly higher the frequency more near zone, less
beam divergence, higher resolution and the attenuation
(in both absorption and scattering). Also, a lower
frequency is a better choice for coarse grain structure
material and to detect multi-directional crack.
Hence, it is required to select an optimum frequency
transducer to get a better sensitivity.

Beam With Respect To Discontinuity

Orientation
This is one of the most important parameter to be
considered for getting higher sensitivity.
One should know the possible orientation of the
discontinuity and direct the beam normal to it
A multi directional examination will result a better
sensitivity. Also in the case of weld examination a multi
angle examination will result better.
It should be made clear that a smaller amplitude signal is
not necessarily indicating a smaller size discontinuity.
The signal may be lesser due to improper orientation of
the beam.

Sensitivity requirement
Sensitivity requirement depends on the end use of the
job.
In the case of raw material like plate examination, the
discontinuity expected will be mostly bigger in size and
limited in numbers. The sensitivity requirement may be
less severe. Here a back wall may be called for the
sensitivity.
In certain cases a flat bottom hole may be called for.
In the case of fabrication of welding the discontinuity will
be more in numbers and the sensitivity may be varying
according to the end use.
In this case a notch or side drilled hole may be the
requirement.
The forging may be required different sensitivity.

Couplant
Couplant is mainly used for maximum transmission of
energy in to the material.
The type and the thickness of couplant play important
role in achieving sensitivity.
The thickness is limited up to /4.
Also the chemistry of the couplant plays a vital role, as
this will lead post examination problems, like corrosion
and corrosion cracking.
Sulpher 1% by wt; Halogen 25 50 ppm

Type of equipment and its capabilities

Up to the last decade analogue equipments were used
for the examination.
The improvement in the electronics made the availability
of digital and microprocessor based equipments.
These equipments provide vide variation of operating
parameters.
dB change can be up to 0.1 dB. other parameters like
PRF, probe delay, energy, sweep, scale, can be
changed.
The output will be in digitised form and provide the
imaging thereby enhancing discontinuity size, shape &
orientation.
This leads in controlling the parameters thereby
achievement of higher sensitivity.
The use of a microprocessor based, digital equipment
provides better results than analogue equipment in
general usage.

Various calibration criteria (DAC, DGS etc)

DGS Curve

Distance Amp. Correction Curve (DAC)

80

70

60

20
Gain (dB)

Amplitude

50
40
30

40
60

20

80

10

100
No. Near Zone

0
0

Beam Path / Probe Position

DAC

50% DAC

4 mm Dia

3 mm Dia

2mm Dia