Siemens Rolling Stock Pvt. Ltd, Aurangabad.

Ultrasonic Testing

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SRSPL, Aurangabad

Outline
• Introduction
• Basic Principles of sound generation
• Pulse echo and through transmission testing
• Inspection applications
• Equipment
• Transducers
• Instrumentation
• Reference Standards
• Data presentation
• Advantages and Limitations
• Calibration
• Selected Applications
SRSPL, Aurangabad

Introduction

• Ultrasonic testing uses high frequency sound

energy to conduct NDE examinations and make
measurements.
• Ultrasonic examinations can be conducted on a
wide variety of material forms including castings,
forgings, welds, and composites.
• A considerable amount of information about the
part being examined can be collected, such as the
presence of discontinuities, part or coating
thickness; and acoustical properties can often be
correlated to certain properties of the material.
SRSPL, Aurangabad

Basic Principles of Sound

• Sound is produced by a vibrating body and travels in the
form of a wave.
• Sound waves travel through materials by vibrating the
particles that make up the material.
• The pitch of the sound
is determined by the
frequency of the wave
(vibrations or cycles
completed in a certain
period of time).
• Ultrasound is sound
with a pitch too high
to be detected by the
human ear.
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Basic Principles of Sound (cont.)

• The measurement of sound waves from crest to
crest determines its wavelength (λ).

• The sound wavelength

is inversely proportional
to its frequency. (λ = 1/f)
• Several wave modes of
vibration are used in
ultrasonic inspection.
The most common are
longitudinal, shear, and
Rayleigh (surface) waves.
SRSPL, Aurangabad

Basic Principles of Sound (cont.)

• Ultrasonic waves are very similar to light
waves in that they can be reflected,
refracted, and focused.
• Reflection and refraction occurs when
sound waves interact with interfaces of
differing acoustic properties.
• In solid materials, the vibrational energy
can be split into different wave modes
when the wave encounters an interface
at an angle other than 90 degrees.
• Ultrasonic reflections from the presence
of discontinuities or geometric features
enables detection and location.
• The velocity of sound in a given material
is constant and can only be altered by a
change in the mode of energy.
SRSPL, Aurangabad

Ultrasound (UT) Generation

UT inspection system : Pulser/ Receiver, Transducer, Display Device
Pulser / Receiver : Electronic device to produce electrical pulse
High frequency ultrasound is generated with a transducer.

A piezoelectric element
in the transducer
converts electrical
energy into mechanical
vibrations (sound), and
vice versa.

The transducer is
capable of both
transmitting and
receiving sound
energy.
SRSPL, Aurangabad

Principles of Ultrasonic Inspection

• Ultrasonic waves are introduced into a material
where they travel in a straight line and at a
constant speed until they encounter a surface.
• At surface interfaces some of the wave energy is
reflected and some is transmitted.
• The amount of reflected or transmitted energy can
be detected and provides information about the
size of the reflector.
• The travel time of the sound can be measured and
this provides information on the distance that the
sound has traveled.
SRSPL, Aurangabad

Test Techniques
• Ultrasonic testing is a very versatile inspection
method, and inspections can be accomplished in a
number of different ways.
• Ultrasonic inspection techniques are commonly
divided into three primary classifications.
• Pulse-echo and Through Transmission
(Relates to whether reflected or transmitted energy is used)
• Normal Beam and Angle Beam
(Relates to the angle that the sound energy enters the test article)
• Contact and Immersion
(Relates to the method of coupling the transducer to the test
article)

Each of these techniques will be discussed briefly

in the following slides.
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Test Techniques - Pulse-Echo

• In pulse-echo testing, a transducer sends out a pulse of energy
and the same or a second transducer listens for reflected energy
(an echo).
• Reflections occur due to the presence of discontinuities and the
surfaces of the test article.
f
• The amount of reflected sound energy is displayed versus time,
which provides the inspector information about the size and the
location of features that reflect the sound.
initial
pulse
back surface
echo

crack
echo
crack
plate
0 2 4 6 8 10
UT Instrument Screen
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Test Techniques – Pulse-Echo (cont.)

Digital display
showing signal
generated from
sound reflecting
off back surface.

Digital display
showing the presence
of a reflector midway
through material, with
lower amplitude back
surface reflector.
The pulse-echo technique allows testing when access to only one
side of the material is possible, and it allows the location of
reflectors to be precisely determined.
SRSPL, Aurangabad

Test Techniques – Through-Transmission

• Two transducers located on 1

1
opposing sides of the test
specimen are used. One T R

transducer acts as a transmitter,

the other as a receiver.
• Discontinuities in the sound path T R

will result in a partial or total loss 2

of sound being transmitted and
be indicated by a decrease in the
received signal amplitude.
1
1
• Through transmission is useful in
detecting discontinuities that are
not good reflectors, and when 2
signal strength is weak. It does
not provide depth information. 0 2 4 6 8 10
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Test Techniques – Through-Transmission

Digital display
showing received
sound through
material
thickness.

Digital display
showing loss of
received signal
due to presence
of a discontinuity
in the sound field.
SRSPL, Aurangabad

Test Techniques – Normal and Angle Beam

• In normal beam testing, the sound

beam is introduced into the test
article at 90 degree to the surface.
• In angle beam testing, the sound
beam is introduced into the test
article at some angle other than
90.
• The choice between normal and
angle beam inspection usually
depends on two considerations:
- The orientation of the feature of
interest – the sound should be
directed to produce the largest
reflection from the feature.
- Obstructions on the surface of the
part that must be worked around.
SRSPL, Aurangabad

Test Techniques – Contact Vs Immersion

• To get useful levels of sound energy into a material, the air
between the transducer and the test article must be removed.
This is referred to as coupling.
• In contact testing (shown on the previous slides) a couplant
such as water, oil or a gel is applied between the transducer
and the part.
• In immersion testing, the part and the transducer are place in a
water bath. This arrangement allows better movement of the
transducer while maintaining consistent coupling.
• With immersion testing, an echo from the front surface of the
part is seen in the signal but otherwise signal interpretation is
the same for the two techniques.
1 2
IP 1 IP 2 IP = Initial Pulse
FWE FWE FWE = Front Wall
Echo
BWE BWE DE = Defect Echo
DE BWE = Back Wall
Echo

Defect 0 2 4 6 8 10 0 2 4 6 8 10
SRSPL, Aurangabad

Inspection Applications
Some of the applications for which ultrasonic testing may
be employed include:
• Flaw detection (cracks, inclusions, porosity, etc.)
• Erosion & corrosion thickness gauging
• Assessment of bond integrity in adhesively
joined and brazed components
• Estimation of void content in composites and
plastics
• Measurement of case hardening depth in steels
• Estimation of grain size in metals

On the following slides are examples of some

common applications of ultrasonic inspection.
SRSPL, Aurangabad

Thickness Gauging
• Ultrasonic thickness • Applications
gauging is routinely utilized include piping
in the petrochemical and systems, storage
utility industries to and containment
determine various degrees facilities, and
of corrosion/erosion. pressure vessels.
SRSPL, Aurangabad

Flaw Detection - Delaminations

Contact, pulse-echo inspection for delaminations
on 36” rolled beam.

Signal showing multiple back

surface echoes in an unflawed area.

Additional echoes indicate

delaminations in the member.
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Flaw Detection in Welds

• One of the most widely
used methods of
inspecting weldments is
ultrasonic inspection.
• Full penetration groove
welds lend themselves
readily to angle beam
shear wave examination.
SRSPL, Aurangabad

Equipment

Equipment for ultrasonic testing is very

diversified. Proper selection is important to
insure accurate inspection data as desired
for specific applications.
In general, there are three basic components
that comprise an ultrasonic test system:
- Instrumentation
- Transducers
- Calibration Standards
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Transducers
• Transducers are manufactured in a variety of
forms, shapes and sizes for varying applications.
• Transducers are categorized in a number of ways
which include:
- Contact or immersion
- Single or dual element
- Normal or angle beam
• In selecting a transducer
for a given application, it
is important to choose the
desired frequency,
bandwidth, size, and in some cases focusing
which optimizes the inspection capabilities.
SRSPL, Aurangabad

Contact Transducers
Contact transducers are
designed to withstand
rigorous use, and usually
have a wear plate on the
bottom surface to protect
the piezoelectric element
from contact with the
surface of the test article.
Many incorporate
ergonomic designs for
ease of grip while
scanning along the
surface.
SRSPL, Aurangabad

Contact Transducers (cont.)

• Contact transducers are
available with two piezoelectric
crystals in one housing. These
transducers are called dual
element transducers.
• One crystal acts as a transmitter,
the other as a receiver.
• This arrangement improves near
surface resolution because the
second transducer does not
need to complete a transmit
function before listening for
echoes.
• Dual elements are commonly
employed in thickness gauging
of thin materials.
SRSPL, Aurangabad

Contact Transducers (cont.)

• A way to improve near surface
resolution with a single element
transducer is through the use of a
delay line.
• Delay line transducers have a plastic
piece that is a sound path that
provides a time delay between the
sound generation and reception of
reflected energy.
• Interchangeable pieces make it
possible to configure the transducer
with insulating wear caps or flexible
membranes that conform to rough
surfaces.
• Common applications include
thickness gauging and high
temperature measurements.
SRSPL, Aurangabad

Transducers (cont.)
• Angle beam transducers
incorporate wedges to
introduce a refracted shear
wave into a material.
• The incident wedge angle is
used with the material velocity
to determine the desired
refracted shear wave according
to Snell’s Law)
• Transducers can use fixed or
variable wedge angles.
• Common application is in weld
examination.
SRSPL, Aurangabad

Transducers (cont.)
• Immersion transducers are
designed to transmit sound
whereby the transducer and
test specimen are immersed
in a liquid coupling medium
(usually water).
• Immersion transducers
are manufactured with
planar, cylindrical or
spherical acoustic
lenses (focusing lens).
SRSPL, Aurangabad

Instrumentation
• Ultrasonic equipment is usually purchased to
satisfy specific inspection needs, some users
may purchase general purpose equipment to
fulfill a number of inspection applications.
• Test equipment can be classified in a number of
different ways, this may include portable or
stationary, contact or immersion, manual or
automated.
• Further classification of instruments commonly
divides them into four general categories: D-
meters, Flaw detectors, Industrial and special
application.
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Instrumentation (cont.)
• D-meters or digital
thickness gauge
instruments provide the
user with a digital
(numeric) readout.
• They are designed
primarily for
corrosion/erosion
inspection applications.
• Some instruments provide the user with both a
digital readout and a display of the signal. A
distinct advantage of these units is that they allow
the user to evaluate the signal to ensure that the
digital measurements are of the desired features.
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Instrumentation (cont.)
• Flaw detectors are
instruments designed
primarily for the inspection of
components for defects.
• However, the signal can be
evaluated to obtain other
information such as material
thickness values.
• Both analog and digital
display.
• Offer the user options of
gating horizontal sweep and
amplitude threshold.
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Instrumentation (cont.)

• Industrial flaw detection

instruments, provide
users with more options
than standard flaw
detectors.
• May be modulated units
allowing users to tailor
the instrument for their
specific needs.
• Generally not as portable
as standard flaw
detectors.
SRSPL, Aurangabad

Instrumentation (cont.)
• Immersion ultrasonic scanning
systems are used for
automated data acquisition
and imaging.
• They integrate an immersion
tank, ultrasonic
instrumentation, a scanning
bridge, and computer controls.
• The signal strength and/or the
time-of-flight of the signal is
measured for every point in
the scan plan.
• The value of the data is plotted
using colors or shades of gray
to produce detailed images of
the surface or internal features
of a component.
SRSPL, Aurangabad
Images of a Quarter Produced With an
Ultrasonic Immersion Scanning System

Gray scale image produced using Gray scale image produced using the
the sound reflected from the front sound reflected from the back surface
surface of the coin of the coin (inspected from “heads” side)
SRSPL, Aurangabad

Calibration Standards
Calibration is a operation of configuring the
ultrasonic test equipment to known values. This
provides the inspector with a means of comparing
test signals to known measurements.
Calibration standards come in a wide variety of
material types, and configurations due to the
diversity of inspection applications.
Calibration standards are typically manufactured
from materials of the same acoustic properties as
those of the test articles.
The following slides provide examples of specific
types of standards.
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Calibration Standards (cont.)

Thickness calibration
standards may be flat or
curved for pipe and tubing
applications, consisting of
simple variations in ASTM Distance/Area Amplitude
material thickness.
Distance/Area Amplitude
standards utilize flat bottom
holes or side drilled holes to
establish known reflector NAVSHIPS
size with changes in sound
path form the entry surface.
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Calibration Standards (cont.)

There are also calibration IIW

standards for use in angle

beam inspections when
flaws are not parallel to
entry surface. DSC DC Rhompas

These standards utilized

side drilled holes, notches,
and geometric SC
configuration to establish
time distance and
amplitude relationships.

ASME Pipe Sec. XI

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Qualification Standards
Qualification AWS Resolution DC-dB Accuracy
standards differ from
calibration standards
in that their use is for
purposes of varying
proper equipment
operation and
qualification of
equipment use for IOW Beam Profile

specific codes and

standards.
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Data Presentation

• Information from ultrasonic testing can be

presented in a number of differing formats.
• Three of the more common formats include:
• A-scan
• B-scan
• C-scan

These three formats will be discussed in the next

few slides.
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Data Presentation - A-scan

Signal Amplitude
• A-scan presentation
displays the amount of
received ultrasonic energy
as a function of time.
• Relative discontinuity size
can be estimated by
Time
comparing the signal
amplitude to that from a
known reflector.

Signal Amplitude
• Reflector depth can be
determined by the position
of the signal on the
horizontal sweep.

Time
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Data Presentation - B-scan

• B-scan presentations
display a profile view
(cross-sectional) of a test
specimen.
• Only the reflector depth in
the cross-section and the
linear dimensions can be
determined.
• A limitation to this display
technique is that reflectors
may be masked by larger
reflectors near the surface.
SRSPL, Aurangabad

Data Presentation - C-scan

• The C-scan presentation displays a plan type view

of the test specimen and discontinuities.
• C-scan presentations are produced with an
automated data acquisition system, such as in
immersion scanning.
• Use of A-scan in conjunction with C-scan is
necessary when depth determination is desired.

Photo of a Composite C-Scan Image of

Component Internal Features
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Advantage of Ultrasonic Testing

• Sensitive to both surface and subsurface discontinuities.

• Depth of penetration for flaw detection or measurement is
superior to other methods.
• Only single-sided access is needed when pulse-echo
technique is used.
• High accuracy in determining reflector position and
estimating size and shape.
• Minimal part preparation required.
• Electronic equipment provides instantaneous results.
• Detailed images can be produced with automated systems.
• Has other uses such as thickness measurements, in
addition to flaw detection.
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Limitations of Ultrasonic Testing

• Surface must be accessible to transmit ultrasound.
• Skill and training is more extensive than with some other
methods.
• Normally requires a coupling medium to promote transfer of
sound energy into test specimen.
• Materials that are rough, irregular in shape, very small,
exceptionally thin or not homogeneous are difficult to inspect.
• Cast iron and other coarse grained materials are difficult to
inspect due to low sound transmission and high signal noise.
• Linear defects oriented parallel to the sound beam may go
undetected.
• Reference standards are required for both equipment
calibration, and characterization of flaws.
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Glossary of Terms
• Acoustical properties: ultrasonic material characteristics
such as velocity, impedance, and attenuation.
• ASTM: acronym for American Society for Testing and
Materials. This society is extensively involved in
establishing standards for materials and the testing of
materials.
• Back reflection: a display signal that corresponds to the
far surface of a test specimen, side opposite to transducer
when testing with longitudinal waves.
• Band width: a range of frequencies either transmitted or
received, may be narrow or broad range.
• B-scan: presentation technique displaying data in a cross-
sectional view.
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Glossary of Terms
• Calibration: a sequence of instrument control
adjustments/instrument responses using known values to
verify instrument operating characteristics. Allows
determination of unknown quantities from test materials.
• CRT: acronym for Cathode Ray Tube. Vacuum tube that
utilizes one or more electron guns for generating an image.
• C-scan: presentation technique that displays specimen
data in a plan type view.
• DAC (Distance Amplitude Correction-curves): a
graphical method of allowing for material attenuation.
Percentage of DAC is often used as a means of acceptance
criteria.
• Discontinuity: an interruption in the physical structure of a
material, examples include fissures, cracks, and porosity.
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Glossary of Terms
• IIW: calibration standard meeting the specification of the
International Institute of Welding.
• Longitudinal (Compression) waves: ultrasonic mode of
propagation in which the particle vibration is parallel to the
direction of propagation.
• Near Surface Resolution: the ability of an ultrasonic system
to display reflectors located close to the entry surface.
• Pulse-echo: ultrasonic test method that utilizes reflected
sound as a means of collecting test data.
• Rayleigh (Surface) waves: ultrasonic mode of propagation
where the sound travels along the surface, particle vibration is
elliptical.
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Glossary of Terms
• Reflection: the changing in direction of sound waves as they
strike a surface.
• Snell’s Law: an equation of ratios used to determine incident
or refracted angle of sound, denotes angle/velocity
relationship.
• Sweep display: horizontal line on the lower portion of the
display, often called the time base line.
• Through transmission: test technique in which ultrasound is
transmitted from one transducer and received by a separate
transducer on the opposite side of the test specimen.
• Wavelength: the distance that a sound wave travels as it
completes one cycle, normally measured in inches or
millimeters.