Unit- 5

ULTRASONIC TESTING (UT)

1. INTRODUCTION:

The sound range above 20 KHZ (or) 20,000HZ is called as an ULTRASONIC

SOUND (or) ULTRASOUND.

SOUND CLASSIFICATION:

Subsonic < 16HZ

Sonic - 16HZ – 20KHZ

Ultrasonic > 20,000 HZ

 The sound energy is introduced & propagates through the materials in the form of

waves.

 Whenever the sound waves meet another interface of different acoustic impedance

part of energy will be reflected back.

 The same occurs when it meets cracks, lamination or any other discontinuities.

 Sound generated above 20,000 HZ is called Ultrasound.

 The reflected wave signal is transformed into electrical signal by the transducer &

is displayed on a screen.

2. PROCEDURE:

ASME Sec V Article: 4 (Weld) &

Article: 5 (Raw Materials).
3. PRINCIPLE:

Acoustic Impedance mismatch

↓ ↓
Sound Resistance of material.

4. Generation of ultrasonic sound energy:

Sound is created when something vibrates.

Short pulse
( < 1 µs )

ULTRA SOUND
5. ULTRASONIC TRANSDUCERS:

It converts Electrical Energy into ultrasonic energy by utilizing a phenomenon

known as the PIEZOELECTRIC EFFECT.

Electrical Piezoelectrical crystal Ultrasonic wave

energy

6. CRYSTAL MATERIAL:

1. Quartz or Silicon oxide (SiO3)

2. Lithium sulphate (LiSo4)

3. Lead Zirconate (Pb Zr O3)

4. Lead Zirconate Titanate (Pb Z1 O3 T1 O3)

5. Barium Titanate (Ba Ti O3)

7. CABLE:

1) Lemo cable.

2) BNC.

8. FUNDAMENTALS OF WAVE:
a) WAVE LENGTH: ( λ)

The distance covered by one complete cycle.

λ =ν/f

v- Velocity f - Frequency

Shorter λ - Less penetration & Smaller flaws can be detected.

Larger λ - More penetration & larger flaws can be detected.

b) FREQUENCY:

No of cycles per sec

Unit: HZ or CPS.

c) AMPLITUDE:
 Max displacement of the molecules from their equilibrium position.

d) VELOCITY:

It is the rate at which the sound energy is transmitted in a medium.

9. PROPAGATION OF SOUND:

Crystal Focus Angle of divergence

Accoustical axis
6
D0

N
Near field Far field

DEAD ZONE:

Seen on the CRT as an extension of the initial pulse the DZ is the ringing time of the

crystal & it is minimized by the damping medium behind the crystal.

NEAR ZONE:

In this region, the sound intensity is variable owing to wave interference;

therefore flaws lying in this zone may appear smaller or larger than their actual size.

N=D^2/4λ

D- Diameter of crystal

λ – Wavelength of sound

FAR ZONE:
 Beyond the near zone the far zone exists, in this region the beam divergence occurs,

resulting in delay in the sound intensity as the distance from the crystal increased.

10. MODES OF PROPAGATION /TYPES OF WAVES:

1. Longitudinal or Compression waves.

2. Shear or Transverse.

3. Surface or Raleigh waves.

4. Plate or Lamb.

10.1

LONGITUDINAL WAVES:

This type of wave is produced by normal or T/R Probe.

The direction of propagation of the produced sound is parallel to the particle of motion.

It propagates in solid, liquid & gases. Depth of penetration will be high.

10.2 SHEAR WAVES:

This type of wave is produced by Angle Probe only.

The direction of propagation is perpendicular to particle of motion.

 Propagates only in solid.

Depth of penetration is ½ (half) of longitudinal waves.

11. TYPES OF PROBES:

a. Normal probe.

b. T/R Probe.

c. Angle Probe.

socke Delay / protecting

tcrysta face
Electrical
lDampin matching
Cable
g

Straight beam probe TR-probe Angle beam probe

11.a NORMAL PROBE:

 Used for monitor raw material discontinuity.

 Dead zone will be high in normal probe.

11.b T/R PROBE:

 Dead zone less than 2mm.

 Used to measure thickness of the job.

 Used to monitor corrosion, erosion & pitting.

 T-R Probe has better near surface resolution by increasing roof angles (5 to 12

degree)

11.c ANGLE PROBE:

 45 degree,60 degree, 70 degree

 Used for welded jobs.

12. FACTORS AFFECTING THE PROPAGATION OF ULTRASOUND:

General :

Dependent on the density & Elastic properties of that materials & types of waves

transmitted.

Factors:

 Test materials grain size.

 Attenuation
 Acoustic impedance of the test material.

13. Total Attenuation Loss:

Attenuation is defined as the loss in intensity of the ultrasonic beam.

2 main causes for attenuation are,

 Scattering & Absorption.

14. Acoustic Impedance:

Z is the resistance of a material to passage of ultra sound.

Z= e*v e- Density / v- Velocity.

15. SNELL’S LAW:

Sin ө1/Sin ө2 = V1/V2

ө1 – Angle of incident.

ө2 – Angle of refraction.

V1 – Angle of incident.

V2 – Angle of refraction.

16. DECIBEL: (DB)

DB is a logarithmic base unit to compare sound intensities.

DB = 20 log 11 H1/H2.
 H1 = 100%

17. COUPLANT:

Exclude any air that may be present b/w probe & test surface.

E.g.: water, oil, grease, polycell & glycerin.

Air – High acoustic impedance.

18. PROBE SELECTION:

EFFECT OF FREQUENCY:

SL NO LOW FREQUENCY HIGH FREQUENCY

1 Wave length Shorter wave length

19. TYPES OF
2 More beam spread Less beam spread TESTING:

3 Better penetrant Shorter penetrant 1. Pulse

4 Shorter near zone Longer near zone echo

5 Less attenuation More attenuation

6 Less sensitivity Higher sensitivity
7 Longer dead zone Shorter dead zone
technique.
2. Through transmission technique.
3. Reasonance technique.

20. ULTRASONIC FLOW DETECTORS:

UT equipment basically comprises of

 (ULTRA SOUND) Pulse generator.

  Receiver & its amplification.
 Display system.

amplifier

screen
IP horizontal
BE sweep

clock

pulser
probe

work piece

Depending on the display of information, pulse echo equipments divided into

1. A – Scan = Depth in X- axis & Amplitude in Y- axis

2. B – Scan = C.S view / Side view of material being tested
3. C – Scan = Plan view /Top view of being tested.

A – Scan :
B- Scan:

C – Scan:
21. CALIBRATION BLOCK

1. V1 Block (or) I.I.W V1 Block.

2. V2 Block (or) I.I.W V2 Block.

1. Calibration block:

Used to determine the operating characteristics of the flow detectors & probes.

2. Reference block:

Used to set the sensitivity level of the equipment for particular application.

1. V1 Blocks or IIW (V1)

IIW – INTERNATIONAL INSTITUTE OF WELDING

a. Resolution Check:

By this check we are able to conclude that the probe is capable of identifying
two or more defects at the same location.

b. Penetration Check:

By penetration check we can conclude that the probe can able to identify the
given range for any job.

c. Sensitivity Check:

It can conclude that the probe can able to identify even smallest defect.

2. V2 Blocks or IIW (V2)

Aiming towards 25mm radius:

Signals occurs at 25mm , 100mm , 175mm , 250mm, 325mm, 400mm.

Aiming towards 50mm radius:

Signals occur at 50mm, 125mm, 200mm, 275mm, 350mm, 425mm.

22. REFERENCE TEST BLOCK

1. DAC Block.
2. Flat Bottom Block.

1. DAC – Distance Amplitude correction curve.

BLOCK HOLE TEST

THICK DIA RANGE

19mm 2.4 Up to 25mm

38mm 3.2 25-50mm

75mm 4.8 50-102mm

23. UT FORMULAS
 1. Probe selection:

ө = 90(degree) - T (Thickness of job)

Generally:

1. 5-25mm = 70 degree
2. 25-50mm = 60 degree
3. Above 50mm = 45degree

2. Beam path (W):

W or B.P = T/Cosө

3. Skip distance:

S.D = T * Tan ө (or) S.D = B.P * Sin ө

19mm Block: Hole Depth:

Hole Dia – 2.4 1/4= 4.75

Length – 200mm ½= 9.50

Width – 80mm ¾= 14.25

Thickness – 19mm 1= 19

BEAM PATH BEAM PATH BEAM PATH

45 60 70
HOLE DEPTH (degree) (degree) (degree)
 1/4 4.5 mm 6.7 9.5 13.8

1/2 9.50 mm 13.4 19 27.7

3/4 14.25 mm 20.1 28.5 41.6

1 19 mm 26.8 38 55.5

24. MATERIAL VELOSITY

SL MATERIAL ANGLE NORMAL PROBE

NO PROBE
1 Al 3130 6320

2 Brass 2120 4430

25.
3 Cast iron 2200 5300

4 Perspex 1430 2730

5 Steel 3250 5920

6 S.S 3130 5740

ADVANTAGES:

1. Portable – Inexpensive.

2. Immediate result.
 3. Wide range of material thickness can be inspected.

26. DISADVANTAGES:

1. High degree of skill required.

2. Materials are rough, irregular in shape are difficult to inspect.

3. Surface must be accessible to transmit ultra sound.

4. Linear defect – undetected.

5. Calibration needed.