ULTRASONIC TESTING

1) PRINCIPLE : The most common technique used in ultrasonic testing is the

PULSE ECHO TECHNIQUE. Sound waves travel in a straight line and are reflected
by an obstacles placed in their path.
The mechanism is just the same as audible sound waves bouncing back of a bric
and an echo being received. The strength of the echo is controled by the size of the wall.
If the time lapse between sending & receiving the sound is measured , it is possible to determine
the distance of the wall.

2) THE NATURE OF SOUND: a) Sound is caused by the mechanical Vibration.

b) SOUND CAN NOT TRAVEL IN A VACCUM
c) The particles (molecules) within the medium vibrate passing on energy from one to another giving
the effect of sound movement through the material.
d) The ability to support sound depends upon the Elasticity & Density of the medium.
e) Some material will pass sound more easily than others.

wave length
Amplitude

One Cycle

a) VELOCITY - The distance moved in unit time

b) WAVELENGTH - The distance between successive peaks of a wave
c) PERIOD - The time taken for one complete cycle
d) FREQUENCY - The number of cycles per second
e) 1cycle per second = 1 Hertz (Hz)
f) 1 KHz = 1000 Hz
g) 1 MHz = 1,000,000 Hz

Velocity
v
Wave Length = OR =
Frequency f

The minium detectable size in UT =

2
V=5960 mtr/sec (Iron)
Wave Length = or wave Length = 2.98 mm (3mm)
f =2 MHz

wave Length =3 or The minium detectable size in UT is = 1.5 mm

2
 frequency (f) high, & Low wave Length = High sensitivity & High scattering

frequency (f) Low, & High wave Length = Low sensitivity & High Penetration

Acoustic Impedance Mismatch

Sound Resistance Difference

A, B, C Three Position Checking

Normal Probe

Initial Pulse
Transmitting
Sound Screen

B C Screen

JOB A A BWE B DE BWE

Receiving (Back Wall Echo) (Defect Echo)
Sound

3) ADVANTAGE OF ULTRASONIC : Initial Pulse

a) Protable Kit used
b) Instant Result in Display Monitor Screen
c) Single side Access OR One side checking possible
d) All Metals & Non - Metals can be checked

4) DISADVANTAGE OF ULTRASONIC : C DE
(Defect Echo)
a) No Permanent Record Available
b) Detection of Surface Defect is not possible

5) ULTRASONIC SOUND :
a) Frequency Less than 20 Hz is called - Infrasonic Sound
b) Frequency more than 20,000 Hz is called - Ultrasonic Sound
c) Frequency 20 Hz to 20,000 Hz is called - Sonic which is Audiable Sound

6) TYPES OF WAVES :
a) Longitudinal Waves OR Compression Waves
b) Sheer Waves OR Tranverse Waves
c) Surface Waves OR Rayleish Waves
d) Lamp Waves OR Plate Waves

LONGITUDINAL WAVES - ( Normal Probe )

 a) Sound is passing through the specimen in form of mechanical vibration
b) Praticle vibration will be able to parallel to wave propagation
c) High wave Velocity
d) It Travels through Liquid only
e) Upto 5000mm Job thickness checking is possible

Vibration Wave Propagation

Sound
SHEAR WAVE OR TRANVERSE WAVE - ( Angle Probe )

a) Particle Vibration will be able to perpendicular to wave propagation

b) Velocity will be 50% of Longitudinal wave
c) Upto 250mm Job thickness checking is possible
d) Checking done for - Pipe welding or Any welding joint
Wave Propagation
Longitudinal wave (LW)

Sound Shear Wave (SW)

Vibration
SURFACE WAVE OR RAYLEISH WAVES

a) Its maximum penetration will be 1 (wavelength) SW

b) Its velocity will be 90% of shear wave 45% of LW LW
c) It follows Elliptical orbit on its path

LAMP WAVES OR PLATE WAVES

a) It is used to check thin sheet OR plates

b) Its velocity changes w.r.t thickness & frequency Symmetrical
c) It follows symmetrical & Asymmetrical path

FOR HIGH THICKNESS JOB LOW FREQUENCY Asymmetrical

(2MHZ) PROBE IS USED

7) ATTENUATION : Attenuation is defined as the loss of Intensity of the

Ultrasonic Beamas it passes through a material and
is depandant upon the physical properties of the material.

Thre Main Causes of Attenuation -

a) Absorbing Energy
 b) Scattering Energy
c) Friction Loss & Heat Loss

8) COUPLANT : It is used to exclude Air between probe and job.

common couplants -
a) Water b) Oil c) Greas d) Glyce e) Polycell
mostly used
Wall paper paste strach

IDEAL COUPLANT - Whose Acoustic impedance matches both probe and job

ACOUSTIC IMPEDANCE - Acoustic impedance (Z) is the resistance of a material to the

passage of the ultra sound .It is the product of the material density (ρ) and sound velocity (v).

Z=ρXv

ACOUSTIC IMPEDANCE FOR Crystal Quartz = 15.2 & for Steel = 46.8

EFFECT OF ACOUSTIC IMPEDANCE - Incident Sound

Z1 = Acoustic Impedance of 1st medium (Perpex)

Z2 = Acoustic Impedance of 2 nd medium (Steel)

Interface

% of Reflection

(Z1-Z2) ^2
(Z1+Z2) ^2 100 Transmitted sound

(3.2 - 46.5) ^2
(3.2 + 46.5) ^2 100
% Reflecton + % Transmission = 100 %
75.90%
(=75.90 % + 24.09 %)
% of Transmission

4xZ1 X Z2 Initial Face = Either (Perpex or Oil Medium)

(Z1 + Z2) ^2 100

4 X 3.2 X 46.5
(3.2 + 46.5) ^2 100
 24.09%

9) SNELL'S LAW : ANGLE OF INCIDENCE = ANGLE OF REFLECTION

But angle of refraction changes w.r.t 2nd medium velocity

θi θR
Incident
Sin i V1 M1
sin r = V2
M2
Sin i = Angle of Incidence r
Sin r = Angle of Refraction
V 1 = Velocity of 1st Medium 60° Probe
V2 = V elocity of 2nd Medium (LW)
47.5°
Connection point M1 = perpex

60 °
Job = Steel = M2 (medium-2)
Perpex
Sin i V1 OR Sin i 2740 = 0.84
sin r = V2 sin r = 3240
Steel
OR Sin i = 0.87xSin 60

OR Sin I = 0.67 OR i = Sin -1 0.67

OR i = 47.5 °

Sin 47.5° 2740

sin r = 3130

Sin r = 0.78 r = Sin -1 0.78

r = 57°

Calculate For 45° Brass

70° Molybdenum

BRASS -- 45° Perpex

Sin i V1 OR Sin i 2740 = 0.84
sin r = V2 sin 45 = 3240
Steel
OR Sin i = 0.87xSin 45

OR Sin i = 0.54 OR i = Sin -1 0.54

OR i = 36 °
 Sin 36° 2740
sin r = 2100

Sin 36° OR r = Sin -1 0.45 = 26.88°

Sin r =
1.3 r = 57°

MOLY -- 45° Perpex

Sin i V1 OR Sin i 2740 = 0.84
sin r = V2 sin 70 = 3240
Steel
OR Sin i = 0.87xSin 70

OR Sin i = 0.79 OR i = Sin -1 0.79

OR i = 52.56 °

Sin 52.56° 2740

sin r = 3350

Sin 52.56° OR r = Sin -1 0.97 = 76°

Sin r =
0.817 r = 57°

MODE CONVERSION & CRITICAL ANGLES :

mode conversion Splitting of sound beam into two when it enters into two
When it enters into 2nd medium at an Angle other than
normal , out of these first wave will be (LW)
θ followed by shear wave (SW)
Incident
M1 LW

M2 θ
1st C.A SW

1st Critical Angle at which LW

comes to the Surface θ2

LW
θ
Incident Incident
M1 SW
Surface Wave
M2
2nd C.A

The incident angle at which total refletion of LW occurs and SW

 comes to the surface.
All our probes has been designed to work in between 1st C.A & 2nd C. A.

10) TECHNIQUE : Probe

a) Pulse Echo contact Test
Job

b) Through Transmission
Transmitter

Job

c) Immersion Technique
Receiver

d) Wheels Transducer

ADVANTAGE :
a) All emagulations are possible
b) Dectection of surface defects is also possible
c) No need extra couplant

DISADVANTAGE : WPD = Water Path Difference

a) More setup time = 1/4 + 1/4"

Sound will be 4 times more

in water

FSE DE BWE
FSE = Front Surface Echo
DE = Defect Echo
BWE = Back Wall Echo

11) EQUIPMENT & CONTROLS :

UFD : ultrasonic Flow Detector

UTM : Ultrasonic Thickness Meter

a) Pulser : Activation of Probe

b) Timer : Penetration of Sound w. r. t. time
c) Clock : PRF ( Pulse repetion frequency )
Maker : Gate
Synchronizer : (1+2+3)
 Transmitter & Receiver : Transmitting & Receiving Energy
CRT : Cathode Ray Tube

12) CRT : Focusing Coil

Phosphorus Coating

e e e

lectron Gun

X- Plate Y- Plate

DISPLAY :
A - Scan FSH - Full Screen Height
B - Scan Top View Or Plan View
C - Scan Z
Y Cross Sectio View
Y

X
Amplitude X
Time / Distance B - Scan no such Use

A - Scan
For Industrial Use

C - Scan for Medical Use

13) BLOCKS : BLOCKS

Calibration
Blocks

DAC = Distance Amplitude Curve Correction

V1 = I I W (International institute Of Welding)
Area Amplitude Block (Aloca - "A" Series )
V 2 = Miniature Angle Beam Block
Steep Wedge for T/ R Probe Calibration

1.5 mm 23 T - Thickness of Crystal

Dia 50mm

85 mm 25 R
10 mm 100 mm 91mm
15 mm
 Dia 1.5 mm
Focal Point
V1 - Block ( Normal Probe)
25 mm Thickness Block

Normal Probe Maximum 5000 mm checking possible

T R Probe Maximum 20 mm checking possible
No Initial Echo
Calibration Block Steep Edge

Range 50
CRT = 50 = 1 div

14) ANGLE PROBE 60° : FOR DIGITAL M/C CALIBRATION

CRT MONITOR 50 DIVISION

RANGE 100 FOR 2 ECHO

25 R Side
100
50 = 2 Division

R 25
2 = 12.5 1st Echo

R 25+75 [ (R25+R50) =75 = constant]

2 = 50 2nd Echo

RANGE 200 FOR 3 ECHOS

25 R Side
200
50 = 4 Division

R 25
4 = 6.25 1st Echo

R 25+75 [ (R25+R50) =75 = constant]

4 = 25 2nd Echo

R 25+75+75
4 = 43.75 3rd Echo

RANGE 200 FOR 2 ECHOS

 50 R Side Opposite side Probe
200
50 = 4 Division

R 50
4 = 12.3
1st Echo

R 50+75 125 [ (R25+R50) =75 = constant]

4 = 4 = 31.3 2nd Echo

R 25+75+75
4 = 43.75 3rd Echo

15 ) REFERENE BLOCKS :

ALOCA - 'A' - SERIES - 8 BLOCKS

1/ 64" 2 / 64"
8 / 64"
ALOCA - 'B' - SERIES

dia 1/ 64" dia 2 / 64" dia 8 / 64"

Difference between front surface and back surface of the artificial discontinuities

MPD Metal Path Difference

Normal Probe

Mock up pieces

FBH - Flat Bottom Hole

MSD = Main Scale Division

SSD = Small Scale Division

FOR V2 BLOCK
 CRT R25 = 25 , 100 , 175
R50 = 50 , 125 , 200
Suppose Range = 200
Suppose Range = 300
200
MSD =
10 = 20 300
MSD =
10 = 30
20
SSD = =4
5 30
SSD = =6
5

DAC Distance Amplitude Curve

t /4
28.5mm 9.5 mm t/2
38mm
19 mm
3/4 t

Skip Distance = t x tanθ

= 9.5 x tan 70° = 11 mm

= 19 x tan 70° = 22 mm

= 28 x tan 70° = 33 mm

Beam Path = t / cos θ 9.5

= cos 70° = 7.6 = 80%

19
= cos 70° = 15.2

28.5
= cos 70° = 23

16 ) NEAR FIELD FAR FIELD BEAM SPREAD :

FACTORS LOOSE TO SURFACE DEFECTS -

1) DEAD ZONE Normal Probe Crystal

 2) NEAR FIELD
3) TEST RECOVERY TIME

1) 48mm

Initial Pulse

Dead Zone JOB

Dead Zone = Only Initial Pulse No other Echo

D2 f 24x24x2x10 6
= = = 48 mm
2) Near Field 4V 4x6000x 10 3
Dead Zone
D = dia of the Probe = 24
f = Frequency = 2 MHz
V = Velocity of Material (Steel ) = 6000 m/sec

Crystal
Near Field
N . Zone
BEAM SPREAD

1.22 V 1.22 x 6000 x 10 3 1.22

= =
SIN θ = 2 x 10 6 x 24 8
FD

D = dia of the Probe = 24 1.22

f = Frequency = 2 MHz SIN θ = = 0.15
8

θ = Sin -1 0.15 = 8.7°

2θ = 8.7° x 2 = 17.4 °

17 ) PROBES , TRANSDUCER , SENSOR, SEARCH UNIT :

Probes : Converts one from of energy into another from of energy

Electrical Energy to Sound Energy

Piezo Electriucal Effect ( Means Conversion of Energy )

Types of Probes
1) Single Crystal Normal Probe
2) Single Crystal Angle Probe
 3) Twin Crystal Angle Probe

Special Probes
1) High Temperature Probe
2) Water Proof Transducer Damping Area
3) Crystal Mosaic Transducer
4) Paint Brush Transducer

1) Single Crystal Normal Probe

PRF : Pulse Repition Frequency

No of times crystal vibration in one sound

Damping Area To Arrest crystal from continuous Vibration

T/R Probe Transmitter + Receiver

Dual Probe Transmitter

By T/R Probe - - upto 20 mm scann
Possible practically
50 mm Possible by Theoritically
Receiver
< 7°
Angle Probe : Crystal
Damping Area

Perspex

Used For Welding Inspection

Special Probes : Perpex

High Temperature Probe
Clan Non Metalic
Cement
Silica

Water Proof Transducer : Under Water Inspection

Crystal Mosaic Transducer :

Paint Brush Transducer : For Painted Material Like Roof Truss etc.

ACCESSORIES USED IN PROBES

Perpex - shoe
 Concave Convex

Lenses - Glasses

Cylindrical Spherical

Converge Diverge

Focal Point

s
sonic testing is the
aight line and are reflected

aves bouncing back of a brick wall

by the size of the wall.
ed , it is possible to determine

ical Vibration.

energy from one to another giving

ity of the medium.

Time/Distance

Lambda

8 mm (3mm)
 BWE
(Defect Echo)

(Defect Echo)

iable Sound
 Vibration

l wave (LW)

surface wave

Symmetrical

Asymmetrical

ensity of the
erial and
of the material.
 matches both probe and job.

sistance of a material to the

(ρ) and sound velocity (v).

Incident Sound

Reflected Sound

Perpex = M1
Initial Face

Refracted Sound

Steel =M2

Transmitted sound
 Reflected
M1
Interface
M2

Refraction

M1 = perpex

(SW)
when it enters into two
at an Angle other than

M1
Interface
M2
θ1 LW
Refraction
SW

24°
θ
57°
M1 LW

M2
85°

35°
 Water

ater Path Difference

 Top View Or Plan View

Swep Line

C - Scan for Medical Use

Reference
Blocks

stance Amplitude Curve Correction

plitude Block (Aloca - "A" Series )

( Aloca - "B" Series )

Index Point

25 R
50 R
 V2 - Block ( Angle Probe )

Focal Point

10
9
8
7
6
5
4
3
2
1

STEEP WEDGE
Used For T R Probe Calibration

50) =75 = constant]

50) =75 = constant]

 [ (R25+R50) =75 = constant]

iscontinuities

SDH - Side Drilled Hole

ain Scale Division

mall Scale Division

Far Field

Primary Beam

8.7 °

17.4 °

Secondary lobs
 Crystal

By T/R Probe - - upto 20 mm scanning

Possible practically
50 mm Possible by Theoritically