ULTRASONIC TESTING (UT) – SKM Level 2 – MC-113-2 – Public Course

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ULTRASONIC TESTING (UT)

Ultrasonic Testing (UT) uses high frequency sound energy to conduct examinations and make measurements. Ultrasonic inspection can be used for flaw detection/evaluation, dimensional measurements, material characterization, and much more. Although there are a number of technologies employing ultrasound, the simplest explanation of what happens in this method is that sound energy is introduced via a transducer and propagates through the materials in the form of waves. When there is a discontinuity (such as a crack) in the wave path, part of the energy will be reflected back from the flaw surface. The reflected wave signal is transformed into an electrical signal by the transducer and is displayed or recorded in a variety of ways. Both surface and subsurface defects can be detected making ultrasonics a volumetric testing method. Applications vary in complexity from very small, hand-held manual units to very large, sophisticated automated systems. This method is used to inspect a variety of product forms including castings, forgings, and weldments. The structural steel, automotive, petrochemical, power generation, and aerospace industries are a few examples that utilize ultrasonic inspection.

COURSE DESCRIPTION

A Course for those who already have basic understanding of the techniques of ultrasonic inspection and are wanting intensive instruction to improve their knowledge and increase their experience. The course is suitable for candidates who are wishing to progress towards any of the examination qualification. The course has a high practical content, all equipment is provided.

WHO SHOULD ATTEND

This course is opened to all participants, in particular NDT personnel, supervisors, NDT trainers, contractors and researchers and those who are interested in Ultrasonic Testing technique.

COURSE CONTENTS :

Prerequisite for this Class is Level I Ultrasonics

SCOPE

This course introduces the basic principles of ultrasonics and prepares the candidate for Angle Beam Inspections.

This course prepares a candidate to
• Select equipment to conduct test
• Set Equipment
• Steps to conduct test
•Calibration
• Familiarize with codes and standards
• Interpret results with respect to applicable codes and standards
• Understand limitation of the test method
• Write test reports.

MODULE 1: MANUFACTURING DISCONTINUITIES
• Types of Discontinuities: Inherent, Processing and Service
• Casting Discontinuities: Hot Tear, Cold Shut, Porosity, Shrinkage
• Primary Processing Discontinuities including discontinuities in Rolling,
Forging, Drawing, Extruding
• Secondary Processing Discontinuities including discontinuities in Grinding,
Heat Treating, Machining, Welding, Plating
• Service Discontinuities:- Erosion, Wear, Fatigue, Corrosion, Creep

MODULE 2: WAVE MODES (Covered in Level I Training)

MODULE 3: ACOUSTIC IMPEDANCE (Covered in Level I Training)

MODULE 4: REFRACTION AND REFLECTION (Covered in Level I and II)
• Reflection and Refraction
• Snell’s Law
• Mode Conversion
• First and Second Critical Angle
• Creeping Waves
• Problems on Mode Conversion

MODULE 5: PIEZOELECTRIC TRANSDUCER (Covered in Level I Training)

MODULE 6: PULSER RECEIVER
• Calibration of Ultrasonic Equipment – Time and Amplitude Linearity
• All other Topics Covered in Level I Training

MODULE 7: ATTENUATION (Covered in Level I Training)

MODULE 8: THICKNESS MEASUREMENT (Covered in Level I Training)

MODULE 9: IMMERSION TESTING (Covered in Level I Training)

MODULE 10: FLAW DETECTION – 0 DEGREE (Covered in Level I Training)

MODULE 11: CALIBRATION BLOCKS
• IIW Block Type I
• IIW Block Type II
• Miniature Angle Beam / Rompass Block
• DSC Block
• AWS Resolution Block
• Step Wedge
• Area-Amplitude Block
• Distance-Amplitude Block

MODULE 12: ANGLE BEAM INSPECTION
• Selection of Screen Range
• Measurement of Beam Exit Point
• Measurement of Actual Refracted Angle
• Calibration using IIW, Rompass and DSC Block
• Sensitivity and Resolution
• Reference Amplitude
• Distance Amplitude Correction (DAC) Curve
• Time Corrected Gain (TCG)
• Discontinuity Length Sizing using 6 dB and 20 dB drop method
• Discontinuity Evaluation
• Selection of Screen Range
• Surface Distance, Skip Distance, Depth, Full V Path
• Plotting of Discontinuities like Crack, Lack of Fusion, Lack of Penetration, Slag, Porosity in welds
• Worksheet: Plotting of discontinuities for butt welds

MODULE 13: WRITING AN ULTRASONIC PROCEDURE
• ASME Section V
• Essential Variables
• Non Essential Variables

MODULE 14: CODES AND STANDARDS
• ASME Section V, Article 4 Weld Examination
• AWS D1.1/ASME VIII Div. 1 (Option)
• Additional Codes Standards as per student’s requirements (please discuss this at the time of registration)

INTRODUCTION TO ADVANCED TECHNIQUES
• Time of Flight Diffraction
• Phased Arrays

PRACTICALS
Shear Wave Testing on Pipe Samples with embedded weld defects – ID Cracks, OD Cracks, Slag, Porosity, Lack of Fusion, Lack of Penetration

EXAMINATIONS
• General
• Specific
• Practical
• Candidates must score a minimum of 70 % in each test