1.

Module Details
Module name Nominal duration

ULTRASONIC TESTING
3 modules It is anticipated that a learner holding the prescribed entry level skills will achieve the module purpose in 110 to 120 hours

Module Codes Discipline Code

EA613 Non-destructive testing (Code to be allocated) To provide students with knowledge of the principles, procedures and applications of ultrasonic testing, to develop the competency to undertake ultrasonic testing of materials in accordance with the requirements of national and international codes and specifications, and to interpret the results of such tests Nil This module meets the training requirements for Level 2 qualification in ultrasonic testing under AS3998-1992 "Nondestructive Testing - Qualification and Certification of Personnel General Engineering" and AS-3669-1989 "Non-Destructive Testing - Qualification and Registration of Personnel - Aerospace". Currently no national competency standards have been established at national level. However, the learning outcomes in this course relate to ASF level 5-6.

2. Module Purpose

3. Prerequisites 4. Relationship to competency standards

5. Content

Properties and behaviour of ultrasound Fundamental properties - frequency, velocity, wavelength, amplitude Continuous and pulsed waves Modes Velocity/mode/material relationships Acoustic impedance, pressure, energy, intensity Interaction of wavefronts Inverse square law Decibel Behaviour of ultrasound at interfaces Principles of reflection Refraction of ultrasound Mode conversions Calculation of incident and refracted angles Critical angles Mechanisms for detecting defects Characteristics of ultrasound in materials Near and far fields Focussing of ultrasound Secondary waves Attenuation

Generation of ultrasound Types of transducers Properties of piezzo electric materials Energy losses in various media Determination of near and far fields, divergence and beam spread Detection of ultrasound Continuous and pulsed signals Effect of path length Time/distance relationships The flaw detector Function of pulse generator, transmitter, receiver/ amplifier, time base, CRT Function of the various controls Distance/amplitude effects and correction, AGC, gating, interface triggering Types of display Requirements of codes and standards. Linearity, effect of suppression Saturation & amplifier threshold Digital equipment Basic test methods Pulse-echo and transmission methods Resonance methods A, B, C, and P scan. Types of coupling Single, dual and two-probe methods Probes Construction and operation of single and twin crystal normal and angle probes, both fixed and adjustable. Focussed transducers Calibration Types and uses of AS 2083 calibration blocks, and distance/amplitude and area/amplitude blocks and steel balls for immersion testing in accordance with appropriate standards Determination of probe characteristics, measurement of acoustic velocities Plotting beam profiles by contact & immersion methods Variables Instrument performance Variations in test materials Effect of beam incidence Effect of surface condition and curvature. Resolving power/frequency/damping/energy relativity Contact and immersion test methods Setting test sensitivity Surface preparation Couplants Flat and contoured probes Identification of irrelevant signals
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Effect of angle of incidence Surface wave method Tandem techniques Water requirements for immersion testing Interface triggering Through transmission immersion testing Instrumental test methods Automatic recording and computer interfacing Digital & analog presentations Computer interfacing and special recording methods Test applications Thickness testing Weld testing Plate testing Detection of cracks at rivet holes Castings, ferrous and non-ferrous Forgings Austenitic materials Assemblies Bonded materials Non-metallic materials including plastics, ceramics, and concrete Rail testing Flaw size evaluation Material factors Rayleigh criterion DGS curves 6dB and 20dB drop methods Last significant echo Tip diffraction Three dimensional evaluation Interpretation and evaluation Defect types as related to product Codes and standards Recording and reporting Job records. Routine reports. Codes and standards Written procedures Presentation Use of standards Competency based assessment applies. Assessment should be carried out by gathering evidence using a variety of methods or instruments that have validity according to the learning being assessed.

6. Assessment strategy

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Assessment method

Multiple choice and short answer questions. Written assignments and demonstrated competence through assigned tasks. Final assessment will be by a written examination and practical examination as required by AS3998 for Level 2 Certification.

Conditions of assessment

Assessment will be conducted by suitably qualified assessors, as required by AS3998. The candidate will have access to any equipment, materials and documentation as required for the assessment. On completion of this module, the learner will be able to Describe the properties and behaviour of ultrasound 1.1 Describe the fundamental properties of ultrasound, and to determine wavelength/velocity/frequency data for specific situations. 1.2 Describe the different types of waves and how they are transmitted through materials. 1.3 Describe how ultrasound behaves as it travels through a medium, and the changes produced when it strikes, or passes through, an interface and how it interacts with a defect. 1.4 Calculate critical angles and describe the significance of this property. 1.5 Describe the factors that control the near and far fields in ultrasonic testing and determine these values for particular situations. 1.6 Describe the factors that affect attenuation of ultrasonic energy as it passes through a medium, including the generation of secondary waves at interfaces, and measure this attenuation.

Learning outcome details

7. 8. 1 Learning outcome
Assessment criteria

Learning outcome 2
Assessment criteria

Describe how ultrasonic waves are generated and detected. 2.1 Describe and identify the components in the construction of a piezo-electric ultrasonic transducer. 2.2 Explain the operation of a piezo electric transducer.

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Learning outcome 3
Assessment criteria

Describe the function of the principal modules of different types of ultrasonic flaw detectors. 3.1 Describe the function of the various parts and demonstrate how the various controls can be used to calibrate and operate the equipment for optimum performance. 3.2 Describe the various presentations, including automatic recording systems, used in ultrasonic testing and demonstrate their applications and their advantages and limitations. 3.3 Describe the different couplants, including immersion techniques, used for ultrasonic testing and demonstrate their advantages and limitations

Learning outcome 4
Assessment criteria

Calibrate ultrasonic test equipment using standard calibration blocks, and determine system parameters using standard blocks. 4.1 Demonstrate competency in calibrating ultrasonic flaw detection and thickness testing equipment using standard calibration blocks and in accordance with national standards. 4.2 Demonstrate competency in determining system parameters, such as beam spread, using standard blocks. 4.3 Demonstrate how changing system variables can affect system parameters using standard blocks.

Learning outcome 5

Demonstrate proficiency in carrying out ultrasonic testing for flaw detection and thickness testing of various materials in the wrought, cast and/or welded condition. 5.1 Describe the various applications of ultrasonic testing.

Assessment criteria

5.2 Demonstrate competency in setting up, calibrating and testing various materials. 5.3 Describe the various methods for sizing of flaws by ultrasonic methods and demonstrate proficiency in these procedures. 5.4 Interpret ultrasonic test results and identify or describe the types of flaws detected. 5.5 Prepare clear and unambiguous reports on ultrasonic inspection of various materials in accordance with the requirements
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of national and international codes and standards. 5.6 Prepare procedure instructions for the ultrasonic inspection of selected materials or components.

Delivery of the module

7.

This module may be taught by active participation, illustration, demonstration and description. This module is practical in nature and theoretically integrated to complement the acquisition of practical skills. This module will generally be taught and assessed off-the-job. The module has a high practical content. Theory and practice will be taught concurrently. There will be a range of learning activities including modified lectures, practical work and project work.

Delivery strategy

Resource requirements

Human resources trainer/teacher/mentor Physical resources appropriately equipped training room relevant equipment and information legislative and regulatory documents

Major texts and references

RECOMMENDED TEXT Ultrasonic Testing for Technicians, J.C. Drury, Unit Inspection Company, 1983. Ultrasonic Testing - P.A. Sheedy (In preparation - Published by Technical Secretarial Service) PRACTICAL TEXT Practical Ultrasonics - P.A. Sheedy - Technical Secretarial Service, PO Box 188, Forestville NSW, 2087 RECOMMENDED TEXT FOR BACKGROUND READING Ultrasonic Testing, Neasbey & Cheema, NSW TAFECOM REFERENCES Non-Destructive Testing Handbook, 2nd Edition, Vol 7. Ultrasonic Testing. ASNT. 1991

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Ultrasonic Testing Classroom Training Handbook - ASNT. Ultrasonic Testing of Materials, J & H. Krautkramer. SpringerVerlag, 1990. Ultrasonics, Fundamentals, Technology, Applications, D. Ensminger. Marcel Dekker Inc. 1988. Procedures and Recommendations for Ultrasonic Testing of Butt Welds. Welding Institute, 1989. STANDARDS AS 1065 Non-Destructive Testing - Ultrasonic Testing of Carbon and Low Alloy Steel Forgings. AS 1710 Non-Destructive Testing - Ultrasonic Testing of Carbon and Low Alloy Steel Plate - Test Method and Quality Classification. AS 1929 Non-Destructive Testing - Glossary of Terms.

AS 2083 Calibration Blocks and Their Methods of Use in Ultrasonic Testing. AS 2207 Non-Destructive Testing - Ultrasonic Testing of Fusion Welded Joints in Ferritic Steel (under review as DR 92178). AS 2452 Non-Destructive Testing - Determination of Thickness - Use of Ultrasonic Testing. AS 2574 Non-Destructive Testing - Ultrasonic Testing of Steel Castings and Classification of Quality. AS 2824 Non-Destructive Testing - Ultrasonic Methods Evaluation and Quality Classification of Metal Bearing Bonds. Learners and/or employees undertaking this module should have demonstrated competencies as defined in the Metal & Engineering Industry Standards Unit No 1.2F - Apply principles of OH&S in the work environment. This would apply in the classroom, practical room or workplace.

Occupational health and safety requirements

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