Effective application of TOFD method for

weld inspection at the manufacturing stage of

pressure vessels

TOFDPROOF
Contract G6RD-CT-2001-00626
The TOFD procedure – What should
the content be?

Didier FLOTTÉ

TOFDPROOF Seminar, Villepinte 18 March 2005

 The TOFD procedure
What should the content be?

TOFD PROOF Project

page 2 - 18/3/05
 TOFD PROCEDURE – THE CONTENT

• Scope • Interpretation and analysis of

• Reference documents TOFD images

• Personnel requirements • Assessing the quality of the

TOFD images
• Equipment and supplies
• Classification and evaluation
• Datum points of indications
• Extent of scanning • Data storage
• Preparation of examination • Reports
• Testing of parent material • Reference blocks
• Scanning of the weld
IS services,
Sonovation, TWI :
members of the
TC121 ad hoc group

TC 121

TS 14 751

TOFD PROOF Project

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 TOFD PROCEDURE – PERSONNEL REQUIREMENT

a In addition to a general knowledge of ultrasonic weld inspection, all

personnel shall be competent in TOFD inspections. Documented
evidence of their competence (training, experience) is required (no
specific certification up to date).

a Preparation of written test instruction, final off-line analysis of data, and

acceptance of the report shall be performed by personnel certified as a
minimum to level 2 in accordance with EN 473 or equivalent in
ultrasonic testing in the relevant industrial sector.

a Equipment set-up, data acquisition, data storage, and report preparation

shall be performed by personnel certified as a minimum to level 1 in
accordance with EN 473 or equivalent in ultrasonic testing in the relevant
industrial sector.

TOFD PROOF Project

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 TOFD PROCEDURE – EQUIPMENT

ULTRASONIC EQUIPMENT : SCANNING MECHANISM :

¾ comply with the requirements of EN ¾ Imposed by ENV583-6
12668-1, EN 12668-2 and EN12668-3
¾ Can be motorised or not
¾ The requirements of ENV583-6 apply,
taking into account the following:
¾ Can achieved an encoded position with
a resolution of 0.5 mm
o The equipment is able to select an
appropriate portion of the time
base within which A-scans are PROBES :
digitised. ¾ In accordance with ENV583-6 :

o sampling rate of the A-scan of at o Same resonance frequency at ±

least 4 times the nominal probe 20%
frequency. The signal is sampled o Length of the signal less than 2
in 256 levels to construct a 256 period at 10% of max amplitude
grey levels image. (~70% of band size)

TOFD PROOF Project

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 TOFD PROCEDURE – CALIBRATION AND SETTING

Choice of probes and Probe Centre Separation (PCS) - modelling

10 mm / 10 MHz 4
longueur (m m )

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4,

5,

6,

6,

7,

8,

9,

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0
1
2
3 matière
epaisseur (mm)

4 Locus
5 limite du faisceau
6 -20 dB
7 -6 dB
8
9
10

10 mm / 5 MHz longueur (m m ) Modelling of

more than 200 situations
4

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1
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epaisseur (mm)

4 Locus
5 limite du faisceau
6 -20 dB
7 -6 dB
8
9
10

TOFD PROOF Project

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 TOFD PROCEDURE – CALIBRATION AND SETTING

Choice of probes and Probe Centre Separation (PCS)

Number of Centre
Thickness Depth-range Beam-angle Element Beam
TOFD frequency
t / mm ∆t / mm ° mm intersection
set-ups f / MHz

6-10 1 0-t 15 70 2-3 2/3 of t

>10-15 1 0-t 15-10 70 2-3 2/3 of t

>15-35 1 0-t 10-5 70-60 2-6 2/3 of t

>35-50 1 0-t 5-3.5 70-60 3-6 2/3 of t

0-t/2 5-3.5 70-60 3-6 1/3 of t

>50-100 2
5/6 of t for 60°
t/2-t 5-3.5 60-45 6-12
or t for 45º

¾ The maximum allowed frequency should be considered first.

¾ The lower frequencies may be used if the required sensitivity setting cannot be
achieved with the upper frequencies.

TOFD PROOF Project

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 TOFD PROCEDURE – CALIBRATION AND SETTING

Sensitivity setting

¾ The amplitude of the lateral wave is between 40% and 80% full screen
height with noise level less 10% FSH

¾ when no lateral wave, the amplitude of the back wall signal is between
18 dB and 30 dB above FSH.

¾ When the use of neither a lateral wave, nor a back wall signal is
appropriate, sensitivity should be set such that the material grain noise is
between 5% and 10% FSH.

$To limit electronic noise, signal averaging may be used.

TOFD PROOF Project

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 TOFD PROCEDURE – CALIBRATION AND SETTING

Time window
¾ For full thickness examination using only one set-up :
o start at least 1 µs prior to the time of arrival of the lateral wave
o extend up to the first mode converted back wall echo and 1 µs
after

¾ If more than one set-up :

o the time windows shall overlap at least 10% of the depth range.

Scan resolution
¾ Thickness ≤ 10 mm : 0.5 mm
¾ Thickness > 10 mm : ≤ 1 mm

TOFD PROOF Project

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 TOFD PROCEDURE - REFERENCE BLOCKS

¾ Two designs proposed by the TS 14 751 :

o One with side drilled holes and one slot
o One with slots and one side drilled hole
$ we have chosen the reference blocks with side drilled holes

¾ Number of blocks to cover the range 6 mm – 100 mm

o Minimal thickness : the beam crossing point in the reference block
o Maximal thickness : the angle of the beam with the bottom face
greater than 40°
$ 8 blocks necessaries

TOFD PROOF Project

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 TOFD PROCEDURE - REFERENCE BLOCKS

200 mm

Thickness Thickness
Of samples of blocks
6 mm – 12 mm 12 mm
150 15 mm 15 mm
16 mm – 20 mm 20 mm
75 3 mm

50 mm 2 mm
60 mm

25 mm – 25.4 mm 25 mm
35 mm
40 mm 20 mm

1/4 t 30 mm – 40 mm 40 mm
t
1/4 t
Diameter holes: 3 mm +/- 0,5 50 mm – 60 mm 60 mm
1/4 t

1/4 t 75 mm 75 mm
100 mm 100 mm

0.2 mm

2 mm
UT Testpiece
For calibration of

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Step of analysis of TOFD image

¾ Assessing the quality of the TOFD-image
¾ Identification of relevant indications and discrimination of
non-relevant indications from the weld geometry
¾ Classification of remaining indications in terms of:
o embedded (point-like, elongated with a measurable
height or without a measurable height)
o surface breaking
o uncategorised
¾ Determination of location and size (position, length and
through-wall extent)
¾ Evaluation against acceptance criteria

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Quality of TOFD image

Unsatisfactory images may contain:

¾ Coupling losses (drop in, or total loss of amplitude)
¾ Data acquisition errors (e.g. excessive missing or displaced scan lines)
¾ Inappropriate sensitivity setting (gain too low or too high)
¾ Inappropriate time-base setting (incorrect time-window)
¾ Indication not completely in one image.

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Classification of the indication

The indications shall be classified at least in the following categories:

¾ Surface breaking :
o At scanning surface,
o At opposite surface
o Through wall
¾ Embedded indications :
o Point-like
o Elongated with a measurable height
o Elongated without a measurable height
¾ Transverse indications
¾ Uncategorised

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Classification of the indication – surface breaking

¾ Surface breaking at scanning surface shows :
o A weakening, deviation or loss of lateral wave (not always observed)
o An elongated pattern generated by the signal from the lower edge of the
indication or
o A slight shift of lateral wave towards longer time-of-flight (small indication)

¾ Surface breaking at opposite surface shows :

o A weakening, deviation or a loss of the backwall signal (not always observed)
o An elongated pattern generated by the signal emitted from the upper edge of
the indication

¾ Through wall indication shows :

o A loss or weakening of both the lateral wave and the backwall
signal

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Classification of the indication – embedded indication

¾ Point like :
o Pattern characterised by an arc shaped curve fitting with the
theoretical hyperbolic curve corresponding to the depth of the
indication

¾ Elongated with a non measurable height :

o A elongated pattern corresponding to an apparent upper edge
signal (approximately in phase with the backwall)

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Classification of the indication – embedded indication

¾ Elongated with a measurable height :

o Two different elongated patterns located at a different position in
depth, corresponding to the upper and lower edges of the indication

¾ Transverse indication :
o The presence of some mode converted echoes associated with a
point like indication may suggest that transverse defects could be
present.

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Measuring length
¾ Linear indication (depth relatively constant) :
o A hyperbolic cursor is fitted at each o If not possible, the 6dB drop method
extremity ; distance between the cursor shall be used
give the length

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Measuring length

¾ Parabola-like indication (depth not constant) :

o A hyperbolic cursor is positioned at either end of the indication at a time delay of
one third of the indication penetration ; distance between the cursor give the length

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Measuring depth and height

¾ The measurement shall be done :
o On the A-Scan
o After straightening of the position of the lateral wave or the backwall echo

¾ Near surface breaking discontinuity : height determined by measuring the distance

between the near surface and the lower-tip diffraction signal from the indication

¾ Rear surface breaking discontinuity : height determined by measuring the distance

between the rear surface and the upper-tip diffraction signal from the indication

¾ Embedded discontinuity : height determined by the difference in depth between the

upper-tip and lower-tip diffraction. For indications displaying varying depth along their
length, the height is determined at the position along the length of the discontinuity
where the difference is the greatest.

TOFD PROOF Project

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 TOFD PROCEDURE – DATA ANALYSIS

Measuring depth and height

¾ Three methods :
o By measuring the transit timeto the rising signal
o by measuring the transit time to the first maximum
o by measuring the transit time to the peak amplitude

TOFD PROOF Project

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 TOFD PROCEDURE versus TS 14 751

Modification proposed to TS 14 751

¾ Must specify 256 grey level or more

¾ Time windows :
o start at least 1 µs prior to the time of arrival of the lateral wave
o extend up to the first mode converted back wall echo and 1 µs after

¾ Measuring length : add the proposed technique

¾ Measuring height : add the proposed method

TOFD PROOF Project

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EXEMPLES OF ACQUISITION

WHEN MEASURING LENGTH?

TOFD PROOF Project

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EXEMPLES OF ACQUISITION

WHAT IS A SURFACE BREAKING?

TOFD PROOF Project

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EXEMPLES OF ACQUISITION
WHY 1µs AFTER THE CONVERTED MODE ECHO?

TOFD PROOF Project

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 EXEMPLES OF ACQUISITION
WHY CHOSE THE HIGHEST FREQUENCY?

10 MHz

15 MHz

TOFD PROOF Project

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