Download as pdf or txt
Download as pdf or txt
You are on page 1of 313

Radiographic testing (RT)

Welds
NDT20

Copyright © TWI Ltd


Course Objectives

 To explain the basic theory of X- and gamma radiography.


 To select film type and energy levels, select and prepare
techniques for a given specimen.
 To state the theory of film processing and carry out practical
dark-room work.
 To have a working knowledge of basic radiation safety.
 To plot and evaluate film characteristics (sensitometry).
 To recognise film faults.
 To meet the syllabus requirements for CSWIP/PCN Level 2.

Copyright © TWI Ltd


Part 1: Theory
Covering pages 1-15 of your notes

Copyright © TWI Ltd


History of Radiography

W C Roentgen
1895

 Discovered X-rays during


another experiments with
tube containing an anode
and cathode.
 The material around tube
fluoresced and nearby
photographic plates
fogged.

Copyright © TWI Ltd


History of Radiography

Henri Becquerel
1896

 Discovered gamma-rays
whilst working with
fluorescent minerals. After
storing a uranium
compound in his drawer
with some photographic
plates he discovered were
fogged.

Copyright © TWI Ltd


History of Radiography

Marie Curie
1898

 Discovered the radioactive


sources Polonium and
Radium. Radium was the
first gamma source used
for industrial radiography.
 In 1946 man-made sources
were produced including
Cobalt and Iridium.

Copyright © TWI Ltd


History of Radiography

William Coolidge
1920’s

 Invented the X-ray tube


as we know it today
which revolutionised
industrial radiography.

 He was awarded 83
patents due to his
invention.

Copyright © TWI Ltd


History of Radiography

First radiograph 22 December 1895.


Sent to Physicist Franz Exner in
Vienna. (Mrs. Roentgen's hand.)

First x-ray tube belonging


to Roentgen in 1896.

Copyright © TWI Ltd


Radiographic Inspection

 X-rays are capable of passing straight through


a solid object.
 The amount of X-radiation that passes through
a given object depends on the density and
thickness of the object.
 Transmitted X-radiation can be detected by
photographic film or fluorescent screens.
 This forms the basis of radiographic
inspection, a powerful technique which is
applicable to virtually all materials.

Copyright © TWI Ltd


Radiographic Inspection

Copyright © TWI Ltd


Advantages of Radiography

 Directly produces a permanent record.


 Capable of detecting internal flaws.
 Useful for the non-destructive testing of
virtually all materials and product forms.
 Real-time imaging is possible in some
applications.

Copyright © TWI Ltd


Disadvantages of Radiography

 Radiation hazard.
 Sensitivity is affected by defect orientation.
 Limited ability to detect fine cracks and other
planar defects.
 Access to two sides is required.
 Limited by material thickness.
 Skilled interpretation is required.
 Relatively slow.
 High capital outlay and running costs.

Copyright © TWI Ltd


What is radiation?

 Radiation
 Radio waves, light, X-rays, g-rays and other
forms of radiation take the form of waves of
energy associated with electrical and magnetic
fields which are at right angles to each other
and the direction of propagation.

 Electromagnetic radiation
 Electromagnetic radiation has no mass and is
not affected by magnetic or electrical fields
nor to any great extent by gravity.

Copyright © TWI Ltd


Electromagnetic Spectrum

Copyright © TWI Ltd


Wavelength v Photon Energy

Copyright © TWI Ltd


Shorter Wavelength = Increased Energy

V

f
V  2.997 x10 m / sec
8

E = hf
Where h is planks constant
(= 6.626196 x 10-34Js)

Copyright © TWI Ltd


Properties of Electromagnetic
Radiation
 Travels at the speed of light.
 Travels through a vacuum.
 Travels in a straight line.
 No electrical charge or mass.
 Intensity proportional to 1/D² where D is the
distance from the source.

Copyright © TWI Ltd


Inverse Square Law

D1

D2

Copyright © TWI Ltd


Properties of Electromagnetic
Radiation
 X and gamma rays
 Absorbed and scattered by matter.
 Not refracted by matter.
 Cause ionisation referred to as ionising
radiation.
 Will darken photographic film emulsion and
will cause some materials to fluoresce in the
visible or ultraviolet spectrum.
 Cannot be detected by human senses.
 Extremely hazardous to health.

Copyright © TWI Ltd


Atomic Structure

 Atoms are thought to consist of a positively


charged nucleus surrounded by one or more
negatively charged electrons that orbit the
nucleus.
 The nucleus consists of positively charged
particles called protons and electrically neutral
particles called neutrons.
 A neutron can be thought of as a proton
closely combined with an electron.

Copyright © TWI Ltd


Atomic Structure

 Protons have positive charge and by definition


an atomic mass of 1.
 Neutrons have no electrical charge, atomic
mass very slightly greater than 1.
 Electrons have negative charge equal in
magnitude to that of a proton but are very
much smaller at a mass of 1/1836 of a proton.
 Number protons equal number electrons,
usually!

Copyright © TWI Ltd


Atomic Structure

The nucleus of the atom is made up of protons and


neutrons. The electrons orbits the nucleus.

Proton: Positive charge.

Neutron: No charge.
Electron: Negative charge.

A neutron can be
thought of as a
proton(+) with an
electron(-) tightly
attached.

Copyright © TWI Ltd


Atomic Structure

HYDROGEN

1 PROTON

1 ELECTRON

No charge

Copyright © TWI Ltd


Atomic Structure

Helium Atom

2 PROTONS

2 ELECTRON

2 NEUTRONS
Positive charge: Ionisation has occurred

Copyright © TWI Ltd


Atomic Structure

LITHIUM

3 PROTONS
3 ELECTRONS
4 NEUTRONS

Copyright © TWI Ltd


Atomic Structure

BERYLIUM

4 PROTONS

4 ELECTRONS

5 NEUTRONS

Copyright © TWI Ltd


Atomic Structure

Copyright © TWI Ltd


Atomic Structure: Hydrogen

Copyright © TWI Ltd


Atomic Structure: Helium

Copyright © TWI Ltd


Atomic Structure

Copyright © TWI Ltd


Atomic Structure

Copyright © TWI Ltd


Isotopes

 Atoms of an element having the same atomic


number but different atomic mass.
 The difference in atomic mass is due to a
difference in the number of neutrons in the
nucleus.
 Some isotopes are stable while others are
unstable.

Copyright © TWI Ltd


Isotopes of Hydrogen

DEUTERIUM

1 PROTON

1 NEUTRON

1 ELECTRON

Copyright © TWI Ltd


Deuterium

Copyright © TWI Ltd


Isotopes of Hydrogen

TRITIUM

1 PROTON
Isotopes of Hydrogen

2 NEUTRONS

1 ELECTRON

Copyright © TWI Ltd


Tritium

Copyright © TWI Ltd


Radioactive Isotopes

 Some isotopes are stable, others are not.


 Unstable isotopes transform into another
element and in so doing emit radiation.
 Three forms of radiation:
1. Alpha .
2. Beta .
3. Gamma .
 Neutrons may also be emitted.

Copyright © TWI Ltd


Radioactive Emissions

Alpha particles: +
 Emitted by large nuclei such as uranium or
plutonium.
 Composed of two protons and two neutrons
with a helium nucleus.

226
88 Ra 222
86 Rn He 4
2

Copyright © TWI Ltd


Radioactive Emissions

Beta particles: -
 Emitted by neutron rich nuclei such as
uranium or plutonium.
 Composed of high speed electrons.


14
6 C N  e 14
7

Copyright © TWI Ltd


Radioactive Emissions

Gamma particles or photons: 


 Emitted following the emission of an alpha
or beta particle.
 Composed of photons of energy not
particles.

Copyright © TWI Ltd


Radioactive Decay

Pb Bi  Po Pb
210
82
210
83
210
84
206
82

    

Copyright © TWI Ltd


Rate of Decay

 Curie: 3.7 x 1010 disintegrations/second.


 Becquerel: 1 disintegration/second.
 Half Life: Time taken for the activity of an
isotope to reduce by a half.

Cobalt 60: 5.3 years.


Iridium 192: 74 days.
Ytterbium 169: 32 days.
Uranium 238: 4.47 x 1010 years.
Selenium 75: 118 days

Copyright © TWI Ltd


Rate of Decay

 At the level of individual atoms radioactive


decay is random but for each isotope each
individual atom has the same probability of
decay.

 A 2 x 1mm cylinder of Iridium contains around


1020 atoms; when so many atoms all have the
same probability of decay the result is a
constant half life even though each individual
decay event is random.

Copyright © TWI Ltd


Rate of Decay

Copyright © TWI Ltd


Industrial Radiography

 Gamma Rays
 X - Rays
 Generated by the
 Electrically
decay of unstable
generated.
isotopes.

Copyright © TWI Ltd


Part 2: Equipment
Covering pages 16-40 of your notes

Copyright © TWI Ltd


X-Ray and Gamma Equipment

X-Ray Production

Copyright © TWI Ltd


X-Ray Production

 X-rays are produced by the deceleration of


high velocity electrons.
 Part or all of the kinetic energy of the electron
is converted into electromagnetic radiation
(X-rays).
 Kinetic energy is controlled by velocity:
Ek = ½mv2 and is usually stated in keV or
MeV.
 Electron velocity in an X-ray tube is controlled
by tube voltage.

Copyright © TWI Ltd


X-Ray Production

 Requirements
 Electron source.
 Means of accelerating electrons to a high velocity.
 Means of halting electrons.

Copyright © TWI Ltd


X-Ray Production

1. Electron source: Tungsten filament

Copyright © TWI Ltd


X-Ray Production

1. Electron source: Tungsten filament

Current

Copyright © TWI Ltd


X-Ray Production

1. Electron source: Tungsten filament

Current
Free electrons

Thermionic emission of electrons

Copyright © TWI Ltd


X-Ray Production

2. Accelerating electron: Potential difference

-ve
-ve +ve

Copyright © TWI Ltd


X-Ray Production

2. Accelerating electron: Potential difference

-ve +ve

Copyright © TWI Ltd


X-Ray Production

2. Accelerating electron: Potential difference

-ve +ve

Focusing cup concentrates electrons into a beam

Copyright © TWI Ltd


X-Ray Production

3. Means of halting electrons: High density


material

-ve +ve

Tungsten
target

Copyright © TWI Ltd


X-Ray Production

3. Means of halting electrons: High density material

-ve +ve

Copyright © TWI Ltd


X-Ray Production

Kinetic energy converted to heat and x-rays

-ve +ve

X-rays / Bremsstrahlung

Copyright © TWI Ltd


Problems

 Electrons travel for only short distances


through gasses.
 Kinetic Energy converted into ± 95 % heat
and ± 5 %
X-rays.

Copyright © TWI Ltd


X-Ray Production

Copyright © TWI Ltd


X-Ray Production: HEAT

 In any x-ray tube around 95 % of the energy


generated is in the form of heat.
 For typical 200 kV portable equipment around
1 kW of heat has to be dissipated.
 For a 300 kV constant potential laboratory unit
heat generation is typically 7.5 kW.
 X-ray tubes of all types therefore require a cooling
system in order to prevent overheating and
increase duty cycle.
 Older type sets having glass envelope tubes are
generally oil or gas cooled.

Copyright © TWI Ltd


X-Ray Production: HEAT

 A rotating anode may be used in order to help


dissipate heat. This type of arrangement is
generally limited to X-ray units intended for
medical use.
 Modern X-ray units have so-called metal-ceramic
envelopes. The use of such envelopes makes it
practical to have a much higher potential
difference between the electrodes and the
envelope than was the case with glass.
 This in turn permits the use of grounded anodes.
 Such anodes are at zero volts and can therefore
be cooled directly by water.

Copyright © TWI Ltd


X-Ray Production: Anodes

Directional Type
Tungsten target
Hood

Beryllium window Heavy high conductivity


Copper heat sink

Copyright © TWI Ltd


X-Ray Production: Anodes

Panoramic Type
Beryllium window

Tungsten target

Hood
Heavy high conductivity
Copper heat sink

Copyright © TWI Ltd


X-Ray Production: Anodes

Rod-anode

Tungsten target

Beryllium window

Aluminium tube

Copyright © TWI Ltd


X-Ray Production: Anodes

Rotating-anode

Used mainly for low


kV, very high tube
current, equipment
in medical
applications.

Copyright © TWI Ltd


X-Ray Production

 Tube current  Tube voltage


controls the amount controls the quality
or intensity of or penetrating ability
radiation. of the radiation.

Copyright © TWI Ltd


X-Ray Production

LT transformer
X-ray
tube
AC
Power

HT transformer Rheostat

Autotransformer
mA
AC
Power
kV

Copyright © TWI Ltd


X-Ray Production

 Current can flow across an X-ray tube only


when the cathode (i.e. the filament) is
negative and the anode (i.e. the target) is
positive.
 Therefore if an X-ray tube is energised using a
simple AC supply X-rays will be produced only
when the supply polarity is such that the
cathode is negative and the anode is positive.
 Simple AC X-ray machines are therefore
referred to as self-rectified.

Copyright © TWI Ltd


X-Ray Production

 Output of C-rays can be more than doubled if


the AC supply is rectified.
 X-ray equipment fitted with a rectifying circuit
is referred to as constant potential.
 Most CP units use a Greinacher circuit to
rectify the AC supply.
 CP units produce harder radiation than SR
even when operating at the same tube
voltage.

Copyright © TWI Ltd


X-Ray Production

Radiation intensity Decreasing energy

X-Ray Production

Increasing wavelength

Copyright © TWI Ltd


X-Ray Production

Radiation intensity Decreasing energy

Increasing wavelength

Copyright © TWI Ltd


X-Ray Production

Radiation intensity Decreasing energy

Increasing wavelength

Copyright © TWI Ltd


X-Ray Production

Copyright © TWI Ltd


X-Ray Production

Copyright © TWI Ltd


High Energy X-Ray Sources

 X-Ray energies of up to 30 MeV are produced using


linear accelerators or betatrons. Electrostatic (Van
der Graaf) generators are also used occasionally.
 Linear accelerators (Linacs) accelerate electrons to
high velocity using an electric wave (RF). Electrons
surf the electrical waves and attain high velocity.
 Betatrons accelerate electrons along a spiral path by
means of magnetic fields.
 Van der Graaf generators can develop high electrical
potentials by mechanical means such electrical
potentials can be used to accelerate electrons.

Copyright © TWI Ltd


X-Ray and Gamma Equipment

Gamma rays

Copyright © TWI Ltd


Sealed Sources

Copyright © TWI Ltd


Gamma-Ray Equipment

Copyright © TWI Ltd


Gamma-Ray Equipment

Isotope container
Projection
tube

Wind-out

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Isotope Half life mm of steel


Iridium 192 74.4 days 20 - 100
Cobalt 60 5.3 years 40 - 200
Ytterbium 169 32 days 1 - 15
Selenium 75 119 days 10 - 40
Thulium 170 128 days up to 5
Caesium 137 30 years 20 - 80

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Relative intensity/% of total

Radiation energy/MeV

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Relative Intensity/% of total

Radiation energy/MeV

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Relative intensity/% of total

Radiation energy/MeV

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Relative intensity/% of total

Radiation energy/MeV

Copyright © TWI Ltd


Isotopes Used in Industrial
Radiography

Relative intensity/% of total

Radiation energy/MeV

Copyright © TWI Ltd


Advantages

Gamma rays compared with X- rays


 No water or electrical supplies needed.
 Equipment smaller and lighter therefore more
portable.
 Easier to perform radiography in confined or
difficult to access areas.
 Equipment simpler and more robust.
 Less scatter no low energy radiation.
 Less initial cost.
 Greater penetrating power.

Copyright © TWI Ltd


Disadvantages

Gamma rays compared with X- rays


 Reduced radiographic contrast.
 Exposure times generally longer.
 Sources need replacing potentially greater in-
service costs.
 Radiation cannot be switched off.
 Generally inferior geometric unsharpness, SFD
is usually minimised to obtain economic
exposure time.
 Remote handling necessary.
 Penetrating power cannot be adjusted.

Copyright © TWI Ltd


Part 3: Image processing
Covering pages 40-48 of your notes

Copyright © TWI Ltd


Radiographic Film

Base

Copyright © TWI Ltd


Radiographic Film

Subbing

Base

Subbing

Copyright © TWI Ltd


Radiographic Film

Emulsion mainly AgBr in gelatine base

Subbing

Base

Subbing

Emulsion mainly AgBr in gelatine base

Copyright © TWI Ltd


Radiographic Film

Supercoat

Emulsion mainly AgBr in gelatine base


Subbing

Base

Subbing

Emulsion mainly AgBr in gelatine base

Supercoat

Copyright © TWI Ltd


Radiographic Film

Pre-exposure After exposure

Un-sensitised: Sensitised: Unstable


Stable
During exposure a latent image is formed by
sensitised Silver Halide crystals.

Copyright © TWI Ltd


Latent Image Formation

Bromine ion Br-


Silver Ion Ag+
Interstitial Silver Ion Ag+
Free electron
Silver atom Ag

Copyright © TWI Ltd


Latent Image Formation

 Silver bromide crystals are not perfect they


contain interstitial silver ions.
 When an interstitial silver ion accepts a free
electron it becomes a silver atom.
 The silver atom is larger than the ion and
exerts a stress on the crystal lattice.
 In the presence of developer this stress causes
instability and the crystal breaks down
resulting in the whole of the crystal changing
to black metallic silver.

Copyright © TWI Ltd


Latent Image Formation

 The interstitial silver atoms nucleate silver


crystals.
 A single interstitial silver atom is sufficient to
cause an entire silver bromide crystal to
convert to metallic silver.
 The typical size of a silver bromide crystal in a
typical photographic film emulsion is about
1 μm.
 Sensitisation of a silver bromide crystal can be
caused by just a single photon of X-ray
energy.

Copyright © TWI Ltd


Film Types

Grain Size Speed Quality


Coarse Fast Poor
Medium Medium Medium
Fine Slow Good
Ultra Fine Very Slow Very Good

Copyright © TWI Ltd


Intensifying Screens

 Film is usually placed between front and back


intensifying screens.
 Generally lead of 0.03 - 0.15 mm occasionally
salt screens may be used.
 Lead screens shorten exposure time and
improve image quality by helping to reduce
the effects of scattered radiation.
 Salt screens shorten exposure time, often
dramatically but produce inferior image
quality.

Copyright © TWI Ltd


Intensifying Screens

 Metallic: Usually lead but other metals such as


copper may be used.
 Salt: Usually calcium tungstate.
 Fluorometallic: These are salt screens with a
metal foil backing. They combine the
advantages of metallic and salt screens,
however, they are extremely expensive and
they are easily damaged.

Copyright © TWI Ltd


Intensifying Screens: Metallic

 For radiation energy of 120 keV or greater front and


back lead intensifying screens are commonly used.
 The optimum thickness of such screens varies with
radiation energy but 0.03 - 0.15 mm is typical.
 The front screen reduces the effect of radiation
scattered by objects situated in front of the film
including the object which is being radiographed and
helps to shorten exposure time.
 The back screen reduces the effect of radiation
scattered by objects situated behind the film and to a
lesser extent when compared with the front screen
helps to shorten exposure time.

Copyright © TWI Ltd


Intensifying Screens

Front screen
Primary radiation
Front emulsion
Secondary electrons

Base Grain sensitised by


primary radiation

Back emulsion Grain sensitised by


secondary electrons
Back screen

Copyright © TWI Ltd


Intensifying Screens

No screens Pb screens: Poor contact

Pb screens: Good contact

Copyright © TWI Ltd


Intensifying Screens

 Metal usually Pb: Intensification factor about


2x for radiation energies in excess of 120 keV.
 Salt: Intensification factor may be as high as
500x.
 Fluorometallic: Intensification factor about
50x.

Copyright © TWI Ltd


Film Processing

 Developer: Reducing agent: Alkaline.


 Stop bath: Acetic acid.
 Fixer: Dissolves silver halide: Acidic.
 Washing.
 Drying.

Copyright © TWI Ltd


Film Processing

 Development
 Latent image converted into metallic silver in
3-5 minutes at 20°C.
 The four main constituents of developer:
 Reducing agent: Metol/hydroquinone.
 Accelerator: Keeps solution alkaline.
 Restrainer: Ensures only sensitised silver
halides converted.
 Preservative: Prevents oxidation by air.

Copyright © TWI Ltd


Developer

 In order to increase the working life of the


developer replenisher should be added in
accordance with manufacturer’s recommendations.
 Replenisher replaces used reducing agent and
maintains alkalinity. It also maintains the depth of
developer in the processing tank, during
processing there are losses due to carry-over and
evaporation.
 Keeping a record of how much film has been
processed helps in deciding how much replenisher
to add.

Copyright © TWI Ltd


Film Processing

Stop bath
3% acetic acid neutralises the developer, stops the development
process and increases fixer life.

It is common to add an indicator to the stop bath to confirm it’s


acidity.

The stop bath should always be held at approximately the same


temperature as the developer and fixer as sudden temperature
changes can damage the film emulsion.

A soaking time in the stop bath of just a few seconds is


sufficient to arrest development and neutralise alkalinity.

Copyright © TWI Ltd


Film Processing

Fixer
A solution of sodium thiosulphate or ammonium thiosulphate.

Fixer is mildly acidic, acetic acid stabilises the solution.

Unexposed undeveloped silver halides are leached out of the


film emulsion.

Fixer commonly contains a hardener. This helps to promote


rapid even drying it also makes the wet film easier to handle.

Fixing time is generally taken to be twice the clearing time.


Leaving film in fixer for an extended period may cause the film
emulsion to peel away from the base.

Copyright © TWI Ltd


Fixer

Like developer fixer may be replenished.

When unexposed film is placed in the fixer bath it will be


observed to clear as the silver halides are dissolved by the
fixer. Clearing time is an important measure of fixer condition.
Clearing time for new fixer will usually be less than 30
seconds.

Radiographs are usually fixed for a time equal to twice the


clearing time.

Fixer contains a hardener which helps to prevent swelling of


the film emulsion and accelerate drying.

Copyright © TWI Ltd


Fixer

During the fixing process large amounts of silver


accumulate in the fixer solution.
Therefore it is common practice to recover silver
from spent fixer.

Copyright © TWI Ltd


Film Processing

Washing
20-30 minutes in clean running water.

Usually followed by dipping in a clean water bath containing a


wetting agent which helps to promote even drying.

Note: Over washing must be avoided.

Over washing will cause swelling and excessive softening of


the film emulsion a major cause of drying marks.

Insufficiently washed radiographs will discolour and their shelf


life will be limited.

Copyright © TWI Ltd


Advanced Imaging Techniques

Computed
radiography Optical
Photo-multiplier
scanner
tube

Laser
beam
A/D
converter

Imaging 110010010010110
plate
Motor

Copyright © TWI Ltd


Image Software

Image (1) Edge detection (2)

Subtraction of (2) from (1)

Copyright © TWI Ltd


Real Time Radiography

Copyright © TWI Ltd


Real Time Radiography

 Image type
 The image formed is a positive image since
brighter areas on the image indicates where
higher levels of transmitted radiation reached
the screen.

Positive image Negative image

Copyright © TWI Ltd


Computed Tomography

Copyright © TWI Ltd


Computed Tomography

As the component is rotated


a series of 2D slices are
collected when these are
superimposed and merged
using computer software
according to the radial
1 2 position a 3D image is then
produced.
The cross section of the test
piece becomes more
defined as it is rotated the
stretched density
information is added to the
3 4 image.

Copyright © TWI Ltd


CT Images

 As shown below the 3-D image can then be


manipulated and sliced in various ways to
provide a thorough understanding of the
structure and nature of defects.

Copyright © TWI Ltd


Part 4: Image quality
Covering pages 48-65 of your notes

Copyright © TWI Ltd


Radiographic Sensitivity

The ability of a radiograph to detect a small


change in section thickness

Affected by:
 Definition: The degree of sharpness of a
radiographic image.
 Contrast: The degree to which two adjacent
areas of different film density can be
distinguished one from the other.

Copyright © TWI Ltd


Factors Influencing Sensitivity

Sensitivity

Contrast Definition

Copyright © TWI Ltd


Factors Influencing Sensitivity

Sensitivity

Contrast Definition

Film Film Quality of Subject Film


density type radiation contrast processing

Copyright © TWI Ltd


Factors Influencing Sensitivity

Sensitivity

Contrast Definition

Film Film Quality of Subject Film


density type radiation contrast processing

Agitation Development Developer Developer Type of


time temperature concentration developer

Copyright © TWI Ltd


Factors Influencing Sensitivity

Sensitivity

Contrast Definition

Type of Intensifying Radiation Relative Geometry Film


film screens quality movement processing

Copyright © TWI Ltd


Factors Influencing Sensitivity

Sensitivity

Contrast Definition

Type Intensifying Radiation Relative Geometry Film


of screens quality movement processing
film

Agitation Development Developer Developer Type of


time temperature concentration developer

Copyright © TWI Ltd


Image Quality
 Contrast
 The ability to differentiate areas of different
film density

Copyright © TWI Ltd


Radiographic Contrast

 Insufficient Contrast  Excessive Contrast


 kV too high.  kV too low.
 Over exposure  Incorrect developer.
compensated for by  Incorrect film: Screen
shortened development. combination.
 Incorrect film: Screen
combination.
 Scatter.
 Fogged film.
 Poor film processing.

Copyright © TWI Ltd


Radiographic Quality

Definition
The sharpness of the dividing line between
different density fields.

There are two types of unsharpness in


radiography:
1. Film or inherent unsharpness.
2. Geometric unsharpness or penumbra.

Copyright © TWI Ltd


Geometric Unsharpness

Copyright © TWI Ltd


Geometric Unsharpness

f x OFD
U𝑔 =
FOD

Copyright © TWI Ltd


Geometric Unsharpness

Long Film to Object


Distance

Low Ug

Copyright © TWI Ltd


Geometric Unsharpness

Short Film to Object


Distance

High Ug

Copyright © TWI Ltd


Geometric Unsharpness

Small focus

Low Ug

Copyright © TWI Ltd


Geometric Unsharpness

Large Focus

High Ug

Copyright © TWI Ltd


Geometric Unsharpness

Short Object to Film


Distance

Low Ug

Copyright © TWI Ltd


Geometric Unsharpness

Long Object to Film


Distance

High Ug

Copyright © TWI Ltd


Reducing Geometric Unsharpness

 Source size as small as possible.


 Source to object distance as long as practical.
 Object to film distance as short as possible.
 In a good quality technique geometric
unsharpness should be not more than the
inherent unsharpness of the film screen
combination in use.

Copyright © TWI Ltd


Measuring Geometric Unsharpness

 The drilled holes in step: Hole and plaque type


IQIs are intended as an indicator of geometric
unsharpness.
 Standard wire type IQIs (EN ISO 19232-1) are
poor indicators of geometric unsharpness.
 A special type of IQI called a duplex wire IQI
is designed with a view to measuring
geometric unsharpness (EN ISO 19232-5).

Copyright © TWI Ltd


Duplex IQIs

 EN ISO 19232-5 defined duplex wire IQI


containing 13 pairs of circular cross-section
wires made of platinum and tungsten.

Note: EN 462-5 was former standard which is technically identical with EN ISO
19232-5

Copyright © TWI Ltd


BS 3971 Duplex IQI

Achieved
Wire Achieved basic
Duplex geometrical
diameter spatial resolution 𝑆𝑅𝑏
identification unsharpness 𝑈𝑔 [mm]
[mm] [mm]

D1 0,80 0,80 1,60


D2 0,63 0,63 1,26
D3 0,50 0,50 1,00
D4 0,40 0,40 0,80
D5 0,32 0,32 0,64
D6 0,25 0,25 0,50
D7 0,20 0,20 0,40
D8 0,16 0,16 0,32
D9 0,13 0,13 0,26
D10 0,10 0,10 0,20
D11 0,08 0,08 0,16
D12 0,063 0,063 0,13
D13 0,05 0,05 0,10

Copyright © TWI Ltd


BS 3971 Duplex IQI

First unresolved duplex is ...


Achieved
Wire Achieved basic
Duplex geometrical
diameter spatial resolution 𝑆𝑅𝑏
identification unsharpness 𝑈𝑔 [mm]
[mm] [mm]

D7 0,20 0,20 0,40


D8 0,16 0,16 0,32
D9 0,13 0,13 0,26
D10 0,10 0,10 0,20

Copyright © TWI Ltd


Inherent Unsharpness

Inherent or film unsharpness is due to:


 The graininess of the film, fast films have
larger grain size than slow films.
 The type of intensifying screens, metallic foil
screens are much better than fluorescent
screens.
 The radiation energy, film unsharpness is
increased at high radiation energy.
 Film processing, development time and
temperature affect grain size.

Copyright © TWI Ltd


Inherent Unsharpness

Actual
object

Ultrafine grain
film
Fine grain
film

Coarse grain
film

Copyright © TWI Ltd


Scattered Radiation

Scattered radiation can seriously effect the


quality of a radiographic image and needs to
be considered with a view to reducing its
effect on the final image quality.

Copyright © TWI Ltd


Scatter

 Radiation originating from any source other than


the primary source.
 Primary radiation is absorbed then re-emitted in
all directions.
 Scatter is a major contributor to poor radiographic
contrast and definition.
 Scatter may also cause a radiation hazard, dose
rates maybe locally increased by scattering
effects.

Copyright © TWI Ltd


Scatter

Three major causes of scatter are:


 Photoelectric effect.
 Compton scattering (incoherent scatter).
 Pair production.

 Other scattering mechanisms exist for


example: Rayleigh scattering (coherent
scattering).

Copyright © TWI Ltd


Photoelectric Effect

 In the photoelectric effect an electron absorbs


all of the energy of the incident X-ray photon.
 If the photon energy is sufficient the electron
will be completely ejected from the atom and
ionisation will occur.
 Where the incident photon has exactly the
right amount of energy the electron may
simply jump from one energy level to another.
 As the affected atom returns to its base state
low energy X-rays are emitted in all directions.

Copyright © TWI Ltd


Photoelectric Effect

Copyright © TWI Ltd


Compton Scattering

 In Compton scattering an electron absorbs


part of the energy of the incident X-ray
photon.
 In Compton scattering the affected electron is
ejected from the atom and ionisation results.
 The photon energy not absorbed by the
electron is deflected from the original path of
the incident photon as an X-ray of lower
energy.
 As the affected atom returns to its base state
low energy X-rays are emitted in all directions.

Copyright © TWI Ltd


Compton Scattering

Copyright © TWI Ltd


Pair Production

 In pair production a high energy X-ray photon


converts to an electron, positron pair following
interaction with either an orbital electron or an
atomic nucleus.
 Pair production occurs only above a threshold
energy of 1.02 MeV.
 A positron has a very short life expectancy, it
quickly interacts with an electron causing
annihilation of both particles.

Copyright © TWI Ltd


Pair Production

 Annihilation of an electron, positron pair


produces scattered radiation at a characteristic
photon energy of 0.51 MeV.
 The electron produced in the pair production
event has high velocity and causes ionisation
and further production of scattered radiation.

Copyright © TWI Ltd


Pair Production

Copyright © TWI Ltd


Coherent (Rayleigh) Scattering

 In coherent scattering there is no loss of


photon energy.
 The incident photon is effectively deflected
from its original path as it interacts with an
atom.
 The incident photon is momentarily absorbed
by the atom setting its orbital electrons in
oscillation, then re-emitted without energy
loss but in a new direction.
 Coherent scattering affects only very low
energy X-ray photons and is of little
importance in industrial radiography.

Copyright © TWI Ltd


Coherent (Rayleigh) Scattering

Copyright © TWI Ltd


Mode of Scatter vs Radiation Energy

 At radiation energies up to approximately


600 eV the photoelectric effect is the dominant
scattering mechanism.
 From 600 eV to approximately 6 MeV Compton
scattering predominates.
 Above 6 MeV pair production takes over as the
dominant effect.
 The total amount of scattering as a proportion
of the incident radiation is much greater at
energies below 1 MeV than it is at higher
energies.

Copyright © TWI Ltd


Scatter

 Internal scatter: Originating within the


specimen.
 Side scatter: Walls and nearby objects in the
path of the primary beam.
 Back scatter: Materials located behind the
film.

Copyright © TWI Ltd


Scatter

 Internal scatter originating within the


specimen

Copyright © TWI Ltd


Scatter

 Side scatter from walls and nearby objects in


the path of the primary beam

Copyright © TWI Ltd


Scatter

 Back scatter materials located behind the film

Copyright © TWI Ltd


Checking For Back Scatter

British, European and American codes and


standards describe a method of checking for
back scatter.
 A lead letter B is attached to the back of the
film cassette during exposure.
 If a light image of the letter B appears in the
radiographic image then excessive back
scatter is present and the radiograph must be
retaken.
 A dark image of B does not indicate
backscatter!!!

Copyright © TWI Ltd


Checking For Back Scatter

Light image
of B:
Reshoot

Dark image
of B:
Accept

Copyright © TWI Ltd


Scattering Angle

 The angle formed between the direction of the


primary radiation beam and the direction of
travel of the scattered radiation is referred to
as scattering angle or angle of scatter.

Angle
of
scatter

Primary radiation

Copyright © TWI Ltd


Scattering Angle

 Scattered radiation with a scattering angle of


less than or equal to 90 is side scatter or
internal scatter.
 Scattered radiation with a scattering angle of
greater than 90 is back scatter.

Copyright © TWI Ltd


Scatter

Low scatter High scatter

Copyright © TWI Ltd


Control of Scatter

 Collimation.
 Lead screens.
 Protection from back scatter.
 Beam filtration (X-ray only).
 Blocking.
 Diaphragms.
 Grids (oscillating).
 Increased beam energy.

Copyright © TWI Ltd


Inherent Unsharpness

Typical inherent unsharpness for


Pb screens/fine grain film
Radiation source Inherent unsharpness
(mm)
100 kV X-rays 0.05
200 kV X-rays 0.09
300 kV X-rays 0.12
400 kV X-rays 0.15
1000 kV X-rays 0.18
Iridium 192 0.17
Cobalt 60 0.35

Copyright © TWI Ltd


Part 5: Exposure calculation
Covering pages 65-83 of your notes

Copyright © TWI Ltd


Determining The Correct Exposure

Knowing how to determine the correct exposure


to achieve the required radiographic film density
is essential for those involved in radiographic
testing.

Incorrect calculation can lead to lost time


caused by countless reshoots and the
subsequent increase in film costs.

Copyright © TWI Ltd


Image Quality Film density

The degree of darkening of a processed film is


called optical density.

Optical density is a logarithmic unit:


𝐼1
𝐹𝑖𝑙𝑚 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 = 𝑙𝑜𝑔10
𝐼2
Where I1 is the incident light intensity and I2 is the
transmitted light intensity.

Thus if film density = 2, the incident light intensity is 100 x


greater than the transmitted intensity.

Copyright © TWI Ltd


Radiographic Film Density

National codes and standards for radiography of


welds and castings invariably define a minimum
level of film density:
 ASME V requires a minimum film density of
1.8 for X-radiography of welds and a minimum
of 2.0 for gamma techniques.
 EN ISO 17636-1 requires a minimum film
density of 2.0 for class A (basic techniques of
X- or gamma radiography of welds) and a
minimum of 2.3 for class B (improved
techniques).

Copyright © TWI Ltd


Radiographic Film Density

 Radiographic films provide good contrast at


film densities exceeding about 1.5.
 Radiographs with a density exceeding 3.5 or
perhaps 4.0 cannot be properly viewed and
assessed on standard radiographic film
illuminators.
 Film density is easily measured using a
densitometer or by comparison with a
calibrated density strip.

Copyright © TWI Ltd


Radiographic Film Density

Film density

Copyright © TWI Ltd


Radiographic Film Density

Lack of density Excessive density


 Under exposure.  Over exposure.
 Developer  Developer
temperature too temperature too
low. high.
 Exhausted  Excessive
developer. development.
 Developer too weak.  Too strong a
solution.

Copyright © TWI Ltd


Factors Affecting Exposure

 Specimen Radiographic
 Material type.  Film speed.
 Thickness.  Quality of radiation.
 FFD or SFD.
 Screens.
 Filters.
 Development.
 Density required.
 Intensity of radiation.

Copyright © TWI Ltd


Exposure Charts

Exposure/ mAmin

45
45

40 35 30
Steel Thickness / mm

Steel Thickness / mm
30 35 40

25 20
20 25

15
15

10
10

5
5

Exposure / mAmin

Copyright © TWI Ltd


Exposure Calculations

Radiographic equivalence chart


Radiation energy/isotope

100keV 150keV 220keV 400keV Ir192


Material
Steel 1.0 1.0 1.0 1.0 1.0

Copper 1.5 1.6 1.4 1.4 1.1

Aluminium 0.08 0.12 0.18 - 0.35

Al alloy 4.5% Cu 0.13 0.16 0.22 - 0.35

Titanium 0.5 0.45 0.35 - -

Copyright © TWI Ltd


Equivalence Factors

 Equivalence factors vary with radiation quality.


 Equivalence factors are used to convert a
thickness of a given material to a
radiographically equivalent thickness of
another material for which exposure times are
known.

 For example: Convert 10mm of steel to an


equivalent thickness of copper using 100 kV
X-rays:

Te = 10 x 1.6 = 16 mm

Copyright © TWI Ltd


Film Factors

Classification Manufacturer designation and film factor CF

EN ISO ASTM E
AGFA CF KODAK CF FUJI CF FOMA CF
11699-1 1815

9.0 6.5 9.0


C1 Special D2 DR 50 7.2 IX 25 R2
4.2 3.3 4.2
C2 D3 M 100 4.2 IX 50 R3
2.6 2.6
C3 Class 1 D4 MX 125 2.8 --- R4
1.6 1.6 1.6
C4 D5 T 200 1.7 IX 80 R5
1.0 1.0 1.0
C5 Class 2 D7 AA 400 1 IX 100 R7
0.7 0.6 0.7
C6 Class 3 D8 CX 0.7 IX 150 R8

Copyright © TWI Ltd


Exposure Calculation

 Film speed chart

D7 D5 D4
Agfa

CX AA 400 MX12
Kodak 5

IX IX IX 80
Fuji 150 100
2 2.5 3 3.5 4 5 6 7 8
10 12 14
Relative exposure
Copyright © TWI Ltd
Exposure Calculation

 Change of film: From CX to MX125.

Original exposure: 4 minutes.


Film factor for CX: 0.7
Film factor for MX: 2.8

2.8
New Exposure = 4∙ = 16 minutes
0.7

Copyright © TWI Ltd


Exposure Calculation

Change of FFD

Original exposure: 4 minutes.


Original FFD: 1000 mm.
New FFD: 750 mm.

2
750
New time = 4 ∙ = 2.25 minutes
1000

Copyright © TWI Ltd


Characteristic Curves

 Increasing exposures are applied to successive areas of


a film.
 After development the film density is measured.
 The density is then plotted against the log of the
relative exposure.

The resultant graph is called the


characteristic curve
or
sensitometric curve
or
Hurter-Driffield curve (H&D curve)

Copyright © TWI Ltd


Characteristic Curves

Shoulder

Straight line
section

Toe

Copyright © TWI Ltd


Characteristic Curves

The relationship between


exposure time and
resultant film density is
non-linear.

The gradient of the film


characteristic curve is a
measure of film
contrast.

Copyright © TWI Ltd


Characteristic Curves

Film A is coarse grain and is


faster than Film B and C.

Film B is fine grain and it’s


speed is intermediate
between Film A and C.

Film C is ultra-fine grain and


is the slowest of the three.

A fast film requires a shorter


exposure time than a slow
film.

Copyright © TWI Ltd


Characteristic Curves

1.63 - 1.31 = 0.32 Antilog 0.32 = 2.1


Original exposure = 10 mAmin
New exposure = 2.1 X 10 = 21 mAmin
Using D7 film a
density of 1.5 was
achieved using an
exposure of
10 mAmin.
What exposure is
required to achieve
a density of 2.5?

Copyright © TWI Ltd


Characteristic Curves

2.07 - 1.63 = 0.44 Antilog 0.44 = 2.75 Using D7 film a


Original exposure = 10 mAmin
New exposure = 2.75 X 10 = 27.5 density of 2.5
mAmin was achieved
using an
exposure of
10 mAmin.

What exposure is
required to
achieve a
density of 2.5
using MX film?

Copyright © TWI Ltd


Image Quality Indicators

 Image quality indicators (IQIs)

or

 Penetrameters

are used to measure radiographic sensitivity and


the quality of the radiographic technique used.

Copyright © TWI Ltd


Image Quality Indicators

Definitions
 Radiographic sensitivity is the ability of
radiographic system to reveal discontinuity of
certain size on the radiographic image.

 It can also be defined as a measure of quality


of radiographic image. True radiographic
sensitivity is difficult quantity to measure.

Copyright © TWI Ltd


Image Quality Indicators

Definitions
 IQI sensitivity: Is not an exact measure of the
true sensitivity of a radiographic technique.

 IQIs are used in radiography to ensure that


the general overall quality of a radiographic
technique is adequate.

Copyright © TWI Ltd


Image Quality Indicators

 EN ISO 19232-1 Wire type IQIs

Copyright © TWI Ltd


Image Quality Indicators

 EN ISO 19232-2 Step-hole type IQIs

Copyright © TWI Ltd


Image Quality Indicators

 ASTM E 1025 Plaque type IQIs

Sensitivity is
measured in terms
2-2T where 2 equals
a plaque thickness of
2T 2T
2 % of the test
specimen thickness
1T
4T 1T and 2T is the hole
XX: IQI thickness thousandths of that is visible on the
an inch.
T: Plaque radiographic image.
thickness.

Copyright © TWI Ltd


Image Quality Indicators

 IQI sensitivity is usually expressed as a


percentage of subject thickness.
 For single wall single image and double wall
single image techniques the single wall
thickness is generally taken as subject
thickness.
 For double wall double image techniques the
double wall thickness is used.

Copyright © TWI Ltd


Determining The Correct Sensitivity

100 t
Sensitivity =
T
T: Subject thickness.
t: Thickness of thinnest discernible wire or step.

Copyright © TWI Ltd


Image Quality Indicators

 IQIs should wherever possible be placed on


source side.
 For the double wall single image technique
this is not possible and IQIs are therefore
placed film side.
 Different requirements apply dependent on
whether the IQI is source or film side.

Copyright © TWI Ltd


Part 6: Techniques
Covering pages 84-96 of your notes

Copyright © TWI Ltd


Radiographic Techniques

 Single wall single image (SWSI).


 Double wall single image (DWSI).
 Double wall double image (DWDI).

Copyright © TWI Ltd


Radiographic Techniques

Technique: SWSI
(panoramic)

Required number of
exposures: 1

Location marker
placement: External

IQI placement: External


(followed by comparative exposure)

Copyright © TWI Ltd


Radiographic Techniques

Technique: SWSI
(source internal and offset)

Required number of exposures:


See EN ISO 17636-1 figures.

Location marker placement:


External

IQI placement: External

Copyright © TWI Ltd


Radiographic Techniques

Technique: SWSI (source


external)

Required number of exposures:


See EN ISO 17636-1 figures.

Location marker placement:


External

IQI placement: External

Copyright © TWI Ltd


Radiographic Techniques

Technique: DWSI

Required number of exposures:

See EN ISO 17636-1 figures.

Location marker placement:


External

IQI placement: External

Copyright © TWI Ltd


Radiographic Techniques

Technique: DWDI (elliptical)

Required number of exposures:


See EN ISO 17636-1 figures.

Location marker placement:


Source side preferred

IQI placement: Must be source


side

Copyright © TWI Ltd


Radiographic Techniques

Technique: DWDI
(superimposed)

Required number of exposures:


See EN ISO 17636-1 figures.

Location marker placement:


Source side preferred

IQI placement: Must be source


side

Copyright © TWI Ltd


Radiographic Techniques

Copyright © TWI Ltd


Radiographic Techniques

 Identification
 Unique identification.

Copyright © TWI Ltd


Radiographic Techniques

 Identification
 Unique identification.
 Pitch markers: Location markers.

Copyright © TWI Ltd


Radiographic Techniques

Identification
 Unique identification.
 Pitch markers.
 IQI’s.

Copyright © TWI Ltd


Localisation

 The through thickness position of a defect


cannot be determined by single exposure
radiography.

 A technique called tube shift or source shift


can be used to determine through thickness
position.

Copyright © TWI Ltd


Localisation

Using similar
triangles:

(𝐗−𝐙) (𝐘−𝐙)
=
𝐭 (𝐭−𝐝)

Therefore:

𝒕(𝒀 −𝒁)
𝒅=t-
(𝑿−𝒁)

Copyright © TWI Ltd


Part 7: Interpretation
Covering pages 97-125 of your notes

Copyright © TWI Ltd


Radiographic Interpretation

 In order to correctly interpret radiographs it is


essential that the interpreter has a good
knowledge of the product under examination and
the possible defects that may arise due to various
processes carried out on the test piece.

Copyright © TWI Ltd


Welding Terminology

 Butt joints
Square Edged
Closed Open

Single Sided Butt


Vee Bevel

Double Sided Butt


Vee Bevel

Copyright © TWI Ltd


Welding Terminology

 Fillet joints
Lap
Tee

Corner

Copyright © TWI Ltd


Welding Definitions

 BS 499-1  NASA
 A union between  A continuous defect
pieces of metal at surrounded by
faces rendered parent material.
plastic or liquid by
heat pressure or
both.

Copyright © TWI Ltd


Welds

An ideal weld must give a strong bond between


materials with the interfaces disappearing

To achieve this:

 Smooth, flat or matching surfaces.


 Surfaces shall be free from contaminants.
 Metals shall be free from impurities.
 Metals shall have identical crystalline structures.

Copyright © TWI Ltd


Welding

A union between pieces of metal at faces rendered plastic or


liquid by heat, pressure or both.

BS 499-1
Possible energy sources
 Ultrasonics.
 Electron beam.
 Friction.
 Electric resistance.
 Electric arc.

Copyright © TWI Ltd


Electric Arc Welding

Electrode

Power
supply

Work piece

Clamp
(earth)

Copyright © TWI Ltd


Electric Arc Welding

 Electric discharge produced between cathode


and anode by a potential difference (40-60
volts).
 Discharge ionises air and produces -ve
electrons and +ve ions.
 Electrons impact upon anode, ions upon
cathode.
 Impact of particles converts kinetic energy to
heat (7000oC) and light.
 Amperage controls number of ions and
electrons, voltage controls their velocity.

Copyright © TWI Ltd


Electric Arc Welding

Arc welding processes:


 Manual metal arc.
 Tungsten inert gas.
 Metal inert gas.
 Submerged arc.

Differences between them:


 Methods of shielding the arc.
 Consumable or non-consumable electrode.
 Degree of automation.

Copyright © TWI Ltd


Zones in Fusion Welds

 Parent material or base metal


 Heat affected zone
 Fusion zone

Copyright © TWI Ltd


Manual Metal Arc Welding

 Shielding provided  Welder controls


by decomposition of  Arc length.
flux covering.  Angle of electrode.
 Electrode  Speed of travel.
consumable.
 Amperage settings.
 Manual process.

Copyright © TWI Ltd


Manual Metal Arc (MMA)

Consumable
electrode
Flux
Arc coating
Evolved gas
shield
Core
Slag
wire
Parent metal

Weld metal

Copyright © TWI Ltd


Tungsten Inert Gas (TIG)

Gas nozzle
Non-
Filler wire consumable
tungsten
electrode

Gas shield
Arc

Parent metal Weld metal

Copyright © TWI Ltd


Metal Inert Gas (MIG)

Gas
nozzle
Consumable
electrode (filler wire)
Reel feed

Gas
Arc shield

Parent metal Weld metal

Copyright © TWI Ltd


Submerged Arc

Copyright © TWI Ltd


Submerged Arc

Flux Consumable
retrieval electrode Reel feed

Slag
Flux feed

Weld metal Parent metal

Copyright © TWI Ltd


Welding Defects

Cracks
Classified by shape Classified by position
 Longitudinal  HAZ
 Transverse  Centreline
 Branched  Crater
 Fusion zone
 Chevron
 Parent metal

Copyright © TWI Ltd


Welding Defects

Cracks
Four crack types:
 Solidification cracks.
 Hydrogen induced cracks.
 Lamellar tearing.
 Reheat cracks.

Copyright © TWI Ltd


Welding Defects

Cracks
 Solidification
 Occurs during weld solidification process.
 Steels with high sulphur content (low ductility
at elevated temperature).
 Requires high tensile stress.
 Occur longitudinally down centre of weld,
 eg crater cracking.

Copyright © TWI Ltd


Welding Defects

Solidification cracking

Copyright © TWI Ltd


Welding Defects

Cracks
 Hydrogen Induced
 Requires susceptible grain structure, stress
and hydrogen.
 Hydrogen enters via welding arc.
 Hydrogen source, atmosphere or
contamination of preparation or electrode.
 Moisture diffuses out into parent metal on
cooling.
 Most likely in HAZ.

Copyright © TWI Ltd


Welding Defects

Hydrogen cracking

Copyright © TWI Ltd


Welding Defects

Cracks
 Lamellar tearing
 Step like appearance.
 Occurs in parent material or HAZ.
 Only in rolled direction of the parent material.
 Associated with restrained joints subjected to
through thickness stresses on corners, tees
and fillets.
 Requires high sulphur or non-metallic
inclusions.

Copyright © TWI Ltd


Welding Defects

Lamellar tearing

Restraint

High
contractional
stress

Lamellar tear

Copyright © TWI Ltd


Welding Defects

Cracks
 Re-heat cracking
 Occurs mainly in HAZ of low alloy steels
during post weld heat treatment or service at
elevated temperatures.
 Occurs in areas of high stress and existing
defects.
 Prevented by toe grinding, elimination of poor
profile material selection and controlled post
weld heat treatment.

Copyright © TWI Ltd


Welding Defects

Incomplete root
penetration
Causes
 Too large or small a root
gap.
 Arc too long.
 Wrong polarity.
 Electrode too large for joint
preparation.
 Incorrect electrode angle.
 Too fast a speed of travel
for current.
Copyright © TWI Ltd
Welding Defects

Incomplete root fusion


Causes
 Too small a root gap.
 Arc too long.
 Wrong polarity.
 Electrode too large for joint
preparation.
 Incorrect electrode angle.
 Too fast a speed of travel for
current.

Copyright © TWI Ltd


Welding Defects

Root concavity

Causes

 Root gap too large.


 Insufficient arc
energy.
 Excessive back purge
TIG.

Copyright © TWI Ltd


Welding Defects

Excess root penetration

Causes
 Excessive amperage
during welding of
root.
 Excessive root gap,
poor fit up.
 Excessive root
grinding.
 Improper welding
technique.

Copyright © TWI Ltd


Welding Defects

Root undercut

 Causes
 Root gap too large.
 Excessive arc energy.
 Small or no root face.

Copyright © TWI Ltd


Welding Defects

Cap undercut

Causes
 Excessive welding current.
 Welding speed too high.
 Incorrect electrode angle.
 Excessive weave.
 Electrode too large.

Copyright © TWI Ltd


Welding Defects

Lack of fusion

Causes

 Contaminated weld
preparation.
 Amperage too low.
 Amperage too high (welder
increases speed of travel).

Copyright © TWI Ltd


Welding Defects

Incompletely filled groove


Lack of side wall Fusion
 Causes
 Insufficient weld metal
deposited.
 Improper welding
technique.

Copyright © TWI Ltd


Welding Defects

Inter run incompletely filled groove


Causes
 Insufficient weld metal deposited.
 Improper welding technique.

Copyright © TWI Ltd


Welding Defects

Gas pores/porosity:
Causes
 Excessive moisture in flux or preparation.
 Contaminated preparation.
 Low welding current.
 Arc length too long.
 Damaged electrode flux.
 Removal of gas shield.

Copyright © TWI Ltd


Welding Defects

Inclusions: Slag

Causes
 Insufficient cleaning between passes.
 Contaminated weld preparation.
 Welding over irregular profile.
 Incorrect welding speed.
 Arc length too long.

Copyright © TWI Ltd


Welding Defects

Inclusions: Tungsten
Causes
 Contamination of weld caused by tungsten
touching weld metal or parent metal during
welding using the TIG welding process.

Copyright © TWI Ltd


Welding Defects

Burn through
Causes
 Excessive amperage during welding of root.
 Excessive root grinding.
 Improper welding technique.

Copyright © TWI Ltd


Welding Defects

Spatter

Causes
 Excessive arc energy.
 Excessive arc length.
 Damp electrodes.
 Arc blow.

Copyright © TWI Ltd


Welding Defects

Arc strikes

Causes
 Electrode straying onto parent metal.
 Electrode holder with poor insulation.
 Poor contact of earth clamp.

Copyright © TWI Ltd


Welding Defects

Mechanical damage

Chisel Marks Pitting Grinding


Corrosion Marks

Copyright © TWI Ltd


Interpretation of Radiographs

Radiographic Details

Source of 150 kV X-Ray Film Type Agfa D7


Radiation
Screens Pb 0.125 mm front & back FFD/SFD 450

Technique SWSI Development Standard

TWI Training & Examination Services

Radiographic Interpreter

Name: Joe Bloggs Date: 01/ 01/ 01


Reference No. 097-200 Material Carbon Steel

Welding Details

Root Gap 3 Root Face 1.5 Material 10


Thickness
Process SMAW

Joint Prep. Single Vee

Diameter N/A

Copyright © TWI Ltd


Film Artefacts

 During radiography and film processing


images can be formed which are not due to a
defect or a change in component thickness.
 Such images are referred to as artefacts.

Copyright © TWI Ltd


Film Artefacts

 Crimp marks.
 Dirty intensifying screens.
 Scratched intensifying screens.
 Static marks.
 Reticulation.
 Solarisation.
 Chemical or water splashes.
 Diffraction mottling.
 Drying marks.
 Streakiness.

Copyright © TWI Ltd


Film Artefacts

Film crimped
before exposure

Copyright © TWI Ltd


Film Artefacts

Film crimped
after exposure

Copyright © TWI Ltd


Film Artefacts

Dirty
intensifying
screens

Copyright © TWI Ltd


Film Artefacts

Scratched
intensifying
screens

May appear as either light


or dark images often
difficult to identify.

Copyright © TWI Ltd


Film Artefacts

Static
marks

Release of static electricity


due to poor film handling
and dry ambient
conditions.

Copyright © TWI Ltd


Film Artefacts

Reticulation

Mottled effect caused by


extreme temperature
change during
processing.

Copyright © TWI Ltd


Film Artefacts

Solarisation
 Solarisation is image reversal due to extreme
over exposure or exposure to light during
development.

Copyright © TWI Ltd


Film Artefacts

Water/developer
splashes
(Before development)

Copyright © TWI Ltd


Film Artefacts

Fixer/stop-bath
splashes
(Before development)

Copyright © TWI Ltd


Film Artefacts

Diffraction
mottling

Mottled effect
sometimes seen in x-
radiography of large
grained materials.

Copyright © TWI Ltd


Film Artefacts

Drying marks
 Dark marks caused by uneven drying.

Copyright © TWI Ltd


Film Artefacts

Streakiness
caused by
poor agitation
during development

Copyright © TWI Ltd


Interpretation of Radiographs

Film Density (a) Weld (b) Parent


1.4 Material
2.7
IQI Type No. of wires or steps visible
None N/ A
Sensitivity calculation in full
N/ A

The film density is less than 2.0. No IQI present. No


identification or location markers present. A reshoot is
required.

Copyright © TWI Ltd


Interpretation of Radiographs

Copyright © TWI Ltd


Interpretation of Radiographs

1. Crater crack, 85 from datum 3 long.


2. Tool mark, 90 from datum.
3. Undercut, 125 from datum, 35 long (intermittent).
4. Wormholes and porosity, 145 from datum, 30 long.

Copyright © TWI Ltd


Interpretation of Radiographs

TWI Training & Examination Services

Radiographic Interpreter

Name: Joe Bloggs Date: 01/ 01/ 01


Reference No. 097-201 Material Carbon Steel

Welding Details

Root Gap 3 Root Face 1.5 Material 8


Thickness
Process SMAW

Joint Prep. Single Vee

Diameter 324 mm

Radiographic Details

Source of 180 kV X-Ray Film Type Agfa D7


Radiation
Screens Pb 0.125 mm front & back FFD/SFD 400

Technique DWSI Development Standard

Copyright © TWI Ltd


Interpretation of Radiographs

Film Density (a) Weld (b) Parent


1.2 Material
1.7
IQI Type No. of wires or steps visible
10ISO16 2
Sensitivity calculation in full
0.32/ 8 x 100 = 4%

The film density is less than 2.0. The sensitivity is greater than
2%. No identification or location markers present. The IQI is
cannot be properly identified. A reshoot is required.

Copyright © TWI Ltd


Interpretation of Radiographs

Copyright © TWI Ltd


Interpretation of Radiographs

1. Suspected LORF, difficult to interpret due to thickness


change, 0-75mm.
2. Porosity, Datum + 120, 45mm long.
3. Lack of penetration, 2 sections 110-130mm and 145-
168mm.
4. Undercut (cap), intermittent full length, both weld
toes.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Transverse crack probably caused by Cu pick-up.


2. Scattered pores/wormholes and small slag inclusions.
3. Intermittent minor cap undercut.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Linear porosity indicating lack of fusion.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Tungsten Inclusion.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Lack of fusion.
2. Cap undercut.
3. Dense metal inclusions.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Linear slag inclusions indicating lack of fusion.


2. Weld spatter.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Crack, probably solidification crack.

Copyright © TWI Ltd


Interpretation of Radiographs

1. Lack of root penetration.


2. Burn through.
3. Undercut.
4. Uneven penetration bordering excessive, full
length.

Copyright © TWI Ltd


Part 8: Safety
Covering pages 126-138 of your notes

Copyright © TWI Ltd


Radiation Safety

 Due to the hazardous nature of ionising radiation


it is important to understand the basic principles
of radiation safety and have an understanding of
the current legislation regarding radiation
protection.

Copyright © TWI Ltd


Radiation Safety

Principles
 Justification
 Optimisation ALARA
 Limitation

Copyright © TWI Ltd


Radiation Safety

Units of dose

Gray

The amount of radiation that will deposit one joule


of energy/kg of absorber.

Copyright © TWI Ltd


Radiation Safety

Units of dose

Quality factor

The degree of biological damage caused by a


quantity of radiation.

Copyright © TWI Ltd


Radiation Safety

Units of dose

Sievert: Radiobiological effectiveness,


Grays x QF.

Copyright © TWI Ltd


Radiation Safety

Quality factors
 X or gamma rays: QF = 1.
 Beta particles: QF > 1.
 Alpha particles: QF = 20.

Penetrating power
 X or gamma: 600mm of steel.
 Beta particles: Sheet of paper/layer of skin.
 Alpha particles: Less than 1cm of air.

Copyright © TWI Ltd


Radiation Safety

Safe working
 Controlled area: Any area in which the dose will
exceed 3/10th annual dose for employees aged
18 or over.

7.5mSvh-1: Maximum dose rate at the barrier.

Copyright © TWI Ltd


Radiation Safety

Safe working

 Supervised area: Any area in which the


dose rate will exceed 1/3rd that of
controlled area.

Copyright © TWI Ltd


Shielding

The intensity of radiation is reduced by absorption


as is passes through matter.

Half value layer

The thickness of any material that will reduce the


radiation intensity to one half its initial value.

Copyright © TWI Ltd


Shielding: Half and Tenth Value layers

t
I I x2
0 HVL

t
I I x 10
0 TVL

Copyright © TWI Ltd


Radiation Safety

Calculating safe distances

D1  2
 R1  D2   R2
2

D1: Original distance.


D2: Required distance.
R1: Original dose rate.
R2: Required dose rate.

Copyright © TWI Ltd


Radiation Safety

Calculating safe distances

D1  2
 R1  D2   R2
2

D2 
D1  2
 R1
R2

Copyright © TWI Ltd


Radiation Safety

Calculating safe distances

D2 
D1 2
 R1
R2
Dose rate at 1m also called output.
 Co 60 13 mGy/hr/Ci.
 Ir 192 4.8 mGy/hr/Ci.
 Yb 169 1.25 mGy/hr/Ci.

Copyright © TWI Ltd


Radiation Safety

Calculating safe distances: For 20 Ci of Co60

D2 
1 13mGy / hr / Ci  20Ci 1000 1
7.5 Sv/hr
Safe distance = 186.2m

Copyright © TWI Ltd


Radiation Safety

Personnel
 Radiation protection advisor (RPA).
 Radiation protection supervisor (RPS).
 Classified persons.
 Trainee.
 Others.

Copyright © TWI Ltd


Radiation Safety

Safe distances

 Controlled area: Any area in which the dose


is likely to exceed 6mSv/yr or 3/10th annual
dose for employees 18+.

 7.5mSvh-1: Maximum dose rate at the


barrier.

Copyright © TWI Ltd


Radiation Safety

Safe distances
Supervised area: Any area in which the dose is
likely to exceed 1mSv/yr or 1/10th of annual dose
for employees 18+.

Copyright © TWI Ltd


Controlled Area

You are required to follow special


procedures to restrict exposure/prevent
accidents
 During site radiography: Around the
radiography position, wherever the dose rate
is 7.5Sv/h or more.
 Inside an x or gamma radiography compound.
 Inside a source store.
 Controlled area may be set up following an
incident.

Copyright © TWI Ltd


Controlled Areas

Access is restricted to
• Classified workers.
• Others working under a written arrangement.

 Local rules.
 Radiation protection supervisor.
 Boundary is physically demarcated.
 Warning notices.
 Routine radiation monitoring.
 Personal dosimetry must be used.

Copyright © TWI Ltd


Supervised Area

There are no special procedures to


follow but the area is kept under
review by monitoring to pick up any
change in conditions
Some areas in a radiographic installation:
 Where dose rates are higher than background.
 Around enclosures where gamma sources are used.

Copyright © TWI Ltd


Supervised Area

 Boundaries are not physically demarcated.


 Warning signs not always legally required but
sometimes useful.
 No restriction on access.
 Routine monitoring is carried out.
 Area is described in the local rules.

Copyright © TWI Ltd


Local Rules

Written document describing how to:


 Carry out the work in accordance with the legislation.
 Restrict exposure.
 Prevent accidents.

Copyright © TWI Ltd


Local Rules

Read and work in accordance with your


employer’s local rules

Local rules will always include:


 Name and contact details of the RPS.
 The dose investigation level.
 Description of any controlled or supervised
areas.
 Written arrangements for non classified people
working in a controlled area.
 Summary of the contingency plan.

Copyright © TWI Ltd


Radiation Safety

Monitoring
 Ionisation chamber.
 Geiger muller tube.
 Scintillation counter.
 Film badge.
 Thermo-luminescent dosimeter (TLD).
 Quartz fibre electroscope.
 Audible monitors (personal monitor).

Copyright © TWI Ltd


Survey Meters

Survey meters produce a reading of the current


dose rate, usually in mSv/h or mSv/h.

Three types are used in industrial radiography:

1. Geiger counters.
2. Ionisation chambers.
3. Scintillation counters.

Copyright © TWI Ltd


Survey Meters

 For the detection of X or gamma radiation geiger


counters are usually used.
 Geiger counters are effectively high voltage
ionisation chambers.
 They are designed to produce pulses of current
when exposed to radiation.
 The number of pulses produced can be related to
the radiation dose rate.
 Geiger counters are more compact and more
durable than standard ionisation chambers and
have a wider measurement range.

Copyright © TWI Ltd


Survey Meters

 Ionisation Chamber
When the gas is
ionised a
current can flow
through the
chamber.
The magnitude
of the current is
related to the
AMMETER
intensity of
ionising
radiation.

Copyright © TWI Ltd


Survey Meters

 Scintillation counters are extremely sensitive to low


levels of radiation.
 They are useful for checking for contamination.
 A scintillation counter uses a phosphor which flashes
in the light spectrum when exposed to ionising
radiation.
 Flashes of light are detected by a photomultiplier
tube.
 Different phosphors are used for different
applications: eg sodium iodide for X and gamma ray
detection or zinc sulphide for alpha particles.

Copyright © TWI Ltd


Radiation Dose Monitoring

 Quartz fibre electroscopes, film badges,


thermo-luminescent dosimeters and some
types of personal monitor are all devices for
measuring total radiation dose over a period
of time.
 TLDs use a lithium fluoride (LiF) phospor.
 When exposed to ionising radiation LiF stores
energy which is later released as flashes of
light when the phosphor is heated.

Copyright © TWI Ltd

You might also like