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Ultrasonic Testing: Weld Inspection Using AWS D1.1
Ultrasonic Testing: Weld Inspection Using AWS D1.1
1 06/12/20
Introduction
This presentation will help
students perform testing
using the American
Welding Society Structural
Steel D1.1-2000 code and
procedure.
It is important to
remember that this is a
general training program
and the procedure should
be referenced for specific
information.
2
What you will learn
Completing Form D-11
Determine the proper transducer(s) needed for
testing a weld.
Calibration using an IIW, rumpus, and DSC
block.
Scanning for discontinuities.
Calculate size and location of a discontinuity.
Accept/Reject evaluation of a discontinuity.
3
Form D-11
Some basic information should be completed on form D-11 prior
to the inspection. This information includes the following:
Weld Identification
Material Thickness
Type of Weld Joint
Welding Process
Quality Requirements
Section Number
Year of AWS D1.1 Code used.
Testing Date
Inspected By
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Step 1 – Specimen Measurement
Measure the part thickness. From this thickness you will need to
calculate the skip distance. The skip distance is the area where you
will scan the part with the proper angle transducer. Mark the end of
the skip distance from the edge of the heat affected zone (HAZ).
The area in red will be used to identify the heat affected zone.
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Step 2 – Inspection Layout
The skip distance will equal the surface distance of the two legs.
You will need to know the distance of this area in order to perform
a lamination scan followed by an angle beam examination
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Inspection Layout
Identifying the skip distance from the edge of the
HAZ will ensure complete coverage of the weld
when performing an angle beam examination.
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Step 3 – Lamination Scan
A lamination scan will be performed in the area
where the angle beam inspection will take place.
This scan is performed with a straight beam
transducer.
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Lamination Scan
Perform a lamination scan from face “A”. You will need
to see at least two plate thicknesses on the display. The
first backwall reflection shall be 50 to 75% full screen
height.
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Lamination Scan
If any area of the base metal shows a total loss of
backwall reflection, or if an indication is equal or greater
to the backwall reflection, the size and location and
depth will be reported.
10
Lamination Scan
Move the transducer in all directions until the
amplitude of the signal is reduced by 50%. Mark the
center of the transducer.
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Lamination Scan
The area can be measured and included in the report. This
area should be avoided when performing an angle beam
examination or an alternate scanning procedure shall be
used.
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Lamination Scan
Note the location and size of the lamination on report
form D-11 or write an additional report with a drawing
showing its location.
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Step 4 – Transducer Angle
Table 6.6 will list the transducer angles needed to test the weld.
For material 0.60” the transducer angle used will be 70 degrees
and will be tested from face “A”. On Form D-11 record the
transducer angle and face which you will be testing from. The
face is determined from Table 6.6
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Step 5 – Screen Range
Calculate the full V-path. This is determined by the
material thickness and transducer angle. Choose the
appropriate screen range in order to see a minimum
sound path of two legs.
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Step 6 – Screen Range
Calculate the full V-path. This is determined by the
material thickness and transducer angle. Choose the
appropriate screen range in order to see a minimum
sound path of two legs.
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Transducer
Verify the transducer is coupled to the wedge
and there are no air pockets between the two.
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Calibration - IIW Block
All measurements are taken from where the signal
breaks the baseline of the ultrasonic screen.
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Screen Range – IIW Block
Adjust the ultrasonic machine to obtain the proper
screen range. With an IIW type II block shown, the
backwall reflections will be located at 2” and 4”.
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Exit Point – IIW Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The pictures below shows the location of the
transducer when verifying the exit point using an IIW type II block.
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Exit Point – DSC Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The pictures below shows the location of the
transducer when verifying the exit point.
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Exit Point – Rumpus Block
The exit point and screen range can be performed at the same
time. Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of the
transducer when verifying the exit point.
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Step 8 – Transducer Angle
The angle of the transducer will need to be verified. It
shall be within plus or minus 2 degrees of the required
angle.
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Angle – IIW Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.
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Angle – DSC Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.
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Angle – Rumpus Block
Slide the transducer back and forth until the signal is
maximized. The picture below shows the location of
the transducer when verifying the transducer angle.
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Step 9 – Transducer Resolution
The resolution shall be checked with the instrument controls set at normal
test settings and the indications from the holes brought to midscreen height.
Resolution shall be sufficient to identify the peaks of the three holes.
42
Step 12 – Scanning Level
Scanning level is based on sound path distance and not
material thickness. If table 6.2 (Statically loaded nontubular
connections) are tested, the following scanning levels will be
used.
Above Zero
Sound Path (in) Reference, dB
0.0” to 2.5” 14
>2.5” to 5” 19
>5” to 10” 29
>10” to 15” 39
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Scanning Level
If table 6.3 (Cyclically loaded nontubular connections) are
tested, the following scanning levels will be used.
Above Zero
Sound Path (in) Reference, dB
0.0” to 2.5” 20
>2.5” to 5” 25
>5” to 10” 35
>10” to 15” 45
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Scanning Level
This shows the screen presentation when using a
scanning level 14 dB above the reference level.
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Step 13 – Initial Information Scan
Perform an initial information scan marking the
location of any suspected discontinuities.
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Weld Configuration
You can draw a diagram of the weld on the ultrasonic screen
with a water based marker or grease pencil. The line is drawn
at the end of the 1st, 2nd, and 3rd leg. This may help you
visualize the location of the discontinuity in the weld.
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Step 14 – Surface Distance
Calculate the surface distance in order to determine if
the signal is located in the weld.
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Step 15 – Discontinuity Depth
Calculate the depth in order to determine if the signal
is located in the weld.
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Step 16 – Sound Path
Move the transducer in all directions in order to peak
the signal from the discontinuity. Record the “Sound
Path” on Form D-11.
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Step 17 – Sound Path
Record the “Leg” on Form D-11.
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Step 18 – Indication Level
Increase or decrease the dB until the screen height from the
discontinuity is equal to the reference level. Record the dB
under indication level (column b).
1.9” – 1 = 0.9
0.9 x 2 = 1.8
1.0 – 1 = 0.0
0.0 x 2 = 0.0
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Step 21 – Discontinuity Length
Maximize the signal amplitude from the discontinuity.
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Step 22 – Discontinuity Length
Slide the transducer parallel with the weld until the
signal amplitude has reduced by 50%. Mark the
location next to the weld aligned with the center of the
transducer. Perform this procedure in both directions.
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Discontinuity Length
Record the length on Form D-11.
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Step 23 – Discontinuity Class
From Table 6.2 or 6.3, determine the Discontinuity
Severity Class. This is based on the Indication Rating
and Length.
Class A (large discontinuity)
Any indication in this category shall be rejected regardless of length
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Step 24 – Discontinuity Evaluation
On Form D-11 under “Discontinuity Evaluation” list the
class of the discontinuity.
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Step 25 – Accept/Reject
On Form D-11 under “Remarks” accept or reject the
discontinuity.
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Step 26 – Distance from “Y”
One side of the plate or weld can be identified with a “Y”
location point. From the edge of the weld measure to the
beginning of the discontinuity. Record “Distance from “Y” on
Form D-11.
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