Ut Weld Inspection Using Aws d1.1

8/10/2019 Ut Weld Inspection Using Aws d1.1

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Ultrasonic Testing

Weld Inspection using AWS D1.1


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Introduction

This presentation will helpstudents perform testingusing the AmericanWelding Society StructuralSteel D1.1-2000 code andprocedure.

It is important toremember that this is a

general training programand the procedure shouldbe referenced for specificinformation.


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What you will learn

Completing Form D-11

Determine the proper transducer(s) needed for

testing a weld.

Calibration using an IIW, rumpus, and DSCblock.

Scanning for discontinuities.

Calculate size and location of a discontinuity. Accept/Reject evaluation of a discontinuity.


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Form D-11

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

Some basic information should be completed on form D-11 prior

to the inspection. This information includes the following:


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Step 1Specimen Measurement

Measure the part thickness. From this thickness you will need tocalculate 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 2Inspection LayoutThe skip distance will equal the surface distance of thetwo legs. You will need to know the distance of this areain order to perform a lamination scan followed by anangle beam examination


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Inspection Layout

Identifying the skip distance from the edge of theHAZ will ensure complete coverage of the weld

when performing an angle beam examination.


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Step 3Lamination Scan

A lamination scan will be performed in the areawhere the angle beam inspection will take place.This scan is performed with a straight beamtransducer.


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Lamination Scan

Perform a lamination scan from face A. You will needto see at least two plate thicknesses on the display. Thefirst backwall reflection shall be 50 to 75% full screenheight.


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Lamination Scan

If any area of the base metal shows a total loss ofbackwall reflection, or if an indication is equal or greater

to the backwall reflection, the size and location and

depth will be reported.


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Lamination Scan

Move the transducer in all directions until theamplitude of the signal is reduced by 50%. Mark the

center of the transducer.


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Lamination Scan

Note the location and size of the lamination on reportform D-11 or write an additional report with a drawing

showing its location.


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Step 4Transducer AngleTable 6.6 will list the transducer angles needed to test the weld.For material 0.60 the transducer angle used will be 70 degreesand will be tested from face A. On Form D-11 record thetransducer angle and face which you will be testing from. Theface is determined from Table 6.6


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Step 5Screen Range

Calculate the full V-path. This is determined by thematerial thickness and transducer angle. Choose theappropriate screen range in order to see a minimumsound path of two legs.


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Step 6Screen Range

Calculate the full V-path. This is determined by thematerial thickness and transducer angle. Choose theappropriate screen range in order to see a minimumsound path of two legs.


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Transducer

Verify the transducer is coupled to the wedgeand there are no air pockets between the two.


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Calibration - IIW Block

All measurements are taken from where the signalbreaks the baseline of the ultrasonic screen.


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Screen RangeIIW Block

Adjust the ultrasonic machine to obtain the properscreen range. With an IIW type II block shown, thebackwall reflections will be located at 2 and 4.

Position of the signals

with a 10 screen range.


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Screen RangeIIW Block

The position of the 2 and 4 reflections when using a5 screen range.




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Screen RangeDSC BlockThe distance and sensitivity calibration block (DSC) can be

used for calibration. With the transducer placed in the position

shown, the reflections will take place at 1, 5, 9, etc.




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Screen RangeDSC Block

With the transducer placed in the position shown, thereflections will take place at 1, 5, 9, etc.


with a 5.0 screen range.


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Screen RangeRumpus Block

The miniature calibration block or rumpus block can also beused for calibration. With the transducer placed in the position

shown, the reflections will take place at 1, 4, 7, 10 etc.




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With the transducer placed in the position shown, thereflections will take place at 1, 4, 7, 10 etc.




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Position of the signalswith a 5 screen range.


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Step 7Transducer Exit Point

Determine the exit point of the transducer. Peak the signal onthe ultrasonic machine and verify that the index point on theplastic wedge matches the calibration block. You may use tapeand a pen to mark the exit point. This will allow for easiermeasurements when measuring the surface distance.


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Exit PointIIW BlockThe exit point and screen range can be performed at the sametime. Slide the transducer back and forth until the signal ismaximized. The pictures below shows the location of thetransducer when verifying the exit point using an IIW type IIblock.


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Exit PointDSC BlockThe 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 PointRumpus BlockThe 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 8Transducer AngleThe 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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AngleIIW Block

Slide the transducer back and forth until the signal ismaximized. The picture below shows the location of

the transducer when verifying the transducer angle.


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AngleDSC Block




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AngleRumpus Block




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Step 9Transducer ResolutionThe 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.




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Step 10Reference Level

The amplitude of a known size reflector will beadjusted from 50-75% full screen height. The dB will

be recorded as the reference level on form D-11.

IIW block

DSC block

Rumpus block


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Reference LevelIIW BlockThe transducer shall be placed in the position shown and the signal

amplitude from the hole will be maximized. Adjust the dB in order to obtain a

signal from 50 to 75% full screen height. This will be used as the reference

level b on form D-11.




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Reference LevelDSC BlockThe transducer shall be placed in the position shown and the

signal amplitude from the notch will be maximized. Adjust the

dB in order to obtain a signal from 50 to 75% full screen height.

This will be used as the reference level b on form D-11.




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Reference LevelRumpus BlockThe transducer shall be placed in the position shown and thesignal amplitude from the hole will be maximized. Adjust the dBin order to obtain a signal from 50 to 75% full screen height.This will be used as the reference level b on form D-11.




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Step 11Reference Level

In this example the reference level b would berecorded as 42 dB. The reference screen height used

is 60% FSH.


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Step 12Scanning Level

Scanning level is based on sound path distance and notmaterial thickness. If table 6.2 (Statically loaded nontubular

connections) are tested, the following scanning levels will be

used.

Above ZeroSound 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) aretested, the following scanning levels will be used.

Above ZeroSound 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 ascanning level 14 dB above the reference level.


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Step 13Initial Information Scan

Perform an initial information scan marking thelocation of any suspected discontinuities.


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Weld Configuration

You can draw a diagram of the weld on the ultrasonic screenwith a water based marker or grease pencil. The line is drawn

at the end of the 1st, 2nd, and 3rdleg. This may help you

visualize the location of the discontinuity in the weld.


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Step 14Surface Distance

Calculate the surface distance in order to determine ifthe signal is located in the weld.


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Step 15Discontinuity Depth

Calculate the depth in order to determine if the signalis located in the weld.


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Step 16Sound Path

Move the transducer in all directions in order to peakthe signal from the discontinuity. Record the Sound

Path on Form D-11.


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Step 17Sound Path

Record the Leg on Form D-11.


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Step 18Indication LevelIncrease or decrease the dB until the screen height from the

discontinuity is equal to the reference level. Record the dBunder indication level (column b).

dB reference level - 60% FSH.


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Step 19Attenuation FactorSubtract one inch from the sound path distance and multiply theremainder by two. This number will be rounded to the nearestwhole number. If the number is less than 0.5 dB it will belowered to the nearest whole number. If the number is 0.5 orgreater, it will be increased to the nearest whole number.

In this example, the sound

path is 1.9

1.9 1 = 0.9

0.9 x 2 = 1.8

Rounded to the nearest

whole number - 2


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Attenuation Factor

On Form D-11, fill out the attenuation factor. This islocated under Decibels- Attenuation Factor.

In this example, the sound

path is 1.0

1.01 = 0.0

0.0 x 2 = 0.0

If the attenuation factor is

less than 0.5, the

attenuation factor will be

zero.


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Step 20Indication Rating

The indication rating is calculated by taking theIndication level minus Reference level minus

Attenuation factor. A-B-C=D

The answer D is

your indication rating

and can be positive or

negative. Write this

number in column D

under Decibels,

Indication Rating


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Step 21Discontinuity Length

Maximize the signal amplitude from the discontinuity.


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Step 22Discontinuity Length

Slide the transducer parallel with the weld until thesignal amplitude has reduced by 50%. Mark thelocation next to the weld aligned with the center of thetransducer. Perform this procedure in both directions.


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Discontinuity Length

Record the length on Form D-11.


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Step 23Discontinuity Class

From Table 6.2 or 6.3, determine the DiscontinuitySeverity 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

Class B (medium discontinuity)

Any indication in this category having a length greater than shall be rejected.

Class C (small discontinuity)

Any indication in this category having a length greater than 2 shall be rejected.

Class D (minor discontinuity)

Any indication in this category shall be accepted regardless of length or location in

the weld.

S 24 Di i i E l i


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Step 24Discontinuity Evaluation

On Form D-11 under Discontinuity Evaluation list theclass of the discontinuity.

St 25 A t/R j t


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Step 25Accept/RejectOn Form D-11 under Remarks accept or reject the

discontinuity.


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Step 26Distance from YOne side of the plate or weld can be identified with a Y

location point. From the edge of the weld measure to thebeginning of the discontinuity. Record Distance from Y on

Form D-11.

Distance from Y = 1.0 Distance from Y = 0.3


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Step 27Distance from XFrom the center of the weld (marked in black), if the

discontinuity is located opposite the Y location mark, it will bemeasured as a positive number. This will be recorded under

Distance from X on Form D-11.

Distance from X = 0.2


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Step 28Distance from X

From the center of the weld (marked in black), if the

discontinuity is located on the same side as the Y location

mark, it will be measured as a negative number. This will be

recorded under Distance from X on Form D-11.

Distance from X = -0.2


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Step 29Scanning Level

Return to the scanning level and locate the nextdiscontinuity for evaluation.

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Ut Weld Inspection Using Aws d1.1