1.

SCOPE

1.1 This procedure defines the requirement of equipment, calibration, examination tech-niques
and acceptance standard for Ultrasonic examination of straight butt welds (Fig. 1).
1.2

This standard is based on ASME: Sec V Article 5.

1.3

Surface from examination carried out :

Examination shall be performed from the top surface. The scanning of the examination volume shall
be carried out from both sides of the weld on the same surface. Where configuration or adjacent
parts of the component are such that scanning from both sides is not feasible, this fact shall be
included in the report of the examination.
2.0

PERSONNEL QUALIFICATION:

The personnel conducting the examination shall be qualified according to NDE Written Practice QMI
008 Revision No.07.
3.0

SURFACE CONDITION:

3.1 The Finished Contact surface shall be free from weld spatter and roughness that would
interfere with the free movement of the probe and impair the transmission of ultrasonic vibration.
3.2 The weld surface shall be finished so as not to confuse or mask the reflections from the weld
defects and shall merge smoothly with the surface of the adjacent materials.
3.3 The Finish on the surface of the basic calibration block shall be representative of the surface
finishes of the components.
3.4 Base metal on either side of the weld shall be free from weld spatter, surface irregularities or
foreign matter that might interfere with the examination.
4.0

EQUIPMENT

USM2M, EEC-ESM-2M or Karl Deutsch Echograph 1030 shall be used.

5.0

TECHNIQUE:

5.1 Pulse echo technique and contact method shall be used. Manual operation with visual
monitoring shall be accomplished. Scanning shall be done in two directions 180 to each other to
the extent possible. Areas blocked by geometrical conditions shall be examined from at least one
direction.
5.2 For straight beam technique, longitudinal wave probe of frequency 2MHz or 4 MHz with
contact face not exceeding 25mm (crystal dia.) shall be used.
5.3 For angle beam technique, shear wave probe of frequency 2 MHz or 4 MHz with contact face
not exceeding 20 x 20mm shall be used. The beam angle shall be selected from the table-1.
5.4

Glycerine, SAE 30 Servoway 68, Servo system 46 or Servo system 68 shall be used as couplant.

5.5

Speed of scanning shall not exceed 150mm / second.

6.0

CALIBRATION

6.1

Calibration Block

A flat basic calibration block shall be used as per Fig.2 and conform to the requirements of ASME
Section-V Article 5.
6.2

Sweep range calibration for Straight Beam:

Position the search unit for the maximum first indication from the 1/4T side
drilled hole. Adjust the left edge of this indication to line 2 on the screen with the
delay control.

a)

Position the search unit for the maximum indication from the 3/4 hole.
Adjust the left edge of this indication to line 6 on the screen with the range control.

b)

Repeat delay and range control adjustments until the 1/4T and 3/4T hole
reflections start at sweep line 2 and 6.

c)

6.3

Straight Beam Calibration

A distance amplitude correction curve (Fig. 3) using the calibration block as per figure 2 shall be
constructed.
The probe shall be positioned for maximum response from the hole, which
gives the highest amplitude.

a)

Adjust the sensitivity control to provide an 80% ( 5% of full screen height)

of full screen indication from the hole. Mark the peak of the indications on the
screen with glass marking pencil or other suitable marker.

b)

Position the search unit for maximum response from another hole
indication.

c)

Mark the peak of the indication on the screen.

d)

Position the search unit for maximum amplitude from the third hole
indication and mark the peak on the screen.

e)

Connect the screen marks extended through the thickness to provide the
distance amplitude curve for the side-drilled hole.

f)

6.4

Sweep Range Calibration for angle beam

Position the search unit for the maximum first indication from the 1/4T side
drilled hole.
a)

Adjust the left edge of this indication to line 2 on the screen with the delay control.
Position the search unit for the maximum indication from the 3/4T hole.
Adjust the left edge of this indication to line 6 on the screen with range control.
b)

Repeat delay and range control adjustments until the 1/4T and 3/4T hole
reflections start at sweep line 2 and 6.
c)

Position the search unit for maximum response from the square notch on
the opposite surface.
d)

The indication will appear near sweep line 8.

e)

6.5

Two divisions on the sweep equal 1/4T.

Angle Beam calibration

Distance Amplitude Correction (DAC) curve (Fig. 4) shall be constructed by utilising the response
from the basic calibration holes.
a) Position the search unit for maximum response from the hole, which gives
highest amplitude.

Adjust the sensitivity control to provide an 80% ( 5% of full screen height)

of full screen indication from the hole. Mark the peak of the indications on the
screen.
b)

Without changing the gain control, position the search unit for maximum
response from another hole indication and mark peak of the indication on the
screen.
c)

d) Similarly position the search unit for maximum amplitude from the third
hole indication and mark the peak on the screen.

Position the search unit for maximum amplitude 3/4 T hole indication after
the beam has bounced from the opposite surface.
e)

The indication should appear at sweep line 10. Mark the peak on the screen
for the 5/4 T position.
f)

g)

6.6

Connect the screen marks for the side-drilled holes to provide DAC curve.

Calibration check on basic calibration block

When any part of the examination system is changed, a calibration check
a)
shall be made on the basic calibration block to verify that 1/4 ,1/2 and 3/4 T points on
the sweep and distance amplitude correction values recorded satisfy the
requirements of 6.3 and 6.5.
A calibration check on at least one of the basic reflectors in the basic
calibration block shall be made at the finish of each examination or series of similar
examinations, every 4 hours during the examination and when examination
personnel are changed. The sweep and distance amplitude correction values
recorded shall satisfy the requirements.
b)

6.7

Sweep Range Correction

If a point on the DAC curve has moved on the sweep line more than 10% of the sweep reading or 5%
of full sweep, whichever is greater correct the sweep range calibration and note the correction in
the examination record. If reflectors are recorded on the data sheets, those data sheets shall be
void and a new calibration shall be recorded. All the recorded indications since the last valid
calibration or calibration check shall be re-examined with the corrected calibration and their values
shall be changed on the data sheets.

6.8

DAC Correction

If a point on the distance amplitude correction curves has decreased 20% or 2dB of its amplitude, all
data sheets since the last calibration or calibration check shall be marked void. A new calibration
shall be made and recorded and the area covered by the void data shall be re-examined. If any point
of distance amplitude correction curve has increased more than 20% or 2dB of its amplitude, all
recorded indication since the last valid calibration or calibration check shall be re-examined with the
corrected calibration and their values shall be changed on the data sheets.
7.0

SCANNING

Scanning of the adjacent base metal with normal beam probe shall be performed to
detect reflectors that might affect interpretation of angle beam results and is not to be
used as an acceptance standard. Location and areas of such reflectors shall be recorded.
Sensitivity shall be set at 80% ( 5% of full screen height) of full screen height of back wall
echo.
7.1

Scanning shall be done at twice setting of calibration (6dB more) for both techniques
7.3 The longitudinal wave probe is kept straight over weld directing the beam towards the other
side of the weld.
7.4 For angle beam technique, the shear wave probe shall be used directing the beam towards the
weld. Zigzag scanning with a swivel of 5 to 10 shall be carried out with 10% overlap between
successive scannings.
7.5 The angle beam shall be directed essentially parallel to the weld axis. The search unit shall be
manipulated so that the angle beam passes through the required volume of the weld and the
adjacent base metal. The search unit shall be rotated 180 and the examination repeated.
8.0

EVALUATION OF INDICATIONS

All indications which produce a signal amplitude greater than 20% of the reference level shall
be noted and investigated to determine the nature, shape, identity and location of the reflector.
9.0

DATA RECORDING

9.1

Manual recording of reflectors shall be accomplished.

10.0

ACCEPTANCE CRITERIA

10.1 Indications characterised as cracks, lack of fusion or incomplete penetration are unacceptable
regardless of length.
10.2 Other imperfections are unacceptable if the indications exceed the reference level amplitude
and have lengths which exceed
1.

/4" (6.25mm) for t up to " (18.75mm)

2.

3.

/3 t from 3/4" (18.75mm) to 21/4" (56.25mm)

/4" (18.75mm) for t over 21/4" (56.25mm)

Where t is the thickness of the weld excluding any allowable reinforcement. For a butt weld joining
two members having different thickness at the weld, t is the thinner of these two thicknesses. If a

full penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be included in
t.

Position 1 :

SCANNING ON THE WELD WITH NORMAL BEAM

Position 2 :

Scanning with angle beam directing the beam towards weldment

Position 3 :

Scanning with angle beam directing the beam towards weldment

Fig-1 POSITION OF PROBE & SCANNING

11.0 RECORDING OF TEST CONSTRAINTS:
11.1 Any test restrictions through bolt holes, probe movement etc. shall be recorded in the
ultrasonic examination report.
11.2 Reflections from uncorrected areas having responses that exceed 50% of the reference level
shall be recorded. This record shall locate each area, the response level, the dimensions, the depth
below the surface and classification.
12.0 POST EXAMINATION CLEANING:
After ultrasonic examination the weld and surrounding area shall be thoroughly cleaned by
suitable method.
TABLE 1
Beam angles for different thicknesses
80 for thicknesses 5 - 15 mm
70 for thicknesses 15 - 30 mm
60 for thicknesses 30 - 60 mm

Weld thickness (T)

Basic calibration
block thickness (T)

Hole diameter

Notch size

1 or less

or t

3/32

Width 1/8 to

Over 1 through 2

1 or t

1/8

Depth 2% T

Over 2 through 4

3 or t

3/16

Length 2 (Min)

Over 4 through 6

5 or t

Over 6 through 8

7 or t