Académique Documents
Professionnel Documents
Culture Documents
SSC-253
..
1976
-. --
--
W. M. Benkert
Rear Admiral, U.S. Coast Guard
Chairman, Ship Structure Committee
,.
SSC-253
1976
SHIP STRUCTURE COMMITTEE
AN INTERAGENCY ADVISORY
COMMITTEE DEDICATED TO IMPROVING
THE STRUCTURE OF SHIPS
MEMBERAGENCIES: ADDRESSC
ORRE$PONDENCETO:
Umtcd Stotes Coast Guard Secretary
W.M. Benkert
Rear Admiral, U.S. Coast Guard
Chairman, Ship Structure Committee
SSC-253
Final Report
on
PART ONE
by
under
Corner Joints .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 20
Tee Joints . . . . . . . . . .. .. . . . .. .. . . . . . . . .. . . . . . . . . . . . . . . .. 25
X-Joint. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . .. .
31
Lap Joint .. . . . . . . . . a . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
33
.ACCEPTA.NCE CRITERIA 35
. .. . . . .. . .. . . .. . . . . .. . .. . .. . .. .. . ...**
-iii-
LIST OF FIGURES
30
13A Ultrasonic Procedure for the Inspection of
TJoint Welds with Longitudinal Waves
30
13B Ultrasonic Test Procedure for Shear Wave
Inspection
-iv-
l?iqme Ticle
LIST OF I~BLEs
-v-
SHIP STRUCTURE COMMITTEE
The SHIP STRUCTURE SUBCOMMITTEE acts for the Ship Structure Committee
on technical matters b.yprovidinq technical coordination for the determination
of goals and objectives of the p~ogram, and by evaluating and interpreting the
results in terms of ship structural design, construction and operation.
This report is published in two parts: Part 1 is the guide for the
nondestructive testing of nonbutt welds in commercial ships. Part 2
documents the technical considerations involved in preparing that
guide.
This work was sponsored by the Naval Ship Systems Command under the
direction of the Ship Structures Committee and was accomplished by
the Nondestructive Analysis Group of the Physics Research Department,
>. B. WILCOX
.- ..-
By direction
-vii-
NOTES
1NTRODUCTION
-2-
These aspects of visual inspection can quickly and accurately be
accomplished with any of several pocket-size gauges. Figure 1
illustrates two gauges which are commercially available.
The completed weld may also be inspected for excessive weld splatter
or arc strikes when appearance is of importance. Weld discontinuities
may also be detected. The detection of cracks or other weld flaws
may suggest further examination at particular locations using more
sophisticated methods of nondestructive testing.
-3-
rmom -JJ _
..-
7-----
......-
..
..
, . .
k=- >
il
1
y ...L.%&.,, m.
5
8 .
. . ..
3
,. N.OF
83131-8
..,.* - A -
\ .
-5-
For welds in excess of 3/4 plate thickness, khe current is increased
an additional 257. to 5@A. Table I Iisks the required magnetization
currents according to prod spacing and seckion bhickness. It is
recommended thak the equipment include an ammeter to ensure adequat-e
currenti for proper inspection.
FOK weld inspection, the prod spacing should not be closer than 3;
and prod spacings in excess of 12 are impractical because of exces-
sive current requirements. It is recommended that prod spacing
between 4 and 8 be used.
Maqnetic Particle Test Procedure. After the prods have been firmly
positioned and the current has been turned on, the magnetic particle
powder is applied as a light dust. This can be with a dusking bag,
an atomizer, or a spray gun. Then with the currenk still flowing. a
gentle stream of air should be directed on the inspection area ko
-6-
,, ,,
AMPERES
PROD SPACING (lRICHES)
SECTION T1-llCKhlESS
4 400500 500625
5 500625 625775
6 600750 750900
8 800?000 10001200
9 900-1100 11 001300
10 ?000-1200 72001400
12 1200,1400 1400-1600
remove excess powder and enhance discontinuity indications. This
can be done with a low velocity air hose or with a hand operated
squeeze bulb.
Radiography
1
Such a patkern might be obtained when a weld is made involving a
f~rritic (magnetic) and an austenikic (non-magnetic) steel.
-8-
more complex configurations. This aspect of technique is of
paramount importance. While other technique factors such as kilo-
volkage (kV) , milliamperage (mA) , exposure time, distance, ehc. are
important, a very limited discussion is given here since the information
can be found elsewhere. 2
-1
American Welding Society, WELDING INSPECTION, 1968
-9-
0.1 0.15 0r2 0.3 0.4 0.6 0.81.0 1.5 2 34567810 15 20
30 I
20
15
6
5
4
1 MEV
900
800
7orl
600
Cn
1- 500
-1
0 400
>
0
-1
300
z
200
150
100 -- 34567810 15 : )
0.1 0.150.2 0.3 0.4 0.6 0.87.0. 1.5 2
sTEEL SPECIMEN THICKNESS (INCHES)
* BROKEN LINE INDICATES MARGINAL SEtJSITIVITY
~ 30
z
:
g
a
~
E
a
!-
m
3
~ 20
I k~
10
If khe film densitiy varies more than 15% or +3W~ from that on the
penetrameter, two penetrameters may be used to qualify the radiograph.
If an acceptable image quality level is shown by the penebrameker
located at the dense part of the radiograph and by the okher placed
-12-
i
l-i
H
v)
11-
ak the lower density portion, then the two penetrarneters serve to
qualify the portion of the radiograph between the two density values.
(Note: Densiky measurements are made along the center line of the
weldment) .
The film readers eyes should be exemined ah least once a year for
ability to see small detail at a normal reading distance of 400mm.
The reader should be able to read good print type of 0.5mm height or
better at this distance.
Ultrasonic Inspection
Couplants. Ultrasonics will not propagate through an air gap and some
type of liquid is required to couple the transducer and work piece.
The couplanti should be removed upon comple!zion of inspection.
.14-
Surface Preparation. The surfaces where the probe makes contact with
the weld o+ base metal should be suitable for good acoustical coupling.
Plates with loose scale, flaked paint, excess rust, or pittin9 ~i~~
require some preparation. Weld splatter can interfere with ultrasonic
inspection and must be removed from transducer contact locations.
-15.
T
-i-
38hm
T
44tnm
T
51mm
T
58mm
T
64mm
T
70mm
76mm
{3 in.)
{1.5in.) (1.75 in.) (2 in.} (2.25 in.) (2.5 in.) (2.75 in.)
1
%
/
_.-=. - ..
11
-----
1
c1
cl
c)
0
c1
c1 _.. ..= _ _ . . .. . __
.
1. The weld must be clean and free of any material which might
obstruct the penetrant. This includes materials which might have
penetrated into the cracks or discontinuitiies of interest. Cleaning
with a solvent suited to the removal of grease is recommended.
-18-
NDT-Lewel 11 An NDT Level 11 individual shall be qualified to
direct and carry out tests in the method certified. He must also be
able to set up and calibrate equipment (where applicable), read and
interpret indications, and evaluate them with reference to applicable
codes and specifications. He shall be thoroughly familiar with the
scope and limitations of the method, and shall have the ability Eo
apply detailed techniques to products or parts within his limit of
qualifications. He shall be able to organize and report nondestructive
kesting results.
-19-
The selection of a nondestructive test method should be based
upon the need to detect cerbain types of weld defects which are
acceptable either because of service requirements or company stand
ards. This guide lists khe methods which are most suitable for
detecting specific weld discontinuities and describes the procedures
for applying each method to the various joint configurations.
Corner Joints
r
incomplete pene Radiography
lxation
Full Lack of fusion Radiography
Penetration slag Radiography
Porosity Radiography
F-
Incomplete pene- Ultrasonics
tration
Full Lack of fusion Ultrasonics
Penetration Slag Iladiography
Porosity Radiography
Laminations Ultrasonics
Visual inspection and the magnetic particle method are the primary
nondestructive testing procedures used on corner joints designed for
partial penetration welding.
720-
Visual Inspection. Visual inspection provides:
Yokes are not recommended for use on corner welds because of geometrical
restrictions and the difficulty of making good contact.
-21-
TO DETERMINE THE SIZE OF
TO DETERMINE THE SIZE OF
A CONCAVE FILLET WELD
A CONVEX FILLET WELD
FIG, 7 PROCEDURE FOR MEASUR!NG THE S[ZE OF CONCAVE AND CONVEX FILLET WELDS
TO CHECK THE PERMISSIBLE TOLERANCE OF CC)NVEXiTY
GAUGE
-23-
m
r-
-25-
-26-
\
-27-
FIG 12A FULL PENETRATION CCRI-4ER JOINTS DONE WITHOUT CHAMFERS
NUMERALS
-287
Joj.nt PreparatiQ1l. Defect Methods for inspection
T Partial
Penetration
cracks Visual, magnetic
particle
11 Fu~~
Penetration
Erakion
Lack of fusion ultrasonics, radiography
Slag Radiography. ul~rasonics
Porosity Radiography
Laminations ultrasonics
-29-
TRANSDUCER POSITION TRANSDUCER POSITION
CRACK
-30-
at the edge of Ehe weld. Before the angle beam search is done, a
straight beam transducer is used to locate the edge of the weld.
Simple geometrical considerations can then be used to determine the
proper position for the angle beam transducer. For complete inspection,
the weld should be searched from both sides.
The inspection for toe cracks may also be performed on the web, however,
a web thickness of at least 1/2 is desirable.
X-Joint
-31-
7
A = WELD TtiROAT
i!! = 1.4 X FLANGE THICKNESS
c =A -t B = WELD THROAT PLUS 1.4
MULTIPLIED BY THE FLANGE THICKNESS
45
h-
ill
z
Lu
Q
I
-32-
Visual and Maqnetic Particle Inspection. Each of the four fillets of
an X-joint constitutes a corner joint and visual and magnetic particle
inspection techniques for these fillets are the same as those for cor
ner joints. Critical inspection for subsurface flaws may be accom
plished using radiography or ultrasonics.
Lap Joint
-33-
id
-P
The computed average thickness can be used with the graph of Figure 3
to select a suitable x-ray energy.
ACCEPTANCE CRITERIA
-35-
FIG. 16A CONVEXITY MEASUREMENT OF ALAPJOINTVVELD
GAUGE
-36-
x
PENETRAMETER
I
PENETRAMETER LEAD NUMERALS
1 1
CASSETTE
450
PENETRAMETER . /
CASSETTE
-37-
Visual Inspection.
.3a_
Single illustrations are given of other types of weld discontinuities
which may be detected by radiography but are not usually controlled in
degree.
With the instrument properly calibrated, the planar type flaws such as
cracks or lack of fusion typically produce a high-amplitude signal in
excess of the AR level. Indications less than the DR level are not
usually attributed to serious flaws are disregarded. Signals between
the AR and DR levels are usually related to non-planar weld discon-
tinuities such as slag.
-39-
100
CRACKS CRACK LIKE SLAG
INCOMPLETE PENETRATION PIPING 90
LACK OF FUSION LINEAR POROSITY
80 - ARL
- SEVERE POROSITY 70
MLJLTIPLE SLAG INCLUSIONS
ROUND E13GE SLAG
b 60
- CLUSTERED POROSITY
50
40 - DRL
iVllLD SCATTERED POROSITY
30
20
10
SSC213
Izf!L-J
\./-
A-2
powered equipment must contain an alarm to signal battery
depletion prior to instrument shut-off due to battery exhaustion.
1- .-200
7p I
,5 ~
60
__++.,5 ,/:0 J.
i /
r
I00
55
1
.g , ~~
50 (j
~
-.+d
100,,.
,/
,x 91
@
,. ,
,,
30 ,. 1:
,,,,
;/ 1
I.35+!
PLASTIC DISC
A-3
prove useful. Any couplant should be removed upon completion
of the inspection.
PERSONNEL QUALIFICATION
A-4
CALIBRATION STANDARDS
WELD INSPECTION
A-6
. .
.. .- 100
--- - 90
.- _.., .. 6 db___ 60
IL. . - 50
3: 40 D RL
-. 30
4 20
- 10
I I <I I I o
L\-l \ ; 1
,
ARL
DRL
NOTE: CALIBRATION IS PERFORMED WITH THE REFLECTION OBTAINED FROM THE WALL OF A
1/16 DRILLED HOLE USING D15TANCE-A~lPLITUDE
CORRECTIONS.
A-7
-. .---..
TRANSDUCER SONIC
(a)
TRANSDLICER / /
/~
/ //
/
ANGLE OF
N 30
/ ROTATION
/ 4 /
//
A-8
DISCONTINUITY EVALUATION
RECORD OF INSPECTION
Operators identity
:: Date
3. Instrument identity
4. Transducer type, size, frequency and angle
Identification of test object
:: Location of the weld
Type of material
:: Thickness of base plate
9. Type of joint and configuration
10. Condition of the weld bead
11. Couplant
12. Flaw data
13. Inspection coverage, including reference points.
A-9
. .
50
DRL ~
~ 30
20
10
\, 1 1 I 2 1 1 1
I 1 1 0
10
v 1
1
I 1
1 1
L
I
I
1
8
1 o)
.
100
90
WELDS WHICH PRODUCE INDICATIONS
ARL 80
EQUAL TO OR GREATER THAN THE
70
60 ARL LEVEL ARE REJECTABLE
1 50
DRL 40!
30
20
I 10
I I I
1 I ~~ y: 10
A-10
WITH THE ULTRASONIC INSTRUMENT CALIBRATED IN ACCORDANCE WITH
THE PROCEDURES SET FORTH IN THIS GUIDE, WELD DEFECTS OF THE
TYPES LISTED W!LL USUALLY PRODUCE SIGNAL AMPLITUDES IN RELATION
TO THE ARL AND DRL LEVELS AS SI+OWN:
100
CRACKS CRACK LIKE SL4G
- INCOMPLETE PENETRATION PIPING 90
50
DRL
MILD SCATTERED POROSITY
30
1 I o
A-n
G~SSARY OF TERMS
Active
Element - The piezo-electrical material in the ultrasonic
probe.
ARL (Amplitude
Ftel~ct Level - The horizontal level on the cathode ray tube
established by calibration. After calibration
the ARL is 80% full screen height or 6 dB above
the 40% line if a decibel attenuator is available.
Decibel
~ttenuatir - A gain control calibrated in decibels.
Delay
Controls - An electronic means of horizontally shifting the
pattern obtained on the cathode ray tube.
DRL (Disregard
Level) - The lmrizontal level on the cathode ray tube
established by calibration. After calibration
the DRL is 40% of full screen height.
Longitudinal1
Waves - A wave form in which the particle motion is
essentially in the same direction as the wave
propagation.
Megahertz
- A million cycles per second.
A12
through the medium and return to the source of
energy.
MS (Root
Mean Square) - A type of average used in describing surface
roughness.
Resulting
~ncrle - The angle formed between the ultrasonic beam
as it enters a medium of different characteris-
tics than the one from which it came and a line
drawn perpendicular to the interface between
the two media.
Scanning
Surface - The surface of the base metal where the ultra-
sonic probe is manipulated.
Straight
Seam - An ultrasonic technique which does not involve
an angle. The wave form is longitudinal.
A13
NOTES
UNCLASSIFIED
ECU RITY CLASSIFICATION OF THIS PAGE (Won D.91.9 Entered)
READINSTRU CTIONS
REPORT DOCUMENTATION PAGE BEFORE COMPLETING FORM
SSC-253
1.TITLE (mdSubfifle)
5, T;PEOF REPORT & PERIOD COVEREO
FY73 Final
A GUIDE FOR THE NONDESTRUCTIVE TESTING
OF NON-BUTT WELDS IN COMMERCIAL SKCPS- 6. PERFORMING ORG. REPORT NUMBER
PART 1 NOLTR 74-138
r.AUTHOR(S) 6. CONTRACT OR GRANT NuMBER(H)
Robert A. Youshaw
Edward L. Criscuolo
1. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PRoGRAM ELEMENT,PROJECT, TASK
AREA& WORK UNIT NUMBERS
Naval Surface Weapons Center
thite Oak, Silver Spring, Maryland 20910 NAVSHIP #000141
31 Dec 1974
13, NUMBEROF PAGES
53
14, MONITORING AGENCY NAME h AD DRESS({f dJff~rentf,Om controlling office) 15. SECURITY CLASS. (of thiafowrt)
Unclassified
15a. DECLAS$lFICATION/DOWhiGRADING
sCHEDULE
17. DISTRIBUTION STATEMENT (of the mbatcact mteredin Block 20, IfdJfforent from R-Po*C)
This report has been prepared in two parts: Part 1 is the guide
for the nondestructive testing of non-butt welds in commercial
ships. Part 2 documents the technical considerations involved
in preparing that guide.
Procedures are presented for performing visual inspection,
maqnetic ~article testinq, radiography, ultrasonics, and
I pe~etrant testing on steel welds in the thickness range of
DD !!~~~q
. 1473 EnlT1OM OF lNOV651S OBSOLETE uNCLASSTFKED
$/N 0102-014-6601 I ., -.
.. SECURITY CLASSIFICATION OF THIS PAGE (~mti Da~.Etifarmd)
UNCLASSIFIED
IMTY CLASSIFICATION OF THIS PA GE fwhefl D.s~a Ent=f@
UNCLASSIFIED
SECIJRITY CLASSIFICATION OF THISpAGE~enDa~m~ntOrm~)
SHIP RESEARCHCOMMITTEE
Maritime Transportation Research Board
National Academy of Sciences-National Research Council
MR. G. E. KAMPSCHAEFER, Jr., Chairman, flmage~, Tech. Sew-ices, ARMCO Stee2 Corp.
DR. J. M. BARSOM, Researeh Consultant, U.S. Stad Co?ponztion
PROF. J. R. FREDERICK, Dept. ofMech. Engh-zem<ng, The .tiivazwityof Michigan
MR.-S. GOLDSPIEL, Mechanical Engineer, Board of Wate~ SuppZy, N.QZJYork
MR. T, E. KOSTER, Naval Architect, AMOCO International Oil Company
DR. J. M. KRAFFT, Head, Ocean Makerials Criteria B~anch, Naval Research Lab.
MR. G. E. LINNERT, flori%Ametican Representative, The Welding Institute
PROF. H. W. LIU, fiofesso~ of Mate~ials Science, Symcuse University
PROF. U. H. MUNSE, Dept. of Civil Enginee?&zg, University of IZZinois
MR. W. W. OFFiYER,Consulting Engineer, San Francisco
PROF. H. C. ROGERS, college of Engineering, i2rexe2University
DR. W. F. SAVAGE, Professor of Metallurgy, Renssezae~ PoZytee~ic Institute
DR. W. K. WILSON, Analytical Mechanics, Westinghouse EZeet~ic Corpowtion
The SR-219 Project Advisory Committee provided the liaison
technical guidance, and reviewed the project reports with the investigator:
SL-7-2, (SSC-239) - Wave Loads <n a Modal of the SL-7 Cowtainership Runnhzg at
Oblique Headings in ReguZar Wavas by J. F. Dalzell and M. J. Chiocco.
1974. AD 780065.
MR. G. E. KAMPSCHAEFER, Jr., Chairman, Manage~, Tech. Sazwices, ARMCO S&eel CoXJp.
DR. J. M. BARSOM, Research Consultant, U.S. SteeZ Corporation
PROF. J. R. FREDERICK, Dapt. of Meclz. %ghzee~ing, The !niversity of Miehigan
MR.-S. GOLDSPIEL, Mechan.icaZ Enginee~, Bood of Wa-terSupply, NW York
MR. T. E. KOSTER, Naval Architect, AMOCO Intanationd Oil Company
DR. J. M. KRAFFT, Head, Ocean Materials Crite~ia B~anch, Naval Research tib.
.. MR. G. E. LINNERT,No~th hetican Representative,The WeZd{ng Inst$tute
PROF. H. W. LIU, Professor of Materials Se<enc~, Sy~acuse University
PROF. W. H. MlINSE,Dept. of Civil Engineering, Uniz)ersitiy
of IZZinois
MR. W. W. OFFNER, Consulting Enginee?j San Francisco
PROF. H. C. ROGERS, CoZ2ege of Engineering, tiexel University
DR. W. F. SAVAGE, P~ofessor of Meta22u~gy, Rensselaer Polytechnic Institute
DR. W. K. WILSON, An@.tical Mechanics, Westinghouse ELeet~ic Corpoxtion
.,
SHIP STRUCTURE COMMITTEE PUBLICATIONS
SL-7-2, (SSC-239) - Wave Loads <n a ModeZ of the SL-7 Containership Running at
Oblique Headings in ReguZar Waves by J. F. Dalzell and M. J. Chiocco.
1974. AD 780065.