Practical UT

Copyright TWI Ltd 2008
Practical
Compression
Probe
00 Calibration Exercises
There are two methods of achieving calibration:
NOTES:
Time base linearity of the display is 2% of the whole time base.
This means that an echo could be one small division (or 2 mm on
the 100 mm range scale)
Multiple Back Wall Echo Method

Delaying Off Method
Multiple Back Wall Method

How to calibrate for 0 100 mm full screen of 25 mm calibration block.
Initial Pulse/Standby
echo/Big bang
Compressional Velocities
Air = 320m/s
Steel = 5960m/s
25mm
25mm
Steel
50mm 75mm 100mm
Perspex = 2740m/s
Always use the leading edge where it just lift off

the time base.
METHOD/STEPS (Multiple BWE method)
2. Position the Range control on the required setting.i.e:

Position 10 = Allows calibration from just under 10mm full
screen to 25mm.
Position 25= Allows calibration from just under 25mm full
screen to 250mm.
Position 250 = Allows calibration from just under 250mm full
screen to infinity.
Place onto the 25mm position.
6. .
1. Set the probe selector switch either single/twin crystal.
BACK
METHOD/STEPS (Multiple BWE method)
4. Now, place the probe onto the 25mm thk and using the fine
range control wind in a series of back wall echos (BWEs).
Note: a series of BWEs simply means a group of echos
greater than the number required. Use the Attenuator/Gain
control to ensure the signals are of a suitable height to easily
identify the leading edge position of the signal.
5. Now, decide how many echos are required to calibrate. i.e
Screen Calibration Range/Calibration Block Thick = 100/25 = 4 BWEs
6. Check the calibration on a different thickness for accuracy.
3. Now, using the Delay Control ONLY find the Initial Pulse and
position the signal to the left hand side of the screen.
Delaying Off Method

How to calibrate for 0 100 mm full screen of 100 mm calibration block.
echo/Big bang
Compressional Velocities
Air = 320m/s
Steel = 5960m/s
Perspex = 2740m/s
100mm
100mm
Steel
200mm
300mm
* When using narrow calibration blocks, the

beam is constantly spreading out. This
spreading of the beam cause spurious echos
of the sides of the block
METHOD/STEPS (Delaying Off Method)

1. Set the probe selector switch either single/twin crystal.
2. Position the Range control on the required setting.i.e: see as
previous.
3. Now, using the Delay Control ONLY find the Initial Pulse and
position the signal to the left hand side of the screen.
4. Place the probe onto the calibration block, and using the fine
range control wind in a series of BWEs
1st BWE
Initial Pulse
2nd BWE
3rd BWE
10
5. Using both the fine range & delay controls, position the 1 st BWE
onto zero time base position and 2nd BWE onto the ten position of
the time base (Right hand side)
6. Now using the Delay control ONLY the 1st BWE to the ten position
of the time base (Right Hand Side)
1st BWE
Initial Pulse
2nd BWE
10
100mm
7. Check the calibration on a different thickness for accuracy.
3rd BWE
DIFFERENT MATERIALS
When testing other than steel, the velocity of the

sound wave may be different.
Actual Thickness =
Material Velocity X Time base Reading

Calibration Block Velocity
The following formula can be used to compensate

when the CRT is calibrated using a steel
calibration block:
Testing close to side walls
If care is not taken, these spurious echos

may be misinterpreted as BWE, if a twin
crystal probe is used, to eliminate this effect
ensure the cork separator is at 90 to the
edge of the block & not running parallel.
Cork separator between
the crystal
PLAN VIEW OF BLOCK
* When using narrow calibration blocks, the

beam is constantly spreading out similar to
the light from a torch, this spreading of the
beam by in turn cause spurious echos off
the sides of the block.
SIZING METHODS 0O PROBE

There are four main sizing techniques used with 0o probes:
6 dB drop
Maximum Amplitude
DGS
20 dB drop
Equalization
SIZING TECHNIQUES
1.
6 dB DROP TECHNIQUE (SOMETIMES

CALLED HALF AMPLITUDE OR
BEAM
SPLITTING TECHNIQUE).
20 dB DROP TECHNIQUE (SOMETIMES
CALLED BEAM BOUNDARY
TECHNIQUE).
3.
MAXIMUM AMPLITUDE TECHNIQUE.
2.
6 dB Drop
100% to 50%
80% to 40%
70% to 35%
20% to 10%
Centre of probe marked representing the edge of

defect.
For sizing large planar reflectors only

Signal / echo reduced to half the height
Example:
6 dB Drop
BWE
The back wall echo reduced as some part

of the beam now striking the defect
Plan View
The echo of the defect has NOT yet

maximise as the whole beam Not yet
striking the defect
Defect
6 dB Drop
Now the whole beam is on the defect

Back wall echo is now may be
reduced or disappeared
Plan View
Defect
6 dB Drop
BWE
The probe is moved back until the echo

is reduced by half of its original height
At this point the probe centre beam is
directly on the edge of the defect
Plan View
The probe is then removed and the

centre is marked, and repeat to size the
whole defect
Defect
Maximum Amplitude Technique
For sizing multifaceted defect eg. crack

Not very accurate
Small probe movement
Multifaceted defect : crack
The whole probe beam is on the defect
At this point, multipoint of the defect

reflect the sound to the probe
The echo (signal) show as a few peaks
Maximum Amplitude
Multifaceted defect : crack

The probe is moved out of the
defect, the signal disappeared
If the edge of the beam strike
the edge of the defect, a very
small echo appears
If the probe is moved into the defect,

the signals height increase
One of the peak maximised
At this point the MAIN BEAM is
directly at the edge of the defect
Maximum Amplitude
Maximum Amplitude
Remember: The peak which maximized does
not have to be the tallest or the first one
The probe is to be moved to the other

end of the defect
The signals will flactuate as the beam hits
the different faces of the defects
The probe is moved back into the defect
and to observe a peak of the signal
maximises
Mark the point under

the centre of the probe
which indicates the
edge of the defect
The length of the defect is
measured
Length
Equalization Technique
At this point the whole beam is on

the back wall
At this point the whole beam is
on the defect
At the edge of the defect, half of
the beam is on the defect, and
another half is on the back wall
BWE
The BWE is at it maximum

The Defect echo is at it
maximum
The defect echo is at equal
height as the back wall
The point is marked as the edge of defect
The equalization technique can ONLY be used

Defect
if the defect is halfway the thickness
1.
THE DIMENSION OF THE REFLECTOR

WHICH IS BEING MEASURED MAY BE
EITHER LARGER OR SMALLER THAN THE
BEAM WIDTH.
2.
THE ULTRASONIC BEAM NEED NOT BE

SYMMETRICAL IN THE DIRECTION OF
PROBE MOVEMENT.
3.
THE BEAM SPREAD PARALLEL TO THE

DIRECTION OF PROBE MOVEMENT MUST BE
KNOWN.
4.
WORKS BEST ON UNIFORM REFLECTORS
WITH
RELATIVELY STRAIGHT EDGES.
20 dB DROP
20 dB Drop
20 dB Beam profile
Defect
BWE
When the main beam is on the defect the defect signal is at it maximum
If the probe is moved and the signal is observed until it is reduced to
10% (20dB Drop), the edge of the beam is on the edge of the defect
Repeat the above at the other side of the defect
Using the pre-constructed Beam profile and a plotting card, the
defect maybe sized
10%
20 dB DROP
LENGTH
Shear Probe
Checking for Index Point

A2 / V1 / IIW BLOCK / DUTCH BLOCK
There is no need to calibrate for the
following exercise.
INDEX
POINT
echo/Big bang
1st echo (MAX)
Place the probe on the A2 block and

move backwards/forwards over the
milled slot until first echo the R100 is
fully maximized
Now mark the index point onto the
probe.
R100
Calibration of Angle Probes with

A4
A4 / V2 / DIN 54/122 / KIDNEY BLOCK

R25
echo/Big bang
450
R25
R50
25mm
100mm
175mm 250mm
The 1st echo always represents the radius the probe faces, after the
1st echo all the remaining echos are separated with 75mm beam path.
EXIT POINT

A4
A4 / V2 / DIN 54/122 / KIDNEY BLOCK
echo/Big bang
R50
450
R25
R50
50mm
125mm
200mm
The 1st echo always represents the radius the probe faces, after the
1st echo all the remaining echos are separated with 75mm beam path.
EXIT POINT
When looking towards the

R25, the first echo is said to
represent 25mm but actual
distance traveled is 50mm.
When the sound leaves the probe,
hits the R25 returns to the probe the
12% of the energy passing through
the interfaces gives the response on
the time base, the remaining 88% of
the energy reflects down towards the
R50 & back again. Some of this
energy enters the probe but instead
of exciting the crystal the energy
absorbed by the damping medium,
the remaining energy has now been
deflected towards the R25 & back. At
this point the energy passing through
the interface may stimulate the
crystal and give response as 2nd
echo. The total journey traveled is
50+50+25+25=150mm
CRYSTAL
echo/Big bang
R25
PERSPEX SHOE SHAPED

TO DISPERSE / ABSORB
INTERNAL REFLECTIONS
25mm
100mm

A2
A2 / V1 / IIW BLOCK / DUTCH BLOCK
R100
echo/Big bang
1st BWE
2nd BWE
3rd BWE
100mm
200mm
300mm
The V1 block has a 100mm

radius to reflect the sound and a
slot cut at the centre to capture
repeat signals. Signals occur
every 100mm a part.
Beam Angle
BEAM ANGLE
A quick check of beam angle can be performed
using the BS EN 12223 or 27963 block
Neither of these quick checks affords sufficient
accuracy if the probe is to be used for weld
testing
A much more accurate method is to use the 1.5
mm side drilled holes in the IOW block
EQUIPMENT CHECKS
IOW Block
I OW block 1.5 mm SDH positions
Hole #
From
From
From
top
btm
end
(mm)
(mm)
(mm)
1
13
62
50
2
19
56
48
3
25
50
83
4
43
32
35
All holes drilled 22 mm deep
EQUIPMENT CHECKS
Method
Choose three 1.5 mm holes which will plot outside
the near zone of the probe
Try to avoid holes that will plot at a range greater
than 100 mm
Maximise the echo from each of the 3 holes and
carefully measure the position of the probe index
relative to the hole
Plot results on graph paper and draw the best fit
straight line through zero and the 3 points marked
Measure the beam angle using a protractor
BEAM ANGLE ON THE IOW BLOCK
e.g. : Beam Angle Check For A 60 Probe
e.g. : Beam Angle Check For A 60 Probe
USUALLY THE BEAM SHOULD BE

WITHIN 2 OF NOMINAL
THE BEAM ANGLE VARIES AS THE
PROBE SHOE WEARS, SO IT IS
IMPORTANT TO CHECK REGULARLY
IN WELD TESTING AN ERROR OF AS
LITTLE AS 1 CAN BE SIGNIFICANT
BEAM ANGLE
20 dB BEAM
PROFILE Shear
Probe
One of the sizing methods used to measure the

throughwall dimension of a weld defect requires a 20
dB beam profile.
Method:
Choose three 1.5 mm holes which will plot outside
the near zone of the probe
Try to avoid holes that will plot at a range greater
than 100 mm
20 dB BEAM PROFILE
For each hole in turn:

Maximise the echo & measure the probe index
position relative to the hole. Using the gain control
set the echo to 100% FSH.
DO NOT RE-ADJUST THE GAIN CONTROL
Move the probe forward until the echo falls to 10%
FSH; measure the probe index position relative to
the hole.
Move the probe backward until the echo again falls
to 10% FSH; measure the probe index position
relative to the hole.
20 dB BEAM PROFILE
e.g. : 20 dB Beam Profile For A 60 Probe
Construction of a 20 dB Beam
Spread
IOW BLOCK BEAM PROFILE BLOCK A5
Trailing
Main Beam
Edge
10%FSH
Step 1 : Place the probe and find out the max position, then increase the gain
until the signal reaches full screen height (FSH) and mark the index point onto
the side of the block.
Step 2 : Move the probe forwards until the signal fall by 20dB (90%) & remark
the index point onto the side of the block
Main Beam
There is no need to calibrate, however it does make the exercise easier
(suggest to calibrate for 0~100mm full screen)
Spread
IOW BLOCK BEAM PROFILE BLOCK A5
Main Beam
Leading Edge
10%FSH
Step 3 : Repeat the whole exercise (step 2) but pulling the probe backwards.
Step 4 : Now, repeat the whole exercise for a min. of 3 different depth holes.
Main Beam
There is no need to calibrate, however it does make the exercise easier
(suggest to calibrate for 0~100mm full screen)
Spread
LE
MB
TE
Surface Distance (mm)
Depth
CL
Remark:
Depth
of hole
(mm)
MB = Main Beam
TE = Trailing Edge
Now repeat the whole exercise for a min 3 different depth holes
1:1 scale
LE = Leading Edge
Spread
Depth of the hole
Surface Distance (mm)

Hole no.1
Hole no.2
Hole no.3
LE
MB
TE
Draw in the best lines through the holes. Note the MB starts from the
corner whilst the LE & TE are just in front & behind.
The other options are using tracing paper.
1:1 scale
SENSITIVITY
Sensitivity
Depends upon:
Probe and flaw detector combination
Material properties
Probe frequency
Signal to noise ratio
The ability of an ultrasonic system to find the

smallest specified defect at the maximum
testing range
Smallest defect at maximum test range

Back wall echo
Disc (flat-bottom hole) equivalent
Grass levels
Side Drilled Holes, DAC Curves
Methods of Setting Sensitivity
ULTRASONIC SENSITIVITY
DISTANCE AMPLITUDE
CORRECTION
VARIOUS STANDARD REFLECTORS ARE USED IN
1.
BACKWALL REFLECTIONS
2.
GRAIN RESPONSE (GRASS)
3.
SIDE DRILLED HOLES
4.
FLAT BOTTOMED HOLES
5.
SURFACE NOTCHES
6.
DISTANCE GAIN SIZE (THEORETICAL METHOD)
ULTRASONIC TESTING IN ORDER TO ACHIEVE

DISTANCE AMPLITUDE CORRECTION. THESE COULD
BE:
NATIONAL CODES AND

STANDARDS SUCH AS BS EN
1714, ASME V OR AWS D1.1
SPECIFY STANDARD METHODS
OF ACHIEVING DISTANCE
AMPLITUDE CORRECTION.
DISTANCE AMPLITUDE
CORRECTION
BS EN 1714 specifies three alternatives for

setting sensitivity for weld inspection:
Option 1: A 3 mm Side drilled hole DAC
Option 2: DGS method, reference reflector
defined as a disc shaped reflector of between
1 & 3 mm diameter dependent on weld
thickness and search unit frequency
Option 3: A 1 mm Surface notch DAC
BS EN 1714 / BS EN 583-2
BS EN 1714 / BS EN 583-2
Option 1: Typical 3 mm SDH

calibration
blocks
BS EN 1714 / BS EN 583-2
BS EN 583-2:
Minimum Hole Depth & Cal Block Width For 4 MHz
10 mm Diameter Shear Wave Probes
Minimum
Minimum
Block
Minimum
Block
Block
Thickness Hole Length
Width
Length
(mm)
(mm)
(mm)
(mm)
10
12
20
150
15
18
25
200
20
22
30
250
30
31
38
280
40
33
40
300
50
33
40
300
60
33
40
300
70
33
40
300
80
33
40
300
Hole length, block width & block length based on a
scanning range of 1st hole beyond full skip with 70
probe or 200 mm whichever is greater.
BS EN 1714 / BS EN 583-2
BS EN 1714 / BS EN 583-2
BS EN 1714 / BS EN 583-2
BS EN 1714 / BS EN 583-2
Therefore The Efficiency With Which

Ultrasound Is Transmitted Into And Through
The Material May Differ Between The
Calibration Block And The Component.
Bs En 583-2 Does Not Require The

Calibration Block Surface Finish And Material
To Be Exactly Similar To The Component
Which Is Being Tested.
BS EN 1714 / BS EN 583-2
The Amount Of Energy Lost For The Same

Material Will Be Less If The Surface Is
Perfectly Smooth And Flat And More If It Is
Not.
As Ultrasound Passes From The Probe

Into The Material There Is Always A Loss
Of Energy.
BS EN 1714 / BS EN 583-2
If The Surface Of The Calibration Block

Differs From That Of The Component Then
The Difference In Transfer Efficiency Has
To Be Compensated For.
Ut Of Welds Is Often Carried Out From As

Rolled, Curved Or Corroded Surfaces.
BS EN 1714 / BS EN 583-2
In The Ultrasonic Testing Of Typical

Engineering Alloys The Primary Cause Of
Attenuation Is Scattering.
As Ultrasound Passes Through Any Material

Energy Will Be Lost Due To Scattering And
Absorption Of The Sound Energy. This Loss
Of Energy Is Termed Attenuation.
BS EN 583-2 Paragraph 6.5 describes two

methods that can be used in ultrasonic testing
to obtain sensible values for transfer and
attenuation correction
Fixed path length technique - this will work
provided that any attenuation difference is
close to zero
Comparative technique - this should be used if
significant attenuation differences exist
BS EN 1714 / BS EN 583-2
BS EN 1714 / BS EN 583-2
TRANSFER CORRECTION: Fixed Path

Length Technique, SHEAR WAVES
This method requires 2 identical 45 search
units and a DGS diagram
Transfer Loss
Correction 1
Transfer Loss Correction (1)
1 Calibrate the screen for 100 or 200 mm

2 Place the two probes on the calibration block,
maximise the pitch-catch response, set to say 80%
FSH & note the equipment gain setting Vt,t
3 Note the range
4 Repeat this procedure on the scanning surface

5 Note the gain setting, Vt,r
6 Note the range
7 Now use the DGS chart to obtain V, the

difference in dB on the backwall echo line at
the 2 ranges determined:
Vt = Vt,t - Vt,r - V
Now calculate the transfer correction, Vt

using:
only 1 zero degree probe is needed
For zero degree scans a similar

procedure can be performed utilising
backwall echoes on the calibration
block and test piece -
Transfer Loss
Correction 2

TRANSFER & ATTENUATION LOSS
CORRECTION COMPARATIVE TECHNIQUE
This method requires the use of 2 identical

45 shear wave probes:
(for shear waves)
Using one of the two probes & with the

flawdetector set to single calibrate for an
appropriate range - in this case
0-100 mm
Now connect the second of the two probes &
without altering the range or delay controls
set the flawdetector to double
Now repeat this procedure on the testpiece:

The single vee path echo was obtained at a
range of 33 mm
The gain setting required to raise this echo to
80% FSH was 26 dB
The double vee path echo was obtained at a
range of 66 mm
The gain setting required to raise this echo to
80% FSH was 34 dB
Now plot the results on a sheet of Log-Linear

graph paper:
The required transfer and attenuation correction

is then the difference between the 2 lines at the
range of detection
NOTE THAT NEGATIVE TRANSFER AND
ATTENUATION LOSS CORRECTION IS NOT
PERMITTED
No correction is necessary if the difference
between the two lines is less than 2 dB
The maximum transfer and attenuation loss
correction permitted is 12 dB
Minimum scanning sensitivity = 3mm SDH

DAC + 14 dB + Transfer correction
All indications reaching DAC at the minimum
scanning sensitivity must be investigated
All indications reaching DAC at the minimum
scanning sensitivity and found to be sizeable
by probe movement must be recorded
SENSITIVITY FOR PCN & CSWIP WELD UT

EXAMINATIONS
Option 2 : BS EN 1714 specifies DGS

Distance Gain Size (DGS)
This technique is based on theoretical flat bottom
hole(FBH) reflectors
All Krautkramer probes are supplied with a DGS
diagram
Most DGS diagrams are specific to a particular
type of probe, but a general diagram is given by
BS EN 583-2 (figure 11)
BS EN 1714 - DGS Method
Some digital flawdetectors are set up to

perform DGS automatically
For analogue flawdetectors screen inserts
with pre-plotted DGS diagrams are
available
BS EN 1714 - DGS Method
EXAMPLE DGS DIAGRAM
For a 0 probe BS EN 1714 specifies a 2 mm FBH

reference level for weld thickness 15 to 40 mm
For thicknesses of 40 mm and above the reference
reflector for a 0 probe is specified as a 3 mm FBH
In order to use the DGS diagram (assuming
attenuation = 0) a backwall reflector is required
If attenuation 0 at least two repeat backwall
reflectors are required
USING THE DGS CHART
EXAMPLE:
Lets Suppose that we have to examine a full
penetration T joint in 25 mm thick plate
Lets assume that the plate is good quality and has
negligible attenuation
This is a cross section of the weld:
USING THE DGS CHART
USING THE DGS CHART
EXAMPLE:
Place the probe upon the testpiece & obtain a
backwall echo
Set the backwall echo to (say) 80% FSH
Note the range (R) and gain setting (G)
USING THE DGS CHART
EXAMPLE:
Now use the DGS diagram to obtain G0 dB, the
calculated backwall echo at range R
USING THE DGS CHART
EXAMPLE:
G = G - G0 = 18 - 2 = 16 dB
G is basically the transfer correction
needed to get on to the diagram
Now calculate G
USING THE DGS CHART
EXAMPLE:
Lets suppose that a slag inclusion is detected as
shown below
Maximise the echo, then use the gain control to set
it to 80% FSH
Note the range (R) and gain setting (G)
USING THE DGS CHART
EXAMPLE:
Now use the DGS diagram to find the flat bottom
hole equivalent:
If using an angle probe a backwall echo

will in general not be available directly
from the testpiece
Krautkramer have developed a method
where the echo from the 100 mm
quadrant of the IIW V1 block is used as
a substitute
USING DGS WITH ANGLE PROBES
Resolution
BS EN 12668-3 does not specify any requirements

for resolution, but a check on resolution is still a
useful way of monitoring the performance of an
ultrasonic test system
Resolution is primarily affected by pulse length
As a piezo electric probe ages pulse length tends
to increase.
This is because the bonding efficiency of the
damping material to the crystal tends to decrease
RESOLUTION
RESOLUTION
The resolution of both shear wave and zero

degree compression probes can be checked
using the BS 2704 A7 block:
RESOLUTION
A good 4 MHz shear

wave probe should be
capable of resolving the
2 mm step
RESOLUTION
A good 5 MHz
compression wave
probe should be capable
of resolving the 3 mm
step
RESOLUTION
An alternative check for shear wave probes is

provided by the BS 2704 A5 (IOW) block:
RESOLUTION
A crude check for zero degree compression

probes can be performed using the 85, 91 &
100 mm steps in the BS EN 12223 calibration
block:
Scanning
Using Plotting
Card - Weld
DEFECT LOCATION IN ULTRASONIC TESTING

IS BASED UPON THE PREMISE THAT A
MAXIMISED ECHO RESPONSE CAN ONLY
COME FROM A REFLECTOR WHICH IS LYING
ON THE BEAM AXIS.
THIS PREMISE CAN BE ASSUMED BECAUSE
THE GREATEST SOUND INTENSITY OR
PRESSURE IS CONCENTRATED IN A SMALL
VOLUME AROUND THE BEAM AXIS.
DEFECT LOCATION
MAKE CERTAIN THAT THE ECHO IS

MAXIMISED!!
Measure the stand-off distance (s) with
your ruler
Measure the range (R) using the A-scan
display
DEFECT LOCATION
USING A FLAW LOCATION SLIDE
PLOT THE BEAM SPREAD FOR THE SEARCH PROBE ON A BEAM

PLOTTING CHART:
Slide your weld sketch over the chart to plot your indications:
Use the mirror image to plot indications beyond

half-skip:
Project skip indications onto the main weld sketch:
When locating a defect always try to confirm

its position from more than one scanning
direction
If this is not possible try to confirm with more
than one probe angle
In single sided welds any defect, close to
the root, plotting far-side of centreline may
not be a defect at all!!!
BE CAREFUL!
DEFECT LOCATION
DEFECT LOCATION
TO ACCURATELY LOCATE DEFECTS IN A BUTT WELD THE
FOLLOWING CRITERIA MUST BE MET:
1.
THE PROBE EXIT POINT MUST BE ACCURATELY
KNOWN.
2.
THE BEAM ANGLE MUST BE ACCURATELY KNOWN.
4.
THE MATERIAL THICKNESS MUST BE ACCURATELY

KNOWN.
5.
THE FLAWDETECTOR MUST BE ACCURATELY

CALIBRATED.
3.
THE WELD CENTRELINE MUST BE ACCURATELY
KNOWN.
Defect location
Using Calculation
Defect Location Using Calculation
Adjacent
Sine function: Sin() = opposite / Hypotenuse

Cosine function: Cos () = adjacent/ Hypotenuse
Tangent function: Tan() = opposite/ adjacent
Opposite
Hy
po
te
n
us
e
Trigonometry
Calculation
Depth
Depth = Cos x Beam Path Length

Stand-off = Sin x Beam Path Length
Beam Path
Length
Sizing
Defect
DEFECT SIZING
TECHNIQUES
2. 20 dB DROP TECHNIQUE (SOMETIMES

CALLED BEAM BOUNDARY TECHNIQUE).
3.
MAXIMUM AMPLITUDE TECHNIQUE.
1. 6 dB DROP TECHNIQUE (SOMETIMES

CALLED HALF AMPLITUDE OR BEAM
SPLITTING TECHNIQUE).
6 dB Drop Technique
6 dB DROP
2. WORKS BEST ON UNIFORM

REFLECTORS HAVING
RELATIVELY STRAIGHT EDGES.
3. FOR DEFECTS DISPLAYING ECHO
HEIGHT VARIATION ALONG THE
LENGTH USE THE LAST MAXIMUM.
1. THE DIMENSION OF THE REFLECTOR

WHICH IS BEING MEASURED MUST
EXCEED THE BEAM WIDTH.
20 dB Drop Technique: Step 1
Maximise the echo, set it to 100% FSH, note

the stand-off distance (s) and the range (R).
20 dB Drop Technique: Step 1.1
PLOT THE MAXIMISED ECHO:
Move the probe back from the weld until the echo
falls to 10% FSH. Note the stand-off (s) and the
range (R)
PLOT THE TOP EDGE OF THE REFLECTOR:
Move the probe forward (towards the weld) until

the echo falls to 10% FSH. Note the stand-off
(s) and the range (R)
PLOT THE BOTTOM EDGE OF THE REFLECTOR:
Sketch the defect:
20 dB Drop Technique
LENGTH
20 dB DROP
THE
THE DIMENSION OF THE REFLECTOR

WHICH IS BEING MEASURED MAY BE
EITHER LARGER OR SMALLER THAN
BEAM WIDTH.
2.
THE BEAM SPREAD PARALLEL TO THE

DIRECTION OF PROBE MOVEMENT
MUST BE
KNOWN.
3. WORKS BEST ON UNIFORM
REFLECTORS
WITH RELATIVELY
STRAIGHT EDGES.
1.
MAXIMUM AMPLITUDE
Many weld defects have multiple facets

Such defects are difficult to size using 20dB drop
Sound pressure is at a maximum on the axis

of a beam of ultrasound
For high frequency (4 or 5 MHz) ultrasound
sound pressure falls very steeply away from
the beam axis
If a signal can be maximised by moving the
probe then the reflector must be on the beam
axis at the point where the echo maximises
MAXIMUM AMPLITUDE
CENTRELINE CRACK 70 PROBE AT SKIP
Carefully maximise
each signal within the
echo envelope, noting
range & stand-off in
each case
Plot in the usual way
Repeat using
alternative scan
directions & beam
angles
CENTRELINE CRACK 70 PROBE AT

SKIP
The maximum amplitude technique is less

effective if the defect is smooth planar (e.g.: lack
of side fusion)
The echo-dynamic pattern for such defects
sometimes includes tip maxima
Where this is the case the maximum amplitude
technique can be effective for throughwall sizing
MAXIMUM AMPLITUDE
Type 2 Echo-Dynamic With Tip Maxima
Most smooth planar defects have no tip-maxima

In such cases a reasonable estimate of
throughwall size can be made as follows:
Maximise the echo, set to 100% FSH move the
probe forward, the echo drops to 80% FSH - the
edge of the defect is now very close to the axis of
the beam
Repeat moving the probe backward
MAXIMUM AMPLITUDE
Type 2 Echo-Dynamic No Tip Maxima
Can measure any defect dimension

Very effective for rough planar and
volumetric reflectors
Less effective, but still possible, for
smooth planar reflectors
MAXIMUM AMPLITUDE
Step by Step
For Scanning
Testing a Weld: OBJECTIVES

1.
Scan all fusion faces with an angle of

incidence within 20 of 0
2.
3.
Scan the entire weld volume for

longitudinal imperfections using at least
2 beam angles
Scan the entire weld volume for
transverse imperfections using at
least 1 beam angle
(within 10 of 0 for ultra-critical examinations)
Ultrasonic Inspection of a Weld
Equipment checking
Sensitivity setting
Parent material scan
Weld scan
Sizing of indications
Evaluation of indications
Reporting
STAGES OF INSPECTION:
1. Linearity of timebase (weekly)

2. Linearity of equipment gain (weekly)
3. Probe index (daily)
4. Probe angle (daily)
5. Pulse length (weekly)
6. Signal to noise ratio (weekly)
7. General condition of equipment (weekly)
EQUIPMENT CHECKING
(BS EN 12668-3)

Sensitivity setting - FOLLOW THE
APPLICABLE PROCEDURE
BS EN 1714 examination level A, B & C

specifies a 3 mm SDH DAC + 10 dB +
transfer & attenuation correction or DGS
e.g. PCN & CSWIP examinations: 3 mm

SDH DAC + 14 dB + transfer &
attenuation correction
Parent material through which shear waves will

pass during weld examination must be scanned,
using a 0 probe, for laminar imperfections and to
accurately confirm thickness
A sensible sensitivity setting for this examination
is 2nd BWE to FSH
Alternatively 3 mm SDH DAC + 10 or 14 dB can
be used
PARENT MATERIAL EXAMINATION
1.
2.
3.
4.
Weld root inspection

Fusion face & HAZ inspection
Weld volume
Scan for transverse imperfections
WELD SCAN - 4 stages:
1. For this scan a 45 or 70 probe should

be used
2. In most cases the 70 is best
3. Owing to its poor sensitivity for corner
reflectors the 60 probe should not be used
4. A screen width of 100 mm should be used
(in some cases a delayed screen maybe
necessary)
FIXED ROOT SCAN (single sided welds only):
But it is not ideal, because the probe shoe fouls

the weld-cap
The 45 probe could be used in this case:
The ideal stand-off position can be calculated: = t

(Tan 70) + half the root gap (where t is the
thickness)
Or it can be determined using a flaw location slide
The 70 probe is therefore preferred:
Put a magnetic straight edge behind the probe, so that it

can be moved along the weld length at a fixed stand-off:
Use a screen calibration of 0-100 mm

FUSION FACE + HAZ SCAN:
ideal angle = 90 - (the bevel angle)

2. Alternatively it can be determined using
the flaw location slide
1. The ideal beam angle can be calculated

as follows:
In this case the bevel angle is 30:
The maximum stand-off distance required

= 2t(Tan 60) + 10 + half the weld cap width
= 2 x 20 x 1.73 + 10 + 14 = 93.2
Range calibration 0-100 mm
Fusion face, HAZ & weld volume scan using the 60

probe
The maximum stand-off distance required

= 2t(Tan 70) + half the weld cap width
= 2 x 20 x 2.75 + 14 = 124
Range calibration 0-200 mm
Weld volume scan using the 70 probe
1. Overlap between adjacent scans should

be at least 10% of the transducer width
2. The rate of probe movement should not
exceed 150 mm/s
3. A slight swivelling motion (10) should
be applied to the probe during scanning
4. 2 MHz shear waves are preferred for
search scans, but 4 MHz may also be used
General notes on fusion face, HAZ & weld

volume scans:
1. In cases of high criticality the weld cap

should be ground flush to permit
scanning for transverse imperfections
directly from the weld-cap
2. Under most other circumstances a
satisfactory scan can be performed
from the parent material
SCANNING FOR TRANSVERSE

IMPERFECTIONS:
Range
calibration: 0200 mm
Scan in both
directions from
both sides of
the weld
In many circumstances the ultrasonic operator

will be called upon to identify defect type
In order that he or she can do this he or she must
have in depth knowledge of the product that he
or she is testing
In particular he or she needs to be familiar with
the types of defect that may be present
Many defects occur only at certain locations
within any given product
Evaluation of Ultrasonic
Indications
Once a recordable condition has been identified

and plotted the defect type can often be identified
by considering:
1. The types of defect that are likely to be
present
2. The defect position
3. The defect size
4. Echo dynamic behaviour
5. Signal amplitude & shape with various
probe angles
Evaluation of Weld Indications
BS EN 1713 identifies 5 basic types of echo

dynamic behaviour typically seen when
performing ultrasonic testing of welds:
Pattern 1: point or threadlike reflector
Pattern 2: smooth planar reflector
Pattern 3a: rough reflector at near normal
incidence
Pattern 3b: rough reflector at oblique
incidence
Pattern 4: multiple (point) reflector
Echo Dynamic Behaviour
BS EN 1713 Pattern 1
Point-like reflector response. At any probe

position the A-scan shows a single sharp echo.
As the probe is moved this rises in amplitude
smoothly to a single maximum before falling
smoothly to noise level.
Definition:
Extended smooth reflector response. At any

probe position the A-scan shows a single sharp
echo. When the ultrasonic beam is moved over
the reflector the echo rises smoothly to a
plateau and is maintained, with minor variations
in amplitude of up to 4 dB, until the beam
moves off the reflector, when the echo will fall
smoothly to noise level.
Definition:
BS EN 1713 Pattern 3a
Extended rough reflector at near normal incidence.

At any probe position, the A-scan shows a single but
ragged echo. As the probe is moved this may
undergo large (> 6 dB) random fluctuations in
amplitude. The fluctuations are caused by reflection
from different facets of the reflector, and by random
interference of waves scattered from groups of
facets.
Definition:
BS EN 1713 Pattern 3a
BS EN 1713 Pattern 3b
Extended rough reflector at oblique incidence. At any

probe position, the A-scan shows an extended train of
signals (subsidiary peaks) within a bell-shaped pulse
envelope. As the probe is moved each subsidiary
peak travels through the pulse envelope, rising to its
own maximum towards the centre of the envelope,
and then falling. The overall signal may show large (>
6 dB) random fluctuations in amplitude.
Definition:
BS EN 1713 Pattern 3b
Multiple reflector response. At any probe

position the A-scan shows a cluster of signals
which may or may not be well resolved in range.
As the probe is moved the signals rise and fall at
random but the signal from each separate
reflector element, if resolved, shows pattern 1
response.
Definition:
A typical weld defect will show different types

of echo dynamic behaviour for different types
of probe movement
Echo dynamic behaviour may also change
when the beam angle is changed
Careful consideration of such echo dynamic
behaviour gives many clues as to the shape
and nature of a reflector
BS EN 1713 Probe Movement
1. LATERAL: the probe is moved parallel to

the weld axis
2. TRANSVERSE: the probe is moved at
90 to the weld axis
3. ORBITAL: the probe is moved along
a circular path with the
reflector at its centre
4. SWIVEL: the probe is rotated about its
own axis
Types of probe movement
Typical echo dynamic behaviour; butt-weld 60 included angle

Defect type:
Lack of sidewall fusion
Type of Probe Movement
Probe
Comments
L
T
O
S
2
1/ 2
1
1
45
Low amplitude, or no response
2
1/ 2
1
1
Very high amplitude
60
2
1/ 2
1
1
Fairly high amplitude
70
Abbreviations: L = Lateral; T = Transverse; O = Orbital; S = Swivel
Plots at the fusion face

May cause mode conversion (all probes may
be affected)
Typical Echo Dynamic Behaviour
Plots probe side of the weld at the root face

May cause mode conversion, especially with
60 probe

Defect type:
Lack of root fusion
Probe
Comments
L
T
O
S
2
1
1
1
45
Usually the highest amplitude
2
1
1
1
Sometimes very low amplitude
60
2
1
1
1
Usually high amplitude
70

Defect type:
Slag inclusion
Probe
Comments
L
T
O
S
1
45 2/ 3a 1/ 3a 1/ 3a
Echo height similar for all probe
1
60 2/ 3a 1/ 3a 1/ 3a
angles
1
70 2/ 3a 1/ 3a 1/ 3a
Amplitude highly variable

Often with associated LOSWF
Can plot anywhere within the weld volume

Defect type:
Centreline crack
Probe
Comments
L
T
O
S
3b
3b
3b
3b
45
Echo height similar for all probe
3b
3b
3b
3b
60
angles
3b
3b
3b
3b
70
Plots at or near weld centreline

Usually surface breaking
Strong response with all beam angles

Defect type:
Heat affected zone crack
Probe
Comments
L
T
O
S
3a
3b
3a
3b Amplitude lower than other probes
45
3a
3a
3a
3b Very high amplitude
60
3a
3a
3a
3b High amplitude
70
Plots at the fusion face or just within the

parent material
Usually reaches the surface at the weld toe

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Copyright TWI Ltd 2008

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Multiple Back Wall Echo Method

Multiple Back Wall Method

50mm 75mm 100mm

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Always use the leading edge where it just lift off

METHOD/STEPS (Multiple BWE method)

2. Position the Range control on the required setting.i.e:

Copyright TWI Ltd 2008

1. Set the probe selector switch either single/twin crystal.

METHOD/STEPS (Multiple BWE method)

Copyright TWI Ltd 2008

Delaying Off Method

Copyright TWI Ltd 2008

* When using narrow calibration blocks, the

METHOD/STEPS (Delaying Off Method)

Copyright TWI Ltd 2008

7. Check the calibration on a different thickness for accuracy.

Copyright TWI Ltd 2008

When testing other than steel, the velocity of the

Material Velocity X Time base Reading

Copyright TWI Ltd 2008

The following formula can be used to compensate

Testing close to side walls

If care is not taken, these spurious echos

Copyright TWI Ltd 2008

* When using narrow calibration blocks, the

SIZING METHODS 0O PROBE

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6 dB DROP TECHNIQUE (SOMETIMES

MAXIMUM AMPLITUDE TECHNIQUE.

Copyright TWI Ltd 2008

Centre of probe marked representing the edge of

Copyright TWI Ltd 2008

For sizing large planar reflectors only

The back wall echo reduced as some part

The echo of the defect has NOT yet

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Now the whole beam is on the defect

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The probe is moved back until the echo

The probe is then removed and the

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Maximum Amplitude Technique

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For sizing multifaceted defect eg. crack

Multifaceted defect : crack

The whole probe beam is on the defect

At this point, multipoint of the defect

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Multifaceted defect : crack

If the probe is moved into the defect,

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The probe is to be moved to the other

Mark the point under

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At this point the whole beam is on

The BWE is at it maximum

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The equalization technique can ONLY be used

THE DIMENSION OF THE REFLECTOR