TOFD Weld Inspection

An Alternative to Radiography
 Presentation Outlines
• R/D Tech Solutions
– Omniscan
– MS5800, Focus family
• TOFD Inspection Codes
• TOFD Principle
– Technique
– Advantages
– Limitations
• TOFD Examples
(Types of Defects)
 R/D Tech TOFD Solutions
OMNISCAN UT
• Omniscan UT is the lowest price TOFD
instrument on the market
• Omniscan TOFD UNIQUE features are:
– Portable: Light and battery powered
– Field rugged
– No PC
• Omniscan is a multi-technology
instrument with same MMI
 CODES
Introduction
• ASME Boiler and Pressure Vessel Code
has attempted to keep up with technology
changes in NDT
 Introduction

• Provision is made in the Appendices for

Computer Imaging Techniques (CITs)
– Synthetic Aperture Focusing Technique
– Broadband Holography Technique
– Phased Array Technique
– Amplitude Time-of-Flight Locus Curve
– Time-of-Flight-Diffraction (later in 2005 this will be
added as a mandatory appendix)
 Introduction

• Some of the systems are for sizing only

(SAFT, ALOK, Holography)
• Phased-array and TOFD are capable of
being used for both detection and sizing
so provide the biggest advances to
increasing speed and reliability of UT
examinations
 Code Expectations

• Weld inspection is addressed by ASME Section

V Article 4 for all UT examinations referenced by
all Sections of the ASME Code
• Providing that the equipment, and procedure
used meet the descriptions in Article 4 the
advance options are open for use! This is
specifically stated in T-421.2
Code Expectations
 Code Expectations

• But it is only necessary to inspect a weld in

accordance with Article 4 when the referencing
Code Section requires it!
• The same applies to radiography, it is only done
when required by the referencing Section of the
Code!
– UNLESS…..
 Code Expectations

• In special cases UT may be used instead

of radiography!
• These are described in the Code Case
2235-6 (original was Code Case 2235
issued in 1996)
– The Code Case states:
Code Expectations
 TOFD and PA Options and
Solutions
• RD Tech was one of the first UT
equipment manufacturers to provide
options for the CITs and Code Case
 Codes and Standard
• British Standard
• European
• ASME code case 2235-6
 TOFD Guides Developed
• BS 7706 (1993) Guide to calibration and
setting-up of the ultrasonic time-of-flight
diffraction (TOFD) technique for detection,
location, and sizing of flaws. British
Standards Institute 1993.
• pr EN 583-6 (1995) Nondestructive testing-
ultrasonic examination - Part 6: Time-of-flight
diffraction technique as a method for defect
detection and sizing.
 ASME Adaptations to TOFD

• ASME VIII Code Case 2235 (2000 Edition)

• Ultrasonic examination to be in accordance
with ASME Section V, Article 4
• “Alternatively, for techniques that do not use
amplitude recording levels, …”.
• This has opened the door for TOFD to be
used on Section VIII pressure vessels
 TOFD
For Weld Inspection
• Description of TOFD technique (Theory)
• Advantages
• Limitations
 The Diffraction Phenomenon
• Huygens’ principle:

The incoming wave

vibrates the defect.

Each point of the

defect generates new
elementary spherical
waves.
 The Diffraction Phenomenon
Incident
wave Diffracted
waves

All directions
Reflected FLAW
wave Low energy

Independent of
Diffracted incidence angle
waves
Diffraction
 Basic Setup
• 2 probes (transmitter, receiver)
• Wide beam, longitudinal waves
• Symmetric to the weld center
• Diffraction signal detection (high
receiver sensitivity)
 TOFD Signals
Transmitter Receiver
Lateral wave

Upper tip

Lower tip

Back-wall reflection
 A-scan signals
Transmitter Receiver
Lateral wave

Back-wall reflection

LW BW

Upper tip Lower tip

 Data Visualization TOFD
• Large amount of data
• Phase information
• Need means to visually detect small
amplitude signals
• Performed by gray scale imaging of RF
signal
 Data visualization
White
+
Amplitude

A-scan

Time
- Black

Time
One A-scan picture is replaced by
one gray-coded line
Data Visualization (TOFD)
A-scan

Indication

Lateral Back-wall
wave
 Typical TOFD Image
Lateral Wave

Back-wall Echo
Signals For Different Flaws
Using TOFD Technique
 Near Surface Crack

1 2
The crack blocks the Lateral Wave
And the lower tip appears on the A-scan
Incomplete Root Penetration

1
2

1 2 3 4

Note the two signals from the top & bottom

Lack of Root Penetration
1
1

2
3

2
3

Note the inverted phase between LW and defect

Lack of Fusion, Side Wall
1
1
2 2
3

4
3

Note the two signals from the top & bottom

 Porosity
1
2 1

2
3

Porosity may image in many forms

whether individual or cluster
 Transverse Crack
1
1
2 2
1
3
2

3 4
3

In the LW we can observe the wide beam effect on the crack

 Concave Root

1
1
2

2
3
3

• Distortion of back-wall echo

Lack of Fusion, Interpass

1
2

3
 TOFD - Advantages
• B-scan type imaging (side view)
• Accurate sizing capability (height)
• Fast scanning
• Interpretation of defects
• Less sensitive to defect orientation
• Repeatable signal
• Results in “real” units i.e. mm, inch
 TOFD – Main Limitation
• Blind area - near surface, backwall
 “Dead zones”
LW BW

A-scan

D-scan

Upper Back-wall
surface
Thank You!