Ultrasonic probe for forging SEP
with high standards, especially for components in turbines 1923
and generator systems
1 Objective
This test sheet deals with the ultrasonic probe for
forging with high standards especially for components
in turbines and generator systems chiefly for
detecting internal flaws as per the Impulse-Echo-
Technique
The ultrasonic probe enables a statement about the
points of reflection as regards their location, size,
extent and frequency. The test sheet comprises
guidelines to determine the scope of testing and
grades with corresponding assessment criteria and
describes the conditions to be adhered to during the
test.
2 Area of applicability
This test sheet is applicable for testing the forging of
transformable steel that is test-oriented. Should the
test sheet be used for the forging of non
transformable steel, then the applicability of the
assessment criteria should be discussed and agreed
upon by the manufacturer and the buyer.
3 Preparation for forging
Forgings should have simple forms (refer to DIN S4
126 Part 1, section 61)) for testing purposes. The test-
surfaces and all reflecting surfaces should be in such
a condition that test statement is not affected.
One of the smooth surfaces freed from the loose
scales should be enough for the test, provided
sufficient coupling is achieved. A mean deviation from
Rillegible < 20 m is valid as per DIN 476 2) as a standard
value for the condition of the surfaces of the
processed bare parts.
4 Time of the test
All rights reserved. Duplication of this sheet or part thereof by way of photo-mechanical copying is not permitted.
Pre-acceptance tests for any decisions regarding the
testability and usability of the forging should be
carried out as soon as possible. Users tests are
carried out in as basic an outline condition as
possible, however, after the heat treatment that is
decisive for the material characteristics or at an
agreed stage of pre production.
5 Testing system
5.1 Testing instrument
The ultrasonic testing instrument should be in
accordance with the requirements of DIN 54 126 Part
11).
5.2 Transceivers
The selection of the transceiver as regards the rated
frequency and oscillating diameter depends on the
size of the circular disc shaped reflector to be verified,
the length of the sonic path and the acoustic
attenuation of the forging to be tested.
STEEL-IRON test sheets (SEP) of the Association of German Ironworks Members
Publisher Steel iron mbH Post box no. 8229 4000
Edition
Transceivers with rated frequency of 2 or 4 MH z
generally used. However, transceivers with o
frequencies may also be used.
Vertical transceivers with transient oscillation are us
used. Other types of transceivers like ultrasonic en
generation and detection probe (SE) transceiver
angle probe can additionally be used for e.g. to de
the points of reflection close to the surface, for be
display resolution in case of forging parts that
difficult to access as well as for hollows or in special
locations.
To assess the displays of each type of transceive
diagram of the amplification and de-amplifica
magnitude (AVG) in mm circular disc shaped refle
(KSR) should be provided or it should be possibl
derive the same from the general AVG diagrams.
5.3 Inspection of the testing system
The DIN 54 126 Part 1 1) forms the basis for
calibration of the appliance. Monitoring of the appli
function and the transceiver should be available to
calibration block 1 as per DIN 54 1225).
The calibration block 2 as per DIN 54 122 5) or ano
comparative body may be used with the refer
reflectors for the inspection of the testing system.
5.4 Couplant
The couplants (refer to DIN 54 128 Part 1 section 5
must properly wet the surface of the work piece. W
(preferably with viscosity enhancing additions),
pastes etc. are suitable for this purpose. The s
couplant should be used to set up the testing sys
and all subsequent testing work. If finished forgings
being tested, the couplant should not cause
corrosive damage. If necessary, the tested surface
be cleaned or dried after the test.
6 Testing personnel
The manufacturer must ensure that the test is ca
out by inspectors who are qualified and experience
properly execute the test according to this steel-iron
sheet.
____________
1)
DIN 54 126 Part 1 rules for testing with ultraso
requirements from testing systems and testing objec
2)
DIN 4762 - surface roughness, definitions, surf
and their statistic
3)
DIN 54 127 Part 1- Calibration of ultrasonic tes
systems and echo height assessment
4)
DIN 54 120 Calibration block 1 and its applicatio
the calibration of ultrasonic impulse echo appliances
5)
DIN 54 122 Calibration block 2 and its applicatio
the calibration and inspection of ultrasonic impulse
appliances
December 1990
Germany
Page 2 SEP 1923
7 Scope of testing
According to the different forging requirements and
depending on the product groups, the buyer should
select the scope of testing as per sheet 1 and state
them using the testing numbers
A Waves
B Discs, plates
C Rings, pipes, hollow shafts, bushings
D Bar steel
8 Execution of the test
8.1 Calibration of the test sensibility
The ultrasonic system should be calibrated
according to DIN 54 127 Part 13).
8.2 Test procedure
The test should be executed according to DIN 54
126 Part 11). The surfaces of the forging to be
tested with the transceiver are callipered according
to the numbers mentioned in sheet one.
In case of manual execution of the test, the test
speed should not exceed 100 mm s-1. In case of
automated testing, the test speed and the impulse
sequence frequency should be coordinated in such a
way that the displays to be indexed are definitely
found.
In case of complete callipering, the test paths
should overlap at about 15 %.
9 Displays
9.1 Description of displays to be indexed
Displays should be described with their echo
heights, echo forms and expansion and if
necessary, with their dynamic ratio and their
frequency sensitivity. In addition to that, the back
surface echo attenuation and the detection limit
must be stated.
9.1.1 Echo height
The displays are assessed depending on their echo
heights according to the AVG method as per DIN 54
127 Part 13), whereby the magnitude of the
replacement reflector should be stated in mm as
the diameter of the equivalent circular disc shaped
reflector (KSR). For this, the sizes characterising
the oscillator (effective diameter, transceiver
frequency, near field length, etc) must be known or
determined from the data sheets.
Usually, the displays are assessed with 2 or 4 MH z
transceivers. If displays to be indexed are detected,
other transceivers can be used for better
assessment of the points of reflection.
The echo height comparisons with reference
reflectors may be permissible in exceptional cases,
after the discussion and agreement with the buyer.
In such cases, the echo height of the points of
reflection should be stated in dB for the respective
echo height of the reference reflector.
9.1.2 Echo form
The displays should be differentiated according to
the echo forms stated in sheet 2. The display
patterns of the corresponding echo forms are also
included there.
9.1.3 Dynamic ratio, expansion of displays
Unless otherwise agreed upon, in case of indivi
displays, the actual expansion of the reflectors
ascertained by the half-value method. The sound
characteristics of the transceiver should be taken
account.
Two individual displays are considered to be joined
thus as one display, if the echo height drops by less
12 dB below the display maximum of the greater dis
while moving the transceiver between the two point
the two display maximums in almost the same sonic
(tolerance 2 mm).
If displays with expansion appear, the actual refle
lengths less than the decisive limits as per sheet 3 sh
not be recorded.
In case of a doubt of a slope-related flaw, the e
height should be identified with the optimization o
the intermission angle.
9.1.4 Back surface echo attenuation
The amplitude of the backward echo in the display
compared to the directly adjoining fields without dis
should be checked in case of displays to be inde
Backward echo attenuations from 4 dB should
recorded and stated in dB.
Backward echo attenuation must be assessed after ta
into account the oscillating diameter, the test frequ
and the ratio of the sonic path to the reflector or to
back surface.
9.1.5 Detection limits
The detection limit is the value of the sma
recognizable KSR with a signal-to-noise ratio of 6 dB
the largest sonic path under consideration. If the sig
to-noise ratio is based on the recording limit < 6 dB,
detection limit for the respective direction of incidence
the transceivers must be identified and recorded in
KSR with corresponding data like transceiver, intermis
direction, sonic path, etc. Discussion and agreement
the buyer regarding the subsequent method is neces
in this case.
9.1.6 Test sensibility
The test sensibility should be selected in such a way
group echo displays to be indexed achieve at least 2/5
the screen height. In this case, the signal-to-noise-
must be at least 6 dB. Discussion and agreement with
buyer regarding the subsequent method is neces
otherwise.
9.2 Indexing, deciding and permissibility criteria
In sheet 3, the recording and decisive limits as reg
echo heights, backward echo attenuation and ac
reflector lengths are stated depending upon the gra
On attaining a decisive limit, the permissibility shoul
decided and the subsequent measures should be ag
upon with the buyer. If the decisive limit is the sam
the permissible limit, the buyer should state the same.
9.3 Sonic attenuation
If sonic attenuation measurements are required after
heat treatment, these should be executed as per shee
The measured sonic attenuation values should be reco
in dB/m. Depending upon the frequency, the dec
limits are
2 MHz: 2dB/m
4 MHz: 6dB/m
5 MHz: 10 dB/m.
_____________
6)
DIN 54 126 Part 2 rules regarding testing
ultrasound, execution of the test.
 SEP 1923 Page 3

10 Test report Displays to be indexed should be described according t

point 9 as per the specifications of their coordinators in
The test report must comprise the following data: work piece 2 and/or should be recorded in a scale sket
a) Technical characteristics of the piece to be tested of the forging, of the cross section or a development o
b) Data regarding the test guidelines surface.
c) Time of test
d) Test appliances and type of transceiver 11 Instructions for the order
e) Condition of the test surface
The test numbers and the grade should be stated by th
f) Coupling medium
buyer for orders as per this test sheet.
g) Type of calibration
h) Scope of testing (test numbers as per sheet 1)
i) Recording and decisive or permissible limits
j) Findings
k) Date, inspector, test supervision
Table 1 A. Product group A: Waves (e.g. turbine waves, generator waves, connecting rod)

Oscillator vertical transceiver

Test no. Test surface Sound direction Tested volume Symbol
A1 2 testing paths in axial Radial Volume recorded by
direction, 90 offset, the sound beams1),
total length essentially the core
area

A2 Half of the surface, total Radial Total volume1)

length

A3 100% of the generated Radial Total volume1)

surface

A4 100% of the front Axial Total volume provided

surface the testing technique
is possible

A5 Minimum 5 points Radial Acoustic attenuation

distributed over the measurement
length and periphery of
the generated surface,
the exact number should
be specified by the buyer
if necessary.

Oscillator- angle probes2)

Test no. Test surface Sound direction Tested volume Symbol
A6 100% of the generated 1 peripheral direction Ring surface determined
surface by the sound or beam
angle

A7 100% of the generated 2 peripheral Ring surface determined

surface directions by the sound or beam
angle

A8 100% of the generated 2 axial directions Total volume1)

surface

Vertical transceiver 1)
If necessary, an area near the
Ultrasonic generation and detection
Probe surface, dependant on the
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
vertical transceiver
Ultrasonic Energy Generation And Detection Probe- vertical transceivers

Test no. Test surface Sound direction Tested volume Symbol

A9 100% of the generated surface radial Area near the surface

Ultrasonic Energy Generation And Detection Probe- angle probes 2)

Test Test surface Sound direction Tested volume Symbol

no.
A 10 100% of the generated 1 peripheral direction Area near the surface
surface

A 11 100% of the generated 2 peripheral directions Area near the surface

surface

A 12 100% of the generated 2 axial directions Area near the surface

surface

Vertical transceiver Ultrasonic generation and detection

1)
If necessary, an area near the
surface, dependant on the
probe
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
vertical transceiver
Table 1 B. Product group B: Disks and plates (e.g. turbine discs, compressor discs, flywheels)

Oscillator- vertical transceivers

Test no. Testing surface Sound direction Tested volume Symbol

B1 Testing paths that are over Thickness or axial Volume recorded by
one another and direction sound beams1)
perpendicular to each other
at a distance of 200 mm
over a plane surface, where
2 paths perpendicular to
each other detect the centre
of the disc
B2 Same as B1, however, at a Thickness or axial Volume recorded by
distance of 100mm direction sound beams1)

B3 100% of a plane surface Thickness or axial Total volume1)

direction

B4 100% of both the plane Thickness or axial Total volume1)

surfaces direction

B5 100% of the peripheral Radial or perpendicular Total volume1)

surface to the peripheral
surfaces

B6 Minimum 2 points on a plane Thickness or axial Acoustic attenuation

surface and minimum 2 direction and axial or measurement
points on the generated perpendicular to the
surface, 90 offset on the peripheral surfaces
periphery, the exact number
should be specified by the
buyer if necessary.

Oscillator- angle probes2)

Test no. Test surface Sound direction Tested volume Symbol
B7 100% of a plane surface 4 sound directions Total volume1)
always rotated by 90

B8 100% of a plane surface 4 sound directions per Total volume1)

plane surface, always
rotated by 90

B9 100% of a peripheral surface 1 peripheral direction Ring surface

determined by the
sound or beam
angle

B 10 100% of a peripheral surface 2 peripheral directions Ring surface

determined by the
sound or beam
angle

Vertical transceiver Ultrasonic generation and detection

1)
If necessary, an area near the
surface, dependant on the
probe
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
vertical transceiver
Ultrasonic Energy Generation And Detection Probe- vertical transceivers

Test no. Test surface Sound direction Tested volume Symbol

B 11 100% of both the plane Thickness or axial Area near the surface
surfaces direction

B 12 100% of peripheral Radial or perpendicular Area near the surface

surface to the peripheral surface

Ultrasonic Energy Generation And Detection Probe-angle probes 2)

Test no. Test surface Sound direction Tested volume Symbol

B 13 100% of peripheral 1 peripheral direction Area near the surface
surface

B 14 100% of peripheral 2 peripheral directions Area near the surface

surface

B 15 100% of both the plane 4 sound directions per Area near the surface
surfaces plane surface, always
rotated by 90

Vertical transceiver Ultrasonic generation and detection

1)
If necessary, an area near the
surface, dependant on the
probe
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
vertical transceiver
Table 1 C. Product group C: Rings, tubes, hollow shafts, bushing, flange and comparable parts

Oscillator- vertical transceivers

Test no. Testing surface Sound direction Tested volume Symbol

C1 Axial testing paths at a distance of Radial Volume not recordable by
200 mm over the total length, sound beams1)
however minimum 3 paths

C2 100% of the generated surface radial Total volume1)

outside

C3 100 % of the generated surface radial Total volume1)

Inside3)

C4 100% of the front surface axial Total volume,

provided the
testing technique is
possible1)

C5 100% of both the front surfaces axial Total volume,

provided the testing
technique is possible1)

C6 Minimum 5 points distributed radial Acoustic attenuation

over the length and periphery of measurement
the generated surface, the exact
number should be specified by
the buyer if necessary.

Vertical transceiver Ultrasonic generation and detection

1)
If necessary, an area near the
surface, dependant on the
probe
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe 3)
If the dimensions permit a
vertical transceiver manual test
Oscillator- angle probes2)

Test no. Test surface Sound direction Tested volume Symbol

C7 100% of the 1 peripheral Ring surface determined by
generated surface direction the sound or beam angle,
outside total volume as a rule1)

C8 100% of the 1 peripheral Total volume1) provided

generated surface direction the testing technique is
inside possible

C9 100% of the 2 peripheral Ring surface determined by

generated surface directions the Sound or beam angle,
outside total volume as a rule1)

C 10 100% of the 2 peripheral Total volume1) provided

generated surface directions the testing technique is
inside possible

C 11 100% of the 1 axial direction Total volume to a large

generated surface extent
outside

C 12 100% of the 1 axial direction Total volume to a large

generated surface extent
inside3)

C 13 100% of the 2 axial directions Total volume

generated surface
outside

C 14 100% of the 2 axial directions Total volume

generated surface
inside3)

Ultrasonic Energy Generation And Detection Probe- vertical transceivers

Test no. Test surface Sound direction Tested volume Symbol

C 15 100% of generated Radial Area near the surface
surface outside

C 16 100% of generated Radial Area near the surface

surface inside3)

C 17 100% of both the axial Area near the surface

front surfaces

Vertical transceiver 1)
If necessary, an area near the
Ultrasonic generation and detection
probe surface, dependant on the
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
3)
If the dimensions permit a
vertical transceiver manual test
Ultrasonic Energy Generation And Detection Probe- angle probes 2)

Test no. Test surface Sound direction Tested volume Symbol

C 18 100% of the generated 1 peripheral direction Area near the surface
surface outside

C 19 100% of the generated 1 peripheral direction Area near the surface

surface inside

C 20 100% of the generated 2 peripheral directions Area near the surface

surface outside

C 21 100% of the generated 2 peripheral directions Area near the surface

surface inside3)

C 22 100% of the generated 1 axial direction Area near the surface

surface outside

C 23 100% of the generated 1 axial direction Area near the surface

surface inside3)

C 24 100% of the generated 2 axial directions Area near the surface

surface outside

C 25 100% of the generated 2 axial directions Area near the surface

surface inside3)

Vertical transceiver 1)
If necessary, an area near the
Ultrasonic generation and detection
probe surface, dependant on the
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
3)
If the dimensions permit a
vertical transceiver manual test
Table 1 D. Product group D: Bar steel

Oscillator- vertical transceivers

Test no. Test surface Sound direction Tested volume Symbol
D1 2 testing paths in the Radial or Volume in the
axial direction, 90 perpendicular to the present core area
offset, total length peripheral surfaces recorded by the
sound beams1)

D2 Half the surface, Radial or Total volume1)

total length perpendicular to the
peripheral surfaces

D3 100% of the Radial or Total volume1)

peripheral surfaces perpendicular to the
peripheral surfaces

Oscillator- angle probes2)

Test no. Test surface Sound direction Tested volume Symbol
D4 Half of the surface, 1 axial direction or 1 Total volume to a
total length Longitudinal direction large extent

D5 Half of the surface, 2 axial directions or 2 Total volume to a

total length Longitudinal directions large extent

D6 100% of the 1 axial direction or 1 Total volume to a

peripheral surfaces Longitudinal direction large extent

D7 100% of the 2 axial directions or 2 Total volume

peripheral surfaces Longitudinal directions

Ultrasonic Energy Generation And Detection Probe- vertical transceivers

Test no. Testing surface Sound direction Tested volume Symbol

D8 100% of the peripheral Radial or perpendicular Area near the
surfaces to the surface
Peripheral surfaces

Vertical transceiver Ultrasonic generation and detection

1)
If necessary, an area near the
surface, dependant on the
probe
Angle probe transceiver is excluded

Ultrasonic
2)
the intermission angle can be
Tested surface specified by the buyer
generation and
detection probe
vertical transceiver
Table 2: Echo forms during the ultrasonic test

Screen image Forms of the echo Symbol

Single echo EE

Group echo, can be defined1) GA

Group echo, cannot be defined1) GN

Ring surface RZ

Many single echoes VE

Grass (noise) GR

Group echoes can be defined if the difference between the peak of the greater echo and bottom of the next echo
is > 18 dB.

Table 3: Class (Refer to table 2 for explanation of abbreviations)

Class Echo form / echo level Back surface Maximum real

EE + VE without expansion EE + VE with expansion echo drop reflector length
GA, GN, RZ EF, VE
Recording limit Decisive limit Recording Decisive limit Decisive limit
mm KSR mm KSR limit mm KSR
dB mm
mm KSR
1a 1 2 All displays1) All displays1) 4 10
1b 2 2 All displays1) All displays1) 4 10
2a 1 3 All displays 1)
1 4 10
2b 3 3 1 1 4 10
3a 2 4 1 2 4 20
3b 4 4 2 2 4 20
4a 2 5 1 3 4 20
4b 5 5 3 3 4 20
5a 3 6 2 4 6 50
5b 6 6 4 4 6 50
6a 3 8 2 5 6 50
6b 8 8 5 5 6 50
7a 5 10 3 6 12 100
7b 10 10 6 6 12 100
8a 5 15 3 8 12 100
8b 15 15 8 8 12 100

1)
detection limit (refer to chapter 9.1.5)