Inaugural Speech of Mr.B.

PRASADA RAO, CHAIRMAN & MANAGING DIRECTOR, BHEL, during

NDE 2009 at Tiruchirapalli

Good Morning to you all,

It is a matter of great privilege to me, to be present amongst this gathering, at a time particularly
BHEL’s association with this event when we at BHEL are steering up our operations in a big way in
line with the countries requirement of power capacity addition programme. It is a gathering of
delegates, authors, exhibitors and organizer who are championing the process of Non Destructive
Evaluation in the country and the world at a large, there is no other time better than this to be associ-
ated with this great event.

At the outset, I must compliment the organising institution, Indian Society for Non Destructive
Testing (ISNT) for putting together this “NDE 2009 National Seminar and Exhibition” with the theme
“Non Destructive Evaluation in power Industry, which is of great significance. As a very active professional body in the country, ISNT
with it wings of 20 chapters and over 7000 members has brought a galaxy of delegates and NDE professionals from International
repute to this large gathering. My sincere compliments to the team, which has made this happen when the demand of power genera-
tion, power generating equipment and power growing exponentially increase with the right kind of importance being provided by the
Government of India.

I believe, we are all active partners of this great growth of power sector in this country. The nation needs un-interrupted power
generation for all it facility to maintain and to achieve the kind of GDP growth being projected for the country of 8 to 9% per annum.
So the themes of Quality, Reliability, Safety, Efficiency and not but the least the economy have taken new dimensions. It is in this
context that NDE professionals have a great role to play. NDE of materials component and structural systems have assured great
importance.

As power plant equipment manufacturers it may be worth stating that our perception and directions that NDT should take and I am
sure this should be interest to the audience, and so let me share some of my own wish list with this learner fraternity who are
equipped to look into these in greater detail. I would like to simply state this in one statement that “we want the NDE to be speedy
dealing in human dependency and interpretation, defect preventive not only controlling but defect preventive easily recordable and
retrievable and of-course reliable and repeatable. If you could pack this with in a reasonable cost you would have certainly delighted,
your customers like us. Let me explain a little bit of in detail what is meant by this. NDE has to match with the speed of manufacturing
process today and its essence. We need to put in this kind of power generating capacity in the country in a quickest possible time.
It will only otherwise lead to pealing up the work in power stations, multiple providable movement of products to different NDE
workstations. As users we have the liberty to ask for NDT to be done when the world for example is hot and just cooling without
waiting times, it may sound ridiculous.

But however situation has come to a stage where we have to demand for such services from the NDE. These are great challenges
some of these requirement are not new. BHEL has been able to use some techniques like real time radiography for tubular
butt-joints a few decades back. But, then there are rules like online Ultrasonic testing for similar butt-joints that we need. Now the
requirement of the day automated online system are also becoming requirements. The use of linear accelerator are certainly
speeded up the radiography of seem weld of thick wall components.

I note that guided way ultrasonic is the instinct in NDE today and I am glad that Prof. Rose who is the authority on this is here of the
dias that he will be giving the plenary talk on this theme. There are issues of inadequacies in qualified NDE personnel today in the
country like lack of awareness and professional integrity on top of all.

This is perhaps aspect of NDE that brings up the strong case for dealing the human dependency and intelligent and automatic
interpretation of NDE, I am indeed glad that automated defect deficiency system are available today in BHEL. BHEL Trichy particu-
larly is working as a one such application, there is so much to be done in this trend and I can only request this forum to take up this
in forge ahead.

I am glad that there are sessions and over 180 papers are presented and being discussed. Improvement and improvement, improve-
ment over improvement have to be realized and sustained and sustained way to achieve this greater goal we have for our humanity.

I am happy to note that an impressive NDE exhibition is also being organized with appropriate technical solution to some of the
issues of quality in productivity that you have faced or want to face in the industry.

I have great pleasure in inaugurating this NDE 2009 and wish you a technically rewarding event.

All the best

Thank you.
 Keynote address of Mr.A.V.KRISHNAN, EXECUTIVE DIRECTOR, BHEL, TRICHIRAPALLI, during
NDE 2009 at Tiruchirapalli

I am really honoured to be on called upon to give the keynote address in this examplary gathering
of NDE professional. I must admit, I did a little bit of soul search before accepting this request. A
Good portion of my career has been in the quality field and always had great expectation from NDE
may be these are one reason my friends in NDE wanted me to stand before you today and share
some of the concern and as well as successes in the NDE field. It is indeed a great privilege that
our CMD Sri.B.P.Rao is here to inaugurate this event, rather inaugurated this event.

The committments he demonstrate to quality of manufactured products, systems that build the
power stations and the professionalism he maintains in ensuring customer delight it all being
demonstrated by us under his presence today and inaugurated this event sir, we are very grateful
to you and I am deeply heartened that our president ISNT has chosen Trichy after 17 years to conduct this event which is really the
need of the hour for the country. I am also happy that other eminent personality from NDE world like Dr.J.L.Rose, Dr.Krishnan
Balasubramaniam, and many others have come today and become part of the NDE 2009.

The theme as such NDE in power industry which is a very appropriate theme, the CMD of BHEL in his inaugural address has put up
lot of challenges challenges to NDT fraternity bur sir I am sure that all this challenges would be taken up and the NDE fraternity will
definitely come up with innovative solutions which will benefit the power industry as well as the other industries. The CMD mentioned
that the country poised for the big growth in power sector almost one lakh mega watt addition in every five year plan and in this
competitive environment the role of NDE to be part of the processes is very very important. As all of you know that the power industry
and the power plant equipments, constitutes the various products like Boilers turbines, and so on and in every aspect you will find
the first and foremost important thing is the raw materials.

The raw materials which would be boiler and pressure vessel quality plates, tubes, pipes, forgings and so on. If I take a typical 500
mega watt unit we have some thing close to 450 kilometers of tubing and about twenty eight thousand to thirty thousand numbers of
high pressure joints, spread over thirty thousand units, one can imagine the role of an industry to supply this as a error free products
to the customer. One just cannot afford to live any internal defect or inherent defect to be passed to the customer. Because the
consequence of such a defect in an operating power plant in very very dangerous.

Sir, in line with the challenges you have post today most manufacturers of seamless steel tube plant had created online NDE and
robust systems like Ultrasonic, Eddy Current, Seal claps etc. They have been able to screen the most difficult defects in the tubes
and ensure that good quality tubes are send to the customers. Similarly we have thick and large boiler quality plates which are used
to making boiler drums, nuclear vessels and they have to be free from weakness. I think we have a lot to do and we are geared up
for that.

I would like to touch upon is the Positive Material Identification (PMI) which has today becoming the very important especially the
nuclear steam generators, and Iam glad today BHEL has been able to get into this frontier. Development of materials design and
inspection methodology and power equipment to enhance the reliability, safety and productivity posses several challenges, which
can be equated by adopting suitable NDE techniques.

NDE definitely plays an important role in manufacturing of boiler and pressure vessels components. It is greater need to build the
NDE systems for online monitoring and processes like welding rather than using them as mere inspection tools.

All of these along with the challenges presented today by the chairman of BHEL becomes a very good agenda to this NDE 2009 and
I am sure who else can take convent this opportunity into a technology for the industry. Its you the august gathering here and I am
sure the technical deliberations of this three days seminar would bring out lot of solution for the manufacturing industries as well as
service centers. Let me wish you a good luck.

Thank you very much.

Chapter Activities from March 2009 to January 2010
Course:
S.No Name of the course From To No of participants Course Director Examiner
S/Shri S/Shri
Course Exam
01. MT & PT L-II (ASNT) 15.05.09 24.05.09 09 09 M.V.Rajamani J.Shanmugam

02. UT L-II (ASNT) 19.02.09 28.02.09 20 14 B.Ram Prakash C.Srinivasan

03. UT L-I (ASNT) 19-21.6.09,3-5,8.7.09 10 10 B.Ram Prakash K.Subramanian

(WIPRO participants)
04. RT L-II (ASNT) 10.07.09 19.07.09 33 33 G.Jothinathan C.Srinivasan
J.Shanmugam K.Subramanian
05. MT & PT L-II (ASNT) 24.08.09 02.08.09 28 27 M.V.Rajamani C.Srinivasan

06. U L-II (ASNT) 04.09.09 13.09.09 22 28 B.Ram Prakash C.Srinivasan

J.Shanmugam K.Subramanian
07. R L-II (ASNT) 23.10.09 01.11.09 37 39 G.Jothinathan P.N.Udayashank
R.Balakrishnan ar
Uthirapathy
K.Subramanian
08. MT & PT L-II (ASNT) 27.11.09 06.12.09 8 10 M.V.Rajamani C.Srinivasan

09. UT L-II (ASNT) 29.01.10 07.02.10 20 20 R.Balakrishnan K.Subramanian

Photos of UT Level-l & Il June 2009 – 30 Participants

UT Level-l Wipro Participants

RT Level – Il July 2009 – 33 Participants

MT & PT Level - Il July 2009 - 28 Participants

RT Level - ll October 2009 - 37 Participants

Technical Talk
Technical Talk on 28.06.2009 by Dr. Krishnan Balasubramanian
Speaker : Dr.Krishnan Balasubramanian, Department of mechanical
Engineering, IIT Madras, Chennai

Topic : “ULTRASONIC IMAGING”

Mr.K.Venkateswara Rao, Chairman presided over the meet which had

good response of having participants of strength around 65 in numbers.
Mr.R.Balakrishnan, gave vote of thanks.

Technical Talk on 05.10.2009 by Mr. Johann Klein / Germany

Speaker : Mr. Johann Klein / Germany

Topic : “NEW GENERATION OF UT EQUIPMENTS, RVI AND FILM

DIGITIZATION PROCESS”

Sponsor : M/s Kronix X-ray & Allied Products, Chennai & GE Sensing
& Inspection Technologies, Chennai. The technical meet was presided by
Mr.M.V.Rajamani, Chairman of our chapter. 107 members attended the
meeting at Hotel Radha Regent, Chennai. Mr.R.Balakrishnan proposed the
vote of thanks.

Technical Talk on 08.01.2010 by Prof. Hajime Hatano

Speaker : Prof.Hajime Hatano, Chairman, International Standards Organi-

sation (ISO) Technical Committee 135 SC7

Topic : “INTERNATIONAL STATUS OF NDT STANDARDS AND ROLE

OF ISO”

Sponsor : NCB – ISNT. The technical meet was presided by Mr.B.Ram

Prakash, Vice Chairman of our chapter. 30 members attended the meeting.
Mr.R.Balakrishnan, gave vote of thanks.
Felicitation to Shri.V.R.Deenadayalu

Felicitation to Shri.V.R.Deenadayalu, First President of ISNT was held on 1st March 2009 on receiving the Life Time
Achievement Award by ISNT. Shri.Dilip Takbhate, president, ISNT, Shri.Balramamoorthy, Past Chairman of NCB,
Shri.R.J.Pardikar, Hon. Secretary of ISNT, and other dignitaries spoke about his wisdom in solving the problems and
remembered his achievements and benefits to its society during his tenure as president of ISNT.

ISNT DAY Celebration 21st April 2009

ISNT DAY had been celebrated on 21.4.2009 at Hotel Radha Regent, Koyambedu, Chennai. About 234 participants
who were inclusive of spouse and children of members had attended the function. Mr.S.Subramanian was the
convenor of the meeting. Mr.K.Venkateswara Rao Chairman presided over the meeting and the Chief Guest of the
day was Mr.K.S.Jayaraman, Managing Director, M/s.Autotech Industries Limited, Chennai. The faculty, the examin-
ers and the dignitaries who were associating with Chapter were honored and presented mementos by the chief
Guest. Gifts were distributed to spouse and children who were accompanied with the members for the meet. Two
awards the best member award & Thambithurai Award which were promoted by Shri.M.V.Rajamani were presented
to Mr.S.Swaminathan, Q & Q Inspection Services the recipient of The best member award and to Dr.B.P.C.Rao,
IGCAR, Kalpakkam the recipient of Thambithurai award. Games were conducted by Mr.P.Guruprasad for the
children and all members presents and gift for the winner of the game was distributed. All Members appreciated the
well conductance of the meet.
Chapter Awards
Mr.M.V.Rajamani, the sponsor of Chapter Awards, announced the names of
Winner of the awards. Mr.S.Swaminathan, Q & Q Inspection and
Dr.B.P.C.Rao, Head, IGCAR, named for the THAMBITHURAI AWARD as his
technical paper presentation at our chapter technical meet was declared as
the best one. The awards were presented with a high sense of appreciation
to the winners by the Chief Guest.
Mr.S.Swaminathan, Q & Q Inspection receiving the Best Member Award

Dr.B.P.C.Rao, Head, IGCAR, Kalpakkam received the Thambidurai Award for

Technical Paper Presentation

Accreditation to our Chapter

AGM on 18.07.2009

The Annual General Body meeting was held on 18.07.2009 at Module No.60, Readymade Garment Complex,
SIDCO Industrial Estate, Guindy Chennai-32. About 58 members attended the meeting. Memento was presented
to members present for the AGM.

Executive Committee Member

Shri.M.V.Rajamani --- Chairman Members
Shri. T.V.K.Kidao --- Chairman Elect Major.V.V.Chandrasekaran Shri.R.V.Sanjeevi
Shri.V.Pari --- Vice Chairman Shri.P.Guruprasad Dr.B.N.Sankar
Dr.Krishnan Balasubramaniam --- Vice Chairman Dr.Ing Helmut Wolf Shri.R.Sreedharan
Shri.B.Ram Prakash --- Vice Chairman Shri.G.Jothinathan Shri.V.L.Sridharan
Shri.S.Subramanian --- Vice Chairman Smt.Latha Mohandass Shri.C.Srinivasan
Shri.R.Balakrishnan --- Honorary Secretary Shri.A.L.Mehta Shri.K.Subramanian
Shri.RG.Ganesan --- Hon. Joint Secretary Shri.B.D.Prasad Shri.S.Swaminathan
Shri.J.Shanmugam --- Hon. Joint Secretary Shri.M.S.Ramachandran Shri.M.S.Viswanathan
Shri.N.Karunanidhi --- Honorary Treasurer Shri.S.D.M.Rao Shri.R.Vivek
Shri.M.Ravi Kumar --- Hon. Co. Treasurer Shri.S.R.Ravindran Shri.MU.Subramanian
 ULTRASONIC EXAMINATION OF
AUSTENITIC STAINLESS STEEL WELDS – OUR EXPERIENCE
R.Subbaratnam, A.S.L.K.Rao and B.Venkatraman
Quality Assurance Division - Engineering Services Group, IGCAR, Kalpakkam 603 102
1. Introduction beam can be used for this. To establish and quantify the effects further,
Austenitic stainless steel (Aus. SS) is used in many industries, like chemical, two weld mockups, one with 45 mm thick and the other with 75 mm
nuclear, space etc., for its high corrosive resistance, excellent fracture thick of AISI 316 Aus. SS were prepared with double V butt joint employing
toughness and creep properties over a range of temperature. It also shielded metal arc welding (SMAW) process. Three side drilled holes at
possesses good mechanical formability. Normally, its weldability is ensured the gap of ¼ T on parent metal and weld and notches with 3% and 5%
by a judicious choice of welding electrodes, weld joint design and proper depth on weld were made to serve as reference reflectors for both the
joint fit up scheme. The problems encountered by ultrasonic testing samples. The details of holes and notches are given in Fig 1.
while it is used in a weld joint-particularly in medium or thick sections.
The problem is due to the occurrence of coarse and oriented grains in the
weld metal. This occurs due to two reasons. First, there is only one phase
that occurs between the melting point and the room temperature.
Therefore, the contrary to ferritic steel weld metal in which there are
three phase fields, there is no chance for restructuring when the weld is
cooling down. Secondly, since the stainless steel has a low thermal
conductivity, only a thin layer gets molten in a previously deposited
weld metal, when the succeeding weld pass is given. By this, epi-axial Fig 1 Cross Section of weld and the details
growth takes place leading to coarse grains with oriented fiber axes.
During ultrasonic testing, the coarse grains then lead to scattering at the 3.1. Effect of Attenuation
grain boundaries, lower signal to noise ratio, and beam skewing. A similar The welds were scanned with various probes / transducers of Shear and
situation occurs during change in the process, more heat input and during Longitudinal wave angles. The data obtained from different trials with
weld repair when repeated heating and cooling takes place. 45mm an75mm weld pads are presented in the Tables 1 and 2. It was
noted, in the case of 45mm thick weld, that an extensive noise has been
2. Ultrasonic Examination of Austenitic Stainless Steel picked-up by the shear wave probes (MWB45 N2 & MWB45N1), as
Ultrasonic examination of austenitic stainless steel welds is difficult indicated in Table 1. It was also noted in the case of 75mm weld, that the
considering the variation in acoustic velocity, attenuation and scattering shear wave probes indicated above could not bring out any meaningful
due to grain coarsening during welding. This occurs due to various welding defect signal, as the noise was very high. It indicates that the shear wave
parameters followed like welding process, weld heat input and weld repairs. probes are not suitable for examination of SS weld metal thickness above
The thickness of the weld specimen is another feature for the above 40mm, whereas the longitudinal angle beam probes (WSY45-4
factors occurrences. Apart from the above the beam skewing also (single),VRY45-4 & VSY45-4 (Twin)) are better suited with good signal-
experienced in the thicker welds. to-noise ratio. It was noted that single crystal longitudinal angle beam
probes provided better results even with higher thickness of 75mm as
2.1. Ultrasonic Beam Propagation in Austenitic Stainless Steel compared to twin crystal probes (VSY 45 -4 (Twin)& RTD 45 – 2
welds (Twin)) as it could be seen that twin crystals ones need high gain, with
relatively increased noise. The signal amplitudes obtained from the side
2.1.1. Attenuation and Velocity
drilled holes and notches (reference reflectors) on the parent metal and
Lot of studies and works has been carried out by Tomlinson, Wagg and
the weld metal varied quite extensively as the thickness increases,
Whittle and Salmutter and Bradfield [1] on ultrasonic wave velocity,
therebyindicating that the sensitivity level set on parent metal reflectors
wave propagation, attenuation etc. It was found that in Austenitic stainless
will no longer be valid for weld metal.
steel weld metal; the ultrasonic beam undergoes higher attenuation than
in the parent metal. They further concluded studies shows that the
dependence of the transmitted signal on beam orientation arises as a
result of the macroscopic anisotropy of the assembly of grains, and is
not related to the composition of the weld metal. The velocity of the
beam decreases if any angular deviation increases. The variation in velocity
leads to variation in resolution and sensitivity as the wavelength varies
for a particular frequency.
2.1.2. Beam Scattering and Skewing
An important feature of wave or energy propagation in any anisotropic
medium is that it will not be perpendicular to the wave front. This
phenomenon gives rise to skewing of the beam off the axis of transducer.
The largest angle of skew for compression wave is about 15 , but for
shear waves the calculation showed the beam might deviate by up to 50
from the expected direction of propagation. It is clear that with deviations 3.2. Extent and effect of beam Skewing
of this order of magnitude a shear wave examination would be extremely Another problem encountered during the examination of higher thickness
difficult to carry outdefect delectability with shear wave is established as is the ultrasonic beam skewing during the propagation (3). This will lead
0.2!, where ! is wave length of ultrasound in the material in mm [2]. to the wrong assessment of the defects, both in size and position. This
will be more pronounced when the examination is carried out over the
3. Experimental Studies
weld. The experimental study explained earlier was used to evaluate the
Experimental study was undertaken to analyze the problems as discussed
extent of beam skewing on the 75-mm thick weld sample. Through
above on thicknesses ranging from 15mm to 75mm of Aus. SS welds. It
transmission technique was employed to quantify the beam skewing as
was found that for the lower thickness up to 15 mm the effects were not
described in Fig.. The weld was scanned by keeping the transmitter at
significant. Over 15 mm, the noise (grass) was found very much and
regular intervals of 8mm (1/3rd of weld face width) on both sides of the
hence the use of shear wave is not suitable. Only longitudinal wave angle
face with respect to the centerline of the weld and the receiver was
moved to obtain the maximum signal. This was repeated for 2MHz
transmitter and 4 and 6 MHz receiver combinations. It was noted that
best result was achieved by the combination of 2 MHz transmitter and 2
MHz receiver. This could be attributed to the fact that the higher the
frequency the more in attenuation in the weld with increase in noise due
to scatter and grain boundary reflections in the case of austenitic stainless
steel. The amount of beam skewing with respect to transmitter’s position
is given in Table 3 and the scheme is shown in Fig. 2.
Fig 2 - Beam Skewing on Aus. SS Weld
4. Effect on Ultrasonic Sensitivity of Welding Processes variation
In Aus. SS welding, the heat input affects the grain size of the weld metal.
The heat input is a function of the welding process. An experiment was
conducted to analyze the welding process variables on ultrasonic
examination sensitivity, using SMAW and GTAW processes. The two
processes were selected, as these are widely used in industries. A few
numbers of weld pads of 15-mm thickness were welded using SMAW and
GTAW processes. The weldment was examined using dye-Penetrant
examination and radiographic examination and cleared. In order to check
the sensitivity of detection, 2-mm diameter side drilled hotels have been
drilled as shown in fig. 3
Ultrasonic examination was conducted from both the sides of the weld
with 2 and 4 MHz shear wave. The gain required for keeping the reference
hole signal at 80% of the full screen height was noted for both, the
parent metal and on the weld. The values are given in
Table 4.
Also scanning was performed on the welds using 4MHz normal beam
probe to measure the gain required to obtain the back wall echo to 80%
FSH. The gain requirements are given below.
Parent Metal (AISI 316):52 dB. Weld (SMAW): 58dB. Weld (GTAW):
61dB. From the above, it is evident that the weld metal deposited by
GTAW process introduces greater attenuation as a result of coarser grain
compared to the weld made by SMAW process. This feature could be
attributed to the increased numbers of passes in GTAW process compared
to SMAW process for the same thickness. This results in higher heat
input and thereby grain growth in weld metal. Also, the arc in GTAW is
more concentrated than in SMAW, which increases the severity of
reheating of previously laid passes, thereby coarsening the grain. The
micrographic examination of the two welds also confirmed the inference.
Fig 3 – Weld specimen details used for the variation in
welding process
5. Effect on ultrasonic sensitivity due to variation in weld heat
input
Many parameters are to be followed to get a good weld. One of them is
the weld heat input. The generally specified heat input is around 800 to
1000 J/mm, according to the welding process followed. More heat input
leads to coarse dendrite arm spacing structure. A series of four AISI 316
weld pads of 25-mm thickness with average weld heat input of 1150,
1250, 1400 and 1650 J/mm were made using Shielded Metal Arc Welding
(SMAW) process. The weld specimens were identified as Plate 1, Plate 2,
Plate 3 and Plate 4 respectively according to the heat input. The thickness
of the specimen was so selected it that makes shear wave examination is
also possible. A 2-mm dia side-drilled hole (SDH) on the weld at 3/4th
thickness was used as reference for ultrasonic examination. The sketch
of the specimen with reference SDH is shown in figure 4.
Pulse Echo technique has been carried out using shear wave and longitudinal
wave angle beam. Equipments of model USD 10 of M/s Krautkramer,
Germany for pulse-echo and model Microplus of M/s AEA Technology,
UK for TOFD techniques were used. Krautkramer make Shear wave
(MWB) and Longitudinal wave (WSY) transducers of 60 and 70 angles
were used, for both the techniques, as the reinforcement was not removed.
The scanning was done within ½ skip distance in both shear and
longitudinal angle beam examination to accommodate the same beam
path. The scanning has been performed from both sides i.e. Side-A and
Side-B. The reference hole signal was taken for analysis. The signal was
kept at 60% full-scale height (FSH) and the gain required for 60% of
signal and the signal-to-noise ratio were noted. The gain requirement
(dB) recorded for pulse echo technique is given below in Table-5.
Fig 4 – Weld specimen details for Ultrasonic Sensitivity
Variation due to weld Heat input
The following graph showing the gain requirement and in turn the sensi-
tivity variation is given in figure 4 for shear and longitudinal wave
modes.
6. Effect on Ultrasonic Examination Sensitivity on Repair /
Repeated Repair of Austenitic Stainless Steel Welds
It is inevitable that welds may have to be subjected to repair, occasionally
repeated repairs, to remove unacceptable defects. It is essential that the
effects of such repairs and the resultant micro-structural changes that
will have influence on ultrasonic examination should be studied, analysed
and quantified. A study was conducted on 12-mm AISI 316 LN weld pads.
Five numbers of weld pads were prepared using SMAW process. The
configuration of the fit-up with backing strip is shown in figure 7. After
completion of the welding once, grooves were machined as shown in
figure 8 in order to ensure that the weld metal, parent metal and the heat
affected zone would suffer the influence of heat cycles involved during
the weld repair. After machining the groove, weld repairs were taken up
to four times. In this, the weld and the parent metal face heat cycles and
the structural changes occur in the heat-affected zone and nearby areas,
resulting in severe micro-structural changes which affects the examination
and its sensitivity. Out of the five weld pads, pad 1 represents nil / no
repair, pad 2 represents one weld repair and so on. After finishing the
welds the backing was removed by machining.
A 2-mm diameter side drilled hole was drilled on each weld as reference
(Ref. Fig 9). Each weld was examined ultrasonically on both sides and the
gain required for getting 60% of FSH signal was noted. The weld was
scanned with a variety of probes and the signal to noise ratio noted. The
gain requirements and signal to noise ratio obtained for 45 shear wave
transducer are given in Table. 6. Increase in gain requirement and reduction
in signal to noise ratio was noticed with increase in number of repairs and
this pattern was observed with different probes. This signal to noise ratio
is high when low frequency and longitudinal probes are used.
From the above, it can be noted that the amplitude drops from the
reference amplitude if the number of repairs increases [Fig. 10] Also it
was noted that the signal to noise ratio decreased with the increase in the
number of repairs.
The amplitude drop noted was found to be pronounced if the number of
repairs increased. The amplitude drop was more for the first weld repair
compared to the unrepaired weld. This indicates that the reference taken
for un-repaired weld will not serve as true reference to establish the
sensitivity, even if the weld undergoes one repair. Separate reference
blocks are required representing the same number of repairs, as that of
the production weld. However, it may further be noted that there is a
limit on number of welds which makes the weld fit for effective ultra-
sonic examination.
Fig 5 – Weld specimen detail with Number of repairs and graph
showing the reduction in amplitude due to number of repair.
7. Conclusion
The above experimental studies have shown the difficulties experienced
in ultrasonic examination of thick austenitic stainless steel welds, the
effects of welding processes, welding heat input and weld repairs on
ultrasonic wave propagation and the sensitivity reduction. Knowledge
on these aspects and use of appropriate techniques and transducers would
help to reduce the difficulties.It is concluded with the following
observations:
(a) The reference calibration holes/notches have to be necessarily
provided on the weld metal instead of on the parent material, as is
normally followed, to achieve a better defect detection sensitivity in the
weld. This is more pronounced for sections above approx. 20 mm. as the
thickness increases the beam skewing effect is more and proper
estimation of it is important.
(b) Consideration and control of the weld structure must precede attempts
to improve examination sensitivity by the use of special transducers or
signal processing methods.
(c) The preparation of the reference specimen for standardization of
the ultrasonic examination procedure must address the features like the
type of welding process employed and that of the anticipated number of
weld repairs as that of the component to achieve the required defect
detection sensitivity.
(d) The design engineers should take account of the limitations of
ultrasonic examination when applied to thick austenitic weld structures.
Acknowledgements
The authors are grateful to Dr Baldev Raj, Director, Indira Gandhi Centre
for Atomic Research, Mr.Y.C.Manjunatha, Director, Engineering Services
Group, IGCAR, and our colleagues at IGCAR, for the valuable guidance,
encouragements and assistance in bringing out this paper.
References
[1] J.R. Thomilson, A.R> Wagg, and M. J. Whittle, “Ultrasonic Inspection
of Austenitic Welds”, British Journal of NDT, PP.119-127, (May 1980)
[2] H. W.. Corsepius, “The Ultrasonic Testing of Austenitic Welded
joints”, booklet from M/S. Krauntkramer, Germany
[3] Ogilvy. J. A., “ Ultrasonic beam profiles and beam propagation in an
austenitic weld using theoretical ray tracing model”, Ultrasonics 24(6),
pp.337-347, (1986)
[4] J. A. Ogilvy, “ The influence of austenitic weld geometry and
manufacture on Ultrasonic Inspection of Welded joints”, British Journal
of NDT, pp. 147-156,(May 1987).
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