Download - Alan Calder
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MANUFACTURED
DISCONTINUITIES
or REAL FLAWS
-NDE APPLICATIONS
AND
CHARACTERISTICS
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What Are Real Flaws?
Manufactured Discontinuities or Real Flaws areintentionally created and placed defects in critical
areas, such as weld joints, base materials, parts, etc .
Their intent is to replicate the NDE response of theactual defect
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Two Fundamental Approaches
Induced Actual Creation of the flaw in acontrolled environment where its extents can be
accurately measured
Manufactured Manufacturing of an indicationthat will produce the expected NDE response
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Three Types of Real Flaws
Weld or Base Material Defects
Fatigue Cracks
Alternative Flaws
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Real Flaw Type 1 -
Weld/Base Material DefectsWeld defects occur during the welding process.
Some Examples of weld defects:
Slag or Tungsten Inclusion Lack of Fusion Incomplete Penetration
Porosity
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Real Flaw Type 1
Weld/Base Material DefectsBase Material defects are present in the base material
of machined parts, vessels, structures, or in the raw
material itself
Lamination Single Gas Pores Cracking
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Real Flaw Type 2 -
Fatigue CracksThese cracks are a result of cyclic fatiguing orloading
Thermal Fatigue
Mechanical Fatigue
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Real Flaw Type 3 -
Alternative Flaws Intended to minimize base metal disturbance
Combination of traditional flaw manufacturing withmachining and PWHT
Limited customer base currently
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REAL FLAWS
NDE APPLICATIONS
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Who uses Real Flaws?
Some industries or groups currently benefitting from
their use are:
Commercial Nuclear Power Petrochemical Nuclear Navy Aerospace Training & Education
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Who uses Real Flaws?
Some codes currently being serviced by these flaws
are:
AWS D1.1 & D1.8 ASME Sec V, VII, XI ASME BPVC CASE 2235 API-UT-1 & RP 2X
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The Future
New Materials
New Defect Types
Tighter Tolerances
New Markets
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REAL FLAWS
NDE CHARACTERISTICS
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A36 CS Plate, 12x12 x 0.75T
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A-Scan UT CalibrationPLATEBOTTOM
PLATETOP
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Phased Array CalibrationSECTOR SCAN
40 - 70
A-SCAN (53)
PLATE BOTTOM
CURRENT ANGLE
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Lack of FusionIncompletely fused area in the weld. Typically
between the weld and base material or in
between weld beads or passes.
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Lack of Fusion(Mid-Wall)Expected UT Response
Location Approximately 1.8 or 5.3 screendivisions(conventional)
Signal Crack-like, well-defined Consistent signal as probe is skewed or moved
axially
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Lack of Fusion(Mid-Wall)TOP
BOTT
OM
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Lack of Fusion(Mid-Wall)Probe Skewed Left 15 Probe Skewed Right 15
GATE
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Lack of Fusion(Mid-Wall)
PLATE BOTTOM
LACK OF FUSION
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Slag InclusionNon-metallic byproduct of the welding process,
which becomes trapped in the weld
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Slag InclusionExpected UT Response
Location Anywhere in weld volume Signal Broad, multi-peaked, singularentity
Primarily amplitude change is seenwith axial movement or skewing of probe
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Slag InclusionTOP
BOTT
OM
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Slag InclusionProbe Skewed Left 15 Probe Skewed Right 15
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Slag Inclusion
PLATE BOTTOM
SLAG INCLUSION
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PorosityEntrapped gas in solidified metal. It can be
clustered or linear(wormhole).
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Porosity(Cluster)Expected UT Response
Location Any position through the volume ofthe weld
Signal Broader signal with multiple peaks andmultiple ring cycles
Axial movement or skewing of probe show aconsistent indication response
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Porosity(Cluster)TOP
BOTTOM
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Porosity(Cluster)Probe Skewed Left 15 Probe Skewed Right 15
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Porosity(Cluster)
PLATE BOTTOM
POROSITY
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Incomplete PenetrationArea where the weld does not fully penetrate
through the thickness of the weld joint..
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Incomplete PenetrationExpected UT Response
Location Weld centerline, at or near 3.5 screendivisions
Signal Clean, sharp, well-defined
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Incomplete PenetrationTOP
BOTTOM
TIP SIGNAL
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Incomplete Penetration
TIP SIGNAL
INCOMPLETE
PENETRATION
PLATE BOTTOM
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Fatigue Crack HAZ AreaBase material crack located a short distance from
the weld fusion line, in the HAZ(Heat-Affected
Zone)
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FatigueCrack HAZ AreaExpected UT Response
Location At or near 3.5 screen divisions Signal Single indication with multiple ring
cycles, sometimes accompanied by pre & post-cursor indications
Axial probe movement results in increase &decrease of signal, but no character changes
Skewing of probe may show amplitude changesin signal
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Fatigue Crack HAZ AreaTOP
BOTTOM
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Fatigue Crack HAZ AreaProbe Skewed Left 15 Probe Skewed Right 15
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Fatigue Crack HAZ Area
HAZ CRACK
PLATE BOTTOM
A-SCAN
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Fatigue Crack Toe AreaBase material crack located at the toe of the weld
crown, running parallel to the weld
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Fatigue Crack Toe AreaExpected UT Response
Location At or near 7th screen division Signal Similar response to HAZ crack, with
location being the differentiating factor
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Fatigue Crack Toe AreaTOP
BOTTOM
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Fatigue Crack Toe AreaProbe Skewed Left 15 Probe Skewed Right 15
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Fatigue Crack Toe AreaTOE CRACK
PLATE BOTTOM
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THANK YOU!