ASTM E164-2003 Standard Practice for Ultrasonic Contact Examination of Weldment《焊接件超声接触检验的标准实施规程》.pdf

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1、Designation: E 164 03Standard Practice forUltrasonic Contact Examination of Weldments1This standard is issued under the fixed designation E 164; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revision, the year of last revision. A number in

2、 parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.This standard has been approved for use by agencies of the Department of Defense.1. Scope1.1 This practice covers techniques for the ultrasonicA-scanexamin

3、ation of specific weld configurations joining wroughtferrous or aluminum alloy materials to detect weld disconti-nuities (Note 1). The reflection method using pulsed waves isspecified. Manual techniques are described employing contactof the search unit through a couplant film or water column.1.2 Thi

4、s practice utilizes angle beams or straight beams, orboth, depending upon the specific weld configurations. Prac-tices for special geometries such as fillet welds and spot weldsare not included. The practice is intended to be used onthicknesses of 0.250 to 8 in. 6.4 to 203 mm.NOTE 1This practice is

5、based on experience with ferrous and alumi-num alloys. Other metallic materials can be examined using this practiceprovided reference standards can be developed that demonstrate that theparticular material and weld can be successfully penetrated by anultrasonic beam.NOTE 2For additional pertinent in

6、formation see Practice E 317,Terminology E 1316, and Practice E 587.1.3 Values stated in inch-pound units are to be regarded asthe standard. SI units are given for information only.1.4 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresp

7、onsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM Standards:E 317 Practice for Evaluating Performance Characteristicsof Ultrasonic Pulse-Echo Examinatio

8、n Systems Withoutthe Use of Electronic Measurement Instruments2E 543 Practice for Agencies Performing NondestructiveTesting2E 587 Practice for Ultrasonic Angle-Beam Examination bythe Contact Method2E 1316 Terminology for Nondestructive Examinations22.2 ASNT Standard:Practice SNT-TC-1A Personnel Qual

9、ification and Certifica-tion in Nondestructive Testing32.3 ISO Standard:ISO 2400 Reference Block for the Calibration of Equipmentfor Ultrasonic Examination43. Significance and Use3.1 The techniques for ultrasonic examination of weldsdescribed in this practice are intended to provide a means ofweld e

10、xamination for both internal and surface discontinuitieswithin the weld and the heat-affected zone. The practice islimited to the examination of specific weld geometries inwrought or forged material.3.2 The techniques provide a practical method of weldexamination for internal and surface discontinui

11、ties and arewell suited to the task of in-process quality control. Thepractice is especially suited to the detection of discontinuitiesthat present planar surfaces perpendicular to the sound beam.Other nondestructive tests may be used when porosity and slaginclusions must be critically evaluated.3.3

12、 When ultrasonic examination is used as a basis ofacceptance of welds, there should be agreement between themanufacturer and the purchaser as to the specific referencestandards and limits to be used. Examples of reference stan-dards are given in Section 6. A detailed procedure for weldexamination de

13、scribing allowable discontinuity limits shouldbe written and agreed upon.3.4 Personnel QualificationIn order to meet the intent ofthis recommended practice, it is essential that evaluation beperformed by properly trained and qualified testing personnel.The user is referred to Practice SNT-TC-1A publ

14、ished byAmerican Society of Nondestructive Testing (ASNT) or otherequivalent programs.3.5 Nondestructive Testing Agency EvaluationUse of anNDT agency (as defined in Practice E 543) to perform theexamination may be agreed upon by the using parties. If a1This practice is under the jurisdiction of ASTM

15、 Committee E07 on Nonde-structive Testing and is the direct responsibility of Subcommittee E07.06 onUltrasonic Method.Current edition approved Aug. 10, 2003. Published October 2003. Originallyapproved in 1960. Last previous edition approved in 1997 as E 164 - 97.2Annual Book of ASTM Standards, Vol 0

16、3.03.3Available from TheAmerican Society for Nondestructive Testing (ASNT), P.O.Box 28518, 1711 Arlingate Ln., Columbus, OH 43228-0518.4Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036.1Copyright ASTM International, 100 Barr Harbor Drive, PO B

17、ox C700, West Conshohocken, PA 19428-2959, United States.systematic assessment of the capability of the agency isspecified, a documented procedure such as Practice E 543 shallbe used as the basis for evaluation.4. Search Units4.1 Angle-Beam requirements for angle-beam search unitsare determined by t

18、he test variables. The examination proce-dure should be established by taking into consideration vari-ables such as weld thickness, available surface, maximumallowable flaw size, flaw orientation, and the acoustic proper-ties of the material. Consideration should also be given to thedesirability of

19、using comparable wave lengths within thematerials where both a longitudinal-wave examination and anangle-beam shear-wave examination are employed. This can beaccomplished by conducting the straight-beam (longitudinal-wave) examination at approximately two times the frequencyof the angle-beam (shear-

20、wave) examination.4.2 Frequencies of 1.0 to 5 MHz are generally employed forangle-beam (shear-wave) and for straight-beam (longitudinal-wave) examination.4.3 Transducer sizes recommended for weld examinationrange from a minimum of14-in. 6.4-mm diameter or14-in.square to 1 in. 25.4 mm square or 118-i

21、n. 28.6-mmdiameter.5. Standardization5.1 Two methods of angle-beam standardization are ingeneral use: the polar, and the rectangular, coordinate methods.5.1.1 The polar coordinate method requires measurementsof the beam centerline at the search unit/work interface and thebeam angle in a test block,

22、and the instrument sweep iscalibrated along the beam line. Test information is graphicallyconverted into position and depth coordinates for reflectorlocation. The polar method is detailed in Annex A1.5.1.2 The rectangular coordinate method requires measure-ment of the position of the reflector from

23、the front of the searchunit, and the instrument sweep is calibrated for depth to thereflector as it is moved to different positions in the beamproviding a distance-amplitude curve. Test information is readdirectly for position and depth to the reflector. The rectangularcoordinate method is detailed

24、in Annex A2.6. Reference Standards6.1 IIW-type reference blocks are a class of reference blocksfor checking and calibrating ultrasonic instrumentation, whichmeet the basic geometrical configuration described in ISO2400 but which may deviate in such aspects as non-metricdimensioning, alternate materi

25、als, additional reflectors, anddifferences of scale details. IIW-type blocks are primarilyintended for characterizing and calibrating angle-beam sys-tems, but also provide features for such uses as straight-beamresolution and sensitivity checks.NOTE 3Discussion of the differences among various versi

26、ons of“IIW-Type” reference blocks, illustrations of typical configurations and anextensive bibliography can be found in a published reference.56.1.1 Only blocks fully meeting all the requirements of ISO2400 should be referred to as IIW reference blocks.6.1.2 Blocks qualified to certain other nationa

27、l standardsmay also satisfy all the requirements of ISO 2400 but haveadditional features.6.1.3 The term IIW Block Type I should be used only todescribe blocks meeting the standard cited. The term IIW BlockType II is reserved for the miniature angle-beam block recog-nized by ISO.6.1.4 All other block

28、s derived from the basic ISO 2400configuration, but not fully meeting all its requirements shouldbe referred to as IIW-Type blocks.6.1.5 Suppliers and users of such blocks should identify thespecifications which are met, or provide detailed documenta-tion.6.1.6 Because of the possible differences no

29、ted, not allIIW-type blocks may be suited for every application for whichqualified ISO 2400 blocks may be acceptable.6.1.7 Unless the blocks have also been checked by pre-scribed ultrasonic procedures, they may also produce non-uniform or misleading results.6.2 Distance Standardization:6.2.1 An equa

30、l-radius reflecting surface subtending an arcof 90 is recommended for distance standardization because itis equally responsive to all beam angles. Other reflectorconfigurations may be used. Equal-radius reflecting surfacesare incorporated into IIW-Type Blocks and several otherreference blocks (see A

31、nnex A1)(Note 3). Distance standard-ization on a square-notch corner reflector with a depth of 1 to3 % of thickness may be used. However, full beam reflectionsfrom the square corner of the block will produce erroneousresults when standardizing angle beams near 60, due to modeconversion. The square c

32、orner of the block should not be usedfor distance standardization.NOTE 4Small errors of beam index location are indigenous to thestandardization procedure using the an IIW-Type Block. Where extremelyaccurate standardization is necessary, a procedure such as that outlined in6.2.2 should be used.6.2.2

33、 For examination of welds, a side-drilled hole may beused for distance, amplitude, position, and depth standardiza-tion.An example is shown in Fig. 1. Move the reflector throughthe beam to18 ,38 ,58 ,78 , and98 of the Vee path. Adjust thedelay to place indication 1 at sweep division 1. Adjust the5Ho

34、tchkiss, F.H.C., “Guide to designs of IIW-type blocks”, NDT International,Vol. 23, n. 6, December 1990, pp. 319-331. FIG. 1 Side-Drilled HoleE164032range to place indication 9 at sweep division 9. Since thesecontrols interact, repeat the delay and range adjustments untilindications 1 and 9 are place

35、d at sweep divisions 1 and 9.Adjust sensitivity to provide an 80 %-of-full-screen indicationfrom the highest of the 1, 3, 5, 7, or 9 indications. At thissensitivity, mark the maximum amplitudes on the screen fromthe reflector at 1, 3, 5, 7, and 9. Connect these points for thedistance amplitude curve

36、 (DA Curve). Corner reflections fromthe hole to the surface may be observed at 4 and 8 divisions onthe sweep; these indications will not be used in the DA Curve.Measure the position of the reflector on the surface from thefront of the search unit to the surface projection of the holecenterline. Sinc

37、e the depth to the hole is known, the standard-ization provides means for estimating the position, depth, andrelative size of an unknown reflector.6.3 Sensitivity-Amplitude Standardization:6.3.1 Reference standards for sensitivity-amplitude stan-dardization should be designed so that sensitivity doe

38、s not varywith beam angle when angle-beam examination is used.Sensitivity-amplitude reference standards that accomplish thisend are side-drilled holes parallel to the major surfaces of theplate and perpendicular to the sound path, flat-bottomed holesdrilled at the examination angle, and equal-radius

39、 reflectors.Surface notches can also accomplish this end under somecircumstances. These reference reflectors are described inTable 1.6.3.2 Under certain circumstances, sensitivity-amplitudestandardization must be corrected for coupling variations(Section 7) and distance amplitude effects (Section 8)

40、.7. Coupling Conditions7.1 Preparation:7.1.1 Where accessible, prepare the surface of the depositedweld metal so that it merges into the surfaces of the adjacentbase materials; however, the weld may be examined in theas-welded condition, provided the surface condition does notinterfere with valid in

41、terpretation of indications.7.1.2 Free the scanning surfaces on the base material ofweld spatter, scale, dirt, rust, and any extreme roughness oneach side of the weld for a distance equal to several times thethickness of the production material, this distance to begoverned by the size of the search

42、unit and refracted angle ofthe sound beam. Where scanning is to be performed along thetop or across this weld, the weld reinforcement may be groundto provide a flat scanning surface. It is important to produce asurface that is as flat as possible. Generally, the surfaces do notrequire polishing; lig

43、ht sanding with a disk or belt sander willusually provide a satisfactory surface for examination.7.1.3 The area of the base material through which the soundwill travel in the angle-beam examination should be com-pletely scanned with a straight-beam search unit to detectreflectors that might affect t

44、he interpretation of angle-beamresults by obstructing the sound beam. Consideration must begiven to these reflectors during interpretation of weld exami-nation results, but their detection is not necessarily a basis forrejection of the base material.7.2 Couplant:7.2.1 A couplant, usually a liquid or

45、 semi-liquid, is requiredbetween the face of the search unit and the surface to permittransmission of the acoustic energy from the search unit to thematerial under examination. The couplant should wet thesurfaces of the search unit and the piece, and eliminate any airspace between the two. Typical c

46、ouplants include water, oil,grease, glycerin, and cellulose gum. The couplant used shouldnot be injurious to the material to be examined, should form athin film, and, with the exception of water, should be usedsparingly. When glycerin is used, a small amount of wettingagent is often added to improve

47、 the coupling properties. Whenwater is used, it should be clean and de-aerated if possible.Inhibitors or wetting agents, or both, may be used.7.2.2 The coupling medium should be selected so that itsviscosity is appropriate for the surface finish of the material tobe examined. The following table is

48、presented as a guide:Roughness Average(Ra in.)Equivalent CouplantViscosity5 to 100 SAE 10 wt. motor oil50 to 200 SAE 20 wt. motor oil80 to 600 glycerin100 to 400 SAE 30 wt. motor oil7.2.3 In performing the examination, it is important that thesame couplant, at the same temperature, be used for compa

49、ringthe responses between the standardization blocks and theproduction material. Attenuation in couplants and wedge ma-terials varies with temperature so that a standardization per-formed in a comfortable room is not valid for examination ofeither hotter or colder materials.8. Distance-Amplitude Correction8.1 Use standardization blocks of similar surface finish,nominal thickness and metallurgically similar in terms of alloyand thermal treatment to the weldment.8.2 Alternative techniques of correction may be used pro-vided the results are as reliable as those obtai