NDT Training Program ULTRASONIC METHOD Education In Nondestructive Testing The American Society for Nondestructive TestingUltrasonic Method NOT Training Program Students Guide Table of Contents Page i Lesson 7.. Worksheet #1. Quiz... Lesson Qui: Lesson 9.. Worksheet #1.. Qui Lesson 3... Worksheet #1 Lesson 10. Worksheet #1 Worksheet #1. 129 Worksheet # Quiz. Lesson 4... Worksheet #1 45 Lesson 11 Worksheet #1 Worksheet #1. Lesson 13. Qui Worksheet #1 Quiz.INSTRUCTOR'S GUIDE NDT TRAINING PROGRAM ULTRASONIC METHOD INTRODUGTION TO THE ULTRASONIC TRAINING PACKAGE ‘The training materials inthis package are designed 1o provide a basic knowledge ofthe fundamentals of ultrasonic testing. The training program should contain the following classroom hours to adequate: 'y present the information suggested in the ASNT publication, SNT-TC-1A, Recommended Practice, «June 1980 edition. Level 1 training will include lectures on all 14 lessons with an average of approximately 2.9 hours per lesson. Emphasis by the instructor should be given to lessons 1-8 which cover the basic principles and applications of the ultrasonic method. {the training program is aimed at meeting the guidelines for Level, the instructor can follow the lec: ture guide closely with very itl elaboration or explanation. advanced training is tobe given, the in structor should require additional outside reading with class discussions and should present personal Information to elaborate on the lecture guide outline. Each program can be easily expanded and is limited only by the instructor's experience and expertise. ‘The materials in this course are designed for use ina typical classroom traning situation with an ideal class size of 5.25 students. The instructor will lecture on all essons withthe aid of the lecture guide transparencies provided. CONTENTS OF TRAINING PACKAGES ‘The instructor selected to teach the course need not be a professional educator. However, the in: structor should have expertise in the ultrasonic method, The instructor should be familiar with all materials before attempting to teach the course ‘The following breakdown of the materials and their functions should be carefully studied. 1, STUDENT PACKAGE — Each package contains the following: ‘A. Student's Gulde which describes the course and provides a lesson outline B. 1 Classroom Training Handbook which serves as the major text for the training course (cT6-4), C. 14 Individual lecture guide packets which provide an outline of the ultrasonic test instruc- tion, D. 1 packet of exams (One exam is furnished for each of the 13 lessons in the training course.) 2, INSTRUCTOR PACKAGE — Each package contains the following A. Instructor's Guide which provides instructions to the instructor in preparing for and admin. istering this course B. 1 Classroom Training Handbook (CT-6-4) which is used by the instructor as the main resource text C. 14 Individual lecture guide packets which are identical to those received by the student D. 14 Individual lecture guide transparency packets which are used by the instructor as a basis for the lectures, (See Part Ill of this guide) E. 1 packet of exam keys which provide the questions and answers for all exams in the 14 lessons. F. 1 Special pen tor marking on the transparencies, G._ Sample Certificates available trom ASNT Headquarters for purchase. H. (optional) 1 set of Ultrasonic Testing Filmstrips which would be extremely usetu! to the in structor in providing continuity and protessionalism to the presentation. 1. (@ptional) + Programmed Instruction Handbook Pl-4-1. J. (optional) Programmed Instruction Handbooks P-t-4 (Vol. I ll Il). This may be useful to the instructor as a review for most of the lecture guide packageSUGGESTED USE OF INSTRUCTOR LECTURE GUIDE TRANSPARENCIES 2. The information on the transparency is identi |. The transparencies can be used on any standard overhead projector. I 10 the student lecture guide contained in the stu- ‘ent packet. The "Lecture Guide Transparencies” are intended to serve as memory joggers for the instructor and should not be used as a strict outline or script. ‘A. The instructor should cover the overhead projector with a sheet ot heavy paper and lower it under the transparency after each item is discussed. A special pen is enclosed for use as a pointer and writing on the transparent sheet 8. The instructor should elaborate and discuss supplemental information whenever itis peti ent. . Prior fo the lecture, the instructor may wish to record some additional information on the lec- ture guides. This could either be done directly on the transparencies or on the instructor's set of lecture guides. D. Students should be encouraged to follow along in their set of lecture guides and write in addi- tional information when itis given. Discussions and questions should be encouraged as the instructor proceeds through the lessons, IV, SUGGESTED USE OF CLASSROOM TRAINING HANDBOOK 1. The Classroom Training Handbook (CT-6-4) is the major reference for this ultrasonic training cour Additional information {rom The Programmed instruction Handbook (PI-4-4) is sometimes ‘added to the lecture notes, and the instructor may wish to review this source. 2. Reading assignments should be given to the students to correlate with lectures. The Classroom Training Handbook (CT-6-4) follows the lessons in this training course in the following order: Pages Lesson 1 —_Applleations, Training, and Certitication CT-8-4, Chapter 1 all SNT-TCAA all Lesson 2 Ultrasonic Principles CT-6-4, Chapter 2 251028 Pl-4-a, Volume 1, Chapter + all P44, Volume 1, Chapter 2 21 1026 Lesson 3 Equipment Controls CT-6-4, Chapter 2 2810246 Pl-4-4, Volume 1, Chapter § alt Pl-4-a, Volume 2, Chapter 4 4-1 t0 4.60 Lesson 4 Wave Propagation, Reflection, and Refraction CT-6-4, Chapter 2 2:16 0291 Pi-4-4, Volume 1, Chapter 3 all Lesson 5 Couplants, Material Characteristics, Beam Spread CT-6-4, Chapter 2 2:26 to 2:96 Pi-4-4, Volume 1, Chapter 6 all Pi-4-4, Volume 2, Chapter 2 all Lesson Attenuation, Impedance, and Resonance CT-6-4, Chapter 2 2-92 to end Pitot, Volume 1, Chapters 2 & 4 all Pl-4-4, Volume 2, Chapter 4 461 to endLesson 7 Screen Presentations, Angie UT Catculetor CT-6-4, Chapter 3 33.10 312 4-4, Volume 1, Chapter 5 all Pi-4-4, Volume 2, Chapter § all Pl-4-6, Volume 3, Chapter 3 3460 to end Lesson8 Transducers, Standard Reference Blocks CT-6:4, Chapter 3 3:12 to end Pi-4-4, Volume 2, Chapters 1 & 3 ail Lesson 9 Immersion inspection CT-6-4, Chapter 4 4-4 104-18 Pi-4-4, Volume 3, Chapters 4 & 5 all Lesson 10 Contact Testing, Longitudinal & Shear Waves, Sneit's Law CT-6-4, Chapter 4 4.19 104.28 Pi-é-d, Volume 3, Chapters 1 & 2 all Lesson 11 Applications of Angle Beam Contact Testing CT-6-4, Chapter 4 419 10 4:31 Pi.a.e, Volume 3, Chapter 3 all Lesson 12 Nonrelevent Ultrasonic Indications CT-6-4, Chapter 4 432 to end 1-4-4, Volume 3, Chapter 6 all Lesson 13 Classification of Discontinulties in UT CT-6-4, Chapter 7 7410 7-7 PL4-1, Chapters 1 through 7 aul Lesson 14 Identification and Comparison of Discontinuities CT-6-4, Chapter 7 7.8 to end ‘SUGGESTED USE OF EXAM AND KEYS 1. Its suggested that the exam packet be removed before the student is issued his/her package of training materials. 2. Exams can be given at the end of the lecture or at the beginning of the next lecture period. The umber of exams given at one time will depend on the number of lessons covered, Exams can be corrected in class and should be discussed briefly with the students, Don't permit lengthy argu: ‘ments about interpretation of questions, etc. ‘3. The exam questions in this package are not intended for use in the certification of NDT personnel They are simply teaching tools to aid the instructor in presenting the material. H examinations for ccettiication are needed, itis suggested that the instructor obtain a copy of SNT-TC-14 and follow this recommended practice (Paragraph 8, SNT-TC-1A) 4, If the instructor so chooses, the exam results could be used to arrive at @ percentile score that could be recorded on the students’ certificate of completion along with the number of course hours. Blank certificates are available trom ASNT.vi. vil. vit ‘SUGGESTED USE OF RADIOGRAPHIC FILMSTRIPS (optional) 1. The flmstrips are professionally produced and will add depth and clarity to.the instructor's pre sentation, The ultrasonic filmstrips are available from ASNT catalog and consist of 8 separate strips each with an audio cassette. The use of the filr:....ps are optional but can be used to sup. ‘plement the lessons as follows: UT-Lesson 1 Filmstrip # Introduction Advantages and limitations of UT UT-Lesson2 Filmstrip #1 Theory of UT and basic terminology UT-Lesson3 Filmstrip #5 Pulse-echo testing systems UT-Lesson4 Filmstrip #3 Wave propagation and Snell's Law UT-Lesson 5 — Filmstrip # 2 (1st 3/4) Piezoelectricity and beam spread UT-Lesson6 UT-Lesson 7 UTLesson®@ — Filmstrip # 2 (last 1/4) Transducer construction Flmstrip "6 Use of calibration blocks UT-Lesson 9 Filmstrip # 4 (last 1/4) Advantages and limitations of immersion testing compared to contact testing UT-Lesson 10 Filmstrip # 4 (1st 3/4) Methods and techniques of contact testing UTLesson 11 UT-Lesson 12 Filmstrip #7 ‘Special applications and nonrelevant indications SUGGESTED USE OF PROGRAMMED INSTRUCTION HANDBOOKS (optional) 1. The instructor may wish to read Pl4-4 as a personal review of the ultrasonic testing funde- mentais, 2. Som niormation in the lecture guides was taken from the programmed instruction handbooks. 3. As ne students may learn more effectively from the programmed instruction approach, the in. structor may also wish to assign reading {rom Pi-4-4 (Vol. I, il, and Il, 4. The programmed instruction handbooks contain many questions and answers that may be of use to the instructor. DEMONSTRATIONS ANDIOA LAB EXERCISES 1, tis highly recommendes that the insiructor make every effort to provide the student with some >ractical experience sn ultrasonic testing. The depth of practical exercises will depend on the lume, equipment, and facilities that are available, 2. AS 8 minimum, the instructor should bring an ultrasonic instrument and search unit into the ‘classroom tor demonstration purposes. 3. Theine*-uctor should use whatever resources are available to collect sample parts that will repre- sent svvety of applications. 4, If time, equipment, and facilities are available, each student should be given as much hands-on experience as possible. Where practical. a variety of lab stations should be set up. each with a aif. ferent ultrasonic application, The student should then be rotated through each station with as any resource people as possible available to help answer specific questions. Ultrasonic equip. ‘ment manufacturers may be helplu! in supplying a variety of t@st equipment. 5. Where the instructors tnatall students are from a speci’ —_s of industty e.g. aucratt, foun. ty, welding), the demonstrations and lab work should bec ed accordinglyLesson? BASIC APPLICATIONS OF ULTRASONICS ULTRASONICS IS A VERSATILE INSPECTION TECHNIQUE, IT IS USED TO TEST A VARIETY OF BOTH METALLIC AND NONMETALLIC PRODUCTS SUCH AS WELDS, FORGINGS, CASTINGS, SHEET, TUBING, PLASTICS AND CERAMICS. ULTRASONICS HAS AN ADVANTAGE OF DETECTING SUBSURFACE DISCONTI- NUITIES WITH ACCESS TO ONLY ONE SIDE OF THE SPECIMEN. THE OBJECTIVE OF ULTRASONIC TESTING IS TO ENSURE PRODUCT RELIABIL- ITY BY MEANS OF: 4. OBTAINING INFORMATION RELATED TO DISCONTINUITIES. 2. DISCLOSING THE NATURE OF THE DISCONTINUITY WITHOUT IMPAIRING THE USEFULNESS OF THE PART. 3. SEPARATING ACCEPTABLE AND UNACCEPTABLE MATERIALS IN AC- CORDANCE WITH PREDETERMINED STANDARDS. TRAINING AND CERTIFICATION IT IS IMPORTANT THAT THE TECHNICIAN AND SUPERVISOR BE QUALIFIED IN THE ULTRASONIC METHOD BEFORE THE TECHNIQUE IS USED AND TEST RE- SULTS EVALUATED. THE AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING RECOMMENDS THE USE OF THEIR DOCUMENT “RECOMMENDED PRACTICE NO. SNT-TC-1A.” THIS DOCUMENT PROVIDES THE EMPLOYER WITH THE NECESSARY GUIDE- LINES TO PROPERLY QUALIFY AND CERTIFY THE NDT TECHNICIAN IN ALL METHODS. TO COMPLY WITH THIS DOCUMENT THE EMPLOYER MUST ESTABLISH A “WRIT- TEN PRACTICE” WHICH DESCRIBES IN DETAIL HOW THE TECHNICIAN WILL BE TRAINED, EXAMINED AND CERTIFIED. THE STUDENT IS ADVISED TO STUDY THE CURRENT EDITION OF SNT-TC-1A TO DETERMINE THE RECOMMENDED INITIAL NUMBER OF HOURS OF CLASSROOM INSTRUCTION AND MONTHS OF EXPERIENCE NECESSARY TO BE CERTIFIED AS AN ULTRASONIC TESTING TECHNICIAN.UT Lecture Guide Lesson 1 ASNT PROVIDES A SERVICE TO THE INDUSTRY BY PROVIDING LEVEL III EXAMI- NATIONS IN THE BASIC AND METHOD AREAS. BECAUSE OF THE INDIVIDUAL REQUIREMENTS OF THE MANY INDUSTRIES USING NDT, THE SPECIFIC EXAMI- NATION IS STILL THE RESPONSIBILITY OF THE EMPLOYER. THE FOLLOWING FLOW CHART INDICATES THE PATHS THAT CAN BE TAKEN TO BE CERTIFIED ACCORDING TO THE SNT-TC-1A DOCUMENT. ASNT CERTIFICATION WITHOUT EXAMINATION" ‘Banc, Metros, Specte— ssyeurs Education Esperance [ASNT CERTIFICATION BY EXAMINATION" Base, Method Tevet GERTIFICATION pe RECOMMENDED Pane Ie 5 ig EMPLOYER'S ENTToaa, Warren, shune 1980 EDITION PRACTICE™ [EXAMINATION BY THE EMPLOYER, EXAMINATION BY OUTSIDE AGENCY. EMPLOYER WAIVES EXAMINATION, *Conticatetasues aveue! Tie documentation as freomnen ra Saga 624 anager. the BNT-TE-1A0 1880 ection,bh Rb bb bib ie fs 10, nn 12. Key Name. UT LESSON 1 quiz ‘The selection of one test method over another is usually the decision of the Level | technician performing the test. ASNT provides a service for examining Level I, i and Ill personnel in the General and Specitic areas. ‘The responsibility of Issuing a certificate to the NDT technician Is always retained by the employer in compliance with the SNT-TC-1A document. If the SNT-TC-1A document is to be used as a recommended guideline, the “Written Practice” must be submitted to ASNT for approval Il the SNT-TC-1A guidelines are followed, the Level III technician should have @ knowledge of other commonly used methods of NDT even though certification Is needed only In the ultrasonic ar A Level | technician performing an ultrasonic test Is permitted* to accept or reject the part provided that written instructions or procedures are given to him by a Level er Level Il, “(In accordance with SNT-TC-1A) 1es of SNT-TC-1A, all three levels of technicians must take test If examinations are used to determine To comply with the guid a"Ge Practical” and “Speci cartification. ‘The June 1980 Edition of SNT-TC-1A permits the employer to waive an examination for Level lll personnel provided that documentation Is on file showing the technician's qualifications. It is essential that every employer that uses the SNT-TC-1A document esta! “Written Practice.” It an employer does not have a Level iit in his company, the services of an outside agency may be retained to perlorm these functions. Is Internal discontinuities with access to ha An advantage of ultrasonics Is that It re only one side of the part being inspected. Ultrasonic inspection techniques can be used without impairing the future usefulness of the material. 12 possible pointsLesson2 ULTRASONIC PRINCIPLES IN ULTRASONIC TESTING WE USE SOMETHING CALLED “ULTRASONIC VIBRA- TIONS.” WE MUST KNOW TWO FACTS ABOUT A VIBRATION: 1. A VIBRATION IS A BACK AND FORTH MOVEMENT. 2. A VIBRATION IS ENERGY IN MOTION. A DEPRESSION OF A SURFACE FROM ITS NORMAL POSITION IS CALLED A DISPLACEMENT. RUBBER BALL VIBRATIONS PASS THROUGH A SOLID MATERIAL AS A SUCCESSION OF PARTI- CLE DISPLACEMENTS. THIS CAN BE VISUALIZED AS SHOWN BELOW: ALISR THE STRUCTURE OF A MATERIAL IS ACTUALLY MANY SMALL PARTICLES OR GROUPS OF ATOMS. THESE PARTICLES HAVE NORMAL OR REST POSITIONS, AND CAN BE DIS- PLACED FROM THESE POSITIONS BY SOME FORCE. WHEN THE FORCE IS REMOVED, THE PARTICLES WILL TEND TO RETURN TO THEIR ORIGINAL POSI- TIONS.UT Lecture Guide Lesson 2 ENERGY IS TRANSMITTED THROUGH A SOLID MATERIAL BY A SERIES OF ‘SMALL MATERIAL DISPLACEMENTS WITHIN THE MATERIAL. THE TRANSMISSION OF ULTRASONIC VIBRATIONS THROUGH A MATERIAL IS RELATED TO THE ELASTIC PROPERTIES OF THE MATERIAL. IF YOU TAP A METAL SURFACE, THE SURFACE MOVES INWARD, CAUSING A DISPLACEMENT. zone D> renane support VIEW A view 8 SINCE THE METAL IS ELASTIC THE SURFACE WILL TEND TO MOVE BACK TO ITS. ORIGINAL (REST) POSITION. THE SURFACE WILL ALSO MOVE THROUGH THE ORIGINAL POSITION AND MOVE TO A MAXIMUM DISTANCE IN THE OPPOSITE DIRECTION. THIS COMPLETE SEQUENCE OF MOVEMENTS 'S DEFINED AS A CYCLE. DIRECTION OF DIRECTION OF Bar“ swince ING TRAVEL STRING BALL e one ovce PENCIL Spenci THE T!#*E REQUIRED FOR SOMETHING TO MOVE THROUGH ONE COMPLETE CY- CLE IS CALLED THE PERIOD. EXAMPLE: IF THE SWINGING BALL ABOVE MOVES OVER PATH ABCDE IN ONE SECOND, THEN THE PERIOD OF Tt 2YCLEIS ONE SECOND.