Alternatives to Radiographic Weld Inspection

October 2007

Puget Sound Naval Shipyard & IMF

Radiographic Testing
Definition:
Radiography is a method for nondestructive inspection of components and assemblies that is based on differential absorption of penetrating radiation by the part being inspected.

Radiography
The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense sections stop more of the radiation. The film darkness (density) will vary with the amount of radiation reaching the film through the test object. = less exposure = more exposure
Top view of developed film

X-ray film

Radiographic Images

Radiographic Testing
Advantages:
a) Volumetric inspection.
Magnetic Particle and Liquid Penetrant are for surface inspections even when applied to each layer.

b) Can be used on a variety of materials. c) Film provides a permanent record. d) Gamma radiography does not require electrical power.

Radiographic Testing
PSNS Applications:
a) Piping Welds. b) Structural Welds. c) Castings. d) Various components for internal structure (info).

Radiographic Testing
Detectable Flaws:
a) Slag. b) Porosity. c) Cracks. d) Inclusions. e) ID Root Conditions (contour and oxidation)

Structural

Piping

Slag

Porosity

Cracks

Casting Cracks and Inclusions

Butt Weld RT Pipe Size and Material Pipe sizes (IPS)

Range - in to 20 Inches

Material
Carbon Steel 2-1/2 to 16 inches CuNi (70:30 & 90:10) Mostly 2 to 5 inch NiCu (Monel) Mostly 2 to 5 inch Grade 300 Series CRES - 4 inch and less Inconnel 4 inch and less

Field Radiography

In the field and shipboard, structures are radiographed using radioactive sources

Radiography Challenges
Limitations:
Safety considerations lead to:
Large, expensive crews needed to guard RT areas. Limited (1 or 2) joints inspected per shift. Disruption of other work.

Potential safety hazard. Certain types of flaws are difficult to detect. Film interpretation requires skill.

Radiography Challenges
Further Limitations:
Crew size is approximately 15 people; can be as many as 30 on aircraft carriers. Training personnel: 80 hours initial training; 24 hours of training annually to maintain proficiency. Cost/Schedule impact on projects.

Radiography Challenges
Global Pacific Operations
Designing/installing shielding to reduce crew size is costly. Exposure devices are shielded with depleted uranium; some foreign countries do not allow the exposure devices on their soil. Shipping expenses involved with performing RT in other countries. Access to spaces by foreign nationals.

Radiography Challenges
Could crew sizes be smaller? Could exposure devices be shielded with a different material? Could X-ray machines be more portable to facilitate performing x-ray shipboard? (i.e., source-film distance difficult to maintain with shipboard interferences, weight of machine ~400 lbs.) What digital equipment is available?

Ultrasonic Testing
Definition:
Ultrasonic inspection introduces beams of high frequency sound into the piece. The sound reflected at material interfaces is analyzed to define the presence and location of discontinuities.

Ultrasonic Inspection
High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and the inspector can visualize a cross section of the specimen showingf the depth of features that reflect sound.
initial pulse back surface echo

crack echo

crack
0 2 4 6 8 10

plate

Oscilloscope, or flaw detector screen

Ultrasonic Testing
Uses:
Detect internal flaws Bonding of materials Measure material thickness.

Ultrasonic Testing
Advantages.
Deep penetration, for thick materials. Detects extremely small flaws. Only one surface needs to be accessible. Volumetric scanning Portable.

UT
PSNS Applications:
Thickness gauging. Pipe/tank liquid level. Silver Braze joint bond. Welds for discontinuities. Cracks. Voids. Porosity. Laminations. Unbond in materials. Thickness variations.

Detectable Flaws:

Ultrasonic Testing
Limitations:
Requires experienced technicians. Rough, irregular or thin parts are difficult to test. Surface flaws may not be detectable. Requires direct coupling. Reference standards are required.

Ultrasonic Inspection
Angle beam ultrasonic flaw detection is used to inspect welds using the shear wave mode of transmission to detect welding discontinuities such as lack of fusion and slag inclusions.

Ultrasonic Challenges
A-scan must be recordable. Samples with known defects are required to prove new processes.
Root convexity, oxidation, porosity.

Surface/ID detection of discontinuities. False positives (too sensitive). Joint configuration (fittings, elbows, wall thicknesses).

Ultrasonic Specifications
Military Specifications 1688, 1689, 2035A, TP-278 are similar to ASME, API, and ABS. Current acceptance criteria is for structural welds not piping welds.

Points of Contact
Engineering
Ole Hovland Dennis Yeats 360.476.7418 360.476.8744

Radiography (RT)

Primary - Richard Franklin 360.476.2990 Secondary - Christina Klinkert 360.476.3321 Primary - William Robbins 360.476.2990 Secondary - Nona Brown 360.476.3321

Ultrasonic (UT)