Application of Time-Of-Flight Diffraction (TOFD) for Weld Inspections

Michael Moles

Presentation Outline
History What is TOFD? Advantages of TOFD Limitations of TOFD Typical images Defect depth measurement Codes Some TOFD examples Summary

History
Developed in UKAEA Harwell in ~70s Manufactured commercial Zipscan Used very effectively in nuclear PISC II and DDT trials => Showed good detection and excellent sizing Recently adopted by petrochemical and other industries

DDT Defect Sizing using Ultrasonics

Comparison of measured vs. actual defect sizes: left, all UT techniques; right, TOFD only. (DDT Plate 1)

What is TOFD?
Time-Of-Flight Diffraction (TOFD) relies on the diffraction of ultrasonic energies from 'corners' and 'ends' of internal structures (primarily defects) in a component being tested.

Source: NDT On-line

TOFD: Typical Setup

Transmitter Lateral wave

Receiver

Upper tip Lower tip Back-wall reflection

TOFD Waves
The Lateral wave: A sub-near-surface longitudinal wave generated from the wide beam of the transducer. The Backwall reflection: A longitudinal wave reflected from the back wall The Reflected wave: A longitudinal wave reflected by a lamellar planar defect The Tip Diffracted wave: A circular longitudinal (or L-wave) diffracted by the edge of a defect.

Advantages of TOFD
Good midwall defect detection. Accurate sizing of defects using the time of arrivals of diffracted signals. Defect detection even if defects are mis-oriented or located away from the weld centreline. Very rapid linear scanning (raster scanning not required) Non-amplitude scanning and detection. Set-up independent of weld configuration.

Limitations of TOFD
Dead zone at top surface (OD). Dead zone at bottom surface (ID). Sensitive to very small defects with a risk of false calls if not combined with pulse echo. Analysis can be difficult; specialist interpretation required. Some sizing errors possible from lateral position of defect. Low signal-to-noise ratio.

Alternative Diffraction Arrangements

Shear-shear diffraction Longitudinal-shear diffraction Single transducer diffraction (called back diffraction or the tip echo method in Japan) Twin transducer TOFD with both transducers on the same side of the defect/weld. Complex inspections, e.g. nozzles.

Typical TOFD Display

Gray scale and rf for phase info. OD and ID visible Defects detectable in middle L-wave display only (usually)

Defect Depth
S
Transmitter

S
Receiver

t0 d

t0

Signals NOT linear; either correct, or remember

c 2 2 d = (t 2t0 ) S 2

Defect Analysis with Cursors

A-scan d1 h d1 t1 t2

Cursors Build-in calculator l

t1,t2 d1, d2 and h are automatically calculated

P D-scan

Use cursors on top and bottom of defect (note phase changes) Use calculator or math for analysis.

TOFD Codes
Two European guidelines: BS7706 and EN583_6. ASTM E-2373-04 now available ASME working on TOFD codes due out soon ASME TOFD Interpretation Manual (Nonmandatory App. N) due out very soon. ASME CC 2235 permits TOFD

Examples Inside Surface-breaking Defect

1
Transmitter

Lateral wave

Receiver

2 3

Back wall echo blocked LW No back wall echo

Tip

No, or reduced, backwall echo Signal from tip for detection and sizing

Example Near-Surface Breaking Defect

Transmitter

Lateral wave is blocked

Receiver

1 2

Back-wall reflection B W No Lateral wave Crack tip

Lateral wave blocked Sizing by measuring crack tip

Example Midwall Defect

No break in lateral wave or backwall Top and bottom signals visible (if defect deep enough) Can measure lengths using hyperbolic signals

2 3 4

Typical Defect for TOFD

TOFD is very strong on midwall defects where pulse echo is weak Strengths of TOFD complement PE, and vice versa

Example Lack of Root Penetration

Sometimes see break in backwall signal; should see perturbation Defect can be sized using timeof-arrival Similar to other root defects

1 2 3

Example Lack of Sidewall Fusion

Should see no perturbations in lateral wave or backwall In this case, top signal is buried in lateral (OD) wave Can size if signals clear.

1 2 3 4

Example - Porosity

Multiple small reflectors, each with hyperbolic tails. Usually can characterize, but sizing difficult.

Example Transverse Cracks

1 2 3

Transverse cracks are rare, and similar to porosity No perturbation of lateral or backwall

Example Interpass Lack of Fusion

Lateral wave Reflected signal Back wall reflection

Transmitter

Receiver

L W Reflection echo

B W

1 2 3

Strong signal, but defect benign. Cannot size depth.

TOFD What can go wrong?

TOFD scans can go wrong, just like any NDE inspection. Some reasons:
Incorrect gain levels (too high or too low) Incorrect gate positions Incorrect transducer separation Poor coupling Noise interference

TOFD Equipment
New portable system reduces TOFD cost significantly Needs encoded data e.g. handscanner or automated system

TOFD Advantages
Excellent PoD for mid-wall defects Good detection of mis-oriented defects Can characterize surface-breaking defects Excellent sizing for defects in transverse TOFD mode, especially with signal processing Tolerable sizing for defects in linear mode Works very well in conjunction with pulse-echo Rapid (and relatively low cost) inspections

TOFD Limitations
Dead zone of ~3mm at outer surface Potential dead zone at inner surface Prone to noise Over emphasizes some benign defects, e.g. porosity, laminations, interlamellar LoF Hard to interpret Finally we have a TOFD code!

A Few Final Words on TOFD

Good for detection, especially midwall Much the best defect sizing technique available when correctly set-up Always use in conjunction with pulse-echo for code and PoD reasons Well worth including in inspections, even with company specs.

Thank you
Any questions?