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Title Licensee Conditions of use This is a licensed electronic copy of a document where copyright is owned or managed by Standards Australia International. Your licence is a single user licence and the document may not be stored, transferred or otherwise distributed on a network. You may also make one paper copy of this document if required. Web Check-up AS 2207-1994 Non-destructive testing - Ultrasonic testing of fusion welded joints in carbon and low alloy steel Licensed to SAIPEM (SPCM) on 11 Sep 2002 AS 2207—1994 Australian Standard Non-destructive testing—Ultrasonic testing of fusion welded joints in carbon and low alloy steel Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. This Australian Standard was prepared by Committee MT/7, Non-destructive Testing of Metals and Materials. It was approved on behalf of the Council of Standards Australia on 16 February 1994 and published on 16 May 1994. The following interests are represented on Committee MT/7: Australian Institute for Non-Destructive Testing Australian Nuclear Science and Technology Organization Australian Pipeline Industry Association Austroads Bureau of Steel Manufacturers of Australia Department of Defence Electricity Supply Association of Australia Institute of Australian Foundrymen, N.S.W. Division Metal Trades Industry Association of Australia National Association of Testing Authorities, Australia Railways of Australia Committee Society of Automotive Engineers, Australasia Welding Technology Institute of Australia WorkCover Authority, N.S.W. Additional interests participating in preparation of Standard: Division of Applied Physics, CSIRO Non-destructive testing contractors and consulting organizations Royal Melbourne Institute of Technology Sydney TAFE College Review of Australian Standards. To keep abreast of progress in industry, Australian Standards are subject to periodic review and are kept up to date by the issue of amendments or new editions as necessary. It is important therefore that Standards users ensure that they are in possession of the latest edition, and any amendments thereto. Full details of all Australian Standards and related publications will be found in the Standards Australia Catalogue of Publications; this information is supplemented each month by the magazine ‘The Australian Standard’, which subscribing members receive, and which gives details of new publications, new editions and amendments, and of withdrawn Standards. Suggestions for improvements to Australian Standards, addressed to the head office of Standards Australia, are welcomed. Notificationof any inaccuracy or ambiguity found in an Australian Standard should be made without delay in order that the matter may be investigated and appropriate action taken. This Standard was issued in draft form for comment as DR 92178. Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. AS 2207—1994 Australian Standard Non-destructive testing—Ultrasonic testing of fusion welded joints in carbon and low alloy steel AS 2207 first published in part as AS B261.1 —1968. AS B260.1A first published 1968 (being endorsement of BS 3889.1A:1965 without amendment). AS B261.1 —1968 and AS B260.1A —1968 revised, amalgamated and redesignated AS 2207— 1979. Second edition 1980. Third edition 1994. PUBLISHED BY STANDARDS AUSTRALIA (STANDARDS ASSOCIATION OF AUSTRALIA) 1 THE CRESCENT, HOMEBUSH, NSW 2140 ISBN 0 7262 8836 5 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. AS 2207— 1994 2 PREFACE This Standard was prepared under the direction of the Multitechnics Standards Policy Board by the Standards Australia Committee on Non-destructive Testing of Metals and Materials, to supersede AS 2207—1980, Methods for the ultrasonic testing of fusion welded joints in steel. The format of this edition has been changed to align more closely with recently published Standards on ultrasonic testing of metallic materials. The five levels of sensitivity specified in the 1980 edition have been reduced to four because the requirements for the sensitivity Level No. 5 were not specific and were subject to contractual agreement. In this edition the testing of stainless steels is not covered, as it requires the use of specialized techniques and equipment. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance. Copyright STANDARDS AUSTRALIA Users of Standards are reminded that copyright subsists in all Standards Australia publications and software. Except where the Copyright Act allows and except where provided for below no publications or software produced by Standards Australia may be reproduced, stored in a retrieval system in any form or transmitted by any means without prior permission in writing from Standards Australia. Permission may be conditional on an appropriate royalty payment. Requests for permission and information on commercial software royalties should be directed to the head office of Standards Australia. Standards Australia will permit up to 10 percent of the technical content pages of a Standard to be copied for use exclusively in-house by purchasers of the Standard without payment of a royalty or advice to Standards Australia. Standards Australia will also permit the inclusion of its copyright material in computer software programs for no royalty payment provided such programs are used exclusively in-house by the creators of the programs. Care should be taken to ensure that material used is from the current edition of the Standard and that it is updated whenever the Standard is amended or revised. The number and date of the Standard should therefore be clearly identified. The use of material in print form or in computer software programs to be used commercially, with or without payment, or in commercial contracts is subject to the payment of a royalty. This policy may be varied by Standards Australia at any time. Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 3 AS 2207— 1994 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 4 1.2 REFERENCEDDOCUMENTS 4 1.3 DEFINITIONS 4 SECTION 2 EQUIPMENT AND CALIBRATION 2.1 SCOPEOFSECTION 5 2.2 EQUIPMENT 5 2.3 CALIBRATIONOFEQUIPMENT 5 2.4 COUPLANTS 6 SECTION 3 METHODS OF TEST 3.1 SCOPEANDGENERAL 7 3.2 DESIGNATION OF TEST METHODS AND SURFACE PREPARATION CATEGORIES 7 3.3 PREPARATIONOFTESTSURFACES 8 3.4 METHODS FOR SCANNING AND DISCONTINUITY EVALUATION . . . . 9 3.5 SENSITIVITY 10 3.6 SIZINGOFDISCONTINUITIES 11 3.7 OPTIONAL VARIATIONS IN SIZING FOR LEVELS 2, 3 AND 4 . . . . . . 12 SECTION 4 PRESENTATION OF TEST DATA 4.1 GENERAL 20 4.2 RECORDOFTEST 20 4.3 TESTREPORT 20 APPENDICES A PURCHASINGGUIDELINES 22 B WELDINGTERMINOLOGYANDSYMBOLS 23 C FACTORSINFLUENCINGPROBESELECTION 25 D METHODS FOR THE DETERMINATION OF ATTENUATION AND TRANSFERLOSS 27 E ALTERNATIVE METHODS FOR ESTABLISHING SENSITIVITY . . . . . . . . 29 F GUIDANCE ON ULTRASONIC TESTING OF WELDS . . . . . . . . . . . . . . . . 31 G PROCEDURES FOR SIZING OF DISCONTINUITIES . . . . . . . . . . . . . . . . . 39 H GUIDANCE ON THE IDENTIFICATION OF DISCONTINUITIES . . . . . . . . 46 I COMPENSATIONFORCONVEXCURVATURE 49 J USEOFREFLECTIVITYDIAGRAMS 51 Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. AS 2207— 1994 4 STANDARDS AUSTRALIA Australian Standard Non-destructive testing—Ultrasonic testing of fusion welded joints in carbon and low alloy steel SECTION 1 SCOPE AND GENERAL 1.1 SCOPE This Standard sets out methods and requirements for the manual ultrasonic testing of full or partial penetration fusion welded joints in carbon and low alloy ferritic steels, 6 mm or greater in thickness, using A-scan presentation and employing four sensitivity levels. This Standard does not cover the testing of stainless steels. It does not cover the testing of longitudinal welds when— (a) the radius of curvature of fabrications is less than 125 mm; or (b) for tubular fabrications having an outside diameter exceeding 250 mm, the ratio of thickness to outside diameter exceeds 0.22. NOTE: Advice and recommendations on information to be supplied by the purchaser at the time of enquiry or order are contained in the purchasing guidelines set out in Appendix A. 1.2 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1101 Graphical symbols for general engineering 1101.3 Part 3: Welding and non-destructive examination 1929 Non-destructive testing—Glossary of terms 2083 Calibration blocks and their methods of use in ultrasonic testing 2536 Surface texture 2812 Welding, brazing and cutting of metals—Glossary of terms 3669 Non-destructive testing—Qualification and registration of personnel—Aerospace 3998 Non-destructive testing—Qualification and certification of personnel—General engineering 1.3 DEFINITIONS For the purpose of this Standard, the terms and definitions given in AS 1929 apply (see also Appendix B for terms, symbols and notations used in welding technology). COPYRIGHT Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 5 AS 2207— 1994 SECTION 2 EQUIPMENT AND CALIBRATION 2.1 SCOPE OF SECTION This Section specifies requirements for the ultrasonic testing equipment and its calibration. 2.2 EQUIPMENT The ultrasonic testing equipment shall be capable of displaying the presence of discontinuities likely to be present in fusion welded joints and of delineating their boundaries and contours. The equipment shall employ A-scan presentation and shall have a reserve of sensitivity of at least 20 dB at the maximum beam path used. The equipment and probes shall be capable of operation within a frequency range of 2 MHz to 6 MHz. Either single or twin compression-wave probes, and angle beam probes are used for the testing of welded joints. NOTES: 1 This Standard allows the use of ultrasonic units equipped with data processing facilities. 2 Guidance on probe frequency selection is given in Paragraph C2 of Appendix C. 2.3 CALIBRATION OF EQUIPMENT 2.3.1 General The equipment characteristics shall meet the requirements specified in Clauses 2.3.1.1 to 2.3.1.5 when calibrated in accordance with methods specified in AS 2083. 2.3.1.1 Assessment of horizontal and vertical linearity Horizontal and vertical linearity shall be assessed for the test ranges to be used. Any deviation of the horizontal linearity exceeding 2% over the full screen width, or of the vertical linearity exceeding ±2dB, between 30% and 100% graticule height shall be determined and recorded. Suppression should not be used for weld testing, unless its effect on vertical and horizontal linearity is determined and recorded. 2.3.1.2 Gain control The gain control shall be calibrated in steps not exceeding 2 dB. 2.3.1.3 System gain The overall system gain shall be not less than 20 dB. 2.3.1.4 Dominant frequency The dominant frequency of the instrument/probe combination shall be recorded for information. NOTE: To optimize the ultrasonic response of the system, it may be necessary to inductively match the probes with the test unit, using tuning coils. 2.3.1.5 Resolution The equipment shall be capable of resolving adjacent reflectors separated by a distance of 2.5 wavelengths along the beam axis. The distance requirements for the separation of reflectors along the beam axis, for various frequencies, are given in Table 2.1. 2.3.2 Voltage stability Voltage fluctuations shall be within −15% to +10% of nominal line voltage and shall not be capable of producing either of the following— (a) variations in sensitivity exceeding ±1dB,or (b) variations of linearity exceeding the limits specified in Clause 2.3.1.1. 2.3.3 Calibration blocks The calibration blocks specified in AS 2083 shall be used to calibrate the testing equipment. 2.3.4 Reference blocks This Standard requires the use of ferritic steel reference blocks which contain side-drilled holes of specified diameters to establish sensitivity. Reference blocks should be machined from a steel which has similar ultrasonic attenuation COPYRIGHT Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. AS 2207— 1994 6 characteristics to the material under test. Where such material is not available, corrections for attenuation and transfer differences shall be made in accordance with Appendix D. NOTE: Appendix E gives details of alternative methods which may be used to establish sensitivity. 2.4 COUPLANTS Couplants shall possess good wetting characteristics and be compatible with the steel under test. When establishing sensitivity, a couplant with similar sound energy transfer characteristics shall be used on the reference block as is used for the test. TABLE 2.1 REQUIREMENTS FOR THE SEPARATION OF REFLECTORS FOR RESOLUTION CALIBRATION millimetres Nominal frequency MHz Distance of separation of reflectors along beam axis Compression-wave probes Shear-wave probes 2 2.5 4 5 10 7.4 5.9 3.7 3.0 1.5 4.1 3.3 2.0 1.6 0.8 NOTE: For carbon and alloy steels the nominal velocity of compression waves is 5920 m/s and of shear waves is 3230 m/s. COPYRIGHT Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. 7 AS 2207— 1994 SECTION 3 METHODS OF TEST 3.1 SCOPE AND GENERAL This Section specifies designations for test methods and surface preparation, and specifies the test method requirements for seven common basic configurations of welds. For each method, requirements are given for— (a) the minimum preparation of the test surface (see Clause 3.3); (b) the preferred scanning positions for normal and angle probes; (c) the evaluation of discontinuities; and procedures are given for— (i) the examination of the parent metal over the entire scanning surface; (ii) the examination of the heat-affected zone; and (iii) the examination of the weld metal. The test method shall be specified in the relevant product specification or application code. The scanning sensitivity for normal probes used for the detection of parent metal discontinuities which may interfere with the test, is specified in Clause 3.5.2.2. If such discontinuities are present and no alternative scanning method is specified for subsequent examination, the test report shall state the reasons why sections of the weld have not been fully examined. The test report shall also include all instances where it has not been possible to scan from specified surfaces because of limitations of access. The examination of the weld should be carried out on scan lines parallel to, or at right-angles to, the weld axis and at a separation not exceeding the width of the transmitting probe crystal. Beam angles should be chosen to ensure that the angle of incidence to the major reflecting surfaces of expected discontinuities is essentially normal. Where this is not possible, additional gain should be added as follows: Angle of incidence, degrees Additional gain, dB ≤10 >10 ≤15 >15 ≤20 0 6 12 The use of more than one beam angle to obtain a maximum indication from a particular discontinuity should be considered. NOTES: 1 Incident angles greater than 20° to the major expected reflecting surface should not be used. 2 Planar discontinuities normally lie along the welding preparation faces. 3 Guidance on the development of testing procedures for welds is given in Appendix F and factors influencing probe selection are outlined in Appendix C. 3.2 DESIGNATION OF TEST METHODS AND SURFACE PREPARATION CATEGORIES 3.2.1 Designation of test methods Ultrasonic test methods are designated as follows: (a) The initial letters, UM, to signify ‘ultrasonic method’. COPYRIGHT Licensed to SAIPEM (SPCM) on 11 Sep 2002. Single user licence only. Storage, distribution or use on network prohibited. [...]... to the parent metal and as such are corner reflector Such a reflector when subjected to an COPYRIGHT AS 2207 1994 26 ultrasonic beam having an angle of incidence of 60° will give a greatly reduced response due to mode changes In this case, an angle of incidence of 40° to 55° should be used or, if due to lack of access, these angles are not obtainable an angle of incidence of 65° to 75° should be used... an acceptable noise (grass) level The internal noise from a probe should not interfere with the detection or the interpretation of ultrasonic signals resulting from testing C2 PROBE CHARACTERISTICS C2.1 Frequency The choice of probe frequency is influenced by the following factors: (a) The nature of the steel through which the ultrasonic beam will pass Attenuation of the ultrasonic beam is largely... the purchaser requires for assessment of test results (n) The date and place of test (o) The identification number of test (p) Identification of testing personnel 4.3 TEST REPORT (a) The name of the laboratory or testing authority (b) The identification details of all welds tested (c) The relevant product specification or application code (d) The number of this Australian Standard, i.e AS 2207, the... dimensions of acceptable and non- acceptable discontinuities is essential Test procedures rely on structures being designed to accommodate testing To ensure that testing fulfils its aim, cooperation between designers and non- destructive testing (NDT) specialists at an early stage is recommended As non- destructive testing methods are complementary to one another, it is emphasized that the results of one... may require reassessment by an alternative method F2 TESTING AUTHORITIES The effectiveness of ultrasonic testing depends on the technical competence of the personnel performing the tests and on their ability to interpret indications However, the responsibility for assessing the significance of discontinuities detected does not lie with the testing authority Personnel who perform ultrasonic testing to... in the specific area of test NOTE: The Australian Standards for qualification of personnel are AS 3669 and AS 3998 F3 WRITTEN TESTING PROCEDURES Some purchasers, codes of practice or regulatory authorities may require documented evidence of the ultrasonic testing procedures used The laboratory or the testing authority should provide a copy to all interested parties and to the testing personnel prior... over a distance of 2.5T* from the toe of the weld 1 and 2, or 3 and 4, over a distance of 2.5T* from the toe of the weld 1 and 2, or 3 and 4, over a distance of 2.5T* from the toe of the weld 1 and 2, or 3 and 4, over a distance of 2.5T* from the toe of the weld 5† over full length of fusion face 5† over full length of fusion face 5† over full length of fusion face 5† over full length of fusion face... use of reflectivity diagrams is given in Appendix J COPYRIGHT Licensed to SAIPEM (SPCM) on 11 Sep 2002 Single user licence only Storage, distribution or use on network prohibited AS 2207 1994 FIGURE E1 30 TYPICAL REFLECTIVITY COMPARISON DIAGRAM FOR A MINIATURE 45-DEGREE, 6 MHz ANGLE PROBE COPYRIGHT 31 AS 2207 — 1994 APPENDIX F GUIDANCE ON ULTRASONIC TESTING OF WELDS (Informative) F1 GENERAL The testing. .. § UMA-1 1 and 2, or 3 and 4, over a distance of 2.5T* from each side of the toe of the weld 5† UMA-2 1 and 2, or 3 and 4, over a distance of 2.5T* from each side of the toe of the weld — UMA-3 1 and 2, or 3 and 4, over a distance of 2.5T* from each side of the toe of the weld UMA-4 1 and 2, or 3 and 4, over a distance of 2.5T* from each side of the toe of the weld — — 1, 2, 3 and 4; 5 and 6‡, or 7... The test report shall include at least the following information: COPYRIGHT 21 AS 2207 — 1994 The test data and whether it complies with the product standard or application code (j) Any other information the purchaser requires for assessment of test results (k) The date and place of test (l) The report number and date of issue (m) The identification of the officer or officers responsible for carrying . make one paper copy of this document if required. Web Check-up AS 220 7-1 994 Non-destructive testing - Ultrasonic testing of fusion welded joints. Welding and non-destructive examination 1929 Non-destructive testing Glossary of terms 2083 Calibration blocks and their methods of use in ultrasonic testing 2536