Teknik Pengujian Logam

Bagian NDT-1 : Ultrasonik

Koeharjanto dan Sutarno

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 A Career in NDT
Careers can be in a variety of areas:
1. Service Inspection Companies
2. Smelters & Foundries
3. Rolling & Forging Mills
4. Petro Chemical & Refineries
5. Mining & Mineral Processing
6. Aircraft Maintenance & Manufacturing
7. Vehicle Maintenance & Manufacturing
8. Engineering Firms
9. Research & Development Facilities
10.Education & Training
11.Equipment Manufacture & Sales
12.Maintenance, Service & Repair of Equipment
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 Introduksi

1. Pengujian non-destruktif (NDT) merupakan salah satu

bagian dari fungsi kontrol kualitas komplemen dengan
metode destruktif lainnya.
2. NDT adalah pengujian bahan, untuk permukaan maupun
cacat internal atau kondisi metalurgi, tanpa mengganggu
dengan integritas materi atau fungsi.
3. NDT ini dapat diterapkan secara sampling atau untuk
100% memeriksa bahan dalam sistem kontrol kualitas
produksi.

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 4. NDT banyak diaplikasi dalam lingkungan industri pada setiap
tahap pembuatan baja sampai pemeriksaan komponen in-
services
5. NDT mensyaratkan keterampilan yang tinggi, pengalaman serta
kompetensi untuk dapat memastikan komponen rejected atau
accepted dan sekaligus umpan balik kondisi fasilitas produksi.
6. NDT bukan hanya sebuah metode standar untuk menolak
komponen atau produk dalam jaminan kualitas. Metoda NDT
ini menggunakan berbagai prinsip; tidak ada metode tunggal
untuk menjamin kualitas produk

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 Metoda umum NDT mencakup
1. Visual Inspection (VT)
2. Magnetic Particle Inspection (MT)
3. Liquid (Dye) Penetrant Inspection (PT)
4. X-Ray inspection (RT)
5. Ultrasonic testing (UT)
6. Air or water pressure testing (LT)
7. Thermography

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 Visual Inspection (VT)
1. Visual is the most common inspection
method
2. VT reveals spatter, excessive buildup,
incomplete slag removal, cracks, heat
distortion, undercutting, & poor
penetration
3. Typical tools for VT consist of Fillet gauges
Magnifying glasses, Flashlights, & Tape
measures or calipers.
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 Visual Inspection (VT)

1. Fillet gauges measure

1. The “Legs”of the weld
2. Convexity
• (weld rounded outward)
3. Concavity
• (weld rounded inward)
4. Flatness

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 Magnetic Particle Inspection (MT)
1. Magnetic Particle Inspection (MT)
(commonly referred to as Magnaflux testing) is only
effective at checking for flaws located at or
near the surface.
2. MT uses a metallic power or liquid along
with strong magnetic field probes to locate
flaws. (Particles will align along voids)
3. MT can only be used on materials that can
be magnetized
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 Magnetic Particle Inspection (commonly referred to as
Magnaflux testing) is only effective at checking for flaws
located at or near the surface.
 MT uses a metallic power or liquid along with strong
magnetic field probes to locate flaws. (Particles will align
along voids)
 MT can only be used on materials that can be magnetized.
It can not be used be used for nonmagnetic materials such
as Austenitic Stainless steel and aluminum.

Principle:
An electric current is allowed to flow in or an electromagnet
is applied to part of the specimen to cause magnetic flux to
flow in the specimen.
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If a defect exist in the surface layer, it blocks the flux flow, so
the flux flow is directed around the defect while it partially
leaks to the air. The leaking flux forms a pair of magnetic
poles, S and N, on both sides of the defect.(as shown)
S
N
S
N

N S
Fig. A

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 MAGNETIC PARTICLE INSPECTION OPERATING MODE
Logo perusahaan
SEQUENCE NO.4A Illustration

NUMBER OF PART 1 by 1
MAGNETIZATION DEVICES COIL

Tool
BAR  20
COMPLEMENTARY DEVICES
Support Put 3 Parts together for extender
Autre

NB IMPULSION OF PEDAL MIN.

a) Spraying of zone to be
checked on part(s) with
fluorescent magnetic
developer, without
magnetizing
b) Simultaneous spraying and
MAGNETIZATION HWDC 3
magnetizing
LONGITUDINAL
c) Final magnetizing step(s)
without spraying
d) The duration of each pulse
will be 1 second minimum for
current flow and 3 second
minimum for field flow.

TIME TOTAL MIN. 4S

SETTING VALUE 3300 A
MEMORY(PROGRAM) -
8880 A/m from reference ( 37Gauss )
FIELD STRENGTH
(Actual value need to be between 6400 and 12800 A/m)
ADD. INSPECTION
AREA TO BE INSPECTED
OBSERVATIONS
DESIGNATION PART NAME SECURITY CLASS
FIXED PARAMETER 1
FITTING
REFERENCE PART NUMBER
31 MPI MACHINE
MAGNETIC BENCH UNIT DFCB01 01/MPI/EC(REV.1) 332A24064820
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 Liquid (Dye) Penetrant Inspection (PT)

1. Liquid penetrant inspection uses colored or

fluorescent dye to check for surface flaws.
2. PT will not show sub-surface flaws.
3. PT can be used on both metallic and non
metallic surfaces such as ceramic, glass,
plastic, and metal.
4. PT dose not require the part to be
Magnetized.
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 X-Ray inspection (RT)
1. Welds may be checked for internal discontinuities
my means of X- Rays
2. An X-Ray is a wave of energy that will pass
through most materials and develop the negative
image of what it passes through on film.
3. A Radiograph ( X-Ray picture) is a permanent
record of a weld used for quality inspection
purposes
4. RT inspections can reveal flaws deep within a
component

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 Ultrasonic testing (UT)
1. Ultrasonic testing (UT) is a method of
determining the size and location of
discontinuities within a component using
high frequency sound waves.
2. Sound waves are sent through a transducer
into the material and the shift in time require
for their return or echo is plotted.
3. Ultrasonic waves will not travel through air
therefore flaws will alter the echo pattern.
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 Air or water pressure testing (LT)
1. Pressure testing or leak testing can be
performed with either gasses or liquids.
2. Voids that allow gasses or liquids to escape
from the component can be classified as
gross (large) or fine leaks.
3. Extremely small gas leaks measured in PPM
(parts per million) require a “Mass
Spectrometer” to Sniff for tracer gases

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Air or water pressure testing (LEAK TEST)

 Pressure testing or leak testing can be performed

with either gasses or liquids.

 Voids that allow gasses or liquids to escape from

the component can be classified as gross (large)
or fine leaks.

 Extremely small gas leaks measured in PPM (parts

per million) require a “Mass Spectrometer” to
Sniff for tracer gases
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 Leak test

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 Sniff for tracer gases

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 Quiz time

• True or False ?

• Dye penetrate inspections can only be used

on non magnetic material.

• Answer: False

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 1. True or False ?
• X-Rays can only be used to locate flaws at or near the surface of a weld.
• Answer: False

1. True or False ?
• Virtually all welds have flaws.
• Answer: True

1. True or False ?
• Magnetic particle testing can only detect flaws at or near the surface.
• Answer: True

1. True or False ?
• Magnet particle testing can only be done on materials that can be magnetized.
• Answer: True

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 1. The letters NDE Mean ___________ ?
A: nondestructive inspection
B: nondestructive evaluation
C: nondisruptive evaluation
D: nondestructive examination

1. The method most often used to check for leaks as small as one part
per million (PPM) from a gas line or cylinder is the _________
Method ?
A: hydrostatic
B: mass spectrometer
C: soap suds bubble
D: scleroscope

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 Ultrasonic testing (UT)
1. Ultrasonic testing (UT) is a method of
determining the size and location of
discontinuities within a component using
high frequency sound waves.
2. Sound waves are sent through a transducer
into the material and the shift in time require
for their return or echo is plotted.
3. Ultrasonic waves will not travel through air
therefore flaws will alter the echo pattern.
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 Sound reflection at a flaw

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 Block diagram: Ultrasonic Instrument

amplifier

screen
IP horizontal
BE sweep

clock

pulser
probe

work piece

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 Sound reflection at a flaw

Probe
Sound travel path
Flaw

Work piece

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Plate testing

IP

BE

delamination 0 2 4 6 8 10
plate

IP = Initial pulse
F = Flaw
BE = Backwall echo

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Wall thickness measurement

s
s

Corrosion 0 2 4 6 8 10

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Through transmission testing

Through transmission signal

1 T R 1

2 T R 2
0 2 4 6 8 10

Flaw

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 Weld inspection

a = s sinß
F
a' = a - x ß = probe angle
s s = sound path
a = surface distance
d' = s cosß a‘ = reduced surface distance
d‘ = virtual depth
0 20 40 60 80 100
d = 2T - t' d = actual depth
T = material thickness

a
x a'

ß d
Lack of fusion
Work piece with welding s

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 Straight beam inspection techniques:
Direct contact, Direct contact, Fixed delay
single element probe dual element probe

Through transmission Immersion testing

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 Immersion testing

1 2
surface = water delay
sound entry

backwall flaw

IP 1 IP
IE IE 2

BE BE
F

0 2 4 6 8 10 0 2 4 6 8 10

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Spectrum of sound

Frequency range Hz Description Example

0 - 20 Infrasound Earth quake

20 - 20.000 Audible sound Speech, music

> 20.000 Ultrasound Bat, Quartz crystal

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 Basic principle
1. A-pulsa gema sistem UT inspeksi khas
terdiri dari beberapa unit fungsional,
seperti pulser / receiver, transduser,
dan perangkat layar.
2. Sebuah pulser / receiver adalah
perangkat elektronik yang dapat
menghasilkan tegangan tinggi pulsa
elektrik.

3. Didorong oleh pulser, transducer menghasilkan frekuensi tinggi energi

ultrasonik. Energi suara diperkenalkan dan menyebar melalui bahan dalam
bentuk gelombang.
4. Ketika ada diskontinuitas (seperti retak) di jalur gelombang, sebagian energi
akan dipantulkan kembali dari permukaan cacat.
5. Gelombang sinyal yang dipantulkan diubah menjadi sinyal listrik oleh
transducer dan ditampilkan pada layar.
6. Mengetahui kecepatan gelombang, waktu perjalanan dapat langsung
berhubungan dengan jarak yang sinyal bepergian. Dari sinyal, informasi tentang
lokasi reflektor, ukuran, orientasi dan lainnya
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 Keuntungan
1. Sensitif terhadap permukaan diskontinuitas.
2. Penetrasi deteksi cacat dalam
3. Hanya perlu akses satu sisi benda
4. Sangat akurat dalam menentukan posisi reflektor dan
memperkirakan ukuran dan bentuk.
5. Gambar rinci diproduksi secara langsung
6. Aman bagi operator dan benda atau material yang
diuji.
7. Dapat untuk mengukur ketebalan, selain mendeteksi
cacat.
8. Peralatan portabel atau sangat otomatis.

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 Kekurangan

1. Permukaan dapat mengirimkan USG.

2. Perlu keterampilan dan pelatihan teknisi
3. Perlu media kopling untuk media transfer energi
suara ke dalam benda uji.
4. Sulit untuk memeriksa bahan yang kasar, tidak teratur
bentuknya, sangat kecil, sangat tipis atau tidak
homogen.
5. Sulit untuk memeriksa Besi cor dan berbutir kasar
bahan lain karena transmisi suara rendah dan
kebisingan sinyal tinggi.
6. Sulit mendeteksi cacat linear paralel
7. Perlu standar acuan untuk kedua kalibrasi peralatan
dan karakterisasi benda kerja.
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 Distance Amplitude Correction (DAC)

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 Distance Amplitude Correction (DAC)

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 Distance Amplitude Correction (DAC)

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 Distance Amplitude Correction (DAC)

ASTM - Miniature Angle-Beam Calibration Block (V2)

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IIW Type US-1 Calibration Block
 Calibration Methods

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 Deteksi Cacat

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 Automated Testing
Estimated 1 tie per sec

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 Non Destructive Examination (NDE)
Non Destructive Examination is the act of evaluating a
welded component (or material to be welded) without
affecting the serviceability of the part or material.

1. All Welds have flaws.

2. Another name for a flaw is a discontinuity
3. Discontinuities are interruptions in the normal
crystalline structure (or grain) of the metal.
4. Discontinuities are NOT always defects

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 1. The purpose of welding inspections is to locate and
determine the size of any discontinuities
2. Discontinuities that are to large or repeat too often within
the weld become defects
3. Defects will compromise the welds overall strength

What are some common defects?

1. Porosity
2. Undercutting
3. Rollover or “Cold Lap”
4. Slag inclusion
5. Poor penetration
6. Voids
7. Hydrogen Embrittlement
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 Typical faults in a finished weld.

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