- 44 -

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

CEFDA04-1202 Task Title: TW5-TVV-RFUT: COMPARATIVE ASSESSMENT OF ULTRASONIC INSPECTION SYSTEMS FOR THE NARROW GAP AUSTENITIC WELDS IN THE ITER VACUUM VESSEL
Figure 2 presents a schema of the T-joint mock-up D. This is the T-shape adaptor of the poloidal rib with one joint of weld. The material of this mock-up is not ITER Grade steel but a 316L steel. The dimensions of this mock-up are 500mm length, 60 mm thick and 496 mm wide. The poloidal rib is 10 mm high along the coupon.

INTRODUCTION
This work is carried out in co-operation with PHOENIX, SINTEZ/ECHO and EURATOM-CEA Association [1]. The main objective of the global project is to prepare three methods for acceptance by manufacturing code and the French Certification Authorities so that they may be used successfully during the ITER Vacuum Vessel fabrication. This project officially started in September 2005 and it will in operation until October 2007. The kick-off meeting of the project was held in Paris in February 2006. This report presents the status of the project up to 2006 [2] and in particular the mock-ups manufacturing and the beginning of the round trials ultrasonic inspections.

2006 ACTIVITIES
The main activities during 2006 were the following: - The manufacturing of four mock-ups following the related technical specifications - The beginning of the round robin trials of the mock-ups manufactured. MOCK-UPS MANUFACTURING Four mock-ups have been designed in the frame of this project. Two mock-ups were designed and paid for our Association. The other two were designed and paid for Phoenix. The Finland Company TRUEFLAW manufactured all of these mock-ups. The technical specification of the mock-ups are presented in reference [3] Figure 1 presents a picture of mock-up A. This mock-up is manufactured with ITER Grade steel and the coupon was welded using TIG narrow gap process. This mock-up is 486mm length, 60 mm thick and 475 mm wide.

Figure 2: Mock-up D designed by CEA Figure 3 shows a scheme of mock-up B designed by PHOENIX and manufactured by TRUEFLAW Company. The material of this mock-up is ITER grade steel and the planar faces of this mock-up have an angle of 10, which is one situation of actual vacuum vessel design.

Figure 3: Mock-up B designed by Phoenix Figure 4 shows a mock-up partial welded designed by Phoenix. This sample will be manufactured to inspect defects, which could appear in realistic situation, in particular when the weld pass are stopped and started during the welding process.

Figure 1: Mock-up A designed by CEA

Figure 4: Mock-up C designed by Phoenix

- 45 CALIBRATED DEFECTS INCLUDED In all of these mock-ups were included calibrated flaws. Different types of defects were chosen in order to simulate several realistic situations: - To detect defects immediately after production of weld joint; - To test the inspections UT systems near the limits of detect ability; - To compare abilities of systems to detect different types of flaws (lack of fusion in the line of chamfer, centreline cracks, and incomplete groove weld (crow area). The location of the flaws was distributed across the weld and in the heat affected zone (HAZ). In particular at root area of the weld were included several flaws since this zone is considered a more HAZ critical weld area. Thus inner breaking defects, embedded flaws and outer breaking defect at surface were included. To carry out these defects, different fabrication methods were applied, thermal fatigue cracks, solidification cracks and electro-discharge cracks. In order to maximise the benefits of this project a blind is required in terms of inspection of flaws. Thus, partners in sightless approach carried out the specification of the flaws related to the dimension and location. The sizes of flaws vary between 1x25 mm and 10x20 mm located across the HAZ area. PROGRESS OF INSPECTION SINTEZ/ECHO - SINTEZ/ECHO has optimized his inspection UT system. For this ECHO manufactured several new transducers and carried out inspection on existing mock-ups; - SINTEZ/ECHO has described his system in the report in reference [4]. This task has been selected in order to facilitate the information exchange between partners; - SINTEZ/ECHO started the inspection of the mock-ups sent by CEA; - The assessment of results will be published in next months. PHOENIX - Phoenix designed and manufactured a mechanical probe pan for transducers carrying. This device will be used for simultaneously driving several UT transducers. - The round robin trials of Phoenix will be started in April. INSPECTION Our Association started the inspection of both mock-ups.

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

The phased array technique is used for the present measurements. The configuration was already described in references [5], [6] and [7]. This experimental configuration consists in an angular scanning associated with an in-depth focusing. Two linear phased arrays are configured as a dual-element transducer. This probe is composed of two linear arrays of 32 elements (1.2x20 mm for each element) with a 2 MHz frequency. Dual element configuration is efficient to reduce backscattering noise in coarse-grained material as in TIG weld. Delay laws are calculated to generate longitudinal waves in the area of the joint, using two configurations: Zone 1) vertical scanning focusing the beam along the axis (between z=1mm and z= 20 mm) of the weld joint, 2) angular scanning between 25 and 70 focusing along a constant radius of curvature (figure 5).
Zone 1 Vertical scanning 1<Z<20 mm

a)

Vertical scanning

77

Zone 2 Angular scan 20<Z<60

Wedge
b)

TIG weld 70 25 S1 S2 Focal points

Figure 5: Phased array technique for inspection for a) 1<Z<20mm, b) 20<Z<60mm Calibration Mock-ups For the inspection of both mock-ups, the calibration was performed using a ITER grade planar mock-up containing the following flaws: - Nine drilled holes produced by EDM of 90 cm and = 2 mm. The first hole is at 10 mm from the surface at 130 mm from the side plane.

Figure 6: Calibration mock-up

- 46 - Two notchs produce by EDM ( 0.2mm opening) of 3 mm and 10 mm high and 20 mm long placed at 120 mm and 200 mm from the opposite side plane (figure 6). The results of the inspection will be present in next report.

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

[7] Simulation of phased array technique for qualification of UT methods for one sided welds during VV manufacture. SYSSC/05 RT0167/Rev 0, October 2005

TASK LEADER
NEXT MEETING The next meeting is planned to be held in June 21 and 22, 2007. The objective of this meeting is to exchange information about the inspection of four mock-ups. The conclusion of this meeting will be useful for the final assessment of inspection. SCHEDULE OF THE PROJECT Jorge TIRIRA DRT/DeTECS/SYSSC/LMC CEA-Saclay F-91191 Gif-sur-Yvette Cedex Tel. Fax : 33 1 69 08 40 02 : 33 1 69 08 75 97

e-mail : jorge.tirira@cea.fr

REPORTS AND PUBLICATIONS

[1] EFDA Contract TW5-TVV-RFUT, EFDA ORDER/04-1202 Comparative assessment of ultrasonic inspection systems for the narrow gap austenitic welds in the ITER vacuum vessel [2] Progress report RFUT N1; technical specification for RFUT tasks. SYSSC/06 RT0231/Rev.0 October 2006 [3] Flaws technical SYSSC/05-385 specification -CEA/DETECS/

[4] Automatic ultrasonic system SINTEZ/ECHO Report. 2007

AUGUR

[5] Development of ultrasonic non destructive testing method for the vessel inter-sector weld of ITER: development of dynamic phased array techniques, SISC/03-RT0096/Rev. 0, September 2003. [6] Development of phased array techniques for the inspection of one sided welds in ITER vacuum vessel, SYSSC/04-RT0143/Rev. 0 September 2004.

- 47 -

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

CEFDA05-1226 Task Title: TW5-TVM-LIP: MODIFICATION OF ITER MATERIALS DOCUMENTS, ASSESSMENT OF MATERIALS DATA AND MAINTENANCE OF A DATABASE
Euratom-CEA contribution to MPH, in addition to supporting ITER-IT, EFDA-CSU, and ITER database groups, is to provide MPH files for Type 316L(N) steel weld metals and joints. In 2005, the work was focussed on low temperature (316L) and high temperature (19-12-2, OKR3U) weld metals. In 2006 work is extended to 16-8-2 weld metal, see table 1 for compositions.

INTRODUCTION
The properties of materials used in fusion components need to be known in detail by designers, by licensing authorities and the materials specialists. ITER Materials Properties Handbook is a document that provides such information in an internationally accepted format.

Table 1: Weld metal compositions used for welding Type 316L(N) steel (FWC= Flux Wire Couple, C.E.= Coated Electrode, MA= Manual Arc, AC= Automatic Covered) RCC-MR WELD METAL RS 2915 ER 316L (Z2 CND 19-13) RS 2925 E 316L (Z 1912-3 L) RS 2945 316L (SA 19-122L) Flux Wire Couple In deposit In weld deposit C.E. In weld deposit Min 18.00 12.00 2.00 5 15* 5 15* 5 15 3 7 0.30 0.25 3 7 3 7 0.030 1.8 0.5 0.025 0.020 16.0 17.0 18.0 19.0 16.0 17.0 8.0 9.0 11.0 1.8 2.2 2.0 0.100.10 0.1 0.250.25 3 7 3 7 3 7 FILLER METAL Wire for TIG Min 1.00 18.00 12.00 2.00 0.020 20.00 14.00 3.00 Range C Mn Si P S Cr Ni Mo Nb* Cu B (ppm) Co N2 d ferrite Calculated 5 15*

Max 0.030 2.50 0.60 0.30

Max 0035 2.50 0.90 0.025 0.025 20.00 14.00 3.00 Min 1.00 18.00 10.00 2.00

Max 0.025 2.50 0.60 0.020 0.020 20.00 13.00 3.00 Min Max 1.00 17.00 10.00 2.00

0030 2.50 1.00 0.030 0.030 20.00 13.00 3.00 0.045 1.20 0.40 18.0 19.0 15.5 0.5 0.025 0.020 16.5 11.0 1.90 12.0 7.5 9.0 2.2 1.8 2.5

RS 9513.1 19-12-2 RS 9513.2 16-8-2 RS 9523.1 19-12-2 RS 9523.2 16-8-2 RS 9543.1 19-12_2 RS 9543.2 16-8-2

C.E. for MA

Min

Max 0.055 1.80 0.70 0.025 0.020 C.E. for MA Min 0.045 1.80

Max 0.055 2.5 Wire for TIG Min Max Wire for TIG Min

Max 0.045 2.5 FWC for AC Min 0.030 1.20

Max 0.055 2.0 0.70 0.025 0.020 Submerged Arc Min 0.030 1.8 -

12.0 2.20 8.0 9.0 1.80 2.50

Max 0.045 2.5

0.5 0.025 0.020

- 48 -

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

2006 ACTIVITES
All deliverables of the task agreement have been met by their due dates. The full report is too large to be reported here. Only, an example of the many file codes prepared for MPH will be given, namely the file code for tensile strength of 16-8-2 weld metal. Even there, several figures and tables will be left out to reduce the length of the paper. For more information the reader is referred to ITER MPH files. File Code: ITER-AA09-2101 Tensile Strength CODE RECOMMENDATIONS The 16-8-2 weld metal given in the File Code ITERAA09-1100 is an RCC-MR Code qualified material [1]. This metal is also used in other international codes [2 , 3]. ITER MPH recommends the code data, whenever available, for ITER Structural Design Criteria. For weld metals, these are often in the form of knock down factors applied to the base metal properties values [4], according to the type and category of welds (see File Code: ITER-AA09-1100). RS 9513.2: Covered Electrode / Manual Arc Welding Process Sheet Number RS 9513.2 of RCC-MR [1] gives the requirements for 16-8-2 covered electrodes / manual arc process (111). Tests performed on weld metal in flat position (as-welded) with specimens taken in longitudinal weld orientation should satisfy: Su (RT) 550 MPa Su (550 C) 380 MPa

Su (RT)

490 MPa 350 MPa

Su (550 C)

Other recommendations are given in RS 9523.2 for wire for TIG process (141) and in RS 9543.2 for wire associated with flux for automatic arc process (121). ADDITIONAL ANALYSES General Codebooks such as RCC-MR do not give materials properties data that are at the origin of their recommendations. These are usually available in the supporting documents, such as the Appendix A (see e.g. Appendix A for 316L(N)-IG), [5]. In the additional analysis that follows, we will compare the materials properties data available for 16-18-2 weld metal with the code recommendations. The main purpose of this comparison is to see if the safety margins incorporated in the code recommendations are still valid when these materials are used under present ITER operating conditions and the anticipated future evolutions. We shall pay a particular attention to the effects of irradiation that are not currently fully covered by the international codes.

Mechanical Properties Tensile properties of Type 316L(N) weld metals have been investigated by ITER partners [6 , 15]. RCC-MR recommendations are made for specific types of 16-8-2 metals and specific welds and welding conditions. Without such constraint a large scatter in results is observed [6]. For instance, NRG [7] has tested specimens taken from TIG welds and TIG weld deposits. Specimens taken from the weld deposit are full weld specimens and show less scatter, while specimens taken from TIG weld joins, depending on the orientation of the specimen (T or L) and on the position of the specimen (root weld or bulk weld) show large scatter. The very low yield stress in TIG welds may be due to failure in the base metal. The earlier French work on Shielded Manual Arc Welding (SMAW), used as a source for RCC-MR specifications, is called here reference (see also reference 6). This work covers weld deposits and welded plates in horizontal and vertical positions (10-20 mm weld thickness) using coated filler metals (with 0.045 to 0.055 % C). The results (mainly in L orientation) are situated in the upper part of the scatter band of 16-8-2 data collected in reference 6. Figure 1 also shows the established trend curves for Su average and Su minimum. RCC-MR min specified values at RT and 550 C are also shown.

Tests on qualification test coupons (RS 3334) should satisfy the same Su value at RT. For materials subjected to dimensional stabilization heat treatment, 50 h at 650 C, a lower Su limit is allowed (500 MPa). For transverse tests, the specification is given according to the type of base metal. For the type Z2 CND 17-12 with controlled nitrogen addition (similar to ITER 316 L(N)IG) and Z2 CND 18-12 with controlled nitrogen addition, in the as-welded condition, the values are: Su (RT) 525 MPa 380 MPa

Su (550 C)

Specified values are the same following a stabilization heat treatment (longitudinal orientation). For base metal without controlled nitrogen addition (Z2 CND 17-12, similar to 316L) the values in transverse orientation are slightly lower:

- 49 800 Type 16-8-2 Weld Metal 700

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

Effect of Weld Thickness and Welding Position The effects are expected to be similar to Type 19-12-2. See section 2.3 of the File code AA08-2101. Structural Stability Tests
RCC-MR Ref (min) Ref (ave)

600 Ultimate Tensile Strength, MPa

500

400

300 RCC-MR 200

100

0 0

Figure 3 shows effects of aging at temperatures ranging from 450 to 750 C on tensile strength of 16-8-2 weld metal. The large scatter in aged results is mainly due to the scatter in the initial results. At aging temperatures 400-450C, that are even higher than the operating conditions of ITER (<300 C), the effect of aging is negligible.
700 800

100

200

300

400

500

600

Test Temperature, C

Figure 1: Dependence of average and minimum Su on test temperature for 16-8-2 weld metal (SMAW, higher carbon content, early French work). Experimental data shown are mainly for longitudinal specimens and flat welding position Equations describing these trend curves are:

The effect of different ITER first wall module fabrication cycles, such as HIPing treatments, remain to be investigated but one would expect significant softening, as observed for Type 19-12-2 welds.
Rp (450-500C), MPa Rm (450-550C), MPa Rp (600C), MPa Rm (600C), MPa Rp (650C), MPa Rm (650C), MPa Rp (750C), MPa Rm (750C), MPa Rm (initial) 600

900

800

(eq. 2) Su (min) = 567.3 - 0.91 + 0.00226

- 2.23x10-6

Tensile Stress at 20C, MPa

(eq. 1) Su (ave) = 699.2 - 1.2741 + 0.0031629

- 3.1193x10-6

700

500

Rm (50h/650 C min) Rp (Initial)

Figure 2 shows plot of all collected experimental data, independent of the welding type and orientation of specimens, on one figure. Clearly most of the data collected fall below the above reference curves. However, even then the results are mostly above the RCC-MR specifications. Equations describing curves for all collected data are: (eq. 3)
Su (ave) = 700.07 - 2.2049 + 0.0060031
2

400

300

Effect of Aging Type 16-8-2 Weld metal

200 0 1000 2000 3000 Aging Time, h 4000 5000 6000

- 5.3191x10-6

(eq. 4)
Su (min) = 600.68 1.8919 + 0.0051509
900 Type 16-8-2 Welds 800

4.564x10-6

Figure 3: Effect of aging on tensile strengths of Type 16-8-2 weld metal. Notice that Rm values remain above lower limit specified for structural stability test of 50h at 650C

Effect of Irradiation Unfortunately, weld metals used in some investigations [6 , 15] do not correspond to the RCC-MR specifications or some results obtained are not fully traceable, others are obtained at temperatures and doses outside the ITER operating conditions. As a result, only data generated at NRG for TIG deposits and TIG welds for EU fusion programme are retained here [7]. The filler metal used at NRG is Type SMA 16-8-2 SP (from metal FX-456). Its nickel concentration (9%) is near the maximum specified level. Its carbon content is in the range of filler metal for TIG welding (0.04%), but lower than that of the MMA and filler metal associated with flux. The hardness of the TIG deposit is around 195 HV5 (225 in HAZ), while that of the TIG weld is 225 HV5 (195 in HAZ).

Ultimate Tensile Strength, MPa

700

600 RCC-MR 500

400

300

RCC-MR

200 0

100

200

300

400

500

600

700

800

Test Temperature, C

Figure 2: Dependence of average and minimum Su on temperature for 16-8-2 weld metal for a large set of data (independent of welding type and specimen position)

- 50 Figure 4 shows that the unirradiated results are below the average reference curve, but once irradiated, even to very low doses, are higher. Similar results are obtained after 11 dpa irradiation at 250C [8]. Here, the hardening is about the same level as 6 dpa irradiation, suggesting a decrease in the rate of hardening or its saturation. Also, notice that the yield and UTS of irradiated material merge leaving practically no plastic work hardening capability.
1000 Su, MPa Su (0.73 dpa), MPa Su (6.1 dpa), MPa Rm(ave) Rm(min)

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

CONCLUSIONS
The additional analyses performed here on Type 16-8-2 weld metal for ITER application support RCC-MR recommendations provided filler materials and welding parameters correspond to those specified in the code.

REFERENCES
1 Design and Construction Rules for Power Generating Stations, Design and Construction Rules for Mechanical Components of the FBR Nuclear Islands, RCC-MR, Section IV Welding, AFCEN, Edition 2002. Design and Construction Rules for Mechanical Components of the LWR Nuclear Islands, RCC-M, AFCEN. ASME "Boiler and Pressure Vessel Code", Code Cases, Nuclear Components N-47-24, Class 1 Components in Elevated Temperature Service, Section III Div. 1, 1986. ITER Interim Structural Design Criteria (ISDC), S 74 RE 2 97-02-30 W 1.2, IRB/Welds / Revision 3. A-A. F. Tavassoli, "Assessment of Austenitic Stainless Steels," N.T. SRMA 94-2061, F.A. 3591ITER, March 1994. See also Fusion Engineering and Design 29 (1995) 371-390. See also Appendix A of ISDC for 316L(N)-IG. T. Forgeron (Fr), A-A. F. Tavassoli (Fr), J. Wareing (UK), D. Lehmann (Fr), C. Escaravage (Fr), B. Breitling (D), et C. Picker (UK) "Effect Of Thermal Aging on Mechanical Properties of Type 316l (N) Base and Weld Metals", CEC Study Contract CT-92-0211-F, CEA Report 94. J.W. Rensman, J.Boskeljon, M.G.Horsten, M.I.De Vries, Irradiation Testing of Stainless Steel Plate Material and Weldments, Tensile Properties After 0.5 and 5 dpa at 350K and 500K, report ECN-C-97-088, Oct. 97, (ITER Library Number - SS17). J.L. Puzzolante, M. Scibetta, R. Chaouadi, W. Vandermeulen, Tensile and Low Cycle Fatigue Properties of Solution annealed Type 316L SS Plate and TIG Weld Exposed to 5 dpa at Low Temperature (42C), BLG-821, SCK.CEN, Sept. 1999, (ITER Library Number - SS39, SS50). G.L. Tjoa, J Boskeljon, D.S. D'Hulst, M.I.de Vries, Results of Tensile tests on Type 304 and 316 Stainless Steel Plate and Welded joints, Report ECN-I--94-007, Feb. 1994, (ITER Library Number SS100).

800 Ultimate Tensile Strength, MPa

600

16-8-2 SP TIG NRG data

400

2
Su (ref) Tirr

200

3
0 0 100 200 300 400 500 600 700 800

Test Temperature, C

Figure 4: Comparison of ultimate tensile strengths of Type 16-8-2 SP TIG deposit welds, before and after irradiation at 227 C, with the reference average and minimum curves derived for 16-8-2 weld metal. Filler metals used in NRG experiments are for TIG welding and have lower carbon contents than the Su (ref) Design Allowable Sm is governed by base metal properties, see figure 5. Neither aging nor irradiation hardening under ITER conditions modify this situation.

700

600 Su (ave) 500 Su (min) Stress, MPa 400 Sy (ave) 300 Sy (min) 200 Sm 100 Base Metal 0 0 100 200 300 400 500 600 700 800 Temperature, C 16-8-2 Weld

[8

Figure 5: Comparison of Sm derived for 316L(N) base metal with reference average and minimum tensile curves of 16-8-2 weld metal

- 51 10 H.Yamada, H.Kawamura, Qualification of structural materials and joints, Final report on ITER task T427 JA, Task No G 16 TT fr 97 FJ, May 2001, (ITER Library Number - SSCuJ19). 11 W. Vandermeulen, W. Hendrix, V. Massaut, J. Van de Velde, and Ch. Raedt, FAFUMA 1 test results, FT/MOL/90-01, WV/MJW-V, Mol, February 1990, (ITER Library Number - SS87, SS1). 12 Kllstrom R., Josefsson B., Haag Y., Resultfrom Tensile Testing of 316L Plate and Weld Material, Studsvik Nuclear - Report No. Studsvik/M-93/45, April 1993, (ITER Library Number - SS7). 13 Horsten M.G., Van Hoepen J., de Vries M.I., Tensile Tests on Plate and Electron-Beam Welded Type 316L(N) Material, ECN, Petten, NL - Report No. ECN-CX--93-112, November 1993, (ITER Library Number - SS9). 14 A.Rowcliffe, Irradiation testing of stainless steel and Inconel including welding and rewelding of irradiated materials, Final report on ITER task T214 US Task No G 16 TT fr 75 95-07-04 FU, March 1998, (ITER Library Number - SS29). 15 H.Sagawa, Irradiation testing of stainless steel and Inconel including welding and rewelding of irradiated materials, Final report on ITER task T214 JA, Task No G 16 TT fr 73 95-07-04 FJ, June 1998, (ITER Library Number - SS30).

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

TASK LEADER
Farhad TAVASSOLI DEN/DMN/DIR CEA-Saclay F-91191 Gif-sur-Yvette Cedex Tel. Fax : 33 1 69 08 60 21 : 33 1 69 08 80 70

e-mail : tavassoli@cea.fr

Not available on line

Not available on line

Not available on line

Not available on line

Not available on line

Not available on line

58

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

TW5-TVV-MPUT Task Title: TIG NARROW GAP INFLUENCE OF WELD STRUCTURE AND GEOMETRY ON PHASED ARRAY TECHNIQUE PERFORMANCES
manufactured near the surface. All of these flaws are 10 mm high and 20 mm wide.
New Notches included
80 10 20 10 500 20 15

INTRODUCTION
For ITER vacuum vessel inspection, studies were performed to investigate the performances of the ultrasonic techniques [1], [2]. It has been shown that phased array technique is a valuable technique for inspection of TIG narrow gap welds. The techniques used consist in dynamical inspection methods based on angular scanning associated with beam focusing [3], [4], and [5]. The objective of this study in the frame of TW5-TVV-MPUT project is to study the influence of both the TIG narrow gap weld structure and geometry on the performances of phased array method for one sided welds mock-up that may be used during ITER VV manufacture. In particular, this report presents the set of the results of this project.

287

Existing notch embedded

5 4

View 1

Side drilled holes 258

View 2
10 10

218

217 TIG weld area

Figure 1: Mock-up including flaws to analyse the weld structure

2006 ACTIVITIES
The main activities during this period were the following: - To carry out the inspections of critical areas (root of weld and near the surface) using an UT phased array technique; - To synthesize the results in terms of the influence of the weld structure and geometry for detecting defects in the root weld area and near the surface in the crown area. MOCK-UP INSPECTED In order to evaluate the influence of the TIG weld structure two mock-ups are used in the present work: - One existing TIG mock-up is devoted to study the attenuation of the sound through the joint weld; for that, three new flaws are included in the mock-up; - One new mock-up is dedicated to analyse the role of weld root geometry on the inspection of flaws in the root area; for that, a new mock-up is designed with two beads to simulate the deposit of weld metal produced by a fusionwelding process. Figure 1 presents the TIG narrow gap mock-up which was already described in reference [3]. In particular, this mockup has both breaking surfaces defects and the embedded flaws. In this mock-up are included for the present study three new flaws which are used to perform test related to the weld structure. Two surface breaking flaws are included outside of the joint weld. One supplementary notch is

Figure 2 presents the scheme of the new mock-ups in which was manufactured a bead to simulate the longitudinal deposit of weld metal produced by a fusion-welding process and two breaking surface defects of 3mm high and 20 mm wide.

Inner breaking flaw (15x20mm) 45mm

Scanning X Flaws Joint beads

r =5

r =3

Figure 2: Manufactured mock-up for analysing the influence of the root weld geometry

59 TECHNIQUE USED FOR INSPECTION The phased array technique [1], [2], and [3] has been used for inspection of mock-ups. The probe is composed of two linear arrays of 32 elements (1.2x20 mm for each element) with a 2 MHz frequency. Dual element configuration (one in emission and another in reception) is efficient to reduce back-scattering noise in coarse-grained material as in TIG weld. This technique consists in an angular scanning associated with an in-depth focusing. Delay laws are calculated to generate longitudinal waves in the area of the joint, using two configurations: Zone 1) vertical scanning focusing the beam along the axis (between z = 1mm and z = 20 mm) of the weld joint, Zone 2) angular scanning between 25 and 70 focusing along a constant radius of curvature (figure 3).

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

Before the weld Scanning X
gY nin an Sc

Through the weld

Breaking surface notch

Weld

Figure 4: Configuration of inspection near the surface Figure 5 presents the detections of the outer surface breaking notch 10 mm high. This experimental data show both signals detected separately; the diffraction at the bottom of the notch and the signal coming from the breaking surface area.
60 mm 60 mm

Zone 1 Vertical scanning 1<Z<20 mm

surface

a)

Signal from breaking surface

10mm

Bottom diffraction

Bottom diffraction

Vertical scanning

Before the weld

Through the weld

77

Zone 2 Angular scan 20<Z<60

Wedge
b)

Figure 5: Experimental vertical scan data for 10 mm high braking surface notch placed at the inspection surface (a) before the weld (b) through the weld Table 1 presents the amplitude ratio for the notch inspection before and through the weld. In particular, the amplitude of the bottom diffraction is -13 dB before the weld and -15 dB through the weld. The signal to noise ratio is 3dB through the weld and 9 dB before the weld. The high of the flaw is measured with 2mm. Table 1: Experimental amplitude ratio for 20x10 mm inner notch breaking at the surface of inspection

TIG weld 70 25 S1 S2 Focal points

Figure 3: Phased array technique for inspection for a) 1<Z<20mm, b) 20<Z<60mm

RESULTS OF THE INSPECTION NEAR THE SURFACE The objective of this inspection is to characterise flaws located near the surface up to 20mm. In order to analyse this area a specific wedge is used which can generates 60 longitudinal waves focused at 10mm. The flaws are inspected in two opposite directions before and through the weld. To optimise the detection of the notch outer breaking the surface, the transducer drives mechanically in directions X and Y (figure 4) around defects so that the maximum of the amplitude for the bottom diffraction is reached. Afterward, the inspection of all flaws near the surface in the block is carried out in automatic mode driving the transducer only in Y direction when the transducer is located at 60 mm from the axis of the weld.

ATTENUATION OF THE SOUND DUE TO THE WELD STRUCTURE The weld structure is analysed in terms of the beam attenuation through the weld area. The sample inspected is the TIG mock-up shown in figure 1 and the flaw under analysis is 10 mm high breaking surface notch which is located at 40 mm from the center line of the weld joint. The inspection has been performed in automatic mode, the transducer drives mechanically in direction X and Y. The

60 flaw is inspected in two opposite directions before and through the weld as displayed in figure below (figure 6).

EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

The mock-up has two beads; one of them has a radius of 3 mm and the second a radius of 5mm. In previous annual report was presented the preliminary measurement. In the present paper is given the analytical evaluation. Figure 7A presents the UT angular B-scan considering a direct inspection of the 3mm high breaking surface notch and for the bead R=5mm. This experimental data shows both the signals resulting from the geometry of bead and signals related to the interaction of the ultrasonic beam and the notch. In this figure the signals of the bead and the notch (tip diffraction and the corner echo) are detected apart. Figure 7B shows the UT angular B-scan considering an indirect inspection. In particular, in this case experimental data show that the corner echo and the signal of the bead can not be detected apart. Nevertheless, the tip diffraction signal is separately detected. The amplitude ratio is presented in table 3.
76 76

3mm

Signals from the notch Tip diffraction

Figure 6: Inspection of the inner breaking notch before the weld and through the weld Table 2 presents the amplitude ratio for both the corner echo and the tip diffraction for the flaw inspected before and through the weld. The amplitude of the corner echo decreases through the weld of about 5 dB and those corresponding to the tip diffraction decreases of 4 dB. The frequency of the signal detected in both cases is 1.55 MHz. The joint weld is relatively thin (~10mm) so than the sound is not filtered in frequency (in the interval of measurement accuracy) through the weld. The number of shot to detect the corner echo and the tip diffraction is shifted of about 5 shots. It means a deviation of the beam of about 5 when it passes through the weld joint. Table 2: Amplitude ratio for inner breaking surface located at 40 mm outside the weld axis

A
Echo of the bead joint

Corner echo Echoes from the geometry of bead and corner echo Scan direction

Scan direction

3mm R=5mm

3mm

Figure 7: The 3 mm inner breaking notch inspection the radius of the bead is 5 mm. A) The notch is inspected before the bead B) the notch is inspected after the bead Table 3: Amplitude ratio for the 3mm notch the radius of the bead is 5mm

INFLUENCE OF THE BEAD WELD GEOMETRY IN THE INSPECTION The objective of this experimental measurement is to evaluate the influence of the bead of the weld on the detection of flaws near the weld root area. For this measurement the mock-up presented in figure 2 is used. The bead and the block are composed of the steel 316 L.

Figure 8A presents the UT angular B-scan considering a direct inspection of the 3mm high breaking surface notch and for the bead of R=3mm. This experimental data shows the signal of the bead of joint and the notch (tip diffraction and the corner echo) are detected apart. Table 4 presents the amplitude rate. Figure 8B shows the UT angular B-scan considering an indirect inspection. In particular, experimental data shows that both signals the bead of joint and the notch are not detected apart. The signals from the flaw are completely included in the signal coming from the geometry.

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EFDA Technology / Vessel-In Vessel / Vessel-Blanket and Materials

signal coming from the bead of weld for a radius of 3mm and 5mm. Nevertheless, it depends on the configuration of the experimental inspection. In general, the inspection of notch 3 mm high is difficult to characterise if the inspection is performed in the direction through the weld. It is due to the geometrical echo generated by the weld root area. The final results of this project were presented in the report [5]. Figure 8: Inspection of 3 mm height inner breaking notch the radius of the bead is 3 mm. A) The notch is inspected before the bead B) the notch is inspected after the bead Table 4: Amplitude ratio for the 3mm notch the radius of the bead is 3 mm

REPORTS AND PUBLICATIONS

[1] Development of ultrasonic non destructive testing method for the vessel inter-sector weld of ITER: development of dynamic phased array techniques, SISC/03-RT0096/Rev. 0, September 2003 [2] Development of ultrasonic non destructive testing method for the vessel inter-sector weld of ITER: simulation of welding process, DECS/SISC/LMUS/02-RT0052, July 2002 [3] Development of phased array techniques for the inspection of one sided welds in ITER vacuum vessel, SYSSC/04-RT0143/ Rev. 0 September 2004

The result of this inspection shows that flaws of 3mm high can be detected and sized when the flaw is located before the bead. In this case the spatial resolution allows us to separate echoes coming from the flaw and those coming from the geometry. In the opposite direction the 3mm high notch is hidden by the geometrical echoes.

[4] Simulation of phased array technique for qualification of UT methods for one sided welds during VV manufacture. SYSSC/05 RT0167/ Rv. 0 October 2005 [5] TIG Narrow gap influence of weld structure and geometry on phased array techniques performances. SYSSC/06 RT0233/ Rv. 0 October 2006

CONCLUSIONS TASK LEADER

Results presented in this report and those obtained in previous experimental data show that phased array is a valuable technique in detecting and sizing embedded and surface breaking notches in TIG narrow gap welds. In particular, this report presents the analysis of the effect of the TIG joint weld structure related to the UT inspection using phased array techniques. Special effort is paid to analyse the role of both the root joint weld geometry and the attenuation through the weld when flaws are inspected. Near the surface, experimental inspection was carried out to analyse the detection and sizing performances of flaws located near the surface. In particular, the results show that before the weld flaws can be detected and sized up to 4mm.Through the weld, these flaws can be detected but not sized. Concerning the weld structure effect, the experimental results show a slight attenuation and relatively low level of noise in the area of weld. The most important level of noise comes from the weld backwall. Regarding the effects of the geometry, the results show that it is possible to detect apart notch of 3mm high and the Jorge TIRIRA DRT/DeTECS/SYSSC/LMC CEA-Saclay F-91191 Gif-sur-Yvette Cedex Tel. Fax : 33 1 69 08 40 02 : 33 1 69 08 75 97

e-mail : jorge.tirira@cea.fr

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