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CHAPTER 1
INTRODUCTION TO
TOFD
INTRODUCTION
Time of Diffraction is an Ultrasonic Testing technique which relies on the detection of
diffraction signals which are generated from the edges and corners of a flaw.
HISTORY
TOFD was invented in the UK in the 1970s initially
as a research tool in the 1970s by Maurice Silk.
The use of TOFD enabled crack sizes to be
measured more accurately, so that expensive
components could be kept in operation as long as
possible with minimal risk of failure.
TOFD gained wider acceptance in the 1980s and 1990s.
Development of quality control codes related to ToFD in the late 1990s and 2000s.
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Time of Flight Diffraction (ToFD) has a good accuracy for measuring the
through - wall size of crack like defects.
The accuracy in general is 1mm and it can achieve 0.3mm when the
defects are monitored.
TOFD BEHAVIOUR
Normally up to 10% coverage loss is observed due to the two dead zones
(OD surface and ID surface), but the actual percentage depends on the
TOFD setup parameter selection.
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ToFD SUPPLEMENT
Two dead zones are located near the lateral wave and the back wall
reflection.
To get full coverage ToFD should be combined with pulse echo (PE)
technique.
Conveniently, ToFD and PE are complimentary, the strong features of ToFD
are the weak points of PE and vice versa.
THE PROBLEMS WITH THE PULSE ECHO TECHNIQUE
Pulse echo (PE) techniques are based on the reflected echoes coming from
planar reflectors which are suitably angled to give a specular reflection
back to the transducer.
Clearly it must be quite rare for defects to be exactly normal to the beam
as would be required for a perfectly smooth large specular reflector. Flaws
which are not favorably oriented are found to be less significant or
sometimes may be not found .
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TOFD Summary
It is fast, efficient. 'sees' everything and records all raw data for presentation
in a proportionate and representative fashion.
TOFD is an ideal detection tool which provides an accurate and invaluable
'fingerprint' of condition as a quality control function at the time of
construction.
DISCUSSION
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CHAPTER 2
TOFD Vs OTHER NDT
METHODS
UT Vs ToFD
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RT Vs ToFD
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DISCUSSIONS
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CHAPTER 3
PHYSICS - TIP
DIFFRACTION
1. 0 Diffraction
Diffraction of waves is a phenomenon in which waves spread out at the edges
when they pass through an aperture or round a small obstacle.
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1.1 Mechanism
Diffraction is a resultant of wave displacement at edges
and superposition of waves along the plane of
Propagation.
This is described by the Huygens-Fresnel principle.
1.2 Effects of Diffraction
No change in frequency, wavelength and velocity
of the waves.
But a change in the direction and amplitude of the
waves upon diffraction.
This diffracted wave from the tip of the crack is used to accurately size the
depth of the crack from the ID or the OD.
The diffracted Waves are much weaker than specularly reected waves
used for conventional ultrasonic inspection, but they radiate from the tips
in all directions along the same plane as the incident ultrasonic waves.
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Amplitude in dB
Angle in degrees
DISCUSSIONS
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CHAPTER 4
FUNDAMENTALS OF TOFD
Basic Setup
2 probes (transmitter, receiver) in pitch catch
arrangement.
Wide weld volume coverage
Longitudinal waves
Probes symmetrical to the weld center
Amplifier at receiver side
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TOFD Signals
Signals received
Lateral wave (LW), subsurface
Back-wall echo(BW)
Mode converted ( shear wave echo)
Diffracted signals from defects
Receiver
Transmitter
Lateral wave
Upper tip
Mode
converted
shear wave
Lower tip
Back-wall reflection
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The back wall is observed after the lateral wave because of the greater distance travelled.
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Because of the basic pitch-catch probe arrangement the signals from the
near surface region are very compressed in time and these signals may be
hidden beneath the lateral.
Thus the importance of a minimum number of cycles in the signals in
order to improve the resolution of the signals from the top and bottom
of small defects.
lt is often very useful to collect signals in this region since genuine defect
signals are repeated at longer times and near surface defect signals may
be clearer since they are spread out in time more for the shear waves.
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Transmitter
Receiver
Lateral wave
Back-wall reflection
BW
LW
Upper tip
Lower tip
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A-Scan to B-Scan
A-Scan
B-Scan
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TOFD dead zones due to lateral waves and backwall. Dead zone size depends on
frequency, pulse length, probe center separation, material thickness, and velocity.
Errors can occur with TOFD if the defect is not symmetrically placed between the two
probes.
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Note:
V- speed for the longitudinal wave in
steel
L1, L2 Half of the path of the
diffracted signal so it takes time t1/2
S Half distance of the probes
separation.
t1 The arrival time of the top tip
diffracted signal
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DISCUSSION
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CHAPTER 5
EQUIPEMENT SETUP
AND PARAMETERS
SELECTION
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Probe
Transducers / probe that are used for TOFD are different from the
conventional manual ultrasonic testing. The various properties of TOFD
probe, the effect of change in frequency , diameters and PCS will be discussed
in the following slides.
Parameter to be considered before selection of a probes:
Use of the high frequency probes for testing is a compromise on the wider
beam coverage.
Beam spread
Higher the bream spread more volume on the test material can be covered.
High dampened and broad band probes are generally used in ToFD to get
wider beam coverage ( larger volume coverage).
Effect of increase in frequency and diameters on the beam spread is
discussed in following slides.
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Calculate the beam spread using different frequency and diameter and see
the changes in beam spread.
Sample calculation to find the beam spread:
Sample1: Use the following data for solving the problems
Formulae to find beam spread: Sin = [K x( v / f)]/ D
K = 0.7, D = 6mm, f = 5MHz
Perspex velocity is 2760 m/s
Carbon steel velocity is 5960 m/s
Use Snell's law to find the incident angle of Perspex, for 5 MHz probe with refracted
angle is 600 in steel is used to carry out ToFD :
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1.Calculate the beam spread in steel for longitudinal wave and shear wave
for the following probes :
i.450
ii.600
iii.70
Given:
Velocity in Perspex = 2760 m/s
Velocity in steel = 5960 m/s(longitudinal wave)
Velocity in steel = 3240 m/s(shear wave)
Frequency of the probe = 5 MHz
Diameter of the probe = 6mm
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10MHz, 6mm, 60
Probe frequency
Higher the frequency, resolution will be better, however with increase in
frequency attenuation will also increase.
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Probe angle
Probe angle
To achieve a satisfactory data many scans may be required with different
probe angles and different PCS.
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Probe-Centre Separation
Change in PCS will effect the focus and the coverage of the volume.
Following figures shows the effect on depth of focus for increase and
decrease in PCS.
PCS decreased to 36 mm
When PCS is increased weld coverage increases, if all other parameters are
remains the same.
Low PCS gives a very good near surface resolution.
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Settings
Gain setting
Setting gain (dB) in TOFD is difficult as its works on the principle of
diffraction, the diffracted signals received are quite weak as compared to
the reflected signals.
Amplitude of the defects in TOFD cannot be used to decide the size of the
defect and for its evaluation.
Time window settings
For full-thickness testing using only one set-up, the time window recorded
should start at least 1seconds prior to the time of arrival of the lateral
wave, and should where possible extend up to the rst mode converted
back wall signal.
For more than one set-up used, the time windows shall overlap at least
10 % of the depth-range.
The start and extent of the time windows have to be verified on the test
object.
Sensitivity settings
For all examination levels the sensitivity shall be set on the test object.
The amplitude of the lateral wave shall be between 40% and 80 % full screen
height (FSH).
Note Any change of the TOFD set-up, e,g. probe centre separation (PCS),
thickness requires a new setting.
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Calibration
The following parameters shall be set based on the thickness of the item being
tested :
Type of Scan : Non Parallel / Parallel
Type of Ultrasonic Wave :Voltage :
Pulse Width :
PRF :
Filters :
Averaging :
Sizing curves :
Measurement cursors etc.
Set the lateral wave, back wall and the mode converted signals on the screen using
the reference block and verify the timing of lateral wave and the back wall signals
against the manually calculated timings. Range start and range (parameters in the
equipment) shall be used to set the screen.
Calibration
Pre inspection and post inspection calibration shall be carried out using A2
/ V1 blocks or other blocks similar in thickness as the object being tested.
Scan area of 0 to 50mm shall be selected.
1mm or 2mm thickness tolerance may be allowed depending on the
thickness of the object being used, if the readings exceeds the tolerance
then check the system and the accessories and repeat the process.
This is the system performance check to ensure the equipment (its
software) as well as accessories like probe, wedges, preamplifier (if used),
encoder, cables etc. are functioning properly.
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Scanning
Longitudinal scan - Non-Parallel
or D-scan or line scan
Scan direction is Perpendicular to
the probe beam direction.
Most frequently used for weld
inspection.
Detection Initial sizing.
High speed inspection.
Weld
Limitations
Defect depth only accurate when
the probes are symmetrically
positioned with regard to the
defect.
Defect lateral position is unknown.
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Mechanical Scanner
Very simple to use.
Magnetic wheels.
Manual (or motorized).
One axis position encoding.
Basically 2 probes, must be able
to hold more (PE).
Easy and precise adjustment of
probe separation is needed.
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Based on the material and the thickness of the weld the following
parameters should be selected :
1.
2.
Calculate the initial PCS focusing at 2/3T and subsequent PCS at the
required depth or coverage.
3.
Select the type of scan i.e parallel or non parallel scan. Initial scans
for welds are non parallel scans.
b.
c.
d.
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j.
Select the encoder and calibrate the encoder to record the position
of the probes. Defect locations may be wrong if encoder is not
calibrated properly. Verify the encoder resolution after calibration
with the resolution manufacturers given by the manufacturer.
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Twin transducer TOFD with both transducers on the same side of the
defect/weld.
Complex inspections, e.g. nozzles
Probe frequency
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DISCUSSIONS
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CHAPTER 6
ERRORS IN TOFD
OUTLINE
Errors in the timing
Near Surface errors
Dead zone errors
Resoultuion of top and bottom tips
Off-Axis depth error
PCS errors
Multiple arcs
Other errors
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Errors in Timing
Problem
All depth calculations are based on the assumption that the defects are
symmetrically(centrally) located to the two probes.
Depth error is high in near surface area as compared to the mid wall.
Solution
Small dimensional defects may be missed as the signal may go around the
defect.
Solutions
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Solution
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Calculate the dead zone for the lateral wave with 2 cycles, 10 MHz probe
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In practice:
Maximum error on
absolute depth position
lies below 10%.
Error on height
estimation small defect
is negligible.
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Effects of velocity
For an uniform, homogeneous, isotropic material, the velocity accuracy is easily
met by timing the interval between back wall reflections for a beam normal to the
surface.
In more complex geometries or with material with less ideal properties, the
inaccuracy of velocity estimates may become significant source of error.
The error is reduced if the PCS is reduced. Independent calibration of the velocity
by measurement of the delay of the back wall echo, with a known wall thickness,
greatly reduces this error.
Overall effects
Overall effects will be all the effects (errors) discussed in this lesson, if all the
effects are added the overall depth effect may be derived. However some of
the major effects ( like timing effect) may contribute more than the other
effects which may be minor or negligible.
Other effects
using different transducers or changing transducers
changes in probe angle due to wear and tear of the wedge
changes in probe position
angle of diffractions
changes in angular velocity
attenuation in the material
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DISCUSSION
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CHAPTER 7
DIGITIZATION PRINCIPLES
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Digitization
Conversion of analogue A-scan (amplitude) to digital numbers (digits) by taking
samples of a signal at a regular interval.
Analog signals are continuous electrical signals; digital signals are non-continuous.
Digital information exists as one of two digits, either 0 or 1. These are known as bits
and the sequences of 0s and 1s that constitute information are called bytes.
Analog signal can be converted to digital signal by ADC. The reading of an analog
signal at regular time intervals (frequency), is the sampling value of the signal at
the point.
Each such reading is called a sample (a particular combination of 0s and 1s) and is
considered to contain exact information for that stage;
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Digitization Continued.,
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Pulser Receiver
Digitizer
Gain/ booster
Voltage
Digitizing frequency
Type of Wave
Pulse width
Averaging
Material Velocity
Rectification
Ultrasonic Start
Band-pass filters
Acquisition rate
Ultrasonic range
Pulse Width
An ultrasonic probe consists of a piezoelectric material which when set into
vibration with a voltage pulse produces a
burst of ultrasound.
The use of different voltages ranging
dependents on the probe frequency and
the type of crystal element.
The pulse width helps to optimise the
shape of the received signal. The rst edge
of the rectangular pulse sets the crystal
element into oscillation.
The second edge of the rectangular pulse
also sets the crystal element into oscillation
again but the phase of the burst of
ultrasound is 180 degrees out of phase with
the rst set of oscillations.
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Effect of PRF
Selecting low PRF results in loss of data or missing scan data which are
caused due to high scan speed, wide beam angles chosen, high resolution,
low communication speed.
Under sampling
Sub-sampled image:
Nyquist is not met
Amplitude error, phase shift,
distortion
Over sampling
A higher sampling rate will result in more data points, thus larger files.
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Aliasing Effect
An alias is a false lower frequency component that appears in sampled data
acquired at too low a sampling rate.
The Nyquist theorem states that a signal must be sampled at a rate greater than
twice the highest frequency component of the signal to accurately reconstruct the
waveform; otherwise, the high-frequency content will alias at a frequency inside
the spectrum of interest (passband).
The dotted line indicates the aliased signal recorded by the ADC and is sampled as a 1
MHz signal instead of a 5 MHz signal
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Signal Averaging
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No. of samples depend on the time required for one wave length (i.e. we
call as no. of samples per one time period)
If you divide time period by sampling rate you will get no. of samples
Calculate the no. of samples for
Probe frequency of 5MHz at digitization rate of 50MHz, 75MHz and
125MHz
Probe frequency of 10MHz at digitization rate of 40MHz, 65MHz and
110MHz
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High pass filter is set at 0.5 times of the probe center frequency
Low pass filter is set at 2.0 times or more of the probe center
frequency
Choosing according to probe center frequency
DISCUSSION
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CHAPTER 8
INTEPRETATION,
ANALYSIS & SIZING
Transmitter
Receiver
Positive
Negative
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Top Tip
Bottom Tip
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Gain Settings
Low
High
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Missed Scan
Loss of Signal
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Screen Calibration
Identify the Phase of the lateral and back wall for screen calibration ( suggested to
keep the cursor on good portion prominently displaying phase information in the
D-scan and then go to from A-scan to place the blue and red cursors before
performing the screen calibration option).
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Before
After
Lateral wave removal done to view masked defects by lateral wave. This
operation is not always completely successful.
Before
After
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Sizing Techniques
Location & Length measurements
Flaw length from a non-parallel scan( DScan), is measured from end to end of the
signal after compensating for beam spread.
If the flaw is curved, then it is difficult to
accurately measure the length and done
more often with errors.
Length of the flaw is defined by the
difference of the x-coordinates of the
extremities of the indication.
Curved flaw
Height measurements
Uses the accurate time of arrival of the signal unlike the length
measurement technique.
The height is defined as the maximum difference of the z- coordinates.
For indications displaying varying z-coordinates along their length, the
height should be determined at the x-position where the difference of the
z-coordinates is greatest.
Another method is counting the number of rings when the resolution of
the tips is not seen.
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DISCUSSIONS
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CHAPTER 9
CODES & STANDARDS
- TOFD
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When ToFD is used to replace RT, then should also be used with an additional
surface technique.
Magnetic Particle Testing
Penetrant Testing
Manual UT
DISCUSSIONS
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CHAPTER 10
APPLICATIONS OF
TOFD
Applications
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Manual Scanning
Manual scanning is achieved by the use of jigs which has the probe
holders and it allows the probes to be moved (adjusted) horizontally to
set the PCS. Encoders are fixed to the jigs to record the position of the
probes.
In manual scanning we can mark the PCS and the edges of the probe so
that the inspector knows if he is deviating from the marked positions. Use
of guides (magnetic strips, rulers etc.) will also help to get the scan
straight. Always set the probes such that the weld axis is in the centre of
the two probes.
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Mechanical Scanning
DISCUSSIONS
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