AWS D1.1/D1.1M2015 Annex Q (Informative) UT Examination of Welds by Alternative Techniques This annex is not part of AWS D1.1/DI.1M:2015, Structural Welding Code—Steel, Dut is included for informational purposes only. QI. General The purpose of this annex is to describe altemative tech- niques for UT of welds. The techniques described are proven methods currently being used for other appli- cations but not presently detailed in the code, The alter- native techniques presented require qualified, written procedures, special UT operator qualifications, and spe- cial calibration methods needed to obtain the required ac curacy in discontinuity sizing. The use of this annex and the resulting procedures developed, including the appli= cable acceptance criteria, ae subject to approval by the Engineer. This annex is nonmandatory unless specified in the con= tract documents. When so specified, however, the entire requirements contained herein (as applicable) shall be considered mandatary unless specifically modified in the contract dacuments, Applicable requirements of the code regarding in strumentation and operator qualifications, except as amended herein, may be used to supplement this annex. However, it is not intended that these techniques be used to supplement the existing requirements of Clause 6 of the code since the procedures and techniques specified therein are complete and represent a different approach for the UT of welds. Part A Basic UT Procedures Q2. Introduction The basic UT procedure, instrumentation and operator requirements contained in this Part A are necessary to 419 censure maximum accuracy in discontinuity evaluation and sizing, The methods described herein are not new. ‘They have been used by other industries, including the shipbuilding and offshore structures, for the past 25 years, Although they have not been prohibited, they have not been organized and specifically made available for use in AWS documents, Some of the methods included in this section are also contained in the American Petto- eum Institute’s API RP 2X, Recommended Practices for Ultrasonic Examination of Offshore Structural Fabrica- tion and Guidelines for Qualification of Ultrasonic Tech- nicians. Additional, useful information can be obtained by reference, For maximum control of discontinuity siz- ing, emphasis has been placed upon: the UT procedure which shall be written and qualified; UT technician spe- cial requirements; and UT instrumentation and calibration requirements, AWS recognizes the inherent limitations and inconsistencies of UT examination for discontinuity characterization and sizing, The accuracies obtainable are roguired to be proven by the UT technician using the ap- plicable procedures and equipment, Procedure qualification results should be furnished to the Engineer. AWS makes no claim for accuracies possible for using the methods contained herein, Q3. UT Procedure AILUT shall be performed in conformance with a written procedure which shall contain a minimum of the follow= ing information regarding the UT method and examina- tion techniques (1) The types of weld joint configurations to be examinedANNEX (2) Acceptance criteria for the types of weld joints to bbe examined (additional criteria when the acceptance cri= teria of Clause 6, Part C are not invoked by the Engineer) (3) Type of UT equipment (manufacturer, model ‘number, serial number) (4) Type of transducer, including frequency, size, shape, angle and type of wedge if it is different than that in 6.21.6 or 6.21.7 (5) Scanning requirements surface preparation and couplant (6) Type of calibration test Block(s) with the appro- priate reference reflectors (1) Method of calibration and calibration interval (8) Method for examining for laminations prior to weld evaluation ifthe method is different from 6.25.5 (9) Weld root index marking and other preliminary weld marking methods (10) Scanning pattern and sensitivity requirements (11) Methods for determining discontinuity location height, length and amplitude level (12) Transfer correction methods for surface rough- ness, surface coatings and part curvature, if applicable (13) Method of verifying the accuracy of the com= pleted examination. This verification may be by re-UT by others (audits), other NDE methods, macroetch speci men, gouging or other visual techniques as may be approved by the Engineer (14) Documentation requirements for examinations, including any verifications performed (15) Documentation retention requirements. The writ- fen procedure shall be qualified by testing mock-up welds which represent the production welds to be exam- ined. The mock-up welds shall be sectioned, properly examined, and documented to prove satisfactory per- formance of the procedure. The procedure and all quali- fying data shall be approved by an individual who has been certified Level Ill in UT by testing in conformance with ASNT SNI-TC-1A and who is further qualified by experience in examination of the specific types of weld joints to be examined Q4. UT Operator and Equipment In addition to the requirements of 6.14.6, 620, and 9.30.2, the UT operator shall demonstrate ability to use ihe written procedure, including all special techniques required and, when discontinuity height and length are 420 AWS D1.1/D1.1M:2015 required, shall establish ability and accuracy for deter- mining these dimensions, UT equipment shall meet the requirements of 6.21 and as, required in this annex. Altemate equipment which uti- lizes computerization, imaging systems, mechanized scanning, and recording devices, may be used, when ap- proved by the Engineer. Transducers with frequencies up to 6 MHz, with sizes down to. 1/4 in [6 mm] and of any shape may be used, provided they are included in the procedure and properly qualified. QS. Reference Standard The standard reflector shall be a 1.5 mm diameter side- drilled hole or equivalent. The reflector may be placed in any design of calibration block, weld mock-up or actual production part at the option of the user. Orientation and tolerances for placement of the reflector are shown in Figure Q.1. A recommended calibration black is shown in Figure Q.2. Altemate possible uses of the reflector are shown in Figure Q.3. When placed in weld mock-ups and sections of production weldments, the reflector should be in locations where itis difficult to direct sound bbeams, thereby ensuring detection of discontinuities in all areas of interest. Q6. Calibration Methods Calibration methods described herein are considered ac- ceptable and are to be used for accomplishing these alter- nate UT procedures, The code recognizes that other calibration methods may be preferred by the individual user, If other methods are used, they should produce results which can be shown to be at least equal to the methods recommended herein, The standard reflector described in QS should be considered the standard reflec~ tor for these and for all other methods which might be used, Q6.1 Standard Sensitivity. Standard sensitivity should Consist of the sum of the following: (1) Basic Sensitivity. The maximized indication from the standard reflector, plus 2) Distance Amplitude Correction. Determined from indications from multiple standard reflectors at depths representing the minimum, middle and maximum to be examined, plus (3) Transfer Correction. Adjustment for material type, shape and scanning surface conditions as described below:AWS D1.1/01.1M:2018 For precise sensitivity standardization, transfer correc tion should be performed. This will ensure that the dif ferences in acoustical properties, scanning surfaces and part shape between the calibration standard and the cali- bration block are utilized when performing the standard sensitivity calibration, Transfer correction values should bbe determined initially before examination and when ma- terial type, shape, thickness and scanning surfaces vary such that different values exceeding + 25% of the origi nal values are expected. The transfer correction values should be determined as shown in Figure Q.4. Q6.1.1 Scanning Sensitivity. Scanning sensitivity should be standard sensitivity + approximately 6 dB— 12 4B or as required to verify sound penetration from indications of surface reflections. Indication evaluation should be performed with reference tothe standard sensi tivity except that standard sensitivity is not required if higher or lower sensitivity is more appropriate for deter- mining the maximum discontinuity size (height and length). Q6.2 Compression Wave 96.2.1 Depth (Horizontal Sweep). Indications from rmulltple reflections obtained from the thickness of the calibration standard or from a gaged area of a mock-up or production weldment should be used, as shown in Fig- ure Q.5. Accuracy of calibration should be within + 5% of actual thickness for examination of base metal for laminations and +2% for determining discontinuity size (height) and location Q6.2.2 Sensitivity Calibration (Standard). The search unit should be placed over the standard reflectors at a minimum of 3 depths to ensure coverage throughout the thickness to be examined in conformance with Figure Q.6, The dB values obtained from the maximized indications from each reflector should be recorded, A distance amplitude curve (DAC) should be established or electronic methods used to know the display indication locations which represent the standard reflector at the various thicknesses to be examined. Q6.3 Shear Wave Q6.3.1 Depth (Horizontal Sweep). Indications from the selected standard reflectors should be used to cover the maximum depth to be used during examination in conformance with Figure Q.7. Accuracy should be within + 1% to facilitate the most accurate discontinuity height measurement. The delay technique should be used for discontinuities with depth greater than approximately 15 into maximize the most accurate discontinuity depth reading (and discontinuity height) accuracy. Q6.32 Sensitivity (Standard). Standard reflectors, located at the minimum, middle, and maximum depths 21 ANNEX Q below the surface to be used for examination should be used in conformance with Figure Q.7. Indications should bbe maximized and a DAC established or electronic meth= ‘ods used to locate the display indications wich represent the standard reflector at the various depths selected. The DAC should be adjusted, based upon the results of the twansfer correction. The sensitivity calibration methods described herein are not essential when actual discon- tinuity size (height and length) is required. In this case, itis only necessary to maintain sufficient sensiivi throughout the part being examined so that all disconti- nuities are found and properly evaluated, Q7. Scanning ‘Scanning shall be as described in 6,30 and 9.30.7, In ad- dition, for special applications not covered in the above code references, the scanning methods of Figure Q.8 should be used, as applicable Q8. Weld Discontinuity Characterization Methods QB.1 Discontinuities should be characterized as follows: (1) Spherical (individual pores and widely spaced porosity, nonelongated slag) @) Cylindrical (clongated slag, aligned pores of porosity, hollow beads) (3) Planar (incomplete fusion, inadequate joint pene- tration, cracks) Q82 The following methods should be used for det ‘mining basic discontinuity characteristics: Q8.2.1 Spherical, Sound is reflected equally in all, directions. Indication remains basically unchanged as the search unit is moved around the spherical discontinuity as shown in Figure Q.9. Q8.2.2 Cylindrical, Sound is reflected equally in one direction but is changed in other directions. Indication remains basically unchanged when the search unit is ‘moved in one direction but is drastically changed when ‘moved in other directions as shown in Figure Q. 10. Q8.2.3 Planar. Sound is reflected at its maximum from only one angle of incidence with one plane. Indica tion is changed with any angular movement of the search unit as shown in Figure Q.11. Indications from cracks typically have multiple peaks as a result of the many discontinuity facets usually present.