OmniSX - MX2 - Training - 14H - Phased Array Analysis - Flaw Characterization
OmniSX - MX2 - Training - 14H - Phased Array Analysis - Flaw Characterization
V4.3R2
OmniScan SX\MX2 Training – Analysis – Flaw Characterization Overview
Flaw characterization is defined as the ability to identify flaw types and geometry
based on failure mechanism, location, and imaging.
Knowledge of the weld process is extremely helpful. You can eliminate porosity or
slag as a possibility for processes that do not produce them.
For some weld bevel types and processes typical of the pipeline industry >90% of
the defects are either lack of side wall fusion or inadequate penetration.
In-service inspections are typically for cracks and metal loss. Although cracks can
occur in any environment new construction welds are primarily for fabrication
defects such as IP, LOF, LOSWF, slag, porosity, etc.
It is normally necessary to have participated in the data acquisition to be proficient in
the analysis due to differences in weld processes and inspection conditions from
one job to another. The exception to this is factory or fabrication facilities were
welds of the same process, configuration, and size are inspected repeatedly.
There is no substitute for experience. The benefit of analysis on welds for which the
inspector is familiar or for which testing was performed on notches or SDHs in the
weld cannot be overcome with software features and training.
OmniScan SX\MX2 Training – Analysis – A-scan \ S-scan Imaging
Weld flaws can be classified as either planer or volumetric based on their unique A-
scan imaging and characterization.
Volumetric flaws such as slag, porosity, and cracks with multiple ligaments will be
characterized in the A-scan as having a long rise and fall time on the time base.
(Also called a long echo dynamic)
Volumetric flaws are characterized by multiple peaks and facets of varying
amplitude typically embedded in the middle volume of the weld.
Volumetric flaws are often best detected in the second leg skipping off the inner
surface. Volumetric flaw example (Porosity cluster)
OmniScan SX\MX2 Training – Analysis – A-scan \ S-scan Imaging cont.
Planer flaws such as inadequate penetration, lack of root fusion, lack of side wall
fusion, will be characterized in the A-scan as having a very short rise and fall time or
short echo dynamic on the time base.
Planer flaws are characterized by high amplitude sharp signals that are orientation
dependent and fall rapidly upon probe skew.
Planer flaws can be embedded or surface connected and are most likely to generate
a sharp tip diffracted signal for precision measurements.
Volumetric flaw example (Acceptable porosity cluster) Planer flaw example (Rejectable SW lack of fusion)
OmniScan SX\MX2 Training – Analysis – Flaw Characterization Overview
The 3 primary indicators in determining flaw type in typical weld inspections in
descending order or priority are:
1. Flaw location.
2. A-scan and S-scan imaging and characterization.
3. When accessible and available, was the flaw detected from both sides of the weld?
TF_5_Slag.Opd
OmniScan SX\MX2 Training – Analysis – Flaw Characterization Overview cont.
Moving the scan axis data cursor on the C-scan or B-scan allows a dynamic view of
the A-scan and S-scan at different positions along the weld line.
Not isolated or cluster porosity based on a continuous line at same depth.
Not LOF based on amplitude, counter indicated S-scan image, and location.
The flaw is a low amplitude slag line contained within one weld pass.
1 2 3 4 5
1 2 3 4 5
OmniScan SX\MX2 Training – Analysis – TF_5_Slag.Opd
From the same data point, select the A-B-C-S layout and use the B-scan to
characterize the slag line across the scan axis to visualize the flaw at each focal law
and depth.
Select the angle on the title bar and use the OmniScan rotary knob or mouse wheel
to scroll through the focal laws while observing the B-scan and repositioning
cursors.
The B-scan provides more confirmation that this is a slag line and not porosity or
non fusion.
Slag line
OmniScan SX\MX2 Training – Analysis – TF_5_Slag.Opd cont. FIX length
A 20mm slag line is contained within 1 weld pass (2mm) at the same depth (5mm)
along the weld line at varying amplitude.
1. Flaw amplitude (A%): 44.6% measured at 38.5mm scan, 59 degrees.
2. Flaw volumetric position: +.11mm
3. Embedded\ Surface connected?: Embedded
4. Flaw start on scan axis (Sr): 36.02mm
5. Flaw end on scan axis (Sm): 56.49mm
6. Flaw length (Sm-r): 20.46mm
7. Flaw depth (DA): 5.17mm
8. Flaw upper extremity (Ur): 17.93mm
9. Flaw lower extremity (Um): 19.84mm
10. Flaw height (Um-r): 1.91mm
11. Flaw type: Slag line
OmniScan SX\MX2 Training – Analysis – TF_12_ID_Crack.Opd
Open the file and move the axis data cursor to 50mm scan axis and 58.5 degrees,
then zoom in tight on the S-scan over the crack area.
Drag the top of the color bar scale from 100% to 46% and observe the center of the
energy of the crack tip.
The color palette can also be manipulated in >Display>Properties>Category: Color
Palette>46%.
Place the red Ur cursor at 7.80mm and the green Um cursor at 12.70mm.
OmniScan SX\MX2 Training – Analysis – TF_12_ID_Crack.Opd cont.
Select the A-B-C-S layout and on the S-scan zoom in on the area of interest of the
crack adjacent to the weld like pictured below.
The image below is at 50mm scan axis, 58.5 degrees, color palette end= 46.
The angle data cursor on the title bar is used to scroll through the focal laws with the
while observing the crack image on the B-scan.
Observe the crack profile across the scan axis at different depths. The signals in the
B-scan are ligaments of the crack generating diffracted energy.
Position the red Sr cursor and green Sm cursor at the crack extremities on the C-
scan and B-scan.
Crack ligaments
OmniScan SX\MX2 Training – Analysis – TF_12_ID_Crack.Opd cont.
A 31mm long ID connected crack is detected and sized in a 12.7mm V weld. There
are two relative data points. One of the crack base and one for the crack tip.
1. Flaw max amplitude (A%): 59.1% measured at 41mm scan, 51.5 degrees. (Crack base)
2. Flaw volumetric position: -4.15mm measured at 50mm scan, 58.5 degrees. (Crack tip)
3. Embedded \ Surface connected?: Inside surface connected
4. Flaw start on scan axis (Sr): 31mm
5. Flaw end on scan axis (Sm): 62mm
6. Flaw length (Sm-r): 31mm
7. Flaw depth (DA): 7.80mm
8. Flaw upper extremity (Ur): 7.80mm
9. Flaw lower extremity (Um): 12.70mm
10. Flaw height (Um-r): 4.90mm
11. Flaw type: HAZ crack
OmniScan SX\MX2 Training – Analysis – TF_7_Porosity.Opd
An 11mm long porosity cluster is detected and sized in a 12.7mm V weld. 3
individual porosity pores can be seen as the data cursor is moved on the scan axis.
1. Flaw max amplitude (A%): 62.6% measured at 50mm scan, 61 degrees.
2. Flaw volumetric position: +0.76mm
3. Embedded \ Surface connected?: Embedded
4. Flaw start on scan axis (Sr): 44.5mm
5. Flaw end on scan axis (Sm): 55.5mm
6. Flaw length (Sm-r): 11mm
7. Flaw depth (DA): 8.68mm
8. Flaw upper extremity (Ur): 14.5mm
9. Flaw lower extremity (Um): 18.60mm
10. Flaw height (Um-r): 4.10mm
11. Flaw width (Im-r): 2.66mm
12. Flaw type: Porosity cluster
OmniScan SX\MX2 Training – Analysis – PA Weld.Opd Flaw 1
A 22mm long embedded lack of fusion indication is detected and sized in a 25mm V
weld.
1. Flaw max amplitude (A%): 62.6% measured at 50mm scan, 61 degrees.
2. Flaw volumetric position: -.039 measured at flaw tip, 80mm scan, 67 degrees.
3. Embedded \ Surface connected?: Embedded
4. Flaw start on scan axis (Sr): 76mm
5. Flaw end on scan axis (Sm): 98mm
6. Flaw length (Sm-r): 22mm
7. Flaw depth (DA): 20.45mm
8. Flaw upper extremity (Ur): 19.93mm
9. Flaw lower extremity (Um): 23.47mm
10. Flaw height (Um-r): 3.54mm
11. Flaw type: Lack of fusion
OmniScan SX\MX2 Training – Analysis – PA Weld.Opd Flaw 2
32mm of side wall lack of fusion is detected and sized in a 25mm V weld.
Original one line scan crack image (Unfocused w\ 16 element aperture) Manual prove up of crack (Optimized focus w\ 32 element aperture)
TF_28_IDcrack.Opd TF_28_IDcrack_ProveUp.Opd
OmniScan SX\MX2 Training – Analysis – TF_CobraSS304.Opd Flaw 1
Multigroup layout visualizing side wall lack of fusion detected on skew 270 group 2,
9mm long X 1mm high.
1. Flaw max amplitude (A%): 125.6% measured at 9mm scan, 56 degrees.
2. Flaw volumetric position: 2.12mm.
3. Embedded \ Surface connected?: Embedded
4. Flaw start on scan axis (Sr): 4mm
5. Flaw end on scan axis (Sm): 13mm
6. Flaw length (Sm-r): 9mm
7. Flaw depth (DA): 1.89mm
8. Flaw upper extremity (Ur): 8.20mm
9. Flaw lower extremity (Um): 7.20mm
10. Flaw height (Um-r): 1mm
11. Flaw type: Embedded
OmniScan SX\MX2 Training – Analysis – TF_CobraSS304.Opd Flaw 1 cont.
The same flaw as previous slide displayed in the single group A-B-C-S layout.
Zoomed and optimized for flaw length, depth, and height sizing.
No single factor should be weighted more than location for characterizing flaws.
It is normal that side wall lack of fusion is only detected from near side only due to
defect orientation.
OmniScan SX\MX2 Training – Analysis – TF_CobraSS304.Opd Flaw 2
Multigroup layout visualizing OD connected crack on skew 270 group 2, 10mm long
X <1mm deep. No clear distinguishable diffracted tip signal on main crack section.
1. Flaw max amplitude (A%): 142.5% measured at 37mm scan, 43 degrees.
2. Flaw volumetric position: 6.29mm
3. Embedded \ Surface connected?: OD connected
4. Flaw start on scan axis (Sr): 34.5mm
5. Flaw end on scan axis (Sm): 44.5mm
6. Flaw length (Sm-r): 10mm
7. Flaw depth (DA): <1mm
8. Flaw upper extremity (Ur): 8.60mm
9. Flaw lower extremity (Um): 9.60mm
10. Flaw height (Um-r): <1mm
11. Flaw type: OD connected crack
OmniScan SX\MX2 Training – Analysis – TF_CobraSS304.Opd Flaw 2 cont.
The same flaw as previous slide displayed in the single group A-B-C-S layout.
Zoomed and optimized for flaw length, depth, and height sizing.
Crack ligaments detected at 40mm scan, 43 degrees <1mm in depth \ height.
Length sizing verified by scrolling through focal laws with rotary knob or mouse
wheel while observing flaw profiled across scan axis of B-scan.
1 1
2 2
OmniScan SX\MX2 Training – Analysis – TF_26_IP.Opd
Inadequate penetration typically does not require depth and height sizing and is only
evaluated based on amplitude and length sizing.
1. Flaw max amplitude (A%): 145.6% measured at 70mm scan, 54 degrees.
2. Flaw volumetric position: -1.16mm
3. Embedded \ Surface connected?: ID connected
4. Flaw start on scan axis (Sr): 64.5mm
5. Flaw end on scan axis (Sm): 82mm
6. Flaw length (Sm-r): 17.5mm
7. Flaw depth (DB): NA
8. Flaw upper extremity (Ur): NA
9. Flaw lower extremity (Um): NA
10. Flaw height (Um-r): NA
11. Flaw type: Inadequate penetration
OmniScan SX\MX2 Training – Analysis – TF_ID_Crack3.Opd
Multiple tips are detected at or near the same depth. Put the cursor on the data
point in #2 below and move the scan cursor while observing the A-scan and S-scan.
1. Flaw max amplitude (A%): 80.2% measured at 20mm scan, 50.5 degrees.
2. Flaw volumetric position: -4.83mm measured at crack tip at 21mm scan, 53 degrees.
3. Embedded \ Surface connected?: ID connected
4. Flaw start on scan axis (Sr): 15mm
5. Flaw end on scan axis (Sm): 35mm
6. Flaw length (Sm-r): 20mm
7. Flaw depth (DB^1): 21.32mm
8. Flaw upper extremity (Ur): 21.31mm
9. Flaw lower extremity (Um): 25mm
10. Flaw height (Um-r): 3.69mm
11. Flaw type: ID connected crack
OmniScan SX\MX2 Training – Analysis – TF_ID_Crack3.Opd cont.
Select the A-B-C-S can view, select the angle cursor from the title bar and scroll
through the focal laws observing the B-scan.
This data view is very useful for length sizing as the crack profile for each focal law
is displayed across the scan axis.
Crack ligaments
V4.3R2