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UT Inspection Procedure for Forged Rings (1)

This document outlines the ultrasonic inspection procedure for forged carbon and alloy steel rings, detailing the requirements for ultrasonic examinations to detect internal discontinuities. It specifies the qualifications for personnel, the necessary equipment and calibration methods, and the scanning and evaluation criteria to ensure the integrity of the forged rings. Additionally, it includes guidelines for record-keeping and acceptance criteria based on inspection results.

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KshirabdhiTanayaSwain
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22 views

UT Inspection Procedure for Forged Rings (1)

This document outlines the ultrasonic inspection procedure for forged carbon and alloy steel rings, detailing the requirements for ultrasonic examinations to detect internal discontinuities. It specifies the qualifications for personnel, the necessary equipment and calibration methods, and the scanning and evaluation criteria to ensure the integrity of the forged rings. Additionally, it includes guidelines for record-keeping and acceptance criteria based on inspection results.

Uploaded by

KshirabdhiTanayaSwain
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Ultrasonic Inspection Procedure for Forged Rings (Manual UT)

(Date: 10/15/2024, Prepared by Seetharami Reddy)


1. Scope

1.1 This standard prescribes the procedure for carrying out straight beam, pulse echo ultrasonic
examination of forged carbon and alloy steel rings.
1.2 This standard establishes the minimum ultrasonic examinations requirements that shall be
carried on forged rings to ensure that the supply of the forged rings is free from gross internal
discontinuities such as voids, porosity, cluster of inclusions, etc.
1.3 A forged and machined ring’s surface roughness shall be < 3.2 μmeters (125 μinch) RA in all the
testing surfaces.

2. Reference

2.1 ASNT SNT-TC-1A:2024 Recommended Practice for Nondestructive Personnel Qualification and
Certification.
2.2 ASTM A388/A388M-09 Standard Practice for Ultrasonic Examination of Steel Forgings.
2.3 ASTM E127-20 Standard Practice for Fabrication and Control of Flat Bottom Hole Ultrasonic
Standard Reference Blocks.
2.4 Timken 10.69 Ultrasonic testing of Steel Forging Rings.
2.5 The operating manual for the ultrasonic flaw detector used.

3. Qualification of Personnel

3.1 Individuals performing examinations in accordance with this specification shall be qualified and
certified in accordance with the requirements of the latest edition of ASNT SNT-TC-1A or ISO
9712 or any other equivalent.
3.2 The personnel shall be certified to minimum Level II to perform the test described in this
procedure.
3.3 Annual vision test reports shall be available for all the certified personnels.

4. Instrument, Probe, Couplant, Calibration Blocks

4.1 Instrument
4.1.1 A portable ultrasonic flaw detector with A -Scan display and a bandwidth of 15MHz or
greater. Equipment shall be GE/Baker hughes or Olympus or Modsonic or EEC.
Approval required for other makes as specified.
4.1.2 A periodical calibration using standard blocks shall be done to verify the accuracy of
the used equipment.
4.1.3 UT equipment shall be valid calibration certificates and records should be maintained.
4.2 Probe
4.2.1 The frequency range of the probe shall be 4 to 10 MHz, “straight beam”, single or dual
crystal based on the part section thickness and height of the part being examined.
4.2.2 For shallow tests for upto 2” (50.8 mm) below surface – Use dual crystal 4MHz with
nominal probe diameter of 0.5” (12.7mm).
4.2.3 For deep tests for > 2” (50.8 mm) – Use single crystal 4MHz or 5 MHz probe.

4.3 Couplant
4.3.1 A liquid couplant shall be used (e.g. gel, oil, or grease) which is capable of conducting
ultrasound between the ultrasonic transducer and the surface of the part to be
examined.
4.3.2 Low viscosity couplant shall be used.
4.3.3 Same couplant shall be used to for equipment calibration and testing.

4.4 Standard Calibration and Reference Blocks


4.4.1 V1 or V2 calibration blocks.
4.4.2 3/64” (1.2mm) flat bottom hole distance amplitude reference blocks.
4.4.2.1 For shallow test minimum 5 set of blocks require for distance amplitude
correction (DAC) calibration for shallow test.
4.4.2.2 The metal paths of 3/64” (1.2mm) FBH blocks shall be 0.06” (1.524 mm),
0.125” (3.175 mm), 0.375”,(9.525), 0.750”(19.05mm), 2.250” (57.15 mm)
respectively for shallow test DAC.
4.4.2.3 Scale and vernier calipers can be used to measure the part thickness.
4.4.3 For course test refer Timken 10.69 standard for usages of DAC blocks and setup.

5 Machine Calibration and DAC Setup


5.1 Basic calibration blocks
5.1.1 The basic calibration reflectors shall be used to establish a primary reference response
of the equipment. Use block V1 & V2 for basic equipment calibration.
5.1.2 A minimum of two back wall echoes from the material under test shall be noted during
the examination.
5.2 Distance amplitude correction (DAC) blocks
5.2.1 A Distance Amplitude Correction curve (DAC curve) shall be produced using the 3/64”
(1.2mm) FHB calibration block. The gain control is adjusted to produce a response of
80% full screen height and the screen is marked. Then the probe is re-positioned to
give the maximized response for each of the remaining holes. At each maximized
position, mark the position of maximum response on the screen. Connect the screen
marks to produce the DAC curve. This gain setting is primary reference level.
5.2.2 Use minimum 3 DAC curves, i.e., 20%, 40%, 80% with the FBH blocks.
5.2.3 DAC block material should be of same type and heat treat condition.
6 Scanning, Evaluation and Acceptance Criteria
6.1.1 A forging ring cross section can be either of cone, cup, double cup, double cone,
cylindrical inner, cylindrical outer, spherical inner, spherical outer. Please see
Annexture 1
6.1.2 Each forging ring type require more then one or more ultrasonic tests. Please see
Annexture 2.
6.1.3 Calibrate the machine as per Section 5.1.
6.1.4 Setup DAC using FBH reference blocks as per the procedure given in Section 5.2. Apply
+6 dB during scanning the parts.
6.1.5 Use and apply the couplant as per Section 4.3.
6.1.6 Scan the parts in all the areas shown in Annexture2. Use the same DAC setup for all the
part scanning area.
6.1.7 Ensure part should be cleaned properly in the all the surface scanning areas.
6.1.8 Scan speed shall not exceed 100mm/Sec.
6.1.9 Scan overlap should be minimum 15% for each scan line.
6.1.10 100% volume shall be scanned.
6.1.11 Proper setup to be arranged for the inspectors to scan the different geometry of the
parts. While scanning proper couplant shall be applied. Semi atomization system shall
be developed for auto part rotation and auto apply of couplant during scanning.
6.1.12 During inspection, If no UT defect indication observed in a particular batch during UT,
the batch can be released to further operations.
6.1.13 If any UT defect observed with cluster of UT indications (closer or deeper to the scan
surface of the part, irrespective of indications height) during scanning, hold the entire
batch.
6.1.14 Re-examine on UT suspected parts and if the re-test confirms as real UT indications,
quarantine the batch and intimate to Timken SQD and GMQ teams.

7 UT Inspection Criteria: Shall be followed as per the below plan.


7.1.1 For Wind and New part development 100%
7.1.2 For other parts as per AQL 0.65%.
7.1.3 Same DAC curve or setup can be used on the different parts having section thickness
within the DAC setup rang.
7.1.4 For every new part inspection DAC shall be verified with the FBH blocks. If noticed any
amplitude on the FBH blocks on the DAC, fresh DAC shall be prepared before scanning
the part. Otherwise continue to use the same DAC for the part scanning.

8 Records and Documents


8.1 UT reports shall be prepared for all the inspected parts.
8.1.1 Batch and shift wise reports shall be available.
8.1.2 All the necessary information shall be mentioned in the report. e.g., part no, max part
A-section thickness, UT machine and probe details, Calibration, DAC block and dB
details, inspector details, number of parts inspected, number of UT OK and NOK part
details, etc.
APPENDIX 1. CROSS SECTIONS OF DIFFERENT GEOMETRY OF FORGINED RINGS

CONE (SINGLE) CUP (SINGLE)

CYLINDRICAL INNER (SINGLE) CYLINDRICAL OUTER

SPHERICAL INNER SPHERICAL OUTER

NOTE: OTHER GEOMETRY PARTS ALSO AVAILABLE BUT NOT SHOWN ABOVE. THOSE PARTS
SIMILAR IN GEOMETRY, (LIKE SINGLE CONE, CUP, INNER, OUTER) AND IT WILL BE EXTENDED
FROM THE LARGE FACE.
APPENDIX 2. UT SCANNING AREAS ON THE DIFFERENT GEOMETRY OF FORGINED
RINGS

CONE – SINGLE (SCANNING AREAS – BOTH FACE, ID AND OD)

CUP – SINGLE (SCANNING AREAS – LARGE FACE, ID AND OD) SMALL FACE ALSO
SCANNED IF THE FACE AREA IS EQUAL OR LARGER THAN PROBE DIA.
APPENDIX 2. UT SCANNING AREAS ON THE DIFFERENT GEOMETRY OF FORGINED
RINGS

CYLINDRICAL INNER – SINGLE (SCANNING AREAS – BOTH FACE, ID AND OD)

CYLINDRICAL OUTER – SINGLE (SCANNING AREAS – BOTH FACE, ID AND OD)


APPENDIX 2. UT SCANNING AREAS ON THE DIFFERENT GEOMETRY OF FORGINED
RINGS

SPHERICAL INNER (SCANNING AREAS – BOTH FACE, ID AND OD

SPHERICAL OUTER (SCANNING AREAS – BOTH FACE, ID AND OD

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