TOFD
TOFD
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TOFD Course 2008 PBE
CONTENTS
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TOFD Course 2008 PBE
PART I
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The most serious types of defects in welds and metal components are planar
cracks since they are the most likely to grow and cause failure of the component
and hence the importance of ultrasonic inspection since ultrasonics is the most
suitable
bl technique
h f determining
for d the
h position and
d sizing such h defects.
d f The
h
importance of developing more accurate sizing techniques than afforded by
conventional pulse‐echo inspections became apparent in the 1960’s, especially in
th nuclear
the l andd chemical
h i l plant
l t industries.
i d ti
For this reason the National NDT Centre at Harwell (then part of the United
Kingdom Atomic Energy Authority ‐ UKAEA) asked Dr Maurice Silk to try and
develop an ultrasonic sizing technique more accurate than the conventional pulse‐
echo method.
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TOFD Course 2008 PBE
Principle of TOFD
Diffraction process
p
When an ultrasonic wave interacts with a long crack‐like flaw it results in the production
of diffracted waves from the crack tips, in addition to any ultrasonic waves reflected
from the surface of the crack. The diffracted waves are much weaker than specularly
reflected waves used for conventional ultrasonic inspection, but they radiate from the
tips in all directions along the same plane as the incident ultrasonic waves as indicated in
figure.
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Basics of TOFD inspection
TOFD Course 2008 PBE
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A‐scan TOFD Course 2008 PBE
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A‐scan TOFD Course 2008 PBE
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Lateral wave
In general a weak lateral wave running between the two probes with the
compression
p velocityy jjust below the surface of the metal is observed first. It obeys
y
Fermat’s principle in that a wave travelling between two points takes the minimum
time. As we shall see later, for a curved surface it will travel straight across the
metal between the two probes. On material with a surface cladding layer the
velocityy of sound in the claddingg mayy be such that the lateral wave travels most of
the way in the material beneath the cladding. The lateral wave is not a true surface
wave but a bulk wave generated at the edge of the beam. The frequency content
of the lateral wave tends to be lower than the waves from the centre of the beam
(the beam spread is frequency related and the lower frequency component has
therefor a wider beam spread). For a true surface wave the amplitude would
decay exponentially with distance from the inspection surface.
The
h lateral
l l wave can be
b very weakk for
f large
l probe
b separations
i and
d may not even
be recognisable.
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 wave.
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TOFD Course 2008 PBE
A much larger signal reflected/diffracted from the back wall is observed after the
lateral wave because of the greater distance travelled. If the probe beams are only
directed at the upper part of the metal or there is no suitable back wall there may
be no back wall signal.
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TOFD Course 2008 PBE
Defect signals
If a planar
l t
type crackk is
i presentt in
i the
th metal
t l in
i the
th overlapping
l i beam
b off the
th two
t
probes diffraction signals from the top and bottom tips are seen between the
lateral wave and the back wall. These signals are generally much weaker than the
backwall signal but stronger than the lateral wave. If the defect has little height
then the signals from the top and bottom may run into each other. 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.
Because the diffraction signals are so weak they cannot always be easily seen on a
single A‐scan and it is only by displaying the successive A‐scans from a scan in B‐
scan form
f th t the
that th pattern
tt off the
th diffraction
diff ti signals
i l becomes
b clear.
l Si l
Signal
averaging is very important in these situations because it improves the signal‐to‐
noise ratio.
Again this is why TOFD is very difficult with an analogue flaw detector where only a
single A‐scan display is available.
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After the compression back wall signal a much large signal generally appears and is
a back wall shear reflected signal and it is often mistaken for the compression back
wall signal. Between these signals other signals are generally observed due to
mode conversion at a defect into shear waves which then takes a longer time for
the signal to arrive at the receiver.
It 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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Depth calculation
DEFINITIONS
C ‐ velocity of sound
λ ‐ wavelength of sound
d ‐ depth of reflector below scanning surface
D ‐ thickness of sample being scanned
PCS ‐ probe centre separation
s ‐ half of probe centre separation 2s
t ‐ time of flight of signal from a reflector
2to ‐ time taken for sound to pass through two probe shoes (probe delay)
tl ‐ time of flight of lateral wave
tb ‐ time of flight of back wall signal
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TOFD Course 2008 PBE
Depth calculation
Depth
h
In practise the depth calculation needs to take into account the extra delay in the
measured time due to the passage of the sound through the probe shoes. This
delay is known as the probe delay2to microseconds. Thus the total transit time
measured, t, is in practice given by :
d = [(c/2)2(t‐2to)2 ‐ s2]1/2
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Signal time TOFD Course 2008 PBE
tl = 2s/c + 2to
By rearranging the two equation the probe delay and velocity can be found if the
PCS = 2s, and the thickness D is known,
c = 2(s2
( + D2)1/2 ) / ‐ 2s
(tb ‐ tl)
and
2to = tb ‐ 2(s2 + D2)1/2
/ /c
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TOFD Course 2008 PBE
Types
yp of TOFD Scan
There are two types of scan. The initial scan generally used for detection is shown
in Figure
g 1 and is called the non‐parallel
p or longitudinal
g scan because the direction
of scan is at right angles to the direction of the ultrasonic beam. The resultant scan
is known as a D‐scan since it produces a cross section along the weld.
The second type of scan is shown in Figure 2 and is called the transverse or parallel
scan. The direction of scan is parallel to the ultrasonic beam direction. The scan
produced is called a B
B‐scan
scan since it produces a cross section across the weld.
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Data Visualization
A‐scan
Indication
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1 2
The crack blocks the Lateral Wave
And the lower tip appears on the A-scan
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1
2
1 2 3 4
Two signals from the top & bottom
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1
1
2
3
2
3
1
2 3
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The two most important differences of TOFD from conventional pulse‐echo are,
‐ the almost independence of angle of the defect for detection of the diffraction
signals
‐ the depth sizing is not dependent on the amplitude of the signals and the
corresponding errors
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TOFD Course 2008 PBE
Advantages
g and Disadvantages
g of TOFD
Disadvantages
g
The amplitude of the diffraction signals does not depend on the size of the defects
and a simple amplitude threshold cannot be applied for selecting the important
reportable defects, unlike pulse‐echo inspections. TOFD easily detects pores, slag
lines, inclusions etc.
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TOFD Course 2008 PBE
PART II
TOFD SET‐UP
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Set up of probes TOFD Course 2008 PBE
The probes shall be set up to ensure adequate coverage and optimum conditions
for the initiation and detection of diffracted signals in the area of interest.
interest
Selection of probes for full coverage of the complete weld thickness (typically pre‐
service
i inspection)
i ti ) should
h ld follow
f ll Table.
T bl
If set‐up parameters are not in accordance with follow Table, the capability shall
be verified byy the use of reference blocks.
For in‐service inspection the intersection point of the beam centre lines should be
optimised for the specified examination volume.
volume
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TOFD Course 2008 PBE
Set up
p of p
probes
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Set up of probes
Transmitter Receiver
PCS
2/3T
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1 µS 1 µS
1 2 3
1 : LLateral
t l wave
2 : Back Wall
3 : Shear waves
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TOFD Course 2008 PBE
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).
In cases where the use of the lateral wave is not appropriate (e.g. surface conditions,
use of steepp beam‐angles),
g ) the sensitivityy shall be set such that the amplitude
p of the
back wall signal is between 18 dB and 30 dB above FSH.
80%
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TOFD Course 2008 PBE
The scan increment setting is dependent upon the wall thickness to be examined.
For thickness up to 10 mm the scan increment shall be no more than 0,5 mm.
For thickness between 10 mm and 150 mm the scan increment shall be no more
than 1 mm.
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TOFD Course 2008 PBE
PART III
IInterpretation
t t ti andd analysis
l i
of
TOFD images
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TOFD Course 2008 PBE
General
Interpretation and analysis of TOFD images is generally performed as follows
• Identification
d f off relevant
l indications
d and
d discrimination
d off non‐relevant
l indications.
d
• Determination of location (typically position in x‐ and z‐direction) and size (length and
through‐wall extent).
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TOFD Course 2008 PBE
Assessingg the q
qualityy of the TOFD‐image
g
Examples of typical scans
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TOFD Course 2008 PBE
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Inappropriate time window setting Missing scan lines caused by too high scanning speed
Lateral wave is not present in the time window
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TOFD Course 2008 PBE
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TOFD Course 2008 PBE
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Classification of relevant indications TOFD Course 2008 PBE
Amplitude,
li d phase,
h location
l i and d pattern off relevant
l indications
i di i may contain
i
Information on the type of discontinuity.
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TOFD Course 2008 PBE
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TOFD Course 2008 PBE
E b dd d discontinuities
Embedded di ti iti can be
b classified
l ifi d into
i t 3 categories
t i
1. Point‐like discontinuity:
This type shows up as a single hyperbolic shaped curve which may lie at any depth
depth.
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Typical TOFD‐images TOFD Course 2008 PBE
Indications of scanning surface notch (disturbance of Elongated indication of an opposite surface breaking
lateral wave) and of opposite di
discontinuity
ti it
surface notch (straight diffracted signal corresponding
to slight disturbance of backwall signal)
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Typical TOFD‐images TOFD Course 2008 PBE
Elongated indication of a far‐surface breaking Indication of through‐wall crack (note the loss of lateral
discontinuity (nearly through‐wall) wave and backwall signal and
also the corresponding diffracted signal patterns left
and right to this region)
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Typical TOFD‐images TOFD Course 2008 PBE
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Typical TOFD‐images TOFD Course 2008 PBE
geometrical features
I di ti off change
Indication h i wallll thickness
in thi k D bl backwall
Double b k ll reflection
fl ti dued to
t diff
differentt wallll thi
thicknesses
k
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Typical TOFD‐images TOFD Course 2008 PBE
geometrical features
Image of misalignment in circumferentially welded pipes Indication of corrosion in the root‐area on both sides of
the weld in the heat‐affectedzone
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TOFD Course 2008 PBE
PART IV
BASICS OF DIMENSIONING
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Height measurement
A principle
i i l ini measuring
i theh height
h i h off the
h indication
i di i is i determined
d i d during
d i the h
calibration of the time scale. The height measurement shall be done from the A‐
scan image.
The measuring the height of the indications must be done with similar principles
as the calibration of the timescale has been made.
Three possibilities for time base calibration and dimensioning are presented.
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Method 1 TOFD Course 2008 PBE
E h corner
Echo
Time base calibration is based on the corner of the first rising echo. On this type of
calibration,, inspector
p must take in count the error p
possibilityy in case of high
g noise.
The first and sixth red lines presents the measuring point of wall thickness. The second
and third red lines presents the measuring point of indication upper tip and lower tip.
In these figures the fist echo is presented as a negative. The firs echo may also appear
as a positive. This alternation must be taken in to account in calibration and in
dimensioning the height.
height
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Method 2 TOFD Course 2008 PBE
Fi t maximum
First i
Time base calibration is based on the middle point of the first echoes maximum. On this
type of calibration,
calibration inspector must take in count the error possibility in case of echoes
with same level of amplitude.
The first and sixth red lines presents the measuring point of wall thickness. The second
and third red lines presents the measuring point of indication upper tip and lower tip.
I th
In these fi
figures the
th fist
fi t echo
h is
i presented
t d as a negative.
ti TheTh firs
fi echoh may also
l appear
as a positive. This alternation must be taken in to account in calibration and in
dimensioning the height.
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Method 3 TOFD Course 2008 PBE
M i
Maximum echo
h
Time base calibration is based on the maximum amplitude of the indication. On
this type of calibration,
calibration inspector must take in count the error possibility in case of
phase shift that may increase the amplitude of an echo.
The first and sixth red lines presents the measuring point of wall thickness. The
second and third red lines presents the measuring point of indication upper tip
and lower tip.
tip
In these figures the fist echo is presented as a negative. The firs echo may also
appear as a positive. This alternation must be taken in to account in calibration
and in dimensioning the height.
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Exemples TOFD Course 2008 PBE
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Length measurement
The
h llengthh measurement shall
h ll b
be made
d ffrom the
h echo
h off the
h upper tip
i or from
f the
h
echo of the lower tip, that presents the maximum measurable dimension of the
indication.
If this parabolic shape is visible the length is measured from the point where the
reduction of the maximum amplitudep can be noticed,, an alternative method the 6
dB drop method may be applied if possible.
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Scanning surface discontinuity
Scanning surface discontinuity appears as a disturbance in the lateral wave or a change in the
time scale of the lateral wave. If the disturbance has parabolic ends the dimensioning is done as
shown in the figure 1. The dimension is based on the drop of the amplitude of the echo.
In the case of lack of parabolic ends the length dimensioning is done in most conservative way
(see figure 2).
2) The indication is assumed to begin immediately after a drop or change in the
lateral wave.
Figure 1. Figure 2.
Length measurement from parabolic ends. The Length measurement from the point of the disturbance. The
difference of the yellow lines presents the length of difference of the yellow lines presents the length of the
the indication. indication.
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Opposite
pp surface discontinuityy
Opposite surface discontinuity appears as a disturbance in the back wall echo, a change in
the time scale of the back wall echo or as an echo veryy close to the back wall echo. If the
disturbance has parabolic ends the dimensioning is done as shown in the figure 3.
In the case of lack of parabolic ends the length dimensioning is done in most conservative
way (see figure 4). The indication is assumed to begin immediately after a drop or change in
the back wall echo. For far surface a special dimensioning method is used. This method is
described in the figure 5.
Figure 3. Figure 4.
Length measurement from parabolic ends. The Length measurement from the point of the
difference of the yellow lines presents the length of disturbance. The difference of the yellow lines
the indication. presents the length of the indication.
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Opposite
pp surface discontinuityy
Figure 5.
Length measurement of surface open indication. The cursors are set to place where the height of the
indication is 1 / 3 of the total height of the indication. The difference of the yellow lines presents the
length of the indication. This method is valid for both surfaces.
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TOFD Course 2008 PBE
Figure 6. Figure 7.
I di ti is
Indication i embedded
b dd d withith measurable
bl hheight.
i ht Parabolic
P b li Indication is embedded with measurable height. No
pattern is visible in the echo. The length of the indication parabolic pattern is visible in the drawn echo. Length
is measured from the parabolic ends. The difference of measurement is made from the point of the
the yellow lines presents the length of the indication. disturbance. The difference of the yellow lines
presents the length of the indication.
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TOFD Course 2008 PBE
Embedded point
point‐like
like indication
Measuring
M i theh position
i i off a point
i like
lik indication
i di i is i done
d from
f middle
iddl off the
h highest
hi h echo
h
visible. For an example see figure 8.
Figure 8.
Point like indication. The yellow line presents the position of the echo.
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TOFD Course 2008 PBE
PART V
Test report
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d) geometrical configuration
h) stage of manufacture
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TOFD Course 2008 PBE
a)) manufacturer
f and
d type off TOFD
O equipment
i i l di scanning
including i mechanisms
h i with
ih
identification numbers if required
b) manufacturer, type, frequency, element size and beam angle(s) of probes with
identification numbers if required
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a)) examination
i i level
l l and
d reference
f to a written
i test iinstruction,
i if required
i d
f) details
d il off signal
i l averaging
i and
d scan increment
i setting
i
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TOFD Course 2008 PBE
a)) TOFD
O iimages off at least
l those
h llocations
i where
h relevant
l iindications
di i h
have b
been
detected
c) tabulated data recording the classification, location and size of relevant indications
and results ofevaluation
d) date of test
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TOFD Course 2008 PBE
Bibliography
g p y
• BS 7706
Calibration and setting‐up of the ultrasonic time‐of‐flight‐diffraction (TOFD) technique for the
detection, location and sizing of flaws
• EN 473
Qualification and certification of NDT personnel
• ENV 583‐6
Non‐Destructive testing Ultrasonic examination Part 6 : TOFD technique as a method of
detection and sizing discontinuities
• XP CEN/TS 14751
Technical specification – Welding – used of TOFD for examination of welds
• TOFDPROOF project
Recommedations for applying TOFD
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