67 @ Training Guidelines in Non-destructive Testing Techniques Testing in Non-destructive Guidelines Training Training Guidelines in Non-destructive Testing Techniques Manual for Ultrasonic Testing at Level 2 TRAINING COURSE SERIES TRAINING ISSN 1018–5518 VIENNA, 2018 TRAINING COURSE SERIES 67 TRAINING GUIDELINES IN NON-DESTRUCTIVE TESTING TECHNIQUES The following States are Members of the International Atomic Energy Agency: AFGHANISTAN GERMANY PALAU ALBANIA GHANA PANAMA ALGERIA GREECE PAPUA NEW GUINEA ANGOLA GRENADA PARAGUAY ANTIGUA AND BARBUDA GUATEMALA PERU ARGENTINA GUYANA PHILIPPINES ARMENIA HAITI POLAND AUSTRALIA HOLY SEE PORTUGAL AUSTRIA HONDURAS QATAR AZERBAIJAN HUNGARY REPUBLIC OF MOLDOVA BAHAMAS ICELAND ROMANIA BAHRAIN INDIA BANGLADESH INDONESIA RUSSIAN FEDERATION BARBADOS IRAN, ISLAMIC REPUBLIC OF RWANDA BELARUS IRAQ SAINT VINCENT AND BELGIUM IRELAND THE GRENADINES BELIZE ISRAEL SAN MARINO BENIN ITALY SAUDI ARABIA BOLIVIA, PLURINATIONAL JAMAICA SENEGAL STATE OF JAPAN SERBIA BOSNIA AND HERZEGOVINA JORDAN SEYCHELLES BOTSWANA KAZAKHSTAN SIERRA LEONE BRAZIL KENYA SINGAPORE BRUNEI DARUSSALAM KOREA, REPUBLIC OF SLOVAKIA BULGARIA KUWAIT SLOVENIA BURKINA FASO KYRGYZSTAN SOUTH AFRICA BURUNDI LAO PEOPLE’S DEMOCRATIC SPAIN CAMBODIA REPUBLIC SRI LANKA CAMEROON LATVIA SUDAN CANADA LEBANON SWEDEN CENTRAL AFRICAN LESOTHO SWITZERLAND REPUBLIC LIBERIA CHAD LIBYA SYRIAN ARAB REPUBLIC CHILE LIECHTENSTEIN TAJIKISTAN CHINA LITHUANIA THAILAND COLOMBIA LUXEMBOURG THE FORMER YUGOSLAV CONGO MADAGASCAR REPUBLIC OF MACEDONIA COSTA RICA MALAWI TOGO CÔTE D’IVOIRE MALAYSIA TRINIDAD AND TOBAGO CROATIA MALI TUNISIA CUBA MALTA TURKEY CYPRUS MARSHALL ISLANDS TURKMENISTAN CZECH REPUBLIC MAURITANIA UGANDA DEMOCRATIC REPUBLIC MAURITIUS UKRAINE OF THE CONGO MEXICO UNITED ARAB EMIRATES DENMARK MONACO UNITED KINGDOM OF DJIBOUTI MONGOLIA GREAT BRITAIN AND DOMINICA MONTENEGRO NORTHERN IRELAND DOMINICAN REPUBLIC MOROCCO UNITED REPUBLIC ECUADOR MOZAMBIQUE OF TANZANIA EGYPT MYANMAR UNITED STATES OF AMERICA EL SALVADOR NAMIBIA ERITREA NEPAL URUGUAY ESTONIA NETHERLANDS UZBEKISTAN ESWATINI NEW ZEALAND VANUATU ETHIOPIA NICARAGUA VENEZUELA, BOLIVARIAN FIJI NIGER REPUBLIC OF FINLAND NIGERIA VIET NAM FRANCE NORWAY YEMEN GABON OMAN ZAMBIA GEORGIA PAKISTAN ZIMBABWE The Agency’s Statute was approved on 23 October 1956 by the Conference on the Statute of the IAEA held at United Nations Headquarters, New York; it entered into force on 29 July 1957. The Headquarters of the Agency are situated in Vienna. Its principal objective is “to accelerate and enlarge the contribution of atomic energy to peace, health and prosperity throughout the world’’. TRAINING COURSE SERIES No. 67 TRAINING GUIDELINES IN NON-DESTRUCTIVE TESTING TECHNIQUES MANUAL FOR ULTRASONIC TESTING AT LEVEL 2 INTERNATIONAL ATOMIC ENERGY AGENCY VIENNA, 2018 COPYRIGHT NOTICE All IAEA scientific and technical publications are protected by the terms of the Universal Copyright Convention as adopted in 1952 (Berne) and as revised in 1972 (Paris). The copyright has since been extended by the World Intellectual Property Organization (Geneva) to include electronic and virtual intellectual property. Permission to use whole or parts of texts contained in IAEA publications in printed or electronic form must be obtained and is usually subject to royalty agreements. Proposals for non-commercial reproductions and translations are welcomed and considered on a case-by-case basis. Enquiries should be addressed to the IAEA Publishing Section at: Marketing and Sales Unit, Publishing Section International Atomic Energy Agency Vienna International Centre PO Box 100 1400 Vienna, Austria fax: +43 1 26007 22529 tel.: +43 1 2600 22417 email: [email protected] www.iaea.org/books For further information on this publication, please contact: Radioisotope Products and Radiation Technology Section International Atomic Energy Agency Vienna International Centre PO Box 100 1400 Vienna, Austria Email: [email protected] TRAINING GUIDELINES IN NON-DESTRUCTIVE TESTING TECHNIQUES: MANUAL FOR ULTRASONIC TESTING AT LEVEL 2 IAEA, VIENNA, 2017 IAEA-TCS-67 ISSN 1018–5518 © IAEA, 2018 Printed by the IAEA in Austria December 2018 FOREWORD The IAEA has been active in the promotion of non-destructive testing (NDT) technology for many decades. The prime reason for this interest has been the need for stringent standards for quality control for safe operation of nuclear and other industrial installations. The IAEA has successfully carried out a number of programmes, including technical cooperation projects (national and regional) and coordinated research projects having NDT was an important part. Through these programmes, many people in IAEA Member States have received training, leading to the establishment of national certifying bodies responsible for training and certification of NDT personnel. Consequently, many Member States have achieved self- sufficiency in this area. There has long been a realization that well established training guidelines and related books are needed to guide the IAEA experts involved in this training programme and to achieve a level of international uniformity and harmonization of training materials and consequently competence of NDT personnel. The IAEA has issued numerous syllabi for these training courses, beginning in 1987 with the publication of IAEA-TECDOC-407, Training Guidelines in Non-destructive Testing Techniques, containing syllabi for five basic methods (i.e. liquid penetrant testing, magnetic particle testing, eddy current testing, radiographic testing, ultrasonic testing). To accommodate advancements in NDT technology, updated versions of this publication were issued in 1991, 2002 and 2008. The current version, IAEA-TECDOC- 628/Rev.3 (2013), includes information on additional and more advanced NDT methods. The next logical step was to compile textbooks and training manuals in accordance with these syllabi. Manuals on visual, liquid penetrant, magnetic particle, leak and eddy current testing have already been published in the IAEA’s Training Course Series. These play a vital role in the training and certification of NDT personnel in Member States. Compilation of the present book on ultrasonic testing is a continuation of that effort. The IAEA wishes to express its appreciation to S. Ahmed (Pakistan) for his many contributions to the current publication. The IAEA officer responsible for this publication was P. Brisset of the Division of Physical and Chemical Sciences. EDITORIAL NOTE This publication has been prepared from the original material as submitted by the contributors and has not been edited by the editorial staff of the IAEA. The contributors are responsible for having obtained the necessary permission for the IAEA to reproduce, translate or use material from sources already protected by copyrights. Any errors identified following publication will be rectified as soon as possible. The views expressed remain the responsibility of the contributors and do not necessarily reflect those of the IAEA or the governments of its Member States. Neither the IAEA nor its Member States assume any responsibility for consequences which may arise from the use of this publication. This publication does not address questions of responsibility, legal or otherwise, for acts or omissions on the part of any person. The use of particular designations of countries or territories does not imply any judgement by the publisher, the IAEA, as to the legal status of such countries or territories, of their authorities and institutions or of the delimitation of their boundaries. The mention of names of specific companies or products (whether or not indicated as registered) does not imply any intention to infringe proprietary rights, nor should it be construed as an endorsement or recommendation on the part of the IAEA. The IAEA has no responsibility for the persistence or accuracy of URLs for external or third party Internet web sites referred to in this publication and does not guarantee that any content on such web sites is, or will remain, accurate or appropriate. CONTENTS 1. CHAPTER 1. GENERAL KNOWLEDGE ............................................................. 1 1.1. BASIC PRINCIPLES OF NON-DESTRUCTIVE TESTING (NDT) ...... 1 1.1.1. Definition and methodology of applications of basic NDT methods .......................................................................................... 1 1.1.2. NDT methods ................................................................................. 1 1.1.3. New developments in NDT ......................................................... 10 1.1.4. Inspection Methodology .............................................................. 16 1.1.5. Responsibilities of levels of certification ..................................... 18 1.2. MATERIALS AND DEFECTS - PHYSICAL AND MECHANICAL PROPERTIES OF MATERIALS ............................................................ 19 1.2.1. Metallic materials ........................................................................ 19 1.2.2. Non-metallic materials ................................................................. 22 1.2.3. Structures of metals and alloys .................................................... 23 1.2.4. Indications, discontinuities and defects in materials ................... 29 1.3. PROCESSING AND DEFECTS ............................................................. 30 1.3.1. Casting ......................................................................................... 30 1.3.2. Powder metallurgy processes ......................................................