steel 6500. construction testin g and examination · • 6430 ‐aws d1.1 structural welding code...

6000 STEEL6000. STEEL6100 &

• 6130 ‐ Design Data, Principles and Tools6100 & 6200 • 6140 ‐ Codes and Standards

• 6200 ‐Material

6300• 6310 ‐Members and Components• 6320 ‐ Connections, Joints and Details

d bl• 6330 ‐ Frames and Assembles

6400• 6410 ‐ AISC Specifications for Structural Joints6420 AISC 303 C d f St d d P ti• 6420 ‐ AISC 303 Code of Standard Practice

• 6430 ‐ AWS D1.1 Structural Welding Code 6500 • 6510 Nondestructive Testing Methods6500 • 6510 ‐ Nondestructive Testing Methods

• 6520 ‐ AWS D1.1 Structural Welding Code Tests

6600 • 6610 ‐ Steel Construction

BMA Engineering, Inc. – 6000 1

6600 • 6610 Steel Construction• 6620/6630 ‐ NUREG‐0800 / RG 1.94

6500. Construction Testing and gExamination ‐

6510. Nondestructive Testing Methods

• Definition of NDT• Definition of NDT

• Methods of NDTlVisual

Liquid Penetrant

Magnetic

Ultrasonic

Eddy Current

X‐ray

• Usage of NDTBMA Engineering, Inc. – 6000 2

Definition of NDTThe use of noninvasive

Definition of NDTThe use of noninvasive techniques to determine the integrity of a material,the integrity of a material, component or structure

oror quantitatively measuresome characteristic ofsome characteristic ofan object.

i.e. Inspect or measure without doing harm.


What are Some Uses of NDE Methods?What are Some Uses of NDE Methods?

• Flaw Detection and EvaluationFlaw Detection and Evaluation

• Leak Detection

• Location Determination

• Dimensional MeasurementsDimensional Measurements

• Structure and Microstructure Characterization Fluorescent penetrant indication

• Estimation of Mechanical and Physical Properties

• Stress (Strain) and Dynamic Response ( ) y pMeasurements

• Material Sorting and Chemical Composition• Material Sorting and Chemical Composition Determination


When are NDE Methods Used?When are NDE Methods Used?There are NDE application at almost any stage in

T i t i d t d l t

There are NDE application at almost any stage in the production or life cycle of a component

– To assist in product development

– To screen or sort incoming materials

– To monitor, improve or control manufacturing processes

– To verify proper processing such as heat treatingtreating

– To verify proper assembly

T i t f i i d– To inspect for in‐service damage


Nondestructive TestingNondestructive Testing

d• Advantages– Can test in‐service structures– Evaluate surface and internal conditions

– Cost efficient

• Disadvantages– Reliability (measurements are made indirectly)– Qualitative– Requires a skilled professional for interpretation of results


Destructive TestingDestructive Testing

d• Advantages– Reliable (direct measurements)– Quantitative– Directly relates to material properties

• Disadvantages– Cannot test in‐service structures– Requires a model

• Costly & Time Consuming

– Multiple tests are sometimesrequired


Methods of NDTMethods of NDT

Visuall


Six Most Common NDT MethodsSix Most Common NDT Methods• Visual• Liquid Penetrant • Magnetic

Ult i• Ultrasonic• Eddy Current• X-rayX ray


Visual InspectionMost basic and common inspection method

Visual Inspectioninspection method.

Tools include fiberscopes, borescopes magnifyingborescopes, magnifying glasses and mirrors.

Portable video inspection unit with zoom allows

i i f l kinspection of large tanks and vessels, railroad tank

cars, sewer lines.

Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.


Liquid Penetrant Inspection• A liquid with high surface wetting characteristics is

applied to the surface of the part and allowed time to seep into surface breaking defects

q p

seep into surface breaking defects.• The excess liquid is removed from the surface of

the part. • A developer (powder) is applied to pull the

trapped penetrant out the defect and spread it on the surface where it can be seen.the surface where it can be seen.

• Visual inspection is the final step in the process. The penetrant used is often loaded with a fl orescent d e and the inspection is done nderfluorescent dye and the inspection is done under UV light to increase test sensitivity.


Liquid PenetrationLiquid Penetration

Process:

• Clean surfaceClean surface

• Apply liquid penetrant

• Remove excess penetrant

• Apply developerApply developer

• Inspect

• Post‐cleaning


Magnetic Particle InspectionMagnetic Particle InspectionThe part is magnetized. Finely milled iron particles coated with a dyeThe part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity This indication can be visually detected under properover the discontinuity. This indication can be visually detected under proper lighting conditions.

13BMA Engineering, Inc. – 6000

Magnetic ParticleMagnetic ParticleProcess:Process:

• Magnetize surface– Discontinuities create a

magnetic fluxg

• Sprinkle magnetic particles

• Inspect


Magnetic Particle Crack IndicationsMagnetic Particle Crack Indications


Radiographyg p yThe radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that High Electrical Potentialversion of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a

g

Electrons-+come from an X ray generator or a

radioactive source. X-ray Generator or Radioactiveor Radioactive Source Creates

Radiation

Radiation Penetrate

Exposure Recording Device

the Sample


Fil R di hFilm RadiographyThe part is placed between the radiationThe part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker andstop some of the radiation. Thicker and more dense area will stop more of the radiation.

The film darkness (density) will vary with

X-ray filmthe amount of radiation reaching the film through the test object

= less exposurethe test object.

Top view of developed film= more exposure


UltrasonicUltrasonic


Radiographic ImagesRadiographic Images


Eddy Current Testing

C il'

y g

CoilCoil's magnetic field

Eddy current's magnetic field

Eddy currents

g

Conductive

currents

materialBMA Engineering, Inc. – 6000 20

Eddy Current Testingy gEddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness

ll f b d h fmeasurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack.


Ultrasonic Inspection (Pulse‐Echo) High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws.

p

Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect soundshowing the depth of features that reflect sound. f

initial pulse

back surface

crackecho

back surfaceecho

plate

crack

0 2 4 6 8 10

Oscilloscope, or flaw detector screenBMA Engineering, Inc. – 6000 22

Ultrasonic ImagingHi h l ti i b d d b l tti i lHigh resolution images can be produced by plotting signal strength or time-of-flight using a computer-controlled scanning systemscanning system.

Gray scale image produced using Gray scale image produced using theGray scale image produced using the sound reflected from the front surface of the coin

Gray scale image produced using the sound reflected from the back surface of the coin (inspected from “heads” side)BMA Engineering, Inc. – 6000 23

Usage: Inspection of Raw ProductsUsage: Inspection of Raw Products

• Forgings,• Castings,• Extrusions,• etc.


Usage: Inspection Following

• Machining

g p gSecondary Processing

• Machining• Welding• Grinding• Grinding• Heat treating• Plating• Plating• etc.


Usage: Inspection ForUsage: Inspection For In‐Service Damage

• Crackingg• Corrosion• Erosion/Wear• Erosion/Wear

• Heat Damage

• etc.


Usage: Power Plant InspectionUsage: Power Plant InspectionPeriodically, power plants are shutdown for inspectionshutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes t h k f i dto check for corrosion damage.

ProbPipe with damagee

Signals produced by various amounts of

corrosion thinning.


Usage: Storage Tank Inspectiong g pRobotic crawlers use ultrasound to inspect h ll f lthe walls of large above ground tanks for signs of thinning g gdue to corrosion.

Cameras on long garticulating arms are used to inspectto inspect underground storage tanks for damagefor damage.


Usage: Pressure Vessel Inspectiong pThe failure of a pressure vessel can result in the rapid release of a large amount of energy To protectlarge amount of energy. To protect against this dangerous event, the tanks are inspected using

di h d lt i t tiradiography and ultrasonic testing.


Usage: Pipeline InspectionNDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection,

g p p

p ,radiography and electromagnetic testing are some of the NDT methods used.

Remote visual inspectionRemote visual inspection using a robotic crawler.

Magnetic flux leakage inspectionMagnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it i h d l b h t i

Radiography of weld joints.

it is pushed along by whatever is being transported.


6500. Construction Testing and E i iExamination ‐

6510 Nondestructive Testing Methods6510. Nondestructive Testing Methods Objective and Scope Met• Definition of NDT

• Methods of NDTVisual

Liquid Penetrant q

Magnetic

Ultrasonic

Eddy Current

X‐rayX ray

• Usage of NDTBMA Engineering, Inc. – 6000 31

6000 STEEL6000. STEEL6100 &

• 6130 ‐ Design Data, Principles and Tools6100 & 6200 • 6140 ‐ Codes and Standards

• 6200 ‐Material

6300• 6310 ‐Members and Components• 6320 ‐ Connections, Joints and Details

d bl• 6330 ‐ Frames and Assembles

6400• 6410 ‐ AISC Specifications for Structural Joints6420 AISC 303 C d f St d d P ti• 6420 ‐ AISC 303 Code of Standard Practice

• 6430 ‐ AWS D1.1 Structural Welding Code 6500 • 6510 Nondestructive Testing Methods6500 • 6510 ‐ Nondestructive Testing Methods

• 6520 ‐ AWS D1.1 Structural Welding Code Tests

6600 • 6610 ‐ Steel Construction


6600 • 6610 Steel Construction• 6620/6630 ‐ NUREG‐0800 / RG 1.94

6500. Construction Testing and gExamination ‐

6520. AWS D1.1 Structural Welding Code

• Destructive Test for Welds

• Nondestructive Test for Welds

– Dye Penetrate Testing

– Magnetic Particle TestingMagnetic Particle Testing

– Radiographic Testing of Groove Welds in Butt Joints

l f ld– Ultrasonic Testing of Groove Welds

– Acoustic & Pressure Testing


Weldability• Capacity to be welded into a specific structure that has certain

properties and characteristics and will satisfactorily meet service requirementsrequirements

• Thorough knowledge of the phase diagram is essential

• Factors such as strength, toughness, ductility, notch sensitivity, elastic modulus, specific heat, melting point, thermal expansion, surface tension characteristics of the molten metal, corrosion resistance.

Testing Welded JointsTesting Welded Joints

• Quality of the welding joint is established by welded joint

• Each technique has capabilities ,limitations and sensitivity reliability and requirement for special equipment and operator skilland requirement for special equipment and operator skill.


Destructive Techniques

Tension Test :• Longitudinal and transverse tension tests are performed• Stress strain curves are obtained

i hTension‐Shear Test • Specifically prepared to simulate actual welded joints and procedures.• Specimen subjected to tension and shear strength of the weld metal• Specimen subjected to tension and shear strength of the weld metal

Bend test :Bend test :• Determines ductility and strength of welded joints.• The welded specimen is bend around a fixture • The specimens are tested in three‐point transverse bending • These tests help to determine the relative ductility and strength of

the welded jointsthe welded joints


Destructive Techniques

T t f i f t iTwo types of specimens for tension‐shear testing of welded joints.

(a) Wrap‐around bend test method. (b) Th i b di f ld d i(b) Three‐point bending of welded specimens.


Other destructive testingF T h T• Fracture Toughness Test:

• Corrosion and creep tests• Testing of spot weldsg p• Tension‐Hear• Cross‐tension• T i t• Twist• Peel

Non Destructive testingNon‐Destructive testing• Often weld structures need to be tested Non‐Destructively

• Non‐Destructive testing are :

• Visual

• Radiographic• Radiographic

• Magnetic‐particle

• Liquid‐penetrant

• Ultrasonic


Testing of Spot Welds

(a) Tension‐shear test for spot welds. (b) Cross‐Tension test. (c) Twist test. (d) Peel test


TENSILE

Material is sectioned d d d dand edges rounded

of to prevent kicracking.

Punch marks are made to see elongation.


BEND TESTINGBEND TESTING

• Shows

Physical condition of the weld

Determine welds efficiencyDetermine welds efficiency • Tensile strength

• Ductility• Ductility

• Fusion and penetration


BEND TESTBEND TEST

B d h h 180O

• Bend through 180• the specimen should be a minimum of 30mm wide• The fulcrums diameter is 3x thickness of the plate• The bottom rollers have a distance of the diameter of the former + 2.2 times the thickness of the plate

• Upper and lower surfaces ground or filed flat and edges rounded off.

• the tests should be one against the root ‐another against the face ,and in some cases a side bend.


Root bend


FACE BEND


IMPACTIMPACT

• CHARPY AND IZOD

• Gives the toughness and shock loading of theGives the toughness and shock loading of the material and weld at varying temperatures with a notch such as under cutwith a notch such as under cut

• The measurement is the energy required to to break a specimen with a given notch

• 2mm depth at a 45obevel or a “U” notch• 2mm depth at a 45 bevel or a U notch.


TEST MACHINETEST MACHINE


CHARPYCHARPY


HARDNESS TESTS.hi i h l bili h i• This gives the metals ability to show resistance to indentation which show it’s resistance to wear and abrasion.

• The tests are– Brinell– RockwellRockwell– Vickers diamond pyramidScleroscope– Scleroscope


VICKERS HARDNESS


DYE PENETRANTSDYE PENETRANTS

• These are an aid to visual inspection

• Will only find surface defectsy

• Use correct type


DYE PENETRANTS


DYE PENETRANTS

• Types– Red

– Flouresant

• CAUTION– Oil based

– Water washable


Dye Penetrant Test

• Dye penetrant testing locates minute surface cracks and porosity

• Dye types that may be used include:

Color contrast dye ‐ which shows up under ordinary light

Fluorescent dye – which shows up under black light

52

• The dye is normally applied by spraying it directly on the weld

(AISC & NISD 2000)BMA Engineering, Inc. – 6000

MAGNETIC PARTICLE

• Mainly for surface defectsdefects

• Some sub surface d f b f ddefects can be found

• Only ferrous metal


Magnetic Particle Inspection

• Magnetic particle inspection uses powdered magnetic particles to indicate defects inmagnetic materials

• A magnetic field is induced in the part

54

• The magnetic powder is attracted to and outlines cracks within the material


RADIOGRAPHIC

X‐RAY

GAMMA RAY

Electro magnetic gradiation of short duration

Both of these methods are a danger toare a danger to health


Radiographic Inspection

• Radiographic inspection or X ray can also be used to detect flaws inside welds• Radiographic inspection, or X‐ray, can also be used to detect flaws inside welds

• Invisible rays penetrate the metal and reveal flaws on an x‐ray film or fluorescentscreen (above)

56

• This is the most costly of the inspection methods


X‐ RAY


X‐ RAY



X‐RAY VIEWER

Pictures taken are i d iviewed as negatives

will only give flat image not in three dimensional

darkened area must be used for viewingg


ULTRASONIC TESTINGULTRASONIC TESTING

This uses high pitched dsound

The sound will not pass through an air gap so bounces back and is picked up on a receiver

The reader is a oscilloscope


ULTRA SONIC DeviceULTRA SONIC Device



Ultrasonic Inspection

• Ultrasonic inspection can be used to detect flaws inside welds

• High frequency sound waves are directed into the metal with a probe held at a specificangleangle

• The flaws reflect some energy back to the probe

• Flaws show up as indications on a screen (above) and are subject to interpretation by

64

• Flaws show up as indications on a screen (above) and are subject to interpretation byan inspector


ACOUSTICS

Striking with a rounded bjobject

Ringing tone if no defect

Tone changes when object is crackedobject is cracked


APPLICATION OF A LOADAPPLICATION OF A LOAD

• Used to test pressure vessels

• Pipe linesPipe lines

• The item for testing is filled with water or oil it i h i d iis then pressurised using a pump

• A safety valve is set 1.5 to 2 times below the yworking pressure.



PRESSURE TEST


6500. Construction Testing and Examination ‐

6520 AWS D1 1 Structural Welding Code6520. AWS D1.1 Structural Welding CodeObjective and Scope Met• Destructive Test for Welds

• Nondestructive Test for WeldsNondestructive Test for Welds

– Dye Penetrate Testing

M ti P ti l T ti– Magnetic Particle Testing

– Radiographic Testing of Groove Welds in Butt Joints

– Ultrasonic Testing of Groove Welds

– Acoustic & Pressure TestingBMA Engineering, Inc. – 6000 69

steel 6500. construction testin g and examination · • 6430 ‐aws d1.1 structural welding code...

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