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ABSTRACT
1 Introduction
Specification of codes and regulations for non-destructive inspection of austenitic
stainless steel welds with ultrasound, e. g. [1, 2], needs considering that:
ultrasound velocity and polarisation are direction dependent due to the
macroscopic elastic anisotropy of the weld metal, e. g. [3],
ultrasonic scattering is occurring due to the polycrystalline character of the
columnar grained weld metal, the ultrasound scattering being also direction
dependent because of the anisotropy.
In contrast to ultrasound velocity and polarisation, ultrasound scattering mechanisms
in polycrystalline anisotropic media are less understood.
Specimens containing test welds and weld metal samples have been prepared for:
experimental validation through attenuation measurement,
microstructure characterisation of austenitic stainless steel weld metal,
capability assessment of ultrasonic testing for austenitic welds.
The specimen manufacture is detailed in the mid-term assessment report of this SMT
project [4].
As a first cross check, perfect agreement with the results for the single plate has
been obtained, if more layers but with equal crystallographic rotation angles are
taken into account.
A second approach was undertaken: by solution of the stochastic wave equation the
scattering (attenuation) coefficient in polycrystalline austenitic weld metal, which
consists of cubic columnar grains, is achieved as the imaginary part of the
propagation constant [6].
the hydrophone is Fourier transformed into the angular frequency domain. The
transformation yields a complex pressure field at discrete angular frequencies.
Then, the complex pressure field is further decomposed into a two-dimensional
spectrum of plane waves in the k-space domain. The amplitudes of the planewave components of the incident and transmitted pressure field are corrected for
the appropriate angular dependent acoustical impedance mismatches at the
water/solid/water interfaces. Finally, the energy of the incident and transmitted
field is evaluated by integrating the intensities of each component over the whole
k-space.
The following has been shown:
The longitudinal wave attenuation versus the texture direction obtained with the
simulated finite beam approach exhibits a local maximum near the grain growth
direction. The relevance of this exercise relies on the fact that the raw data
acquired by the hydrophone exhibits, after a conventional signal processing, the
same odd behaviour versus the texture direction as it was found in previous
investigations.
The longitudinal wave attenuation versus the texture direction obtained with the
energy approach does not display any relative maximum in the proximity of the
grain-growth direction. Following this approach the theoretical predictions of the
longitudinal wave attenuation versus the texture direction are recovered at least in
a qualitative sense.
The main conclusions of this part of the work are:
The energy approach suggests that interference effect between the plane-wave
components of the beam as well as inappropriate corrections for the acoustical
impedance mismatches are responsible for the observed maximum in previous
investigations.
For the first time, the predictions of the theoretical models of ultrasonic wave
propagation in polycrystalline materials with texture have been validated applying
a novel experimental approach.
In order to prepare attenuation measurements of transverse waves with electrodynamical transducers, preliminary attenuation measurements of longitudinal waves
have been performed on the specimens of Group 1, Group 3 and Group 4.
Attenuation of Group 4 weld metal (Duplex) is the same as in ferritic weld metal.
Especially, no dependency of attenuation on the beam-to-grain angle could be found.
This is not the case with both other weld metal groups. An example of measured
longitudinal wave attenuation in Group 1 material shows the relation between the
beam and the grain angle.
A set of 12 specimens cut in different depths from a X 6 Cr Ni 18 10 austenitic weld
for repeated sound field measurements under varying conditions has been
manufactured and used for sound field measurements.
The first series of tests carried out on 6 specimens with the weld fusion face parallel
to the coupling surfaces, both with the electrodynamic and the piezoelectric probe,
show that the beam skewing, beam spreading, and distortion is low, as the shape of
the sound field patterns are revealing. They are circular as obtained with a test block
of ferritic steel.
From the preliminary investigations no hints on a scattering effect of the longitudinal
waves have been obtained yet in the area of the weld material. This could be due to
the size of the piezoelectric transducer and would probably be visible with the use of
the electrodynamic sensors where it now may be obstructed by noise especially for
the thick specimens.
In conclusion of this project part, the attenuation of the weld metal of the four steel
groups has been measured, revealing qualitatively fairly good agreement with the
theoretical predictions, which are calculated with the plane wave.
However, corrections for impedance mismatch and phase differences due to beam
divergence are necessary to get quantitative agreement with the theoretical
predictions. The attenuation of the Duplex steel is as low as the attenuation of ferritic
weld metal and no direction dependence could be observed.
the 3 mm side drilled holes, which were introduced in the weld, the base metal
and in the along the weld-base metal interface, are essential for conducting an
efficient ultrasonic inspection of austenitic welds.
8 Examination procedure
A proposal for a standard on ultrasonic examination of welds in austenitic steels has
been already submitted to the European standardisation bodies CEN [1].
Requirements for the examination technique to minimise ultrasonic back scattering
have been defined:
wave modes to be used,
probe techniques (piezoelectric transducer or EMAT, single, twin, or multitransducer),
frequency,
beam angles and beam scanning directions.
9 Conclusions
The intention of this project is to improve examination procedures for austenitic
stainless steel welds by better understanding of ultrasound scattering in the columnar
grained austenitic stainless steel weld metal. Consequently, the following research
works were performed:
theoretical modelling of ultrasound columnar grain boundary scattering and
validation of models with experiment,
metallurgical and acoustic microscopy investigations of columnar grain structure,
ultrasonic inspection capability on welded austenitic test pieces.
Four groups of materials comprising the full scale of industrially relevant stainless
steels were investigated: austenitic stainless Cr-Ni steels, fully austenitic stainless
steels with increased Ni-content, Nickel-base-alloys, and Duplex steels (Ferriticaustenitic steels).
Theoretical concepts have been followed to model the ultrasonic amplitude, which is
attenuated due to grain boundary scattering. Other inhomogeneities in the weld
structure, e. g. different degrees of segregations within grains and beads, or grain
boundary precipitations, only seem to play a minor role in causing ultrasound
scattering.
Validation of the theoretical models is by measuring attenuation of the ultrasonic
beam in austenitic weld metal plates. A novel approach called Scanning Technique
has been developed to measure the longitudinal wave attenuation versus the texture
direction. By applying this technique, the results show that the longitudinal wave
attenuation does not display any relative maximum in the proximity of the graingrowth direction. For the first time, the predictions of the theoretical models of
ultrasonic wave propagation in polycrystalline materials with texture have been
validated applying this novel experimental approach.
Test specimens with reference reflectors and realistic defects in the weld area, were
prepared and inspected using various ultrasonic testing techniques. The Round
Robin Test results demonstrate the importance of the transducer frequency on the
weld inspectability.
A proposal for a standard on ultrasonic examination of welds in austenitic steels has
been already submitted to the European standardisation bodies CEN and is under
review in the corresponding Technical Committee.
Acknowledgement
This research project, referenced as Project No. SMT4-CT95-2012, is funded by the
Commission of the European Communities under the Standards, Measurements &
Testing Programme, 1996 - 1999, DG XII, Brussels.
References
[1] CEN/TC 121/SC 5B/WG 2 N 102, WI 121188, Non-destructive examination of
welds. Ultrasonic methods. Examination of welds in austenitic steels, March
1998, Secretariat DS, Kollegievej 6, DK-2920 Charlottenlund
[2] Handbook on the ultrasonic examination of austenitic and dissimilar welds,
Working Group `Ultrasonic Testing of Austenitic Welds' of Subcommission VC
`Ultrasonically Biased Weld Inspection Topics' of Commission V `Quality Control and
Quality Assurance of Welded Products' of the International Institute of Welding (IIW),
Draft of the second edition, March 1998
[3] Neumann, E.; Hirsekorn, S.; Huebschen, G.; Just, T.; Schmid, R.: Ultrasonic
Testing of Austenitic Claddings, Dissimilar Metal Welds, and Austenitic Welds,
Theory - Practice Regulations, Renningen - Malmsheim, Expert-Verlag, 1995,
ISBN 3-8169-1078-5
[4] Neumann, E., Pers-Anderson, E. B., Bith, M., Fraser, F. E., Jeppesen, L.: Midterm assessment report of the SMT4-CT95-2012 project Effect of ultrasonic
scattering on inspection of austenitic welds.
[5] Nayfeh, A. N.: Wave propagation in layered anisotropic media, Elsevier Science
B. V., Amsterdam, 1995, ISBN 0-444-89018-1
[6] Munikoti, V. K.; Neumann, E.: Extension of Ahmed & Thompson theory to general
elastic plane quasi-wave propagation in textured polycrystalline material, Review of
Progress in Quantitative Nondestructive Evaluation 17 (1997), 1657-1664, Edt. D. O.
Thompson, D. E. Chimenti, ISBN 0-306-45901-9
[7] Seldis, T.; Pecorari, C.; Bith, M.: Measurement of longitudinal wave attenuation
in austenitic steels, 1st International Conference on NDE in Relation to Structural
Integrity for Nuclear and Pressurised Components, 20-22 October, 1998, Amsterdam