AINDTUT2

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1. Module Details

Module name ULTRASONIC TESTINGNominal duration 3 modules

It is anticipated that a learner holding the prescribed entry level

skills will achieve the module purpose in 110 to 120 hours

Module Codes EA613

Discipline Code Non-destructive testing (Code to be allocated)

2. Module Purpose To provide students with knowledge of the principles, proceduresand applications of ultrasonic testing, to develop the competency to

undertake ultrasonic testing of materials in accordance with the

requirements of national and international codes and specifications,and to interpret the results of such tests

3. Prerequisites Nil

4. Relationship to

competency

standards

This module meets the training requirements for Level 2

qualification in ultrasonic testing under AS3998-1992 "Non-

destructive Testing - Qualification and Certification of Personnel -

General Engineering" and AS-3669-1989 "Non-Destructive Testing

- Qualification and Registration of Personnel - Aerospace".

Currently no national competency standards have been established

at national level. However, the learning outcomes in this courserelate to ASF level 5-6.

5. Content Properties and behaviour of ultrasoundFundamental properties - frequency, velocity, wavelength,

amplitude

Continuous and pulsed waves

Modes

Velocity/mode/material relationships

Acoustic impedance, pressure, energy, intensity

Interaction of wavefronts

Inverse square lawDecibel

Behaviour of ultrasound at interfaces

Principles of reflection

Refraction of ultrasound

Mode conversions

Calculation of incident and refracted angles

Critical angles

Mechanisms for detecting defects

Characteristics of ultrasound in materials

Near and far fields

Focussing of ultrasound

Secondary wavesAttenuation

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Generation of ultrasound

Types of transducers

Properties of piezzo electric materials

Energy losses in various media

Determination of near and far fields, divergence and beam spread

Detection of ultrasound

Continuous and pulsed signals

Effect of path length

Time/distance relationships

The flaw detector

Function of pulse generator, transmitter, receiver/ amplifier, time

base, CRT

Function of the various controls

Distance/amplitude effects and correction, AGC, gating, interface

triggering

Types of display

Requirements of codes and standards.

Linearity, effect of suppressionSaturation & amplifier threshold

Digital equipment

Basic test methods

Pulse-echo and transmission methods

Resonance methods

A, B, C, and P scan.

Types of coupling

Single, dual and two-probe methods

Probes

Construction and operation of single and twin crystal normal and

angle probes, both fixed and adjustable.

Focussed transducersCalibration

Types and uses of AS 2083 calibration blocks, and

distance/amplitude and area/amplitude blocks and steel balls for

immersion testing in accordance with appropriate standards

Determination of probe characteristics, measurement of acoustic

velocities

Plotting beam profiles by contact & immersion methods

Variables

Instrument performance

Variations in test materials

Effect of beam incidence

Effect of surface condition and curvature.Resolving power/frequency/damping/energy relativity

Contact and immersion test methods

Setting test sensitivity

Surface preparation

Couplants

Flat and contoured probes

Identification of irrelevant signalsTAFE METAL AND ENGINEERING NATIONAL CURRICULUM PROJECT Page 2 of 8 ACTRAC PRODUCTS

Module: EA613 - Ultrasonic Testing - May, 1998

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Effect of angle of incidence

Surface wave method

Tandem techniques

Water requirements for immersion testing

Interface triggering

Through transmission immersion testing

Instrumental test methods

Automatic recording and computer interfacing

Digital & analog presentations

Computer interfacing and special recording methods

Test applications

Thickness testing

Weld testing

Plate testing

Detection of cracks at rivet holes

Castings, ferrous and non-ferrous

Forgings

Austenitic materialsAssemblies

Bonded materials

Non-metallic materials including plastics, ceramics, and concrete

Rail testing

Flaw size evaluation

Material factors

Rayleigh criterion

DGS curves

6dB and 20dB drop methods

Last significant echo

Tip diffraction

Three dimensional evaluationInterpretation and evaluation

Defect types as related to product

Codes and standards

Recording and reporting

Job records.

Routine reports.

Codes and standards

Written procedures

Presentation

Use of standards

6. Assessment

strategy

Competency based assessment applies. Assessment should be

carried out by gathering evidence using a variety of methods or

instruments that have validity according to the learning being

assessed.

TAFE METAL AND ENGINEERING NATIONAL CURRICULUM PROJECT Page 3 of 8 ACTRAC PRODUCTS


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Assessment method Multiple choice and short answer questions.Written assignments and demonstrated competence through

assigned tasks.

Final assessment will be by a written examination and practical

examination as required by AS3998 for Level 2 Certification.

Conditions of assessment Assessment will be conducted by suitably qualified assessors, asrequired by AS3998. The candidate will have access to any

equipment, materials and documentation as required for the

assessment.

7. Learning

outcome details

On completion of this module, the learner will be able to

8. Learning outcome

1

Describe the properties and behaviour of ultrasound

Assessment criteria 1.1 Describe the fundamental properties of ultrasound, and todetermine wavelength/velocity/frequency data for specific

situations.

1.2 Describe the different types of waves and how they are

transmitted through materials.

1.3 Describe how ultrasound behaves as it travels through a

medium, and the changes produced when it strikes, or passes

through, an interface and how it interacts with a defect.

1.4 Calculate critical angles and describe the significance of

this property.

1.5 Describe the factors that control the near and far fields in

ultrasonic testing and determine these values for particular

situations.

1.6 Describe the factors that affect attenuation of ultrasonic

energy as it passes through a medium, including the generation of

secondary waves at interfaces, and measure this attenuation.

Learning outcome 2 Describe how ultrasonic waves are generated and detected.

Assessment criteria 2.1 Describe and identify the components in the construction ofa piezo-electric ultrasonic transducer.

2.2 Explain the operation of a piezo electric transducer.



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Learning outcome 3 Describe the function of the principal modules of different types ofultrasonic flaw detectors.

Assessment criteria 3.1 Describe the function of the various parts and demonstratehow the various controls can be used to calibrate and operate the

equipment for optimum performance.

3.2 Describe the various presentations, including automatic

recording systems, used in ultrasonic testing and demonstrate their

applications and their advantages and limitations.

3.3 Describe the different couplants, including immersion

techniques, used for ultrasonic testing and demonstrate their

advantages and limitations

Learning outcome 4 Calibrate ultrasonic test equipment using standard calibrationblocks, and determine system parameters using standard blocks.

Assessment criteria 4.1 Demonstrate competency in calibrating ultrasonic flawdetection and thickness testing equipment using standard calibration

blocks and in accordance with national standards.

4.2 Demonstrate competency in determining system

parameters, such as beam spread, using standard blocks.

4.3 Demonstrate how changing system variables can affect

system parameters using standard blocks.

Learning outcome 5Demonstrate proficiency in carrying out ultrasonic testing for flaw

detection and thickness testing of various materials in the wrought,

cast and/or welded condition.

Assessment criteria 5.1 Describe the various applications of ultrasonic testing.

5.2 Demonstrate competency in setting up, calibrating and

testing various materials.

5.3 Describe the various methods for sizing of flaws by

ultrasonic methods and demonstrate proficiency in theseprocedures.

5.4 Interpret ultrasonic test results and identify or describe the

types of flaws detected.

5.5 Prepare clear and unambiguous reports on ultrasonic

ins ection of various materials in accordance with the re uirements



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of national and international codes and standards.

5.6 Prepare procedure instructions for the ultrasonic inspection

of selected materials or components.

7. Delivery of themodule

This module may be taught by active participation, illustration,demonstration and description. This module is practical in nature

and theoretically integrated to complement the acquisition of

practical skills.

Delivery strategy This module will generally be taught and assessed off-the-job.

The module has a high practical content. Theory and practice will

be taught concurrently. There will be a range of learning activities

including modified lectures, practical work and project work.

Resource requirements Human resources

trainer/teacher/mentorPhysical resources

appropriately equipped training room

relevant equipment and information

legislative and regulatory documents

Major texts and references RECOMMENDED TEXT

Ultrasonic Testing for Technicians, J.C. Drury, Unit Inspection

Company, 1983.

Ultrasonic Testing - P.A. Sheedy (In preparation - Published by

Technical Secretarial Service)

PRACTICAL TEXT

Practical Ultrasonics - P.A. Sheedy - Technical Secretarial Service,

PO Box 188, Forestville NSW, 2087

RECOMMENDED TEXT FOR BACKGROUND READING

Ultrasonic Testing, Neasbey & Cheema, NSW TAFECOM

REFERENCES

Non-Destructive Testing Handbook, 2nd Edition, Vol 7. Ultrasonic

Testing. ASNT. 1991



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Ultrasonic Testing Classroom Training Handbook - ASNT.

Ultrasonic Testing of Materials, J & H. Krautkramer. Springer-

Verlag, 1990.

Ultrasonics, Fundamentals, Technology, Applications, D.

Ensminger. Marcel Dekker Inc. 1988.

Procedures and Recommendations for Ultrasonic Testing of Butt

Welds. Welding Institute, 1989.

STANDARDS

AS 1065 Non-Destructive Testing - Ultrasonic Testing of

Carbon and Low Alloy Steel Forgings.

AS 1710 Non-Destructive Testing - Ultrasonic Testing ofCarbon and Low Alloy Steel Plate - Test Method and Quality

Classification.

AS 1929 Non-Destructive Testing - Glossary of Terms.

AS 2083 Calibration Blocks and Their Methods of Use in

Ultrasonic Testing.


Fusion Welded Joints in Ferritic Steel (under review as DR 92178).

AS 2452 Non-Destructive Testing - Determination ofThickness - Use of Ultrasonic Testing.


Steel Castings and Classification of Quality.

AS 2824 Non-Destructive Testing - Ultrasonic Methods -

Evaluation and Quality Classification of Metal Bearing Bonds.

Occupational health and

safety requirements

Learners and/or employees undertaking this module should have

demonstrated competencies as defined in the Metal & Engineering

Industry Standards Unit No 1.2F - Apply principles of OH&S in the

work environment. This would apply in the classroom, practical

room or workplace.



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AINDTUT2