Ultrasonic simulation studies for sizing of planar flaws in thick carbon steel welds

Ultrasonic non-destructive testing typically involves detection of flaws that may affect the integrity of component under test. Once detected, the flaw is sized for its critical dimensions and its nature. The detection of flaw in the component by ultrasonic test is based on the principle of echo or reflection. Once the echo from a flaw is received, there are several approaches for analyzing the signal so that more and accurate information is obtained on the size of the flaw and its nature. The 6dB drop method is commonly used for sizing of flaws. This technique is based on determining the end points where the ultrasonic signal amplitude from the flaw drops to half of the peak amplitude. Though this method works well for large flaws whose size is larger than the beam width, it has a tendency to oversize the flaw which is smaller than the beam dimensions. In addition to beam divergence, flaw sizing also depends upon the orientation of the flaw with respect to incident sound beam. The paper describes the results of simulation studies on ultrasonic response from planar flaws of various orientations, their imaging and the methodology to be adopted for their accurate depth sizing. The paper also describes the experimental results to validate the flaw sizing approach