Critical review of selection of NDT methods

Objectives:

To understand the factors affecting the choice of NDT method for an inspection
including the sensitivity of detection and cost implications

Scope:

Items to be considered for the selection of NDT methods (ISO 17635):

- welding processes;
- parent metal, welding consumable and treatment;
- joint type and geometry (CEN/TR 15135);
- component configuration (accessibility, surface condition, etc.);
- quality levels;
- discontinuity, location (internal and surface), type and orientation expected
Reliability of detection
Defect identification
Defect sizing
Personnel factors
Costs

Learning outcomes for IWI-C

1. A thorough understanding of factors affecting the choice of NDT method.
2. Select NDT methods for complex welded constructions.

Learning outcomes for IWI-S

1. Understand the factors affecting the choice of NDT method.
2. Select NDT methods for basic and standard welded constructions.

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 Critical review of selection of NDT methods

1. Introduction

National and International Standard gives guidelines for the choice of non-
destructive testing (NOT) methods for welds and evaluation of the results for quality
control purposes, based on quality requirements, material, weld thickness, welding
process, and extent of testing.

This Standard also specifies general rules and standards to be applied to the
different types of testing, for either the methodology or the acceptance level for
metallic materials.
Acceptance levels cannot be a direct interpretation of the quality levels defined in
some standard; They are linked to the overall quality of the produced batch of
welds.

Requirements for acceptance levels for NDT comply with quality levels stated in ISO
5817 or ISO 10042 or others (moderate, intermediate, stringent) only on a general
basis and not in detail for each indication.

2. Limitations
2.1. Stage of manufacture

This International Standard (ISO 17635) has been prepared for the testing of
completed welds (see 10.3). Testing of parent materials prior to welding or
between welding sequences is not covered by this International Standard. It is,
however, recommended that such testing be performed in accordance with
the reference standards for methods and acceptance levels.
2.2. Extent of testing

The extent of testing shall be given in an application standard or defined in a

specification.
2.3. Materials

This International Standard includes requirements for testing of fusion welds in

the following materials, their alloys and their combinations:
a) steel; b) aluminium; c) copper; d) nickel; e) titanium.
The use of this International Standard for other metallic materials shall be
specified

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3. Personnel qualification

Personnel performing NDT and the evaluation of the results for final acceptance of
welds shall be qualified in accordance with EN 473 or ISO 9712 or equivalent at an
appropriate level in the relevant industrial sector.
4. Testing organization

The testing organization should be organized independently of the production and

its activities should be controlled by a quality assurance system.
5. Documentation
5.1. Documentation prior to testing

Prior to testing, all necessary preliminary information required by the testing

method standards shall be provided.
5.1.1. Written procedures

All testing shall be performed in accordance with written procedures as

required by the standard for the individual testing method or as specified.
5.1.2. Testing plan

It can be necessary to carry out additional testing including more than one
NOT method (other than visual testing) or multiple applications of one method.
In such cases, all methods used shall be defined in a testing plan, which shall
determine the sequence and extent of testing and other relevant aspects for
control of testing and other related activities.
5.2. Documentation after testing
5.2.1. Records of individual testing

All testing shall be recorded as required by the referred standard for the
relevant testing method.
5.2.2. Final report

For each component or group of components, a final report shall contain the
information required by the testing plan and shall as a minimum include:
a) reports required by the standards for the individual testing method;
b) identification of the component;
c) reference to the individual testing records, including status (not inspected,
accepted, rejected);

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 d) identification of welds examined and/or reference to documents
identifying these welds;
e) system for marking of the individual welds and/or reference to documents
indicating the description of system used for the coordination of the testing;
f) identification of personnel and organizations that have performed the
testing;
g) record of deviations from the applied standard regarding testing technique
and acceptance levels

6. Selection of testing method

6.1. General

Determines requirements for selection of testing methods for various types of

materials and types of fusion welds. These methods may be used alone or in
combination in order to give the required result.
Before selecting testing methods and levels, the following items should be
considered:
a) welding processes;
b) parent metal, welding consumable and treatment;
c) joint type and geometry;
d) component configuration (accessibility, surface condition, etc.);
e) quality levels;
f) discontinuity type and orientation expected.

If necessary, testing methods and levels other than those listed in Annex A may
be selected. If an application standard only requires another selection of
methods, testing levels listed in Annex A can be used as appropriate. Such
alterations shall be specified
6.2. Butt- and T -joints with full penetration

The generally accepted methods for testing of welds are given in Table 2 for
surface discontinuities and in Table 3 for internal discontinuities

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 Table 2 - Generally accepted methods for detection of accessible
surface discontinuities for all types of welds, including fillet welds
Materials Testing method

Ferritic steel VT
VT and MT
VT and PT
VT and (ET)

Austenitic steel, VT
aluminium, VT and PT
nickel, VT and (ET)
copper and titanium
NOTE: Methods in parentheses are only applicable with limitations.

Table 3 - Generally accepted methods for detection of internal discontinuities

for butt- and T -joints with full penetration
Nominal thickness of the parent material to be
Materials and type of
welded (t ) mm
joint
t≤8 8 < t ≤ 40 t > 40
Ferritic butt-joints RT or (UT) RT orUT UT or (RT)
Ferritic T -joints (UT) or (RT) (UT or (RT) UT or (RT)
Austenitic butt-joints RT RT or (UT) RT or (UT)
Austenitic T -joints (UT) or (RT) (UT) and/or (RT) (UT) or (RT)
Aluminium butt-joints RT RT or UT RT or UT
Aluminium T -joints (UT) or (RT) UT or (RT) UT or (RT)
Nickel and copper alloy
RT RT or (UT) RT or (UT)
butt-joints
Nickel and copper alloy
(UT) or (RT) (UT) or (RT) (UT) or (RT)
T-joints
Titanium butt-joints RT RT or (UT)
Titanium T -joints (UT) or (RT) UT or (RT)
NOTE: Methods in parentheses are only applicable with limitations

6.3. Butt- and T -joints without full penetration and fillet welds

For partial penetration welds and fillet welds, the unfused root can prevent
satisfactory volumetric testing when using the methods given in Table 3. If
special testing methods have not been agreed, the quality of the weld shall be
assured by control of the welding process.
Techniques other than those given in Tables 2 and 3 can be agreed for
determining the actual degree of penetration and the dimensions of other
discontinuity types.
It is recommended that welds in steel with a minimum yield strength above 280
MPa in austenitic steel, in aluminium, in nickel and copper alloys, and in
titanium be examined using one or more methods in addition to visual testing,
in accordance with Table 2.

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7. Performance of testing
7.1. Determination of standard to be applied

Correlation between the quality levels of ISO 5817 or ISO 10042 and the testing
techniques, testing levels and acceptance levels of NDT standards

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Radioscopic testing with digital image acquisition

Testing with computed radiography using storage phosphor imaging plates

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7.2. Conditions for testing

Prior to the testing, the testing personnel shall have access to all information
relevant to the object, including:
a) necessary preliminary information required by the standard for the individual
testing methods;
b) testing plan, if required;
c) actions to be taken if non-conforming welds are detected;
d) responsibility for coordination of the inspection of parts of subassemblies
manufactured by subcontractors;
e) time and place of testing

7.3. Time of testing

The testing should be carried out after completion of all required heat treatments.
Welds in materials sensitive to hydrogen cracking (e.g. high-strength steels) or
other time-delayed cracking shall not be examined until the minimum time
required after welding is achieved or as defined in a specification.
If defined in a specification, special conditions may call for testing prior to final
heat treatment or lapse of a certain time.
If a surface testing method is to be carried out, it shall be performed prior to any
testing for internal
discontinuities.
If accessible, welded joints should typically be tested and evaluated by visual
testing in accordance with
ISO 17637 or with another appropriate surface testing method, before testing for
internal discontinuities.

7.4. Non-acceptable indications

If non-acceptable indications are detected, the criteria shall be given in the

application standard or defined in a specification.
If non-acceptable discontinuities are repaired, the weld shall normally be
examined at least as required for the original weld.
Where testing of a part in an inspection lot reveals non-acceptable indications,
the following guidelines for the extent of additional testing can be used. The
testing should be performed at welds executed with the same parameters which
might be the main cause of failure, e.g. welder, welding procedure or other
a) two additional samples or areas of the same weld should be given the same
type of testing; and
b) if the samples or areas of the same weld examined as required by a) are
acceptable, the defective item should be repaired or replaced and retested
and all items represented by these two additional samples or areas of the
same weld should be accepted; but

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 c) if any of the samples or areas of the same welds tested as required in a)
reveal a non-acceptable indication, two further samples or areas of the
same defective weld should be tested; and
d) if the samples or areas of the same weld tested as required by c) are
acceptable, the defective item(s) should be repaired or replaced and
retested and all items represented by the additional samples or areas of the
same weld should be accepted; but
e) if any of the samples or areas of the same weld tested as required by c)
reveal a non-acceptable indication, all items represented by the progressive
sampling should be either:
1) repaired or replaced and retested as required; or
2) fully tested and repaired or replaced as necessary, and retested.

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8. Other Reference

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