Development of an ultrasonic inspection system using array transducers

A new ultrasonic inspection system was developed to obtain ultrasonic images of defects. This system adopts an electronic beam control method using array transducers. The beam control modes are a compound scanning mode and a linear scanning mode. Both modes are performed by timing control of ultrasonic wave transmission and reception at each transducer element.In the focal beam, the refraction of the ultrasonic wave at the boundary between water and metal in immersion testing is utilized to improve the lateral resolution of the ultrasonic beam. In steel, the improvement is a maximum of 25% for focal lengths from 5 to 35 mm as compared to lateral resolution not utilizing refraction.This system successfully imaged two side drilled holes in a steel block.     

Models for the computation of ultrasonic fields and their interaction with defects in realistic NDT configurations

Developments in quantitative ultrasonic non-destructive testing (subsequently denoted by NDT) require simulation tools for cost-effective research and engineering works. The present paper reviews the two models developed for several years at the French Atomic Energy Commission (CEA) for this purpose. The first one is dedicated to the computation of the ultrasonic field radiated by arbitrary transducers into pieces under examination. The second simulates actual testing configurations, that is, includes beam/defect interaction as well as the transducer scan over the piece so as to synthesise images typical of those actually measured in NDT experiments. Examples of their application in the context of nuclear engineering are given. They demonstrate the usefulness of such modelling tools in ultrasonic NDT either to study and optimise testing configurations, including transducer design or to help NDT-experts to interpret actual data, possibly by means of model-based automatic data inversion.     

Monitoring the filling level of the rpv using stationary emus-probes

The determination of the filling level and the initiation of growth of bubbles in vessels and pipes containing fluids is an essential component of monitoring during operation.The ultrasonic pulse-echo-method is a measuring procedure suited for this purpose and applicable from the outside. Piezoelectric ultrasonic transducers can be used in principle at a temperature of 300°C, but in practice these transducers are not preferred because of the expense and inconvenience in coupling them to the vessel wall.These problems are solved using lectro agnetic- ltrasonic-(EMUS-)transducers. Due to physical reasons a longitudinal wave is generated in the fluid by the refraction of a shear wave in the vessel-wall. The filling level is measured in a pitch and catch-technique by a mirror reflection of the longitudinal wave at a construction element inside the vessel. This paper reports on laboratory investigations concerning the applicability of the technique and first experiences with an EMUS-prototype system installed in a nuclear power plant.     

The newest two-phase flow control devices in LWR equipment based on ultrasonic and WAT-technology

This paper deals with new acoustic methods of two-phase flow diagnostics used to carry out research in the fields of nuclear power thermophysics and nuclear power plant (NPP) technologies equipment control. All the designs are to be used under extreme conditions, characteristic for water coolant, with temperature up to 350°C and pressure 20 MPa. All the safety and reliability requirements are met. The methods use waveguide ultrasonic transducers for longitudinal and bending waves, made according to specially designed technology (waveguide acoustic transducers — WAT technology). This paper deals with the operating principles of transducers and processing device physical models as well as some results on the practical use of this equipment. The method of acoustic impedance is based on measuring attenuation of a longitudinal or bending ultrasonic wave in a thin-walled tube diameter vapour fraction or the level of the coolant in the tank. The waveguide transducers, designed by the centre, use bending waves of a surface type. They enable us to carry out diagnostics of the liquid film on the inner surface of the tube or discover gas inclusions in the liquid flow. The paper touches upon the method of acoustic emission for measuring moisture content in a steam flow.     

Waveguide ultrasonic liquid level transducer for nuclear power plant steam generator

This paper deals with the development and utilization of a new acoustic method to control the level of the coolant in industrial power-generating equipment. The development research was carried out on the basis of the method of acoustic impedance, based on measuring attenuation of a longitudinal ultrasonic wave in a waveguide sensing element. Ultrasonic attenuation is determined by the degree of submergence of the sensing element in liquid. For this purpose waveguide ultrasonic transducers are used, made with specially designed technology (waveguide acoustic transducers—WAT-technology). The transducers are adapted for operation under extreme conditions in the water coolant with temperatures up to 350°C and pressure up to 20 MPa. The paper tackles: principle of operation of transducers, methods of testing under laboratory conditions, design and results of calibration in a thermophysical test facility, results of the operational trial of the level transducer at the nuclear power plant in Zaporozhye.     

Fracture toughness of narrow-gap welded joints in the nuclear pressure vessel steel 22 NiMoCr 37

The mechanical testing of narrow-gap welded joints in 100 and 200 mm thick sections of the steel 22 NiMoCr 37 has revealed that the weld metal, and not the heat affected zone (HAZ) or the weld metal-parent metal boundary. is the critical region. This modified gas-shielded welding process operates with a very low heat input of the order of 6.500 J cm⁻¹ pass⁻¹ and the combination of small diameter welding wires and high welding speeds contributes to the excellent joint properties in the as-welded condition.To investigate the effect of preheating and post-welding heat treatment on the mechanical properties of narrow-gap welds, tensile, notch impact, flat bend and fracture toughness test specimens were extracted from joints welded with the following conditions: (1) no preheating: no post-weld heat treatment; (2) no preheating: soaking at 300°C: (3) no preheating: stress-relief heat treatment at 600°C; (4) preheating 200–250°C; no post-weld heat treatment; (5) preheating 200–250°C; soaking at 300°C; (6) preheating 200–250°C; stress relief heat treatment at 600°C. Tensile testing at room temperature and at 250°C of round specimens oriented across the seam revealed the ultimate fracture to be always located in the base material remote from the welded zone. Although pores or slag inclusions had an influence on bend-test results of specimens in the as-welded condition, the results generally show failure free bends to 180°C with no evidence of cracking in the HAZ or at the fusion boundary.Using sharp-notched impact bend specimens with the notch located in the centre of the seam as well as in and across the HAZ, absorbed energy-test temperature curves have been determined for each welding condition. In comparison with the base material impact toughness, the weld exhibits superior toughness in the temperature range − 60 – 0°C, but yielded lower values at room temperature. After stress relieving at 600°C, the impact toughness of the weld reduced significantly, apparently due to precipitations occurring in the weld-metal microstructure. Test results from welded specimens with the no notch in the HAZ show this region to have superior notch impact toughness to the base material.Crack opening displacement (COD) specimens 45 × 90 × 380 mm with the fatigue crack located in the weld metal and in the HAZ were tested at 0 and 20°C using both the recommendation in BS DD 19: 1972 as well as acoustic emission measurements for the determination of COD values. For this method of fracture toughness testing it has been shown that the occurrence of a critical event must be clearly defined as corresponding to stable crack growth or alternatively to unstable crack propagation.     

蒸汽发生器换热管电磁超声纵向导波换能器设计与优化

高温气冷堆蒸汽发生器换热管特殊的螺旋结构导致传统外置型电磁超声导波换能器难以进行有效检测。本文针对蒸汽发生器不锈钢换热管的缺陷检测,开发了一种新型内置型电磁超声纵向导波换能器,建立了有限元多物理场耦合模型,研究了换能器铁磁结构的静态磁场分布,并对换能器激励出的纵向导波进行了时域仿真。结果表明：采用挤压聚磁的换能器结构可保证线圈附近的垂直方向磁场远大于水平方向磁场,能高效地在管道内部激励单一模式的纵向导波;优化后的探头可检测直径为5 mm的通孔缺陷和长×宽×深为20 mm×1.5 mm×1.2 mm的环向槽缺陷。因此,新型电磁超声纵向导波换能器可有效激励纵向导波,并有望应用于高温气冷堆蒸汽发生器换热管的在役缺陷检测。     

Investigation of samples taken from Kozloduy unit 2 reactor pressure vessel

Within the framework of the 6 month WANO program, small samples were cut from the inside surface of the Kozloduy NPP unit 2 reactor pressure vessel to assess the actual condition of the pressure vessel material before and after annealing. The actual values of the weld metal characteristics required for estimating radiation-limited lifetime—the ductile-to-brittle transition temperature (DBTT) in the initial state (T_ko) and the phosphorus and copper contents which affect the radiation stability of steel—were not determined during manufacturing. The Kozloduy unit 2 pressure vessel had no surveillance program. Radiation stability was evaluated using dependencies based on analysis results for surveillance samples taken from other VVER-440 reactors. For this reason, the actual pressure vessel characteristics and their changes in the course of reactor operation, as well as comparison of experimental with calculated data were the principle objectives of the study.Instrumented impact tests were carried out on sub-size specimens of base and weld metal. Correlation dependencies were used with standard tests to determine DBTTs for the base and weld metal (in accordance with Russian standards): base metal before annealing 40 °C, after annealing 16 °C; weld metal before annealing 212 °C, after annealing 70 °C.The estimated value of T_ko, for the initial, unirradiated weld metal, was 50 °C. The experimental results were compared with a prediction of the extent of radiation-induced embrittlement of Kozloduy unit 2 pressure vessel materials. It was confirmed that radiation-induced embrittlement of the base metal does not impose any limits on the radiation-limited lifetime of the pressure vessel.The predicted increase in the DBTT of the weld metal as a result of irradiation (about 165 °C) is practically equal to the experimental result (162 °C). However, the value of T_f obtained from tests before annealing (212 °C) is about 40 °C higher that the estimated value, i.e. the calculation does not produce a conservative estimate. This was explained by a low estimate of T_ko (10 °C), which had been calculated using data from chemical analysis of the weld metal, performed by the manufacturer. The investigations on the samples, however, yielded an estimated value of T_ko = 50 °C.The effectiveness of annealing in restoring the mechanical properties of irradiated VVER-440 reactor pressure vessels was confirmed. Recovery annealing lowered the DBTT of the weld metal by 85% or more of its radiation-induced shift.     

Investigation of the ductile fracture properties of type 304 stainless steel plate, welds, and 4-inch pipe

J-integral fracture toughness tests were performed on welded 304 stainless steel 2-inch plate and 4-inch diameter pipe. The 2-inch plate was welded using a hot-wire automatic gas tungsten arc process. This weldment was machined into 1T and 2T compact specimens for single specimen unloading compliance J-integral tests. The specimens were cut to measure the fracure toughness of the base metal, weld metal and the heat affected zone (HAZ). The tests were performed at 550°F, 300°F and room temperature. The results of the J-integral tests indicate that the J_Ic of the base plate ranged from 4400 to 6100 in lbs/in² at 550°F. The J_Ic values for the tests performed at 300°F and room temperature were beyond the measurement capacity of the specimens and appear to indicate that J_Ic was greater than 8000 in lb/in². The J-integral tests performed on the weld metal specimens indicate that the J_Ic values ranged from 930 to 2150 in lbs/in² at 550°F. The J_Ic values of the weld metal specimens tested at 300°F and room temperature were 2300 and 3000 in lbs/in² respectively. One HAZ specimen was tested at 550°F and found to have a J_Ic value of 2980 in lbs/in² which indicates that the HAZ is an average of the base metal and weld metal thoughness. These test results indicate that there is a significant reduction in the initiation fracture toughness as a result of welding.The second phase of this task dealt with the fracture toughness testing of 4-inch diameter 304 stainless steel pipes containing a gas tungsten arc weld. The pipes were tested at 550°F in four point bending. Three tests were performed, two with a through wall flaw growing circumferentially and the third pipe had a part through radial flaw in combination with the circumferential flaw. These tests were performed using unloading compliance and d.c. potential drop crack length estimate methods. The results of these test indicate that the presence of a complex crack (radial and circumferential) reduces in the initiation toughness and the tearing modulus of the pipe material compared to a pipe with only a circumferentially growing crack.     

EPR项目蒸汽发生器下封头与管板环焊缝超声检验技术改进

欧洲先进压水堆（EPR）项目蒸汽发生器下封头和管板环焊缝是一回路的重要边界,焊缝厚度大且焊缝的一侧为球面,制定超声检验工艺时要充分考虑探头声束衰减、探头角度变化等影响,以满足相关检验标准的要求。对RCC-M和EN 1713等标准深入研究后,通过对探头能量和角度变化的分析与模拟演算,可得出:该焊缝超声检验增加60°探头,不仅满足标准要求,而且从检验工艺上大大降低了危险性缺陷漏检的风险。      

High velocity tensile test of austenitic stainless steel at elevated temperatures

This paper presents experimental results concerning the tensile properties of JIS Type SUS 316 stainless steel. The test was carried out at room temperature, 400°C and 550°C at strain rates of 10⁻³ 1/s and 10² 1/s. Base metal, weld joint and weld metal specimens were chosen for the test. The aim of this test is to clarify the effects of strain rate and test temperature on the mechanical properties such as 0.2% yield strength, ultimate tensile strength and elongation of JIS Type SUS 316 stainless steel.     

Development of an ultra sonic phased array system for nondestructive tests of nuclear power plant components

A phased array ultrasonic inspection (PAULI) system is being developed to obtain electronically scanned ultrasonic images of the inside of nuclear power plant components for nondestructive evaluation. The development strategy of PAULI system was the modification of a medical ultrasound imaging system that had 64 individual transceiver channels. Optimization of array transducers has been also pursued based on the systematic investigation of the radiation beam field simulated by the use of the boundary diffraction wave models. 7.5 MHz phased array transducers was, then, fabricated and tested with the carbon steel specimen having side-drilled holes. For the nondestructive tests on power plant component, a sample mockup of turbine blade root with EDM notches was fabricated and the detection capability was demonstrated. The developed system can provide electronically scanned ultrasonic images in real time fashion and greatly enhance the efficiency and reliability in the flaw detection and location in comparison with the classical ultrasonic testing (UT) using A-scan signals. For the flaw classification, the analysis of the electronically scanned ultrasonic images was not sufficient at this moment but analysis of features obtained from A-scan signals of flaws at the various steering angles showed the potential capability.     

Measurement of three-dimensional wave form and interfacial area in an air-water stratified flow

A method of measuring three-dimensional wave forms in a thin liquid film is presented, with experimental data. Water film thicknesses were measured instantaneously across the width direction by a newly developed multi-conductance probe, along nearly horizontal (4.1°) and near vertical (87.0°) flat plates with air - water concurrent stratified flow. The multi-conductance probe was composed of a large flush electrode and eleven wire electrodes, made of fine platinum wire of 0.05 mm diameter to minimize the flow disturbance. The measured data were processed to show the three-dimensional interface shapes, using wave celerity and computer graphics, and the reconstructed wave shape is compared with the real photographic image. The measuring technique is applicable for the shapes of both two and three-dimensional waves. The interfacial areas were also calculated from the measured three-dimensional wave shape. The increase in interfacial area is less than a few percent in a moderate range of the water film flow (500 < Re₁ < 1250).     

Leak rate test of personnel airlock for LWR containment subject to pressures and temperatures beyond design

As part of the U.S. Nuclear Regulatory Commission's (USNRC) Containment Integrity Program, a full-size personnel airlock for a nuclear containment building was subjected to conditions simulating a severe accident.The objective of the test was to characterize the performance of an airlock when subjected to conditions that exceeded design. The gasket tested was a “double dog-ear” configuration made from an elastomer known as EPDM E603. The data obtained from this test will be used by SNL as a benchmark for development of analytical methods.Strain, temperature, displacements, pressure, and leak rate data were measured and recorded from over 330 transducers. The test lasted approximately 60 hours. Data were recorded at regular intervals during heating, pressurization and depressurization.The airlock was originally designed for 340°F and 60 psig. The airlock inner door and bulkhead were exposed to a maximum air temperature of approximately 850°F and a maximum air pressure of 300 psig. Two heating and pressurization cycles were planned; one to heat the air to 400°F and pressurize to 300 psig, and the second to heat to 800°F and pressurize to 300 psig. No significant leakage was recorded during these two cycles. A third cycle was added to the test program. The air temperature was increased to approximately 850°F and held at this temperature for nearly 12 hours. Pressure was increased and the inner door seal failed at a pressure of 150.5 psig. The maximum leak rate recorded past the inner door seal was 706 SCFM. The outer door seal did not fail.     

Prototype EMAT system for tube inspection with guided ultrasonic waves

A prototype system with full computer support for ultrasonic inspection of ferritic tubes using guided waves is described. The ultrasonic waves are launched and received with the aid of electromagnetic acoustic transducers which are layed out as linear phased arrays. The array structure provides a good axial directivity for the transducers so that the probe can be positioned anywhere along the tube length sequentially transmitting ultrasonic pulses in the foreward and backward directions. While the probe is fixed at one axial position during inspection the tube length is measured by the system and flaws are detected from returning ultrasonic echos. Results of the inspection of tubes with natural flaws are given and the wavelength-spectrum of the ultrasonic mode used for the inspection is discussed with respect to flaw depth sizing.     

Low-temperature mechanical properties of superconducting radio frequency cavity materials

Low-temperature mechanical behaviors have been investigated for the constituent materials of superconducting radio frequency cavities. Test materials consist of small grain Nb, single crystal Nb, large grain Nb (bicrystal), Ti45Nb-Nb weld joint (e-beam welded), and Ti-316L bimetal joint (explosion welded). The strength of all test metals displayed strong temperature dependence and the Ti-316L bimetal showed the highest strength and lowest ductility among the test materials. The fracture toughness of the small grain Nb metals decreased with decreasing test temperature and reached the lower shelf values (30-40 MPa √m) at or above 173 K. The Ti45Nb base and Ti45Nb-Nb weld metals showed much higher fracture toughness than the small grain Nb. An extrapolation and comparison with existing data showed that the fracture toughness of the small grain Nb metals at 4 K was expected to be similar to those at 173 and 77 K. The results from optical photography at a low magnification and fractography by a scanning electron microscope were consistent with corresponding mechanical properties.     

核电厂蒸汽发生器锥体焊缝超声波检测技术研究

介绍了核电厂蒸汽发生器（SG）筒体与锥体对接环焊缝超声检查技术。通过声束角度的修正及声程定位法解决了SG锥体斜面扫查时缺陷定位的问题,并推导出缺陷定位的计算公式。对比2种不同声学特性材料的声速变化导致探头角度的变化及信号在深度方向上位置的变化,通过调整声速对发现的信号进行分析,确定该信号由焊缝结构产生,并解决了由于标准试块与参考试块声速的不同,导致缺陷深度方向上定位存在的误差问题。      

Detection of embedded fatigue cracks in Inconel weld overlay and the evaluation of the minimum thickness of the weld overlay using eddy current testing

This study evaluates the applicability of eddy current testing to the detection and sizing of fatigue cracks embedded in Inconel weld overlays. Welded plate specimens, which model head penetration welds and their weld overlays, are fabricated, and fatigue cracks are artificially introduced into the specimens. Eddy current inspections are performed using a uniform eddy current probe driven with 10 kHz, and all of the fatigue cracks are detected with clear signals. Subsequent numerical inversions estimate that the minimum thicknesses of the weld overlays are 1.47, 2.17, and 2.23 mm, whereas true thicknesses revealed through destructive testing are 1.51, 3.25, and 2.10 mm, respectively. Thicknesses are also evaluated using potential drop and ultrasonic testing methods; the results demonstrate that eddy current testing is the most efficient of the three methods.     

Inspection procedure assessment using modelling capabilities

Before carrying out inspections on technical components, criteria have to be met to qualify the inspection procedure. The inspection qualification can be performed by technical justification or performance demonstration. The qualification of non-destructive testing methods can be checked on full scale mock-ups where real or realistic defects are implemented. To minimize costs it will become mandatory to model the inspection procedure. In the case of ultrasonic testing, the modelling includes the ultrasonic probe, the pulse-defect interaction and the probe geometry. The applied modelling code is the elastodynamic finite integration technique (EFIT) which includes mode conversion effects. The results of the code are either wave fields, A-scans at different probe positions or complete r.f. data fields. Examples demonstrate the efficiency in modelling angle beam probes which transmit both pressure, shear and subsurface longitudinal waves. These waves are scattered by horizontal or surface breaking cracks. The modelled r.f. data fields are used within the synthetic aperture focusing approach to predict the ultrasonic image which would be obtained in performing the experiment. In addition it will be shown that the EFIT wave fronts for anisotropic homogeneous media are explicitly related to the group velocity in these media.     

UT digitized data processing for in service inspection of pressurized water reactor vessels

Pressurized reactor vessels in France have been examined from the inside with ultrasonic focused transducers since the very first inspection (Gagnor and Levy, 1993, Proc. 7th Asian-Pacific Conference on Nondestructive Testing, Shangaï, China, 867 pp.). The developments carried out in collaboration with the French Atomic Energy Commission (CEA) to improve the characterization of flaws detected in the body of the vessels or in the nozzles, in the vicinity of the inner or the outer surfaces now have application throughout the CIVAMIS software. The processing modules of CIVAMIS, which are implemented on site since 1994 and used by INTERCONTROLE during the in service inspections of the French PWR vessels, allow full characterization of these specific flaws. The first module is devoted to the characterization of defects located near the outer surface of the vessel or the bottom head welds (OSD module). It includes the modeling software MEPHISTOMIS which predicts the echoes coming from the interaction between the ultrasonic beam and the defects. The second module of CIVAMIS (inner surface defect module called ISD), applied to the analysis of flaws expected near the inner surface of the vessels, has been used during performance demonstration exercises on qualification mock-ups, and also on-site in five expert appraisals since its qualification in 1995. The third module available on the system has been developed and qualified for the analysis of flaws likely to appear near the inner surface of the nozzles. This module, named ‘Undercladding Crack Defect' (UCD) module, provides the operators with a set of pre-defined processing configurations well adapted to the characteristics of the transducers and of the digital acquisitions triggered in this examination case. The last new module (SAFE-END module) has been developed for the evaluation of defects located close to the bimetallic weld in the nozzles. The capacity of CIVAMIS to be adapted to each examination area and the characterization tools included in the different modules are developed in the present paper.