TEST OPERATIONS PROCEDURE' (0 N..'4SER PERFORMING ...of the test item will show whether there are any symptoms of failure or exten-sions of any discontinuit4.es previously noted. Test

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U.S. ARMY TEST' AND EVALUATION COMMAND FinalTEST OPERATIONS PROCEDURE'______________

(0 "NONDESTRUCTIVE TESTING OF MATERIALS" S. PERFORMING OAG. REPORT N..'4SER

SAUTN(e) I. CONTRACT OR GRANT NUNER(s)

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*IS. SUPPLEMENTARY NOTES

1!QE!VOROS (,Continue on rovers, a ds If necessary and Identify by block number)

Art Met nallurgical .teste erAf ct* ~Inspection .Equipment, FPr- r^4

1 Nmeftructive Tesing of Materials Weldments.* inspection, fiftest ~ -hysical Weeasurement;* >- Liquid Ie ern,~ pection, Radiographic eZnspection;-

Cft;'4tescribes standard techniques and facilities for evaluat'n surface and subsur-face characteristics of metallic/nonmetallic materials. 4jdentifies current non-

i destructive test methods and ultrasonic test techniques applicable to cannonStubes, cast armor plate, welded joints, projectile fuzes, vehicle track shoes,

and other items in which detection of cracks, voids, corrosion, and thicknessvariations is important. gf.c

D I'D' 43 EDiTIoM or t Mov Gs IS OBSOLETE

SECUITY CLASSIFICATION OF ThIS PArE (Wtsn Dot& Entered)

Reproduced FromBest Available Copy

U.S. ARMY TEST AND EVALUATION COMMANDTEST OPERATIONS PROCEDURE

A TE-&P-702-102. *Test Operations Procedure 3-2-807 4 December 1985" ADNo.

NOIDSTRUCTIZVE TESTING OF MATERIALSPi~

Paragraph 1. SCOPE . . . . . . . . . . .. . . . . . . . . . . . . . 12. FACILITIES AND INSTRUMENTATION ............ 23. RQUIRED TEST CONDITIONS .. T.. ..... . 24. TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . 24.1 Magnetic Particle Inspection .... . . . . . . . .. 24.2 Liquid Penetrant Inspection ........... . . . 44.3 Radiographic Inspection . . . . . . . ........ . 54.4 Pulse-Echo Ultrasonic Inspection . . 64.5 Ultrasonic Inspection of Gun Tubes - Normal. . . . . . . 6

Beam Technique4.6 Miscellaneous Nondestructive Test Methods. . . . . . . . 7

Appendix A. ADDITIONAL ULTRASONIC TFST TECHNIQUES. . . . . . . . . . A-IB. REFERENCES . .. . . . . . . . . . . . . . . . . . . . . B-I

1. SCOPE. This TOP describes standard techniques and facilities for conductingnondestructive tests (NUT) of material used in the manufacturing a test item, fordetermining surface/subsurface characteristics of the material without sig-nificantly affecting the item.

Nondestructive tests provide information about structural soundness of material,i.e., they reveal surface/subsurface discontinuities without altering the proper-ties of or damaging the test item. These tests are therefore particularlybeneficial during pre-test inspections. As the test progresses, re-examinationof the test item will show whether there are any symptoms of failure or exten-sions of any discontinuit4.es previously noted. Test item failure by frac ture or

"* deformation may be analyzed in the laboratory as described in TOP 3-2-806* to*determine the nature and cause of failure.

'*This TOP supersedes TOP 3-2-807 dated 11 September 1972 and Change 1 dated 14November 1975. Accession For'

" **Footnote numbers correspond to reference numbers in Appendix B. NTIS GRA&I-" IC TAB 5

* Approved for public 'release; distribution unlimited. Unannounced .lJustificat ion

BYDi stribut I on/

Availability CodesQUA.Y Avail and/or

INSPEOTED Dist Special

9

4 December 1985 TOP 3-2-807

2. FACILITIES AND INSTRUMENTATION.

2.1 Facilities.

REQUIRE(ENT

Magnetic particles dry powder; powder suspended inliquid; fluorescent powder suspendedin liquid

X-ray machineFilm and contact screens

2.2 Instrumentation.PERMISSIBLE ERROR

*ITEM OF MEASUREMENT

Penetrameters Xt applicableUltrasonic unitTransducers

3. REQUIRED TEST CONDITIONS. Nondestructive examination of test item materialshould be conducted in at least five situations:

a. To determine whether the test item is safe to test (e.g., armed fuze)

b. When there are recurring component failures or suspected deficiencies instructural integrity

c. When required by the test plan

d. For conformance with drawings and specification nondestructive test

requirements for acceptance tests

e. When directed by higher headquarters

4. TEST PROCEDURES.

4.1 Maxnetic Particle Inspection. This is performed to inspect material that canbe magnetized fe: surface/subsurface dialcontinuities such as cracks, seams,porosity, and inclusions. This technique is limited to magnetic materials and isused for such items as gun tubes and associated components, vehicle track shoes,

*and high-speed rotors.

4.1.1 Method. The detection capability of this method depends on the intensityof the magnetizing current, the size of the magnetic particles, the size andorientation of discontinuities, and the permeability and retentivity of thematerial. Micro-cracks can be detected by this method under ideal conditions.Magnetic particle inspection is accomplished by creating an induced magneticfield in the part, applying the magnetic particles while current is floving,visually inspecting the part, and de-magnetizing the part once the inspection iscompleta. Perform inspection as follows:

2

* 4 December 1985 TOP 3-2-807

* .a. Induce a magnetic field in the material to be inspected by eitherdirect magnetization or by placing the part in a magnetic field. Exercisecaution wher using direct magnetization on finished and hardened surfaces toprevent arcing or overheating at the contact points. This could result in hardspots or micro-cracks. Perform the magnetization of parts such as gun tubes todetect discontinuities perpendicular to the longitudinal and circumferentialdirections as follows:

(1) Longitudinal. Place the central conductor through the bore of thetube. A current passing through the central conductor sets up a magnetic fieldperpendicular to the direction of the current. This reveals longitudinal defectsin the tube that are at right angles to the lines of force.

(2) Circumferential. Place the tube in a coil. Current passing through

the coil induces a magnetic field whose lints of force are perpendicular to cir-cumferential discontinuities. Consult applicable drawings or specifications forproper amperage or ampere turns. (Too low a current will not reveal significantdiscontinuities, while too high a current will reveal spurious patterns, e.g.,flow lines.)

'b, Apply the inspection medium of fine magnetic particles, in one of thefollowing forms, to the magnetized surface while the magnetized current is momen-tarily flowing:

(1) Dry powder(2) Powder suspended in liquid(3) Fluorescent powder suspended in liquid

(The magnetic particles collect at the magnetic leakage field created by thediscontinuity.)

c. Interpret the collected magnetic particles (referred to as indications)by visual examination under near ultraviolet or black light (approximately 3,650

) if a fluorescent powder suspension is used. Standard incandescentillumination is used for nonfluorescent powders.

d. Demagnetize the test item by alternately reversing the current direc-tion and decreasing the amperage.

4.1.2 Data Reeuired. Obtain the following:

a. Description of the item inspectedb. Configuration, size, and location of defects detectedc. Amount and length of time of current application during magnetization;

for gun tubes, the number of turns in the coil

4.1.3 Analytical Plan. Compare surface/subsurface discontinuities with available

eval!ation criteria, e.g., drawing requirement, ASTM specification, militaryspecification, SAE-ASHE boiler code. If no acceptance/iejection criteria areavailable, continued inspection during testing will reveal extension of anypreviously noted defects. If no discontinuities are recorded during the initialinspection, interim inspections can be used as a tool to bracket the appearance

" .: of discontinuities found during subsequent testing.

3

h


4.2 Liguid Pentrant Inspection. This is used to inspect either magnetic ornonmagnetic material. Typically, this method is used for inspecting universaljoints, machine Sun parts, and aluminum mortar baseplates for discontinuitiesopen to the surface of the test item.

% -4.2.1 Method. The detection capability of this method depenls on the penetrantN type, the surface condition, and the discontinuity dimension open to the part.

surface. Pinhole porosity and micro-cracking can be detected by this method.t This method remains essentially same, regardless what penetrant is used. The

basic steps include surface cleaning, application of the penetrant, removal ofexcess penetrant, application of the developer, inspection and interpretation.Perform'the inspection as follows:

a. Cleaning. The item to be examined must be cleaned since anything thathinders the penetrant from entering the defects will defeat the inspection:

(1) Use a brush, buffer, etc., to remove scale and rust.

(2) Use a solvent to remove grease or oil deposits, e.g., vapordegrease, swab solvent on part.

(3) To avoid masking indications, do not sandblast 'or shotblast.

b. Penetrant application.

(1) Swab the item with or izuerse it in penetrant; several types an beused: color-contrast or dyed kerosene, water wash fluorescent, post-emulsifiedfluorescent, or water base fluorescent penetrant.

(2) Dwell time, i.e., the time the liquid penetrant remains on the sur-face of the part, depends on the material, type of defect, and penetrant.Typical dwell times range between 2 and 30 minutes.

c. Removing excess penetrant. Excess penetrant must be removed so that nobackground penetrant remains to interfere with the defect indications; however,the cleaning operation must not remove the penetrant from the defects. Remove byusing one of the following methods:

(1), Wipe the surface using a lint-free rag moistened with a suitablesolvent.

(2) Spray solvent on the surface.

(3) Water wash.

(4) Dip in hydrophilic emulsifier (for post-emulsified penetrants).

(5) Immerse in agitated water bath; use coarse spray at 207-345 kPa(30-50 lb/in.2); water temperature 160 to 43' C (600 to 110 ° F). Avoidoverwashing.

(5) Once the excess penetrant is removed, allow the item to dry.

4


(6) Hot air dryer temperatures are usually maintained between 79 ° and107 C (1750 and 225' F). Part temperature should not exceed 52" C (125' F) andshould be rmoved from beat when part surface is dry to touch. Excessive dryertime can cause damage to part and evaporation of penetrant.

d. Application of developer. The developer consists of a uniform thicknessof fine powder applied over the surface of the part being inspected, Four typesof developers are currently used: dry powder, water suspensions of powder, solu-tions in water, and solvent suspensions of powder. The uniform coating ofdeveloper acts as a blotter, absorbing penetrant from the defects and increasingvisibility. Developers can be applied by brushing, spraying, or imersing.

e. Inspection and interpretation. Color contrast or dyed kerosenepenetrants should be inspected under a standard incandescent "white" light.Fluorescent penetrants should be inspected using near ultraviolet or black light(approximately 3,650 I). Highest illumination is obtainable by using a mercuryvapor spot bulb with a blacklight filter. Both vetbench and portable models areavailable. Once inspection and interpretation are completed, discontinuiLiesshould be visibly marked, and the developer should be removed.

4.2.2 .ata Reuired. Obtain t., fo! lowing:

a. Description of the ii;- ' ected

b. Configuration, size, an' *ocation of defects detected

c. Type penetrant used

4.2.3 Analytical Plan. Follow instructions specified in 4.1.3.

4.3 Radiographic Inspection. This is performed to inspect the interior condi-tions of metallic and nonmetallic items such as artillery projectile fuzes, ex-plosive fillers, cast armor plate, an. welded joints. This method employspenetrating radiation such as X-rays produced by machine or gamma rays emitted byradioactive isotope. Radiographic inspection is routinely used for detectingcracks, voids, hot tears, and separations, variations in material density, andshrink inclusions and corrosion. It is also used for examining the arrangerntof interior components of items such as fuzes. Steel (or equivalent thicknessesof other materials) as thick as 25 cm (10 in.) can be inspected using 4000- and11,000-kv X-ray machine. Sensitivity and exposure time vary, depending onmaterial density, thickness, geometry of piece, and proper radiographictechnique.

4.3.1 Method. Measure detection capability and technique sensitivity by usingpenet-ameters. Normal requirements are 2% of the thickness for detail and con-trast sensitivity. Under ideal conditions, sensitivities of 1/Z of thicknesscan be achieved.

a. Select an X-ray voltage, amperage, and exposure time to conform to thenature of the material to be examined. A long focal distance should be selectedto minimize the distortion effect of focal spot size and distance of the defectto the film.

5


b. Select suitable film and contact screens., The finer grained filmsrender better detail but require increased exposure. The use of chemicalintensifying screens should be avoided, when possible, since they reduce detailquality.

c. Place appropriate penetrameters, usually 2% of the thickness of thetest item, up%.n the corresponding part thickness so that they vill be between itand the radiation source. Place the film.behind the test object. Lead numbersor other means of identification should be used to identify the item and as anorientation device.

d. After exposure is completed, process the film ascording to the manufac-turer's instructions. The processed film shows intensity variations as visibleimages.

e. When the inspection must be conducted in a remote location (i.e., nowater or electricity available) or when the area to be inspected is inaccessibleto the X-ray beam, gamma radiography should be employed. Gamma ray sourcesusually produce lower image contrast than X-rays, thus permitting a larger rangecf metal thickness to be recorded du-ing one exposure. Lowered image contrastmay be objectionable because it results in less than optimum capability to detectdefects. Care must be taken in selecting gamia ray sources to ensure that thedesired sensitivity can be achieved. Cobalt 60, Iridium 192, and Cesium 137 are '

examples of gamma ray sources useful for radiography. Permission must be ob-tained from NRC to acquire, store, and use gmua sources for radiography.

4.3.2 Data Reuired. Obtain the following:

a. Description of the item inspected

b. X-ray voltage, amperage, ,-xposure time, focal distance, type of film,and screen type and thickness for each exposure

c. The nature and location of flaws in the interior of the test item as

interpreted from the images on the film

4.3.3 Analytical Plan. Check subsurface and internal discontinuities (e.g.,cavitation in ammunition, porosity in castings, cracks in veldments, shrink andporosity in castings, improper assembly or internal failures in fuzes and recoilmechanisms) for safety, or compare them with specifications for the test item.Internal discontinuities may also be correlated to their effects upon test itemfunctioning or performance.

4.4 Pulse-Echo Ultrasonic Insvection. This method is used to examine subsurfacearear of test items for discontinuitiei or to measure thickness. Examples ofitems inspected by this method include high-speed impellers, cannon tubes,breechblocks, and weldmeuts. The technique is best suited for lamellar discon-tiruities oriented parallel to the surface or normal to the direction of soundpropagation.

4.4.1 Method. This method can be used to detect discontinuities such as cracks,laminations, and unbonded areas, variations in microstructure or thickness, andlack of fusion. The detection capability depends on the part geometry and thelocation, size, and orientation of the discontinuity. The pulse-echo ultrasonic

6


inspection can be thought of as complementary to radiographic inspection. Testas follows:

a. Obtain a time/distance calibration of the ultrasonic unit, using thesearch unit transducer selected for the thickness and type of material to be in-spected. Use a calibration standard of known dimensions made of the samematerial as the test item for this.

b. Apply a suitable couplant (usually oil) for contact inspection, and scanthe surface of the test item with the transdu, er.

c. Note the location of the reflected pulse between the initial pulse sig-nal on the cathode ray tube (CRT) and back surface reflection signal from thetest item. This reflected pulse will locate the material discontinuity relativeto the front and rear faces of the material being examined.

4.4.2 Data .uired. Obtain the following:

a. Description of the item being tested

b. Data necessary to document calibration of the ultrasonic test unit,such as search unit type and frequency, type of calibration block, etc.

c. Test item thickness and location and extent of defects detected by in-terpretation of the CRT image

4.4.3 Analytical Plan. Compare internal discontinuities in the test item withguidelines. If no guidelines are available, continue investigation during test-ing to reveal extensions of any previourly noted discontinuities or time whenthey occur.

4.5 Ultrasonic Inspection of Gun Tubes -- Normal Beam Technicue. This method isused to locate and measure the depth of longitudinal cracks in gun tubes. Thisis a special application of the pulse-echo technique in which the crack directionis parallel to the direction of sound propagation instead of perpendicular as isnormally the case. Ultrasonic inspection can be used for metals ranging from0.01 cm thick to 1 meter, with sensitivity varying with the thickness,Transducers of lower frequencies are required for the greater thicknesses butresult in loss of discontinuity detection capability.

4.5.1 method.

a. Calibrate the ultrasonic inspection unit by using simulated areaamplitude and distance amplitude reference standards made of the same material asthe gun tube to be inspected. The reflected area amplitude and distanceamplitude signals are displayed as vertical deflections along the horizontal timebase line of the CRT.

b. Use a miniature search unit, couplant, and search unit holding deviceto preclude search unit wobble and to maintain the correct probe-to-test-itemalignment.

c. With the sensitivity of the unit tuned to the highest level possible,scan the outer surface of the gun tube with a normal beam probe to detect

7


internal discontinuities. Extreme care is required to note the mall signalindications.

d. Supplement the pulse-echo ultrasonic technique with the transmit-and-receive method in order to detect discontinuities near the surface but hidden bythe near-zone interference.

e. In many sun tubes, large hoops obscure areas likely to contain discon-tinuities. To facilitate inspection with ultrasonics, remove such barriers.When this is not feasible, supplement ultrasonic testing with magnetic particleinspection.

4.5.2 Data Reauir2d. Obtain the following:

a. Description of the item being inspected

b. For discontinuities (other than radial cracks) larger than the beamspread: depth, length, direction, and location

c. For discontinuities contained within the beam spread: location andequivalent flaw diameters

4.5.3 Analytical Plan. Compare internal discontinuities in the gun tube withavailable guidelines. If none is available, continue investigation during test-iug to reveal extensions of any previously noted discontinuities or time whenthey occur.

4.6 Miscellaneous Nondestructive Test Methods. The NDT methods described inparagraphs 4.1 through 4.5 are those most frequently used by Army test agencies.There are many others, however, used in industry and Government for special ap-plications. These are all contained in Table 1 for quick reference and com-parison. Some of these are not available at each TECOM proving ground.Specialized ultrasonic techniques occasionally used at proving grounds aredescribed in Appendix A.

8


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iRecmended changes of this publication should be forvardediIto Commander, U.S. Army Test and Evaluation Command, ATTN: IIAMSTE-TC-N, Aberdeen Proving Ground, MD 21005-5055. Tech-IInical information can be obtained from the preparing ijactivity: Commander, U.S. Army Combat Systems Test ActivitylIATTI: STECS-AD-A, Aberdeen Proving Ground, MD 21005-5059.1lAdditional copies are available from the Defense Technicallllnformation Center, Cameron Station, Alexandria, VAt122304-6145. This documient is identified by the accession IIntmber (AD No.) iprinted on the first Page. I

J

15


APPENDIX A

ADDITIONAL ULTRASONIC TEST TECHNIQUES

The following is a general description of ultrasonic test techniques other thanthe contact reflection and contact normal beam techniques discussed in paragraphs4.4 and 4.5.

1. Transmission Technique. When both sides of the test item are accessible, thecontact transmission technique can be used to inspect the test item. This methodemploys a transmitting crystal on one surface and a receiving crystal directlyopposite on the other surface. The time delay between transmission and receptionof pulse is calibrated in terms of the material thickness.

2. Res2ance Technique. Ultrasonic resonance is used for measuring materialthickness when access is possible from one or both sides. By varying thewavelength of the incident ultrasonic beam, one can establish points of materialresonance. This facilitates thickness determination, since resonance occurswhenever the thickness of the specimen is equal to an integral number of halfwevelengths of the ultrasonic wave.

a. Resonance instruments with direct-reading thickness scales will yield ac-curate results only when calibrated with test blocks of known thickness and alloycomposition. Two or more test blocks within the range of the direct readingscale can be used for instrument calibration. The length and width of the testblock should be at least twice and preferably five times the thickness. In caseof thick test blocks, slots should be cut into the edges to avoid wave inter-ference from side reflections.

b. Calibration is accomplished using tuned circuits and a matched set oftransducers, coaxial cables, oscillator, and thickness reading screen. Onlymatched sets of components should be used for calibration and thickness measure-ments. The minimum thickness of resonance instruments is about 0.013 cm in steeland aluminum and 0.01 cm in brass and copper. The maximum thickness that can bemeasured depends upon inspection frequency and instrument design; it normallyvaries between 7.6 and 30 cm (3 and 12 in.).

3. Immersion Testinf. Ultrasonic immersion testing is especially useful for in-specting weldments and parts with rough surfaces. The test item must be com-pletely immersed in water or other suitable couplant. The transducer is then lo-cated some distance away from the part surface. Either the angle or normal beaminspection mode can be Used in this technique depending on the geometry of thetest item and suspected defect orientation. Irregularly shaped parts such as as-symetrical forgings can be given a complete inspection, including fillet areas.This type of part cannot be inspected by the contact method by practical means.Two advantages of immersion testing (namely, c-scan mapping and speed of inspec-tion) can be achieved during the inspection of symmetrical parts.

A-1

SI


APPENDIX B

REFERENCES

* 1. TOP 3-2-806, Hetalluriical and Mechanical Tests of Materials 20 December1983.

2. AST-E94-77, "Recommended Practice for Radiographic Inspection".

3. ASTM-E709-80, "Magnetic Particle Inspection".

4. ASTM-EI14-75, "Ultrasonic Pulse Echo Straight Beam Testing by the ContactMethod".

5. AST*-E142-77, "Controlling Quality of Radiographic Testing".

6. ASTM-E165-80, "Liquid Penetrant Inspection Method".

7. AMCP 702-10, Quality Assurance, Guidance to Nondestructive TestingTechniques, April 1970.

8. Handbook: QE-702-4E, Quality Assurance Provisions for NondestructiveTesting, Chapters 6,7,8,10, March 1983.9. AMCP 702-11, Qnality Assurance, Guide to Specifying NDT in Materiel Life

Cycle Applications, November 1970.

10. T.O. 33B-1-1, Nondestructive Inspection Methods.

11. ASTM-E186, "Reference Radiographs for Heavy Walled 51-to-114-um12-to-4-1/2-in. Steel Castings".

12. ASTM-E164, "Practice for Ultrasonic Contact Examination of Weldments".

13. ASTM-E125, "Reference Photographs for Magnetic Particle Indications onFerrous Castings".

14. ASTM*-E797, "Practice for Measuring Thickness by Manual Ultrasonic Pulse EchoContact Method".

15. AST*-ES04, "Practice for the Calibration of the Ultrasonic Test System byV, Extrapolation between Flat Bottom Hole Sizes".

16. ASTM-E689, "Reference Radiographs for Ductile Iron Castings".

17. ATM-E592, E213, E214, E242, E268, E269, E270, E280, E317, E433, E446, E500,

E586, E587, E588, and others as applicable.

.18. McMaster, R.C., "Nondestructive Testing Handbook", Society for NondestructiveTesting.

19. Drabo, M.J., and Edwards, D.W,, "Special Study to Establish a CorrelationBetween Known Discontinuities in Gun Tubes snd Standard Ultrasonics ReferenceBlocks", APG Report APG-T-3762, February 1971.


20. Huddleston, R.L., "Special Study for Verification of Normal Beam Techniquefor Ultrasonic Inspection of CannonTubes", APG Report APG-MT-3950, November1971.

21. Drabo, N.J., "Special Study to Improve Fluorescent Penetrant InspectionMethods", APG Report APG-MT-42% , June 1973.

22. Finfera, J.P., "Materials Testing Technology Test of a Magnetic RecordingBorescope", AG Report APG-MT-3725, January 1971.

23. Finfera, J.P., "Special Study Evaluation of Hall Probe Magnetic RecordingBorescope for Nondestructive Inspection of Cannon, Tubes", ANG Report APG-MT-4577,February 1975.

24. Williams, R.S., and Romerberg, V.0., "Principles of Metallography",I McGraw-Hill, 1948.

25. Finfera, J.P., "Special Study of X-ray Pole Figure to Determine PreferredGrain Orientation in a Polycrystalline Aggregate", AP Report APG-MT-4290, June1973.

26. Huddleston, R.L., "Special Study to Summarize Metallurgical Examinations ofIn-Bore Prematures", APG Report APG-MT-4531, October 1974.

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Documents

TEST OPERATIONS PROCEDURE' (0 N..'4SER PERFORMING ...of the test item will show whether there are any symptoms of failure or exten-sions of any discontinuit4.es previously noted. Test