NEW SOUTH WALES TECHNICAL AND FURTHER EDUCATION COMMISSION

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1 NEW SOUTH WALES TECHNICAL AND FURTHER EDUCATION COMMISSION ULTRASONIC TESTING NSW Module Number: Implementation Date: 1142A 01-Jan-1995 National Module Code: EA613 MANUFACTURING AND ENGINEERING MECHANICAL & MATERIALS PROGRAM AREA

2 1. MODULE DETAILS: 1.1 Module Name: Ultrasonic Testing 1.2 Nominal Student Hours: 108 hours This module is equivalent to three standard modules and so will normally require 108 hours for delivery. 1.3 Module Codes: NSW Module Number: National Module Code: 1142A EA Field of Education Code: Materials Engineering 1.5 Copyright Information: (c)commonwealth of Australia 1.6 Licensing and Franchise Arrangements: Licensing and franchising arrangements are to be negotiated with the Australian National Training Authority (ANTA) (03) MODULE PURPOSE To enable students to describe the principles, procedures and applications of ultrasonic testing, 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. This module meets the training requirements for Level 2 qualification in ultrasonic testing under AS "Non-destructive Testing Qualifications and Certification of Personnel General Engineering" and AS "Non-Destructive Testing Qualification and Registration of Personnel Aerospace". 3. PREREQUISITES Nil Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 2

3 4. RELATIONSHIP TO COMPETENCY STANDARDS: This module fully addresses the National Metal and Engineering Competency Standards Unit MEM24.8AA Perform ultrasonic testing,in developing generic skills. To achieve full workplace competence for Competency Standards Unit MEM24.8AA, the learner will need to have undertaken relevant on the job skill practice. This can be as either part of the module learning process, after completion of the module or through previous experience. 5. CONTENT: 1. Properties and behaviour of ultrasound. fundamental properties - frequency, velocity, wavelength, amplitude. continuous and pulsed waves. modes. velocity/mode/material relationship. acoustic impedance pressure, energy intensity. interaction of wavefronts. inverse square law. decibel 2. 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. 3. Characteristics of ultrasound in materials. near and far fields. focusing of ultrasound. secondary waves. attenuation 4. 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 5. Detection of ultrasound. continuous and pulsed signals. effect of path length. time/distance relationship 6. 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 suppression Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 3

4 . saturation & amplifier threshold. digital equipment 7. 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 8. Probes. construction and operation of single and twin crystal normal and angle probes, both fixed and adjustable. focused transducers 9. Calibration. Types and uses AS 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 10. Variables. instrument performance. variations in test materials. effect of beam incidence. effect of surface condition and curvature. resolving power/frequency/damping/energy relativity. 11. Contact and immersion test methods. setting test sensitivity. surface preparation. couplants. flat and contoured probes. identification of irrelevant signals. effect of angle of incidence. surface wave method. tandem techniques. water requirements for immersion testing. interface triggering. through transmission immersion testing 12. Instrumental test methods. automatic recording and computer interfacing. digital and analog presentations. computer interfacing and special recording methods 13. Test applications. thickness testing. weld testing. plate testing. detection of cracks at rivet holes. castings, ferrous and non-ferrous. forging. austenitic materials. assemblies. bonded materials. non-metallic materials including plastics, ceramics, and concrete. rail testing Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 4

5 14. Flaw size evaluation. material factors. Rayleigh criterion. DGS curves. 6dB and 20dB drop methods. three dimensional evaluation 15. Interpretation and evaluation. defect types as related to product. codes and standards 16. Recording and reporting. job records. routine reports. codes and standards 17. Written procedures. presentation. use of standards 6. ASSESSMENT STRATEGY The assessment of this module is holistic in nature and requires the demonstration of the knowledge and skills identified in the module content, and the integration of that knowledge with those skills. To be successful in this module, the student must show evidence of achievement of the module purpose. Additionally, the module is graded and so allows the student to demonstrate greater depth and/or breadth of achievement. The assessment scheme is designed to assess essential knowledge and skills in a variety of ways throughout the module's assessment events. 7. LEARNING OUTCOME DETAILS 7.1 Learning Outcome 1: Describe the fundamental properties and behaviour of ultrasound. Assessment criteria 1.1 Describe the fundamental properties of ultrasound and to determine wavelength/ velocity/frequency data for specific situations. 1.2 Describe the different type so 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 Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 5

6 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. Conditions Students will carry out practical work to reinforce the theory. Assessment method Written test to include multi-choice, short answer and essay questions to cover the theory and practical work. Students will also be assessed on the reports submitted on practical assignments. 7.2 Learning Outcome 2: Describe how ultrasonic waves are generated and detected. Assessment criteria 2.1 Describe the identify the components in the construction of a piezzo-electric ultrasonic transducer. 2.2 Explain the operation of a piezzo electric transducer. Conditions Students will be provided with a range of transducers to examine and use. Assessment method Written test to include multi-choice, short answer and essay questions to cover the theory and practical work. Students will also be assessed on the reports submitted on practical assignments. 7.3 Learning Outcome 3: Describe the function of principal modules of different types of ultrasonic flaw detectors. Assessment criteria 3.1 Describe the functions of the various parts and demonstrate how 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 in ultrasonic testing and demonstrate their applications and their advantages and limitations. 3.3 Describe different couplants, including immersion techniques, used for ultrasonic testing and demonstrate their advantages and Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 6

7 limitations. Conditions Students will have access to different ultrasonic test equipment and to A/V facilitate to view different types of ultrasonic presentations. Assessment method Written test to include multi-choice, short answer and essay questions to cover the theory and practical work. Students will also be assessed on the reports submitted on practical assignments. 7.4 Learning Outcome 4: Calibrate ultrasonic test equipment using standard calibration blocks, and determine system parameters using standard blocks. Assessment criteria 4.1 Demonstrate competency in calibrating ultrasonic flaw detection 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. Conditions Students will have access to different ultrasonic test equipment and standard blocks. Assessment method Written test to include multi-choice, short answer and essay questions to cover the theory and practical work. Students will also be assessed on their demonstrated competencies and on reports submitted on practical assignments. 7.5 Learning Outcome 5: Demonstrate 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 these procedures. 5.4 Interpret ultrasonic test results and Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 7

8 identify or describe the types of flaws detected. 5.5 Prepare clear and unambiguous reports on ultrasonic inspection of various materials in accordance with the requirements of national and international codes and standards. 5.6 Prepare procedure instructions for the ultrasonic inspection of selected materials or components. Conditions Students will have access to a range of ultrasonic test equipment, calibration blocks, standards and suitable test specimens. Assessment method Written test to include multi-choice, short answer and essay questions to cover the theory and practical work. Students will also be assessed on the reports submitted on practical assignments. 8. DELIVERY DELIVERY STRATEGY This module may be delivered either in an off-the -job environment or, where suitable resources are available, in an on-the-job environment. It would be expected that all learners should be exposed to the testing that make up the module even in those cases where the learning outcome requires only that they should be able to verify, understand, assess results and recommend action. RESOURCE REQUIREMENTS Suitable physical resources should be available to carry out each of the tests that are included in the module. OCCUPATIONAL HEALTH AND SAFETY REQUIREMENTS Learners should be made aware of the occupational health and safety implications at all times. Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 8

9 B. TAFE NSW implementation requirements 1. Module(s) replaced by this module: 2.1 TAFE Advanced Standings: Arrangements Target Modules Source Modules No : A Ultrasonic Testing 1172J Ultrasonic Method Start : End : Sponsor: Manufacturing and Engineering 3. Standard Exemptions: EA613 A student is eligible for an exemption in this TAFE NSW module if they provide documentary evidence from a Recognised Training Organisation that they have successfully completed the national module/s with the specified national module code/s. 4. Recognition of Prior Learning: Students who have completed formal training or who have relevant life/work experience and consider they are able to meet the module purpose, may seek recognition of their prior learning. Applicants will be required to present evidence of their relevant skills and knowledge in an interview with specialist staff. This evidence will be validated either through satisfactory supporting documentation or support from a recognised industry or workplace representative or a challenge test, or other appropriate assessment practice. 5. Module Included in the following Courses: Number Ver Course Name Sponsor Manufacturing Technology Manufacturing and Engineering Manufacturing Technology Manufacturing and Engineering Manufacturing Systems Manufacturing and Engineering Manufacturing Systems Manufacturing and Engineering Quality Systems Manufacturing and Engineering Quality Systems Manufacturing and Engineering Metal and Engineering Competency Standards Manufacturing and Engineering Units Engineering - Higher Engineering Trade Manufacturing and Engineering Non-Destructive Testing Manufacturing and Engineering Non-Destructive Testing Manufacturing and Engineering Engineering - Higher Engineering Trade Manufacturing and Engineering Mechanical Engineering Manufacturing and Engineering Naval Architecture Manufacturing and Engineering Mechanical Engineering Manufacturing and Engineering Naval Architecture Manufacturing and Engineering Mechanical Technology Manufacturing and Engineering Naval Architecture Technology Manufacturing and Engineering Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 9

10 B. TAFE NSW implementation requirements Engineering Manufacturing and Engineering Engineering Manufacturing and Engineering Non-Destructive Testing Manufacturing and Engineering Materials Technology Manufacturing and Engineering Manufacturing Technology Manufacturing and Engineering Manufacturing Technology Manufacturing and Engineering Manufacturing Systems Manufacturing and Engineering Manufacturing Systems Manufacturing and Engineering Quality Systems Manufacturing and Engineering Quality Systems Manufacturing and Engineering Materials Technology Manufacturing and Engineering Materials Technology Manufacturing and Engineering Engineering - Technician Manufacturing and Engineering Metal & Engineering Competency Standard Manufacturing and Engineering Units Mechatronics Manufacturing and Engineering Non-Destructive Testing Manufacturing and Engineering Non-Destructive Testing Manufacturing and Engineering Engineering - Higher Engineering Trade Manufacturing and Engineering (N.D.T.) Engineering (Non-Destructive Testing) Manufacturing and Engineering Manufacturing Technology Manufacturing and Engineering Mechanical and Manufacturing Engineering Manufacturing and Engineering Mechanical and Manufacturing Engineering Manufacturing and Engineering Manufacturing Technology Manufacturing and Engineering Engineering Manufacturing and Engineering Selected Study Selected Study Program Sponsor Manufacturing and Engineering - Mechanical & Materials (c) 2002 The State of NSW, 10