Ultrasonic Testing Level 2

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Course Description

LMS course built from NANTIA lesson plan NAUTD012. Delivers the classroom theory content only; classroom practical sessions, homework, and revision blocks are excluded from LMS modules.

Learning Outcomes

• Introduction To Ultrasonic Testing • Codes, Procedures And Documentation • Apply method principles and equipment requirements • Interpret indications and complete compliant documentation

Course Modules

This lesson introduces ultrasonic testing (UT) as a non-destructive testing method, covering its history, principles, applications, advantages, and limitations. It establishes the foundation for Level I and Level II training and defines the roles and responsibilities of certified UT personnel. Understanding these fundamentals is essential before proceeding to detailed technical content. Topics: Introduction to ultrasonic testing, History and Development, Advantages over other methods, Limitations and management. Learning outcomes include: Define ultrasonic testing and explain its place among NDT methods; Describe the history and development of industrial UT; List typical applications of UT across various product forms; List the main advantages of UT compared with other NDT methods.

This lesson provides the essential mathematical foundation required for ultrasonic testing calculations. Understanding these concepts is critical for Level I and Level II personnel to correctly calibrate equipment, calculate beam paths, interpret amplitude relationships, and apply Snell's Law for angle beam testing. Topics: Scientific notation and units, Trigonometry for angle beam, Decibel Calculations, Velocity, Frequency, wavelength. Learning outcomes include: Describe the basic structure of an atom including protons, neutrons, and electrons.; Express numbers using scientific notation and perform basic conversions; Apply the decibel (dB) scale for amplitude and gain comparisons; Calculate amplitude ratios from dB values and vice versa.

This lesson establishes the fundamental concepts of sound and vibration that underpin all ultrasonic testing. Understanding these principles is essential for Level I and Level II personnel to properly select equipment, calibrate instruments, and interpret inspection results. Topics: Vibration and wave motion, Piezoelectric effect, Wavelength and detection. Learning outcomes include: Explain what vibration and sound are at the atomic level; Define and use the terms: cycle, period, frequency, wavelength, and velocity; Distinguish between audible sound and ultrasound; Describe the piezoelectric effect and its application in UT transducers.

This lesson describes the different modes of ultrasonic wave propagation, their characteristics, and their applications in industrial testing. Understanding wave modes is essential for Level I and Level II personnel to select appropriate techniques for various inspection scenarios. Topics: Wave types, Reflection and refraction, Mode conversion. Learning outcomes include: Explain what vibration and sound are at the atomic level; Describe longitudinal (compression) waves and their applications; Describe shear (transverse) waves and their applications; Describe surface (Rayleigh) waves and their applications.

This lesson explains how sound interacts with materials, including attenuation mechanisms, acoustic impedance at interfaces, and the characteristics of the ultrasonic beam. Understanding these concepts is critical for proper calibration, probe selection, and evaluation of results. Topics: Acoustic Impedance, Attenuation Mechanisms, Beam Zones. Learning outcomes include: Describe the construction and components of an industrial X-ray tube.; Define acoustic impedance and calculate reflection co-efficients; Explain attenuation and its causes (absorption, scattering); Describe the effect of frequency and grain size on attenuation.

This lesson covers the operation of ultrasonic test instruments, explaining the function of key controls and the requirements for equipment qualification. Understanding the A-scan presentation and equipment performance is critical for accurate inspections. Topics: A-scan Instrument Operation, Controls, Qualification Requirements. Learning outcomes include: Explain the operation of a pulse-echo A-scan instrument; Identify and describe key instrument controls: gain, range, delay, PRF, reject, gates; Describe the function and application of Distance Amplitude Correction (DAC); Distinguish between pulse-echo and through-transmission systems.

This lesson covers the three primary ways ultrasonic data is displayed: A-scan, B-scan, and C-scan. Personnel performing manual weld inspection, mastering the A-scan presentation is critical. The lesson also introduces specific terminology and interpretation principles for distinguishing relevant from non-relevant indications. Topics: A-scan Presentation, B-scan Presentation, C-scan Presentation, Terminology uesed. Learning outcomes include: Define radiographic sensitivity and explain how it is measured.; Describe A-scan presentation and identify key features (initial pulse, back wall, discontinuity); Describe B-scan presentation and its application in cross-sectional imaging; Describe C-scan presentation and its use in plan-view mapping.

This lesson describes the construction, operation, and types of ultrasonic transducers used in industrial testing. Understanding transducer characteristics is essential for proper equipment selection and calibration to meet code, standard requirements. Topics: Piezoelectric Principles, Transducer Construction, Probe Types, Angle Tolerance. Learning outcomes include: Explain the piezoelectric effect and its role in transducer operation; Identify common piezoelectric materials and their characteristics; Describe basic transducer construction components; Define sensitivity, resolution, and efficiency.

This lesson covers the critical role of couplants and surface preparation in ultrasonic testing. Without adequate coupling and surface condition, sound energy cannot effectively enter the material, rendering the inspection invalid. Specific requirements regarding approved couplants, surface finish and mandatory post-inspection cleaning are emphasized. Topics: Couplant Purpose, Couplant Types, Surface Preparation, Post-inspection Requirements. Learning outcomes include: State the purpose of couplants and their essential properties; Identify common couplants used for contact testing; Select appropriate couplants based on surface roughness, position, and material; State the requirements for surface finish.

This lesson covers the critical roles of calibration and reference standards in ultrasonic testing. Without accurate calibration with suitable reference standards measurements and discontinuity location size and amplitude will not be correct, rendering the inspection invalid. Specific requirements regarding instrument qualification and frequency of calibration checks are discussed. Topics: Calibration Purpose, Reference Blocks, Calibration Requirements, Beam Verification. Learning outcomes include: Explain the purpose of calibration and reference standards in UT; Describe common reference block types (FBH, SDH, area-amplitude, distance-amplitude); Identify the features and applications of the IIW (V1) and V2 calibration blocks; Calibrate an A-scan instrument for range and sensitivity using standard blocks.

This lesson covers the fundamental contact testing methods used. It combines the principles of straight-beam and angle-beam testing, frequency selection, and scanning techniques. Specific emphasis is placed on requirements for scanning overlap and technique application. Topics: Pulse-Echo Contact Testing, Through-Transmission, Scanning Requirements. Learning outcomes include: Explain the principles of pulse-echo and through-transmission contact testing; Select appropriate test frequencies for various materials; Apply straight-beam techniques for thickness measurement and lamination checks; Apply angle-beam techniques for weld inspection.

This lesson covers the principles and applications of immersion ultrasonic testing. Unlike contact testing, immersion methods use a liquid column to couple sound into the part, enabling automated scanning, higher frequencies, and precise beam control. This method is essential for high-volume inspection of pipes, tubes, plates and aerospace components. Topics: Immersion System Components, Focused Transducers, Technique Setup. Learning outcomes include: Describe the components and operation of an immersion testing system; Explain the function of the water path and its effect on the A-scan; Calculate the correct water path distance to avoid "water multiples" interference; Differentiate between focused and unfocused transducers.

This lesson provides comprehensive instruction on the ultrasonic examination of wrought products, including forgings, wrought bars, extruded materials, and plate/sheet. It emphasizes the specific calibration requirements and test procedures particularly the use of flat-bottom hole (FBH) calibration sizes. Understanding product form evaluation is essential for test personnel. Topics: Forgings Inspection, Plate and Sheet, Bar and Rod. Learning outcomes include: Describe the production processes for forgings, wrought bars, and plate; Identify typical discontinuities in wrought products and their origins; Apply appropriate FBH calibration sizes for longitudinal wave testing; Apply shear wave notch calibration.

This lesson covers the specific challenges and techniques associated with ultrasonic testing of tubular products (pipe/tube). It addresses material characteristics like grain structure and attenuation in castings, as well as the geometric considerations and specific scanning requirements for pipe inspection. Topics: Casting Challenges, Casting Techniques, Pipe and Tube. Learning outcomes include: Describe common casting processes and associated discontinuities; Explain the challenges of UT in castings (grain noise, attenuation); Select appropriate probes and frequencies for casting inspection; Describe pipe and tube manufacturing processes.

This lesson provides comprehensive instruction on the ultrasonic examination of weldments, including different joint configurations. It emphasizes the specific calibration requirements and test procedures for different welds. Understanding weld processes and their typical discontinuities is essential for test personnel. Topics: Weld Joint Types, Scanning Procedures. Learning outcomes include: Identify weld joint configurations (butt, corner, tee, fillet); Describe welding processes and their typical discontinuities; Set up calibration for different weld classes; Select appropriate transducer angle based on plate thickness.

This lesson categorizes discontinuities by their origin (inherent, processing, service) and describes their physical characteristics. Understanding the origin and morphology of discontinuities is critical for a Level II inspector to correctly identify, evaluate, and report indications found during ultrasonic testing. Topics: Classification System, Inherent Discontinuities, Processing Discontinuities, Service Discontinuities. Learning outcomes include: Distinguish between a discontinuity and a defect; Classify discontinuities as inherent, processing, or service-induced; Describe inherent discontinuities in ingots (porosity, pipe, inclusions); Describe processing discontinuities in wrought products (laminations, stringers, laps).

This lesson combines the skills of identifying non-relevant indications (geometry, noise) and characterizing relevant discontinuities (cracks, slag, lack of fusion). Personnel must be able to distinguish between benign geometric reflections and rejectable defects using probe manipulation and signal analysis. Topics: Non-Relevant Indications, Probe Manipulation Techniques, Echo Dynamic Patterns. Learning outcomes include: Identify common sources of non-relevant indications (geometry, electrical, surface waves); Explain the principles of discontinuity characterisation (planar vs. volumetric); Apply probe manipulation techniques: orbital, swivel, traverse, and depth scans; Interpret echo dynamic patterns (signal envelope shape).

This lesson covers the quantitative techniques for determining discontinuity dimensions. Sizing is essential for Level II personnel to evaluate indications against acceptance criteria. Understanding when to apply each method and its limitations is critical for accurate reporting. Topics: Sizing Importance, 6 dB Drop Method, 20 dB Drop Method, Method selection. Learning outcomes include: Explain why accurate sizing is important for acceptance decisions; Apply the 6 dB drop method for large discontinuities; Apply the 20 dB drop method for small discontinuities; Apply the last significant echo method.

This lesson provides comprehensive instruction on the ultrasonic inspection of weld-deposited (clad) materials and thickness measurement techniques. It emphasizes the specific requirements for bond testing of cladding, overlays, and buttering, as well as for thickness measurements. These specialized applications are critical for construction and maintenance. Topics: Bond Testing Principles, Clad Requirements, Special Applications. Learning outcomes include: Describe the purpose and principles of bond testing for clad materials; Explain the difference between cladding, overlay, and buttering; Prepare calibration standards for bond testing; Apply continuous and intermittent scanning techniques.

This lesson provides a comprehensive understanding of the regulatory framework governing ultrasonic testing, focusing on codes and standards, written instruction requirements and documentation practices. It emphasizes the specific requirements for procedure development, qualification and record keeping. Topics: Code Framework, Written Instruction Requirements, Record Format, Procedure Qualification. Learning outcomes include: Describe the role of codes, standards, and specifications in UT inspection; Identify major codes and standards applicable to UT (ASME, AWS, ASTM, ISO, AS/NZ); Interpret acceptance criteria from applicable codes; List the record elements required for weld inspection records.

Scored assessment for Ultrasonic Testing Level 2. Covers the LMS lesson content for this course.

Course Approvals & Recognition

Derived from the uploaded NANTIA lesson plan.

Assessment

Scored LMS assessment modules with minimum pass mark of 70.00.

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22 comprehensive modules

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This course includes:

128 hours total; 20 LMS theory lessons + session test + final assessment of content
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Certificate of completion

Online Only (Refresher)

Course Description

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