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IS 4260:2004

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Indian Standard
RECOMMENDED PRACTICE FOR ULTRASONIC
TESTING OF BUTT WELDS IN FERRITIC STEEL

FOR INTERNAL USE AT THIS LOCATION ONLY

LICENSED TO LANCO INFRATECH LIMITED, UDUOG VIHAR, GURGAON,
( Third Revision)

ICS 77.040.20

0 BIS 2004

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

November 2004 Price Group 4

Non-destructive Testing Sectional Committee, MTD 21

FOREWORD
This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Non-destructive Testing Sectional Committee had been approved by the Metallurgical Engineering Division
Council.
This standard was first published in 1967 and subsequently revised in 1975 and 1986. This has now been
revised again in the light of experience gained and the latest developments in ultrasonic testing of welds. The
requirements for distance amplitude correction examination procedure and periodic calibration have been
modified.
This standard is intended to be a guide for method of ultrasonic testing of welds by direct contact pulse echo
reflection method.

FOR INTERNAL USE AT THIS LOCATION ONLY

LICENSED TO LANCO INFRATECH LIMITED, UDUOG VIHAR, GURGAON,
For general technique relating to ultrasonic testing, reference may be made to IS 3664:1981 ‘Code of practice
for ultrasonic pulse echo testing by contact and immersion methods @st revision).
This standard gives detailed procedure of examination of butt welds in ferritic steel.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2:1960 ‘Rules for rounding off numerical value (revised)’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
 IS 4260:2004

Indian Standard
RECOMMENDED PRACTICE FOR ULTRASONIC
TESTING OF BUTT WELDS IN FERRITIC STEEL
( Third Revision)
1 SCOPE 3 TERMINOLOGY

1.1 This standard prescribes a method for ultrasonic For the purpose of this standard, the definitions given
testing and inspection of welds by direct contact pulse in IS 2417 shall apply.
echo reflection method. This method is applicable to
4 EQUIPMENT
material thickness over 5 mm.
4.1 The ultrasonic apparatus shall be capable of
1.2 These requirements are established for detection,
producing, receiving and displaying high frequency

FOR INTERNAL USE AT THIS LOCATION ONLY

LICENSED TO LANCO INFRATECH LIMITED, UDUOG VIHAR, GURGAON,
location and evaluation of reflection within the weld,
acoustic pulses over the nominal range of 1 to 5 MHL
heat affected zone and adjacent material. The
and shall be of pulse echo reflection type. Other
examination classification are:
frequencies may be used, if equal to better sensitivity
a) Welds in ferritic product forms in wrought and can be demonstrated.
cast materials, other than pipes; and
4.2 The ultrasonic instruments and probes shall be
b) Ferritic welds in ferritic pipes. capable of being used without difficulty in the
temperature range of – 10 to + 50°C.
1.3 This standard covers technique to be employed at
normal temperature. Care shall be taken to ensure 4.3 The ‘ultrasonic instrument shall provide linear
that the temperature of test piece is not above the vertical presentation within + 5 percent of fill screen
temperature for which the probe is designated. height from 20 to 80 percent of the full screen height.
The screen height linearity shall be measured and
2 REFERENCES recorded in accordance with IS 12666.
The following standards contain provisions, which 4.4 The ultrasonic apparatus shall have an amplitude
through reference in this text, constitute provisions of control, accurate over its useful range of* 20 percent
this standard. At the time of publication, the editions of the nominal amplitude ratio to allow measurement
indicated were valid. All standards are subject to of indications beyond the linear range of the vertical
revision, and parties to agreements based on this display on the screen. The amplitude control linearity
standard are encouraged to investigate the possibility shall be measured as described in IS 12666.
of applying the most recent editions of the standards
indicated below 4.5 The ultrasonic apparatus shall be adjusted for sweep
range and calibrated prior to inspection as described in
1S No. Title IS 12666.
2417:2003 Glossary of terms relating to
5 TEST PROCEDURES
ultrasonic testing ( first
revision) 5.1 Basic Calibration Block
3664:1981 Code of practice for ultrasonic ‘5.1.1 The basic calibration reflectors shall be used to
pulse echo testing by contact and establish a primary reference response of the
immersion method (jirst
‘equipment. The basic calibration reflectors may be
revision)
located either in the finished component material
8791:1971 Code of practice for ultrasonic provided the same shall not affect the serviceability
flaw detection of ferritic steel or in a basic calibration block.
forging
5.1.2 The material from which the block is fabricated
12666:1988 Method for performance shall be of the same product form, that is, plate, forging
assessment of ultrasonic flaw bar, tubes, etc, and material specification, having
detection equipment similar acoustic characteristics of the finished
13805:2004 General standard for component. The thickness of basic calibration block
qualification and certification ~iidl be related to finished component thickness as
of non-destructive testing shown in Table 1 corresponding to Fig. 1. When two
j~ersonnel or more base material thicknesses are involved, the

1
IS 4260:2004

calibration block thicknesses shall be determinedly curvature of the surface. Whenever such probes are
average thickness of weld. The finish on the surface used for examination, calibration also has to be done
of the block shall be representative of the surface with the same type.
finishes on the tinished components.
6.3 The nominal frequency shall be in the range of 2
5.1.3 For contact examination the temperature to 5 MHz. Unless variables such as production material
difference between the examination and the calibration and grain structure require the use of other frequencies
block surfaces shall be within 14°C. Calibration and to assure adequate penetration or better resolution.
sensitivity setting shall be performed under temperature
conditions similar to those used in the test or appropriate 7 COUPLANT
compensations for angle and sensitivity changes shall A satisfactory couplant, liquid or paste, having good
be made. wetting properties to permit the transmission of
6 PROBE mechanical vibrations between the probe and material
under test shall be used. Oil, glycerine, water greases;
6.1 A shear wave probe which produces an angle of silicone and white lead paste are among the more
45° to 70° in the examination medium is normally used. commonly used couplants.
The selection of the beam angle is dependent on the
thickness and geometry of the weld. The recommended 8 SURFACE PREPARATION

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beam angles for different thicknesses of material are
8.1 The base metal on each side of the weld shall be
shown below:
free of weld spatter, surface irregularities or foreign
Thickness Beam Angle Inside matter that might interface with the examination.
mm the Medium
degree 8.2 The weld ripples or weld surface irregularities
shall be removed by any suitable mechanical means
up to 30 70
to such a degree that the resulting ultrasonic
Over 30 to 50 60 examination from any remaining irregularities cannot
Over 50 45 mask any objectionable defects. The finished surface
of the reinforcement should merge smoothly into the
6.2 Probes with a beam angle less than 45° and more surface of the adjacent base material.
than 70° may be used, if the geometry of the weld is
more adoptable to the chosen beam angle. Shoes may 8.3 The volume of the base material through which
be found necessary to fit into the probes to suit the the sound will travel in angle beam examination shall

Table 1 Thickness of Basic Calibration Block

(Clause 5.1.2)

SI Weld Thickness, t Basic Calibration Hole Diameter

No. mm Block Thickness, T mm

(i) (2) (3) (4)

i) 25.4 or less 190rt 2:4

ii) Over 25.4 upto51 380rt 3.2

iii) Over 51 up to 102 76 Or t 4.8

iv) Over 102upto 151 1270rt 6.4

v) Over 152 up to 203 1760rt 8.0

vi) Over 203 up to 254 228 or t 9.6

vii) Over 254 (see Notes)

NOTES

1 For such increase in thickness of 51 mm or fraction thereof, the hole diameter shall increase 1.6 mm.

2 Hole shall be drilled and reamed to a minimum of 38 mm essentially parallel to the examination surface.

3 Curved surfaces: For curved surfaces, two curved blocks, one for each representative curvature or two sets of calibration
reflectors oriented 90” from each other shall be used.

4 Notches maybe provided as required.

5 Tolerances for hole diameter shall be+ 0.8 mm.

6 Tolerance on notch depth shall be + 10 and – 20 percent.

7 Tolerance on hole location through thickness shall be + 3.2 mm.

2
 IS 4260:2004

Notch Size — Width= 3.2 mm or 6.4 mm, Depth= 2 percent of T’ or 1.0 mm,
whichever is greater into the base metal, Length=51 mm

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FIG.1 BASICCALIBRATIONBLOCK

be completely scanned with a straight beam search 9.2 The angle beam probe shall be directed towards
unit usually of 2 MHz frequency to detect and record the basic calibration reflectors in the calibration block.
reflections which might affect interpretation of angle The centre-line of the probe shall not point towards
beam results. This is not intended as an acceptance/ the corners of the hole. The sound beam shall be
rejection examination. oriented perpendicular to the axis of the side drilled
holes. The probe is positioned for maximum response
8.4 Dual probes may be employed in plates of from the side-drilled hole that gives the highest
thickness 5 mm to 12 mm for detection of reflectors. amplitude. The sensitivity controls are adjusted to
9 DISTANCE AMPLITUDE CORRECTION provide an 80 percent ( + 5 percent of full screen
height) of full screen indication from the hole. The
9.1 Compensation for the distance traversed by the peak of the indication is marked on the CRT screen.
ultrasonic beam as it passes through the material is The probes are positioned at other nodel positions
provided by the use of curves shown in Fig. 2. covering the expected examination range. The

0- >
SENSITIVITY
80’/.

IN-LINE HOLES AND

NOTCHES USED FOR
ANGLE BEAM CALIBRATION

100/

I SIGNAL
NOTCH
FROM
45°
80-

AMPLITUDE 60-
IN PERCENT

’40-

20-

FIG. 2 DISTANCE AMPLITUDE CORRECTION

3
IS 4260:2004

corresponding peaks are marked on the CRT screen. reflection amplitude.

The peaks are joined by a smooth line whose length
cover the examination range to generate DAC curve. 11.2 When dual probes are employed for examination,
the included angle between the beam paths shall be such
9.3 For evaluation of discontinuities oriented perpendi- that the focal length of the probe is not less than the
cular to examination surface at or near the surfaces, thickness of the weld under examination. The
45° probe is positioned at appropriate distance examination shall be performed with the plane
necessary for maximum signal amplitude from the separating the elements of the dual probe parallel and
square notch machined on the opposite surface of the perpendicular to the axis of the weld in two directions
calibration block. This amplitude reference level is as described in 11.1.
alone chosen for evaluation of discontinuities at or near
the surfaces. 11.3 The scanning shall be performed at a gain setting
6 dB above the reference level. Evaluation shall be
9.4 Ifan electronic distance amplitude correction device performed at the primary reference level for straight
is used the reference response shall be equalised at beam examinations.
50 percent of full screen height over the distance range
employed in the examination. 11.4 Angle beam examinations of weld thickness less
than 10 mm shall be carried out from both sides of the

FOR INTERNAL USE AT THIS LOCATION ONLY

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9.5 For weld thickness 25 mm or less a single weld on the same surface. The total width of the
calibration reflector shall be located at 50 percent T scanning zone shall be equal to twice the skip distance.
thickness of calibration block. No DAC curve need be
established. The signal amplitude obtained from the 11.5 For weld thickness between 10 mm and 100 mm,
reflector is kept as the reference amplitude level for angle beam examination shall be done from both sides
testing. The signal amplitude obtained shall be of the weld on the same surface wherever practicable,
appropriate to the metal path (beam bath) distance the scanning zone being a full skip distance.
employed for the examination ‘ofa welded component. 11.6 For welds over 100 mm in thickness the welds
9.6 For straight beam examination, the straight beam shall be scanned using angle beam probes from four
probe is positioned for maximum response from the sides, that is, from both sides of the weld from inner
hole that gives the highest amplitude. The sensitivity and outer surfaces. The probe shall be moved as near
control of the unit are to be adjusted to provide an 80 as possible to the centre line of the weld to ensure full
percent of full screen height. The probe shall be coverage. The scanning width shall be 5/8th of a skip
positioned for maximum response from the another distance from weld centre line.
holes and the peaks of the indication shall be marked 12 SCANNING FOR REFLECTORS ORIENTED
on the screen. The peaks are smoothly connected and PARALLEL TO WELD
extended through the thickness to provide the distance
amplitude curve from the side drilled holes. 12.1 The angle beam shall be directed as approximate
right angles to the weld axis from two directions where
10 EXAMINATION PROCEDURE possible. The probe shall be manipulated so that the
10.1 The volume of the weld shall be examined by ultrasonic energy passes through the required volumes
moving the probe over the examination surface so as of weld and adjacent base metal. The scanning shall be
to scan the entire examination volume. Each pass of performed at a gain setting of 6 dB above the reference
the probe shall overlap a minimum of 10 percent of the level. Evaluation shall be performed with respect to
transducer (piezo electric element) dimensions the primary reference level.
perpendicular to the direction of the scan. 12.2 Scanning for Reflectors Oriented Transverse
10.2 The rate of probe movement for examination shall to Weld
not exceed 150 mm/s.
The angle beam shall be directed essentially parallel to
10.3 During movement, both towards and away from the weld axis. The probe shall be adjusted so that the
the welded joints of flathear flat surface, the probe shall angle beam passes through the required volumes of
be oscillated over an angle 10°to 15° on each side of a weld metal and adjacent base metal. The scanning shall
line normal to the centre line of the weld. be performed at a gain setting 6 dB above the reference
level and evaluation will be performed with respect to
11 SCANNING the primary reference level. The probe shall be rotated
11.1 For straight beam examination the probe is 180° and the examination repeated.
positioned directly on the weld surface of the 13 EVALUATION
examination material. The weld shall be scanned
progressively along and across the width of weld 13.1 Any imperfection which causes an indication in
inclusive of adjacent heat affected zone to its entire excess of 20 percent DAC shall be investigated
length. Penetration is always verified with back to estimate the nature of flaw, then can be evaluated

4
 IS 4260:2004

in terms of a acceptances standard. The indications Welds may be tested as described in 11, 12 and
of height 50 to 100 percent DAC shall be recorded. 13.
13.2 Recording of indication shall be made with 16.2 Selection of Calibration Reflectors
respect to the reference level.
A side drilled hole may be used for initial acceptance
14 FE RRITIC WELDS IN FERRITIC PIPE of pipe weld, provided that it can be demonstrated
14.1 Basic Calibration Block that the hole calibration produces a sensitivity equal
to or greater than the notch calibration.
14.2 The basic calibration block for weldments shall
be a section of the same nominal size, schedule heat 17 EVALUATION
treatment and material specification as the material
being examined. The surface finish of the calibration 17.1 Any imperfection that causes an indication in
block shall be representative of the surface finish of excess of 20 percent DAC shall be investigated to
the piping. estimate the nature of flaw that can be evaluated in
terms of acceptance standard. The indications of height
14.3 The basic calibration reflections shall be 50 to 100 percent DAC shall be recorded.
longitudinal and circumferential notches on both the

FOR INTERNAL USE AT THIS LOCATION ONLY

LICENSED TO LANCO INFRATECH LIMITED, UDUOG VIHAR, GURGAON,
inner and outer surfaces. The sizes and locations of 17.2 Recording of indications shall be made with
the calibration reflectors are shown in Fig. 3. respect to the reference level.

15 ANGLE BEAM CALIBRATION 18 PROCEDURES FOR DETERMINING THE

LOCATION AND SIZE OF FLAWS
15.1 The nominal frequency shall be 2.0 MHz. Higher
frequencies may be used, ifthere is a need for greater 18.1 Flaw Location
resolution.
The position of flaw within the weld maybe estimated
15.2 The nominal beam angle of 45° shall be used. from the position of the flaw echo on the CRT screen.
Other angles may be used as appropriate based on the The distance between the flaw echo and the initial
configurations of weld joint being examined. pulse as read from the calibrated time base on the
16 DISTANCE-AMPLITUDE CORRECTION screen is the actual beam path distance W’ of flaw.
(DAC) From the known beam angle of the probe used, the
precise location of the flaw from the entry surface can
16.1 A distance-amplitude correction (DAC) curve is be calculated using the formula t= W cos a where t is
established by beaming the angle beam probe towards the thickness of component on which the probe is
the calibration reflector that yields the maximum placed within half skip distance from the centre of the
response to 80 percent of full screen height. The weld. When the crystal is placed between half and
probe is then manipulated without changing full skip distance, the formula is to be corrected as
instrument settings, to obtain maximum response 2 t - W cosa. Alternatively a flaw locating rule or
from the calibration reflectors at the distance accurate sketches may by drawn to locate the flaws in
increment necessary to generate a 3 point DAC curve. a weld.

L
.
A.L
-..-.--—. ------
,,, 0
t

~
.—. — .—.
: ..@ “-

FIG.3 ANGLE BEAM CALIBRATION(PIPEWELDS)

Typical Block Dimensions:

Length (L) 200 mm or 8Twhichever is greater

Minimum ARC Length A.L.i)for O.D.101.6 mm or less 270 deg.

ii) for O.D. greater than 101.6 mm the greater of 3Tor 200 mm.

SpectJ7c Notch Dimensions:

Length 25 mm, Min.

Depth 10 percent, T(tolerance on depth + 10 percent -20 percent).
Width 3.2 mm or 6.4 mm
Location Not closer than Tfrom any block edge.

5
IS 4260:2004

18.2 Size of the Flaw signal height using a swivel scan.

18.2.1 In order to estimate the size of a flaw in any 19.1.2 Elongated cylindrical flaws are indicated by a
particular direction, the effective beam width at the flaw constant signal height over a significant length and a
position has to be known. In the flaw size investigation sharp peak for a shorter length in lateral and depth
it is to be determined first, whether the flaw is a large scanning depending upon the orientation of the
reflector or a small reflector. Large reflector is one flaw.
that is larger than the sound beam at its position, and a
19.1.3 Planner flaws produce sharp peaks when
small reflector is one that is smaller than the sound beam
scanned normal to their direction and drops suddenly
at its position.
when the probe is swivelled.
18.2.2 The size of a large reflector is determined by
20 ACCEPTANCE
scanning the borders of the flaw with the ultrasonic
beam, by moving the probe from the centre of the Ultrasonic acceptance or rejection criteria for individual
discontinuity until the height (6 dB drop). This butt weld shall be based on a realistic appraisal of
operation is repeated to establish the boundary. This is service requirements that shall be established between
true for straight beam probes and in horizontal, vertical the purchaser and the manufacturer on the basis of

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plane for angle beam probes. the quality that can normally be obtained in such
welds.
18.2.3 In case of a small reflector using angle beam
probes measurements of beam spread in the vertical 21 CHECK FOR LINEARITY ON TIME
plane shall be made on the side drilled holes as given BASE, SCREEN HEIGHT AND AMPLITUDE
in Fig. 1 and Table 1 for appropriate thickness at CONTROL
different distance from the shear wave probe. To
21.1 Time Base Linearity
estimate the flaw size the probe is scanned so that the
beam moves parallel to vertical direction and the When the time base is linear, the distance between
distance within which the flaw echo amplitude within repeat echoes shall be equal. The check shall be made
6 dB of the maximum, is determined. The flaw size is at the time of calibration oftest ranges. The position of
given by the difference between the probe distance the echoes are noted without parallax by adjusting the
moved to touch the edges of the calibration hole and echo height to 50 percent of full screen height. The
flaw in the weld multiplied by the cosine of the displayed readings shall not deviate :2 percent of
beam angle inside the medium. The calibration hole the range calibrated or one minor dwision of the
chosen shall be appropriate to the scanning path of screen.
the flaw.
21.2 Linearity of Vertical Scale and Amplitude
18.2.4 To obtain the boundary in the horizontal plane, Control
the shear wave probe is moved parallel to the blind side
drilled hole described in 18.2.3 until the amplitude drips A straight beam search unit frequency 2 MHz or 4 MHz
to 6 dB from its maximum amplitude at different shall be positioned over the depth resolution notch in
distances from the probe. The distance from the edge the IIW block described in IS 12666 so that the signal
of the block to the position of crystal subtracted from from the notch is 20 percent of screen height and the
the depth of the hole gives half-beam width. To estimate signal from the 100 mm block surface is 40 percent of
the flaw size in a horizontal plane the probe is moved screen height. When the sensitivity of the apparatus is
laterally so that the beam axis moves parallel to the altered so that the signal from notch is raised in
lateral direction and the distance is within which the increment of one major vertical scale division until the
flaw echo amplitude is within 6 dB of the maximum is 100 mm location signal reaches full scale and then
determined. The flaw also is given by the difference lowered in increment the smaller indication reading
between the dimensions and effective full beam shall be 50 percent of the larger amplitude within
width. 5 percent of full screen height. The readings shall be
established to the nearest of 1 percent of full screen
19 NATURE OF FLAWS height.
19.1 On determining the location and size of the flaw 21.3 Amplitude Control Linearity
and from the knowledge of defects normally
encountered in different welding processes, an estimate To verify the accuracy of amplitude control of the
of the nature of flaw may be made. These different ultrasonic apparatus an angle beam search unit is
types may be classified, namely, isolated pores, types positioned on the calibration block as shown in Fig. 1
elongated (worm hole) and planar flaws are usually so that the indication from the 1/2 T hole is peaked on
differentiated by various scanning techniques. the screen. With the increase and decrease in the
attenuation shown in the following table the indication
19.1.1 Isolated pores are indicated by a constant echo must fall within the specified limits:

6
 IS 4260:2004

calibration and their values shall be changed on the

Indication Set at Control Indication Limits
data sheets.
Percent Full Chance, Percent of Full
Screen dB Screen 22.3 DAC Correction
80 –6 32 to 48 If a point on the distance-amplitude correction (DAC)
curve has decreased 20 percent or 2 dB of its
60 – 12 16 to 24 amplitude, all data sheets since the last calibration or
40 +6 64 to 96 calibration check shall be marked void. A new
calibration shall be made and recorded and the area
20 + 12 64 to 96 covered by the voided data shall be re-examined. If
any point of the distance-amplitude correction (DAC)
The settings and readings must be estimated to the curve has increased more than 20 percent of 2dB of
nearer one percent of full screen. its amplitude, all recorded indications since last valid
22 CALIBRATION CONFIRMATION calibration or calibration check shall be re-examined
with the corrected calibration and their values shall
22.1 Calibration shall be performed prior to use of be changed on the data sheets.
the system in the thickness range under examination,
a calibration check shall verify the sweep range 23 PERSONNEL REQUIREMENTS

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LICENSED TO LANCO INFRATECH LIMITED, UDUOG VIHAR, GURGAON,
calibration and distance-amplitude correction. Personnel performing ultrasonic examination to the
requirements of this article shall be qualified as
22.2 Sweep Range Correction
required by IS 13805.
Ifa point on the DAC curve has moved on the sweep 24 REPORT
line more than 10 percent of the sweep reading or
5 percent of full sweep, whichever is great, correct A report of the examination shall be made. The report
the sweep range calibration and note the correction in shall include a record indicating the weld or volume
the examination record. If reflectors are recorded on examined, the location of each recorded reflector and
the data sheets, those data sheets shall be avoided the identification of the operator who carried out each
and a new calibration shall be recorded. All recorded examination or part thereof. The report shall be placed
indications since the last valid calibration or calibration in file and maintained in accordance with IS 8791 and
check shall be re-examined with the corrected IS 3364.

7
Bureau of Indian Standards
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harmonious development of the activities of standardization, marking and quality certification of goods and
attending to connected matters in the country.

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copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
CBISCatalogue’ and ‘Standards: Monthly Additions’.

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This Indian Standard has been developed from Dot: No. MTD 21 (4304).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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