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PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT PROJECT, TASK
AREA 6 WORK UNIT NUMeERC
' U.S. ARMY ABERDEEN PROVING GROUND (STECS-AD-A)
ABERDEEN PROVING GROUND, MARYLAND 21005-5059 AMC-R 310-6
I .CONTROLLING OFFICE NAME AND ADGRESS 12. REPORT DATE
4MONITORING AGENCY NAME &AGGRESS(II different too Controling Office) IS ECURITY CLASS. (of this report)
Unclass if ied
Ils.. DECLASSIFICATION4/OOWNGRAOING
SCHEDULE
*17, GISTRIBUTION STATEMENT (of tile astract entered in Stock 20. It differsent hrow Report)
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 cannon
Stubes, cast armor plate, welded joints, projectile fuzes, vehicle track shoes,
and other items in which detection of cracks, voids, corrosion, and thickness
variations is important. gf.c
Reproduced From
Best Available Copy
U.S. ARMY TEST AND EVALUATION COMMAND
TEST OPERATIONS PROCEDURE
A TE-&P-702-102
. *Test Operations Procedure 3-2-807 4 December 1985
" ADNo.
Paragraph 1. SCOPE . . . . . . . . . . .. . . . . . . . . . . . . . 1
2. FACILITIES AND INSTRUMENTATION ............ 2
3. RQUIRED TEST CONDITIONS .. T.. ..... . 2
4. TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . 2
4.1 Magnetic Particle Inspection .... . . . . . . . .. 2
4.2 Liquid Penetrant Inspection ........... . . . 4
4.3 Radiographic Inspection . . . . . . . ........ . 5
4.4 Pulse-Echo Ultrasonic Inspection . . 6
4.5 Ultrasonic Inspection of Gun Tubes - Normal. . . . . . . 6
Beam Technique
4.6 Miscellaneous Nondestructive Test Methods. . . . . . . . 7
1. SCOPE. This TOP describes standard techniques and facilities for conducting
nondestructive tests (NUT) of material used in the manufacturing a test item, for
determining surface/subsurface characteristics of the material without sig-
nificantly affecting the item.
'*This TOP supersedes TOP 3-2-807 dated 11 September 1972 and Change 1 dated 14
November 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 .l
Justificat ion
BY
Di stribut Ion/
Availability Codes
QUA.Y Avail and/or
INSPEOTED
Dist Special
9
4 December 1985 TOP 3-2-807
2.1 Facilities.
REQUIRE(ENT
X-ray machine
Film and contact screens
2.2 Instrumentation.
PERMISSIBLE ERROR
*ITEM OF MEASUREMENT
Penetrameters Xt applicable
Ultrasonic unit
Transducers
3. REQUIRED TEST CONDITIONS. Nondestructive examination of test item material
should be conducted in at least five situations:
a. To determine whether the test item is safe to test (e.g., armed fuze)
4. TEST PROCEDURES.
4.1 Maxnetic Particle Inspection. This is performed to inspect material that can
be magnetized fe: surface/subsurface dialcontinuities such as cracks, seams,
porosity, and inclusions. This technique is limited to magnetic materials and is
used 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 intensity
of the magnetizing current, the size of the magnetic particles, the size and
orientation of discontinuities, and the permeability and retentivity of the
material. Micro-cracks can be detected by this method under ideal conditions.
Magnetic particle inspection is accomplished by creating an induced magnetic
field in the part, applying the magnetic particles while current is floving,
visually inspecting the part, and de-magnetizing the part once the inspection is
completa. Perform inspection as follows:
2
* 4 December 1985 TOP 3-2-807
(1) Longitudinal. Place the central conductor through the bore of the
tube. A current passing through the central conductor sets up a magnetic field
perpendicular to the direction of the current. This reveals longitudinal defects
in the tube that are at right angles to the lines of force.
'b, Apply the inspection medium of fine magnetic particles, in one of the
following forms, to the magnetized surface while the magnetized current is momen-
tarily flowing:
(The magnetic particles collect at the magnetic leakage field created by the
discontinuity.)
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 incandescent
illumination is used for nonfluorescent powders.
3
h
% -4.2.1 Method. The detection capability of this method depenls on the penetrant
N 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 of
excess penetrant, application of the developer, inspection and interpretation.
Perform'the inspection as follows:
b. Penetrant application.
(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.
(1), Wipe the surface using a lint-free rag moistened with a suitable
solvent.
(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). Avoid
overwashing.
(5) Once the excess penetrant is removed, allow the item to dry.
4
4 December 1985 TOP 3-2-807
(6) Hot air dryer temperatures are usually maintained between 79 ° and
107 C (1750 and 225' F). Part temperature should not exceed 52" C (125' F) and
should be rmoved from beat when part surface is dry to touch. Excessive dryer
time can cause damage to part and evaporation of penetrant.
5
4 December 1985 TOP 3-2-807
b. Select suitable film and contact screens., The finer grained films
render better detail but require increased exposure. The use of chemical
intensifying screens should be avoided, when possible, since they reduce detail
quality.
examples of gamma ray sources useful for radiography. Permission must be ob-
tained from NRC to acquire, store, and use gmua sources for radiography.
6
4 December 1985 TOP 3-2-807
b. Apply a suitable couplant (usually oil) for contact inspection, and scan
the 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 the
test item. This reflected pulse will locate the material discontinuity relative
to the front and rear faces of the material being examined.
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 with
guidelines. If no guidelines are available, continue investigation during test-
ing to reveal extensions of any previourly noted discontinuities or time when
they occur.
4.5 Ultrasonic Inspection of Gun Tubes --Normal Beam Technicue. This method is
used to locate and measure the depth of longitudinal cracks in gun tubes. This
is a special application of the pulse-echo technique in which the crack direction
is parallel to the direction of sound propagation instead of perpendicular as is
normally the case. Ultrasonic inspection can be used for metals ranging from
0.01 cm thick to 1 meter, with sensitivity varying with the thickness,
Transducers of lower frequencies are required for the greater thicknesses but
result in loss of discontinuity detection capability.
4.5.1 method.
b. Use a miniature search unit, couplant, and search unit holding device
to preclude search unit wobble and to maintain the correct probe-to-test-item
alignment.
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
4 December 1985 TOP 3-2-807
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 particle
inspection.
b. For discontinuities (other than radial cracks) larger than the beam
spread: depth, length, direction, and location
4.5.3 Analytical Plan. Compare internal discontinuities in the gun tube with
available guidelines. If none is available, continue investigation during test-
iug to reveal extensions of any previously noted discontinuities or time when
they occur.
8
4 December 1985 TOP 3-2-807
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15
4 December 1985 TOP 3-2-807
APPENDIX A
1. Transmission Technique. When both sides of the test item are accessible, the
contact transmission technique can be used to inspect the test item. This method
employs a transmitting crystal on one surface and a receiving crystal directly
opposite on the other surface. The time delay between transmission and reception
of pulse is calibrated in terms of the material thickness.
A-1
SI
APPENDIX B
REFERENCES
14. ASTM*-E797, "Practice for Measuring Thickness by Manual Ultrasonic Pulse Echo
Contact Method".
15. AST*-ES04, "Practice for the Calibration of the Ultrasonic Test System by
V, Extrapolation between Flat Bottom Hole Sizes".
19. Drabo, M.J., and Edwards, D.W,, "Special Study to Establish a Correlation
Between Known Discontinuities in Gun Tubes snd Standard Ultrasonics Reference
Blocks", APG Report APG-T-3762, February 1971.
4 December 1985 TOP 3-2-807
20. Huddleston, R.L., "Special Study for Verification of Normal Beam Technique
for Ultrasonic Inspection of CannonTubes", APG Report APG-MT-3950, November
1971.
23. Finfera, J.P., "Special Study Evaluation of Hall Probe Magnetic Recording
Borescope for Nondestructive Inspection of Cannon,Tubes", ANG Report APG-MT-4577,
February 1975.
25. Finfera, J.P., "Special Study of X-ray Pole Figure to Determine Preferred
Grain Orientation in a Polycrystalline Aggregate", AP Report APG-MT-4290, June
1973.
&-2