Implementation of American Association of State Highway and Transportation Officials/American Welding Society D1.5 Phased Array Ultrasonic Weld Inspection Programs

Abstract

This paper describes highlights of phased array ultrasonic testing (PAUT) nondestructive evaluation (NDE) research activities at the Federal Highway Administration’s (FHWA’s) Advanced Sensing Technology (FAST) NDE Laboratory. The work supports the goal to implement ultrasonic techniques in lieu of radiographic techniques for American Association of State Highway and Transportation Officials (AASHTO)/American Welding Society (AWS) D1.5 Bridge Welding Codeinspection of full penetration bridge fabrication welds. The paper also describes some of the advantages and disadvantages of the process to implement a PAUT inspection program. The results of this study support the goal of broader implementation of ultrasonic testing (UT) with results to date showing a good correlation of the comparative inspection results between PAUT and radiography. There is, however, a need to develop a more comprehensive set of weld flaws to ensure a fully representative flaw set is evaluated. To support that goal, the FAST NDE Laboratory is currently using ultrasonic simulation software to 03611981221090236ement the test plate data with a virtual database of simulated flaws. A successful implementation of PAUT can result in a more efficient inspection process with detailed permanent records and images of the flaw locations mimicking the historic radiograph. As more bridge fabrications incorporate PAUT, there will be a broader PAUT experience base as the AWS committee, teamed with the bridge fabricators, FAST NDE Laboratory, and other contributors continue to work toward replacing all required radiography in AWS D1.5 with an option to use PAUT.