Abstract
This report documents work on the effects of surface roughness on the reliability of an ultrasonic inservice inspection. The primary objective of this research is to develop ASME Code recommendations in order to limit the adverse effects of a rough surface and thereby increase the reliability of ultrasonic inservice inspections. Engineering studies were conducted that included experimental validation of computer codes. The basic problem associated with a rough surface in an inservice inspection is that as the transducer rotates slightly to accommodate the rough surface, the beam direction in the metal changes and the time of flight of the echo changes as well. One problem is the excessive weld crown, where weld material protrudes above the adjoining surfaces. In this research this condition is modeled by considering a step discontinuity on the top surface. CNDE developed several models of increasing complexity in order to model an inservice inspection. This report describes the validation of four computer codes. These codes were used to mimic an inservice inspection in order to understand effects associated with rotation of the transducer as it traverses a step discontinuity.
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