PowerPoint Presentation

[Audio] Ultrasonic Weld Testing Training 1. An Introduction to Ultrasonic Weld Testing 2. The Fundamentals of Ultrasonic Weld Testing 3. Test Ultrasonic Weld Testing Training 1. An Introduction to Ultrasonic Weld Testing 2. The Fundamentals of Ultrasonic Weld Testing 3. Test.

[Audio] An Introduction to Ultrasonic Weld Testing 1. High strength steels in Automotive 2. Chisel check method and high strength steel 3. What is Ultrasonic Testing and How Does it Work? An Introduction to Ultrasonic Weld Testing 1. High strength steels in Automotive 2. Chisel check method and high strength steel 3. What is Ultrasonic Testing and How Does it Work?.

[Audio] High Strength Steels in Automotive High strength steels are stronger but lighter than the mild steel traditionally used in automotive manufacturing. A lighter body makes for a more fuel efficient vehicle. As high strength steels become more common in the automotive industry our ability to work with these materials will enable our future flexibility and growth High Strength Steels In order to remain competitive many new models will contain high strength steels High Strength Steels in Automotive -High strength steels are stronger but lighter than the mild steel traditionally used in automotive manufacturing. A lighter body makes for a more fuel efficient vehicle. -As high strength steels become more common in the automotive industry our ability to work with these materials will enable our future flexibility and growth -In order to remain competitive many new models will contain high strength steels.

[Audio] High Strength Steels and Our Customer In this example the passenger compartment is reinforced with high strength steels. Preventing the compartment from being crushed during impact For demonstration purposes only not a real vehicle In addition to the cost benefits from an improved fuel economy high strength steels create a more rigid structure providing better protection for our customer. High Strength Steels and Our Customer -In this example the passenger compartment is reinforced with high strength steels. Preventing the compartment from being crushed during impact -In addition to the cost benefits from an improved fuel economy high strength steels create a more rigid structure providing better protection for our customer..

[Audio] The Chisel Check Method and High Strength Steels The chisel check method and high strength steels. Or Why we can't chisel check high strength steel welds.

[Audio] The Chisel Check Method and High Strength Steels The most common method used to test weld integrity is the chisel check method This method of testing will not work on high strength steel welds designated as Ultrasonic Tested (U-T---) Why…??? Key Points Currently the most common method for testing a welds integrity at T-M-M-C is the chisel check method. -The chisel check method works by applying tension to the material around the weld effectively trying to force the weld apart . during the chisel check the metal around the weld is distorted or damaged. The malleability of mild steels allow them to bend and distort during the check. Because of this malleability the mild steel can easily be returned to its original shape. – The destructive nature of the chisel check means that welds designated as ultrasonic tested or UT can not be chisel checked But why!.

[Audio] The Chisel Check Method and High Strength Steels Due to their composition high strength steels cool quickly creating brittle welds Cracking begins just outside the heat zone The crack then compromises the nugget of the weld impacting its strength Welds on high strength steels are prone to cracking when chiseled Cracking continues through the heat zone of the weld The cracking will be microscopic and not detectable with a visual check An example of a high strength steel weld that has been chisel checked viewed through a microscope. Key points. Even under normal chisel check pressure if the weld is viewed under a more powerful microscope the damage caused by the chisel check is still present. The cracking begins just outside of the heat zone at the point where the chisel would contact weld. Cracking continues through the heat zone. The cracking may occur immediately or after the weld is placed under stress. Eventually the crack will compromise the nugget of the weld and greatly reduce its strength. Over time the crack could continue through the weld potentially creating a separation. This microscopic cracking will not be immediately detectable by the team member chiseling the weld and could eventually impact the safety of the customer This makes it very important that we do not chisel check any welds labeled UT. If for any reason you hit a weld designated as UT you must report it to your team leader. Failure to report this issue could result in quality concerns or even serious injury to our customer..

[Audio] The Chisel Check Method and High Strength Steels Due to their composition high strength steels cool quickly creating brittle welds An example of a high strength steel weld that has been chisel checked viewed through a microscope. Welds designated as ultrasonic tested (U-T---) hit with a chisel must be immediately reported to your Team Leader for repair. Failure to report this issue could result in quality concerns or serious injury to our customer..

[Audio] What is Ultrasonic testing and how does it work What is ultrasonic testing and how does it work..

[Audio] What is ultrasonic testing and how does it work? Ultrasonic testing (U-T---) works by using a probe to send ultrasonic sound through the material being tested. The echo from that ultrasonic sound is then received by the same probe and turned into wave shapes. Probe Shoe The wave shape created by that echo can be used to determine the thickness of the measured material. See table 1 for examples of how these waves can be used to determine weld quality. Weld Nugget Sheet 1 Sheet 2 Regardless of the method of ultrasonic testing being employed they all work in a similar fashion. A probe is used to send ultrasonic energy through the material being tested the echoes generated by that sound, specifically the time it takes for the echo to be reflected, are then sent back to the probe to be converted into usable data. The table shown illustrates various conditions including the reflected image and the wave shape. All ultrasonic scans use some form of this basic wave shape or A scope/scan. More information on this wave form will be provided in the next gate. Image #1 shows a good weld nugget. Notice the distance between the peaks on the wave form that distance is the amount of time it takes the ultrasonic energy to be reflected back to the probe. this time is actually the total thickness of the combined material. Image #2 shows an "open" or separated weld . Notice that the distance between the peaks is far less than the waves in image #1 because the time it takes for the ultrasonic energy to be reflected is only the total thickness of one piece of material. Image #3 & 4 show two different but similar conditions both small nuggets and pressure or stick welds are welds with insufficient adhesion between the combined material. The waves indicate that only some of the reflected waves are through the combined material. This is an example of a probe descending on a weld for testing. The ultrasonic energy is sent from the probe and travels through the shoe to the welded material. Depending on the device this process could be repeated continuously to create real time information or in snapshots similar to a photograph. The Toshiba Ultrasonic unit uses a combination off these two. More information on this will be provided in the following gate..

[Audio] The Fundamentals of Ultrasonic Weld Testing 1. The Tessonics F2 2. Necessary Conditions for Accurate Ultrasonic Scanning 3. Understanding the Results of a Scan The Fundamentals of Ultrasonic Weld Testing 1. The Tessonics F2 2. Necessary Conditions for Accurate Ultrasonic Scanning 3. Understanding the Results of a Scan.

[Audio] The Tessonics F2 The Tessonics F2 is one of the ultrasonic units currently approved for ultrasonic scanning at Toyota (BW-DOC-ENG-34) (Q-3-5-7) The unit consist of 4 key components The main unit The probe The delay line or shoe Coupling gel These 4 components are the minimum required elements for ultrasonic scanning Key Points The Tessonics F2 is one of the ultrasonic units currently approved for ultrasonic scanning at most Toyota facilities including T-M-M-Cs North and West plants. This section covers in detail the function of each component and how to correctly use them. The main unit consists of 4 key components or variants on those components. These components are… The main unit The probe The shoe Coupling gel.

[Audio] Necessary Conditions for Accurate Ultrasonic Scanning In this section you will learn how to meet all the necessary conditions to obtain the best possible results from the ultrasonic scan..

[Audio] Reaction Plan for Ultrasonic Scanning 1.Visual inspection of the welds being scanned. If OK proceed to the ultrasonic inspection. If NG call Team Leader 2.Ultrasonic Inspection If OK continue If NG ultrasonic reinspection 3.Ultrasonic Reinspection If OK continue If NG ultrasonic reinspection opposite side 4.Ultrasonic Reinspection (Other side) If OK continue If NG call Team Leader 1.Visual inspection of the welds being scanned If OK proceed to the ultrasonic inspection If NG call Team Leader 2.Ultrasonic Inspection If OK continue If NG ultrasonic reinspection 3.Ultrasonic Reinspection If OK continue If NG ultrasonic reinspection opposite side 4.Ultrasonic Reinspection (Other side) If OK continue If NG call Team Leader.

[Audio] Visual Inspection of Spot Welds Before Scanning Before beginning the weld inspection visually inspect the weld for any defects (CBIS 910) that exceed shipping standard such as but not limited to Missing Off Location Pinholes, Blowholes Cracks Burrs If any defects are found that exceed shipping standards follow the defect reporting standard (BW-DOC-ENG-13) and notify your Team Leader Before begining the weld inspection with the Scanner visually inspect both sides of the weld for any defects that exceed shipping standard these defects include but are not limited to….. Missing – no welds are allowed to be missing from the vehicle Off location – delta s, A and B class welds are only allowed to be off location by 5 millimeters. C class welds are allowed a 10 millimeters tolerance. Pinholes, Blowholes – Waterleak areas and Delta S welds are not allowed to have pinholes/blowholes. Al other welds are allowed a maximum of 1 1.5 millimeters pinhole or blowhole per weld Cracks – cracks are not allowed in welds. Burrs – Burrs are not allowed on waterleak, fire hazard, safety or visible welds. welds on trim portions are allowed a maximum of 1 millimeters burr. All other welds are allowed a maximum of 2 millimeters burrs. Always follow your defect identification training if any defects are found that exceed shipping standards follow the defect reporting standard and notify your team leader..