PCN NDT Ultrasonic Testing Level 2 Exam study plan

Explain how piezoelectric transducers generate and receive ultrasound, including the thickness-mode resonance condition and the effect of backing and matching layers on pulse length and bandwidth.

Derive the relationships among frequency, wavelength, velocity, and acoustic impedance, and calculate each quantity given the other three for common steel, aluminum, and titanium alloys.

Describe specular reflection, mode conversion at an interface, and the first and second critical angles, and calculate critical angles for acrylic-on-steel and water-on-steel interfaces.

Set up a personal formula sheet covering velocity, wavelength, impedance, near field, beam spread, attenuation, and decibel ratios, and verify each formula by solving three worked numeric examples.

Compare A-scan, B-scan, C-scan, and phased-array presentation modes and state which discontinuity features each display can and cannot reveal.

Explain pulse-echo, through-transmission, and pitch-catch arrangements and select an appropriate technique for a given geometry constraint such as limited single-side access.

Calculate near-field length and half-angle beam spread for round and rectangular crystals and predict how a focused probe changes the focal zone.

Describe the functions of the pulser, receiver, time base, and damping control, and predict how each instrument setting alters the displayed A-scan.

Explain how acoustic impedance mismatch governs transmission and reflection coefficients at a bond line and predict which interfaces in a layered structure will produce strong echoes.

Describe the formation of internal reflections, ghosts, and interface echoes in thin sections, and explain how pulse length and damping affect their resolution.

Interpret the shape and position of an echo from a lack of fusion, slag, porosity, and a crack in a weld, and distinguish volumetric from planar indications.

Identify the causes of spurious indications such as mode conversion, probe ringing, and electrical noise, and describe a check that isolates each.

Differentiate contact, immersion, and gap-scanning techniques and justify a technique choice for a curved or geometrically complex part.

Explain the purpose and calibration of DAC, TCG, and reference-block setups, and describe how each compensates for attenuation and beam spread with distance.

Describe the steps to construct a distance-amplitude correction curve from side-drilled holes and explain how transfer corrections are applied to a real part.

Solve signal-amplitude problems in decibels, including converting a percentage of full-screen height to dB and comparing two indications of different amplitude and distance.

Describe the calibration sequence for straight-beam and angle-beam probes on reference blocks, including zero offset and velocity calibration.

Explain how to verify refracted angle, index point, and beam spread for an angle-beam probe and state the acceptance tolerances typically applied.

Describe the checks performed at the start and end of each shift and the conditions that require recalibration.

Interpret system linearity, resolution, and penetration checks and explain how a failed check affects inspection validity.

Describe the weld-geometry scan patterns for butt, T-joint, and corner joints and match each pattern to the discontinuities it is intended to detect.

Explain how to select probe frequency, angle, and size for a given thickness and weld configuration, and justify the trade-offs in resolution, penetration, and coverage.

Interpret a written procedure's scan coverage, overlap, and sensitivity requirements and identify where a technician has discretion.

Describe the reporting content required for a weld inspection, including indication location, amplitude, length, and classification.

Apply the acceptance criteria of a typical weld or product standard to given indication data and state accept or reject with a reason.

Identify common discontinuities in castings, forgings, and rolled plate and describe the echo signature each produces.

Explain the limitations of ultrasonic testing for near-surface defects, coarse-grained material, and austenitic welds, and describe mitigation options.

Describe the requirements for personnel qualification and the role of written procedures in inspection traceability.

Complete a full-length timed practice examination under exam conditions and record the score by topic.

Review every missed item and write the underlying principle, not just the correct answer, for each.

Re-drill the two weakest topics from the practice exam until accuracy exceeds 85 percent on a fresh set of items.

Recite the key formulas, calibration tolerances, and acceptance-criteria logic from memory without notes.