Introduction to

Non Destructive Testing

 NDT
 Ability to detect the condition of the object without
destroying the functionality of the object
BASIC METHODS
 Visual Inspection - VT
 Penetrant Testing - PT
 Magnetic Particle Testing- MT
 Ultrasonic Testing - UT
 Radiographic Testing - RT
 Visual Inspection
 Inspection object surface visually is called Visual
Inspection
 May or may not use accessories
 Gauges for identifying the dimensions of surface
 Magnifying glasses
 Borescope for internal inspection
 Thermal chalks, Thermocouple, for the temperature
measurement
 Etching for checking surface condition
 Etching
 for identification of gross
metallurgical discontinuity
such as in welds.
 For detecting the surface
opening – Fore runner to
Penetrant Testing
 Different Etchants available
for different metals
Advantages & Disadvantages
Advantages
 Simple
 Less training required
 Relatively less costly equipment
Disadvantages
 Slow
 Inspector Fatigue is more
 Surrounding environmental factors are important
Penetrant Inspection
 Is a method that reveals
discontinuities open to
surface by the seepage of a
liquid penetrant medium
into a surface open
discontinuity which seeps
out after removing the
excess penetrant revealing
the discontinuity
Stages of Penetrant Testing
 Pre cleaning
 Application of penetrant
 Dwell Time
 Cleaning of Excess
penetrant
 Application of Developer
 Inspection
 Post Cleaning
 DYE SYSTEMS

SOLVENT REMOVABLE DYE

 DYE SYSTEMS

WATER WASHABLE DYE

POST EMULSIFICATION
DYE
PT Indications
 Penetrant Testing
Advantages
 Simple method
 Easy to train personnel
 Cheap
 Quick
Disadvantages
 Only open defects can be detected
Magnetic Particle Testing
 When a ferromagnetic
material is magnetised the
flux lines flow inside the
component
 When there is a discontinuity
in the material there is flux
leakage
 The leaking flux attracts a
magnetic medium resulting in
an indication.
 Types of magnetisation
 LongitudinalMagnetisation
 Circular Magnetisation

 AC Magnetisation
 DC Magnetisation
 HWDC magnetisation
Magnetic Particle Testing
COIL METHOD YOKE METHOD.
Types of Magnetisation -
Circular Magnetisation

HEAD SHOT METHOD

PROD METHOD CENTRAL CONDUCTOR

 Magnetic Particle Testing

PROD METHOD
 MAGNETIC MEDIUM
 Dry
 Wet

 Fluorescent
– Requires Ultra violet lamp in darkened area
– More sensitive than
 Non – Fluorescent
 Magnetic Medium - Dry

 Medium about 30 – 50
microns
 Mixture of spherical and
elongated powders
 Spherical shape helps in
mobility
Dry Medium
 Elongated shape helps in
alignment to magnetic
field
MAGNETIC MEDIUM - WET
 Oxides of iron used in
suspension with water,
kerosene, petroleum oil.
 Size : 20- 30 microns
 More sensitive than dry
medium
Demagnetisation
 Residual magnetism affects
further operation such as
welding.
 Demagnetisation is
preferably done with AC
 Object is moved slowly
away from coil
 After demagnetisation
residual magnetism is
checked with gauss meters
 Magnetic Particle Testing
 Pre - Cleaning
 Magnetisation
 Applying magnetic medium
 Inspection
 Post cleaning
 Demagnetization
 Magnetisation
 Magnetisation to be applied in two
mutually perpendicular direction
 Magnetic medium to applied when the
magnetisation is ‘ON’
 Adequacy of field to be checked by field
indicator ( Pie Gage )
 Magnetic medium could be wet or dry /
Fluorescent or non-fluorescent
Advantages & Disadvantages
Advantages
 For detecting surface & sub-surface discontinuity
 Can be tested rapidly
 Not very costly
 Relatively less skill required for testing
Disadvantages
 Only useful in ferro-magnetic materials
 Demagnetisation may be required for many of the
parts
 Ultrasonic Testing
A beam of high frequency wave is introduced into
the test object which gets reflected from the
surface of any discontinuity
 Used to detect and locate the surface and internal
discontinuities
 Amplitude of a reflected sound pulse is nearly
proportional to the size of the reflector
 Ultrasonic Testing
 For Detecting internal flaws
 For almost all the materials –
metals, ceramic, rubber,
composites etc..
 Requires only one side access
 Portable equipment
 Non hazardous
 Can test up to about 10 m of
steel
 Ultrasonic Testing

 ULTRASONIC TESTING –
PULSE ECHO TECHNIQUE
Transducer acts as a pulser and receiver
Can detect the location and depth of defect
Only one side access is required
 ULTRASONIC TESTING –
THROUGH TRANSMISSION TECHNIQUE

• Separate transmitter
and receiver
• Accurate Alignement
of transmitter and
receiver required
• Cannot locate the
depth of defect
 PROBES

NORMAL BEAM PROBE DUAL CRYSTAL PROBE

 Test Procedure
 Calculate scanning zones
 Calibrate unit
 Draw DAC
 Scan
 When indications
observed - check the
height of signal, location
 Calculate location and
size of discontinuity

Scanning patterns
 Location of defects
BP : Beam Path
Depth of defect :

BP
D = BP Cos α
Position of defect
P = BP Sin α
DEFECT
IE ECHO
 Radiography Testing
 Employs x rays or gamma rays to penetrate an
object, detect discontinuities by recording the
difference on a recording device
 For internal flaws
 Permanent record
 Radiation Safety is a major concern
Basic Principle
X ray machines or Ir
192 or Co 60 main
sources of radiation
 Hole type or Wire type
penetrameters used
for checking
sensitivity of
radiograph

Source Radiation
Radiography
 Uses Penetrameters for
ensuring the quality of the
radiography procedure
 Penetrameters are hole type
and wire type
 Sufficient radiographic
density is required for the
radiograph for proper
evaluation
 Techniques

Single Wall Single Image Double wall Single image

Job Film Weld Source Radiation
 Techniques

Double Wall Double Image Panoramic Exposure

Job Film Weld Source Radiation

 DOUBLE WALL
DOUBLE IMAGE

ASTM Hole Type

Penetrameter

SINGLE WALL
SINGLE IMAGE
DIN Wire Type
Penetrameter

Tungsten
Tungsten
Inclusion
Inclusion

Porosity

Porosity
Slag Inclusion
POROSITY
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