NON DESTRUCTIVE TESTING

NDT - general name for all methods which permit testing / inspection of materials / parts without impairing its future usefulness

NDT&E Techniques
Physics of techniques Types of materials Accessibility Types of defects and damage

Inspect or measure without doing harm

Visual Dye penetrant Magnetic particle Radiography (X, and Neutron) Ultrasonic Eddy current Acoustic emission Infrared thermography

Different NDT Techniques

Definition of NDT
The use of noninvasive techniques to determine the integrity of a material, component or structure or quantitatively measure some characteristic of an object.
i.e. Inspect or measure without doing harm.

Destructive Tests Advantages: 1. Measurements are direct and reliable 2. Usually quantitative measurements 3. Correlation between test measurements and martial properties are direct. Limitations: 1. Test are not made on the objects directly. Hence correlations between the same. 2. A single test may measure only one or a few of the properties. 3. In-service testing is not possible. 4. Measurement of properties over a cumulative period of time cannot readily be possible. 5. Preparation of the test specimen is costly. 6. Time requirements are generally high.

Non-Destructive Tests Limitations: 1. Measurements are in direct and reliability is to be verified 2. Usually qualitative measurements 3. Skilled judgment and experience are required to interpret indications. Advantages: 1. Test are made directly on the objects directly. 100% testing on actual components is possible. 2. Many NDT methods can be applied on the same part and hence many or all properties of interest can be measured. 3. In-service testing is possible. 4. Measurement of properties over a cumulative period of time is possible. 5. Preparation of the test specimen is not costly. 6. Time requirements are generally very low.

TYPES OF DEFECTS
inherent defects - present during initial production of raw materials processing defects - resulted from the manufacturing process service defects - occurred during the operation

Examples of causes of defects

Blowholes - gas trapped during solidification process Segregation - during solidification of alloy Scale - oxide formation on the surface of a metal heated to high temperature Stress - residual stress after cold working or rapid cooling

Cracks
quenching / hardening cracks - rapid volume change tempering cracks - rapid heating shrinkage cracks - rapid cooling grinding cracks - friction heating also caused by residual stress, collapsed blowholes, improper rolling, sharp edge of dies etc. etc.

Outline
Introduction to NDT Overview of Six Most Common NDT Methods Selected Applications

Methods of NDT
Visual

What are Some Uses of NDE Methods?

Flaw Detection and Evaluation Leak Detection Location Determination

Dimensional Measurements

Fluorescent penetrant indication

Structure and Microstructure Characterization Estimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response

There are NDE application at almost any stage in the production or life cycle of a component.

When are NDE Methods Used?

To assist in product development To screen or sort incoming materials To monitor, improve or control manufacturing processes To verify proper processing such as heat treating To verify proper assembly To inspect for in-service damage

Six Most Common NDT Methods Visual

Liquid Penetrant Magnetic Ultrasonic Eddy Current X-ray

Visual Testing
most widely used experienced inspector knows where are likely cracks , orientation of cracks relative to various zones in the weld, surface porosity, weld penetration, potential weakness such as sharp notches or misalignment

Visual Inspection
Most basic and common inspection method. Tools include fiberscopes, borescopes, magnifying glasses and mirrors. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.

Penetrant
extension of visual inspection for detection of surface flaws two kinds ; dye penetrant and fluorescent penetrants

Magnetic particle testing

for locating surface & subsurface discontinuities in ferromagnetic materials leakage current occurs at the discontinuities / surface flaws when magnetized fine particles collect at the leakage sites

Radiography
The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential Electrons + -

X-ray Generator or Radioactive Source Creates Radiation

Radiation Penetrate the Sample

Exposure Recording Device

Eddy Current Testing

Coil
Coil's magnetic field

Eddy current's magnetic field

Eddy currents Conductive material

Ultrasonic testing
use beams of high frequency sound waves to probe the material internal flaws and locations can be determined by analyzing reflected sound waves

ADVANTAGES OF VISUAL INSPECTION

a. Simple b.Easy to Apply c. Quickly carried out d.Low cost

BASIC PRINCIPLE Basic Requirements:

Surface of the specimen should be cleaned Illumination of test specimen with light (800-1000 lux) Human eye

THE EYE:

Most valuable NDT tool is the human eye

The sensitivity of the human eye varies for light with different wavelengths
The eye is most sensitive to yellow green light (wavelength of 5560 A0)

Introduction

Penetrant Testing, or PT, is a nondestructive

testing method that builds on the principle of Visual Inspection.

PT increases the

seeability of small discontinuities that the human eye might not be able to detect alone.

LIQUID PENETRANT TESTING

General Introduction Penetrant Materials and Considerations Basic Steps in Penetrant Testing Common Equipment Advantages and Limitations Summary Glossary of Terms

Penetrant inspection utilizes the natural accumulation of a fluid around a discontinuity to create a recognizable indication of a crack or other surface opening. Capillary action attracts the fluid to the discontinuity as compared to its surroundings. In order to locate the area of excess fluid defect region), the background area must be of sufficient contrast thus leading to distinct detection of the defect on the surface.

PHYSICAL PRINCIPLES
Penetrant Inspection depends upon ability of liquid to wet the surface of a solid work piece or specimen and flow over that surface to form continuous and reasonably uniform coating, thus penetrating into cavities that are open to the surface. The ability of liquid flow over surface and enter into cavities mainly depends upon Surface Tension Capillary Action

 Surface Tension: The cohesive force between the molecules of a liquid causes surface tension Capillary Action: It is phenomenon of rise or dression of liquid in narrow cavities.
Viscosity : Although it has negligible effect on penetrating ability of liquid, affects the following ability of penetrant.

Introduction

Magnetic Particle Inspection (MPI)

can detect both surface and sub subsurface discontinuities (seams, laps, grinding cracks and quenching cracks) and in-service damage (fatigue and overload cracks).

PRINCIPLE OF MPT

Magnetic Particle Testing - (MT) Magnetic particle inspection (MPI) is used for the detection of surface and near-surface flaws in ferromagnetic materials. A magnetic field is applied to the specimen, either locally or overall, using a permanent magnet, electromagnet, flexible cables or hand-held prods. If the material is sound, most of the magnetic flux is concentrated below the material's surface. However, if a flaw is present, such that it interacts with the magnetic field, the flux is distorted locally and 'leaks' from the surface of the specimen in the region of the flaw. Fine magnetic particles, applied to the surface of the specimen, are attracted to the area of flux leakage, creating a visible indication of the flaw. The materials commonly used for this purpose are black iron particles and red or yellow iron oxides. In some cases, the iron particles are coated with a fluorescent material enabling them to be viewed under a UV lamp in darkened conditions.

EDDY CURRENT INSPECTION is

based on the principle of electromagnetic induction and is used to identify or differentiated among a wide variety of physical, structural and metallurgical conditions in electrically conductive ferromagnetic and nonferromagnetic metals and metal parts.

Radiographic Inspection
This technique involves the use of penetrating gamma or X-radiation to examine parts and products for imperfections. An X-ray machine or radioactive isotope is used as a source of radiation. Radiation is directed through a part and onto film or other media. The resulting shadowgraph shows the internal soundness of the part. Possible imperfections are indicated as density changes in the film in the same manner as an X-ray shows broken bones.

Radiography
The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential Electrons + -

X-ray Generator or Radioactive Source Creates Radiation

Radiation Penetrate the Sample

Exposure Recording Device

Film Radiography
The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density) will vary with the amount of radiation reaching the film through the test object. = less exposure

X-ray film

= more exposure
Top view of developed film