NDT 1 PDF

NON--DESTRUCTIVE TESTING
NON
NON--DESTRUCTIVE TESTING/ EVALUATION

NON
(NDT OR NDE)
Faculty of Mechanical Engineering
Ali Ourdjini, UTM - 2006
NON
Introduction
Non
Destructive
Testing/
inspection/ evaluation (NDT/NDE)
is increasingly being used as a
primary
basis
for
assuring
structural integrity, fitness for use
and revalidation of structural
integrity during maintenance and
overhaul operations
NON
What is NDT?
Non Destructive Testing (NDT) is the inspection or testing (of materials
and components) that can verify the structural integrity of the material
service..
or component without compromising its ability to perform in service
In destructive testing, the specimen is destroyed
destroyed.. It can no longer be
used for the purpose it was intended for
for..
In destructive testing, if the destroyed specimen was found satisfactory
for the purpose intended, are all other components made at the same
time and in the same way are also usable?
NON
If the specimen tested was found unsatisfactory, does it mean that all
others are not fit for use?
Unlike destructive testing, NDT may be used on all specimens
specimens:: 100
100%
%
testing with 100
100%
% of satisfactory specimens available for use
NDT plays an important role in everyday life and is necessary to assure
safety and reliability.
Examples of the use of NDT includes aircraft, automotive, pipelines,
bridges, trains, power stations, refineries and oil platforms.
NDT is a Quality Assurance Management tool which can give
impressive results when used correctly.
correctly.
NON
NDT requires understanding of the methods available,

available, their capabilities
and limitations
limitations,, knowledge of the relevant standards and specifications
for performing the tests.
manufacture, and the

NDT can be applied at any stage of a component manufacture,
components being tested by NDT are either accepted, rejected or
repaired
NDT is also used to monitor the integrity of the component throughout

its design life
NDT can be used to find

find,, size and locate surface and subsurface
(internal) flaws and defects.
NON
Where is NDT used?

NDT is used where we need to
ensure the serviceability of a
product::
product
raw material (ingot casting),
fabrication (welding), finished
product or completed system
(machine, plant etc
etc.
.)
NON
Raw Materials
Design
Processing
DT
Technologies
Manufacturing/ Fabrication
In-Service Monitoring
NON
Post Graduate Professional Certificate FMS - MISC Programme
Typical NDT Applications
NON
Post Graduate Professional Certificate FMS - MISC Programme
INDUSTRY TYPE
TESTING
Aerospace Industry
Testing components including aero-engine, landing gear and air frame parts during
production
Aircraft Overhaul
Testing components during overhaul including aero-engine and landing gear components
Automotive Industry
Testing brakes-steering and engine safety critical components for flaws introduced during
manufacture. Iron castings - material quality. Testing of diesel engine pistons up to marine
enghine size
Petrochemical & Gas Industry
Pipe-line and tank internal corrosion measurement from outside. Wel testing on new work.
Automotive LPG tank testing
Railway Industry
Testing locomotive and rolling stock axles for fatigue cracks. Testing rail for heat induced
cracking. Diesel locomotive engines and structures
Mining Industry
Testing of pit head equipment and underground transport safety critical components
Agricultural Engineering
Testing of all fabricated, forged and cast components in agricultural equipment including
those in tractor engines
Power Generation
Boiler and pressure vessel testing for weld and plate defects both during manufacturing
and in subsequent service. Boiler pipe work thickness measurement and turbine alternator
component testing
Iron Foundry
Testing ductile iron castings for metal strength on 100% quality control basis
Shipbuilding Industry
Structural and welding testing. Hull and bulkhead thickness measurement. Engine
components testing
Steel Industry
Testing of rolled and re-rolled products including billets, plate sheet and structural sections
Pipe & Tube Manufacturing Industry
Raw plate and strip testing. Automatic ERW tube testing. Oil line pipe spiral weld testing
NON
Why is NDT used?

NDT is used because of:
Economic advantages,
Avoid physical injuries
Freedom from liability damages
Desire to produce high quality goods and products
NDT saves money, material, time and life when it is properly applied.
NON
When is NDT used?
NDT is used both before and after production of raw material, before
and after fabrication, before and after assembly.
Which materials can be tested by NDT?
Almost all materials can be inspected by using one or more NDT

method.
NON
NDT Advantages
1.
2.
3.
4.
5.
6.
Tested parts can be reused

More than one inspection method can be applied to a similar component
Inspection on a certain part may be repeated
Require minimum or no specimen preparation
Equipment are normally portable (suitable for field inspection)
Inspection may be performed while the component is in service
NDT Limitations
1.
2.
Results are qualitative

Requires highly trained personnel
NON
DT Advantages
1. Results are quantitative
2. Does not require highly trained and experienced personnel.
DT Limitations
1. Tested parts become scrap and considered loss
2.
3.
4.
5.
6.
Repetitive inspection cannot be performed on a similar part

Each part can only tested once
Parts to be inspected have to be taken away from the system and replaced
Require specimen preparation
Equipment are normally stationary
NON
The widely used NDT methods are:
1.
2.
Visual Inspection
Liquid Penetrant Inspection (LPI)
Magnetic Particle Inspection (MPI)
Eddy Current Inspection (EC)
Ultrasonic Inspection (UT)
Radiography (RAD)
The NDT techniques fall into two categories:

techniques which only detect and size defects/flaws present on the
surface of a component
techniques which can detect and size defects/flaws embodied within
a component (internal defects)
NON
Which method is selected depends on the:

Material of Construction
Physical properties of the material
Type of flaws and defects to be detected (surface
(surface or subsurface)
subsurface)
Thus, extensive knowledge of each NDT method is essential to ensure

the suitable method is selected
They all require operation of equipment and interpretation of results by
skilled, well trained personnel
personnel..
NON
Origins of Defect
Two categories of defects

defects::
1.
Processing defects
2.
Gas porosity during casting, welding or heat treatment
In service defects
Cracks due to fatigue, stress corrosion,

Corrosion, erosion
NON
VISUAL INSPECTION
NON
Probability
Visual inspection
Visual
Inspection is probably the first and most widely
of Detection
(PoD)
used method of NDT. Simplest and easiest method to apply
Thus,
It involves inspecting and evaluating components for surface condition,
presence of defects, surface roughness or dimensional changes.
changes
Applications
1.
Weld Inspection
Inspection of correct weld preparation

Inspection for surface defects, e.g. undercuts and cracks
Verification of completed weld profile (cap, root)
NON
2.
Metrology
Probability
of Detection (PoD)
Measurement of component geometry

Measurement of surface roughness
Thus,
3.
Monitoring in service
4.
Detection of corrosion
Detection of defects and cracks
Etch inspection
Detection of grinding defects

Detection of incorrect heat treatment (case depth)
metallographic examination (weld profile, inclusions grain size, cracks,
microstructure)
In visual inspection, access to the surface is required and its capability

relies on good illumination (lighting) and the eyesight of the inspector
Visual inspection can be enhanced by using

various aids
aids::
Magnifying glasses
Borescopes
Borescopes:: allow inspection of internal
surfaces in piping, engines, air frames
TV camera systems
systems:: permits inspection in
difficult and hazardous sites, such as
nuclear installations and underwater
pipelines..
pipelines
Surface replication using strippable films
also permits the remote inspection of
surfaces..
surfaces
NON
LIQUID (DYE) PENETRANT

INSPECTION
(LPI)
NON
Liquid penetrant inspection is a method that is used to reveal surface

breaking flaws by bleed out of a colored or fluorescent dye from the
flaw..
flaw
The technique is based on the ability of a liquid to be drawn into a

"clean"
clean" surface discontinuity or flaw by capillary action
NON
LPI OPERATING STEPS

1.
Cleaning of the subject (material, component) to remove all traces of foreign

material, grease, dirt, etc from the surface
2.
A penetrant is applied and allowed to remain in contact with the surface
3.
The excess penetrant is then removed completely from the surface
4.
A thin coating of developer is applied
5.
After a period of time (development time), the developer draws the dye out of
the crack to form a visual indication in good contrast to the background
NON
STEP 1: SURFACE PREPARATION

All surfaces must be cleaned and completely dried before inspection
Cleaning methods include

include::
1. Vapour cleaning
2. Solvent cleaning
3. Ultrasonic cleaning
NON
What is a penetrant and what makes a good penetrant?

Basically, any liquid could be considered a penetrant.
However, the liquid penetrant must posses certain properties:
Penetration:
ability to enter fine surface defects in the component under test
Fluidity
ability to drain away from the component well
Stability (under temperature & humidity)

stable over a wide range of temperatures and humidity and should not
lose its volatile constituents while it is stored in open tanks or drums
NON
Washability
It must be possible to remove excess penetrant from component
surfaces easily without affecting the penetrant within the defect
Drying characteristics
Must resist drying out during hot air drying of the component after the
wash has been completed
Wetting ability
Must have good wetting ability and be able to maintain a surface film on
the component, and hence continue to feed into a defect over a
considerable period of time
NON
Classifications of Penetrants
LPI is classified based on the indicating method into:

1.
Dye Penetrants : solution of red dye which reveal a red indication on

white developer
2.
Fluorescent penetrants: solution containing fluorescence which emits

green fluorescent indication when viewed in the dark
They are also classified based on the method used for the removal of
excess penetrant into:
1.
Water washable
2.
Solvent removable
3.
Post emulsifier
NON
STEP 2: PENETRANT APPLICATION
Dye penetrant
Fluorescent
penetrant
2. Penetrant applied to the surface and enters defect

NON
STEP 3: REMOVAL OF EXCESS PENETRANT
3. Excess penetrant removed from surface
NON
STEP 4: DEVELOPMENT
Developer
4. Developer powder applied to draw penetrant out of crack

NON
STEP 5: OBSERVATION & INSPECTION
Dye penetrant
Light
Fluorescent penetrant
5. Indication of crack as penetrant spreads around opening

NON
ADVANTAGES OF LPI
Simple method with no sophisticated equipment involved
LPI can be applied for any material except porous materials
Any size and shape can be inspected by LPI
LIMITATIONS OF LPI
LPI can only detect surface breaking defects
NON
MAGENTIC PARTICLE INSPECTION

(MPI)
NON
Magnetic particle inspection (MPI) is a method that can be used to

detect surface and near surface defects or flaws in ferromagnetic
materials such as steel and iron.
MPI is based on the principle that magnetic lines of force (flux) will be
distorted by the presence of a defect in a manner that will reveal its
presence.
Magnetism is the ability of a material to attract other materials to itself
Materials that possess this ability are said to be magnetic:
Ferromagnetic materials
NON
Magnetic field exists within and around a magnet or within and around a
conductor carrying an electric current
Magnetic lines of force can be found in and around the objects
objects.. A
magnetic pole is a point where the a magnetic line of force exits or
enters a material
material..
Magnetic lines of force

around a bar magnet
NON
Leakage field
Occurs when the magnetic field is forced out into the air by the
distortion of the field within a material
When a ferromagnetic material is magnetised, magnetic discontinuities
that lie normal to the field direction will result in the formation of a strong
field or flux leakage
leakage
leakage field
The leakage field can be detected by the use of finely divided magnetic
particles, which collect at the surface defect
defect..
NON
Flux lines
No defect
Presence of a defect
NON
As shown in the Figure below, the crack is located from the "flux
", following the application of fine magnetic particles (usually iron
leakage",
leakage
powders), to the area under examination
examination..
NON
Dry particles
The iron particles can be applied

dry or wet
wet;; suspended in a liquid,
colored or fluorescent.
Before inspection with MPI it is
necessary that careful and proper
preparation of the surface is
conducted.
For example, surface irregularities
and scratches can give misleading
indications.
Wet particles
NON
The main steps involved in MPI are
1. Cleaning the part from oil, grease, or scale (which may prevent
particles from being attracted to leakage fields and also interfere with
interpretation of indications).
2. Magnetisation of the part to be inspected
3. Application of fine magnetic particles (iron particles, dry or wet) while
the part is being magnetised
4. Inspect the part surface for any flux leakage fields
5. Clean the part of any particles residues
6. Demagnetise the part
NON
Magnetising Methods
The required magnetic field can be introduced into a component in a
number of different ways:
1. Using a permanent magnet that contacts the test piece
2. Flowing an electrical current through the specimen
3. Flowing an electrical current through a coil of wire around the part or
through a central conductor running near the part.
NON
Magnetising Methods
Electrical current through the
specimen
Using a permanent magnet
Electrical current through a coil of

wire around the part
NON
Magnetising Methods
The magnetising methods are classified based on:

on:
1. Whether or not the magnetising force is maintained, into
into::
A. Continuous Methods
Used on materials with low remanence
Magnetic particles are applied on the part while it is being
magnetised
NON
B. Residual methods
Used on materials with high remanence
Magnetic particles are applied after the part has been
magnetised and the magnetising force is removed
removed..
Relies on the residual magnetism retained in the part
part..
NON
2. Based on character of the magnetising field used, into:

Circular
Longitudinal
NON
The probability that a defect will be detected depends on its

orientation in relation to direction of magnetic field
Correct direction of magnetic field is required

NON
Examples of MPI indications (using dry particles)
Before
After
NON
Examples of MPI indications (using wet particles)
www.ndt-ed.org
NON
Gear with service Induced Crack
www.ndt-ed.org
NON
Large Bolt with Service Induced Crack

www.ndt-ed.org
NON
Demagnetisation
The amount of magnetism that remain in the part after magnetic
inspection depends on the permeability (the ease with which a
material can be magnetised) of the material and the strength and
direction of the magnetising force
After MPI it is often necessary to demagnetise the part.
NON
This is done for several reasons

reasons::
The part may be used in an area where a residual magnetic force will
interfere with the operation of instruments that are sensitive to magnetic
fields
Abrasive particles may attach to the magnetised part and cause wear
Particles could also stick to the magnetised surface and interfere with
subsequent operations such as painting, electroplating, etc
etc.
.
During arc welding, strong magnetic field could deflect the arc
Demagnetisation is also required if the part is to be magnetised at a lower
magnetising force in a different direction than the previous test
test..

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NON--DESTRUCTIVE TESTING

NON--DESTRUCTIVE TESTING/ EVALUATION

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Ali Ourdjini, UTM - 2006

NDT requires understanding of the methods available,

manufacture, and the

NDT is also used to monitor the integrity of the component throughout

NDT can be used to find

Ali Ourdjini, UTM - 2006

Where is NDT used?

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Typical NDT Applications

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Petrochemical & Gas Industry

Pipe & Tube Manufacturing Industry

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Why is NDT used?

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

When is NDT used?

Which materials can be tested by NDT?

Almost all materials can be inspected by using one or more NDT

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Tested parts can be reused

Results are qualitative

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Repetitive inspection cannot be performed on a similar part

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

The widely used NDT methods are:

The NDT techniques fall into two categories:

Ali Ourdjini, UTM - 2006

Which method is selected depends on the:

Thus, extensive knowledge of each NDT method is essential to ensure

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Two categories of defects

Gas porosity during casting, welding or heat treatment

Cracks due to fatigue, stress corrosion,

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Ali Ourdjini, UTM - 2006

Inspection of correct weld preparation

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

Measurement of component geometry

Detection of grinding defects

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

In visual inspection, access to the surface is required and its capability

Visual inspection can be enhanced by using