Non Destructive Testing Metrology & Instrumentation (3341905)

EXPERIMENT NO. 13

Aim: To study of non destructive testing.

Introduction:
Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials,
components or assemblies for discontinuities, or differences in characteristics without
destroying the serviceability of the part or system. In other words, when the inspection or test
is completed the part can still be used.
Today modern nondestructive tests are used in manufacturing, fabrication and in-service
inspections to ensure product integrity and reliability, to control manufacturing processes,
lower production costs and to maintain a uniform quality level.

Ultrasonic:
Ultrasonic testing uses the same principle as is used in naval SONAR and fish finders. Ultra-
high frequency sound is introduced into the part being inspected and if the sound hits a
material with different acoustic impedance (density and acoustic velocity), some of the sound
will reflect back to the sending unit and can be presented on a visual display. By knowing the
speed of the sound through the part (the acoustic velocity) and the time required for the sound
to return to the sending unit, the distance to the reflector (the indication with the different
acoustic impedance) can be determined.
Straight Beam Technique:

Figure 13.1 Straight beam ultrasonic technique

Straight beam inspection uses longitudinal waves to interrogate the test piece as shown in at
the right. If the sound hits an internal reflector, the sound from that reflector will reflect to the
transducer faster than the sound coming back from the back-wall of the part due to the shorter
distance from the transducer. This results in a screen display like that shown at the right in
Figure 13.1. Digital thickness testers use the same process, but the output is shown as a digital
numeric readout rather than a screen presentation.
Department of Mechanical Engineering
Government Polytechnic Porbandar 13.1
Non Destructive Testing Metrology & Instrumentation (3341905)
Dye Penetration:
This method is used to reveal surface discontinuities by bleedout of a colored or fluorescent
dye from the flaw. The technique is based on the ability of a liquid to be drawn into a "clean"
surface discontinuity by capillary action. After a period of time called the "dwell time", excess
surface penetrant is removed and a developer applied. This acts as a blotter that draws the
penetrant from the discontinuity to reveal its presence.
The general steps can be summarized as follows:
1. Surface Preparation: The surface must be free of oil, grease, water, or other
contaminants that may prevent penetrant from entering flaws.
2. Penetrant Application: Once the surface has been thoroughly cleaned and dried, the
penetrant material is applied by spraying, brushing, or immersing the part in a
penetrant bath.
3. Penetrant Dwell: The penetrant is left on the surface for a sufficient time to allow as
much penetrant as possible to be drawn from or to seep into a defect.
4. Excess Penetrant Removal: This is the most delicate part of the inspection procedure
because the excess penetrant must be removed from the surface of the sample while
removing as little penetrant as possible from defects.
5. Developer Application: A thin layer of developer is then applied to the sample to draw
penetrant trapped in flaws back to the surface where it will be visible.
6. Indication Development: The developer is allowed to stand on the part surface for a
period of time sufficient to permit the extraction of the trapped penetrant out of any
surface flaws.
7. Inspection: Inspection is then performed under appropriate lighting to detect
indications from any flaws which may be present.
8. Clean Surface: The final step in the process is to thoroughly clean the part surface to
remove the developer from the parts that were found to be acceptable.

Figure13.2 Dye Penetration Test

Department of Mechanical Engineering
Government Polytechnic Porbandar 13.2