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TESTING
By
A.GANESH
CMS / AWTI
NON DESTRUCTIVE TESTING
NDT - Inspection of a material using non invasive
techniques to check its integrity. (i.e. Inspect or
measure without damaging the component)
Why NDT ?
Ensuring integrity and reliability of a product.
Visual Inspection
Penetrant test (PT / LPT/DPT)
DISCONTINUITY
INTERPRETATION Judging
• Some examples:
Plants and trees draw water up from
the ground to their branches and
leaves to supply their nourishment.
The human body has miles of
capillaries that carry life sustaining
blood to our entire body.
STEPS IN PENETRANT TEST
Method
A Water Washable
B Postemulsifiable - Lipophilic
C Solvent Removable
D Postemulsifiable - Hydrophilic
Developer Form
Dry Powder
Wet, Water Soluble
Wet, Water Suspendable
Wet, Non-Aqueous for type I
Wet, Non-Aqueous for type II
Specific application
PENETRANT SYSTEM
Important penetrant properties:
Wettability – adhesive, cohesive force
Capillarity – contact angle, surface tension
Fluidity – viscosity
Retention & bleeding
Stability
Contrast – visible & fluorescent
CENTRE PIVOT PIN WITH
SURFACE CRACK
ADVANTAGES
• Relative ease of use.
• Can be used on a wide range of material types.
• Large areas or large volumes of parts/materials can be inspected
rapidly and at low cost.
• Parts with complex geometries are routinely inspected.
• Indications are produced directly on surface of the part providing a
visual image of the discontinuity.
• Initial equipment investment is low.
• Aerosol spray cans can make equipment very portable.
LIMITATIONS
• Only detects surface breaking defects.
• Requires relatively smooth nonporous material.
• Precleaning is critical. Contaminants can mask defects.
• Chemical handling precautions necessary (toxicity, fire, waste).
• Metal smearing from machining, grinding and other operations
inhibits detection. In such case, materials may need to be etched
prior to inspection.
• Post cleaning is necessary to remove chemicals.
SUMMARY
Principle: Capillary action and bleed out
Procedure:
Pre cleaning.
Application of penetrant
Dwell time
Removal of excess penetrant.
Application of developer
Developing time.
Penetrant types.
Developer types.
PRINCIPLE:
Magnetic particles present in a magnetic field
are attracted towards the “flux leakage” caused by
a discontinuity present in a ferromagnetic material.
MAGNETISM
Magnetism is the ability of matter Magnetic field lines:
to attract other matter to itself. • Form complete loops.
Objects that possess the property • Do not cross.
of magnetism are said to be • Follow the path of least
magnetic or magnetized and resistance.
magnetic lines of force can be • All have the same
found in and around the objects. strength.
A magnetic pole is a point where • Have a direction such that
the a magnetic line of force exits they cause poles to attract
or enters a material. or repel.
S N
Demagnetized Magnetized
HOW DOES MPI WORK?
A ferromagnetic test specimen is magnetized
with a strong magnetic field created by a
magnet or special equipment. If the specimen
has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through
the specimen and a leakage field will occur.
HOW MPI WORKS?
Finely milled iron particles coated with a dye
pigment are applied to the test specimen. These
particles are attracted to leakage fields and will
cluster to form an indication directly over the
discontinuity. This indication can be visually
detected under proper lighting conditions.
BASIC PROCEDURE
Basic steps involved:
1. Component pre-cleaning
5. Demagnetisation.
PRE-CLEANING
Part’s surface should be clean and dry before
inspection
When inspecting a test part with the magnetic
particle method it is essential for the particles to
have an unimpeded path for migration to both
strong and weak leakage fields alike.
Contaminants such as oil,
grease, or scale may not
only prevent particles from
being attracted to leakage
fields, they may also
interfere with interpretation
of indications.
INTRODUCTION OF THE MAGNETIC
FIELD
The required magnetic field can be introduced into a
component in a number of different ways.
1. Using a permanent magnet or an electromagnet 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.
DIRECTION OF THE MAGNETIC FIELD
LONGITUDINAL MAGNETIC FIELD
CIRCULAR MAGNETIC FIELD
A longitudinal
magnetic field is
usually established by
placing the part near
the inside or a coil’s
annulus. This
produces magnetic
lines of force that are
parallel to the long
axis of the test part.
CIRCULAR MAGNETIC FIELDS
Magnetic Field
Electric
Current
Wet method.
With the wet method, the part is flooded
with a solution carrying the particles.
The wet method is generally more
sensitive since the liquid carrier gives the
magnetic particles additional mobility.
Visible and Fluorescent type.
CRANE HOOK WITH
SERVICE INDUCED CRACK
Magnetized Demagnetized
ADVANTAGES OF MPI
• Can detect both surface and sub-surface
defects.
• Can inspect parts with irregular shapes
easily.
• Precleaning of components is not as critical
as it is for some other inspection methods.
• Fast method of inspection and indications are
visible directly on the specimen surface.
• Considered low cost compared to many other
NDT methods.
• Is a very portable inspection method
especially when used with battery powered
equipment.
LIMITATIONS OF MPI
•Cannot inspect non-ferrous materials .
•Inspection of large parts may require use of
equipment with special power requirements.
•Some parts may require removal of coating
or plating to achieve desired inspection
sensitivity.
•Limited subsurface discontinuity detection
capabilities. Maximum depth sensitivity is
approximately 6mm (under ideal conditions).
•Post cleaning, and post demagnetization is
often necessary.
•Alignment between magnetic flux and defect
is important
SUMMARY
Principle: Flux leakage
Ferromagnetic materials.
Procedure:
Pre cleaning
Magnetic field
Magnetic Particle (simultaneous / residual)
Interpretation of indication
Demagnetization.
Magnetization types.
Equipments.
Demagnetization & its Importance.
Advantages & Limitations.
ULTRASONIC TESTING
Propagation and echoing of ultrasonic waves
Ultrasonic waves > 20,000Hz.
initial
pulse
0 2 4 6 8 10
COMPONENTS OF
ULTRASONIC TESTING
UT Equipment (CRT monitor and control unit)
Transducer Probe (Normal, Angle)
Couplant.
Calibration block.
Reference block.
APPLICATIONS OF UT IN RAILWAYS
Rails
ULTRASONIC TESTING
Merits:
High penetration, sensitivity and accuracy.
Capability of estimating size, orientation and shape
of the defect.
Non hazardous, portable.
Demerits:
High skill & training required for operation.
Difficult to inspect rough surface & irregular shapes.
RADIOGRAPHIC TESTING
X – Ray:
Gamma Ray:
Produced during radioactive decay of elements.
Sources: Natural: U-235, Artificial: Ir-192, Co-60.
RADIOGRAPHIC TESTING
Electromagnetic radiation of certain wavelengths
penetrate materials and are absorbed differentially
by different materials.
X-Ray or gamma radiation is used.
Interpretation
RADIOGRAPHS OF
WELDMENTS
WELD DISCONTINUITIES AS INDICATED
ON RADIOGRAPHIC FILM
Transverse cracks
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
WELD DISCONTINUITIES AS INDICATED
ON RADIOGRAPHIC FILM
DEMERITS:
Thickness is limited depending upon source.
Radiation hazard.
SUMMARY
Visual Inspection
Dye penetrant test – Capillary action