15-Wis5 NDT 2006

CSWIP 3.
1 Welding Inspection
Non-Destructive Testing
TWI Training & Examination

Services
Course Reference WIS 5

Course notes section reference 15
World Centre for Materials Joining Technology Copyright © 2006, TWI Ltd
A welding inspector should have a working knowledge of NDT
methods and their applications, advantages and disadvantages.
Four basic NDT methods

• Magnetic particle inspection (MT)
• Dye penetrant inspection (PT)
• Radiographic inspection (RT)
• Ultrasonic inspection (UT)
Surface Crack Detection
• Liquid Penetrant (PT or Dye-Penetrant)
• Magnetic Particle Inspection (MT or MPI)
Volumetric Inspection
• Ultrasonics (UT)
• Radiography (RT)
Each technique has advantages & disadvantages with respect
to:
• Technical Capability and Cost
Note: The choice of NDT techniques is based on
consideration of these advantages and disadvantages
Penetrant Testing (PT)
Penetrant Testing
Main features:
• Detection of surface breaking defects only.
• This test method uses the forces of capillary action
• Applicable on any material type, as long they are non
porous.
• Penetrants are available in many different types:
• Water washable contrast
• Solvent removable contrast
• Water washable fluorescent
• Solvent removable fluorescent
• Post-emulsifiable fluorescent
Penetrant Testing
Step 1. Pre-Cleaning
Ensure surface is very Clean normally with the use of a solvent
Penetrant Testing
Step 2. Apply penetrant
After the application, the penetrant is normally left on the
components surface for approximately 15-20 minutes (dwell
time).
The penetrant enters any defects that may be present by
capillary action.
Penetrant Testing
Step 3. Clean off penetrant
the penetrant is removed after sufficient penetration time
(dwell time).
Care must be taken not to wash any penetrant out off any
defects present
Penetrant Testing
Step 3. Apply developer
After the penetrant has be cleaned sufficiently, a thin layer of
developer is applied.
The developer acts as a contrast against the penetrant and
allows for reverse capillary action to take place.
Penetrant Testing
Step 4. Inspection / development time
Inspection should take place immediately after the developer
has been applied.
any defects present will show as a bleed out during
development time.
After full inspection has been carried out post cleaning is
generally required.
Penetrant Testing
Fluorescent Penetrant Bleed out viewed
under a UV-A light
source
Bleed out viewed

under white light
Colour contrast Penetrant
Penetrant Testing
Advantages Disadvantages
• Simple to use • Surface breaking defect
• Inexpensive only
• Quick results • little indication of depths
• Can be used on any non- • Penetrant may
porous material contaminate component
• Portability • Surface preparation
• Low operator skill required critical
• Post cleaning required
• Potentially hazardous
chemicals
Penetrant Testing
Comparison with Magnetic Particle Inspection
ADVANTAGES
•easy to interpret results
•no power requirements
•relatively little training required
•can use on all materials
DISADVANTAGES
•good surface finish needed
•relatively slow
•chemicals - health & safety issue
Penetrant Testing
Any Questions
?
Magnetic Particle testing (MT)
Magnetic Particle Testing
Main features:
• Surface and slight sub-surface detection
• Relies on magnetization of component being tested
• Only Ferro-magnetic materials can be tested
• A magnetic field is introduced into a specimen being
tested
• Methods of applying a magnetic field, yoke, permanent
magnet, prods and flexible cables.
• Fine particles of iron powder are applied to the test area
• Any defect which interrupts the magnetic field, will create
a leakage field, which attracts the particles
• Any defect will show up as either a dark indication or in
the case of fluorescent particles under UV-A light a
green/yellow indication
Collection of ink
particles due to
leakage field
Electro-magnet (yoke) DC or AC
Prods DC or AC
A crack like
indication
Alternatively to contrast inks, fluorescent inks may be used

for greater sensitivity. These inks require a UV-A light source
and a darkened viewing area to inspect the component
Typical sequence of operations to inspect a weld
• Clean area to be tested
• Apply contrast paint
• Apply magnetisism to the component
• Apply ferro-magnetic ink to the component during magnatisin
g
• Iterpret the test area
• Post clean and de-magnatise if required
• Simple to use • Surface or slight sub-surface

detection only
• Inexpensive
• Magnetic materials only
• Rapid results
• No indication of defects
• Little surface preparation depths
required
• Only suitable for linear
• Possible to inspect through defects
thin coatings
• Detection is required in two
directions
Comparison with Penetrant Testing
ADVANTAGES
• much quicker than PT
• instant results
• can detect near-surface imperfections (by current flow
technique)
• less surface preparation needed
DISADVANTAGES
• only suitable for ferromagnetic materials
• electrical power for most techniques
• may need to de-magnetise (machine components)
Any Questions
?
Ultrasonic Testing (UT)
Ultrasonic Testing
Main Features:
• Surface and sub-surface detection
• This detection method uses high frequency sound waves,
typically above 2MHz to pass through a material
• A probe is used which contains a piezo electric crystal to
transmit and receive ultrasonic pulses and display the
signals on a cathode ray tube or digital display
• The actual display relates to the time taken for the ultrasoni
c pulses to travel the distance to the interface and back
• An interface could be the back of a plate material or a defect
• For ultrasound to enter a material a couplant must be introd
uced between the probe and specimen
Ultrasonic Testing
Pulse echo Digital

signals UT Set,
A scan
Display
Compression probe checking the material Thickness
Ultrasonic Testing
defect Back wall

initial pulse echo echo
Material Thk
defect
0 10 20 30 40 50
Compression Probe CRT Display
Ultrasonic Testing
UT Set
A Scan
Display
Angle Probe
Ultrasonic Testing
initial pulse
defect echo
defect 0 10 20 30 40 50
½ Skip CRT Display
initial pulse
defect echo
defect 0 10 20 30 40 50
Full Skip CRT Display
Ultrasonic Testing
 Rapid results  Trained and skilled operator
required
 Both surface and
 Requires high operator skill
sub-surface detection
 Good surface finish required
 Safe
 Defect identification
 Capable of measuring the
depth of defects  Couplant may contaminate
 May be battery powered  No permanent record
 Portable
Ultrasonic Testing
Comparison with Radiography
ADVANTAGES
•good for planar defects
•good for thick sections
•instant results
•can use on complex joints
•can automate
•very portable
•no safety problems (‘parallel’ working is possible)
•low capital & running costs
Ultrasonic Testing
Comparison with Radiography
DISADVANTAGES
• no permanent record (with standard equipment)
• not suitable for very thin joints
• reliant on operator interpretation
• not good for non-planar defects
• good/smooth surface profile needed
• not suitable for coarse grain materials (e.g., castings)
Ultrasonic Testing
Any Questions
?
Radiographic Testing (RT)
Radiographic Testing
The principles of radiography
• X or Gamma radiation is imposed upon a test object
• Radiation is transmitted to varying degrees dependant upon
the density of the material through which it is travelling
• Thinner areas and materials of a less density show as
darker areas on the radiograph
• Thicker areas and materials of a greater density show as
lighter areas on a radiograph
• Applicable to metals,non-metals and composites
X – Rays Gamma Rays

Electrically generated Generated by the decay of
unstable atoms
Source
Image quality indicator

Radiation beam
10fe16
Radiographic film Test specimen
Source
Radiation beam Image quality indicator
10fe16
10fe16
Test specimen
Radiographic film with latent image after exposure

Density - relates to the degree of darkness
Densitometer
Contrast - relates to the degree of difference

Definition - relates to the degree of sharpness
Sensitivity - relates to the overall quality of the radiograph
Radiographic Sensitivity
7FE12
Step / Hole type IQI Wire type IQI

Radiographic Sensitivity
Step/Hole Type IQI
Wire Type IQI

Radiographic Techniques
Single Wall Single Image (SWSI)
• film inside, source outside
Single Wall Single Image (SWSI) panoramic
• film outside, source inside (internal exposure)
Double Wall Single Image (DWSI)
• film outside, source outside (external exposure)
Double Wall Double Image (DWDI)
• film outside, source outside (elliptical exposure)
Single Wall Single Image
(SWSI)
Film
Film
IQI’s should be placed source side
Single Wall Single Image
Panoramic
Film
• IQI’s are placed on the film side

• Source inside film outside (single exposure)
Double Wall Single Image
(DWSI)
Film
• IQI’s are placed on the film side
• Source outside film outside (multiple exposure)
• This technique is intended for pipe diameters
over 100mm
(DWSI)
• Identification
• Unique identification
EN W10
• IQI placing
• Pitch marks indicating A B
readable film length
ID MR11
Radiograph
(DWSI)
Radiograph
Film
• IQI’s are placed on the source or film side
• Source outside film outside (multiple exposure)
• A minimum of two exposures
• This technique is intended for pipe diameters less than 100mm
• Identification 4 3
• Unique identification EN W10
• IQI placing
• Pitch marks indicating
1 2
readable film length
ID
MR12
Shot A Radiograph
4 3
1 2
Elliptical Radiograph
Radiography
PENETRATING POWER
Question:
What determines the penetrating power of an X-ray ?
•the kilo-voltage applied (between anode & cathode)
Question:
What determines the penetrating power of a gamma ray ?
•the type of isotope (the wavelength of the gamma rays)
Radiography
GAMMA SOURCES
Isotope Typical Thickness Range
• Iridium 192 10 to 50 mm (mostly used)
• Cobalt 60 > 50 mm
• Ytterbium < 10 mm
• Thulium < 10 mm
• Caesium < 10 mm
• Permanent record • Expensive consumables
• Little surface preparation • Bulky equipment
• Defect identification • Harmful radiation
• No material type limitation • Defect require significant
depth in relation to the
• Not so reliant upon radiation beam
operator skill
• Slow results
• Thin materials
• Very little indication of
depths
• Access to both sides
required
Comparison with Ultrasonic Examination
ADVANTAGES
good for non-planar defects
good for thin sections
gives permanent record
easier for 2nd party interpretation
can use on all material types
high productivity
Comparison with Ultrasonic Examination
DISADVANTAGES
• health & safety hazard
• not good for thick sections
• high capital and relatively high running costs
• direct image of imperfections
• not good for planar defects
• X-ray sets not very portable
• requires access to both sides of weld (panoramic
technique)
• frequent replacement of gamma source needed
Any Questions
?

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CSWIP 3.

TWI Training & Examination

Course Reference WIS 5

Four basic NDT methods

Bleed out viewed

Alternatively to contrast inks, fluorescent inks may be used

• Simple to use • Surface or slight sub-surface

Pulse echo Digital

Compression probe checking the material Thickness

defect Back wall

Compression Probe CRT Display

½ Skip CRT Display

Full Skip CRT Display

X – Rays Gamma Rays

Image quality indicator

Radiographic film Test specimen

Radiation beam Image quality indicator

Radiographic film with latent image after exposure

Contrast - relates to the degree of difference

Step / Hole type IQI Wire type IQI

Step/Hole Type IQI

Wire Type IQI

IQI’s should be placed source side

• IQI’s are placed on the film side

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