CSWIP 3.

1 Welding Inspection

Non-Destructive Testing

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Course Reference WIS 5
Course notes section reference 5.0
 Non-Destructive Testing

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)

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• Radiographic inspection (RT) ©

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• Ultrasonic inspection (UT)
 Non-Destructive Testing
Surface Crack Detection
• Liquid Penetrant (PT or Dye-Penetrant)
• Magnetic Particle Inspection (MT or MPI)

Volumetric Inspection
• Ultrasonics (UT)
• Radiography (RT)

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Each technique has advantages & disadvantages with respect
to: ©

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• Technical Capability and Cost
Note: The choice of NDT techniques is based on
consideration of these advantages and disadvantages
Penetrant Testing (PT)

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 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

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• Solvent removable contrast
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• Water washable fluorescent

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• Solvent removable fluorescent
• Post-emulsifiable fluorescent
 Penetrant Testing

Step 1. Pre-Cleaning
Ensure surface is very Clean normally with the use of a solvent

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 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.

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 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.

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 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.

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 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.

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 Penetrant Testing

Fluorescent Penetrant
Bleed out viewed
under a UV-A light
source

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Bleed out viewed
under white light Colour contrast Penetrant
 Penetrant Testing

Advantages Disadvantages

• Surface breaking defect only

• Simple to use
• little indication of depths
• Inexpensive
• Penetrant may contaminate
• Quick results component
• Can be used on any non- • Surface preparation critical

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porous material • Post cleaning required
• Portability • Potentially hazardous
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• Low operator skill required chemicals
• Can not test unlimited times
• Temperature dependant
 Penetrant Testing
Comparison with Magnetic Particle Inspection
ADVANTAGES
•easy to interpret results
•no power requirements
•relatively little training required
•can use on all materials

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DISADVANTAGES
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•good surface finish needed

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•relatively slow
•chemicals - health & safety issue
 Penetrant Testing

Any Questions

?
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Magnetic Particle testing (MT)

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 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

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• Any defect which interrupts the magnetic field, will create a ©

leakage field, which attracts the particles

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• 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
 Magnetic Particle Testing

Collection of ink
particles due to
leakage field

Electro-magnet (yoke) DC or AC

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Prods DC or AC
 Magnetic Particle Testing

A crack like
indication

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 Magnetic Particle Testing

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Alternatively to contrast inks, fluorescent inks may be used

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for greater sensitivity. These inks require a UV-A light source
and a darkened viewing area to inspect the component
 Magnetic Particle Testing

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

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g
• Iterpret the test area ©

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• Post clean and de-magnatise if required
 Magnetic Particle Testing

Advantages Disadvantages
• Simple to use • Surface or slight sub-surface
detection only
• Inexpensive
• Magnetic materials only
• Rapid results
• No indication of defects
• Little surface preparation
depths

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required
• Only suitable for linear
• Possible to inspect through ©

defects

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thin coatings
• Detection is required in two
directions
 Magnetic Particle Testing

Comparison with Penetrant Testing

ADVANTAGES
• much quicker than PT
• instant results
• can detect near-surface imperfections (by current flow
technique)
• less surface preparation needed

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DISADVANTAGES ©

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• only suitable for ferromagnetic materials
• electrical power for most techniques
• may need to de-magnetise (machine components)
 Magnetic Particle Testing

Any Questions

?
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Ultrasonic Testing (UT)

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 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

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c pulses to travel the distance to the interface and back
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• An interface could be the back of a plate material or a defect

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• 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

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Compression probe checking the material Thickness
 Ultrasonic Testing

defect Back wall

initial pulse echo echo

Material Thk

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defect
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0 10 20 30 40 50

Compression Probe CRT Display

 Ultrasonic Testing

UT Set
A Scan
Display

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Angle Probe
 Ultrasonic Testing

initial pulse

defect echo
defect 0 10 20 30 40 50

½ Skip CRT Display

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initial pulse ©

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defect echo
defect 0 10 20 30 40 50

Full Skip CRT Display

 Ultrasonic Testing

Advantages Disadvantages
 Rapid results  Trained and skilled operator
 Both surface and required

sub-surface detection  Requires high operator skill

 Safe  Good surface finish required

 Capable of measuring the  Defect identification

depth of defects

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 Couplant may contaminate
 May be battery powered  No permanent record ©

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 Portable  Calibration Required
 Ferritic Material (Mostly)
 Ultrasonic Testing
Comparison with Radiography
ADVANTAGES
•good for planar defects
•good for thick sections
•instant results
•can use on complex joints

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•can automate
•very portable
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•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 <8mm
• reliant on operator interpretation
• not good for sizing Porosity

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• good/smooth surface profile needed
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• not suitable for coarse grain materials (e.g., castings)

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• Ferritic Materials (with standard equipment)
 Ultrasonic Testing

Any Questions

?
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Radiographic Testing (RT)

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 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

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areas on a radiograph
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• Applicable to metals,non-metals and composites

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 Radiographic Testing

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X – Rays Gamma Rays ©

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Electrically generated Generated by the decay of
unstable atoms
 Radiographic Testing

Source

Image quality indicator

Radiation beam

10fe16

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Radiographic film Test specimen
 Radiographic Testing

Source

Image quality indicator

Radiation beam

10fe16

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10fe16
Test specimen ©

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Radiographic film with latent image after exposure
 Radiographic Testing

Density - relates to the degree of darkness

Densitometer

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Contrast - relates to the degree of difference

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Definition - relates to the degree of sharpness
Sensitivity - relates to the overall quality of the radiograph
 Radiographic Sensitivity

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7FE12
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Step / Hole type IQI Wire type IQI
 Radiographic Sensitivity

Step/Hole Type IQI

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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)

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• film outside, source outside (external exposure)
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Double Wall Double Image (DWDI)

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• film outside, source outside (elliptical exposure)
 Single Wall Single Image (SWSI)

Film

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Film
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IQI’s should be placed source side
Single Wall Single Image Panoramic

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Film
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• IQI’s are placed on the film side
• Source inside film outside (single exposure)
 Double Wall Single Image (DWSI)

Film

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• IQI’s are placed on the film side
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• Source outside film outside (multiple exposure)
• This technique is intended for pipe diameters over 100mm
 Double Wall Single Image (DWSI)

• Identification

• Unique identification
EN W10

• IQI placing

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• Pitch marks indicating A B
readable film length ©

ID MR11

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Radiograph
Double Wall Single Image (DWSI)

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Radiograph
 Double Wall Double Image (DWDI)

Film

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• IQI’s are placed on the source or film side
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• Source outside film outside (multiple exposure)

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• A minimum of two exposures
• This technique is intended for pipe diameters less than 100mm
 Double Wall Double Image (DWDI)

• Identification 4 3
• Unique identification EN W10

• IQI placing

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• Pitch marks indicating
1 2
readable film length ©

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MR12
Shot A Radiograph
Double Wall Double Image (DWDI)

4 3

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1 2

Elliptical Radiograph
 Radiography

PENETRATING POWER
Question:
What determines the penetrating power of an X-ray ?
•the kilo-voltage applied (between anode & cathode)

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Question:
What determines the penetrating power of a gamma ray ?
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•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

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• Thulium < 10 mm
• Caesium < 10 mm ©

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 Radiographic Testing
Advantages Disadvantages
Expensive consumables
Permanent record
• Bulky equipment
• Little surface preparation
• Harmful radiation
• Defect identification
• Defect require significant
• No material type limitation depth in relation to the
• Not so reliant upon radiation beam (not good
for planar defects)
operator skill

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• Slow results
• Thin materials
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• Very little indication of

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depths
• Access to both sides
required
 Radiographic Testing
Comparison with Ultrasonic Examination
ADVANTAGES
good for non-planar defects
good for thin sections
gives permanent record
easier for 2nd party interpretation

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can use on all material types
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high productivity

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direct image of imperfections
 Radiographic Testing

Comparison with Ultrasonic Examination

DISADVANTAGES
• health & safety hazard
• not good for thick sections
• high capital and relatively high running costs
• not good for planar defects

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• X-ray sets not very portable
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• requires access to both sides of weld

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• frequent replacement of gamma source needed (half life)
 Radiographic Testing

Any Questions

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