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In this article, we review the most common non-destructive testing techniques used to
examine welded connections (example: welded pipes, fittings or pressure equipment).
Non-destructive tests do not damage the equipment being tests; destructive tests,
instead, may damage the product.
All surfaces to be visually examined must be thoroughly cleaned. This method is used
only to detect surface imperfections.
If these are found, additional tests are employed to discover the extent of the flaw.
This technique requires the surface application of a penetrating liquid containing a dye.
The liquid is given time to seep into any surface flaws, and excess liquid is removed.
The surface is allowed to dry, and the weld is examined. Flaws are indicated by the
presence of dye, which is visible to the naked eye.
Liquid penetrants are a low-cost test to detect cracks or abnormal porosity on the
surface of the equipment.
Some low alloys are magnetic, however, austenitic-chromium stainless steel is very
weakly magnetic and therefore excluded from this type of examination; this is subjected
to dye penetrant examination, which is covered later. The MPE method is very useful for
detecting fine cracks that are invisible to the naked eye.
To carry out the examination, the weld under analysis is first strongly magnetized with
an electromagnet, then fine particles of a magnetic material, such as iron or magnetic
iron oxide, are applied to the surface. The magnetic powder is attracted to the edges of
any surface cracks, making them visible to the naked eye.
If used correctly, the ultrasonic method can approach the accuracy of radiography. The
benefit of ultrasonic testing is that the equipment is portable; therefore, UT is useful
when the weld is in an awkward location or needs to be examined on site.
Radiographic (RT)
examination is the most useful nondestructive test, as it detects subsurface flaws
invisible to the naked eye.
This method originally employed X-rays, but today pipe joints can be examined using
gamma-rays produced by portable radioactive isotopes. All sources of radiation are
potentially dangerous, and exposure over extended periods must be avoided. Personnel
protection is often a requirement for technicians carrying out the radiography.
A film is placed on one side of the weld, and on the other side, the weld is subjected to
X-rays in the direction of the film. As the X-rays pass through the weld, any
imperfections on the surface and through the weld are detected by a dark shadow on
the exposed film.