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Module 10
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Module 10 - 2
Visual Inspection
Very cost effective Limited to surface only Requires
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Module 10 - 3
Application of VT
Before welding During welding After welding
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Module 10 - 4
VT Before Welding
Review documents Check welding procedures Qualify/Certify welders, or check certifications Establish hold points Develop inspection plan Develop system for reject identification Develop defect repair system
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Module 10 - 5
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Module 10 - 6
VT During Welding
Note welder skills Check welding variables/procedure compliance Examine tacks and roots Check backgouged surfaces Check preheat temperatures Check interpass temperatures Check interpass cleaning
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Module 10 - 7
VT After Welding
Examine weld appearance Check weld size and length Check part dimensions Monitor other NDE methods Monitor postweld heat treating Prepare inspection reports
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Module 10 - 8
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Module 10 - 9
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Module 10 - 10
Temperature Measurements
Required for:
Preheat Interpass temperature limits Post weld heat treatments
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Module 10 - 11
Temperature-sensitive Crayons
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Module 10 - 12
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Module 10 - 13
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Module 10 - 14
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Module 10 - 15
Nondestructive Testing
Method of testing to evaluate quality and not effect end-use serviceability
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Module 10 - 16
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Module 10 - 17
PT MT RT UT ET
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Module 10 - 18
Penetrant Testing
Surface discontinuities only Relies on penetrant bleedout Magnifies discontinuity size Several methods
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PT Types
Visible dye Fluorescent dye
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Module 10 - 20
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Module 10 - 21
Apply Penetrant
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Module 10 - 22
Dwell Time
Varies with the nature of the job, typically in the range of 2 to 20 minutes, or longer in special cases
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Module 10 - 24
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Module 10 - 25
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Module 10 - 26
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Module 10 - 27
Apply Developer
In this example, spray can is too close to the weld surface, which can lead to excessive developer on surface. A distance of 10-12 inches is better.
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Module 10 - 28
Excessive Developer
Note runs caused by excess developer; this can mask discontinuities
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Module 10 - 29
Evaluate PT
Note porosity and crack indications
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Module 10 - 30
Clean Part
Post inspection removal of developer residues may be required, particularly if work piece is to be weld repaired or painted.
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Module 10 - 31
PT Advantages
Relatively simple All types of metals Quite sensitive Quite portable
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Module 10 - 32
PT Limitations
Somewhat slow Limited to surface Smooth surfaces required
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PT Results
Sketches Photographs Lift off tapes
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Module 10 - 34
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Module 10 - 35
Aspects of a Magnet
Magnetic flux (field) North and south poles Like sign poles repel Opposite signs attract Flux lines are parallel to each other; do not cross
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Module 10 - 36
Magnetic Fields
Produced by two methods: Permanent magnets Electro magnets
Direct current Alternating current Half wave rectified AC
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Module 10 - 37
Permanent Magnet
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Module 10 - 38
Electromagnets
A current-carrying conductor creates a magnetic flux around the conductor and perpendicular to the current flow.
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Module 10 - 39
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Module 10 - 40
MT Principles
A flaw oriented transverse to magnetic flux creates poles of opposite signs at edges of flaw. Very attractive to iron particles
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Magnetic Particles
Iron based Dry or wet Types
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Longitudinal Magnetism
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Circular Magnetism
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MT Steps
Magnetize part Apply iron particles Evaluate accumulation Clean part Demagnetize part
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Module 10 - 45
MT Equipment
AC / DC bench units AC yokes AC / DC yokes AC / DC prods AC / DC coils
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Module 10 - 46
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Module 10 - 47
MT Method --Yoke
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MT Method --Prods
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MT Advantages
Rapid Very sensitive Low cost Portable
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Module 10 - 50
MT Limitations
Magnetic materials only Poor with thick coatings Limited to surface, or near-surface Demagnetization may be required
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Module 10 - 51
MT Results
Sketches Photographs Lift off tapes
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Module 10 - 52
Radiographic Testing
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Module 10 - 53
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Module 10 - 54
Radiation Absorption
Thicker, or higher density materials absorb more radiation, resulting in less transmission to the film.
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Module 10 - 55
Absorption vs Thickness
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Metal Densities
Grams/cubic centimeter
Aluminum Steel Copper Lead Tungsten 2.70 7.87 8.96 11.34 19.30
Module 10 - 56
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Module 10 - 57
Absorption vs Density
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Module 10 - 58
Radiation Types
X-Ray
Machine
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Module 10 - 59
RT Steps
Position radiation source Position film behind object Expose radiation Develop film Evaluate
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Module 10 - 60
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Module 10 - 61
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Module 10 - 62
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Module 10 - 63
RT Equipment
Radiation source
X-ray machine Gamma radiation source
Film viewers
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Module 10 - 64
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Module 10 - 65
RT Advantages
Detects subsurface flaws Used for all materials Film is permanent record
If stored properly
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Module 10 - 66
RT Limitations
Radiation hazard Requires access to both sides Flaw orientation Flaw types Film interpretation
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Module 10 - 67
RT Results
Film Video tape Sketches
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Module 10 - 68
Ultrasonic Testing
Based on the propagation of sound waves through materials, and the reflected echo from density changes.
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Module 10 - 69
Piezoelectric Effect
Refers to materials which can convert electrical energy to mechanical energy and vice versa.
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Module 10 - 70
Principles of Sound
Sound travels within a given material at a constant velocity, based in part, on material density. Sound will not travel in a vacuum. There are several types of sound waves: Longitudinal (straight beam) Shear (angle beam) Others not pertinent to weld inspection
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Module 10 - 71
Couple probe to part with couplant Carry out testing Evaluate signals
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Module 10 - 72
UT Process
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Module 10 - 73
Longitudinal Calibration
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UT Process - 1 of 2
Module 10 - 74
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Module 10 - 75
UT Process - 2 of 2
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Module 10 - 76
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Module 10 - 77
Weld Testing - 1 of 2
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Module 10 - 78
Weld Testing - 2 of 2
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Module 10 - 79
UT Advantages
A true volumetric test One side access Very accurate Deep penetration - 200 Critical flaws found Equipment fully portable
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Module 10 - 80
UT Limitations
Highly skilled operator Smooth surfaces Groove welds > 1/4 thick
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Module 10 - 81
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Module 10 - 82
Test Coil
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Module 10 - 83
ET Uses
Flaw detection Metal thickness Coating thickness Metal hardness Heat treatment
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Module 10 - 84
ET CRT Displays
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Module 10 - 85
ET Equipment
Base unit, CRT or meter AC probe (coil) Calibration standards
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Module 10 - 86
ET Advantages
No contact required with part No couplant required Readily Automated Applicable to all metals
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Module 10 - 87
ET Limitations
Highly skilled operator Too sensitive Shallow penetration - 3/16 Calibration standards required Requires surface cleanliness Magnetic materials more difficult
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Module 10 - 88
NDE Symbols
Similar to weld symbols Shorthand notation Very useful Combine with weld symbols
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Module 10 - 89
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Module 10 - 90
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Module 10 - 91
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Module 10 - 92
WIT Summary
Have covered much material in 3 days Workbook and Sample Fundamentals Exam are good guides to your grasp of each Module, and may point towards areas needing more study in Manual Urge all to study these subjects in greater depth as part of continuing education
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