Introduction to Nondestructive

Testing
What is Nondestructive Testing
Non-destructive testing is a method of
testing equipment and materials which
does not destroy them or effect their
future performance or properties
i.e. Inspect or measure without doing harm
What are Some Uses of NDT Methods?
Flaw Detection and Evaluation
Leak Detection
Location Determination
Dimensional Measurements
Structure and Microstructure Characterization
Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response Measurements
Material Sorting and Chemical Composition Determination
Visual Inspection (VI)
Penetrant Testing (PT)
Magnetic Particle Testing (MT or MPI)
Ultrasonic Testing (UT)
Radiographic Testing (RT)
Eddy Current
Basic Methods of NDT

Visual Inspection (VI)
It is the most cost effective method of inspection
Most basic and common inspection method
Visual Inspection requires little equipment, to name a few;
Good eyesight & sufficient light
Welding Gauge
Pocket Rule, small steel rule
Inspection mirror
Square for checking straightness, alignment & perpendicularity
Standards, codes & specification
Visual Inspection tools
Inspection Mirror
Checking Fillet Weld Size
Checking Weld Reinforcement
Checking Bevel Angle
Checking Fillet Weld Throat





The following measurements are possible either in inches or millimeters
Weld Gauge or Bridge Cam Gauge

Angle of Preparation
Scale reads 0 to 60 in
5 increments.
Angle is read against the
chamfered edge of the dial.


Fillet Weld Throat
Small sliding pointer reads to 20mm
and 3/4".
Gage also fits flush in 90 corners.


Excess Weld Metal
Scale reads in Inches and Millimeters.
Gage is placed on lower peice and dial
rotated until it contacts higher piece
Fillet weld throat size
Fillet weld length
Misalignment (high-low)

Angle of preparation, 0 to 60
Excess weld metal (capping size)
Depth of undercut
Depth of pitting
Penetrant Testing (PT)
The liquid is pulled into surface-
breaking defects by capillary action
Penetrant solution is applied to the
surface of a precleaned component
Solid
Penetrant
After a period of time called the dwell
time has elapsed, excess penetrant is
carefully cleaned from the surface
Solid
Penetrant
Basic Principles
A developer is applied to pull the trapped
penetrant back to the surface where it
spread out and forms an indication
The indication is much
easier to see than the
actual defect
Solid
Developer
Main Uses of PT
Used to locate cracks, porosity and other defects that is open to
the surface of a material.
i.e. Fatigue cracks Porosity Pin holes in weld
Quench cracks Laps Lack of fusion breaking
Grinding cracks Seams the surface

Can be use to inspect almost any material provided that its
surface is not extremely rough or porous.
i.e. Metals, Glass, Ceramics, Rubber, Plastics

Advantages and Disadvantages
Advantages
Low operator skill
Large surface can be inspected rapidly and at low cost
Portable, simple, cheap and easy to interpret
Applicable to non ferrous material

Disadvantages
Detects only surface breaking defects
Surface preparation is critical as contaminant may mask defect
Not applicable to porous material
Potential hazardous chemicals

Magnetic Particle Testing (MPI or MT)
Magnetic particle inspection is a
method of locating surface and
subsurface defects in ferromagnetic
materials
Basic Principles
A magnetic field is introduced in a
ferromagnetic material. The magnetic lines of
force travel through the material, and exit and
reenter the material at the poles
Defects such as cracks or voids cannot support as much flux,
and force some of the flux outside of the part creating flux
leakage
Magnetic particles distributed over
the component will be attracted to
areas of flux leakage and produces a
visible indication
FLUX LEAKAGE
S
N
Electromagnetic Yoke
Crack Indications
Main Uses of MT
Used to inspect ferromagnetic materials( those that can be
magnetized) for surface defects and those that are slightly
subsurface (near surface defects)
This method may be used to inspect plate edges prior to
welding, in process inspection of each weld pass, and to
inspect repair
It is good method for detecting surface crack of all sizes in
both weld and base metal, subsurface cracks, incomplete
fusion, undercut as well as defects on the repaired edges of
the base metal
Advantages and Disadvantages
Advantages
Pre-cleaning not as critical as PT
Can detect surface and subsurface defects
Relatively low equipment cost and simple equipment
Possible to inspect through thin coating

Disadvantages
Only ferromagnetic materials can be inspected
Requires relatively smooth surface
Proper alignment of magnetic field and defect is critical
Demagnetization is usually required
Ultrasonic Testing (UT)
Basic Principles
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
Oscilloscope, or
flaw detector
screen
A typical UT inspection consist of pulser/receiver, transducer
and display devices
Driven by the pulser, the transducer (probe) generates a high
frequency ultrasonic (sound wave) energy and is introduced
and propagates through the material
Basic Principles
When there is a discontinuity (such as crack) in the wave path,
part of the energy will be reflected back from the flaw surface
The reflected wave signal is transformed into electrical signal
by the transducer and is displayed on the screen
From the signal, information about the flaw location, size,
orientation and other features can sometimes be gained
Main Uses of MT
Used to locate surface and subsurface defects in many
material including metals, plastics and wood

It is also used to measure the thickness of material

Ultrasonic inspection has long been the preferred method for
nondestructive testing in welding application

Ultrasonic scanning systems are used automated data
acquisitioning and imaging
Advantages and Disadvantages
Advantages
Can be used in ferrous and non ferrous material
Portable with instant result
Able to detect subsurface defects, measure depth & through wall
extent
Can easily detect lack of sidewall fusion in welds

Disadvantages
High operator skill level
Requires calibration and difficult to interpret
Not easily applied to complex geometry
Linear defects oriented parallel to the sound beam may go
undetected
Radiographic Testing (RT)
Radiography is based on the ability of X-
rays and gamma rays to pass through
metal and other material.

The object is placed is placed between
radiation source and a piece of film.
Basic Principles
Radiation Source
Object
FILM
The thickness and the density
of the part affects the amount
of radiation reaching the film
Thicker and more dense area
will stop more radiation to
reach the film
The film darkness (density)
will vary with the amount of
radiation reaching the film

Basic Principles
X-ray film
Top view of developed film
= less exposure
= more exposure
Welding Consumable
Images of Porosity on weld
Images of Slag on weld
Main Uses of RT
Used to inspect almost any material for surface and
subsurface defects

Radiography can also be used to locate and measure internal
features of material

It can also be used to confirm the location of a hidden parts in
an assembly and to measure thickness of materials

Advantages and Disadvantages
Advantages
Most material can be tested
Detects internal flaw & give permanent record
Ability to inspect complex shapes
Gives direct images of flaw

Disadvantages
Extensive operator & film interpretation training & skill required
Access to both sides of the structure is usually required
Orientation of the radiation beam to planar flaws is critical
Relatively high capital cost
Radiation Hazard to personnel