METALLIC NDT TECHNIQUES

LIQUID PENETRANT INSPECTION OR DIE PENETRANT TEST

(DPT)

 LPI is a method that is used to

reveal surface breaking flaws/
defects by bleed out of a
colored or fluorescent dye from
the flaw.
 This technique works on the
principle of capillary action; i.e.
when developer is applied,
penetrant is drawn out of the
flaws gap.
 DPT
 In old times; Rubbing of carbon
black was used on glazed pottery;
Oil & whitening method in
railways work shop for iron and
steel components.
 Magnaflux: Visible or color
contrast dye penetrant method;
Fluorescent dye was also added
to liquid penetrant (these dyes
would then fluoresce/ glow when
study under ultraviolet light or
also called black light)
 Why a Penetrant Inspection Improves the
Detectability of Flaws

 LPI predominant over unaided visual inspection is that it makes flaw easier to see for
detector. There are two basically two ways that a penetrant inspection Tech. makes flaw
easier to see.
 First LPI produce flaw indication much larger for the eye than the flaw itself. Due to the
physical features of the eye , the threshold of the visual acuity is around 0.003 inch for a
person with 20/20 vision.
 The second way that LPI improves the detectability of a flaw is that it produces a flaw
indication with a high level of contrast between the indication and the background, that’s also
help to make the indication more easily seen. For example the use of bright red dye that
provide a high level of contrast between the white developer.
 Similarly, when fluorescent penetrant inspection is performed, the penetrant materials are
formulated to glow brightly and to give off light at a wavelength that the eye is most sensitive
to under dim lighting conditions.
 DPT PROCEDURE
 Surface Preparation : It’s a very critical step, because surface should be free of oil,
grease and other contaminations that prevents the penetrants entering into the flaws.
 Penetrant Application: Once the specimen is thoroughly clean & dried, the penetrant
material is properly applied by Brushing, Spraying or Immersing the part in the
penetrant bath. Penetrant is a high surface wetting characteristics.
 Penetrant Dwell: The penetrant applied on the specimen surface is allowed to settle
for sufficient time, so that it become seep into the flaws. Penetrant Dwell time is the
total time the penetrant is in contact with the surface. Dwell time is usually
recommended by the penetrant producers or required in the specifications being
followed. Usually time is 5-60minutes.
 Excess Penetrant Removal: it is the most delicate part of inspection process, because
excess penetrant must be removed from the surface while removing as little penetrant
as possible from defects. Depending upon the penetration system; cleaning solvents,
direct rinsing with water or emulsifier is also recommended.
 DPT PROCEDURE

 Developer Application: A thin layer of developer is then applied to the sample to draw
penetrant trapped in flaws back to the surface (via capillary action) where it will be
visible. Dusting (dry powdered), dipping or spraying (wet developers).
 Indication Development: The developer is allowed to stand on the part surface for a
period of time sufficient to permit the extraction of the trapped penetrant out of any
surface flaws. The development time is usually 10 minutes. For tight/thin cracks
significantly longer time may be necessary.
 Inspection: it is carried out under appropriate lightening for detection.
 Clean Surface: After inspection, thoroughly cleaning of inspected part is mandatory.
 PENETRANTS

 Two Types:
 Fluorescent Penetrants
 Visible Penetrants
 The properties of penetrant materials that are controlled by:
 AMS 2644 (Aerospace Military Specifications)
 MIL-I-25135E
 ASTM 1417
 That include flash point, surface wetting capability, viscosity, color, brightness,
ultraviolet stability, thermal stability, water tolerance, and removability.
 DEVELOPERS

Sample standards
 AMS 2644 (Aerospace Military Specifications)
 MIL-I-25135E
 ASTM 1417
 Form a - Dry Powder
 Form b - Water Soluble
 Form c - Water Suspendable
 Form d - Nonaqueous Type 1 Fluorescent (Solvent
Based)
 Form e - Nonaqueous Type 2 Visible Dye (Solvent
Based)
 Form f - Special Applications
 ADVANTAGES AND DISADVANTAGES OF DPT
Advantages
It is highly sensitive to small surface
discontinuities/flaws.
Metallic, non-metallic, magnetic, non-magnetic,
conductive and non-conductive materials may be
inspected
Large area and volume can be inspected rapidly
with low cost
Parts with complex geometric shapes can be
routinely inspected.
Disadvantages
Only detect Discontinuities that are open to
surface.
No sub-surface detection
Possibilities of fire and explosion
Penetrants can be toxic and hazardous
Water based chemicals may have deleterious effect
on some materials, especially steels.
 ULTRASONIC TECHNIQUE

 For microscopically homogenous materials;

Frequency range is 20KHz to 20 MHz
 With heterogeneous materials (Like Composite materials), frequency range limit is 5MHz
or less.
 In manual UT, the test-area is scanned by probe with hand. Small area is scanned,
requires high level of operator skills, signal amplitude is dependent on the thickness of
the coupling fluid layer and pressure applied by operators hand.
 METHODS OF UT TESTING
Three method are mainly used:
 PULSE-ECHO
 THROUGH TRANSMISSION (ULTRASONIC SPECTROSCOPY)
 PITCH/CATCH (BACK SCATTERED)

PULSE ECHO UT TECHNIQUE

“High frequency sound waves are introduced into a composite material and are reflected back from surfaces
or flaws”

initial
pulse

back surface
echo
crack
echo

crack
0 2 4 6 8 10 plate
ULTRASONIC TRANSDUCERS FOR CARBON FIBERS REINFORCED POLYMERS

 Normally Piezoelectric crystals

 PZT = Lead (Pb) zirconium titanate

 Able to send and receive signals

 Produces a compression wave

ULTRASONIC “A-SCAN” (VOLTAGE Vs TIME TRACE)

B SCAN: It display a 2D Slice through the
specimen is produced by scanning the probe
along the surface and capturing an A-Scan at
each point along the scanning direction i.e.
“Size & Position of Flaw Vs Probe movement”

C-SCAN: It is a “Top down” or “Plan” views

of the component i.e. “Attenuation/X-Y
position”
APPLICATION:
a) Large cracks & Delamination which is normally large in diameter. Therefore the presence and depth of
a de-lamination can be determined.

b) Voids, porosity, foreign inclusions can only be identified.

c) Fiber volume fraction & moisture or chemical ingression can be calculated with pulse-echo set up.
LIMITATION:
a) “DEAD ZONE” region is created at the “near surface”, where the probe cannot detect signals. But this
problem can be overcome by “Using TWIN CRYSTAL PROBE technique”

b) Difficult to cover large area in reasonable time.

c) Don’t work well with core materials in sandwich structures.

THROUGH TRANSMISSION
(ULTRASONIC SPECTROSCOPY)

Pulse arriving at the detecting transducers is analyzed harmonically and information

relating to the composite can be deduced from characteristic changes to the
frequency spectrum. And the ultrasonic velocity changes can be used to monitor the
location of flaw detection.
APPLICATION:
a) This technique is used to measure the small cracks, voids and porosity. The layer of
porosity because of its round size significantly reduces the amplitude of the highest
frequency harmonics but barely alters the lowest frequency.
b) “Poor Matrix Curing” can also be detected with this technique.
c) Through transmission technique is better than pulse echo for the determination of
thin specimens.
LIMITATIONS:
a) This Technique can only be applicable on composites, if attenuation caused by
different materials within the composite structure is known. Because the frequency
spectrum of the returning signal will be affected by attenuation within the material.
PITCH/CATCH (BACK SCATTERED)

In which the transducer is inclined at an acute angle . The echo received by second
transducer is monitored. The component is rotated about the axis normal to the
component surface, the angle being kept constant.

A plot of signal intensity verses the angle of rotation is recorded.

 Bond Testing in Pitch/ Catch Mode

APPLICATION:
a) Stacking sequence e.g. fiber orientation of graphite epoxy laminates, local fiber
waviness, ply-end discontinuities and trans-laminar cracks.
b) Matrix cracks due to thermo-elastic stresses.
LIMITATION:
a) The angle is critical and has to be maintained precisely.
b) This technique is very surface-orientation sensitive and sophisticated set-up is required
to maintain for correct alignment.