Digital Assignment 1

NON DESTRUCTIVE
TESTING METHODS
By
Kabilan.K
18MCD0033
 NDT methods

For surface cracks:

• Visual inspection
• Liquid penetration inspection
For surface and subsurface cracks
• Magnetic particle inspection
• Radiography / X-ray inspection
• Eddy current inspection (Appx. size of the crack can be found)
For surface and center crack
• Ultrasonic inspection (Exact size of the crack can be found)
 Visual inspection
Oldest method and First step in most NDT
• Visual inspection is the process of Processes uses visual inspection:
examination and evaluation of systems • Structural steel
and components by use of human sensory
systems aided only by mechanical • Automotive
enhancements • Petrochemical
• It includes a cognitive component • Power generation
wherein observations are correlated with
knowledge of structure and with
• Aerospace
descriptions and diagrams from service
literature
 Human senses are sensors

Other NDT methods also rely on Visual inspection. Uses of human senses:
• Looking
Methods requires visual judgement/inspection: • Listening
• Liquid penetration inspection • Feeling
• Magnetic particle inspection • Smelling
• Radiography or X-ray inspection • Shaking
• Eddy current inspection • Twisting
 Requirements

Requirements:
• The inspector's vision;
• The amount of light falling on the specimen, which is measured using a light
meter; and
• Whether the area being inspected is obstructed from view.
 Enhancements

Mechanical enhancements:
• Boroscopes
• Magnifying glasses
• Micrometer
• Mirrors
• UV Lights
 Defects

Defects that can be found:

• Cracks • Misalignment
• Corrosion • Improper Assembly
• Gas Holes • Missing Components
• Porosity • Undercut
 Advantages and Disadvantages of VT

Advantages:
Disadvantages:
• Low cost and lesser time • Need of Skilled personnel
• Most productive on macroscopic • Center defects cannot be found
defects.
 Dye or Liquid penetration inspection
Cracks with 150 nanometers can be determined

• DPI is based upon capillary action, Processes uses visual inspection:

where low surface tension fluid • Pressure vessels
penetrates into clean and dry surface- • Boilers
breaking discontinuities • Steel tubes
• Forging
• Die casting
• Aerospace
 Steps involved in LP
• Surface preparation
• Penetrant application
• Penetrant dwell
• Excess penetrant removal
• Developer application
• Indication development
• Inspection
• Clean surface
 Penetrants and lights

Penetrants used for testing: Lights used for testing:

• Water soluable • Ultraviolet
• Post-emulsifiable with water rinse • White light
• Solvent removable • Fluorescent (for max flaw density)
 Advantages and Disadvantages
Advantages:
• Low cost & lesser time
• Skilled personnel may not need
• Applied for complex shapes
• High sensitivity for even small defects
• Portable
Disadvantages:
• Need of Skilled personnel
• Prior experience is required
• Not suitable for very rough surfaces or
dirty surfaces
• Colour contrast may not there for
some materials
 Magnetic particle inspection
Used for Ferro magnetic materials with fine, shallow cracks.
• Any cracks and defects in the Processes uses visual inspection:
material will interrupt the flow of • Iron
current and will cause magnetism. • Cobalt
Magnetic particles spread over the • Nickel
surface will be drawn to the damage
site. • Alloys of the above materials
 PARTICLES & DETECTORS

• Proper lighting may required to

differentiate the high denser
location of particles
• Different equipment also available
to detect the particles
 PARTICLES & DETECTORS

Dry particles: Magnetic Field detectors:

~0.5 to 10 micrometers (L/D 1-2)
Wet Particles:
~5 to 170 micrometers
Lights used for testing:
• Ultraviolet
• Gauss gauge or Hall effect gauge
• Quantitative Quality Indicator(QQI)
• Pie Gauge
• Burmah Castrol strips/Slotted strips
TYPICAL RESULT
 ADVANTAGES AND DISADVANTAGES

Advantages: Disadvantages:

• Easy and fast • Test specimen size should be small & non-
complex shapes
• Portable
• The orientation & strength of the magnetic
• Pre-cleaning activity is not required field is critical

• Even near to surface center cracks can be • Demagnetization required on finished

specimen
determined.
• Large current may required on some materials
• Can be used for rough and dirty surfaces that could even burn the specimen in some
cases.
Radiography or X-ray inspection

Used for uncovering surface cracks.

The electromagnetic Processes uses visual inspection:
radiations is made to pass over • Pressurized piping
the specimen and reach the
photo film on the other side. The • Pressure vessels
density of the radiation varies in • High capacity storage
the defect region so the radiation containers
effect on the film can detected as
per change. • Pipelines
• Structural welds
Working
Radiation Source & defects found

Sources: Issues detected:

– Iridium 192 – Detect internal discontinuities such as
– Cobalt 60 shrinkage, cracking and porosity
– Verify the integrity of internal
components
– Determine the quality of welds
– Identify the extent of corrosion
– Uncover the source in fire investigations
Advantages and Disadvantages
Advantages:
– The picture of the X-ray is a semi
permanent record can be reviewed by no.
of persons in future.
– From the picture a skilled person can find
the defect location also the type and size. – Demagnetization required on
– Detects surface and subsurface defects
– Sensitive to change in thickness,
corrosion, flaws and material density
changes.
– Minimum surface preparation.
Disadvantages:
– Test specimen size should be small
& non-complex shapes
– The orientation & strength of the
magnetic field is critical
finished specimen
– Large current may required on
some materials that could burn
the specimen in some cases.
 EDDY CURRENT INSPECTION
Used for conductive materials.
• When alternating current is applied
to the conductor wire, a magnetic
field develops in and around the
conductor eddy currents are
produced due to the process can be
detected
Processes uses visual
inspection:
• Weld inspection
• Surface inspection
• Corrosion detection
• Bolt hole inspection
• Tube inspection
 PROBES
TYPES OF PROBES USED:
• SURFACE
• PENCIL
• DONUT
• SLIDING
• ID & OD
ADVANTAGES AND DISADVANTAGES
ADVANTAGES:
• TEST PROBE DOES NOT TOUCH THE SPECIMEN.
• SUITABLE FOR COMPLEX SHAPE.
• VERY PORTABLE
• DETECTS SURFACE AND SUBSURFACE DEFECTS
• SENSITIVE TO SMALL CRACKS.
• MINIMUM SPECIMEN PREPARATION.
DISADVANTAGES:
• ONLY CONDUCTIVE MATERIALS CAN BE
INSPECTED.
• SURFACE MUST BE ACCESSIBLE BY PROBE
• SURFACE FINISH AND ROUGHNESS AFFECTS
RESULTS
• FLAWS SUCH AS DELAMINATION THAT LIE
PARALLEL TO THE PROBE COIL WINDING AND
PROBE SCAN DIRECTION ARE UNDETECTABLE
 Ultrasonic inspection

Used for conductive materials.

• Ultrasonic waves are sent over
the specimen and the reflected
waves are recorded and the time
required to return is monitored
for any defect present.
Processes uses visual
inspection:
• Weld inspection
• Surface inspection
• Corrosion detection
• Bolt hole inspection
• Tube inspection
 Working Principle

 The ultrasonic waves are passed over the test specimen the
time required to the reflected is received at the receiver
end.
 The flaw/deflects the ultrasonic wave and the time taken at
the crack location can be found.
 By using 3 directional sensing the exact location and shape
of the crack can be found.
Working
 Advantages and Disadvantages
Advantages:
 Deeper flaws along with surface
defects can be determined.
 Only surface is accessible is enough in
most cases.
 Greater accuracy in finding the depth
and thickness of cracks
 Non hazardous for operators.
 Portable, automatable and
immediate results.
Disadvantages:
 Requires skilled technicians and
careful attention on manual
operations
 Rough, irregular, non homogeneous
very small or thin objects cannot be
inspected
 Couplants for effective transfer of
ultrasonic energy from transducer to
the specimen required.
~End of presentation~