NDT 1

NONNON -DESTRUCTIVE TESTING
NONNON -DESTRUCTIVE TESTING/ EVALUATION (NDT OR NDE)
Faculty of Mechanical Engineering
Ali Ourdjini, UTM - 2006
Introduction
Non Destructive Testing/ inspection/ evaluation (NDT/NDE) is increasingly being used as a primary basis for assuring structural integrity, fitness for use and revalidation of structural integrity during maintenance and overhaul operations
What is NDT? Non Destructive Testing (NDT) is the inspection or testing (of materials and components) that can verify the structural integrity of the material service. . or component without compromising its ability to perform in service In destructive testing, the specimen is destroyed destroyed. . It can no longer be used for the purpose it was intended for for. . In destructive testing, if the destroyed specimen was found satisfactory for the purpose intended, are all other components made at the same time and in the same way are also usable?
If the specimen tested was found unsatisfactory, does it mean that all others are not fit for use? Unlike destructive testing, NDT may be used on all specimens specimens: : 100 100% % testing with 100 100% % of satisfactory specimens available for use NDT plays an important role in everyday life and is necessary to assure safety and reliability. Examples of the use of NDT includes aircraft, automotive, pipelines, bridges, trains, power stations, refineries and oil platforms. NDT is a Quality Assurance Management tool which can give impressive results when used correctly.
Faculty of Mechanical Engineering Ali Ourdjini, UTM - 2006
NDT requires understanding of the methods available, available, their capabilities and limitations limitations, , knowledge of the relevant standards and specifications for performing the tests. manufacture, and the NDT can be applied at any stage of a component manufacture, components being tested by NDT are either accepted, rejected or repaired NDT is also used to monitor the integrity of the component throughout its design life NDT can be used to find, size and locate surface and subsurface (internal) flaws and defects.
Where is NDT used? NDT is used where we need to ensure the serviceability of a product: product :
raw material (ingot casting), fabrication (welding), finished product or completed system (machine, plant etc )
Raw Materials Design
Processing
DT Technologies
Manufacturing/ Fabrication
In-Service Monitoring

Post Graduate Professional Certificate FMS - MISC Programme
Typical NDT Applications

Post Graduate Professional Certificate FMS - MISC Programme
INDUSTRY TYPE
TESTING
Aerospace Industry Aircraft Overhaul Automotive Industry Petrochemical & Gas Industry Railway Industry Mining Industry Agricultural Engineering Power Generation Iron Foundry Shipbuilding Industry Steel Industry Pipe & Tube Manufacturing Industry Faculty of Mechanical Engineering
Testing components including aero-engine, landing gear and air frame parts during production Testing components during overhaul including aero-engine and landing gear components Testing brakes-steering and engine safety critical components for flaws introduced during manufacture. Iron castings - material quality. Testing of diesel engine pistons up to marine enghine size Pipe-line and tank internal corrosion measurement from outside. Wel testing on new work. Automotive LPG tank testing Testing locomotive and rolling stock axles for fatigue cracks. Testing rail for heat induced cracking. Diesel locomotive engines and structures Testing of pit head equipment and underground transport safety critical components Testing of all fabricated, forged and cast components in agricultural equipment including those in tractor engines Boiler and pressure vessel testing for weld and plate defects both during manufacturing and in subsequent service. Boiler pipe work thickness measurement and turbine alternator component testing Testing ductile iron castings for metal strength on 100% quality control basis Structural and welding testing. Hull and bulkhead thickness measurement. Engine components testing Testing of rolled and re-rolled products including billets, plate sheet and structural sections Raw plate and strip testing. Automatic ERW tube testing. Oil line pipe spiral weld testing
Why is NDT used? NDT is used because of: Economic advantages, Avoid physical injuries Freedom from liability damages Desire to produce high quality goods and products NDT saves money, material, time and life when it is properly applied.
When is NDT used? NDT is used both before and after production of raw material, before and after fabrication, before and after assembly. Which materials can be tested by NDT? Almost all materials can be inspected by using one or more NDT method.
NDT Advantages 1.
2. 3. 4. 5. 6. Tested parts can be reused More than one inspection method can be applied to a similar component Inspection on a certain part may be repeated Require minimum or no specimen preparation Equipment are normally portable (suitable for field inspection) Inspection may be performed while the component is in service
NDT Limitations
1. 2. Results are qualitative Requires highly trained personnel

DT Advantages
1. Results are quantitative 2. Does not require highly trained and experienced personnel.
DT Limitations 1. Tested parts become scrap and considered loss

2. 3. 4. 5. 6. Repetitive inspection cannot be performed on a similar part Each part can only tested once Parts to be inspected have to be taken away from the system and replaced Require specimen preparation Equipment are normally stationary
The widely used NDT methods are:

Visual Inspection Liquid Penetrant Inspection (LPI) Magnetic Particle Inspection (MPI) Eddy Current Inspection (EC) Ultrasonic Inspection (UT) Radiography (RAD)
1. 2.
The NDT techniques fall into two categories: techniques which only detect and size defects/flaws present on the surface of a component techniques which can detect and size defects/flaws embodied within a component (internal defects)
Which method is selected depends on the:

Material of Construction Physical properties of the material Type of flaws and defects to be detected (surface (surface or subsurface) subsurface)
Thus, extensive knowledge of each NDT method is essential to ensure the suitable method is selected They all require operation of equipment and interpretation of results by skilled, well trained personnel personnel. .
Origins of Defect Two categories of defects defects: :

1.
Processing defects
Gas porosity during casting, welding or heat treatment
2.

In service defects
Cracks due to fatigue, stress corrosion, Corrosion, erosion
VISUAL INSPECTION
Probability Visual inspection Visual Inspection is probably the first and most widely of Detection (PoD) used method of NDT. Simplest and easiest method to apply Thus, It involves inspecting and evaluating components for surface condition, presence of defects, surface roughness or dimensional changes. changes Applications 1.

Weld Inspection
Inspection of correct weld preparation Inspection for surface defects, e.g. undercuts and cracks Verification of completed weld profile (cap, root)
2. Metrology Probability of Detection (PoD)

Measurement of component geometry Measurement of surface roughness
Thus, 3. Monitoring in service

Detection of corrosion Detection of defects and cracks
4.

Etch inspection
Detection of grinding defects Detection of incorrect heat treatment (case depth) metallographic examination (weld profile, inclusions grain size, cracks, microstructure)
In visual inspection, access to the surface is required and its capability relies on good illumination (lighting) and the eyesight of the inspector
Visual inspection can be enhanced by using various aids aids: : Magnifying glasses Borescopes Borescopes: : allow inspection of internal surfaces in piping, engines, air frames TV camera systems systems: : permits inspection in difficult and hazardous sites, such as nuclear installations and underwater pipelines. pipelines . Surface replication using strippable films also permits the remote inspection of surfaces. surfaces .
LIQUID (DYE) PENETRANT INSPECTION (LPI)
Liquid penetrant inspection is a method that is used to reveal surface breaking flaws by bleed out of a colored or fluorescent dye from the flaw. flaw . The technique is based on the ability of a liquid to be drawn into a "clean" clean" surface discontinuity or flaw by capillary action
LPI OPERATING STEPS

1. Cleaning of the subject (material, component) to remove all traces of foreign material, grease, dirt, etc from the surface
2.
A penetrant is applied and allowed to remain in contact with the surface
3.
The excess penetrant is then removed completely from the surface
4.
A thin coating of developer is applied
5.
After a period of time (development time), the developer draws the dye out of the crack to form a visual indication in good contrast to the background
STEP 1: SURFACE PREPARATION All surfaces must be cleaned and completely dried before inspection Cleaning methods include include: : 1. Vapour cleaning 2. Solvent cleaning 3. Ultrasonic cleaning
What is a penetrant and what makes a good penetrant? Basically, any liquid could be considered a penetrant. However, the liquid penetrant must posses certain properties: Penetration:
ability to enter fine surface defects in the component under test
Fluidity
ability to drain away from the component well
Stability (under temperature & humidity)

stable over a wide range of temperatures and humidity and should not lose its volatile constituents while it is stored in open tanks or drums
Washability
It must be possible to remove excess penetrant from component surfaces easily without affecting the penetrant within the defect
Drying characteristics
Must resist drying out during hot air drying of the component after the wash has been completed
Wetting ability
Must have good wetting ability and be able to maintain a surface film on the component, and hence continue to feed into a defect over a considerable period of time
Classifications of Penetrants
LPI is classified based on the indicating method into:
1. 2. Dye Penetrants : solution of red dye which reveal a red indication on white developer Fluorescent penetrants: solution containing fluorescence which emits green fluorescent indication when viewed in the dark
They are also classified based on the method used for the removal of excess penetrant into:
1. 2. 3. Water washable Solvent removable Post emulsifier
STEP 2: PENETRANT APPLICATION
Dye penetrant
Fluorescent penetrant
2. Penetrant applied to the surface and enters defect

STEP 3: REMOVAL OF EXCESS PENETRANT
3. Excess penetrant removed from surface
STEP 4: DEVELOPMENT
Developer
4. Developer powder applied to draw penetrant out of crack


Dye penetrant
STEP 5: OBSERVATION & INSPECTION
Light
Fluorescent penetrant
5. Indication of crack as penetrant spreads around opening

ADVANTAGES OF LPI Simple method with no sophisticated equipment involved LPI can be applied for any material except porous materials Any size and shape can be inspected by LPI LIMITATIONS OF LPI LPI can only detect surface breaking defects
MAGENTIC PARTICLE INSPECTION (MPI)

Magnetic particle inspection (MPI) is a method that can be used to detect surface and near surface defects or flaws in ferromagnetic materials such as steel and iron. MPI is based on the principle that magnetic lines of force (flux) will be distorted by the presence of a defect in a manner that will reveal its presence. Magnetism is the ability of a material to attract other materials to itself Materials that possess this ability are said to be magnetic: Ferromagnetic materials
Magnetic field exists within and around a magnet or within and around a conductor carrying an electric current Magnetic lines of force can be found in and around the objects objects. . A magnetic pole is a point where the a magnetic line of force exits or enters a material material. .
Magnetic lines of force around a bar magnet

Leakage field Occurs when the magnetic field is forced out into the air by the distortion of the field within a material When a ferromagnetic material is magnetised, magnetic discontinuities that lie normal to the field direction will result in the formation of a strong leakage leakage field or flux leakage The leakage field can be detected by the use of finely divided magnetic particles, which collect at the surface defect defect. .

Flux lines
No defect
Presence of a defect
As shown in the Figure below, the crack is located from the "flux leakage", following the application of fine magnetic particles (usually iron powders), to the area under examination examination. .

Dry particles
The iron particles can be applied dry or wet wet; ; suspended in a liquid, colored or fluorescent. Before inspection with MPI it is necessary that careful and proper preparation of the surface is conducted. For example, surface irregularities and scratches can give misleading indications.
Wet particles

The main steps involved in MPI are 1. Cleaning the part from oil, grease, or scale (which may prevent particles from being attracted to leakage fields and also interfere with interpretation of indications). 2. Magnetisation of the part to be inspected 3. Application of fine magnetic particles (iron particles, dry or wet) while the part is being magnetised 4. Inspect the part surface for any flux leakage fields 5. Clean the part of any particles residues 6. Demagnetise the part
Magnetising Methods The required magnetic field can be introduced into a component in a number of different ways: 1. Using a permanent magnet that contacts the test piece 2. Flowing an electrical current through the specimen 3. Flowing an electrical current through a coil of wire around the part or through a central conductor running near the part.
Magnetising Methods
Electrical current through the specimen
Using a permanent magnet
Electrical current through a coil of wire around the part

Magnetising Methods The magnetising methods are classified based on: on: 1. Whether or not the magnetising force is maintained, into into: : A. Continuous Methods Used on materials with low remanence Magnetic particles are applied on the part while it is being magnetised
B. Residual methods Used on materials with high remanence Magnetic particles are applied after the part has been magnetised and the magnetising force is removed removed. . Relies on the residual magnetism retained in the part part. .
2. Based on character of the magnetising field used, into: Circular
Longitudinal
The probability that a defect will be detected depends on its orientation in relation to direction of magnetic field
Correct direction of magnetic field is required

Examples of MPI indications (using dry particles)
Before
After
Examples of MPI indications (using wet particles)
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Gear with service Induced Crack
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Large Bolt with Service Induced Crack

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Demagnetisation The amount of magnetism that remain in the part after magnetic inspection depends on the permeability (the ease with which a material can be magnetised) of the material and the strength and direction of the magnetising force After MPI it is often necessary to demagnetise the part.

This is done for several reasons reasons: : The part may be used in an area where a residual magnetic force will interfere with the operation of instruments that are sensitive to magnetic fields Abrasive particles may attach to the magnetised part and cause wear Particles could also stick to the magnetised surface and interfere with subsequent operations such as painting, electroplating, etc During arc welding, strong magnetic field could deflect the arc Demagnetisation is also required if the part is to be magnetised at a lower magnetising force in a different direction than the previous test test. .

NDT 1

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NONNON -DESTRUCTIVE TESTING

NONNON -DESTRUCTIVE TESTING/ EVALUATION (NDT OR NDE)

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

NONNON -DESTRUCTIVE TESTING

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Raw Materials Design

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Typical NDT Applications

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

DT Limitations 1. Tested parts become scrap and considered loss

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

The widely used NDT methods are:

NONNON -DESTRUCTIVE TESTING

Which method is selected depends on the:

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Origins of Defect Two categories of defects defects: :

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

2. Metrology Probability of Detection (PoD)

Thus, 3. Monitoring in service

Faculty of Mechanical Engineering

NONNON -DESTRUCTIVE TESTING

LIQUID (DYE) PENETRANT INSPECTION (LPI)

Faculty of Mechanical Engineering

Ali Ourdjini, UTM - 2006

NONNON -DESTRUCTIVE TESTING

Faculty of Mechanical Engineering