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Non-Destructive

Testing
ENMT 604014

Wahyuaji NP – DM Nurjaya
Departemen Teknik Metalurgi dan Material FTUI

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Class info
• Credits : 2
• Semester : 4
• Prerequisite : Physical Metallurgy I
• Grading Systems : Homework, In Class Assgn., Midtest
• Textbook :
• The Testing of Engineering Materials; Harmer Elmer Davis, G.
Troxell and G. Hauck; 1982
• Testing of Materials; Vernon John; 1992
• Properties and Characterization of Modern Materials; Andreas
Ochsner and Holm Altenbach; 2017
• Reference :
• ASM handbook, Vol. 8 Mechanical Testing and Evaluation
Class Schedule
Date Subject Note
WNP 02 April 2018 Introduction, Visual Test, Dye Penetrant Test
WNP 09 April 2018 Magnetic Particle Inspection
WNP 16 April 2018 Ultrasonic Testing
WNP 23 April 2018 Eddy Current Testing Homework
WNP 30 April 2018 Radiography Testing
WNP 07 Mei 2018 Spectroscopy
WNP 14 Mei 2018 In Class Assignment Quiz
WNP 21 Mei 2018 Final Test
Class Rules
• Attendance is important but not mandatory
• No sleep in class
• Candies and drinks are allowed
• Late arrival is acceptable
• Don’t be noisy
• Homework submission
• Submit electronically
• Minus 10 points per day for late submission
• No plagiarism, no copy-paste
• Quiz, Mid test & Final test
• No cheating, no cell-phone, no restroom-break
• Late arrival is acceptable, however, no additional time
• Your answer-book will not be returned
• Any complaints or questions, please come to my office directly
Definition
Non-Destructive Examination
A term used collectively to denote a variety of inspection,
testing, and measurement process that elicit information
about the characteristic of an object without damaging it
or impairing its ability to perform its intended function.
NDE (NDT, NDI, NDEx)
testing, inspection, and examination
• looking at/through; measuring something about an
object
• to determine: some characteristic of the object, whether
the object contain, irregularities, discontinuities, or
flaws.
9 Areas
• flaw detection and evaluation
• leak detection and evaluation
• metrology
• location determination and evaluation
• structure and microstructure characterization
• estimation of mechanical and physical properties
• stress (strain) and dynamic response
• (signature analysis)
• (chemical composition determination)
Flaw Detection and Evaluation
6 primary factors involved in selecting an
NDE method(s):
• The reason(s) for performing the NDE
• The type(s) of flaws of interest in the object
• The size and orientation of flaws that is rejectable
• The anticipated location of the flaws of interest in the object
• The size and shape of the object
• The characteristics of the material to be evaluated
Flaws Definitions
• Discontinuity - Any change of property which can be
detected by means of NDI. (Discontinuities may be
natural features of a component, eg. a bolt hole, or
undesirable features such as cracks.)
• Flaw - An undesirable discontinuity. (Flaws may be
acceptable, e.g. an acceptably small non-metallic
inclusion, or unacceptable as will usually be the case
with a crack.)
• Defect - A flaw, the nature or size of which renders a
material or component unserviceable
TYPES OF DEFECTS
• Inherent defects - present during initial production of raw
materials
• processing defects - resulted from the manufacturing process
• Service defects - occurred during the operation
Examples of causes of defects
• Blowholes - gas trapped during solidification process
• Segregation - during solidification of alloy
• Scale - oxide formation on the surface of a metal heated to
high temperature
• Stress - residual stress after cold working or rapid cooling
Cracks
• quenching / hardening cracks - rapid volume change
• tempering cracks - rapid heating
• shrinkage cracks - rapid cooling
• grinding cracks - friction heating
• also caused by residual stress, collapsed blowholes, improper
rolling, sharp edge of dies etc.
5 Basic Elements
• Source (probe medium)
• Modification (changing as the result of variations or
discontinuities)
• Detection (determining the changes)
• Indication (indicating or recording the signals)
• Interpretation (interpreting the indications)
Indications
• Indication - That which indicates a the presence of a
discontinuity. Indications may be developed directly on
the component being inspected, eg. penetrant and
magnetic particle indications, or on a separate test
instrument eg. in the form of deflections in a CRT trace,
deflections of a pointer on a meter, or on a separate
recording medium, eg. a radiograph or chart recording
• False Indication - An indication arising from an
unintended source
• Non-relevant Indication - An indication of a discontinuity
which is not of the nature of that sought
• Relevant Indication - An indication of significance to the
purpose of the inspection
Methods of NDE
• VISUAL TESTING (VT)
• LIQUID PENETRANT TESTING (LT)
• MAGNETIC PARTICLE TESTING (MT)
• EDDY CURRENT TESTING (ET)
• ULTRASONIC TESTING (UT)
• RADIOGRAPHIC TESTING (RT)
• Acoustic Emissions Testing (AE)
• Neutron Radiographic Testing (NRT)
• Strain measurement (SM)
• Thermographic, etc
Visual Inspection

Metallurgy and Materials Engineering


University of Indonesia
Basic Principles
• Illuminate the test specimen with light
• Examine the specimen with the eye

Optical aid can be used to :


• Magnify defects which can not be detected by the unaided eye
• Assist in the inspection of defects
• Permit visual checks of areas not accessible to unaided eye
Methods
• Optical Aids
• In-Situ Metallography
• Optical Holography

Optical holography: (a) hologram formation (b) image reconstruction


Equipments
• Magnifying Glass
• Magnifying Mirror
• Microscope
• Borescope
• endoscopes or endoprobes
• Flexible Fiber Optic Borescope
• working lengths are normally 60 to 365 cm with
diameters from 3 to 12.5 mm
• Video Imagescope
Borescope
Visual acuity
• "Non-destructive Testing Personnel Qualification and Certification",
which is:
• At least one eye: Capable of reading the letters of an Ortho-Rater 8 or
Jaeger #2 Chart at 12 inches.
• Personnel shall be capable of distinguishing and differentiating between
colours used in the process involved
Liquid Penetrant
Inspection
Metallurgy and Materials Engineering
University of Indonesia
Feature
• Used very extensively
• Relatively inexpensive
• Few limitations to specimens geometry or material
• Equipment is very simple
• Relatively little specialized training to perform inspection
Methods
• Penetrant is drawn into crack by capillarity action. Water
spray removes penetrants from surface (but not from
crack). Developer acts like a blotter to draw penetrant
out of crack.
• If fluorescent penetrant used, black light causes
penetrant to glow in dark
Objective
• surface opening due to cracks, porosity, seams,
laps, fold, small discontinuities, etc.
• Use to :
• Monitoring production technique
• Find and isolating the flaws, before other processes
continue
• Quality cross check for finishing product
Applications
• magnetic and non magnetic materials.
• homogeneous, not porous.
• castings, forgings, machined parts, and cutting tools, field
inspections; turbine blades for surface cracks or porosity

Limitations:
• flaw must be open to surface, surface must be clean and
relatively not porous.
Principles
• Cohesive and adhesive action

Molecular arrangements at a
liquid-wall interface. (a) The
contact angle, θ, as shown,
between the liquid and the
wall is less than 90o, and the
surface of the wall is wetted.
(b) Cohesive forces between
like molecules are greater
than the adhesive forces
between unlike molecules. In
this case, the surface of the
wall is not wetted and the
liquid is in the form of
separate droplets
Principles

Surface tension contact angle and surface wetting. The contact angle, θ and the
surface tension between solid and vapor (γSV), solid and liquid (γSL) and liquid
and vapor (γLV) are related as shown. The surface tensions (γSV), (γSL) and (γLV)
are not the same. Good surface wetting requires θ to be much less than 90°.
Other wise, if θ > 90°, the liquid will form droplets and no surface wetting will
occur
Principles
• Capillarity action

2  LV cos 
h
rg
Principles
Height, h that liquid penetrates in a crack :
• Depends on the capillarity force due to the
surface tension
• Requires a contact angle less than 900
• Increase as the crack width decrease
• Does not depends on the viscosity of the liquid
Materials
• U.S. Military Specification MIL-I-25135E
• Penetrant Systems :
• Type I - Fluorescent dye
• Type II - Visible dye
• Type III - Visible and fluorescent dye (dual mode)

• Method A - Water washable


• Method B - Post emulsifiable, lipophilic
• Method C - Solvent removable
• Method D - Post emulsifiable, hydrophilic

• Sensitivity Level 1/2


• Sensitivity Level 1 - Low
• Sensitivity Level 2 - Medium
• Sensitivity Level 3 - High
• Sensitivity Level 4 - Ultrahigh
Materials
• Developers
• Form a - Dry Powder
• Form b - Water soluble
• Form c - Water suspensible
• Form d - Non-aqueous
• Form e - Specific application
• Solvent removers
• Class (1) - Halogenated
• Class (2) - Non-halogenated
• Class (3) - Specific application
Material Conditions
• Direct use and simple preparation
• Ability to penetrate and remain in fine and coarse
openings
• vaporize and drying slowly
• Easy cleaned off after process
• Good contrast ability or fluorescent ability
• Chemical stability for operating and storage
• Non-corroded
• inexpensive
• Non-flammable
• Non-toxic and other dangerous effect to operator
Equipments
1. Portable kits are used for carrying out inspection of
small areas, for use on site; these often contain the
materials to be used in aerosol form
2. Fixed installations are used for testing components on
a continuous basis, with a series of processing stations
in sequential order to form a flow line. Increasingly,
these are being automated to provide automatic
component handling and timing
3. Self-contained processing booths are used for testing
large components which cannot be moved during
testing.
Portable Kits
Operations
1. Surface preparation. The surface must be free of oil,
grease, water, or other containing flaws. Penetrant
inspection should be scheduled prior to the mechanical
operations such as grit or vapor blasting, which have a
tendency to smear the surface of parts, thus closing the
defects.

2. Penetrant application. Penetrant may be applied by


spraying or immersing parts in a penetrant bath
Operations
3. Penetrant dwell. The penetrant is left on the surface
for a sufficient time to allow penetration into flaws. The
time involved is based on experience.

4. Excess penetrant removal. This is a most delicate


procedure because it is essential not to remove
penetrant from fine surface cracks. Penetrants may be
washed off directly with water, or first treated with an
emulsifier and then rinsed with water, or they may be
removed with a solvent.
Operations
5. Developer application. Developer may be applied by
dusting (dry powdered) or immersion or spray (water
developers) applications. Non aqueous wet developers
may be applied by spray only. The developer should
then be allowed to dwell on the part surface for
sufficient time (usually’ 10 mm minimum) to permit it
to draw penetrant out of any surface flaws to form
visible indications of such flaws. Longer times may be
necessary for tight cracks.
6. inspection. Inspection is then performed under
appropriate lighting to detect any flaws which may be
present.
7. Clean surface.
Operations

Pre-cleaning Apply penetrant Remove excess

Apply developer inspection


Post Emulsifier
Multistation Processing Unit

• Parts cleaning using MEK (methyl ethyl ketone)


• Penetrant application 5-30'
• Emulsifier station (if emulsifiable penetrant used)
• Rinse station (water spray tank), parts washing
• Drying oven (parts drying cabinet), 122F/50C
• Developing station (developer application) 5-15'
• Inspection booth
• Post cleaning
Processes
Test Methods
Designation Method Symbol
Fluorescent Water-washable FA
penetrant testing Post-emulsifiable FB
Solvent-removable FC
Dye Penetrant Water-washable VA
testing Solvent-removable VC

Dry developing Dry developer D


Wet developing Wet developer W
Solvent developer S
Non-developing No develop N
Comparison
Penetrating methods
Penetrating time
Dwell times
Indications

Casting shrinkage
Indications
Flaws Types
• Continuous Lines : Cracks are observed generally as jagged lines; cold
shuts appear as smooth, narrow straight lines; forging laps appear as
smooth wavy lines; scratches tend to be shallow.
• Broken Lines : Continuous lines become partially closed by working,
such as grinding, peening, forging, or machining, resulting in a
discontinuous line.
• Small Round Holes : These are typical of general porosity, gas holes,
pin holes, or very large grains.
Effect of mechanical surface preparation
False indications
Detecting fine cracks
Glossary of Terms
• black light. Electromagnetic radiation in the near-ultraviolet range of wavelength (330
to 390 nm).
• developer. A material applied to the specimen surface to accelerate bleed out and to
enhance the contrast of indications.
• Aqueous. A suspension of developer particles in water.
• Dry. A fine free-flowing powder.
• Liquid film. A suspension of developer particles in a solvent which leaves a resinous
film on the surface after drying.
• Soluble. A developer completely soluble in its carrier.
• Solvent. Developer particles suspended in a non-aqueous vehicle prior to application.
• developing time. The time between the application of the developer and the
examination of the part.
• dwell time. The time that the penetrant or emulsifier is in contact with the specimen
surface, including the time required for application and to drain (see Fig. 4.2).
• emulsification time (emulsifier dwell time). The time that an emulsifier remains on
the specimen to combine with the surface penetrant prior to removal.
• emulsifier. A liquid that interacts with an oily substance making it water washable.
• hydrophilic. Having a strong affinity for water. Substance that is attracted to
a water phase rather than to air in an air-water interphase (e.g., —OH).
Glossary of Terms
• hydrophilic emulsifier. A water-based liquid that interacts with the penetrant oil
rendering it water washable.
• lipophilic. A fat-liking molecular group (e.g., CH3) that has affinity for hydrocarbons.
• lipophilic emulsifier. An oil-based liquid that interacts with the penetrant oil
rendering it water washable.
• lyophilic. Solid-liquid mixture with surface active molecules containing several
molecular groups with both affinities and repulsions for the liquid phase; “solvent
loving” (opposite of lyophobic).
• lyophobic. “Solvent-hating” (opposite of lyophilic).
• penetrant. A liquid that is applied to the surface of a part so that it penetrates
surface- breaking defects.
• • Dual purpose. Produces both fluorescent and color contrast visible indications.
• • Fluorescent. Emits visible radiation when excited by black light.
• • Solvent-removable. Traces removable by wiping with a material lightly moistened
with solvent remover.
• • Visible. Characterized by an intense color, usually red.
• • Water-washable. With a built-in emulsifier.
• Post emulsifications penetrant. Requires the application of a separate emulsifier to
render the excess surface penetrant water washable.

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