Non Destructive

Malaysian Institute of Aviation Technology
NON DESTRUCTIVE
TESTING
TheDefinition
use of noninvasive
of NDT
techniques to determine
the integrity of a material,
component
or structure or
Testing/Inpection/
quantitatively
measure
Evaluation
without doing
scteristic of
harm
to the parts/materials
an object.
Ujian tanpa musnah

i.e. Inspect or measure without doing harm.
What are Some Uses

of NDE 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
Fluorescent penetrant indication
When are NDE Methods Used?
There are NDE application at almost any stage

in the production or life cycle of a component.
To assist in product development
To screen or sort incoming materials
To monitor, improve or control manufacturing
processes
To verify proper processing such as heat treating
To verify proper assembly
To inspect for in-service damage
Methods of NDT
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Visual
NDT Certification in Malaysia

1.Sijil Kemahiran Malaysia(SKM)-Jabatan
Pembangunan Kemahiran
2.British Institute of NDT(BINDT)
3.American Society for NDT(ASNT)
Six Most Common NDT Methods
1. Visual
2. Liquid Penetrant
3. Magnetic
4. Ultrasonic
5. Eddy Current
6. X-ray
VISUAL INSPECTION
Basic Inspections
The most basic method
Basic tools
Light/ torch light
Mirror
Magnifying glass
Borescope optical device similar in
principle to a telescope in that it
enlarges the objects.
Inspect inside the engine e.g turbine blade
Robotic crawlers permit

observation in hazardous or
tight areas, such as air
ducts, reactors, pipelines.
Portable video inspection

unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Fiberoptic scope
Similar with standard borescope
Probe can be bend
Optical glass fiber transmit light from light
source to the scopes end/ probe.
Special attachment for camera to record a
photo
Video scope
Similar with fiberoptic scope except the image
recorded by light sensitive chip at the end of
the probe then transmitted electronically to
video monitor
Can be video recorded for inspection record
and review.
WELD INSPECTION
A good weld must have : Uniform width

No oxide form more than from the weld
Free gas pocket, porosity and inclusion.
Good penetration
Butt weld penetrate 100% of metal thickness
Fillet weld penetrate 25-50% of metal
thickness
If defect occurs welded part must be removed and
rewelding again
LIQUID PENETRANT
INSPECTION
Introduction
used to reveal surface breaking flaws by bleed out of
a colored or fluorescent dye from the flaw
Suitable for ferrous/nonferrous metals
Primary limitation of dye penetrant is that a defect
must be open to the surface
Based on principle of capillary attraction
A liquid with high surface wetting

characteristics is applied to the surface of the
part and allowed time to seep into surface
breaking defects.
The excess liquid is removed from the surface

of the part.
A developer (powder) is applied to
pull the trapped penetrant out the
defect and spread it on the surface
where it can be seen.
Visual inspection is the final step in the

process. The penetrant used is often loaded
with a fluorescent dye and the inspection is
done under UV light to increase test
sensitivity.
BASIC PROCESSING STEPS OF A LIQUID

PENETRANT Inspection
Surface Preparation:
surface must be free of oil, grease, water, or other
contaminants that may prevent penetrant from
entering flaws
Best method using volatile petroleum based solvent
cleaner
Shouldnt cleaned with abrasive blasting, scraping or
heavy brushing ( it will hide the defect )
After clean, rinse and dry it thoroughly
TYPE OF SURFACE
PENETRANT
Water Soluble Penetrants
Easiest to remove with water spray gun 30-40psi at 45 degree angle to

avoid washing the penetrant out of cracks
Post Emulsifying
Not water soluble - must treated with emulsifying agent before washed
from part surface
Absorbed penetrant will remain to expose the defect
Solvent Removable
Remove with absorbent towel
Part surface is wiped with clean towel dampened with solvent
Dont wash, spray or immersed in the solvent to prevent
penetrant gone away
Penetrant Application:
Once the surface has been
thoroughly cleaned and dried,
the penetrant material is applied
by spraying, brushing, or
immersing the parts in a
penetrant bath.
Dwell Time
total time that the penetrant is in contact with the part surface
(seep into a defect )
Minimum dwell times typically range from 5 to 60 minutes depend
on type of the materials and type of defect
Penetrant are not allowed to dry on the material
Application of Developer
- 3 type of Developer
1. Dry Developer
2.Wet Developer
3. Nonaqueous Developer
Application of Developer
Dry Developer
Loose powder material (talcum) act as blotter to draw
penetrant out of surface faults
Often used with flouroscent or colored dye red dye
appear clearly visible on the faults surface &
flouroscent dye need to used black light (glow in the
dark)
Wet Developer
Consist of a white powder mixed with water flowed over surface
or immersed in it
The part then air dried & inspected
Can be used with either red dye or flouroscent penetrant
Nonaqueous Developer
Most commonly used

Chalk like powder stored in pressure spray can
Part must be dry & moist coat of developer is applied
Can be used with either red dye or flouroscent penetrant
MAGNETIC PARTICLE
INSPECTION
Introduction
Used for part made of iron or iron alloys
Part is magnetized & an oxide containing magnetic
particles is poured or sprayed over the parts surface
Any discontinuities in the material, create disruptions
in the magnetic field around the part
Magnetic particles in the oxide align with these
disruptions
Useful for detecting cracks, splits, seams & inclusion
of foreign matter occurred during metal was cast or
rolled
Electromagnetic Field
Using right hand rules

Thumb directing the current flow
Finger directing the magnetic
field
Principles of Magnetic Inspection
Magnet bar has magnetic field around it. A

pole where a magnetic line of force exits the
magnet is called a north pole and a pole where a
line of force enters the magnet is called a south
pole.
Principles of Magnetic Inspection
If the magnet is just cracked but not broken completely in

two, a north and south pole will form at each edge of the
crack. The magnetic field exits the north pole and reenters the
at the south pole.
The magnetic field spreads out when it encounter the small
air gap created by the crack because the air cannot support
as much magnetic field per unit volume as the magnet can.
When the field spreads out, it appears to leak out of the
material and, thus, it is called a flux leakage field.
If iron particles are sprinkled on a cracked magnet, the

particles will be attracted to and cluster not only at the poles at
the ends of the magnet but also at the poles at the edges of the
crack. This cluster of particles is much easier to see than the
actual crack and this is the basis for magnetic particle
inspection.
MAGNETIC ORIENTATION
Longitudinal magnetism
Current flow through a coil or a coil around a soft iron yoke
Line of flux pass through a material longitudinally
Faults that run across the part can be detected
Magnetic field flow
Yoke magnetization
Longitudinal magnetism
Coil/solenoid magnetization
Circular magnetization
Current flow through part being inspected & magnetic field
created encircle the part
For tubular part, conductive rod is used put inside the tube
Magnetic field flow
For large flat object, circularly magnetized by

using test probe where magnetic field oriented
perpendicular to current that flows between the
probes
Test probe
Either circular or
longitudinally, both can
detect 45 degree defects
Longitudinal
Circular
Methods of Magnetization
3 ways of material magnetization

Direct current
Half wave rectified DC
Alternating current
Methods of Magnetization
Direct Current
Used pure direct current from 110-440
volt
Excellent penetrating qualities
Magnetizing part using coils or yokes
Disadvantage difficult to change its
value as required for inspecting objects
of different sizes
Half Wave Rectified DC

Alternating current frequency rectified to
DC with a half wave rectifier
DC output can be adjust to any values
Identical penetrating qualities as straight
DC
Its pulsating nature helps distribute the
magnetic particles so they arrange
themselves over any fault.
Alternating Current
Magnetizing force produced by AC
always reverse each cycle, thus
changing magnetic polarity
AC magnetic field differ from DC
magnetic field
Limits to locating surface faults only
because AC current interruption make
the penetration very shallow
Testing Medium
Using ferromagnetic material
High permeability, low retentivity & nontoxic
Extremely fine iron oxides that are dyed gray, black, red
or flouroscent color
Often used in dry form but can be mixed with kerosene
Wet particle are flowed over part as a bath
Testing Method
2 type of testing method
Residual magnetism
Continuous magnetism
Residual Magnetism
Part will be magnetize then remove it before
testing medium is applied
Relies on parts residual/ permanent magnetism
Only used with steel with heat treated for stress
application
Only the residual field of the magnetized
component is used to attract magnetic particles
and produce an indication
Continuous magnetism
Magnetizing force is applied and
maintained while the magnetic particles
are dusted or flowed onto the surface of
the component
Most often used to locate invisible
defects since it provides a greater
sensitivity in locating subsurface
discontinuities
Magnetic flux will be highest when
current is flowing and, therefore,
leakage fields will also be strongest
Inspection
Fatigue cracks
Sharp, clear patterns, uniform & unbroken
Highly stress concentration area
Heat treat crack

Smooth outline & less clear than fatigue
Have a characteristic form, consisting of short jagged lines
grouped together
Shrink crack
Sharp, clear patterns & line usually very jagged
Grinding cracks
Fine, sharp & limited depth
Related to direction of grinding
Seams
Straight, sharp & fine
Hairline cracks
Very fine seam & sharp
Highly stressed part
Inclusions
Nonmetallic materials trapped during manufacturing process ( casting/
rolling )
Broad & fuzzy indication for subsurface inclusion
Larger inclusion appear more clearly
Demagnetization
2 ways of demagnetization
AC demagnetization
Part is subjected to a magnetizing force opposite the force
used to magnetize it
Part are slowly remove from the field while current still
flowing, the reversing action progressively become weaker &
left with random orientation
DC demagnetization
Part is placed in a coil & subjected to more current than
initially used to magnetize the part
Direction of current flow will be reverse & decreased until
lowest values
Residual magnetism is check by using magnet strength
indicator
Indication of a crack in a saw

Indication of cracks in a weldm
blade
Indication of cracks
originating at a
fastener hole
Before and after

inspection pictures
of cracks emanating
from a hole
Indication of
cracks running
between
attachment holes
in a hinge
Example of MPI Sample

Result
Magnetic particle wet

fluorescent indication of a
cracks in a drive shaft

crack in a bearing

fluorescent indication of a crack
in the crane hook

crack at a sharp radius

crack in casting
EDDY CURRENT
INSPECTION
INTRODUCTION & THEORY
Requires little or no part preparation

Detect surface & subsurface in most metals
Can differentiate : Metals & alloys
Metals heat treatment conditions
Eddy current are electrical current that flow through

electrically conductive material under the influence of an
induced electromagnetic field.
Materials that accept the induced eddy current determine
by 4 properties:
Conductivity
Permeability
Mass
Presence of any voids/ faults
Conductivity differentiate through metal alloy type,

.
grain size, heat treatment & tensile strength
Null indication meter is balance (zero) after the comparison &
test probe is place on a reference/ sample material
The meter will deflect from null indication if the test material is
different from reference material
Permeability ability of material to accept lines of

magnetic flux
Mass determine the ease with which eddy current flow
Meter will deflect if material decrease in mass
Meter remain steady if no faults/ defects
Coil
Coil's
magnetic field
Eddy current's
magnetic field
Eddy
currents
Conductive
material
Absolute Method of
Inspection
Using bridge-type eddy current equipment
Used to identify materials characteristic by measuring the

amount of probe current flows when current is induced into test
specimen
meter deflect off zero if the test specimen differ from those of the
reference material
Comparison Method of
Inspection
Using double-coiled probe

Indicates differences in characteristics between the material
under reference probe & under the test probe
Very effective for inspection of conductive material
Limited in that only part of the output information is represented
by the meter
ULTRASONIC
INSPECTION
INTRODUCTION &
THEORY
The only form of NDT that can be used on plastic,

ceramics and most metal
When a body vibrates, it produces sound waves that are
transmitted by the surrounding air
Longitudinal waves sound travel longitudinally from the
source of vibration
Tranverse/shear waves wave propagation occurs at right
angles to the direction of the sound
Surface/ Raleigh wave - Shear wave that travel along the
surface & didnt extend into the material
Ultrasonic waves used frequency range from 200 Khz

25Mghz either reflected, focused or refracted
PIEZOELECTRICITY
Materials produced electricity when they are struck,
pressed, bent or distorted
Piezoelectric material vibrate when subject to AC
current or supplied current.
Transducers component for introducing physical
vibrations into other materials
Theory ultrasonic : Based on electronic oscillator that produces AC of

the proper frequency, which amplified to proper
strength & sent to a transducer that touching the test
material
Transducer causes the material to vibrate at the
oscillator frequency
Vibration reach the other side of the material &
bounce back, creating electrical impulse at the
transducer that can be seen on the CRT display
Energy Introduced into Test

Material
3 basic way to introduced energy

Direct contact on only 1 side
Energy is transmitted from this point & return echo
is received from the same side
Transducer on both side of material
1st introduces a pulse into the material; 2nd
receives the signal & send it to the CRT
Immersion method
Test specimen immersed in water & the transducer
beam its energy through the water to the test
materials surface
Energy Introduced into Test

Material
Coupling
Sound wave direction depend on
the transducer orientation & this is
achieved by using acrylic wedges
between transducer & surface
materials
To ensure better contact, a film of
water or oil is used
Fault
Indications
Use 2 basic system of ultrasonic for

fault indications
Pulse-echo system
Resonance system
Fault Indications
Pulse-echo system
Use cathode ray osciloscope in conjunction with
CRT as a fault indicator
Time based signal produces a straight line on
CRT & 1st pulse energy will make a pip or peak
on CRT
Pulse energy travel through the material until it
reach its opposite side, then reflect back to the
transducer & cause a 2nd peak on CRT
Contd
Calibrated grid is used on CRT to place the front surface peak
as a reference line
2nd adjustment allow the distance between front surface peak
and rear surface peak
Any change in material thickness is indicated in distance
between peak such as corrosion or crack
initial
pulse
crack
echo
back surface
echo
crack
0
Oscilloscope, or
flaw detector
10
plate
Ultrasonic Imaging
High resolution images can be produced by

plotting signal strength or time-of-flight using a
computer-controlled scanning system
Gray scale image produced

using the sound reflected
from the front surface of
the coin
Gray scale image produced

using the sound reflected
from the back surface of the
coin (inspected from heads
Resonance System
Measured material thickness with consistent thickness & smooth
surface
Depend on matching the oscillators frequency to the resonance
point of the material being test
Determined by comparing the test information to a transparent
scale that is overlaid on the CRT display
Effective in locating wear or corrosion which result in a reduction
of material thickness
Also used to ensure plexiglass window have been polished to
remove surface defect still maintain their minimum thickness
RADIOGRAPHIC
INSPECTION
INTRODUCTION &
THEORY
Radiographic inspection allows a photographic view inside a

structure or uses certain sections of the electromagnetic
spectrum to photograph an objects interior
X-ray & Gamma ray radiation form of high energy, short
wavelength electromagnetic waves
Amount of energy these rays related inversely to their
wavelength ( the shorter the wavelength; the greater the
energy )
Travel in straight line at the speed of light & able to penetrate
matter but the penetration depth depend on rays energy
The amount of absorption (penetration) is proportional to the
material density
These rays can ionize certain materials making it possible to
expose photographic film & cause material to fluoresce or
glow
PRINCIPLE OF
RADIOGRAPHY INSPECTION
based on differential absorption of penetrating

medium
3 basic elements for radiography;
source of radiation
object to be inspected
radiographic film.
after exposure, film is

processed to produce
image.
01/26/17
72
The radiation used in radiography testing is a

higher energy (shorter wavelength) version of
the electromagnetic waves that we
see as visible light. The radiation can come
from an X-ray generator or a radioactive source.
Generation of X-rays
Tube containing heavy insulating
envelope
Coil
cathode end emits electrons when it is
heated with electrical current.
anode end is mounted target made from
material that has a high atomic number.
X-ray intensity beam is determine by

number of electrons available which
controlled by amount of current used to
heat the cathode
Wavelength which velocity of the electron
striking the anode controlled by voltage
applied measured in kilovolts
High Electrical Potential

Electrons
+
X-ray Generator
or Radioactive
Source Creates
Radiation
Radiation
Penetrate
the Sample
Exposure Recording Device
Classification of X-rays
Related to distance between the film and the radiation
source
If distance double, amount of radiation fall to on
each unit of area. If tripled, energy decreases to 1/9
Low current low intensity low energy soft x-ray
High current high intensity - high energy hard x-ray
Gamma Rays
Energy produced by the disintegration of very specific
chemical element (isotope)
Isotope have same number of protons but different
number of neutrons
When nucleus emits gamma rays, it will return to its
ground state (low energy state)
Most damaging type of radiation
Cant be controlled, shut off or directed
Keep in safe radiation proof storage
Set up and Exposure
Radiation penetrates and pass an amount of radiation

proportional to the specimen density.
Denser the specimen-less radiation-less film exposed.
Factors that determine proper exposure;
Material thickness & density

Shape & size object
Type of defect
Characteristic of the equipment used
Exposure distance
Exposure angle
Film characteristic
Type of intensifying screen
Film
Displays as a negative or reverse image
of the part that was photographed
Less dense area get most radiation
exposure will be darker
More density area get less radiation and
clearer image
Internal flaw can be examine and
evaluate by the image on the film
Fluoroscopy
No permanent record required
Radiation pass through specimen
causes fluorescent screen to glow.
View in real time, test piece can be
moved or rotated in front of the screen
to get clear image.
Disadvantage bulky equipment, less
capable detecting small defect and
design & constructed with special
attention to operator safety.
Radiographic Safety Procedures

Can cause death if expose in large dose of
radiation
Blood & intestinal disorder
Leukemia & cancer
Lead is the best material for shielding

radiation
Personnel must wear radiation monitoring film
badges (dosimeters)
Facilities must have visible radiation indication
Display label & symbol material
COMPOSITE
INSPECTION
Inspecting composites
Number of methods of NDT that effective on
composites;
Coin Tap Test
Most simple and effective on laminated, bonded and
honeycomb materials.
Undamaged material gives a solid sound ; damaged area
makes a hollow thud (dull sound)
Thermography
Locate flaws by measuring temperature variations
Part is heated ; temperature different are then measured with
infrared camera or film then compared to a reference
standard.
Radiography
Not effective on bonded structures but can
detect surface cracks and internal damages
Can detect water inside honeycomb core cells
Laser holography
Part is heated then photograph using a laser
light and special camera system
Can detect disbonds, entrapped water and
impact damage.
Thank You
DCAM No. AO/0110/03
KP(JPS)5195/US/38

Non Destructive

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Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Ujian tanpa musnah

What are Some Uses

Malaysian Institute of Aviation Technology

Flaw Detection and Evaluation

Structure and Microstructure Characterization

Estimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response Measurements

Material Sorting and Chemical Composition

Fluorescent penetrant indication

When are NDE Methods Used?

Malaysian Institute of Aviation Technology

There are NDE application at almost any stage

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

NDT Certification in Malaysia

Six Most Common NDT Methods

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Robotic crawlers permit

Portable video inspection

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

A good weld must have : Uniform width

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

A liquid with high surface wetting

Malaysian Institute of Aviation Technology

The excess liquid is removed from the surface

Malaysian Institute of Aviation Technology

Visual inspection is the final step in the

BASIC PROCESSING STEPS OF A LIQUID

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Water Soluble Penetrants

Easiest to remove with water spray gun 30-40psi at 45 degree angle to

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Most commonly used

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Using right hand rules

Principles of Magnetic Inspection

Malaysian Institute of Aviation Technology

Magnet bar has magnetic field around it. A

Principles of Magnetic Inspection

Malaysian Institute of Aviation Technology

If the magnet is just cracked but not broken completely in

Malaysian Institute of Aviation Technology

If iron particles are sprinkled on a cracked magnet, the

Malaysian Institute of Aviation Technology

Magnetic field flow

Malaysian Institute of Aviation Technology

Malaysian Institute of Aviation Technology

Magnetic field flow

Malaysian Institute of Aviation Technology