By

AVINASH RANJAN (1SI08ME022)

Non-destructive testing is the testing of materials, for surface or internal flaws or metallurgical condition, without interfering in any way with the integrity of the material or its suitability for service. Major types of NDT

1. Radiography. 2. Magnetic Particle Inspection. 3. Dye Penetrant Testing. 4. Ultrasonic Testing. 5. Eddy Current and Electro-magnetic Testing.

The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation. The film darkness (density)
will vary with the amount of radiation reaching the film through the test object.
X-ray film

Defects, such as voids, cracks, inclusions, etc., can be detected.

= less exposure

Top view of developed film

= more exposure

Advantages

Application

Suitable for any material. Information is presented pictorially There is an upper limit of thickness through which the radiation can penetrate The operator must have access to both sides of an object Highly skilled operator is required because of the potential health hazard of the energetic radiations

Disadvantage

Can be used in any situation when one wishes to view the interior of an object To check for internal faults and construction defects, e.g. faulty welding To see through what is inside an object

The magnetic flux line close to the surface of a ferromagnetic material tends to follow the surface profile of the material Discontinuities (cracks or voids) of the material perpendicular to the flux lines cause fringing of the magnetic flux lines, i.e. flux leakage The leakage field can attract other ferromagnetic particles MPI uses magnetic fields and small magnetic particles, such as iron filings to detect flaws in components

The magnetic particles form a ridge many times wider than the crack itself, thus making the otherwise invisible crack visible

Cracks just below the surface can also be revealed

Advantage fast, simple and inexpensive direct, visible indication on surface can be used on painted objects

Limitations Only good for ferromagnetic materials objects must be demagnetized before and after the examination the current magnetization may cause burn scars on the item examined

Liquid penetration inspection is a method that is used to reveal surface breaking flaws by bleed out of a colored or fluorescent dye from the flaw. The technique is based on the ability of a liquid to be drawn into a "clean" surface breaking flaw by capillary action. Advantage:

The method has high sensitive to small surface discontinuities. The method has few material limitations Large areas and large volumes of parts/materials can be inspected rapidly and at low cost. Parts with complex geometric shapes are routinely inspected.

Basic processing steps of LPI

1. 2. 3. 4. 5.

6.

SurfacePreparation Penetrant Application Penetrant Dwell Excess Penetrant Removal Developer Application Indication Develop .

In ultrasonic testing, high-frequency sound waves are transmitted into a material to detect imperfections or to locate changes in material properties.
The most commonly used ultrasonic testing technique is pulse echo, whereby sound is introduced into a test object and reflections (echoes) from internal imperfections or the part's geometrical surfaces are returned to a receiver.
The time interval between the transmission and reception of pulses give clues to the internal structure of the material.

High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound.
initial pulse

crack echo

back surface echo

crack
0 2 4 6 8 10

plate

Oscilloscope, or flaw detector screen

Eddy current testing can be used on all electrically conducting materials with a reasonably smooth surface. The test equipment consists of a generator (AC power supply), a test coil and recording equipment, e.g. a galvanometer or an oscilloscope Used for crack detection, material thickness measurement (corrosion detection), sorting materials, coating thickness measurement, metal detection, etc.

When a AC passes through a test coil, a primary magnetic field is set up around the coil The AC primary field induces eddy current in the test object held below the test coil A secondary magnetic field arises due to the eddy current

Eddy Current Instruments

Voltmeter

Coil

Coil's magnetic field

Eddy current's magnetic field

Eddy currents Conductive material

APPLICATIONS

Periodically, power plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage.

Pipe with damage

Probe
Signals produced by various amounts of corrosion thinning.

Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices.

 Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassembled. Fluorescent penetrant inspection is used to check many of the parts for cracking.

Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment.

NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.

Remote visual inspection using a robotic crawler.

Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.

Radiography of weld joints.

Thank you