Non-Destructive Testing

(a technical writing work submitted under the course work to)

Prof. Tarapada Roy
by

CHINTA SIVARAMPRASAD
218ME1192
M.Tech – 1st year
Machine Design and Analysis

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 CONTENTS
1 ABSTRACT 3

2 INTRODUCTION 3

3 WHAT IS NDT? 4

3.1 COMMON APPLICATION OF NDT 4

3.2 OBJECTIVE 4

4 TYPES 5

4.1 VISUAL INSPECTION 5

4.2 LIQUID PENETRANT METHOD 6

4.3 ULTRASONIC FLAW DETECTION 7

4.4 RADIOGRAPHY 9

4.5 MAGNETIC PARTICLE TESTING 11

5 CONCLUSION 12

6 REFERENCES 12

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1 ABSTRACT
Non-destructive testing (NDT) is a wide group of analysis techniques used in science and
industry to evaluate the properties of a material, component or system without causing
damage. The terms Nondestructive examination (NDE), Nondestructive inspection
(NDI), and Nondestructive evaluation (NDE) are also commonly used to describe this
technology. Because NDT does not permanently alter the component being inspected, it
is a highly-valuable technique that can save both money and time in product evaluation,
troubleshooting, and research.
In certain applications, the evaluation of engineering materials or structures without
impairing their properties is very important, such as the quality control of the products,
failure analysis or prevention of the engineered systems in service. This kind of
evaluations can be carried out with Non destructive test (NDT) methods. It is possible to
inspect and/or measure the materials or structures without destroying their surface
texture, product integrity and future usefulness.
2 INTRODUCTION
Non-destructive Testing is one part of the function of Quality Control and is
Complementary to other long established methods. By definition 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.
A certain degree of skill is required to apply the techniques properly in order to obtain the
maximum amount of information concerning the product, with consequent feed back to
the production facility. Non-destructive Testing is not just a method for rejecting
substandard material; it is also an assurance that the supposedly good is good. The
technique uses a variety of principles; there is no single method around which a black
box may be built to satisfy all requirements in all circumstances.
These methods can be performed on metals, plastics, ceramics, composites, cermets, and
coatings in order to detect cracks, internal voids, surface cavities, delamination,
incomplete defective welds and any type of flaw that could lead to premature failure.

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3 What is NDT?
NDT stands for non-destructive testing. In other words it is a way of testing without
destroying. This means that the component- the casting, weld or forging, can continue to
be used and that the non destructive testing method has done no harm. In today's world
where new materials are being developed, older materials and bonding methods are being
subjected to higher pressures and loads, NDT ensures that materials can continue to
operate to their highest capacity with the assurance that they will not fail within
predetermined time limits.
NDT can be used to ensure the quality right from raw material stage through fabrication
and processing to pre-service and in-service inspection .Apart from ensuring the
structural integrity, quality and reliability of components and plants, today NDT finds
extensive applications.

3.1 Common Application of NDT

 Inspection of Raw Products

 Inspection Following Secondary Processing

 In-Services Damage Inspection

3.2 Objectives

 To ensure product integrity, and in turn, reliability;

 To detect internal or surface flaws

 To measure the dimensions of materials

 To determine the materials’ structure

 To evaluate the physical and mechanical properties of materials


 To avoid failures, prevent accidents and save human life;

 To make a profit for the user;

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  To ensure customer satisfaction and maintain the manufacturer's reputation;

 To aid in better product design;

 To control manufacturing processes;

 To lower manufacturing costs;

 To maintain uniform quality level;

4 Types
 Visual Inspection

 Liquid penetrant method

 Ultrasonic Inspection

 Radiography methods

 Magnetic particle testing etc.

4.1 VISUAL INSPECTION

VI is particularly effective detecting macroscopic flaws, such as poor welds. Many
welding flaws are macroscopic: crater cracking, undercutting, slag inclusion, incomplete
penetration welds, and the like. Likewise, VI is also suitable for detecting flaws in
composite structures and piping of all types. Bad welds or joints, missing fasteners or
components, poor fits, wrong dimensions, improper surface finish, large cracks, cavities,
dents, inadequate size, wrong parts, lack of code approval stamps and similar proofs of
testing.
This test method is applied to almost every product as a quality assurance tool. Generally,
the most detrimental unacceptable discontinuities in the objects or items are the surface
opening discontinuities. Visual scanning, inspection or testing can successfully detect
these unacceptable surface discontinuities without applying expensive test methods.
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4.2 LIQUID PENETRANT METHOD
Principle:
A liquid penetrant is applied at the surface of the specimen. The penetrant is drawn by the
surface flaws due to capillary action and this is subsequently revealed by a developer, in
addition with visual inspection. Liquid penetrant inspection (LPI) is one of the most
widely used non destructive evaluation (NDE) methods. Its popularity can be attributed
to two main factors, which are its relative ease of use and its flexibility. The technique is
based on the ability of a liquid to be drawn into a "clean" surface breaking flaw by
capillary action.

This method is frequently used for the detection of surface breaking flaws in non
ferromagnetic materials. The subject to be examined is first of all chemically cleaned,
usually by vapour phase, to remove all traces of foreign material, grease, dirt, etc. from
the surface generally, and also from within the cracks. Next the penetrate (which is a very
fine thin oil usually dyed bright red or ultra-violet fluorescent) is applied and allowed to
remain in contact with the surface for approximately fifteen minutes. Capillary action
draws the penetrate into the crack during this period.

The penetrate on the surface is then removed completely and thin coating of powdered
chalk is applied. After a further period (development time) the chalk draws the dye out of
the crack, rather like blotting paper, to form a visual, magnified in width, indication in
good contrast to the background. The process is purely a mechanical/chemical one and
the various substances used may be applied in a large variety of ways, from aerosol spray
cans at the most simple end to dipping in large tanks on an automatic basis at the other
end. The latter system requires sophisticated tanks, spraying and drying equipment but
the principle remains the same.

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 Fig 1 An Illustration of Liquid Penetrate Testing

Advantages

 Simplicity of operation and inexpensive.

 Best method for surface breaking cracks in non-ferrous metals.

Disadvantages

 Restricted to surface breaking defects only.

 Surface cleaning before & after inspection
 Uses a considerable amount of consumables.

4.3 ULTRASONIC FLAW DETECTION

Principle:
Whenever there is a change in the medium, the ultrasonic waves are reflected. Thus, from
the intensity of the reflected echoes, the flaws are detected without destroying the

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material. Ultrasonic Testing (UT) uses a high frequency sound energy to conduct
examinations and make measurements. The sound energy is introduced and propagates
through the materials in the form of waves and reflected from the opposing surface. An
internal defect such as crack or void interrupts the waves' propagation and reflects back a
portion of the ultrasonic wave. The amplitude of the energy and the time required for
return indicate the presence and location of any flaws in the work-piece.
The ultrasonic inspection method has high penetrating power and sensitivity. It can be
used from various directions to inspect flaws in large parts, such as rail road wheels
pressure vessels and die blocks. This method requires experienced personnel to properly
conduct the inspection and to correctly interpret the results.

Advantages
 Sensitive to surface & subsurface discontinuities
 Superior depth of penetration for flaw detection
 High accuracy – position, size & shape of defect
 Minimal part preparation
 Instantaneous result
 Automated detailed images
 Non hazardous
 Portable

Limitations
 Surface accessibility for ultrasonic transmission
 Highly skilled & trained manpower
 Irregular, rough, coarse grained or non homogenous parts, linear defects oriented
parallel to the beam cannot be inspected – low transmission & high noise
 Coupling medium required
 Reference standards – equipment calibration & flaw characterization

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4.4 RADIOGRAPHY

This technique is suitable for the detection of internal defects in ferrous and nonferrous
metals and other materials. X-rays, generated electrically, and Gamma rays emitted from
radio-active isotopes, are penetrating radiation which is differentially absorbed by the
material through which it passes; the greater the thickness, the greater the absorption.
Furthermore, the denser the material the greater the absorption. X and Gamma rays also
have the property, like light, of partially converting silver halide crystals in a
photographic film to metallic silver, in proportion to the intensity of the radiation
reaching the film, and therefore forming a latent image. This can be developed and fixed
in a similar way to normal photographic film. Material with internal voids is tested by
placing the subject between the source of radiation and the film. The voids show as
darkened areas, where more radiation has reached the film, on a clear background. The
principles are the same for both X and Gamma radiography.

To produce an X or Gamma radiograph, the film package is placed close to the surface of
the subject. The source of radiation is positioned on the other side of the subject some
distance away, so that the radiation passes through the subject and on to the film. After
the exposure period the film is removed, processed, dried, and then viewed by transmitted
light on a special viewer. Various radiographic and photographic accessories are
necessary, including such items as radiation monitors, film markers, image quality
indicators, darkroom equipment, etc. Where the last is concerned there are many degrees
of sophistication, including fully automatic processing units. These accessories are the
same for both X and Gamma radiography systems. Also required are such consumable
items as radiographic film and processing chemicals.

The part is placed between the radiation source and a piece of film. The part will stop
some of the radiation. Thicker and denser area will stop more of the radiation.

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 Fig 2 Illustration of Radiagraphy

Advantages

 Information is presented pictorially.

 A permanent record is provided which may be viewed at a time and place
 Distant from the test.
 Useful for thin sections.
 Sensitivity declared on each film.
 Suitable for any material.

Disadvantages

 Generally an inability to cope with thick sections.

 Possible health hazard.
 Not suitable for surface defects.
 No indication of depth of a defect below the surface

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4.5 MAGNETIC PARTICLES
Magnetic particle inspection is one of the simple, fast and traditional nondestructive
testing methods widely used because of its convenience and low cost. This method uses
magnetic fields and small magnetic particles, such as iron filings to detect flaws in
components. The only requirement from an inspect ability standpoint is that the
component being inspected must be made of a ferromagnetic material such iron, nickel,
cobalt, or some of their alloys, since these materials are materials that can be magnetized
to a level that will allow the inspection to be effective.
On the other hand, an enormous volume of structural steels used in engineering is
magnetic. In its simplest application, an electromagnet yoke is placed on the surface of
the part to be examined, a kerosene-iron filling suspension is poured on the surface and
the electromagnet is energized. If there is a discontinuity such as a crack or a flaw on the
surface of the part, magnetic flux will be broken and a new south and north pole will
form at each edge of the discontinuity.

Fig 3 Illustration of magnetic particle testing

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Then just like if iron particles are scattered on a cracked magnet, the particles will be
attracted to and cluster at the pole ends of the magnet, the iron particles will also be
attracted at the edges of the crack behaving poles of the magnet. This cluster of particles
is much easier to see than the actual crack and this is the basis for magnetic particle
inspection. For the best sensitivity, the lines of magnetic force should be perpendicular to
the defect.

Advantages

 Simplicity of operation and application.

 Quantitative.
 Can be automated.

Disadvantages

 Restricted to ferromagnetic materials.

 Restricted to surface or near surface flaws.

5 CONCLUSION
It is possible to inspect and/or measure the materials or structures without destroying
their surface texture, product integrity and future usefulness. NDT can save and/or avoid
costs in millions of dollars for facilities that use its methods. There are proven NDT
technologies to do this, from conventional to more advanced ones that are essentially
based on the conventional ones. Their required training requirements and proper
application are paramount for realizing ever-increasing benefits.

6 References
 www.ndt-ed.org
 www.google.com
 www.wikipedia.com
 www.InsightNDT.com.

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