INTRODUCTION TO NON-DESTRUCTIVE TESTING TECHNIQUE

Workshop for Skyline Aeronautical Engineering on 20th to 22nd May 2013

Testing

Destructive testing (DT)

Semi-destructive testing

Non-destructive testing (NDT)

Tensile test Bend test Charpy test Hardness test Fatigue test Creep test Metallography Chemical analysis, etc.

Coring test Tension test Carbonation test Mortar test

Ultrasonic test Eddy current test Radiography test Visual test Magnetic particle test Penetrant test IR thermography Leak test Acoustic emission Laser shearography
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NDT
Definition Non-destructive testing (NDT) is the testing of material to detect internal and surface defects or discontinuities using methods that do not damage or destroy the material under test.

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Engineering Materials
Materials
Metals
Ferrous

Ceramics
Non-Ferrous

Polymers

Composites

Steel Stainless steel Cast iron

Aluminum Copper Zinc Titanium Tungsten Nickel

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Material Discontinuities
Should identify the types of metal manufacturing and service discontinuities (i.e. to know what causes the defects)
Defects Inherent Processing Defects The refining stage where metals are extracted from ores - Inclusions (Slag) - Porosity (Blown hole) - Pipe - Segregation Primary Processing Defects Metal ingots are worked into usable forms such as billets or blooms by wrought processing or casting - Seams - Laps - Lamination - Forging bursts - Inclusions - porosity Secondary Processing Defects Final stages of parts manufacturing - Grinding cracks (thermal cracks) - Machining cracks - Welding defects - Heat treat cracks (quenching cracks)

Service Defects Occurs during the use of the part - Fatigue cracks - Stress cracks - Corrosion

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Where is NDT used?

where we need to ensure the serviceability of a specimen where we cannot afford the cost of a failure of the specimen because failure would be financially unacceptable or cause harm to us exist to prevent injury or death to the human user of the tested item
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Why we need NDT?

Generally, NDT is employed in various industries for the following reasons; i. To prevent accidents and save human lives ii. To improve product reliability iii. To give profit to the user by;
a. b. c. d. e. Ensuring customer satisfaction Helping in better product design Controlling manufacturing processes Lowering manufacturing processes Maintaining a uniform quality level
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When is NDT used?

NDT is used both before, during and after construction Using NDT "before or during construction" prevents a substandard material or part from wasting time and increasing scrap production Using NDT after to monitor performance after being service.

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NDT METHODS
There are six major NDT methods ; Visual testing (VT) Radiography testing (RT) Ultrasonic testing (UT) Magnetic particles testing (MT) Liquid penetrant testing (PT) Eddy current testing (ET)

Eddy Current Testing

NDT

Visual Testing

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Other NDT methods;

Leak testing Strain gauging Acoustic emission IR Thermography Laser shearography

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The choice of test method to be carried out on a certain piece depends on several factors, the most important ones being;

NDT.

Types of discontinuity expected Inherent limitations of each method Working conditions Material to be tested

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Indication
Each non-destructive test is designed to provide visual evidence of discontinuities in parts, which are not normally visible to the unaided eye. The visual evidence left by each method is called an indication.
NOTE: There is no single NDT method capable of detecting all type of discontinuities
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VISUAL TESTING
Eye of a qualified technician can be supplemented with various optical aids and mechanical gauges for visual inspection.

It is a most commonly used NDT method for detecting and evaluating defects. Inspect using human eye. Optical equipment use to enhance sensitivity. But decreases the area of coverage.
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Visual Testing.
Employs the eyes to look directly at the component Mostly used on detection of corrosion Needs lot of skill and training

Training- 01
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Visual Testing..
Training- 02
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Training- 03

Visual Testing

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Visual Inspection
Most basic and common inspection method. Tools include Lights, Mirrors, fiberscopes, borescopes, magnifying glasses and CCTV. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.
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RADIOGRAPHY TESTING (RT)

Principle of Operation
Using electromagnetic radiation (X-, Gamma-, Neutron-, etc.) to penetrate through materials. Discontinuities is recorded on film

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Radiography..
Testing by means of radiation is based on the following factors: The capacity that radiation has to pas through matter Different radiation absorption depending on the piece being tested The possibility of measuring this absorption differences The testing involves the use of, A radiation source A radiation detector (film)
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Radiographic Image
A radiographic image is a document composed of a photographic film on to which the image of an object which the radiation has passed through is recorded.

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Radiography..
The radiographic technique gives a true image of the piece section (a photographic image) allowing many different types of material to be examined, even very thick materials.

Main disadvantages

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Applications

RADIOGRAPHY

Applicable to almost all metals and non-metals Capable of detecting (and subsequently recording on the film) surface and internal discontinuities

Limitations

High capital and running cost Require source of electricity (in the case of X-ray) Trained and skill operators are necessary Pose potential radiation hazard Not sensitive to planar defect SURESH SENANAYAKE | AEA

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ULTRASONIC TESTING (UT)

Principle of Operation
Ultrasonic testing is based on the reflection that on acoustic wave is subjected to when, while moving through a certain material, it finds its propagation impared. Signal due to discontinuities is presented on cathode ray tube screen (CRT)

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Ultrasonic
The test requires a system comprising the following elements:
A probe (which emits the acoustic beam) A detection unit (which records the reflected beam on a screen)

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Ultrasonic..
The ultrasonic beam emitted by the probe passes through the test piece and, after reaching the bottom wall, is reflected back to the probe which signals it on the screen. If the beam finds a discontinuity along its path, it returns to the probe more quickly, in this way signaling the presence of a defect.

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Ultrasonic..
The ultrasonic technique allows for immediate examination of the piece with extremely low working times. It is easy to carry out and proves particularly suitable for creating automatic or semi-automatic systems as the discontinuity is detected by the presence or lack of signal from the reflected waves.

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ULTRASONIC..
Applications Applicable to almost all metals and non-metals Capable of detecting surface and internal discontinuities Automatic inspection and new computerized image processing allows signal to be permanently recorded on paper Measure thickness Material characterization (e.g. measure elastic modulus, etc.)

Crankshaft - Northern Power Plant Ultrasonic Testing

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ULTRASONIC..
Limitations
Relatively high capital cost Requires highly trained and experienced operator Interpretation of results can be extremely difficult Not sensitive to defects parallel to the beam direction

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MAGNETIC PARTICLE TESTING (MT)

Principle of Operation
Using magnetic or current flow to produce magnetic field in the materials The pattern of field distribution provides indication of the existence discontinuities

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Magnetic Particle..
Magnetic testing is based on the following factors: The possibility of magnetizing the piece to be tested; Magnetic field variations generated by the piece discontinuities; The possibility of detecting surface and sub-surface variations piece in the pieces magnetic field.

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MAGNETIC PARTICLE

Applications

Applicable to ferromagnetic materials Capable of detecting surface and subsurface discontinuities Easily operated portable equipment makes it suitable for field inspection

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Magnetic Particle
The test requires a system comprising the following elements: Equipment for piece magnetization; Magnetic powders (or particles) to be spread over the piece to reveal the magnetic field variations.
Magnetization Equipment (Yoke)

Limitations

Magnetic powders

Not applicable to non-ferromagnetic materials Requires a sources of electricity Magnetization in two perpendicular directions is necessary Inspected objects have to be demagnetized
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Magnetic Particle crack indications

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PENETRANT TESTING (PT)

Principle of Operation
Using liquid to penetrate materials Image of discontinuities become visible after development

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Penetrant Testing..
Penetrant testing requires a use of: Penetrant liquids Developer

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Penetrant Testing
Advantages It can be applied to any material (ferromagnetic and non-ferromagnetic); It can also be carried out on parts that are not easily accessible; It is relatively simple in terms of procedure and interpretation; Compared to other examinations, the equipment is much more economical.

Limitations It can detect only discontinuities opened to the surface; Discontinuities filled with extraneous matter (dirt, oxides, etc.) cannot be detected; Surface conditioning must be more accurate than in other types of examination.

Applications

Inspect non porous materials (metals, glass, ceramic, etc.) Detect surface defects Simple equipment SURESH SENANAYAKE | AEA

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EDDY CURRENT TESTING (ET)

Principal of Operation
Use electrical current in coils to induce eddy current within specimen Indicator will be deflected when discontinuities disturb the path of eddy current

The test probe in eddy current inspection is basically a coil of wire through which AC is passed. When AC is passed through the coil, a magnetic field is generated in and around the coil. When the probe is brought in close proximity to a conductive material, the magnetic field generates current flow in the material. The induced current flows in closed loops in planes perpendicular to the magnetic flux and are named eddy currents.

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Eddy Current.
Coils magnetic field Coil Eddy Currents magnetic field

Conductive material Eddy Currents

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Eddy Current.
CRACK DETECTION

PROBE

PROBE

PROBE

PROBE

FLAW
5/20/2013

MATERIAL
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Eddy Current
Sub surface flaw detection
Multi-layered aircraft structures. - Fuselage - Wings - Around Fasteners Phase indicates flaw depth Magnitude indicates flaw severity at depth

Applications

Inspect conducting materials Detect surface and sub-surface disc Measure hardness and thickness of layer and thin sheet
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Eddy Current..
Conductivity measurement
Raw materials sorting Manufacturing process verification Heat damage Reference measurement

Limitations
Defect detection is limited to only few mm below surface Does not indicate the shape of discontinuities
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Eddy Current..
A typical NDT job
AC failure or fault found Define DEFECT Choose NDT method Specify technique and equipment Risk analysis of fleet(s) Inspection plan Review design of faulty part

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 Who is involved in Aerospace in service NDT?

Airline operators Airworthiness authorities Component part manufacturer NDT equipment supplier Aircraft manufacturer Qualified NDT inspector

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What needs to be avoided?

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A defect that went undetected in an engine disk was responsible for the crash of United Flight 232.

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Reliability of NDT
Discontinuity Method Detection VT PT MT UT
Adequate Adequate Adequate Applicable with limitations Adequate

Superficial Length evaluation

Adequate Adequate Adequate Low efficiency

Internal Height evaluation

Inapplicable Inapplicable Applicable with limitations Low efficiency

Detection
Inapplicable Inapplicable Low efficiency Adequate

Length evaluation
Inapplicable Inapplicable Low efficiency Good

Height evaluation
Inapplicable Inapplicable Inapplicable Low efficiency Low efficiency Low efficiency

Depth evaluation
Inapplicable Inapplicable Inapplicable

Adequate Applicable with double exposure and calculus Low efficiency

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RT ET

Adequate

Inapplicable

Adequate Low efficiency

Good Low efficiency

Good

Good

Adequate

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 Tested objects or parts can be re-used (unless proven defective) Tests can be conducted to all samples (100% inspection) or representative samples More than one inspection techniques can be applied to a similar object Inspection on a certain product may be repeated Requires minimum (or no) specimen preparation Equipment are normally portable and suitable for field inspection Inspection may be performed while the objects or parts are in service
Results are normally qualitative Requires highly trained and experienced personnel
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Advantages of NDT

Limitations of NDT

Advantages of DT
Results are normally quantitative Does not require highly trained and experienced personnel

Limitations of DT
Tested objects or parts become scrap and considered loss Tests can only be conducted to representative samples (100% inspection is not possible) Each object or part can only be tested once Repetitive inspection cannot be performed on a similar object Objects or parts to be inspected have to be taken away from the system and replaced Require systematic specimen preparation Equipment are normally stationary
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Thank you!
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