Chapter Four Week 11

27/9/2014
Diploma in Mechanical Engineering (Material)
JF 302 MATERIAL TECHNOLOGY 1

www.pis.edu.my
CLO 3 : Show various principles of materials testing

and material defects.
Week 11
peneraju ilmu sejagat
materials testing mechanical properties
destructive tests
non destructive tests
VISUAL INSPECTION
Describe materials testing
Define mechanical properties
Describe destructive tests
Describe non destructive tests
destructive tests
It is an inspection of equipments and structures using vision,

hearing, touch and smell or any non-specialized inspection
equipment.
VISUAL INSPECTION
Method
Visual
Advantages
1)
2)
3)
4)
5)
Cheaper
Portability
Immediate result
Minimum special skills
Minimum part
preparation
Disadvantages
1)
2)
3)
Suitable only for

surface which can be
viewed
Generally detect only
larger defects
Misinterpretation of
cracks and scratches
destructive tests
LIQUID PENETRANT
INSPECTION (LPI)
It is a low-cost inspection method used to locate surfacebreaking defects in all solid and non-porous materials
(metals, plastics, or ceramics).
Types of defects:
1. Porosity
2. Cold shuts
3. Hot tears
4. Inherent wrought flaws
5. Laps
6. Fatigue/ quench cracks
7. Impact fractures
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destructive tests
LIQUID PENETRANT
INSPECTION (LPI)
Types of penetrants:
1. Water washable
Principles:
Surface preparation: Surface of specimen must be free of oil,

grease, water, or other contaminants.
Liquid
Penetrant application: The penetrant material is applied by

spraying, brushing, or immersing the part in a penetrant bath.
Post-emulsified penetrant
Penetrant dwelling time: The penetrant is left on the surface for a

sufficient time to allow penetrantion into a defect.
This penetrant can be divided into lipophilic (oil based) and hydrophilic
(water soluble). Lipophilic penetrant is removed by applying the
emulsifier to the parts surface after the penetrant dwell time has
elapsed; whereas hydrophilic penetrant can be diluted by water.
3.
Liquid
Excess penetrant removal: Excessive penetrant is removed from

the surface of the specimen.
Solvent removable
Developer application: A thin layer of developer is then applied to

the sample to draw penetrant trapped in flaws back to the surface
where it will be visible by capillary action.
Developer
The solvent removable process when in visible dye form is the most
portable liquid penetrant system available.
destructive tests
LIQUID PENETRANT
INSPECTION (LPI)
Method
LPI
Advantages
1)
2)
3)
4)
5)
Disadvantages
Portability
1)
Inexpensive
High sensitivity to small
surface discontinuities 2)
Complex geometric
shapes are routinely
inspected
Minimum skill required 3)
Only surface breaking

defects can be
detected
Only materials with a
relatively nonporous
surface can be
inspected
Pre and post cleaning
of samples are
required
destructive tests
LIQUID PENETRANT
INSPECTION (LPI)
A water washable penetrant has a built-in emulsifying agent allowing it

to be easily washed off with a coarse water spray.
2.
destructive tests
destructive tests
Pop Quiz 1
1. Which type of developer is considered the most sensitive?
a) Water suspendable
b) Water soluble
c) Dry powder
d) Non-aqueous wet
Think critically 4.14
2. Developers are used to:

a) Make the penetrant fluoresce
b) Reduce the dwell time
c) Pull trapped penetrant material out of the defect
d) All of the above
3. Which emulsifier system is oil based?
a) Hydrophilic emulsifier
b) Lipophilic emulsifier
c) Solvent removable emulsifier
d) All of the above have an oil base
destructive tests
MAGNETIC PARTICLE
INSPECTION (MPI)
Pop Quiz 1
1. Which type of developer is considered the most sensitive?
a) Water suspendable
b) Water soluble
c) Dry powder
d) Non-aqueous wet
2. Developers are used to:
a) Make the penetrant fluoresce
b) Reduce the dwell time
c) Pull trapped penetrant material out of the defect
d) All of the above
It uses magnetic fields and small magnetic particles to detect

flaws locating surface and sub-surface (not more than 10mm
below the surface) in ferro-magnetic materials.
Types of defects:
1. Cracking
2. Surface-breaking
3. Sub-surface flaws
3. Which emulsifier system is oil based?

a) Hydrophilic emulsifier
b) Lipophilic emulsifier
c) Solvent removable emulsifier
d) All of the above have an oil base
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destructive tests
MAGNETIC PARTICLE
INSPECTION (MPI)
Types of magnetic powders:
1. Dry magnetic particles can be obtained in red,
black, gray, yellow and several other colours
so that a high level of contrast between the
particles and the part being inspected can be
achieved.
2.
destructive tests
MAGNETIC PARTICLE
INSPECTION (MPI)
Principles:
Magnetization: Magnetize the specimen to be tested.

Particles application: Iron particles, either in a dry or wet
suspended form, are applied to the surface of the magnetized
part. The particles will be attracted and cluster at the flux leakage
fields, thus forming a visible indication that the inspector can
detect.
Wet magnetic particle is generally more

sensitive than the dry because the suspension
provides the particles with more mobility and
makes it possible for smaller particles to be
used since dust and adherence to surface
contamination is reduced or eliminated.
destructive tests
MAGNETIC PARTICLE
INSPECTION (MPI)
Method
Advantages
1)
2)
MPI
3)
4)
5)
Disadvantages
Portability
1)
surface discontinuities
Immediate results
2)
Moderate skill required
Detect surface and
sub-surface
3)
discontinuities
4)
Only for magnetized

material (ferromagnetic)
Magnetic current has to
be dispose after the
test
In need of power
source usage
Surface must be
cleaned and
magnetized prior the
test
destructive tests
destructive tests
Pop Quiz 2
1.When all the magnetic domains are aligned, the material is said to be:
a) Magnetically saturated
b) Partially magnetized
c) Magnetically stable
d) Unmagnetized
2. The number of magnetic lines of force cutting thorugh a plane of a given area at a
right angle is known as the:
a) Magnetic flux leakage
b) Magnetic flux density
c) Magnetic ampere
d) None of the above
3. An object that has a magnetic pole on one end and a second equal but opposite
magnetic pole on the other is called a:
a) Dipole
b) Inductor
c) Capacitor
d) A ferromagnetic material
destructive tests
EDDY CURRENT
INSPECTION
Pop Quiz 2
1.When all the magnetic domains are aligned, the material is said to be:
a) Magnetically saturated
b) Partially magnetized
c) Magnetically stable
d) Unmagnetized
2. The number of magnetic lines of force cutting thorugh a plane of a given area at a
right angle is known as the:
a) Magnetic flux leakage
b) Magnetic flux density
c) Magnetic ampere
d) None of the above
It is a methods that use the principal of electromagnetism as

the basis for conducting examinations.
Types of defects:
1. Cracking
2. Surface-breaking
3. An object that has a magnetic pole on one end and a second equal but opposite
magnetic pole on the other is called a:
a) Dipole
b) Inductor
c) Capacitor
d) A ferromagnetic material
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destructive tests
EDDY CURRENT
INSPECTION
Principles:
destructive tests
EDDY CURRENT
INSPECTION
Principles:
A probe is used to generate eddy current. A length of electrical

conductor is placed inside the probe which is formed into a coil.
Alternating current is allowed to flow in the coil at a constant

frequency.
destructive tests
EDDY CURRENT
INSPECTION
Principles:
destructive tests
EDDY CURRENT
INSPECTION
Principles:
A dynamic expending and collapsing magnetic field forms around

the coil as the alternating current.
When electrically conductive materials placed in the coil, induction

will occur and eddy current will be induced in the material.
destructive tests
EDDY CURRENT
INSPECTION
Principles:
destructive tests
EDDY CURRENT
INSPECTION
Principles:
Eddy current generates secondary magnetic field which will

oppose the primary magnetic field.
When a flaw is introduced to the conductive material , the eddy

current are disrupted.
This entire electromagnetic induction process to produce eddy

currents may occur from several hundred to million times each
second depending upon inspection frequency.
27/9/2014
destructive tests
EDDY CURRENT
INSPECTION
Method
Advantages
1)
2)
EDDY
CURRENT 3)
4)
Disadvantages
Portability
surface discontinuities
Immediate results
Detect surface and
sub-surface
discontinuities
1)
2)
3)
4)
Only for magnetized

material (ferromagnetic)
In need of power
source usage
High skill required
Surface must be
accessible to probe
destructive tests
Pop Quiz 3
1. The coil in an eddy current probe is most often made from:
a) Iron
b) Copper
c) Silver
d) Platinum
2. When testing for surface flaws, the probe drive frequency used:
a) Should be as high as possible
b) Should be as low as possible
c) Depends on the conductivity and permeability of the material
d) Depends only on the material conductivity
3. Probe shielding is used to:
a) Shape the eddy currents to the curvature of the part
b) Reduce the inductive coupling of the probe and part
c) Increase the probe impedance
d) Reduce the effects of non-relevant features in close proximity to the probe
destructive tests
destructive tests
ULTRASONIC
TESTING (UT)
Pop Quiz 3
1. The coil in an eddy current probe is most often made from:
a) Iron
b) Copper
c) Silver
d) Platinum
Ultrasonic Testing (UT) uses high frequency sound energy to

conduct examinations and make measurements for internal or
external (surface) in ferrous, non-ferrous, ceramics and plastic
materials.
2. When testing for surface flaws, the probe drive frequency used:
a) Should be as high as possible
b) Should be as low as possible
c) Depends on the conductivity and permeability of the material
d) Depends only on the material conductivity
Uses:
1. Flaw detection/evaluation
2. Dimensional measurements
3. Material characterization
3. Probe shielding is used to:

a) Shape the eddy currents to the curvature of the part
b) Reduce the inductive coupling of the probe and part
c) Increase the probe impedance
d) Reduce the effects of non-relevant features in close proximity to the probe
destructive tests
ULTRASONIC
TESTING (UT)
destructive tests
ULTRASONIC
TESTING (UT)
Principles:
Principles:
Pulser/ Receiver
Transducer
Pulser/Receiver
Receiver
Pulser/
This test uses beams (piezoelectric crystal) of high-frequency

sound waves (ultrasonic waves), introduced into the test piece.
Transducer
Transducer
Initial pulse
Crack
echo
Back surface
echo
Plate
Plate
Plate
The sound waves travel through the test piece with some
attendant loss of energy and are reflected in interfaces. The
reflected beam is detected and analyzed to define the presence
and location of flaws.
The frequency used for ultrasonic testing lie between 0.5 and 15
MHz depending upon the test piece.
When the sound waves meet any discontinuity, the waves are
reflected back into the transducer (probe) where they are
converted into electrical pulses which can be displayed on the
screen of a Cathode Ray Tube (CRT).
27/9/2014
destructive tests
destructive tests
ULTRASONIC
TESTING (UT)
Components:
Advantages
1)
Transducer
Transducer
A pulser/receiver is an electronic device that can produce high

voltage electrical pulses.
Initial pulse
Crack
echo
ULTRASONIC
TESTING (UT)
Method
Pulser/Receiver
Receiver
Pulser/
Back surface
echo
Plate
Plate
The transducer generates high frequency ultrasonic energy. The

sound energy is introduced and propagates through the materials
in the form of waves. When there is a discontinuity (such as a
crack) in the wave path, part of the energy will be reflected back
from the flaw surface. The reflected wave signal is transformed
into an electrical signal by the transducer and is displayed on a
screen.
UT
2)
3)
4)
5)
destructive tests
Disadvantages
Sensitive to both surface

and subsurface
discontinuities
High accuracy to estimate
size/shape of flaws
Minimal part preparation
is required
Detailed images can be
produced with automated
systems
provides instantaneous
results
1)
2)
3)
4)
5)
Surface must be
accessible to transmit
ultrasound
Skill and training is more
extensive
Requires a coupling
medium to promote the
transfer of sound energy
into the test specimen.
Limited testing materials
Rough surface are
difficult to inspect
Pop Quiz 4
destructive tests
Pop Quiz 4
1. What is the material called that is used to improve the transmission of ultrasonic
sound energy from the transducer into the part?
a) Gel
b) Goo
c) Couplant
d) Contact paste
1. What is the material called that is used to improve the transmission of ultrasonic
sound energy from the transducer into the part?
a) Gel
b) Goo
c) Couplant
d) Contact paste
2. The ability to locate a small discontinuity is called:

a) Resolution
b) Sensitivity
c) Wavelength
d) Frequency
2. The ability to locate a small discontinuity is called:

a) Resolution
b) Sensitivity
c) Wavelength
d) Frequency
3. Which type of transducer will have better resolution?

a) A slightly damped transducer
b) A small size and low frequency transducer
c) A highly damped transducer
d) All of the above
3. Which type of transducer will have better resolution?

a) A slightly damped transducer
b) A small size and low frequency transducer
c) A highly damped transducer
d) All of the above
destructive tests
RADIOGRAPHY
TESTING (RT)
The formation of an image of the test piece either on a
photographic film or on a fluorescent screen due to x-rays or
-rays passing through the test piece.
Law of Absorption of X-rays
I I o e x
destructive tests
RADIOGRAPHY
TESTING (RT)
Principles:
X-rays are passed through the specimen under
inspection and it is differentially absorbed by the
specimen.
The transmitted x-rays are received by the
photographic film and the film is developed. The
dark and light shadows reveal the defects present
in the specimen and hence the defects are
defected.
27/9/2014
destructive tests
destructive tests
RADIOGRAPHY
TESTING (RT)
Principles:
RADIOGRAPHY
TESTING (RT)
Method
X-rays are exposed over the specimen by keeping

the x-ray source at position A and then at B by
displacing the source through a certain distance.
The images are recorded at positions A and B.
From the displacements of the x-ray tube and the
images, the exact position of the defect can be
determined.
RT
Advantages
destructive tests
Disadvantages
1) Can be used for metal and

non-metal materials
2) Able to detect for upto
1.5m of thickness
3) Effective and reliable
4) Clean and did not
contaminated the
components
5) Portable to anywhere
6) With high precision and
sensitivity
7) Permanent test record
1)
2)
Expensive equipment
In need of expertise to
read the machine
Pop Quiz 5
destructive tests
Pop Quiz 5
1. X-rays and Gamma rays are a form of:

a) Light
b) Particle radiation
c) Electromagnetic radiation
d) Both B and C
1. X-rays and Gamma rays are a form of:

a) Light
b) Particle radiation
c) Electromagnetic radiation
d) Both B and C
2. On a film radiograph, an area of high density in the test component will appear:
a) Lighter than the surrounding area
b) Darker than the surrounding area
c) More defined than the surrounding area
d) Less defined than the surrounding area
2. On a film radiograph, an area of high density in the test component will appear:
a) Lighter than the surrounding area
b) Darker than the surrounding area
c) More defined than the surrounding area
d) Less defined than the surrounding area
3. The main advantage of real-time radiography over film is:

a) Higher image contrast sensitivity
b) Inspection can be performed more rapidly
c) Higher image definition
d) Lower equipment costs
3. The main advantage of real-time radiography over film is:

a) Higher image contrast sensitivity
b) Inspection can be performed more rapidly
c) Higher image definition
d) Lower equipment costs
destructive tests
Differentiate between LPI and MPI.

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Chapter Four Week 11

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27/9/2014

Diploma in Mechanical Engineering (Material)

JF 302 MATERIAL TECHNOLOGY 1

CLO 3 : Show various principles of materials testing

peneraju ilmu sejagat

peneraju ilmu sejagat

materials testing mechanical properties

non destructive tests

peneraju ilmu sejagat

materials testing mechanical properties

It is an inspection of equipments and structures using vision,

peneraju ilmu sejagat

non destructive tests

materials testing mechanical properties

Suitable only for

peneraju ilmu sejagat

non destructive tests

peneraju ilmu sejagat

materials testing mechanical properties

non destructive tests

materials testing mechanical properties

Surface preparation: Surface of specimen must be free of oil,

Penetrant application: The penetrant material is applied by

Penetrant dwelling time: The penetrant is left on the surface for a

Excess penetrant removal: Excessive penetrant is removed from

Developer application: A thin layer of developer is then applied to

materials testing mechanical properties

peneraju ilmu sejagat

non destructive tests

Only surface breaking

peneraju ilmu sejagat

materials testing mechanical properties

non destructive tests

A water washable penetrant has a built-in emulsifying agent allowing it

materials testing mechanical properties

non destructive tests

Think critically 4.14

2. Developers are used to:

peneraju ilmu sejagat

non destructive tests

materials testing mechanical properties

non destructive tests

Think critically 4.14

It uses magnetic fields and small magnetic particles to detect

3. Which emulsifier system is oil based?

peneraju ilmu sejagat

peneraju ilmu sejagat

materials testing mechanical properties

non destructive tests

materials testing mechanical properties

non destructive tests

Magnetization: Magnetize the specimen to be tested.

Wet magnetic particle is generally more

materials testing mechanical properties

peneraju ilmu sejagat

non destructive tests

Only for magnetized

peneraju ilmu sejagat

materials testing mechanical properties

materials testing mechanical properties

non destructive tests

Think critically 4.15

peneraju ilmu sejagat

non destructive tests