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K. SURESH SENANAYAKE ,B.Sc. (Hons) Phy. (Sp.), Grad. IP (SL), NDT Qualification as per ISO 9712
Testing
Destructive testing
(DT)
Tensile test
Bend test
Charpy test
Hardness test
Fatigue test
Creep test
Metallography
Chemical analysis,
etc.
Semi-destructive
testing
Coring test
Tension test
Carbonation test
Mortar test
Non-destructive
testing (NDT)
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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SURESH SENANAYAKE | NCNDT
Engineering Materials
Materials
Metals
Ferrous
Steel
Stainless
steel
Cast iron
Ceramics
Polymers
Composites
Non-Ferrous
Aluminu
m
Copper
Zinc
Titanium
Tungsten
Nickel
SURESH SENANAYAKE | NCNDT
Material Discontinuities
Should identify the types of metal manufacturing and service discontinuities
(i.e. to know what causes the defects)
Defects
Inherent
TheProcessing
refining
Defects
stage
where
metals
are
extracted from
ores
- Inclusions
(Slag)
- Porosity
(Blown hole)
- Pipe
- Segregation
Final
stages of
Primary
Secondary
parts
Processing
Processing
MetalDefects
ingots are manufacturing
Defects
worked
into - Grinding
cracks
usable
forms
(thermal
such as billets or
cracks)
blooms
by
- Machining
wrought
cracks
processing or
- Welding
casting
- Seams
defects
- Heat
- Laps
treat
- Lamination
cracks
- Forging bursts
(quenching
- Inclusions
cracks)
- porosity
SURESH SENANAYAKE | NCNDT
Service Defects
Occurs
during
the use of the
part
- Fatigue cracks
- Stress cracks
- Corrosion
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
Eddy Current
Current
Testing
Testing
NDT
Visual
Visual
Testing
Testing
Leak testing
Strain gauging
Acoustic emission
IR Thermography
Laser shearography
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NDT.
The choice of test method
to be carried out on a
certain piece depends on
several factors, the most
important ones being;
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
SURESH SENANAYAKE | NCNDT
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VISUAL TESTING
Eye of a qualified technician can be supplemented with
various optical aids and mechanical gauges for visual
inspection.
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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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Visual Testing
Training03
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SURESH SENANAYAKE | NCNDT
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Visual Inspection
Most basic and
common inspection
method.
Tools include Lights,
Mirrors, fiberscopes,
borescopes,
magnifying glasses and
Portable video inspection
CCTV.
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.
SURESH SENANAYAKE | NCNDT
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SURESH SENANAYAKE | NCNDT
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
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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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SURESH SENANAYAKE | NCNDT
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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RADIOGRAPHY
Applications
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
SURESH defect
SENANAYAKE | NCNDT
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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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SURESH SENANAYAKE | NCNDT
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.)
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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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SURESH SENANAYAKE | NCNDT
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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)
Magnetic powders
Limitations
Not applicable to non-ferromagnetic materials
Requires a sources of electricity
Magnetization in two perpendicular directions is necessary
Inspected objects haveSURESH
to beSENANAYAKE
demagnetized
| NCNDT
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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 | NCNDT
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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
6/17/15
MATERIAL
SURESH SENANAYAKE | NCNDT
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Eddy Current
Sub surface
flaw detection
Applications
Multi-layered aircraft
structures.
- Fuselage
- Wings
- Around Fasteners
Phase indicates flaw
depth
Magnitude indicates
flaw severity at depth
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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
SENANAYAKE
Does not indicateSURESH
the shape
of| NCNDT
discontinuities
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Eddy Current..
A typical NDT job
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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
Superficial
Method
Internal
Detecti
on
Length
evaluat
ion
Height
evaluati
on
Detecti
on
Length
Height
Depth
evaluati evaluati evaluati
on
on
on
VT
Adequat
e
Adequat
e
Inapplica
ble
Inapplica
ble
Inapplica
ble
Inapplica
ble
Inapplica
ble
PT
Adequat
e
Adequat
e
Inapplica
ble
Inapplica
ble
Inapplica
ble
Inapplica
ble
Inapplica
ble
MT
Adequat
e
Adequat
e
Applicabl
e with
limitatio
ns
Low
efficienc
y
Low
efficienc
y
Inapplica
ble
Inapplica
ble
UT
Applicabl
e with
limitatio
ns
Low
efficienc
y
Low
efficiency
Adequat
e
Good
Low
efficienc
y
Adequat
e
Good
Low
efficienc
y
Applicabl
e with
double
exposure
and
calculus
Low
Low
Low
RT
Adequat
e
Adequat
e
Inapplica
ble
Adequat
e
Adequat
Low
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Advantages of NDT
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
Limitations of NDT
Results are normally qualitative
Requires highly trained and experienced
personnel
SURESH SENANAYAKE | NCNDT
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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
SURESH SENANAYAKE | NCNDT
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Thank you!
SURESH SENANAYAKE | NCNDT
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