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INTRODUCTION TO

NON-DESTRUCTIVE TESTING TECHNIQUE

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

SURESH SENANAYAKE | NCNDT

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

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
SURESH SENANAYAKE | NCNDT

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
SURESH SENANAYAKE | NCNDT

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.
SURESH SENANAYAKE | NCNDT

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

SURESH SENANAYAKE | NCNDT

Other NDT methods;

Leak testing
Strain gauging
Acoustic emission
IR Thermography
Laser shearography

SURESH SENANAYAKE | NCNDT

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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

SURESH SENANAYAKE | NCNDT

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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.

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.
SURESH SENANAYAKE | NCNDT

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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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SURESH SENANAYAKE | NCNDT

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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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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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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

The testing involves the use of,


A radiation source
A radiation detector (film)
SURESH SENANAYAKE | NCNDT

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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

SURESH SENANAYAKE | NCNDT

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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 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)

SURESH 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.

SURESH SENANAYAKE | NCNDT

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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.

SURESH SENANAYAKE | NCNDT

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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
SURESH SENANAYAKE | NCNDT

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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

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

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.

SURESH SENANAYAKE | NCNDT

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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

SURESH SENANAYAKE | NCNDT

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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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Magnetic Particle crack indications

SURESH SENANAYAKE | NCNDT

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PENETRANT TESTING (PT)

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

SURESH SENANAYAKE | NCNDT

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

Developer

SURESH SENANAYAKE | NCNDT

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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 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.

SURESH SENANAYAKE | NCNDT

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Eddy Current.
Coils
magnetic field
Coil
Eddy Currents
magnetic field

Conductive
material
Eddy Currents

SURESH SENANAYAKE | NCNDT

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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

Inspect conducting materials


Detect surface and sub-surface disc
Measure hardness and thickness of layer and thin
sheet
SURESH SENANAYAKE | NCNDT

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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

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

SURESH SENANAYAKE | NCNDT

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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

SURESH SENANAYAKE | NCNDT

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What needs to be avoided?

SURESH SENANAYAKE | NCNDT

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

SURESH SENANAYAKE | NCNDT

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SURESH SENANAYAKE | NCNDT

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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

SURESH SENANAYAKE | NCNDT

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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