329 Corrosin

15-19 Nov

Dr M.G.Hassan
For Dr Magdi NasrAllah
This presentation is no substitution for reading
the chapter Some information is only found in the
book

2.2 Corrosion Detection and

Monitoring
Page 16-46

2.2.1 Visual Examination

2.2.2 Laser Methods
2.2.3 Replication Microscopy
2.2.3 Replication Microscopy
2.2.4 Radiographic Methods
2.2.5 Liquid Penetrant Testing Method
2.2.6 Magnetic Particle Testing
2.2.7 Eddy Current Inspection Method
2.2.8 Ultrasonic Inspection Method
2.2.9 Acoustic Emission Technique
2.2.10 Other Nondestructive Methods
2.2.11 Thermal Methods of Inspection

nondestructive techniques
Inspection is usually done by
nondestructive techniques.
This is usually known as nondestructive
examination (NDE).
The general term nondestructive
evaluation describes the various terms
used such as nondestructive inspection
(NDI),
nondestructive testing (NDT)
and nondestructive examination (NDEx).

particular nondestructive
evaluation
the type of flaw to be detected,
the size and orientation of the flaw,
the location of the flaw in the
sample,
the size and shape of the sample
the nature of the sample.

characterization of the flaws

2.2.1 Visual Examination

This method is the simplest of all the methods
and is capable of detecting

surface flaws such as corrosion,

contamination,
surface finish and surface discontinuities on joints.
The discontinuities on joints such as welds, seals,
solder connections and adhesive bonds

the technical personnel in charge of detecting

and monitoring corrosion in the plant
periodically keep micrographs of known samples
illustrative of various forms of corrosion

2.2.2 Laser Methods

Laser inspection of the sample surface can also
yield information on surface flaws such as the
surface roughness
The laser beam incident on the surface of the
sample is scattered, and the scattered light
intensity decreases when a crack is present on the
surface
Holographic imaging can also lead to detection of
defects and has been used in detection of defects
in automobile clutch plates, brake drums, gas
pipelines, high-pressure tanks and turbine blades.

2.2.3 Replication
Microscopy
This method can be used for in situ measurement of
the microstructural deterioration and damage of
materials exposed to environments in power plants
and petrochemical industries for the purpose of
determining remaining service life of components
A surface replica, using acetate, acrylic or rubber
taken from a sample is examined by a microscopic
technique such as electron microscopy
Surface cracks in boiler tubes, creep damage in power
plant components and precipitate analysis in
components subjected to high temperature and stress
have been successfully assessed by this technique

 The following is an example of the

type and severity of defects and the
necessary action taken in the context
of power plant operations

2.2.4 Radiographic
Methods
The source of radiation used in the method can
be either X-rays or y-rays emitted by a
radioactive element
The difference in intensities of radiation
absorbed by the test sample due to the internal
flaw and the surroundings devoid of flaws
produces an image of the flaw on the sensor
used, such as film.
It is important to recognize the radiation hazards
in using the technique and all precautions should
be taken in handling the instrument.

 The choice of the source and type of incident radiation

used depends upon the thickness of the sample to be
tested.
The energy of the incident beam needs to be matched
with the thickness of the sample
The experimental radiographic procedure for materials
involving simple shapes such as flat plates
Flaws detected in castings are: microshrinkage,
shrinkage porosity same as spongy shrinkage, gas
porosity, dispersed discontinuities, tears, cold cracks,
cold shuts,, inclusions, unfused chaplets, core shift,
centerline shrinkage, shrinkage cavities, segregation
and surface irregularities.

Neutron Radiography
A neutron beam is directed on the test sample and
the resulting attenuated beam falls on a conversion
screen and a radiographic image is obtained
The thermal neutron sources are radioactive isotopes
which emit neutrons,
The neutrons from the sources are moderated with
materials such as paraffin, graphite, water, heavy
water or beryllium.
Some of the radioisotopes used as sources of thermal
neutrons are: antimony, polonium, americium curium
and californium. The various sources have different
half-lives, ranging from days to years.

2.2.5 Liquid Penetrant

Testing Method
This method consists of application of liquid to
the surface of a sample, allowing the liquid to
penetrate into the discontinuities in the sample.
After some time the excess liquid on the surface
is removed, leaving the liquid in the
discontinuity intact.
Then a developing agent is applied, which draws
the liquid penetrant from the discontinuity to the
surface of the sample, leaving a visible
indication of the discontinuity on the sample.

 The true indications of the discontinuities

may appear as continuous lines due to
cracks, cold shuts, forging laps, scratches
or die marks

2.2.6 Magnetic Particle

Testing
This method involves magnetization of
the sample coated with a liquid
dispersion of magnetic particles, and
then observing the magnetic medium
patterns.
Discontinuities in the samples result in
indications in the magnetic medium
patterns different from normal patterns

2.2.7 Eddy Current Inspection

Method
This method is based on the principles of
electromagnetic induction.
A coil carrying an alternating current in the vicinity
of the test sample produces an induced or eddy
current in the sample, and the changes in the
magnetic field due to the induced currents are
monitored.
The induced currents in the test sample are
affected by electrical conductivity, permeability, the
dimensions and the homogeneity of the sample
Need to use ref Standards

2.2.8 Ultrasonic Inspection

Method
This method consists of high-frequency
sound waves (0.1-25 MHz) incident upon
the test sample and measuring the energy
of the reflected beam
Attenuation loss in energy of the beam due
to the flaws in the sample
Cracks, laminations, shrinkage cavities,
bursts, flakes, disbonds and other
discontinuities can be detected by this
method.

 The display consists of one signal in

the reasonance technique.
The pulseecho technique can be
further used in the A-scan, B-scan or
C-scan modes of presentation of the
signal resulting in the test

 In the A-scan display the three peaks corresponding

to front surface reflection, reflection at the
discontinuity and the back surface reflection along
with the respective intensities (y-axis) and the
distance along the x-axis giving the depth of
penetration in the sample are obtained.
In the B-scan mode the cross-section view and the
distribution of discontinuities within are displayed.
In the C-scan the length and width of the
discontinuity is displayed.

2.2.9 Acoustic Emission

Technique
Acoustic emissions are the stress waves resulting
from sudden movements in the stressed sample
material.
The most obvious example is the 'tin cry' due to
stress in a wooden structure due to the load.
It is very important that the measured acoustic
emission signal be corrected for the background
noise signal.
Acoustic emission energy is due to the elastic stress
field in the sample material.
Acoustic emission is monitored by applying a
controlled variable load.

 Brittleness and homogeneity of a

sample are indicated by a high acoustic
emission pattern,
while the ductile deformation
mechanism due to microvoid
coalescence of soft steels is
characterized by low-emission signals.
The acoustic emission technique is used
in the frequency range 20-1200 kHz.

2.2.11 Thermal Methods of

Inspection
Thermal methods of inspection can be used to
detect flaws in materials of complex shape,
The methods detect subsurface flaws or voids
in the samples.
The limitation is that the depth of the flaw
should not be large compared with its
diameter.
When heat flows into or out of the sample, the
surface temperature is measured or
continuously mapped.

 The resulting contours of the surface temperature

indicate the morphology of the defect in the sample.
Thermal inspection can be done by using either
contact or noncontact sensors.
The noncontact sensor consists of an infrared
imaging element which may be either a portable
imaging hand-held scanner or high-resolution
infrared imaging system.
The contact type of sensors measuring changes in
temperature are material coatings and
thermoelectric devices.