Introduction To NDT

INTRODUCTION TO
NON-DESTRUCTIVE TESTING TECHNIQUE

Testing
Non-destructive testing
Destructive testing (DT) Semi-destructive testing
(NDT)
Ultrasonic test
Tensile test Eddy current test
Bend test Coring test Radiography test
Charpy test Tension test Visual test
Hardness test Carbonation test Magnetic particle test
Fatigue test Mortar test Penetrant test
Creep test IR thermography
Metallography Leak test
Chemical analysis, etc. Acoustic emission
Laser shearography
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SURESH SENANAYAKE
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
Engineering Materials
Materials
Metals Ceramics Polymers Composites
Ferrous Non-Ferrous
Steel Aluminum
Stainless steel Copper
Cast iron Zinc
Titanium
Tungsten
Nickel 4
SURESH SENANAYAKE
Material Discontinuities
Should identify the types of metal manufacturing and service discontinuities
(i.e. to know what causes the defects)
Defects
Inherent Processing Primary Processing Secondary

Service Defects
Defects Defects Processing Defects
The refining stage Metal ingots are Final stages of parts Occurs during the
where metals are worked into usable manufacturing use of the part
extracted from ores forms such as billets - Grinding cracks - Fatigue cracks
- Inclusions (Slag) or blooms by (thermal cracks) - Stress cracks
- Porosity (Blown wrought processing - Machining cracks - Corrosion
hole) or casting - Welding defects
- Pipe - Seams - Heat treat cracks
- Segregation - Laps (quenching
- Lamination cracks)
- Forging bursts
- Inclusions
- porosity
SURESH SENANAYAKE 5
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 6
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. Ensuring customer satisfaction
b. Helping in better product design
c. Controlling manufacturing processes
d. Lowering manufacturing processes
e. Maintaining a uniform quality level
SURESH SENANAYAKE 7
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 8
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
SURESH SENANAYAKE 9
Other NDT methods;
Leak testing
Strain gauging
Acoustic emission
IR Thermography
Laser shearography
SURESH SENANAYAKE 10
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
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
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.
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
Training- 03
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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. 17
SURESH SENANAYAKE
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
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)
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
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
21
SURESH SENANAYAKE
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 22
ULTRASONIC TESTING (UT)
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)
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)
24
SURESH SENANAYAKE
Ultrasonic..
The ultrasonic beam emitted If the beam finds a
by the probe passes through discontinuity along its path,
the test piece and, after it returns to the probe more
reaching the bottom wall, is quickly, in this way signaling
reflected back to the probe the presence of a defect.
which signals it on the
screen.
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.
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

27
SURESH SENANAYAKE
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
28
SURESH SENANAYAKE
MAGNETIC PARTICLE TESTING (MT)
Using magnetic or current flow to produce magnetic field in the
materials
The pattern of field distribution provides indication of the
existence discontinuities
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.
MAGNETIC PARTICLE
Applications
Applicable to ferromagnetic materials
Capable of detecting surface and sub-
surface discontinuities
Easily operated portable equipment
makes it suitable for field inspection
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 have to be demagnetized
Magnetic Particle crack indications
PENETRANT TESTING (PT)
Using liquid to penetrate materials
Image of discontinuities become visible after
development
Penetrant Testing..
Penetrant testing requires a use of:
Penetrant liquids Developer
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 36
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.
Eddy Current.
Coils
magnetic field
Coil
Eddy Currents
magnetic field
Conductive
material
Eddy Currents SURESH SENANAYAKE 38
Eddy Current.
CRACK DETECTION
PROBE PROBE PROBE PROBE
FLAW
11/24/2017 MATERIAL
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
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
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
Who is involved in Aerospace in service NDT?
Airline operators
Airworthiness authorities
Component part manufacturer
NDT equipment supplier
Aircraft manufacturer
Qualified NDT inspector
What needs to be avoided?
A defect that went
undetected in an
engine disk was
responsible for the
crash of United Flight
232.
Reliability of NDT
Discontinuity
Method Superficial Internal
Length Height Length Height Depth

Detection Detection
evaluation evaluation evaluation evaluation evaluation
VT Adequate Adequate Inapplicable Inapplicable Inapplicable Inapplicable Inapplicable
PT Adequate Adequate Inapplicable Inapplicable Inapplicable Inapplicable Inapplicable
Applicable
Low Low
MT Adequate Adequate with
efficiency efficiency
Inapplicable Inapplicable
limitations
Applicable
Low Low Low
UT with
efficiency efficiency
Adequate Good
efficiency
Adequate
limitations
Applicable
Low with double
RT Adequate Adequate Inapplicable Adequate Good
efficiency exposure
and calculus
Low Low Low Low
ET Good Good Adequate
efficiency efficiency efficiency efficiency
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
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
Thank you!

Introduction To NDT

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Introduction To NDT

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INTRODUCTION TO

NON-DESTRUCTIVE TESTING TECHNIQUE

Metals Ceramics Polymers Composites

Inherent Processing Primary Processing Secondary

It is a most commonly used NDT method for detecting and

Tools include Lights, Mirrors,

Portable video inspection

The testing involves the use of,

Crankshaft - Northern Power Plant Ultrasonic Testing

PROBE PROBE PROBE PROBE

Sub surface flaw

A typical NDT job

Method Superficial Internal

Length Height Length Height Depth

VT Adequate Adequate Inapplicable Inapplicable Inapplicable Inapplicable Inapplicable

PT Adequate Adequate Inapplicable Inapplicable Inapplicable Inapplicable Inapplicable

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