Inspection

Destructive
• Cutting samples and examining properties
• Tensile, Compression and Torsion Testing

Hardness Testing

Non-Destructive
The use of non-invasive techniques (Inspect or measure
without doing harm) to determine the integrity of a
material, component or structure
Internal surface flaws, dimensions, materials (chemistry,
physical structure), mechanical properties
Destructive Testing
Advantages:
• Provides a direct and reliable measurement of how a component will
respond to service condition
• Provide quantitative results
• Does not require interpretation of results by skilled operators
• Usually finds as to meaning and significance of test results

Disadvantages:
• Applied only to a sample
• Tested parts are destroyed during testing
• Usually can not repeat test on same item
• May be restricted to few numer of parts
• Extensive work required in preparation of test samples
• High labor cost
Non-Destructive Testing (NDT)
• Means of probing material
• Means by which flaw, material property or
specimen feature interacts with or modifies
whatever is probed
• Sensor to detect response
• Device to record response
• Means to interpret and evaluate quality
Non-Destructive Testing Methods
• Visual Inspection
• Liquid Penetrant Inspection
• Eddy Current Inspection
• Radiographic Inspection
• Ultrasonic Inspection
• Magnetic Inspection
NDT
Visual Inspection (Macroscopic/Microscopic)
• Human eye + brain training = interpret signals
• May uses optical aids like – magnifying glasses, microscopes
etc
• Automations and quantitative evaluations are possible - video
camera, digital image analyzers
• Only surfaces can be examined
• Reveal corrosion, contamination, surface finish flaws and
surface discontinuities
• Illuminate test specimen and observe surface
NDT

Visual Inspection
• Simple, easy to use and relatively inexpensive

• Inspection results are limited to knowledge and perception of

inspector

• No material limitations

• Provide permanent records in form of photographs/video

tapes etc
NDT
Liquid Penetrant Inspection (Dye Penetrant Inspection)
• Surface defects in metals and other non-porous materials
• Penetrant
– Liquid material capable of wetting entire surface and being drawn in
openings
– Dipping, spraying or brushing
– Bright color or fluorescence
– Inspection is done under UV light to increase test sensitivity
• Developer
– Absorbent material capable of drawing traces of penetrant from
defects back on surface
– Contrast colour of penetrant
NDT
Liquid Penetrant Inspection (Dye Penetrant Inspection)
NDT
Liquid Penetrant Inspection (Dye Penetrant Inspection)
NDT

Liquid Penetrant Inspection (Dye Penetrant Inspection)

• Simple, inexpensive, portable, applicable to complex shapes

• Only surface flaws – through cleaning before and after

inspection

• Used only for cold products

• Any size or shape permitting accesability of surfaces to be

inspected

• Provide permanent records in form of photographs/video

tapes etc
NDT
Eddy Current Inspection
• Ferrous and Non- ferrous metals
• Detecting surface and near surface irregularities, wall
thickness, crack depth
• When an electrically conductive material is brought near AC
coil (that produces alternating magnetic field), surface
currents (eddy currents) are generated in material. These
surface currents generate their opposing magnetic field which
interact with the original, modifying the impedance of the
originating coil. The change in magnetic field causes a change
in impedance of coil => changes magnitude of current
flowing through it
• This test works best for materials of uniform section
NDT
Eddy Current Inspection
 Inspection
NDT
Eddy Current Inspection Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
NDT
Eddy Current Inspection
• Intimate contact with specimen is not required
• Automation is possible
• High speed operation
• Final cleaning is not required
• Pass/fail inspection is very easy
• Trained operators are required
• Depth of inspection is limited
• Constant separation distance between coil and specimen is
required for good results
• Electronic signals can be recorded using strip-chart recorders
Radiographic Inspection
• A shadow pattern is created when certain types of radiation (X-
rays, gamma rays or neutron beams) penetrate an object and are
differentially absorbed due to variations in thickness, density,
chemistry or defects in specimen
• The transmitted radiation may be registered on a photographic film
• Fluorescent screens can also provide direct conversion of radiation
into visible light (no film processing is required)
Steps:
1. An X-ray tube emits rays of radiation, which pass through the
component, forming an image on a photographic film placed
behind it.
2. If a defect is present in the component, less radiation will be
absorbed by the defect resulting in a darker image on the
photographic film.
NDT
Radiographic Inspection
Part placed between the radiation source and
X-ray film
Beam Part stops some of the radiation

The film darkness (density)

will vary with the amount
of radiation reaching the
X-ray film film through the test object.

= more exposure
Top view of developed film = less exposure
NDT
Radiographic Inspection
• A standard test piece (penetrameter) is included in a
radiographic exposure. Penetrameters are made of same
material as specimen and contain features with known
dimensions. It is used for comparison purposes.
• The presence of hydrogen in castings is revealed by neutron
absorption (hydrogen has high neutron absorption)
• Costly method
• Requires strict safety precautions
• Defect must be atleast 2% of total section thickness
• High degree of operator training is required
• A photographic image is part of standard test procedure
NDT
Ultrasonic Inspection
• Ultrasonic Inspection involves using a piezoelectric effect /
magnetostriction to generate high frequency sound vibrations
(20kHz) beyond the range of the human ear
• A probe (transceiver) emitting high freequency vibrations is passed
over the material to be tested
• If the material has internal defects, some vibrations will be
reflected back to the probe and they will show up on the cathode
ray tube.
• Ultrasonic testing is ideal for testing thick components such as
castings
• Ultra-sonic testing is rapid and has the ability to probe deeply
without damaging the piece
NDT
Ultrasonic Inspection
Types:

Pulse-Echo
Through Transmission
Resonance Testing
NDT
Ultrasonic Inspection Pulse-Echo
High frequency sound waves are introduced into a material and they are reflected
back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can visualize a cross
section of the specimen showing the depth of features that reflect sound.

initial
pulse

back surface
echo
crack
echo

crack
0 2 4 6 8 10
plate
Oscilloscope
 Inspection
NDT
Magnetic Particle Inspection
• Ferromagnetic materials (alloys of iron, nickel and cobalt
when magnetized, will have distorted magnetic fields in the
vicinity of defects.
• Steps:
– The part is magnetized
– Finely milled iron particles coated with a dye pigment are then
applied to the specimen
– These particles are attracted to magnetic flux leakage fields and will
cluster to form an indication directly over the discontinuity
– This indication can be visually detected under proper lighting
conditions.
 Inspection
NDT
Magnetic Particle Inspection
 Inspection
NDT
Magnetic Particle Inspection
 Inspection
NDT
Magnetic Particle Inspection
NDT
Magnetic Particle Inspection
• Simple, fast, easy to interpret, portable,
• Reveal surface and subsurface flaws (6 mm deep)
• Specimen should be clean before inspection
• Allignment of flaw is necessary
• Material must be ferromagnetic
• Unlimited shape and sizes can be inspected
• Photographs, videotapes, defect pattern etc can be kept as
permanent record