Nondestructive Tests

Prepared by: BHAVANA SINGH

Introduction
We use Non Destructive Testing (NDT) when we wish to assess the integrity of a structure without destroying it.
Types of NDT used are: 1. Dye penetrant inspection (PT)

2. Magnetic particle inspection (MT)

3. Radiographic inspection (RT) 4. Ultrasonic inspection (UT)

5. Eddy current tests

6. Freon tests 7. Hydraulic/Pneumatic pressure test

Dye penetrant inspection (PT)

Introduction
Surface breaking defects only detected. Penetrant applied to the component and drawn into the defects by capillary action.

Applicable to all non- porous materials.

Procedure

Procedure
First the testing specimen must be cleaned thoroughly, then a penetrant is applied for a specified time. Once the contact time has elapsed, the penetrant is removed and a developer is then applied.

Two types of penetrants are: 1)Colour contrast 2)Fluorescent Penetrant

Any penetrant that has been drawn into a crack by capillary action will be drawn out into the developer.

Method

Apply Penetrant

Clean then apply Developer

Result

PENETRANT (PT)

APPLICATIONS

It is used for determining surface discontinuties,cracks,porosity,seams,laps, leaks.

PENETRANT (PT)

ADVANTAGES

Inexpensive; easy to apply; more sensitive than visual alone; use on most materials; rapid; portable.
LIMITATIONS

Surface only; not useful on hot, dirty, painted, or very rough surfaces. Requires some technique.

Magnetic particle inspection (MT)

Introduction
Surface and slight sub-surface detection.

Relies on magnetization of component being tested.

Ferro-magnetic materials only can be tested. Methods of applying a magnetic field, yoke, permanent magnet and prods. Any defect which interrupts the magnetic field, will create a leakage field, which attracts the particles.

Method
Collection of ink particles due to leakage field Electromagnet (yoke) DC or AC

Crack like indication Prods DC or AC

Crack like indication

Procedure
First the work must be cleaned and a whitener applied for contrast. A magnetic flux is then applied by permanent magnet, electro magnet, or straight current. A magnetic ink is applied which will concentrate in areas of flux leakage, as those caused by flaws.

The weld length must be crossed at 90 by the magnetic field.

The types of magnetic media used are: 1) Wet ink 2) Dry powder 3) Fluorescent ink

Method
Contrast paint Magnet & Ink
Result

MAGNETIC PARTICLE (MT)

Applications
It is used for surface and near surface discontinuties,cracks,voids,porosity,inclusions, seams,laps.

Advantages
Low cost; fast; more sensitive to tight cracks than PT; can do near subsurface; portable.

MAGNETIC PARTICLE (MT)

LIMITATIONS

Material must be ferromagnetic; surface must be clean; part may be demagnetised, alignment of field is important. Requires operator technique.

Radiographic inspection (RT)

Introduction
Radiation is transmitted to varying degrees depending upon the density of the material through which it is travelling.

Thinner areas and materials of a less density are shown as darker areas on the radiograph.

Thicker areas and materials of a high density are shown as lighter areas on a radiograph.

Applicable to metals, non-metals and composites.

Procedure
A film is placed inside a cassette between lead screens. It is then placed to the rear of the object to be radiographed A radiographic source, is exposed to the work and film for a pre-calculated time.

Any imperfections in line with the beam of radiation will be shown on the film after exposure and development.
The 2 types of radiation used in industrial radiography: 1) X rays (from Cathode Ray Tube)

2) Gamma rays (from a Radioactive Isotope)

Method
Source Radiation beam Image quality indicator

Radiographic film

Test specimen

Method
Source Radiation beam Image quality indicator

Test specimen

Radiographic film with latent image after exposure

RADIOGRAPHY (RT)
APPLICATIONS
Subsurface discontinuities: Cracks, voids, inclusions, thickness variation, lack of fusion, incomplete penetration, corrosion, missing components, composition.

COMMENTS
One of the most frequently used methods.

RADIOGRAPHY (RT)

ADVANTAGES
Easily understood permanent record; usually moderate cost; can be portable; applicable to a wide range of materials.

LIMITATIONS
Cannot detect laminations; radiation hazard and regulations; access to both sides can be high cost; requires trained operators.

Ultrasonic inspection (UT)

Introduction
This detection method uses high frequency sound waves, typically above 2MHz to pass through a material. A probe is used which contains a piezo electric crystal to transmit and receive ultrasonic pulses and display the signals on a cathode ray tube or digital display. The actual display relates to the time taken for the ultrasonic pulses to travel the distance to the interface and back. An interface could be the back of a plate material or a defect.

Procedure
First the work must be cleaned thoroughly, then a couplant is applied to increase sound transmission A probe is then applied with the correct angle for the weld preparation and sound waves are transmitted Any imperfections will rebound the sound waves causing a signal to occur on the cathode ray tube

Method
Apply Couplant Sound wave
CRT display

Result

Signal rebounded from Lack of fusion

Method
initial pulse defect echo Back wall echo

Material Thk defect

10

20

30

40

50

Compression Probe

CRT Display

ULTRASONIC (UT)
APPLICATIONS
Surface and deep subsurface discontinuities:

Surface and deep subsurface discontinuties cracks,lamination,porosity,lack of fusion,inclusions,thickness.

COMMENTS

Need good standards. Frequently used method.

ULTRASONIC (UT)

ADVANTAGES
Rapid if automated but manual is slow ;applicable to very thick specimens;can give location and size of discontinuity; good sensitivity; inspect from one size; Portable.

LIMITATIONS
Couplant required; thin complex shapes are difficult ; orientation of discontinuity Important; very operator dependent.

EDDY CURRENT METHOD

Introduction
This test is useful for assessing and detecting the flaws and for determination of variation in wall thickness of metallic non magnetic materials. It is complicated test and requires highly trained operator to perform the test and interpret the results.

Eddy currents are induced in the object which produces secondary magnetic field.
Test is useful for heat exchanger tubes testing. It is not commonly used in chemical industries.

FREON TEST

Introduction
Useful in determining the leakages, cracks in welded joints,flange joints, tube joints, tube sheet joints. The snuffing device of the instrument traces the leakage in a vessel filled with halogen containing liquid either Freon 11 or Freon 12. It can detect a leakage through which Freon can escape at the rate of 300 mg/year.It means the test is highly sensitive.

HYDRAULIC/PNEUMATIC PRESSURE TESTING

Introduction
Hydraulic testing
Used for equipments operating under pressure.e.g. pressure vessels , boiler etc.
To test the surfaces, cracks the vessels are subjected to 30-50% higher than the design pressure. Test pressure is calculated as follows: Test pressure =(1.3-1.5) design pressure x (ft/fd) ft- permissible stress of material at test temperature. fd-permissible stress of material at design temperature.

Pneumatic pressure test:

The vessels which cannot be filled with water or liquid and the service conditions are such that even a trace of water cannot be permissible, then in such cases, pressure testing is carried out with gas or air, it is called as pneumatic testing.
Pneumatic test pressure applied is not less than design pressure of the equipment and more than hydraulic test pressure. The air or gas pressure is gradually increased to not more than 50% of the test pressure.