22UME928 - Non Destructive Testing
[Link] K
AP/Mechanical
Dr.N.G.P IT
Course objectives
• Objective 1: Introduce the concepts of Non Destructive testing and visual
inspection.
• Objective 2: Describe appropriate techniques to detect the surface defects in the
components.
• Objective 3: Learn the principles, techniques, and applications of thermography
and Eddy Current Testing (ET).
• Objective 4: Impart knowledge on ultrasonic and acoustic emission testing.
Objective5: Gain in-depth knowledge of RT principles, imaging techniques, and
advanced methods such as Fluoroscopy and CT.
Course outcome(s)
• CO1: Summarize the fundamental concepts of NDT.
• CO2: Outline the functions and features of surface NDE methods.
• CO3: Explain the concept of Thermography and Eddy current testing.
• CO4: Describe the concepts, principles and testing procedure of
ultrasonic and acoustic emission testing.
• CO5: Illustrate the concepts and principles of Radiography.
UNIT- I
INTRODUCTION AND VISUAL INSPECTION
METHODS
• NDT Versus Mechanical testing, Overview of the Non-Destructive Testing
Methods for the detection of manufacturing defects as well as material
characterization. Relative merits and limitations, Various physical
characteristics of materials and their applications in NDT., Visual inspection –
Unaided and aided.
In this type of testing, the component or specimen to be tested is
destroyed and cannot be reused.
After testing, the component or specimen either breaks or remains
no longer useful for future use.
As the name suggests, destructive testing (DT) includes
methods where the component or specimen is broken down in
order to determine physical and mechanical properties such as
strength, toughness, ductility and hardness.
Destructive testing is more suitable and economical for mass
production, as the cost of destroying a small number of pieces
is negligible. It is not economical to do destructive testing
where only one or very few items are to be produced.
Tensile test
Compression test
Shear test
Hardness test
Impact test
Bending test
Fatigue test
Creep test
Torsion test
Chemical analysis, etc.
NDT stands for Non-Destructive Testing
As its name implies, non-destructive testing means
testing of materials without destroying them.
A non-destructive test is an examination of an object
which will not produce any kind of damage or
destruction to the sample and after testing the
material can be reused.
Non-Destructive testing is the process of inspecting,
testing or evaluating materials, components or
assemblies for discontinuities, or differences in
characteristics without destroying the serviceability of
the part or system. In other words, when the inspection
is completed, the part can be used.
NDT is a procedure which covers the inspection
and/or testing of any material, component or
assembly by means which do not affect its ultimate
serviceability.
Material sorting
Material characterization
Property monitoring
Thickness measurement
Defect detection/ location
Defect characterization
Major task of NDT is to detect and identify the range of
defects.
Main objectives
(i) To detect internal or surface flaws
(ii)To measure the dimensions of the specimen
(iii) To determine material structure or chemistry
(iv) To evaluate material’s physical or mechanical
properties.
Flaw Detection and Evaluation
Leak Detection
Location Determination
Dimensional Measurements
Structure and Microstructure Characterization
Estimation of Mechanical and Physical
Properties
Stress (Strain) and Dynamic Response
Measurements
Material Sorting
Chemical Composition Determination
NDT allows parts and material to be inspected and measured
without damaging them. Because it allows inspection without
interfering with a product's final use, NDT provides an excellent
balance between quality control and cost-effectiveness.
What is NDE:
Non destructive evaluation (NDE) is a term that is often
used interchangeably with NDT.
However, technically, NDE is used to describe
measurements that are more quantitative in nature.
For example, an NDE method would not only locate a
defect, but it would also be used to measure something
about that defect such as its size, shape, and orientation.
NDE may be used to determine material properties,
such as fracture toughness, formability, and other
physical characteristics.
There are NDE application at almost any stage in
the production or life cycle of a component.
To assist in product development
To screen or sort incoming materials
To monitor, improve or control manufacturing processes
To verify proper processing such as heat treating
To verify proper assembly
To inspect for in-service damage
To ensure product integrity and reliability
To control manufacturing processes
To lower production costs
To maintain a uniformity in quality level NDT
tests can be performed …
o During manufacturing
o After manufacturing
o Even on parts that are already in service
Inspection of Raw Products
Inspection Following Secondary Processing
In-Services Damage Inspection
Inspection of Raw Products
Forgings
Castings
Extrusions etc.
Machining
Welding
Grinding
Heat treating
Plating
Cracking
Corrosion
Erosion/Wear
Heat Damage
Using NDT, an entire production lot can be inspected, or
selected samples can be inspected.
Also different tests can be applied to the same item, either
simultaneous or sequentially, and the same test can be
repeated on the same specimen for additional verification.
It may be added that the NDT equipment is often portable.
This permits the use of NDT methods for on-site testing in
most locations.
NDT does not permanently alter the specimen being inspected,
it is a high valuable technique that can save both time and
money in product evaluation, trouble shooting, and research.
NDT make components more reliable, safe and
economical.
The equipments are easy to handle.
Defects can be detected without damaging the
components.
Methods are quick and accurate.
Components can be sorted out on the basis of
electrical, magnetic or chemical properties.
Test results and other information can be
conveniently recorded on paper films, cassettes,
floppies, DVD, CD, etc.
NON DESTRUCTIVE TEST DESTRUCTIVE TEST
Used for finding out defects of Used for finding out the properties
materials of the material
Load is not applied on the material Load is applied on the material
No load applications, so no chance Due to load application, material
for material damage gets damaged
No requirement of special Special equipments are required
equipments
Non expensive Expensive
Less skill Skill is required
e.g: dye penetrate test, ultrasonic, e.g: tensile test, compression test,
radiography, etc hardness test, etc
Non-destructive Testing Methods
1. Visual Inspection
2. Liquid Penetrant Testing
3. Magnetic Particle Testing
4. Thermography
5. Eddy Current Testing
6. Ultrasonic Testing
7. Accoustic Emission Testing
8. Radiographic Testing
9. Laser Testing
[Link] Testing
Visual inspection is the simplest, fastest and most widely
used non-destructive testing method.
Visual inspection is carried out with naked eye(unaided)
or using some optical aids (aided) such as mirrors,
magnifying glasses and microscopes etc.
Definition:
Visual inspection is defined as the examination of material
or component for conditions of non- conformance using
light and the eyes alone or in conjunction with various aids.
Visual inspection often also involves shaking, listening,
feeling and sometimes even smelling the component
being inspected.
Visual inspection is commonly employed to support
other NDT methods
Other NDT methods require visual intervention to
interpret images obtained while carrying out
examinations. At some point, all NDT methods fall back
on visual testing.
For Example, LPT uses dyes that rely on the
inspectors ability to visually identify surface
indications.
Digital detectors and computer technology have made
it possible to automate visual inspections. This is
known as machine vision.
Visual testing is commonly used
To detect surface characteristics such as surface
finish, scratches, cracks, colour, wear and corrosion
To check alignment of mating surfaces
To check of the components
To check the evidence of leaking
To check internal side defects
Simple and easy to use
Relatively inexpensive
Testing speed is high
Testing can be performed on components which are in-
service
Permanent records are available when latest
equipments are used
Almost all materials can inspect
Limitations:
Limited to detection of surface flaws
The test results depend on skill and knowledge of
tester
Eye resolution is week
Eye fatigue
Classified on the basis of use of aids used
Unaided or direct visual testing
Aided visual testing
Unaided or direct visual testing
As the name suggests, the unaided visual testing is
carried out with naked eye (without using any optical
aids)
The most important instrument in visual
inspection is human eye
Human eye is the most fascinating and valuable tool in NDT
It has greater precision and accuracy than many of the most
sophisticated cameras. It has unique focusing capabilities and
has the ability to work in conjunction with the human brain so
that it can be trained to find specific details or characteristics in a
test specimen.
It has the ability to differentiate and distinguish between
colours and their tones/shades characteristics as well
Human eye is capable of assessing many visual
characteristics and identifying various types of
discontinuities
The eye can perform accurate inspections to detect size, shape,
colour, depth, brightness, contrast and texture
As the name suggests, the aided inspection is carried out
with the help of optical aids (such as magnifying glasses,
microscopes, borescopes, fiberscopes) and a variety of
other optical imaging and image enhancement tools.
The optical aids are mainly used for
Magnification of defects which cannot be
detected by unaided visual inspection
Assisting in the inspection of defects
Areas where not easily accessible to human eye
The optical aids used for visual inspection are
(i) Magnifying Mirrors (small, angled mirrors)
(ii) Magnifying glasses, eye loupes, multi-lens
magnifiers, measuring magnifiers
(iii) Microscopes(optical and electron)
(iv) Boroscopes
(v) Fiberscopes and videoscopes
(vi) Telescopes
(vii) Periscopes
(viii) Optical comparators
(ix) Optical flats(for surface flatness measurements)
(x) Photographic records
(xi) Closed-circuit television (CCTV) systems
(xii) Machine vision systems
(xiii) Image enhancement (computer analysis and
enhancement)
When inspecting areas not easily accessible, a magnifying mirror can
be used.
Depending on the test specimen, the mirror can be of any size.
(ii) Magnifying Glass
A magnifying glass can be used for closer inspection of suspicious
looking areas.
It generally consists of a simple lens for lower power magnification
and double or multiple lenses for higher magnification.
(iii) Microscopes:
Microscope is a multiple element magnifier for providing very high
magnified image of small object.
The simple microscopes consists of a convex lens. The object is placed
between lens and focus length of lens, so that an erect, virtual and
magnified image is formed. The size of the image of an object depends
upon the angle subtended at the eye by the object.(known as visual
angle).
Borescope are optical instrument designed for remote
viewing of objects. They are used to inspect the inside of
a narrow tube, bore or chamber.
Borescopes is a precision optical instrument with built-
in illumination
Borescopes, also called endoscopes or endoprobes
consist of superior optical systems and high
intensity light sources.
Some Borescopes provide magnification option,
zoom controls.
Because of the variety of applications,
Borescopes are manufactured in rigid,
extended, flexible and micro designs.
Modern fiberscope and videoscopes, due to their small
size and flexibility, can provide access to internal areas
inaccessible to rigid borescopes.
Using these, digital images can be captured and
processed in real time. With the aid of laser lights, the
area and depth of many surface defects can also be
determined.
(vi) Telescopes
Telescope is an instrument that collects radiation from a
distant object in order to produce an image of it.
An optical telescope uses visual radiations
The telescopes are used for providing visual
examination of the inaccessible surfaces.
Optical comparators are the magnifying devices
for visual examination and measurement.
A comparator produces 2D enlarged image of an object
on a large ground-glass screen.
Optical comparators project the image of small parts
onto a large projection screen. The magnified image is
then compared against an optical comparator chart,
which is a magnified outline drawing of the workpiece
being gauged.
Periscope is an instrument used for remote
observation of inaccessible areas.
In simple periscope, two right angle reflecting prisms
are utilized in combination with a series of lenses.
The periscopes are commonly used for remote
visual inspection in hazardous situation such as
radiations areas, toxic environment and for
overhead viewing of areas involving obstacles.
Inspection of cleaning in machines
Checking for corrosion, erosion and deformities of machine
components
Checking for ruptures, cracks and wear of parts in the
equipment.
Monitoring of manometers, pressure and
temperatures
Monitoring of oil level, greasing and greasing apparatus.
Monitoring of the operational conditions of systems or
machines.
Visual Testing of welds
Visual Testing of Pumps
Visual Testing of hydraulic systems
Visual Testing of Belt Pulley
Visual Testing of Forging Discontinuities
o Most basic and common
inspection method.
o Tools include
fiberscopes, borescopes,
magnifying glasses and
mirrors.
o Portable video inspection unit
with zoom allows inspection of
large tanks and vessels, railroad
tank cars, sewer lines.
o Robotic crawlers permit
observation in hazardous or
tight areas, such as air ducts,
reactors, pipelines.