By,

OM PRAKASH (711/12)
RAJNEESH KUMAR (712/12)
 Introduction
 Purpose of Non Destructive Testing
 Types of Non Destructive Testing
 Visual Inspection
 Magnetic Particle Inspection
 Liquid Penetrant Testing
 Ultrasonic Testing
 Eddy Current Testing
 Acoustic Emission Technique
 Holography
 Thermal Inspection
 Radiography
 Reference
• Non-Destructive testing is carried out in
such a manner that product integrity and
surface texture remain unchanged.
• These technique generally require
considerable operator skill.
• NDT refer to a method of detecting
internal flaw in engineering materials,
machine components and structures
without breaking them.
 Test piece too precious to be destroyed

 Test piece to be reuse after inspection

 Test piece is in service

 For quality control purpose

 Something you simply cannot do harm.

Visual Inspection
Magnetic Particle Inspection
Liquid Penetrants Inspection
 Radiography
 Ultrasonic Inspection
 Eddy current Inspection
 Holography Inspection
 Acoustic emission testing
 Thermal Inspection
Visual Inspection
Most basic and common
inspection method.

Tools include fiberscope's,

bore scopes, magnifying
glasses and mirrors.

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.
• Leakage in components

• Misalignment of parts

• Cracks and fractures

• Corrosion and erosion

• Minute discontinuities

• Defects in welds
 MPI consists of placing fine ferromagnetic particles on the
surface of the part.
 The particles can be applied either dry or in a liquid carrier
such as water or oil.
 When the part is magnetized with a magnetic field, a defect on
the surface causes the particles in gather visibly around it.
 The particles generally take the shape and size of the defect.
 It can also detect the subsurface defect provided they are not
deep.
 Basic Principles
In theory, magnetic particle inspection (MPI) is a relatively
simple concept. It can be considered as a combination of two
nondestructive testing methods: magnetic flux leakage
testing and visual testing.
Consider a bar magnet. It has a magnetic field in and around
the magnet. Any place that a magnetic line of force exits or
enters the magnet is called a pole. A pole where a magnetic
line of force exits the magnet is called a north pole and a
pole where a line of force enters the magnet is called a south
pole.
Ferromagnetic materials become magnetized when the
magnetic domains within the material are aligned. This can
be done by placing the material in a strong external magnetic
field or by passes electrical current through the material.
Some or all of the domains can become aligned. The more
domains that are aligned, the stronger the magnetic field in
the material. When all of the domains are aligned, the
material is said to be magnetically saturated. When a material
is magnetically saturated, no additional amount of external
magnetization force will cause an increase in its internal level
of magnetization.

Unmagnetized material Magnetized material

When a bar magnet is broken in the center of its length, two
complete bar magnets with magnetic poles on each end of each
piece will result. If the magnet is just cracked but not broken
completely in two, a north and south pole will form at each
edge of the crack.
The magnetic field exits the north
pole and reenters the at the south pole.
The magnetic field spreads out when
it encounter the small air gap created
by the crack because the air can not
support as much magnetic field per
unit volume as the magnet can. When
the field spreads out, it appears to leak
out of the material and, thus, it is
called a flux leakage field.
MPI is not sensitive to shallow
and smooth surface defects

The effectiveness of MPI

depends strongly on the
orientation of the crack related
to the flux lines
• Indirect magnetization: using a strong external magnetic
field to establish a magnetic field within the component

(a) permanent magnets

(b) Electromagnets

(c) coil shot

 One of the most dependable and sensitive methods
for surface defects
 fast, simple and inexpensive
 direct, visible indication on surface
 unaffected by possible deposits, e.g. oil, grease or
other metals chips, in the cracks
 can be used on painted objects
 surface preparation not required
 results readily documented with photo or tape
impression
 Only good for ferromagnetic materials
 sub-surface defects will not always be indicated
 relative direction between the magnetic field and the
defect line is important
 objects must be demagnetized before and after the
examination
 the current magnetization may cause burn scars on
the item examined
 In this technique, fluids are applied to the part and allowed
to penetrate into surface cracks, seams, and pores .

 Two common types of liquids used for this test

a) Fluorescent penetrants ( which fluoresce under ultraviolet
light)

b) Visible penetrants or Dye penetrants ( which appear as

bright outlines on the surface)
Dye penetrants Fluorescent penetrants
 The liquids are colored so that they  Liquid contain additives to give
provide good contrast against the fluorescence under UV
developer  Object should be shielded from
 Usually red liquid against white visible light during inspection
developer  Fluorescent indications are easy to
 Observation performed in ordinary see in the dark
daylight or good indoor
illumination
 Developer
The role of the developer is to pull the trapped penetrant material out
of defects and to spread the developer out on the surface of the part
so it can be seen by an inspector. The fine developer particles both
reflect and refract the incident ultraviolet light, allowing more of it
to interact with the penetrant, causing more efficient fluorescence.
The developer also allows more light to be emitted through the same
mechanism. This is why indications are brighter than the penetrant
itself under UV light. Another function that some developers
performs is to create a white background so there is a greater degree
of contrast between the indication and the surrounding background.
 Advantage
 Simplicity of operation.
 Best method for surface breaking cracks in non-ferrous
metals.
 This method can be used to detect a variety surface defects.
 Equipment is simple and easy to use and portable.
 This equipment is les costly to operate than that of other
methods.
 Disadvantages of LPI
• Only surface breaking defects can be detected.
• Only materials with a relative nonporous surface can be inspected.
• Pre-cleaning is critical as contaminants can mask defects.
• Metal smearing from machining, grinding, and grit or vapor
blasting must be removed prior to LPI.
• The inspector must have direct access to the surface being
inspected.
• Surface finish and roughness can affect inspection sensitivity.
• Multiple process operations must be performed and controlled.
• Post cleaning of acceptable parts or materials is required.
• Chemical handling and proper disposal is required.
• In ultrasonic inspection, an ultrasonic beam travels through the
part.

• An internal defects interrupts the beam and reflects back a

portion of the ultrasonic energy.

• The amplitude of reflected energy and the time required for

return indicate the presence and location of any flaws in the
work-piece.

• It has high penetrating power and sensitivity.

• It can be used from various directions to inspect flaws in large

parts.
 Equipment & Transducers
Piezoelectric Transducers
The active element of most acoustic
transducers is piezoelectric ceramic.
This ceramic is the heart of the
transducer which converts electrical
to acoustic energy, and vice versa.
A thin wafer vibrates with a
wavelength that is twice its thickness,
therefore, piezoelectric crystals are
cut to a thickness that is 1/2 the
desired radiated wavelength. Optimal
impedance matching is achieved by a Direction of wave
matching layer with thickness 1/4 propagation
wavelength.
 Characteristics of Piezoelectric
Transducers
Contact: are used for direct contact
inspections. Coupling materials of
water, grease, oils, or commercial
materials are used to smooth rough
surfaces and prevent an air gap
between the transducer and the
component inspected. Contact type
Immersion: do not contact the
component. These transducers are
designed to operate in a liquid
environment and all connections are
watertight. Wheel transducers is
examples of such immersion
applications.
immersion
 Advantage
• Position, size and type of defect can be determined.

• Instant test results.

Disadvantage
• Considerable degree of skill necessary to obtain the
fullest information from the test

• Very thin sections can prove difficult

 Weld testing in pressure vessels, structures, bridges,
aircrafts, marines.
 Testing of Ferrous and non ferrous pipes, rods, bars,
sheets etc.
 Testing of rails, rolled steel sections, casting, forging
( such as crank shaft, connecting rod.)
 Detection fatigue cracks in boiler and welds.

 In determining the thickness of components such as

piping's, tubing's, heat exchangers fins
 In detection of slag, porosity, inclusion.
• This method is based on the principle of electromagnetic
induction.
• The part is placed in or adjacent to an electric coil through
which alternating current flows.
• This current causes eddy current to flow in the part.
•Defects in the part impede and change the direction of eddy
currents.
• It cause change in the electromagnetic field and affect the
exciting coil and monitored voltage is used to determine the
presence of flaws.
 When a AC passes through a
test coil, a primary magnetic
field is set up around the coil
 The AC primary field
induces eddy current in the
test object held below the test
coil
 A secondary magnetic field
arises due to the eddy current
 Depth of Penetration
Eddy currents are closed loops of induced current circulating in planes
perpendicular to the magnetic flux. They normally travel parallel to the coil's
winding and flow is limited to the area of the inducing magnetic field. Eddy
currents concentrate near the surface adjacent to an excitation coil and their
strength decreases with distance from the coil as shown in the image. Eddy current
density decreases exponentially with depth. This phenomenon is known as the skin
effect.

The depth at which eddy current density has decreased to 1/e, or about 37% of the
surface density, is called the standard depth of penetration ().
 Applications
•Crack Detection
•Material Thickness
Measurements
•Coating Thickness Measurements
•Conductivity Measurements For:
•Material Identification
•Heat Damage Detection
•Case Depth Determination
•Heat Treatment Monitoring
 Advantages of EDDY CURRENT
•Sensitive to small cracks and other defects
•Detects surface and near surface defects
•Inspection gives immediate results
•Equipment is very portable
•Method can be used for much more than flaw detection
•Minimum part preparation is required
•Test probe does not need to contact the part
•Inspects complex shapes and sizes of conductive materials
Limitations of EDDY CURRENT
•Only conductive materials can be inspected
•Surface must be accessible to the probe
•Skill and training required is more extensive than other
techniques
•Surface finish and roughness may interfere
•Reference standards needed for setup
•Depth of penetration is limited
•Flaws such as delaminations that lie parallel to the probe
coil winding and probe scan direction are undetectable
This detects signals generated by the work piece itself
during plastic deformation, crack initiation and propagation
and abrupt reorientation of grain boundaries .

It is performed by elastically stressing the part or structure,

bending of a beam, applying torque to the shaft. This
method is effective for continuous surveillance of load
bearing structures.
In this technique we perform …….
Firstly we are doing tapping of the surface of an object
Listening them and analyzing the signals to detect
discontinuities and flaws.

It is easy to perform and can be instrumented and

automated. Results obtained from this technique
depend on geometry and mass of the part.
This technique creates a 3D image of the part, using an
optical system.
It records the image on a photographic film based on
simple shapes and highly polished surfaces.

Due to the limitation of holography further we use

Holographic Interferometry.
In this technique we use the inspection of the parts with
various shapes and surface conditions.
While the part is being subjected to external forces,
changes in images reveal defects in the part.
 It involves using contact or non
contact type heat-sensing devices to
determine temperature changes.

 Defects in the work-piece cause a

change in temperature distribution.
Thermo graphic Inspection
• materials such as heat sensitive paints, liquid crystals,
and other coatings are applied to the surface.
• Change in their color indicate defects.
• It uses infrared detectors, these have high response time
and sensitivities of 1 ºC.

Thermometric Inspection
• It utilizes devices such as thermocouples, radiometers
and sometimes melt able material like wax like crayons.
•It detects internal flaws such as cracks and porosity.

•The principle involved is difference in density, the metal

surrounding the defect is denser and shows up as lighter than
the flaws on an X-ray films.

• Radiography has three types

(a) Conventional Radiography
(b) Digital Radiography
(c) Computed Tomography
 The operator must have access to both sides of an
object

 Highly skilled operator is required because of the

potential health hazard of the energetic radiations

 Relative expensive equipment

 Advantages
• Suitable for any material.
• Useful for thin sections.
• Information is presented pictorially.

Disadvantage
 Not suitable for surface defects.
 Possible health hazard.
 No indication of depth of a defect below the surface
 Manufacturing Science And Technology By Kalpakjian

 Material Science By K.M. Gupta

 Wikipedia

A Brief Description of NDT Techniques A Paper By MARK

WILLCOX & GEORGE DOWNES