NON-DESTRUCTIVE TESTING

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 INTRODUCTION
 A non-destructive test is an examination of a component in
any manner which will not impair its future use.
 It does not provide direct measurement of mechanical
properties.
 They are extremely useful in revealing defects in
components that could impair their performance when put
in service.
 It has ability to detect the invisible subsurface defects not
only for maintaining high quality standards, but provides a
valuable help to the development of manufacturing
methods.
 This testing make the components more reliable, safe, and
economical.
 ADVANTAGES OF NON DESTRUCTIVE TESTING
OVER DESTRUCTIVE TESTING
 Can be performed directly on production items without
regard to cost or quantity available.
 Can be performed on 100% of production lot.
 Little or no specimen preparation is required.
 The test of equipment is often portable.
 Labour cost is usually low.
 Different tests can be applied to the same item, and a
test can be repeated on the same specimen.
 DIS-ADVANTAGES OF NON DESTRUCTIVE
TESTING OVER DESTRUCTIVE TESTING
 Results often require interpretation by skilled operators.
 Properties are measured indirectly and results are often
qualitative or comparative.
 Different observers may interpret the test results
differently.
 Some test equipment requires a large capital
investment.
 TYPES OF NDT METHODS
 Visual Inspection
Hammer Test
Liquid Penetrant Test (Dye Penetrant Test)
Magnetic Particle Test (Magnaflux Test)
Ultrasonic Flow Detection
Radiography
 VISUAL INSPECTION
 Defects which are easily located by visual inspection
are cracks, tears, blowholes, metal penetration, surface
roughness, shrinkage, etc.
 It can be inspected by naked eye or by using magnifying
glass.
 It is simplest, fastest, and most commonly employed
method but it requires greater skill of inspector to
locate and identify different manufacturing defects.
 It may be sufficient for many castings such as manhole
covers, drains, counter balance weight etc.
 ADVANTAGES

 It is a routine procedure.
 The cost of visual
inspection is low.
 It can be very effective
where examination is
made before, during, and
after welding.
 HAMMER TEST
 Certain defects such as internal shrinkage, porosity,
blowholes, slag inclusion, etc. which contribute to lack of
casting soundness if present.
 But it do not effect its adequate functioning and casting is
quite acceptable to the user, are detected in the following
manner:
1. The casting is suspended above the floor, clear from all
sides.
2. At different places, it is gently struck with hammer.
3. The sound produced is carefully noted either by ear or with
the help of electronic equipments.
4. If there is difference in pitch and quality of sound coming
out from metal casted then above defects can be detected.
 LIQUID PENETRANT TEST (DYE PENETRANT TEST)
 This method detect flaws that are open to the
surface E.g. Cracks, laps, lack of bond, porosity,
etc.
 It can be effectively used not only in inspection of
ferrous metals but is especially useful for non-
ferrous metal products such as ceramics, plastics,
glass.
 PROCESS
 The surface of the material must be thoroughly
cleaned of all material that would obstruct the
entrance of liquid into the defect.
 After cleaning, the liquid Penetrant is applied
evenly over the surface and allow to remain long
enough so that it penetrate in the surface.
 The liquid is then completely removed from the
surface of the component and either a wet or dry
developer is applied.
 The liquid that has penetrated the defect will then bleed out onto
the surface, and developer will help delineate them.
ADVANTAGES
• The method has high sensitive to small surface discontinuities.
• Large areas and large volumes of parts/materials can be
inspected rapidly and at low cost.
• Parts with complex geometric shapes are routinely inspected.
• Indications are produced directly on the surface of the part and
constitute a visual representation of the flaw.
• Aerosol spray cans make penetrant materials very portable.
• Penetrant materials and associated equipment are relatively
inexpensive.
 DIS-ADVANTAGES:-
• Only surface breaking defects can be detected.
• Only materials with a relative nonporous surface can
be inspected.
• Metal smearing from machining, grinding, and grit or
vapour 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.
 MAGNETIC PARTICLE TEST
 This method of inspection is used on magnetic
ferrous castings for detecting invisible surface or
slightly subsurface defects.
 The defects commonly revealed by magnetic particle
inspection are quenching cracks, seams, thermal
cracks, grinding cracks, overlaps, non-metallic
inclusions, fatigue cracks, etc.
 It is relatively simple and easy technique.
 It is almost free from any restriction as to size, shape,
composition and heat-treatment of a ferromagnetic
specimen.
 MAGNETIC PARTICLE TEST
 PROCEDURE :-

1. Magnetising the component part

2. Applying magnetic particles on the
component part.
3. Locating the defects.
 TYPES OF MAGNETIC FIELDS IN MAGNETISING
1. LONGITUDINAL :
 It has magnetic lines of force that run parallel to
the long axis of the part.
 Circumferential cracks are detected by this
method.
 TYPES OF MAGNETIC FIELDS IN MAGNETISING
2. CIRCULAR:
 It has magnetic lines of force that run
circumferentially around the perimeter of a part.
 Longitudinal cracks are best detected by this method.
 MAGNETIC PARTICLES
DRY MAGNETIC PARTICLES

 Dry magnetic particles can typically be purchased in are red, black, gray,
yellow and several other colors so that a high level of contrast between the
particles and the part being inspected can be achieved.
 The size of the magnetic particles is also very important. The fine particles
are around 50 mm (0.002 inch) in size are about three times smaller in
diameter and more than 20 times lighter than the coarse particles (150 mm or
0.006 inch), which make them more sensitive to the leakage fields from very
small discontinuities.
 It should also be recognized that finer particles will be more easily blown
away by the wind and, therefore, windy conditions can reduce the sensitivity
of an inspection.
 The dry particles is not recommended because the small particle are less
likely to be recaptured and the "once used" mix will result in less sensitive
inspections.
 EXAMPLES OF VISIBLE DRY MAGNETIC PARTICLE INDICATIONS

 
Indication Of A Crack In A Saw Blade
                             
                            

Indication Of Cracks In A Weldment

Indication Of Cracks Running Between

Before And After Inspection Pictures Of Cracks Attachment Holes In A Hinge
Emanating From A Hole
MAGNETIC PARTICLES
 MAGNETIC PARTICLES
WET MAGNETIC PARTICLES
 Magnetic particles are also supplied in a wet
suspension such as water or oil.
 The wet magnetic particle testing method is generally
more sensitive than the dry because the suspension
provides the particles with more mobility.
 And it make possible for smaller particles to be used
since dust and adherence to surface contamination is
reduced or eliminated.
 The wet method also makes it easy to apply the
particles uniformly to a relatively large area.
EXAMPLES OF FLUORESCENT WET
MAGNETIC PARTICLE INDICATIONS
Magnetic particle wet fluorescent
indication of a cracks in a drive shaft

Magnetic particle wet

fluorescent indication
of a crack in a
bearing

Magnetic particle wet fluorescent indication

of a cracks at a fastener hole
 MAGNETIZING THE OBJECT
• There are a variety of methods that can be
used to establish a magnetic field in a
component for evaluation using magnetic
particle inspection.
• It is common to classify the magnetizing
methods as either direct or indirect.
 MAGNETIZING THE OBJECT

 Direct magnetization: current is passed

directly through the component.
 MAGNETIZING THE OBJECT
 Indirect magnetization: using a strong external magnetic field to
establish a magnetic field within the component.

ELECTOMAGNETS PERMANENT MAGNETS

COIL SHOTS
 DETECTION OF CRACKS
 The magnetic particles form a ridge many times wider
than the crack itself, thus making the otherwise invisible
crack visible.
 Cracks just below the surface can also be revealed
 DEMAGNETIZATION
 Parts inspected by such testing sometime have residual
magnetic field that may interfere with subsequent
manufacturing operations or service of the component.
 Hence they are required to be demagnetized.
 It can cause following defects:-
1. May interfere with welding and machining operations
2. Can affect gauges and devices that are sensitive to magnetic
fields.
3. Cause abrasive particle to cling to bearing surfaces and
increase wear.
 ADVANTAGES OF MPT
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.

 DIS-ADVANTAGES OF MPT
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
 APPLICATIONS OF MPT

Flaw detection of components made from

iron, nickel, cobalt and their alloys.
Grinding cracks, fatigue cracks, welding
cracks, quenching cracks, porosities and
inclusions.
Used for inspection of crane hooks,
railway axles and rails, crank shaft, welded
joints.
 ULTRA SONIC FLAW DETECTION
 Ultrasonic inspection is employed to detect and locate
defects such as shrinkage cavities, internal cracks,
porosity and large non-metallic inclusions.
 Ultrasonic vibrations can be used to locate defects in
ferrous and non-ferrous metallic objects as well as
plastics and ceramics.
 Ultrasonic inspection for flaw detection make use of
acoustic waves with frequencies in the range between
20kHz and 20MHz.
 This waves can transmitted through solids, liquid and
even air and get reflected by subsurface defects.
ULTRA SONIC FLAW DETECTION
 ULTRASONIC INSPECTION (PULSE-ECHO)
 PROCESS

 The principle of ultrasonic inspection depends on the

fact that pulses of ultrasonic energy are reflected from
any surface which they encounter.

 Virtually total reflection occurs at an air-metal

interface, and therefore to get the ultrasonic wave
into the metal a liquid (usually grease) is placed
between the source and metal.

 Pulsed beams of ultrasonic waves pass through the

object.
 ULTRASONIC INSPECTION (PULSE-ECHO)
 Waves traveling through a plate may be reflected
from the surface of the metal and also from the
surfaces of any flaws in the metal

 A receiver detects the reflected waves signal,

which is displayed after signal amplification and
analysis by the instrument

 The pattern of reflection is revealed on either

Cathode ray tube or liquid crystal display

 From that we will be able to recognize type and

location of flaws
ULTRASONIC INSPECTION (PULSE-
ECHO)

initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate
ADVANTAGES OF ULTASONIC INSPECTION

1. Low cost and high speed operation.

2. Equipments used are easy to handle.
3. No health hazards.

4. They can also be used for assessing the

thickness of structural members.
 LIMITATIONS OF ULTASONIC INSPECTION

1. This method is sensitive to surface roughness.

Thus, some preliminary machining is required on
castings components before inspection.
2. Waves reflected from corners or other surfaces
may give false indication of defects.
APPLICATIONS OF ULTASONIC INSPECTION

1. Inspection of large casting and forging for internal

soundness.
2. Inspection of strips or plates regards to its
thickness.
3. Routine inspection of locomotive axle.
4. Inspection of rails for bolt-hole breaks without
dismantling the rail assembly.
5. It is used on aircraft, the power stations generating
plant, or welds in pressure vessels at an oil refinery
or paper mill.
 RADIOGRAPHY
 The use of X-ray and γ-ray radiography, in inspection
casting for such defects as blow holes, shrinkage
cavities and slag inclusions.
 Radiography techniques is based upon exposing the
component to short wavelength radiations in the
form of X-rays.
 X-ray operating at 40,0000 volts can inspect steel
castings having thickness up to 62mm.
RADIOGRAPHY
High Electrical Potential

Electrons
+ -

X-ray Generator or
Radioactive Source
Creates Radiation

Radiation
Penetrate
the Sample

Exposure Recording Device

 RADIOGRAPHY INSPECTION
 PROCESS

 A material is subjected to radiation from one side, and record

the radiation emitted from the opposite side.
 Either x ray or gamma ray devices may be used to provide the
source of radiation.
 Any obstacle in the path of the radiation will affect the
radiation density emitted and may be recorded.
 As radiation will expose photo graphic plates, they are used
to record the emitted rays.
 The photographic plates records changes in radiation density
emitted.
 Thus any defects in welding can be found out by this method.
EQUIPMENTS USED
RADIOGRAPHIC IMAGES
 ADVANTAGE OF RADIOGRAPHY
 It can give a permanent record of the test
for future evidence.

 It is a quick process.

 Accurate results.
DISADVANTAGE OF RADIOGRAPHY
 Cannot use for thick sections.

 Cannot use in places of difficult access.

 The process fails without electricity.

 To interpret the weld radiograph a large

amount of experience is required
EXAMPLES OF RADIOGRAPHY
 EXAMPLES OF RADIOGRAPHY

GAS POROSITY OR BLOW SAND INCLUSIONS

HOLES
 APPLICATION OF RADIOGRAPHY
 Can be used in any situation when one wishes
to view the interior of an object.
 To check for internal faults and construction
defects, e.g. faulty welding.
 To ‘see’ through what is inside an object.
 To perform measurements of size, e.g.
thickness measurements of pipes
 EDDY CURRENT TESTING
 Electrical currents are generated in a conductive
material by an induced alternating magnetic
field.
 The electrical currents are called eddy currents
because the flow in circles at and just below the
surface of the material.
 Interruptions in the flow of eddy currents,
caused by imperfections, dimensional changes,
or changes in the material's conductive and
permeability properties, can be detected with the
proper equipment.
 EDDY CURRENT TESTING
• Eddy current testing can be used on all electrically
conducting materials with a reasonably smooth
surface.
• The test equipment consists of a generator (AC
power supply), a test coil and recording equipment,
e.g. a galvanometer or an oscilloscope
• Used for crack detection, material thickness
measurement (corrosion detection), sorting
materials, coating thickness measurement, metal
detection, etc.
 EDDY CURRENT INSTRUMENTS
Voltmeter
Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
 PRINCIPLE OF EDDY CURRENT
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.
 PRINCIPLE OF EDDY CURRENT
The strength of the
secondary field depends on
electrical and magnetic
properties, structural
integrity, etc., of the test
object.
If cracks or other in
homogeneities are present,
the eddy current, and hence
the secondary field is
affected.
 APPLICATIONS
•Crack Detection
•Material Thickness
Measurements
•Coating Thickness
Measurements
•Conductivity Measurements
•Material Identification
•Heat Damage Detection
•Case Depth Determination
•Heat Treatment Monitoring
 ADVANTAGES OF EDDY TESTING
• Sensitive to small cracks and other defects.
• Detects surface and near surface defects.
• Inspection gives immediate results.
• Equipment is very portable.
• 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 TESTING
• 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.