NON-

DESTRUCTIVE
TESTING
(BMENT714)
Dr. Shivashankar R
Assistant Professor
VVCE, Mysuru.
 Material Sorting
Material
Characterization
Property monitoring
OBJECTIVE
S OF NDT Thickness
measurement
Defect
detection/location
Defect
Characterization
shivashankar R, ME, VVCE
shivashankar R, ME, VVCE
 SYLLABUS

MODULE 1: Introduction to Non-Destructive Testing (NDT)

Need for NDT, Types of NDT, Comparison of Destructive and Non-Destructive

Testing, Benefits of NDT, Nature of Flaws, Types of defects: Casting defects,
Forging & Rolling defects, Extrusion defects, Welding defects, defects introduced
during service, types of material failures, Selection of NDT method, selection of
NDT instrumentation, Steps involved in Non-destructive testing.
Textbook 1: Ch. 1-1.1 -1.6
Textbook 2: Ch. 12: 12.1 -12.3
Self-Study Component: Applications of NDT
shivashankar R, ME, VVCE
MODULE 2:
Visual Examination, Magnetic particle & Liquid Penetrant
Testing
Visual Examination: Basic principle, optical aids used for visual inspection:
microscope, borescope, endoscope, flexiscope, telescope and holography,
Applications.
Liquid Penetrant Testing (LPT): Principles, procedure for penetrant testing,
penetrant testing materials, Penetrant testing methods, Applications, limitations.
Magnetic Particle Testing (MPT): Principle of magnetic particle testing,
Magnetizing techniques, MPT Procedure and equipment, Applications.
Textbook 1: Ch.2- 2.1 -2.4, Ch.3- 3.1-3.4, 3.6, Ch4. 4.1-4.4,
Self-Learning Component: Dyes for LPT.

shivashankar R, ME, VVCE

Module-3
Eddy current Testing and Radiography
Eddy Current Testing (ECT): Principle, Instrumentation for ECT, ECT Techniques,
Advanced ECT methods, Applications.
Radiography: Principle, Electromagnetic radiation sources, Radiographic imaging,
Inspection techniques: Single wall and double wall techniques, Applications,
limitations.
Textbook 1: Ch.5-5.1 -5.6, Ch.6-6.1,6.2,6.5-6.8
Self-Study Component: Neutron Radiography

shivashankar R, ME, VVCE

Module-4
Ultrasonic Testing and Leak Testing
Ultrasonic Testing: Basic properties of sound beam, Ultrasonic transducers,
Inspection Methods- Normal incident pulse echo inspection, Angle beam pulse
echo testing, criteria for probe selection, Ultra flaw detection equipment,
applications,limitations.
Leak Testing: Measurement of leakage, leak testing methods, Leak detection:
Bubble testing, helium leak detector.
Textbook 1: Ch.7: 7.1-7.3, Ch.11: 11.1-11.3
Self-Learning Component: Pipe inspection using Angle beam inspection

shivashankar R, ME, VVCE

Module-5
Advanced NDT techniques and NDT Standards
Advanced NDT techniques: SQUID based eddy current testing, Real time
radiography, laser induced ultrasonic testing, acoustic emission inspection, In situ
metallographic examination.
NDT Standards: Code, Industry Standards, Specifications, Indian standards for NDT,
International standards for NDT.
Textbook 1: Ch. 5-5.5.4, Ch.6-6.9, Ch.8- 8.1-8.3, Ch.15-15.1-15.7
Self-Learning Component: Multi-phase flow analysis.

shivashankar R, ME, VVCE

Textbooks:
1. Practical Non-Destructive Testing by Baldev Raj, Jayakumar, Thavasimuthu, Wood Head Publishing Ltd.
2nd edition, 2002.
2. Non- Destructive Testing technique, 1st edition -Ravi Prakash, New age international publishers, 2010.
3. ASME Metals Handbook [Link], Non-destructive inspection and quality control, 2008.

Reference Books:
1. Non-Destructive Testing, Barry Hull, Vernon John, ELBS,2012.

shivashankar R, ME, VVCE

COURSE OUTCOMES
(COS):
Upon completion of the course students will be able to:
CO1 Explain the basic concepts and principles of NDT methods.
CO2 Apply NDT techniques for detecting flaws in any given component.
CO3 Analyze the various process parameters governing NDT.
CO4* Conduct NDT for inspecting the defects in any engineering component and
prepare a suitable report.

shivashankar R, ME, VVCE

 INTRODUCTION
 Today rapidly growing industrial world where the requirement of reliability is
increasing day by day
 The newer and advanced modern materials are being introduced on a
large scale

 Reliability : The ability of a product, system, or component to perform its

intended function consistently without failure over a specified period of
time under stated conditions.
 Durability : The ability of a product or material to withstand wear, stress,
or environmental conditions over its lifetime.
shivashankar R, ME, VVCE
 Non-destructive testing (NDT) is a wide group of analysis
techniques used in science and technology industry to evaluate the
properties of a material, component or system without causing
damage.
 “Nondestructive Testing (NDT) 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 or test is completed, the part can
still be used. –ASNT (American Society for Nondestructive testing)
shivashankar R, ME, VVCE
 THE CRUCIAL NEED FOR NDT
 Non-Destructive Testing (NDT) is paramount in engineering to ensure the safety,
reliability, and cost-effectiveness of components and structures.
 It allows for early detection of flaws without compromising the material's future
use, preventing catastrophic failures and extending asset lifespan.
Ensuring Safety
 Detecting defects before they lead to structural failures, protecting lives and
property.
Maintaining Reliability
 Verifying material integrity for consistent performance and operational uptime.

Cost Efficiency
 Preventing costly repairs, replacements, and downtime through proactive
inspection.
shivashankar R, ME, VVCE
1. Detect hidden flaws without damaging the material.
2. Ensure safety of structures, machines, and components in
service.
3. Increase reliability of products by early detection of
defects.
4. Save cost by avoiding destructive testing and material
wastage.
5. Evaluate material properties (hardness, toughness,
thickness, etc.) without cutting samples.
6. Prevent catastrophic failures in industries like aerospace,
nuclear, oil & gas, and power plants.
7. Check weld quality in fabrication and construction.
8. Control manufacturing quality by monitoring defects
during production.
shivashankar R, ME, VVCE
9. Extend service life of components through condition
monitoring.
10. Support preventive maintenance by detecting cracks,
corrosion, and fatigue before breakdown.
11. Test large structures (bridges, pipelines, tanks) that
cannot be tested destructively.
12. Ensure product reliability in critical applications
(defense, aerospace, medical devices).
13. Assist in failure analysis to identify the root cause of
defects after accidents.
14. Improve customer confidence by ensuring defect-free,
high-quality products
shivashankar R, ME, VVCE
15. Non-invasive inspection – does not alter the shape, size, or
usability of the component.
16. Time-saving compared to destructive testing methods.
17. Environment-friendly since it avoids waste of materials.
18. Applicable at different stages – raw material, in-process, and
finished product testing.
19. Ensures compliance with safety certifications and international
codes (e.g., ASME,ISO).
20. Reduces downtime by enabling in-service inspection without
dismantling equipment.
21. Provides accurate data for repair, replacement, or continued use
decisions.
22. Supports mass production by enabling rapid quality checks.
23. Helps monitor degradation due to fatigue, creep, corrosion, and
erosion.
25. Minimizes human risk by ensuring components are safe before
being used in hazardous environments.
shivashankar R, ME, VVCE
26. Improves operational efficiency by preventing
unexpected breakdowns.
27. Versatile methods available (ultrasonic,
radiography, eddy current, etc.) for different materials and
defect types.
28. Essential in high-precision industries like
aerospace, nuclear, shipbuilding, and railways.
29. Validates repairs to ensure welds or restored
components meet safety standards.
30. Supports asset management by providing a record
of inspection history and condition monitoring.
shivashankar R, ME, VVCE
 Materials Scientists and Materials Engineers know that no material
can be categorised as absolutely perfect (ie, having zero defect).
 One can only minimize the amount of defect or may reduce the
defect size by proper selection of manufacturing processes or by
improving the production processes.
 As one has to live with the defects, he/she should be able to locate
and assess the severity of the defects present in any material,
component, product, system or plant without impairing their
future usefulness. To meet this requirement, various NDT
techniques are used.
shivashankar R, ME, VVCE
•Eye → Visual Testing
•Drop of liquid → Penetrant Testing
•Magnet + Iron particles → Magnetic Particle Testing
•Sound wave → Ultrasonic Testing
•X-ray symbol → Radiographic Testing
•Coil → Eddy Current Testing
•Infrared camera → Thermography
•Bubble/pressure gauge → Leak Testing

shivashankar R, ME, VVCE

TYPES OF NON-DESTRUCTIVE TESTING
1. Visual Inspection (VT)
 Direct observation of surface defects using the naked eye,
magnifying glasses, or borescopes.
Example: Detecting surface cracks, corrosion, weld defects.
2. Liquid Penetrant Testing (PT)
 A liquid dye is applied on the surface → penetrates into cracks →
developer highlights defects.
Example: Detecting hairline cracks on non-porous metals, ceramics,
plastics.
3. Magnetic Particle Testing (MT)
 Magnetic field applied to a ferromagnetic material → iron particles
gather at defect locations.
Example: Detecting surface and near-surface cracks in steels.
shivashankar R, ME, VVCE
4. Ultrasonic Testing (UT)
•High-frequency sound waves are transmitted → reflections
show internal defects.
Example: Flaw detection in welds, thickness measurement of
pipes.
5. Radiographic Testing (RT)
•X-rays or Gamma rays pass through the material → defects
appear as dark/light areas on film or detector.
Example: Detecting internal voids in castings, welds.
6. Eddy Current Testing (ET)
•Alternating current passed through a coil induces eddy
currents in the material → changes in flow detect flaws
Example: Inspecting tubing, aircraft structures, conductive
materials.
shivashankar R, ME, VVCE
[Link] Emission Testing (AE)
•Monitors sound waves released by cracks under stress.
Example: Pressure vessel monitoring, structural health
monitoring.
8. Thermography (Infrared Testing)
•Uses infrared cameras to detect heat patterns → reveals
cracks, delamination, or leaks.
Example: Electrical inspections, composite materials,
insulation checks.
9. Leak Testing (LT)
•Detects leaks using pressure drop, soap solution, mass
spectrometry, or helium testing.
Example: Pipelines, tanks, valves.
shivashankar R, ME, VVCE
BENEFITS OF NON-
DESTRUCTIVE TESTING
To verify properties of a material

To determine quality of welds

To reduce failures, accidents, and

costs
To ensure compliance with
regulations
shivashankar R, ME, VVCE
BENEFITS OF NDT WITH EXAMPLES
1. No Damage to Component
 The test piece remains intact and usable after inspection.
 Example: Checking a pipeline weld with ultrasonic testing without cutting it.
2. Ensures Safety
 Detects hidden cracks or defects before failure, preventing accidents.
 Example: Inspecting aircraft wings with radiographic testing to avoid in-flight
failures.
3. Cost-Effective
 Avoids wastage of expensive materials and components.
 Example: Testing turbine blades using eddy current testing instead of
destructive tests.
4. Early Detection of Defects
 Identifies cracks, porosity, or corrosion at an early stage.
 Example: Magnetic particle testing detects small surface cracks in railway
axles before breakdown.
shivashankar R, ME, VVCE
•Ensures products meet required safety and quality standards.
•Example: Radiographic testing of welded pressure vessels to ensure defect-free
performance.
6. Applicable During Service (In-situ Testing)
•Components can be inspected while in operation.
•Example: Ultrasonic thickness testing on pipelines during refinery operation.
7. Wide Range of Applications
•Can be used on metals, composites, ceramics, and plastics.
•Example: Infrared thermography used for detecting delamination in composite
aircraft panels.
8. Saves Time
•Quick testing methods improve inspection speed compared to destructive
methods.
•Example: Liquid penetrant testing of multiple welded joints in a short time.
9. Supports Preventive Maintenance
•Helps plan repairs before failure occurs.
•Example: Acoustic emission testing used to monitor pressure vessels for crack
growth.
10. Meets Standards and Regulations
•Helps shivashankar
industries comply with codes like ASME, ISO, ASTM.
R, ME, VVCE
CLASSIFICATION OF MATERIAL
TESTING

Non-
Destructiv
Destructiv
e tests
e tests
shivashankar R, ME, VVCE
shivashankar R, ME, VVCE
Nature of flaws OR Discontinuities (Voids, inclusions, labs ,cracks,
porosity etc.)
Inherent discontinuities- → Born with the material (casting &
working).
 Inherent wrought discontinuities
 Inherent cast discontinuities
Processing discontinuities- Introduced during manufacturing.
Service induced discontinuities- Developed during use.

shivashankar R, ME, VVCE

INHERENT DISCONTINUITIES
DURING THE SOLIDIFICATION STAGE OF THE MATERIAL (CASTING OR INGOT MAKING)

 The discontinuities originated during initial casting process

 usually removed by chopping the ingots but some of them are still change
their shape and nature during subsequent operations etc.
 Found in rolled, forged, or drawn products after mechanical working.

Examples:
 Laminations → Caused by non-metallic inclusions (slag/oxides) that
elongate during rolling.
 Surface cracks or folds rolled into the product.
 Long inclusions aligned in the direction of working
 Porosity, blowholes, shrinkage cavities, hot tears, cold shuts, inclusions,
segregation
 Central cavity in wrought products due to incomplete closure during
forging.(pipe)
shivashankar R, ME, VVCE
  Inherent discontinuities

shivashankar R, ME, VVCE

INHERENT CAST
DISCONTINUITIES
FOUND IN CAST PRODUCTS DURING SOLIDIFICATION

 Blowholes/Porosity → Gas trapped during

solidification.
 Shrinkage cavities → Voids due to volume contraction
on cooling.
 Inclusions → Entrapment of slag, sand, or oxides.
 Segregation → Variation in chemical composition
across the casting.

shivashankar R, ME, VVCE

shivashankar R, ME, VVCE
 PROCESSING DISCONTINUITIES

 originates during hot or cold forming process.

 Some of the inherent discontinuities in the material can propagate
further
 Primary Processing Discontinuities are Seams, lamination,
Cooling cracks, forging and rolling laps, Slugs, CRACKS due bad
geometry ,residual stresses and distortions etc.
 Secondary Discontinuities originate during grinding, machining,
heat treating, plating and related finishing operations

shivashankar R, ME, VVCE

  Processing discontinuities

shivashankar R, ME, VVCE

SERVICE DISCONTINUITIES.
 The originates while component in service.
 The service conditions like loading, unloading, material
handling etc. this may develop even in maintenance conditions.
 Service Discontinuities are fatigue cracks, creep cracks, Wear
stress corrosion cracks, hydrogen cracks etc.

shivashankar R, ME, VVCE

  Service induced discontinuities

shivashankar R, ME, VVCE

 STEPS INVOLVED IN NON-DESTRUCTIVE
TESTING (NDT):
[Link] of Test Method
 Choose a suitable NDT method based on the material, type of defect
expected, geometry, accessibility, and service conditions.
 Example: Dye Penetrant for surface cracks, Ultrasonic for internal flaws.

2. Preparation of Test Surface / Component

 Clean the surface (remove oil, rust, paint, scale, or dirt).
 Ensure proper conditions like temperature and smoothness for accurate
testing.
3. Test Setup and Calibration
 Select and calibrate the testing equipment according to standards or
specifications.
 Example: Ultrasonic flaw detector calibration with reference blocks.

shivashankar R, ME, VVCE

4. Application of Test / Examination
•Perform the test using the chosen method.
•Example: Apply penetrant and developer (DPT), pass magnetic current (MPT), or send ultrasonic waves
(UT).
5. Observation and Detection
•Carefully monitor the response/signals from the test.
•Detect any discontinuities, flaws, or variations in results.
6. Interpretation of Results
•Analyze the indications (signals, marks, images, or patterns).
•Distinguish between relevant (actual flaws) and non-relevant indications (false signals, surface roughness,
geometry effects).
7. Evaluation
•Compare the results with applicable standards, codes, or acceptance criteria.
•Decide whether the defect is acceptable, repairable, or rejectable.
8. Documentation and Reporting
•Record test details: method used, equipment, calibration details, defects found, and final decision.
•Prepare a report for traceability and quality assurance.
9. Post-Test Actions
•Clean the component (e.g., remove penetrant/developer, demagnetize if MPT).
•Carry out repairs if necessary, followed by re-testing.
shivashankar R, ME, VVCE
 CASTING DEFECTS
The solidification from liquid at pouring temperature to the solid at
room temperature occurs in three stages :
1. contraction of liquid metal
2. Liquid to solid contraction
3. contraction of the solid to room temperature
The flaws which may be formed during the solidification process are as
follows
4. Non-metallic inclusions
5. porosity
6. blow holes,
7. shrinkage flaws (Macro, Center and Micro),
8. cold shut
shivashankar R, ME, VVCE
9. crack
shivashankar R, ME, VVCE
FORGING AND ROLLING DEFECTS
 Working material into useful shape by hammering or pressing
 The process of plastically deforming a material by passing it between rolls

The defects can occur during forging and rolling as follows

1. Forging lap
2. Forging bursts or crack
3. Lamination
4. stringer

shivashankar R, ME, VVCE

shivashankar R, ME, VVCE
EXTRUSION DEFECTS
 The process by which a block material is reduced in cross
section by forcing it to flow through a die under high pressure
 Carried under hot or cold condition
 Defects are cracks and internal pipe
 Internal pipe- occurs during hot extrusion due to presence of
impurities or oxides
 Crack occurs due to high extrusion temperature ,ram speed and
friction

shivashankar R, ME, VVCE

 SURFACE CRACK
INTERNAL CRACK

shivashankar R, ME, VVCE

WELDING DEFECTS
 Processes of joining materials in which the pieces to be joined are
bonded with alloying taking place at the interface
 Types -Fusion and pressure welding
 Gas inclusion –gas may be in molten weld metal for various reasons and
may get trapped if there is not sufficient time for it to escape before
solidification
 Uniformly scattered, Cluster and linear porosity,
 Slag inclusion : oxides and other nonmetallic solid materials –poor fusion
,over size root faces
 Lack of fusion
 Crack – Transverse and under bead crack
shivashankar R, ME, VVCE
shivashankar R, ME, VVCE
shivashankar R, ME, VVCE
DEFECTS INTRODUCED DURING
SERVICE
The response of metallic materials during service can vary widely as a function of
 Chemical composition
 Thermal treatment
 Mechanical characteristics
 Service condition
 Presence of discontinuities

Causes of material failures

Static load and dynamic load
Service at high temperature and stresses above elastic limit
Corrosion environment ,vibration and Abuses.

shivashankar R, ME, VVCE

TYPES OF MATERIAL
FAILURES
Two types of material failure in service.
 Recognized fracture or separation into two or more parts- ductile and brittle
 Excessive plastic deformation or Change in shape

Fatigue – S-N diagram

Corrosion

shivashankar R, ME, VVCE

SELECTION OF NDT METHOD
Increasing recognition is being given to the importance of NDT in various
Engineering disciplines at all the stages during material production to in-service
Reliability of material /technique, used, cost etc

Selection of one method over another is based on the following factor

1. Type and origin of discontinuity
2. Material manufacturing process
3. Accessibility of the components to perform NDT
4. Type of equipment available
5. Time available
6. Cost
shivashankar R, ME, VVCE
SELECTION OF NDT INSTRUMENTATION
 All NDT method simple in principle ,but success in their use depends
heavily on the intelligent and interpretation of the results
 Reference standards, when properly used ensure the success of the NDT
 Discontinuity is usually indicating rather than the performance capability of
the components
 Visual testing –EYE- Instrument - optical aids used for visual inspection:
microscope, borescope, endoscope, flexiscope, telescope
 Liquid penetration testing – ultraviolet black light for use with
fluorescent penetrants –kit

shivashankar R, ME, VVCE

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