MODULE-III
NON-DESTRUCTIVE TESTING
Non-Destructive Testing
In industry today we need to know the amount of
deterioration in a piece of equipment or the condition of a
finished product without destroying or dismantling the
product.
There are seven main types of non-destructive testing used in
preventive maintenance activities.
[Link] penetrant
[Link] particles
[Link]-sound
[Link] Inspection
[Link] analysis
6.X ray
[Link]
VISUAL INSPECTION
Basic Principle:
•Illuminate the test specimen with light
•Examine the specimen with the eye
Used to:
•To magnify defects which can not be detected by the unaided eye
•To assist in the inspection of defects
•To permit visual checks of areas not accessible to unaided eye
Most widely used of all the nondestructive tests
Simple easy to apply, quickly carried out and usually low in cost.
Visual Inspection Equipment
•Magnifying Glass
•Magnifying Mirror
•Microscope
•Borescope
•Flexible Fiber Optic Borescope
•Video imagescope
Video Imagescope
LIQUID PENETRANT (LP)
Principle:
Examples of Applications:
• Defection of cracking and porosity in welded joints
• Detection of surface defects in castings
• Detection of fatigue cracking in stressed materials
MAGNETIC
PARTICLE (MP)
This nondestructive testing method uses the principle of magnetic
fields to indicate defects in materials that can be strongly
magnetized. It's not effective on material that cannot be magnetized
, for example, brass, copper and aluminum.
General Uses:
• Location and identification of surface or near-surface defects on or
in ferromagnetic materials.
Examples of Applications:
• Fatigue cracks in steel dies.
• Shrinkage in machined castings.
• Stringers or cold shunts in forgings after finish machining
ULTRA-SOUND
General Uses:
• Ultrasonic (UT) is ideal for the detection of cracks, voids and
inclusions
• Detection of density variations of the order 0.25% or less.
• Samples which require resolution as small as 2 microns in three
dimensions.
• Samples can be inspected for both surface characteristics (surface
cracks, etc) as well as bulk prop0erties (such as porosity).
Examples of Applications:
• Examining bolts or rivets in aircraft wings to find cracks and defects.
• Inspection of carbon composites for aging or impact damage.
• Weld penetration inspection.
• Weapons stock pile surveillance.
VIBRATION ANALYSIS
Vibration has two main characteristics frequency and amplitude .
Frequency Is the number of times that a part oscillates through a
cycle in one second. This is usually exp0ressed in hertz. The other
measure is cycles per minute (CPM). This measure is usually reserved
for equipment of a slower speed. Amplitude, which is the measure of
the severity of the vibration, can be measured in three ways.
1. Displacement
2. Velocity
3. Acceleration
Displacement is the actual amount of movement that takes place.
Usually it's measured in Peak-to-peak displacement, which is the total
movement that takes place. It's usually measured in thousandths of an
inch ( Figure 1 ).
Figure 1:
Velocity is the speed at which the displacement takes place. It can
be comp0ared to traveling at different rates of speed in your
automobile, for example, 50 mph, 25 mph, 45 mph. This velocity is
usually expressed in inches / second since it's usually not traveling
too great a distance.
Acceleration is the time rate of change in velocity. When your car is
at rest and your speed up to 60 mph in 5 seconds you are
accelerating 12 mph per second.
The three parameters making up amplitude (displacement, velocity
and acceleration)
Some of the conditions that can be determined by vibration analysis are:
• Unbalance
• Defective bearings
• Misalignment
• Looseness
• Oil whip
• Bend shaft
INFRARED IMAGING
Thermo graphic Principle
• Heat flow in a material is altered by the presence of some types of anomalies.
• These changes in heat flow cause localized temperature differences in the material.
• Slow heating of part reveals these anomalies.
General uses:
• To remotely examine surface temperatures of objects.
Examples of Applications:
• Measuring temperature of hot pressings.
• Temperature measurement of material inside furnaces, and material
being heated by microwaves.
• Observing temperature gradients across molded plastic parts
immediately after opening the mold.
• Measuring temperatures of circuit board components during
operation.
• Line scan mode enables measurement of a single line at 125
microsecond intervals.
X – RAY
Principle:
A source of radiation is directed toward an object. A sheet of
radiographic film is placed behind the object The density of the
image is a function of ther quantity of radiation transmitted through
the object, which in turn is inversely proportional to the atomic
number, density and thickness of the object.
Figure
General Uses:
• Generation of images corresponding to density, atomic number,
and thickness variations of static, solid objects.
Examples of Applications:
• Check for internal defects such as voids, cracks or inclusions in
materials.
• Determination of internal clearances between parts in an assembly,
to check for displacement of internal components.