Material Technology and Testing

(MNF 222)

CHAPTER 8
Non Destructive Testing

Material Technology and Testing Dr. Gamal Abdou

1
 Non Destructive Testing

Nondestructive testing (NDT) has been

defined as comprising those test methods
used to examine an object, material or
system without impairing its future
usefulness. The term is generally applied
to nonmedical investigations of material
integrity .
 Objectives of NDT
(1) to ensure product integrity, and in turn, reliability;
• To detect internal or surface flaws
• To measure the dimensions of materials
• To determine the materials’ structure
• To evaluate the physical and mechanical properties of
materials
(2) to avoid failures, prevent accidents and save human
life;
(3) to make a profit for the user;
(4) to ensure customer satisfaction and maintain the
manufacturer's reputation;
(5) to aid in better product design;
(6) to control manufacturing processes;
(7) to lower manufacturing costs;
(8) to maintain uniform quality level;
(9) to ensure operational readiness.
 Characteristics of NDT
• Applied directly to the • Can be performed on
product parts that are in
• Tested parts are not service
damaged • Low time
• Various tests can be consumption
performed on the • Low labour cost
same product
• Specimen preparation
not required
NDT
 NDT Methods
1. Visual Inspection
2. Liquid penetrant method
3. Ultrasonic Inspection
4. Radiography methods
• X-ray radiography & fluoroscopy
• γ- ray radiography
5. Eddy current testing
6. Magnetic particle testing
7. Thermography
 ADVANTAGES OF NDT
• 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 and
floppies
 DIFFERENCE BETWEEN DESTRUCTIVE AND
NON DESTRUCTIVE TEST
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
Visual Inspection
Most basic and common
inspection method.

Tools include
fiberscopes,
borescopes, 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.
 Dye Penetrant Inspection
 Surface breaking defects only detected
 Penetrant applied to the component and drawn into
the defects by capillary action
 Applicable to all non- porous and non absorbing
materials.
 Penetrants are available in many different types
 Water washable contrast
 Solvent removable contrast
 Water washable fluorescent
 Solvent removable fluorescent
 Post-emulsifiable fluorescent
Dye Penetrant Inspection
 Dye Penetrant Inspection
Step 1. Pre-Cleaning
Cleaning preparation is very important on this method.
Usually solvent removal is been used
 Dye Penetrant Inspection
Step 2. Apply penetrant
After the application of the penetrant the penetrant is normally
left on the components surface for approximately 15 minutes
(dwell time). The penetrant enters any defects that may be
present by capillary action
 Dye Penetrant Inspection
Step 3. Clean off penetrant
After sufficient penetration time (dwell time) has been
given,excess removal penetrant stage take place. A damped
lint free tissue with solvent is used to clean the excess
penetrant.
 Dye Penetrant Inspection
Step 3. Apply developer
After the excess penetrant is been removed, a thin layer
of developer is applied.A penetrant drawn out by reversed
capillary action.
 Dye Penetrant Inspection
Step 4. Inspection / development time
Inspection should take place immediately after the developer
has been applied .Any defects present will show as a bleed
out during development time.
 Dye Penetrant Inspection
Step 5. Post-Cleaning
After the inspection has been performed post cleaning is
required to prevent corrosion.
 Dye Penetrant Inspection
Fluorescent Penetrant
Bleed out viewed
under a UV-A light
source

Bleed out viewed

under white light
Colour contrast Penetrant
Magnetic Particle Inspection
 Magnetic Particle Inspection
 Surface and slight sub-surface detection
 Relies on magnetization of component being tested
 Ferro-magnetic materials only can be tested
 A magnetic field is introduced into a specimen being tested
 Methods of applying a magnetic field, yolk, permanent
magnet, prods and flexible cables.
 Fine particles of iron powder are applied to the test area
 Any defect which interrupts the magnetic field, will create a
leakage field, which attracts the particles
 Any defect will show up as either a dark indication or in the
case of fluorescent particles under UV-A light a green/yellow
indication
 Magnetic Particle Inspection
The picture can't be display ed.

Electro-
magnet
(yolk) DC or
AC
Collection of ink
particles due to
leakage field

Crack
like
indicati
on
Prods
DC or
AC

Crack
like
indicati
on
 Magnetic Particle Inspection

A crack like
indication
Magnetic Particle Inspection
Alternatively to contrast
inks, fluorescent inks
may be used for greater
sensitivity. These inks
require a UV-A light
source and a darkened
viewing area to inspect
the component
 Magnetic Particle Inspection
Typical sequence of operations to inspect a
weld
Clean area to be tested
Apply contrast paint
Apply magnetisism to the component
Apply ferro-magnetic ink to the component
during magnetising
Interpret the test area
Post clean and de-magnatise if required
 Magnetic Particle Inspection
 Advantages  Disadvantages
 Simple to use  Surface or slight sub-

 Inexpensive
surface detection only
 Magnetic materials
 Rapid results
only
 Little surface
 No indication of
preparation required
defects depths
 More sensitive than
 Detection is required
visual inspection in two directions
Basic Principles of Ultrasonic Testing
• To understand and
appreciate the
capability and
limitation of UT
 Ultrasonic Inspection
 Sub-surface detection
 This detection method uses high frequency sound
waves, typically above 2MHz to pass through a material
 A probe is used which contains a piezo electric crystal
to transmit and receive ultrasonic pulses and display the
signals on a cathode ray tube or digital display
 The actual display relates to the time taken for the
ultrasonic pulses to travel the distance to the interface
and back
 An interface could be the back of a plate material or a
defect
 For ultrasound to enter a material a couplant must be
introduced between the probe and specimen
 Ultrasonic Inspection
Ultrasonic testing is a good technique for the
detection of plate laminations and thickness surveys

Laminations detected using compression probes

 Ultrasonic Inspection

defect Back wall

initial pulse echo echo

Material Thk
defect

0 10 20 30 40 50

Compression Probe CRT Display

 Ultrasonic Inspection
Pulse echo UT Set, Digital
signals
A scan Display

Compression probe Thickness checking the material

 Ultrasonic Inspection

Ultrasonic testing requires high operator for defect

identification

Most weld defects detected using angle probes

 Ultrasonic Inspection
UT Set
A Scan
Display

Angle Probe
 Ultrasonic Inspection

initial pulse defect echo

Surface distance

defect

sound path
0 10 20 30 40 50

Angle Probe CRT Display

 Ultrasonic Inspection
 Advantages  Disadvantages
 Rapid results  Trained and skilled

 Sub-surface detection
operator required
 Requires high operator
 Safe
skill
 Can detect planar defect
 Good surface finish
 Capable of measuring the
required
depth of defects  Difficulty on detecting
 May be battery powered
volumetric defect
 Portable
 Couplant may

contaminate
 No permanent record
 Radiographic Inspection
The principles of radiography
 X or Gamma radiation is imposed upon a test
object
 Radiation is transmitted to varying degrees
dependant upon the density of the material through
which it is travelling
 Thinner areas and materials of a less density show
as darker areas on the radiograph
 Thicker areas and materials of a greater density
show as lighter areas on a radiograph
 Applicable to metals,non-metals and composites
 Industrial Radiography

• Gamma Rays
• X - Rays
Generated by the decay
Electrically generated of unstable atoms
Industrial Radiography
• X - Rays
Electrically generated
Industrial Radiography
• Gamma Rays
Generated by the decay of
unstable atoms
 Radiographic Inspection

Source

Radiation beam Image quality indicator

Radiographic film Test specimen

 Radiographic Inspection

Source

Radiation beam Image quality indicator

Test specimen

Radiographic film with latent image after exposure

 Radiographic Sensitivity

7FE12

Step / Hole type IQI Wire type IQI

 Image Quality Indicators

Step/Hole Type IQI

Wire Type IQI

 Radiographic Techniques
• Single Wall Single Image (SWSI)
- film inside, source outside
• Single Wall Single Image (SWSI) panoramic
- film outside, source inside (internal exposure)
• Double Wall Single Image (DWSI)
- film outside, source outside (external exposure)
• Double Wall Double Image (DWDI)
- film outside, source outside (elliptical exposure)
 Single wall single image SWSI

Film

Film

IQI’s should be placed source side

 Single wall single image SWSI
panoramic

Film

• IQI’s are placed on the film side

• Source inside film outside (single exposure)
 Double wall single image DWSI

Film
• IQI’s are placed on the film side
• Source outside film outside (multiple exposure)
• This technique is intended for pipe diameters
over 100mm
 Double wall single image DWSI

Identification
• Unique identification
EN W10

• IQI placing
• Pitch marks A B
indicating readable
ID MR11
film length
Radiograph
 Double wall double image DWDI
elliptical exposure

Film
• IQI’s are placed on the source or film side
• Source outside film outside (multiple exposure)
• A minimum of two exposures
• This technique is intended for pipe diameters
less than 100mm
 Double wall double image DWDI

Identification 4 3
• Unique identification EN W10

• IQI placing
• Pitch marks 1 2
indicating readable ID MR12
film length
Shot A Radiograph
 Radiographic Inspection

 Advantages  Disadvantages
 Expensive equipment
 Permanent record
 Bulky equipment ( x-ray )
 Little surface preparation
 Harmful radiation
 Defect identification
 Detection on defect
 No material type
depending on orientation
limitation  Slow results

 Required license to operate