Presentation Topic: Non-Destructive Testing

Guided By: Dr. A.M.Nikalje

Presented By: Dipak S. Phoke (ME20F11F015)

NON-DESTRUCTIVE TESTING
1. In these testings, the material is tested for any flaws without applying any
kind of stress or force.
2. The test piece is not destroyed or deformed.
3. Non-destructive tests are desirable for materials that are costly or difficult to
fabricate.
4. At the end of these tests there are no damage to the components.
What are Some Uses of NDT Methods?
● Flaw Detection and Evaluation.
● Leak Detection.
● Location Determination.
Characteristics of NDT:
1. Applied directly to the product.
2. Tested parts are not damaged.
3. Various tests can be performed on the same product.
4. Specimen preparation not required.
5. Can be performed on parts that are in service.
6. Low time consumption.
When are NDT Methods Used?
● To assist in product development.
● To screen or sort incoming materials.
● To monitor, improve or control manufacturing processes.
VISUAL EXAMINATION (TESTING)
1. This is most basic and common
inspection method as any surface
defects are noticed by the experienced
and responsible person.
2. Visual inspection can be simply visual
i.e. with the naked eye or at
magnifications up to many times by
magnifying devices such as
magnifying glasses, mirrors,
borescope,videoscope.
3. This forms the simplest form of
investigation used.
Applications:
● Some of the defects are:
Incorrect shape or size, High spatters, Undercutting, Incorrect
alignment,Surface cracks, etc. can be detected.
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
manufacturing products.
● Lot of sampling can be done.
Disadvantages:
● Internal defects of specimen can not be detected by visual testing.
LIQUID PENETRANT TESTING
Process:
1. The surface of the metal to be inspected is cleaned first and a low viscosity
penetrant (a liquid containing dye with high surface wetting characteristics)
is applied onto specimen.
2. The excess liquid is removed from the surface of the specimen.
3. The liquid is drawn into the crack by capillary action, then a
developer(powder) is applied to pull the trapped penetrant out the defect and
spread it on the surface where it can be seen.
4. Visual inspection is the final step in the process.It will show up a surface
flaw.
5. The penetrant used is often loaded with a fluorescent dye and the inspection
is done under UV light to increase test sensitivity.
 Applications:
● Turbine rotor discs & blades.
● Aircraft wheels, castings, forged
components, welded assemblies.
● Automotive parts – pistons,
cylinders, etc.
● Bogie frames of railway
locomotives & rolling stock.
● Electrical ceramic parts – spark plug
insulators,etc.
● Moulded plastic parts.
 Characteristics of a Penetrant: Characteristics of a Developer:
● High degree of wettability ● Highly absorptive
● Quick & complete penetrability ● Fine grain size & particle shape for
● Low viscosity easy dispersion
● Sufficient brightness & permanence ● Provision of contrast background
of colour ● Easy application
● Chemical inertness ● Formation of thin uniform coating
● Low toxicity over surface
● Slow drying ● Easily wettable
● Ease of removal ● Low toxicity
Advantages: Disadvantages:
● Cannot be used for rough and
● A simple way to detect surface
dirty surfaces.
opening cracks and porosities in clean
● Non-porous surface for material
specimen.
i.e. does not work well on porous
● Low-cost( Inexpensive).
materials(powder metallurgical
● It can detect small defect on smooth
components).
and clean surfaces.
● Surface cleaning before & after
● Applicable to ferrous, non-ferrous,
inspection.
non-magnetic & complex shaped
● Only surface defects can be
materials which are non-porous & of
detected.
any dimension.
MAGNETIC PARTICLE TESTING

Process:
1. Magnetic Particle Testing uses one or more magnetic fields to locate
discontinuities in ferromagnetic materials.
2. It is carried out by locally magnetizing the specimen by a yoke or a coil.
3. Then by coating a fluid of magnetic particles on its surface.
4. Any discontinuity such as a surface crack will show up as the particles will
concentrate directly over the discontinuity where there is an alteration in the
magnetic field.
5. This indication can be visually detected under proper lighting conditions.
Applications:
● Best and very fast method for the detection of surface and near to the surface
cracks in ferromagnetic materials, fast method of inspection aerospace
components and automobile parts.
● Generally used to detect internal cracks like shrinkage cavities, hot tears,
zones of corrosion and non-metallic inclusions.
Disadvantages:
Advantages: ● Can be used only in Ferromagnetic
● Fast and simple testing. material only.
● Low cost(inexpensive). ● Detects surface and near-to-surface
● Defects like cracks, slag inclusions discontinuities only.
and gas porosities can be detected. ● Large current are required to
● Not need pre-cleaning operations. produce magnetic field.
● Will work through thin coating. ● After testing, demagnetization is
must be done.
RADIOGRAPHIC TESTING

The formation of an image of test piece either on a photographic film or on a

fluorescent screen due to X-rays passing through the test specimen.
Process:
1. A material is subjected to radiation from one side, and record the radiation
emitted from the opposite side
2. X-rays are passed through the specimen under inspection and it is
differentially absorbed by the specimen.
3. The transmitted x-rays are received by the photographic film and the film is
developed by variation in intensity of x-rays.
4. The dark and light shadows reveal the defects present in the specimen.
Applications:
● For detection of
internal defects.
● For detection of
porosity, casting,
lack of fusion in
welding, cracks.
● For
measurement of
geometry
variation and
thickness of
components.
Advantages: Disadvantages:
● It can give a permanent record of the ● Cannot use for thick sections.
test for future evidence. ● Cannot use in places of difficult
● It is a quick process and gives to access.
accurate results. ● The process fails without
● No need of washing and developing electricity.
films. ● To handle a radiograph-large
● Image viewed immediately on amount of experience is
screen. required.
● Movement of defects detected (real ● It is health hazards- high safety
time images). required.
ULTRASONIC TESTING
Process:
1. The principle of ultrasonic inspection depends on the fact that pulses of
ultrasonic waves are reflected from any surface which they encounter as the
same principle as is used in naval SONAR and fish finders.
2. Whenever there is a change in the medium, the ultrasonic waves are reflected
traveling through a specimen as any flaws in it.
3. A receiver detects the reflected waves signal, which is displayed after signal
amplification and analysis by the instrument.
4. Thus, from the intensity of the reflected echoes, the flaws are detected
without destroying the material.
5. Most common sound frequencies
used in UT are between 1.0 and 10.0
MHz, which are too high to be
heard and do not travel through air.
UT consists of 3 units:
1. Pulser : An electronic device
that can produce high voltage
electrical pulses.
2. Transducer: Generates high
frequency ultrasonic energy.
3. Receiver: Receive signals and
displays it to on digital or LCD
screen.
Applications:

● Quality control & material inspection.

● Detection of failure of rail rolling stock axes, pressure columns, earthmoving
equipments, mill rolls, mixing equipments, etc.
● Thickness measurements –metal section thickness,refinery & chemical
processing equipments, submarine and aircraft sections, pressure vessels, etc.
● Inspect pipe & plate welds,pins, bolts & shafts for cracks.
● Detect internal corrosion.
Advantages: Disadvantages:
● Sensitive to surface & subsurface ● Surface accessibility for ultrasonic
discontinuities. transmission.
● Superior depth of penetration for ● Highly skilled & trained
flaw detection. manpower.
● High accuracy – position, size & ● Irregular, rough, coarse grained or
shape of defect. non homogenous parts, linear
● Instantaneous result. defects oriented parallel to the
● Equipments used are easy to handle. beam cannot be inspected.
● No health hazards. ● Couplants are needed for testing.
● They can also be used for assessing
the thickness of structural members.
EDDY CURRENT(ELECTROMAGNETIC) TESTING
1. It uses the fact that when an alternating
current coil induces an electromagnetic
field into a conductive test piece, a
small current is created around the
magnetic flux field, much like a
magnetic field is generated around an
electric current.
2. The flow pattern of this secondary
current, called an "eddy" current, will
be affected when it encounters a
discontinuity in the test piece, and the
change in the eddy current density can
be detected and used to characterize the
discontinuity causing that change.
Applications:
● Crack detection,Commonly
used in aerospace, automotive,
marine and manufacturing
industries.
● Used to detect surface flaws, to
measure thin walls from one
surface only and measurement
of coating thickness.
● Corrosion monitoring,
Conductivity measurement.
● This test method can be
applied to flat surfaces or
tubular products.
 Disadvantages:
Advantages:
● Only conductive materials can be
● Sensitive to small cracks and other
inspected .
surface defects.
● Surface finish and roughness may
● Inspection gives immediate results.
interfere.
● Inspects complex shapes and sizes
● The instrument standardization and
of conductive materials.
calibration is necessary from time
● Test is quick and less time
to time.
consuming.
● Instruments and display units are
● Permanent record of test results can
costly.
be easily available.
LEAK TESTING

Used to detect through leaks using one of the four major LT techniques: Bubble,
Pressure Change, Halogen Diode and Mass Spectrometer Testing.
● Bubble Leak Testing:
1. As the name implies, relies on the visual detection of a gas (usually air)
leaking from a pressurized system.
2. Small parts can be pressurized and immersed in a tank of liquid and larger
vessels can be pressurized and inspected by spraying a soap solution that
creates fine bubbles to the area being tested.
3. If there are through leaks, bubbles will form, showing the location of the
leak.
Acoustic Emission Testing
1. It is performed by applying a localized external force such as mechanical
load or rapid temperature or pressure change to the part being tested.
2. The resulting stress waves in turn generate high frequency elastic waves in
the form of small material displacements, or plastic deformation, on the part
surface that are detected by sensors that have been attached to the part
surface. When multiple sensors are used, the resulting data can be evaluated
to locate discontinuities in the part.
Applications:
Acoustic Emission Testing include testing of pipelines and storage tanks (above
and below the ground), fibreglass structures, rotating machinery,etc.
Thank You...