NDT Workshop for Welders
Introduction to NDT
K. A. S. I Saranath
Scientific Officer
NCNDT
1
Basic Principles of
Non Destructive Testing (NDT)
2
Definition of NDT
NDT is a group of inspection
techniques used in industry to
detect defects and evaluate
properties of a material,
component or system without
causing any damage to
material.
3
Importance of NDT
NDT plays an important role in the quality control of a
product. There are NDT application at almost any stage in
the production or life cycle of a component.
• Inspection of Raw Products
• Inspection Following Secondary Processing
• In-Services Damage Inspection
4
Importance of NDT
Use of NDT during all stages of manufacturing results in
the following benefits:
• Increases the safety and reliability of the product
during operation.
• Decreases the cost of the product by reducing scrap
and conserving materials, labor and energy.
5
Overview of NDT
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Non relevant indication - An NDT indication that is
caused by a condition or type of discontinuity that is not
rejectable;
• Usually result from intentional interruptions in a part such as a
change in section geometry , thickness, or by a physical
conditions.
False Indication - An indication caused by improper
processing
Relevant indication - An NDT indication that is caused by
a condition or type of discontinuity that requires evaluation.
Flaw - An imperfection or discontinuity that may be
detectable by nondestructive testing and is not
necessarily rejectable.
Defect - One or more flaws whose aggregate size, shape,
orientation, location, or properties do not meet specified
acceptance criteria and are reject.
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Methods of NDT
Visual
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Basic NDT Methods
• Visual Testing (VT)
• Liquid Penetrant Testing (PT)
• Magnetic Particle Testing (MT)
• Ultrasonic Testing (UT)
• Radiographic Testing (RT)
• Eddy Current Testing (ET)
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Visual Testing (VT)
10
Visual Testing (VT)
• It is a most commonly used NDT method for detecting
and evaluating defects
• Inspect using human eye
• Optical equipment use to enhance sensitivity. But
decreases the area of coverage.
11
Visual Testing (VT)
• Requires adequate illumination of the test surface and
proper eye-sight of the tester.
• It is also a fact that all defects found by other NDT
methods ultimately must be substantiated by visual
inspection.
• Visual testing can be classified as direct visual testing,
remote visual testing and translucent visual testing.
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Visual Testing (VT)
Tools / Equipments
• Lights
• Mirrors
• Magnifiers
• Borescopes
• Rigid Probe Borescopes
• Fiberscopes
• Close Circuit Television (CCTV)
13
Liquid Penetrant Testing (PT)
14
Liquid Penetrant Testing (PT)
• This is a method which can be employed for the
detection of open-to-surface discontinuities in any
industrial product which is made from a non-porous
material.
• PT widely used for testing of Non-magnetic materials.
15
Liquid Penetrant Testing (PT)
Basic Steps of PT
• Clean & Dry Component
• Apply Penetrant
• Keep Dwell time
• Remove Excess penetrant
• Apply Developer
• Visual Inspection
• Post Cleaning
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Liquid Penetrant Testing (PT)
• The liquid is allowed to properties of the liquid.
remain on the surface of • Developer aids in drawing
the part for a period of time any entrapped penetrant
called dwell time. from the defect and
• Every step of the penetrant improves background
process is done to promote visibility.
capillary action.
• Capillary Action is the
phenomenon of a liquid
rising or climbing when
confined to small openings
due to surface wetting
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Liquid Penetrant Testing (PT)
Penetrant Type
According to Penetrant
Type 1. Fluorescent
Use Florescent penetrant and Inspect Under UV Light.
Type 2. Visible
Use Visible Penetrant and inspect under Visible light.
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Liquid Penetrant Testing (PT)
• Penetrants are also classified by the method of
removing the excess penetrant.
Method A - Water Washable
Method B - Postemulsifiable - Lipophilic
Method C - Solvent Removable
Method D- Postemulsifiable - Hydrophilic
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20
Magnetic Particle Testing (MT)
Magnetic Particle Testing (MT) is a non destructive
Inspection (NDI) method used to detect surface and near
surface defects in Ferromagnetic materials.
Example of ferromagnetic materials are iron, cobalt and
nickel.
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Magnetic Particle Testing (MT)
• Magnetic domains point randomly in demagnetized
material.
• Magnetic domains can be aligned using electrical
current or an external magnetic field.
22
Magnetic Particle Testing (MT)
Theory Behind MT
• When ferromagnetic test specimen is magnetized
specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the
specimen and a leakage field will occur.
23
Magnetic Particle Testing (MT)
• Finely milled iron particles coated with a dye pigment
are applied to the test specimen.
• These particles are attracted to leakage fields and will
cluster to form an indication directly over the
discontinuity.
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Magnetic Particle Testing (MT)
Basic Steps of MT
1. Component pre-cleaning
2. Magnetize the part
• Using electrical current or an external magnetic field
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Magnetic Particle Testing (MT)
3. Finely milled iron particles coated with a dye pigment
are then applied to the specimen.
• Magnetic particles are attracted to magnetic flux
leakage fields and will cluster to form an indication
directly over the discontinuity.
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Magnetic Particle Testing (MT)
4. Interpretation of magnetic particle indications
• This indication can be visually detected under proper
lighting conditions.
5. Demagnetization
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Magnetic Particle Testing (MT)
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Ultrasonic Testing (UT)
• UT is one method of NDT to the study and application
of sound wave frequencies higher than those to which
the human ear can respond (greater than 20 KHz) for
detecting defects (Typical frequency range 1MHz –
10MHz)
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Ultrasonic Testing (UT)
• Ultrasonic waves is mechanical vibrations of high
frequency low energy.
• Ultrasonic waves is created by applying high frequency
electrical pulses to a crystal mounted in a transducer .
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Ultrasonic Testing (UT)
• A piezoelectric element in the transducer converts
electrical energy into mechanical vibrations (sound),
and vice versa.
• The transducer is capable of both transmitting and
receiving sound energy.
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Ultrasonic Testing (UT)
Ultrasonic testing is a very versatile inspection method,
and inspections can be accomplished in a number of
different ways.
Ultrasonic inspection techniques are commonly divided
into three primary classifications.
• Pulse-echo and Through Transmission
(Relates to whether reflected or transmitted energy
is used)
• Normal Beam and Angle Beam
(Relates to the angle that the sound energy enters
the test article)
• Contact and Immersion
(Relates to the method of coupling the transducer
to the test article)
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Ultrasonic Testing (UT)
Transducers / Probes / 2.Angle beam transducers
search units In angle beam testing, the
There are two types of sound beam is introduced into
probe. the test article at some angle
1.Normal beam transducers other than 90.
In normal beam testing, the
sound beam is introduced
into the test article at 90
degree to the surface.
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Ultrasonic Testing (UT)
Pulse-Echo Technique
• High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
• Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound.
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Radiographic Testing (RT)
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Radiographic Testing (RT)
• An NDT method that utilizes x-rays or gamma radiation
to detect discontinuities in materials, and to present
their images on recording medium.
• It is mostly used to detect sub surface discontinuities.
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Radiographic Testing (RT)
• The radiation used in radiography testing is a higher
energy (shorter wavelength) version of the
electromagnetic waves.
• The radiation can come from an X-ray generator or a
radioactive source.
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Radiographic Testing (RT)
38
Radiographic Testing (RT)
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Radiographic Testing (RT)
Basic Process of RT
• The part is placed between the radiation source and a
piece of film. The part will stop some of the radiation.
Thicker and more dense area will stop more of the
radiation.
• Then radiographic film is develop.
• The film darkness (density) will vary with the amount of
radiation reaching the film through the test object.
• So we can identify the defects. ( Defects are more
dense)
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Radiographic Testing (RT)
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Eddy Current Testing (ET)
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Generation of Eddy Currents
• Eddy currents are induced electrical currents that flow
in a circular path.
• In order to generate eddy currents a “probe” is used.
Inside the probe is a length of electrical conductor
which is formed into a coil.
43
Generation of Eddy Currents (Cont.)
• A dynamic expanding and collapsing magnetic field
forms in and around the coil as the alternating current
flows through the coil.
44
Generation of Eddy Currents (Cont.)
• When an electrically conductive material is placed in
the coil’s dynamic magnetic field electromagnetic
induction will occur and eddy currents will be induced
in the material.
45
Eddy Current Testing (ET)
Coil's
Coil magnetic field
Eddy current's
magnetic field
Eddy
currents
Conductive
material
46
Eddy Current Testing (ET)
• There are three characteristics of the specimen that
affect the strength of the induced eddy currents.
Electrical conductivity of the material
Magnetic permeability of the material
Amount of solid material in the vicinity of the test coil
• Information about the strength of the eddy currents
within the specimen is determined by monitoring
changes in voltage and / or current that occur in the coil.
• The strength of the eddy currents changes the electrical
impedance (Z) of the coil.
47
Uses of Eddy Current Testing
• Crack detection (Surface and Near Surface)
• Tube and wire testing
• Condenser tube inspection
• Material sorting
• Weld testing
• Coating thickness measurement
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Common Application of NDT
• Inspection of Raw Products
• Inspection Following Secondary
Processing
• In-Services Damage Inspection
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Inspection of Raw Products
• Forgings,
• Castings,
• Extrusions,
• etc.
Inspection Following
Secondary Processing
• Machining
• Welding
• Grinding
• Heat treating
• Plating
• etc.
Inspection For
In-Service Damage
• Cracking
• Corrosion
• Erosion/Wear
• Heat Damage
• etc.
Power Plant Inspection
Periodically, power plants are
shutdown for inspection.
Inspectors feed eddy current
probes into heat exchanger
tubes to check for corrosion
damage.
Pipe with damage Probe
Signals produced
by various
amounts of
corrosion
thinning.
53
Storage Tank Inspection
Robotic crawlers
use ultrasound to
inspect the walls of
large above ground
tanks for signs of
thinning due to
corrosion.
Cameras on
long
articulating
arms are used
to inspect
underground
storage tanks
for damage.
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Aircraft Inspection
• Nondestructive testing is used
extensively during the
manufacturing of aircraft.
• NDT is also used to find cracks
and corrosion damage during
operation of the aircraft.
• A fatigue crack that started at
the site of a lightning strike is
shown below.
Pressure Vessel Inspection
The failure of a pressure vessel
can result in the rapid release of
a large amount of energy. To
protect against this dangerous
event, the tanks are inspected
using radiography and
ultrasonic testing.
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Rail Inspection
Special cars are used to
inspect thousands of miles
of rail to find cracks that
could lead to a derailment.
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Bridge Inspection
• The US has 578,000
highway bridges.
• Corrosion, cracking and
other damage can all
affect a bridge’s
performance.
• The collapse of the Silver
Bridge in 1967 resulted in
loss of 47 lives.
• Bridges get a visual
inspection about every 2
years.
• Some bridges are fitted
with acoustic emission
sensors that “listen” for
sounds of cracks growing.
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Responsibilities of personnel certified to
level 1, 2 and 3 personnel
Level of competence
• Three levels of competence are defined:
Level 1-The basic operator
Level 2- The advanced operator/ Inspector
Level 3- The supervisor
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Responsibilities of personnel certified to
level 1, 2 and 3 personnel
Level 1:
May be authorized to:
• Set up NDT equipment
• Perform the tests
• Record and classify the results of the tests in terms of
written criteria
• Report the results
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Responsibilities of personnel certified to
level 1, 2 and 3 personnel
Level 2:
• Set up and verify equipment settings
• Perform and supervise tests
• Interpret and evaluate results according to applicable codes,
standards or specifications
• Prepare written NDT instructions
• Carry out and supervise all tasks at or below level 2
• Provide guidance for personnel at or below level 2, and organize
and report the results of non-destructive tests
• Select the NDT technique for the test method to be used
• Define the limitations of application of the testing method
• Translate NDT codes, standards, specifications and procedures into
practical testing instructions adapted to the actual working
conditions
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Responsibilities of personnel certified to
level 1, 2 and 3 personnel
Level 3:
• Establish and validate NDT instructions and procedures
• Designate the particular test methods, procedures and NDT
instructions to be used
• Carry out and supervise all level 1 and level 2 duties
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Certification Requirements
Training
+
Vision
Qualification Requirements
Industrial
Experience
Certification
63
Examination
Qualification Examination Certification Examination
Level 1
Written Practical
General
Specific
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For More Information on NDT
The Collaboration for NDT Education
www.ndt-ed.org
The American Society for Nondestructive
Testing
www.asnt.org
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Thank you
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