MET 312 – NON DESTRUCTIVE TESTING

MODULE 1

1. Define Non-destructive testing?

Non − Destructive Testing (NDT) is the process of determining the characteristics of

the materials, components or systems where we can detect and locate the
discontinuities and harmful defects without reducing the usefulness of such materials,
components or systems. NDT is the means of testing the materials without causing
any damage or destruction to the material. In NDT, even after testing or inspecting,
the sample will serve its purpose.

2. Explain the advantage of Visual Inspection

It is used to inspect whether there is a misalignment of parts in the equipment. It

checks for corrosion, erosion, cracks and deformities of machine components. It
inspects the plant components for any leakage (or) abnormal operation. It is used in
pumps, compressors, turbo generator to check for minute discontinuities. .It is used to
identify the defects in weldments

3. Explain the advantage of Non-destructive testing?

Applied directly to the product
Tested parts are not damaged
Various tests can be performed on the same product
Specimen preparation not required
Can be performed on parts that are in service
Low time consumption
Low labour cost

4. Explain Visual Perception related with NDT?

Visual Inspection is one of the simplest, fastest and most commonlyused non-
destructive testing method
Visual Inspection involves the visual observation of test specimen to detect the
presence of surface discontinuities.
Corrosion, misalignment of parts, physical damage and cracks are some of the
discontinuities which can be detected by visual inspection

5. Explain the necessity of NDT (6 points).

NDT increases the safety and reliability of the product during operation.
It decreases the cost of the product by reducing scrap and conserving materials, labour
and energy
Various tests can be performed on the same product
Specimen preparation is not required
Can be performed on parts that are in service
Low time consumption.
6. Compare destructive and non destructive testing?
Destructive testing is the method where the specimen is broken down to determine the
physical and mechanical properties such as strength, toughness and ductility.
The commonly used destructive methods include tensile test, hardness test, shear test,
compression test etc.
Non−Destructive Testing (NDT) is the process of determining the characteristics of
the materials, components or systems where we can detect and locate the
discontinuities andharmful defects without reducing the usefulness of such materials,
components or systems.
The commonly used destructive methods include visual inspection, liquid penetrant
test, magnetic particle test, ultrasonic test etc.
7. What are the limitations for visual inspection?
Using unaided inspection, only large discontinuities are identified.
Limited to detection of only surface discontinuities
Skilled labour is required.
Results depend on the eye resolution of the inspector.
It may cause eye fatigue to the inspector.
8. What are the limitations of NDT?
Lack of skilled operators.
There may be an interference of background noises with the actual signal which is
reflected back from the original material.
Difficulties like wrong positioning, orientation and the wrong determination of the
defect type will be there.
Lack of protective equipment may cause damage to the operating person as in case of
radiography testing by radiations.
Surface preparation is necessary. Presence of oil, grease, paint, dirt may cause error in
the output.
9. Write short note on Fibroscope?
It is also known as flexible fibre-optic borescope (or) flexiscopes.
It is used to provide clear and sharp images of parts and interior surfaces which are
not easily accessible
Fibre optics is used to carry the information and it permits several dimensional
changes depending on the object
Tip can be adjusted using rotating control mechanism depending on the object size
and it also has a wide-angle objective lens with a 100° field of view
10. Write short note on Boroscope?
Borescope is an optical instrument which is used to inspect the inside of a narrow
tube, bore or chamber.
It consists of a rigid or flexible tube with an eyepiece at one end and an objective lens
on the other end.
 It consists of a complex arrangement of prisms and plain lenses through which the
light is passed to obtain a clear image
MODULE 2

1. Enumerate the reasons for false indications in Liquid Penetrant Inspection.

Indication created by improper cleaning of the test surface by any dirt, paint, oil, grease
or any loose scale that could either keep penetrant out of a defect, or cause irrelevant or
false indications.
The false indication is caused by the poor washing of penetrant material in the washable
water system

2. Mention the desirable characteristics of a good penetrant in Liquid Penetrant Inspection

(LPI)
spread easily over the surface of the material being inspected to provide complete and
even coverage
Remain in the defect but remove easily from the surface of the part.
Remain fluid so it can be drawn back to the surface of the part through the drying and
developing steps.
Be highly visible or fluoresce brightly to produce easy to see indications
Not be harmful to the material being tested or the inspector

3. What is the sequence of operation of Liquid Penetrant Testing?

Preperation of part
Penetrant application and dwell time
Penetrant removal process
Developer application
Indication development
Inspection of surface
Clean the surface

4. Explain the properties of liquid penetrant?

Wetting ability
Specific gravity
Flash point
Volatility
Chemically inert
Viscosity
Solubility
Capillarity
Tolerance to contaminants
Availability and cost

5. Describe the basic principle of Liquid Penetrant inspection?

 This method is used to reveal Nsurface discontinuities by bleed out of a colored or
fluorescent dye from the flaw. The technique is based on the ability of a liquid to be
drawn into a "clean" surface discontinuity by capillary action. Afte a period of time
called the "dwell time", excess surface penetrant is removed and a developer applied.
This acts as a blotter that draws the penetrant from the discontinuity to reveal its
presence.
6. What are the properties of a good developer?
Material must be absorptive to perform blotting action
Must have fine texture
Must mask out background contours and colours
Must be easily and evenly applicable
Must form light and even coat
Must be no fluorescing of developer when fluorescent penetrant is used
Penetrant bleeding must easily wet the material
Must be high colour contrast, white is the best
Must be readily removable after test
Must be in-toxic and non-irritant
7. List out the applications of LPI?
Small round defects than small linear defects.
Deeper flaws than shallow flaws.
Flaws with a narrow opening at the surface than wide open flaws.
Flaws on smooth surfaces than on rough surfaces.
Flaws with rough fracture surfaces than smooth fracture surfaces.
Flaws under tensile or no loading than flaws under compression loading
Turbine rotor discs & blades
Aircraft wheels, castings
Assemblies Automotive parts – pistons, cylinders, etc.
Bogie frames of railway locomotives & rolling stock
Electrical ceramic parts – spark plug insulators, glass-to-metal seals, etc.
Moulded plastic parts
8. What are the factors depending on the dwell time of penetrant?
The surface tension of the penetrant.
The contact angle of the penetrant.
The dynamic shear viscosity of the penetrant.
The atmospheric pressure at the flaw opening.
The capillary pressure at the flaw opening.
The pressure of the gas trapped in the flaw by the penetrant.
The radius of the flaw or the distance between the flaw walls.
The density or specific gravity of the penetrant.
Microstructural properties of the penetrant