TWI CSWIP 3.1 Wis 5 Welding Inspection NDT: World Centre For Materials Joining Technology

TWI CSWIP 3.
1 WIS 5 WELDING INSPECTION NDT

.
Copyright 2004, TWI Ltd
World Centre for Materials Joining Technology
Surface Testing Dye Penetrant Inspection Magnetic Particle Inspection Eddy Current Inspection
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Volumetric Inspection
Ultrasonic Inspection Radiographic Inspection

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Dye Penetrant Inspection
Liquid Penetrant Inspection

A.K.A. Dye Penetrant Inspection (DPI) Penetrant Flaw Detection (PFD)
Penetrant Testing (PT)
Surface inspection method Applicable to all non-porous, non-absorbing materials

Penetrant Inspection
Penetrating
fluid applied to surface of component
Penetrating fluid enters defect by means of capillary action
Excess penetrant removed from surface
Developer applied to surface
Development time for indications to appear on surface
System classification
Type of penetrant Method of penetrant removal Type of developer
Advantages of Penetrant Inspection

Applicable to non-ferromagnetic materials Able to test large parts with portable kit Suitable for batch testing May not require electricity or water Applicable to small parts with complex geometry Simple, cheap and easy to interpret Sensitivity
Disadvantages of Penetrant Inspection

Will only detect defects open to the surface Requires careful surface preparation Not applicable to porous surfaces
Temperature dependant
Cannot retest indefinitely Compatibility of chemicals
System Classification - Penetrant

Colour contrast Fluorescent Dual
System Classification - Removal
Solvent Water washable Post emulsifiable
System Classification - Development

Dry powder Aqueous Non aqueous (solvent based)
Fluorescent v Colour Contrast

Fluorescent more sensitive
Less operator fatigue with fluorescent More difficulty in monitoring excess penetrant removal Requires UV-A lamps, with subdued background lighting for fluorescent
Magnetic Particle Inspection
Magnetism
Materials will strongly attract pieces of iron to themselves Phenomenon discovered in the ancient Greek city of Magnesia Magnets utilised in navigation Oersted discovered the link between electricity and magnetism Faraday revealed that electrical and magnetic energy could be interchanged
Magnetic Particle Inspection

Test method for the detection of surface and sub-surface indications in ferromagnetic materials Magnetic field induced in component Defects disrupt the magnetic flux Defects revealed by applying ferromagnetic particles
Principle of MPI : Flux Leakage

No Defect
Defect
Permeability of Material
Paramagnetic: Weakly attracted by magnets Examples: Aluminium,Tungsten Diamagnetic: Slightly repelled by magnets Examples Gold,Copper and Water
Ferromagnetic: Strongly attracted Examples Iron,Cobalt and Nickel

Magnets
Lines of force / Lines of flux

Electromagnetism
A current flows through a conductor and sets up a magnetic field around it Field is at 90o to the direction of the electrical current Direction of current flow
Direction of magnetic field

Depth below surface
Defect Orientation
Defect at 90 degrees to flux : maximum indication

Defect Orientation
>45 Degrees to Flux:

Acceptable indication
Defect Orientation
<45 Degrees to Flux

Unacceptable indication
Defect Orientation
Test 1 Test 2
Defects
FIELD Defects Defects
MPI requires 2 tests at 90o to one another

Equipment
Permanent Magnet
Electromagnets
Permanent Magnet
Longitudinal field between poles Defects detected at 90 degrees to poles
Permanent Magnet
Advantages No power supply No electrical contact problems Inexpensive No damage to test piece Lightweight Disadvantages Direct field only Deteriorate over time No control over field strength Poles attract detecting media Tiring to use
Electromagnetism
A current flows through a conductor and sets up a magnetic field around it Field is at 90o to the direction of the electrical current Direction of current flow
Direction of magnetic field

Coil Magnetisation
Changes circular field into longitudinal

Increases the strength of the field
Electromagnets
Soft iron laminates within a coil. Defects detected at 90 degrees to poles
Electromagnets
Advantages AC,DC or rectified Controllable field strength No harm to test piece Can be used to demagnetise Easily removed Disadvantages Power supply required Longitudinal field only Carry mains supply Poles attract particles Legs must have area contact
Demagnetisation
Removal of residual magnetisation
Required if Rotating parts Components to be welded,machined or electroplated Aircraft parts

Check for removal with Field strength meter (magnetometer)
Control and Maintenance Checks

Ink settlement Equipment performance check Viewing efficiency
Eddy Current Inspection
Coil Eddy currents
Coils magnetic field
Conductive material
Eddy currents magnetic fields

An alternating current is passed through a coil A.C. generates an alternating field Alternating field generates eddy currents in conductors
Eddy currents generate opposing field which modifies current in coil


Electrical currents induced in metals by alternating magnetic fields The size of the current is affected by:Electrical conductivity Stand off distance Flaws
Permeability
Specimen dimensions

Advantages
Sensitive to surface defects Can detect through several layers Can detect through surface coatings Accurate conductivity measurements
Can be automated
Little pre-cleaning required Portability

Disadvantages
Very susceptible to permeability changes Only works on conductive materials
Will not detect defects parallel to the surface

Not suitable for large areas and /or complex geometry Signal interpretation required No permanent record (unless automated)
Ultrasonic Inspection
Ultrasonic Inspection
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Acoustic Spectrum
Human 16Hz - 20kHz Ultrasonic Range + 20kHz
Testing
0.5MHz - 50MHz
Principle waveforms in ultrasonic

There are three Principle waveforms used in ultrasonic inspections
Compression Shear Surface
Compression waves
Vibration and propagation in the same direction Travel in solids, liquids and gases
Propagation Particle vibration

Shear waves
Vibration at right angles to direction of propagation Travel in solids only Velocity 1/2 compression (same material) Particle vibration
Propagation
Surface Waves
Elliptical vibration Velocity 8% less than shear Penetrate one wavelength deep
Sound travelling through a material

Velocity varies according to the material
Compression waves Steel Shear waves 3245m/sec NA NA 2330m/sec
5960m/sec Steel
Water
Air
1490m/sec Water
344m/sec Air
Copper
4700m/sec Copper
Probe Design
Probe housing Damping Wear shoe
Electrical connections
Transducer
Probe Design
Shear Wave
Damping
Transducer
Shear wave
Perspex wedge
Ultrasonic Test Methods

Pulse Echo Through Transmission Transmission with Reflection
Pulse Echo Testing

Single probe sends and receives sound
Gives an indication of defect depth and dimensions
Not fail safe
Pulse Echo Testing

Sound travels through the steel block at 5.9Km/sec. The returning sound vibrates the crystal, which produces an electrical pulse which is amplified and is shown on the cathode ray tube.
Pulse Echo Testing

If a large defect is present all the sound will be returned to the probe. The signal on the CRT can show the depth of the defect.
Pulse Echo Testing

If a smaller defect is present some of the sound will be returned to the probe, some will continue to the back wall.
Note the reduction in size of the defect signal
Pulse Echo Testing

Defects parallel to the surface will reflect sound back to the probe Defects at an angle to the surface will reflect the sound at an angle
The signal will not appear on the CRT

Pulse Echo Testing

Angle probes used to reflect sound off inclined defects
Pulse Echo Testing

Angle probes used to test welds
Through Transmission Testing
Through Transmission Testing
Immersion Testing
Water path distance
Front surface Back surface
Water path distance

Transmission with Reflection

T R
Transmission with Reflection

T R
Time of Flight Diffraction
Time of Flight Diffraction
Time of Flight Diffraction (TOFD)

D-scan is made up of dozens of A-scans set side by side
Top of defect
The echo amplitude is displayed as grey for zero, black for maximum negative and white for maximum positive signals

Advantages
Does not depend on defect orientation Defect height can be exactly determined Inspection results are immediately available Permanent print is available Higher test speed means costs are less

Disadvantages
The weld must be reasonably accessible from both sides
There is a dead zone for defect detection close to the surfaces Is more a sizing tool than a detecting tool
Radiographic Inspection
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 Variations in transmission detected by photographic film or fluorescent screens Applicable to metals,non-metals and composites
Lower density
Higher density
Radiograph of weld showing:-
Crack Slag Lack of fusion Porosity Undercut
Advantages
Permanent record Internal flaws Can be used on most materials Direct image of flaws Real - time imaging
Disadvantages
Health hazard Sensitive to defect orientation Limited ability to detect fine cracks Access to both sides required Limited by material thickness Skilled interpretation required Relatively slow High capital outlay and running costs
What is radiation?
Waves of energy associated with electrical and magnetic fields Electrical and magnetic fields at right angles to each other and to the direction of propagation
Electromagnetic Radiation
Electromagnetic Spectrum
Industrial radiography
Ultra violet Infra red
Microwaves TV
Electric Waves
X-Ray Production
-ve
+ve
X-ray tube is evacuated to create a vacuum

Disadvantages of Gamma over X rays

Poorer quality radiographs Exposure times can be longer Sources need replacing
Radiation cannot be switched off

Poorer geometric unsharpness Remote handling necessary
Radiographic Techniques
Single Wall Single Image(SWSI) Double Wall Single Image(DWSI) Double Wall Double Image(DWDI)
Advantages of Gamma over X rays

No electrical or water supplies needed Equipment smaller and lighter-More portable Equipment simpler and more robust More easily accessed Less scatter
Equipment initially less costly

Greater penetrating power
Radiographic Technique
Single wall, single image (SWSI)
Panoramic
Double wall, single image (DWSI) Double wall, double image (DWDI)
DWSI DWDI
Unique identification Interval markers Image Quality Indicators (IQIs) TWI weld 101
Thank you for staying awake
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TWI CSWIP 3.1 Wis 5 Welding Inspection NDT: World Centre For Materials Joining Technology

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TWI CSWIP 3.

1 WIS 5 WELDING INSPECTION NDT

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Ultrasonic Inspection Radiographic Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Dye Penetrant Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Liquid Penetrant Inspection

Penetrant Testing (PT)

Surface inspection method Applicable to all non-porous, non-absorbing materials

Copyright 2004, TWI Ltd

fluid applied to surface of component

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Advantages of Penetrant Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Disadvantages of Penetrant Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

System Classification - Penetrant

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

System Classification - Development

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Fluorescent v Colour Contrast

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Magnetic Particle Inspection

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

World Centre for Materials Joining Technology

Magnetic Particle Inspection

World Centre for Materials Joining Technology

Principle of MPI : Flux Leakage

Copyright 2004, TWI Ltd

World Centre for Materials Joining Technology

Ferromagnetic: Strongly attracted Examples Iron,Cobalt and Nickel

World Centre for Materials Joining Technology

Lines of force / Lines of flux

World Centre for Materials Joining Technology