Non-Destructive Testing (NDT)

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 Non-Destructive Testing
(NDT)
Non-Destructive testing is the
use of noninvasive techniques to
determine the integrity of a
material, component or structure
or quantitatively measure some
characteristics of an object. It is
the testing of materials, for
surface or internal flaws or
metallurgical condition, without
interfering in any way with the
integrity of the material or its
suitability for service.

i.e. Inspect or measure without doing harm.

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 Importance of NDT
1. NDT increases the safety and reliability of the product
during operation.
2. It decreases the cost of the product by reducing scrap and
conserving materials, labor and energy.
3. It enhances the reputation of the manufacturer as a
producer of quality goods. All of the above factors boost
the sales of the product which bring more economical
benefits for the manufacturer.
4. NDT is also used widely for routine or periodic
determination of quality of the plants and structures during
service.
5. This not only increases the safety of operation but also
eliminates any forced shut down of the plants.

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 Methods of NDT
Ther
mo grap
Visual Mi cr o hy
wave
ar t ic le
netic P
Ma g
Acoustic
X-ray Microsco
py
Acousti
c Emissio e n ts nt
n em t r a
as ur
id P e ne
t ic Me Liqu
Ult ag ne
ra M
son
ic
Laser Eddy
I nterfe Curr
L e ak age romet en
Fl ux ry t
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Six Most Common NDT
Methods
1. Visual Testing (VT)
2. Dye Penetrant Testing (DPT)
3. Magnetic Particle Testing (MPT)
4. Ultrasonic Testing (UT)
5. Eddy Current Testing (ECT)
6. Radiography Testing (RT)

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 Visual Testing
Visual testing is the most basic and common inspection method
involves in using of human eyes to look for defects. But now it
is done by the use special tools such as video scopes,
magnifying glasses, mirrors, or borescopes to gain access and
more closely inspect the subject area.
Visual Testing Equipments:

•Mirrors (especially small, angled mirrors),

•Magnifying glasses,
•Microscopes (optical and electron),
•Borescopes and fiber optic borescopes,
•Closed circuit television (CCTV) systems,
•Videoscope.

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 Visual Testing Equipments

Fig: Videoscope Fig: Advanced Videoscope Fig: Borescopes

Fig. Microscope Fig: Magnifying glass

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 Dye Penetrant Testing

This method is commonly used for detect the surface cracks or

defects. Dye penetrant Testing (DPT) is one of the most widely
used nondestructive Testing (NDT) methods. DPT can be used
to inspect almost any material provided that its surface is not
extremely rough.

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Dye Penetrant Testing Process

Three liquids are

used in this method.
1. Cleaner
2. Penetrant
3. Developer

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 Dye Penetrant Testing of a Boiler

At first the surface of the material that is to be tested is cleaned

by a liquid. The liquid is called cleaner.
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 Dye Penetrant Testing of a Boiler

Then a liquid with high surface wetting characteristics is applied

to the surface of the part and allowed time to seep into surface
breaking defects. This liquid is called penetrant. After five or ten
minutes the excess penetrant is removed from the surface. 11
 Findings

After Dye Penetrant Testing

there are two surface cracks are
Detected.

Two surface cracks

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 Advantages of Dye Penetrant
Testing

 This method has high sensitivity to small surface

discontinuities.
 Large areas and large volumes of parts/materials can be
inspected rapidly and at low cost.
 Indications are produced directly on the surface of the part
and constitute a visual representation of the flaw.
 Aerosol spray can make penetrant materials very portable.
 Penetrant materials and associated equipments are relatively
inexpensive.

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 Limitations of Dye Penetrant
Testing
 Only surface breaking defects can be detected.
 Precleaning is critical since contaminants can mask defects.
 The inspector must have direct access to the surface being
inspected.
 Surface finish and roughness can affect inspection sensitivity.
 Post cleaning of acceptable parts or materials is required.
 Chemical handling and proper disposal is required.

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 Magnetic Particle Testing

This method is suitable for the detection

of surface and near surface
discontinuities in magnetic material,
mainly ferrite steel and iron. Magnetic
particle Testing (MPT) is a
nondestructive testing method used for
defect detection. MPT is fast and
relatively easy to apply, and material
surface preparation is not as critical as it
is for some other NDT methods.

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 Basic Principle of MPT www.sajetc.com

Magnetic Flux Leakage Crack

Magnetic Flux Line

S N
N S N S

Fig.1: Magnetized Metal with no crack Fig.2: Magnetized Metal with crack

In the first figure the magnetized metal has no crack and there only two
poles that is north pole and south pole. And in second figure the
magnetized metal has a crack and at the crack point there creates
another north and south pole for the magnetic flux leakage.
 Magnetic Particle Testing
www.sajetc.com
Process
The first step in a magnetic
particle testing is to magnetize the

test component by a MPT

equipment. If there any defects on
the surface or near to the surface
are present, the defects will create
a leakage field.
Then finely milled iron particles coated with a dye pigment are
applied to the specimen. These particles are attracted to
magnetic flux leakage fields and will cluster to form an
indication directly over the defects. This indication can be
visually detected under proper lighting conditions.
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 Magnetic Particle Testing in Superheater
www.sajetc.com
Pipe Welding

First the welding joint is magnetized by MPT equipment. Then finely

milled iron particles are applied to the magnetized weld joint.
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 Magnetic Particle Testing in Gas
www.sajetc.com
Pipe Welding
Iron particles make a
cluster at the welding
joint for magnetic
flux leakage because
of welding defects.

Cluster

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 Advantages Magnetic Particle
www.sajetc.com
Testing
 It does not need very stringent pre-cleaning operation.
 It is the best method for the detection of surface and near to
the surface cracks in ferromagnetic materials.
 Fast and relatively simple NDT method.
 Generally inexpensive.
 Will work through thin coating.
 Highly portable NDT method.
 It is quicker.

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 Limitations of Magnetic Particle www.sajetc.com

Testing
 Material must be ferromagnetic.
 Orientation and strength of magnetic field is critical.
 Detects surface and near-to-surface discontinuities only.
 Large currents sometimes require.
.

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 Ultrasonic Testing www.sajetc.com

This technique is used for the detection

of internal surface (particularly distant
surface) defects in sound conducting
materials. In this method high
frequency sound waves are introduced
into a material and they are reflected
back from surface and flaws. Reflected
sound energy is displayed versus time,
and inspector can visualize a cross
section of the specimen showing the
depth of features.

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 Basic Principle of Ultrasonic www.sajetc.com
Testing
A typical UT system consists of several functional units, such as
the pulser/receiver, piezoelectric transducer, and display devices. A
pulser/receiver is an electronic device that can produce high
voltage electrical pulses. Driven by the pulser, the transducer
generates high frequency ultrasonic energy. The sound energy is
introduced and propagates through the materials in the form of
waves. When there is a discontinuity (such as a crack) in the wave
path, part of the energy will be reflected back from the flaw
surface. The reflected wave signal is transformed into an electrical
signal by the piezoelectrical transducer and is displayed on a
screen.

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 Basic Principle of Ultrasonic
Testing www.sajetc.com

In the figure below, the reflected signal strength is displayed

versus the time from signal generation, when a echo was
received. Signal travel time can be directly related to the
distance. From the signal, information about the reflector
location, size, orientation and other features can sometimes
be gained.
initial Piezoelectric
pulse Transducer
back surface
echo
crack
echo

crack
0 2 4 6 8 10 plate

Oscilloscope, or flaw
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detector screen
 Piezoelectric Transducer www.sajetc.com

A transducer is a device that converts energy from one form to

another. Presently, piezoelectric material is commonly used as a
basic component of transducers. A piezoelectric element is a
crystal which delivers a voltage when mechanical force is
applied between its faces, and it deforms mechanically when
voltage is applied between its faces. Because of these
characteristics piezoelectric element is capable of acting as both
a sensing and a transmitting element. Piezoelectric transducers
have been conventionally used to convert electric signals into
sound wave, or to convert sound wave into electric signals.

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 Piezoelectric Transducer
www.sajetc.com

case

Signal wire
Piezoelectric element

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 Test Techniques: www.sajetc.com
Normal and Angle Beam
• In normal beam testing, the sound beam
is introduced into the test article at 90
degree to the surface.
• In angle beam testing, the sound beam is
introduced into the test article at some
angles other than 90.
• The choice between normal and angle
beam inspection usually depends on two
considerations:
- The orientation of the feature of
interest – the sound should be
directed to produce the largest
reflection from the feature.
- Obstructions on the surface of the
part that must be worked around. 27
 Couplant www.sajetc.com

A couplant is a material (usually liquid)

that facilitates the transmission of ultrasonic
energy from the transducer into the test
specimen. Couplant is generally necessary
because the acoustic impedance mismatch
between air and solids (i.e. such as the test
specimen) is large. The couplant displaces
the air and makes it possible to get more
sound energy into the test specimen so that
a usable ultrasonic signal can be obtained.
In contact ultrasonic testing a thin film of
oil, glycerin or water is generally used
between the transducer and the test surface

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 Calibration Standards www.sajetc.com

Calibration is a operation of configuring the ultrasonic test

equipment to known values. This provides the inspector with
a means of comparing test signals to known measurements.
Calibration standards come in a wide variety of material
types, and configurations due to the diversity of inspection
applications.

The following slides provide examples of specific types of

standards.

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 Calibration Standards www.sajetc.com

Thickness calibration standards

may be flat or curved for pipe and
tubing applications, consisting of
simple variations in material
thickness.
Distance/Area Amplitude standards ASTM Distance/Area Amplitude
utilize flat bottom holes or side
drilled holes to establish known
reflector size with changes in
sound path form the entry surface.
IIW
This calibration standards for use
in angle beam inspections when
flaws are not parallel to entry
surface.

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 Advantages of Ultrasonic Testing www.sajetc.com

 Thickness and lengths up to 30 ft can be tested.

 Position, size and type of defect can be determined.
 Instant test results.
 Portable.
 Capable of being fully automated.
 Access to only one side necessary.

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 Limitations of Ultrasonic Testing www.sajetc.com

 The operator can decide whether the test piece is defective or

not while the test is in progress.
 Considerable degree of skill necessary to obtain the fullest
information from the test.
 Very thin sections can prove difficult.

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 Eddy Current Testing www.sajetc.com

This method is widely used to detect

surface flaws, to measure thin walls from
one surface only, to measure thin coatings
and in some applications to measure
depth. This method is applicable to
electrically conductive materials only. In
this method eddy currents are produced in
the product by bringing it close to an
alternating current carrying coil. The main
applications of the eddy current technique
are for the detection of surface or
subsurface flaws, conductivity
measurement and coating thickness
measurement.
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 Application of ECT www.sajetc.com

Crack Detection
Corrosion Monitoring
Material Thickness Measurements
Coating Thickness Measurements
Conductivity Measurements

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 Electromagnetic Induction www.sajetc.com

•Eddy currents are created through a process called

electromagnetic induction.
•When alternating current is applied to the conductor, such as
copper wire, a magnetic field develops in and around the
conductor.
•This magnetic field expands as the alternating current rises to
maximum and collapses as the current is reduced to zero.

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 Electromagnetic Induction www.sajetc.com

If another electrical conductor is brought into the proximity of

this changing magnetic field, the reverse effect will occur.
Magnetic field cutting through the second conductor will cause
an “induced” current to flow in this second conductor. Eddy
currents are a form of induced currents!

Current Flow

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 Crack Detection www.sajetc.com

Crack detection is one of the primary uses of eddy current

inspection. Cracks cause a disruption in the circular flow patterns
of the eddy currents and weaken their strength. This change in
strength at the crack location can be detected.

Magnetic Field
From Test Coil

Magnetic Field
From
Eddy Currents

Crack
Eddy Currents

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Eddy Current Testing www.sajetc.com
Equipments

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 Probes - Mode of Operation www.sajetc.com

Eddy current probes are available in a large variety of shapes

and sizes. In fact, one of the major advantages of eddy current
inspection is that probes can be custom designed for a wide
variety of applications. Eddy current probes are classified by the
configuration and mode of operation of the test coils.

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 Different Types of Probes www.sajetc.com

Absolute Probes Surface Probes Bobbin Probes

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 Advantages of Eddy Current www.sajetc.com

Testing
Sensitive to small cracks and other defects
Detect surface and near surface defects
Inspection gives immediate results
Equipment is very portable
Method can be used for much more than flaw detection
Inspects complex shapes and sizes of conductive materials

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 Limitations of Eddy Current www.sajetc.com

Testing
Only conductive materials can be inspected.
Surface must be accessible to the probe.
Skill and training required is more extensive than other
techniques.
Surface finish and roughness may interfere.
Depth of penetration is limited.

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 Radiography Testing www.sajetc.com
 
Radiography Testing (RT), or industrial
radiography is a nondestructive testing (NDT)
method of inspecting materials for hidden flaws
by using the ability of short wavelength
electromagnetic radiation (high energy photons)
to penetrate various materials.  
Radiographic Testing Method is nothing but to
take the shadow picture of an object onto a film
by the passage of X-ray or Gamma ray through
it. It is the same as the medical radiography (X-
ray). Only difference in their wave length.

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 Radiography Testing Process www.sajetc.com

The principles are the same for both X and Gamma radiography.
In X-radiography the penetrating power is determined by the
number of volts applied to the X-Ray tube - in steel
approximately 1000 volts per inch thickness is necessary. To
produce an X or Gamma radiograph, the film package is placed
close to the surface of the subject. The source of radiation is
positioned on the other side of the subject some distance away,
so that the radiation passes through the subject and on to the
film.

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 Radiography Testing Process www.sajetc.com

After the exposure period the film is removed, processed, dried,

and then viewed by transmitted light on a special viewer.
Various radiographic and photographic accessories are
necessary, including such items as radiation monitors, film
markers, image quality indicators, darkroom equipment, etc.
Where the last is concerned there are many degrees of
sophistication, including fully automatic processing units.
These accessories are the same for both X and Gamma
radiography systems. Also required are such consumable items
as radiographic film and processing chemicals

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 Radiography Testing Process www.sajetc.com

Radioactive Source

Electrons
+ -
X-ray Generator or
Radioactive Source
Creates Radiation

X-ray film
Radiation
Penetrate
the Sample

Top view of developed film 46

 Essential Elements for Radiography www.sajetc.com

Testing
1. A source of penetrating radiation, such as an X-ray machine.
2. The object to be radiographed, such as a weldment.
3. A recording or viewing device, usually photographic (X-ray)
film enclosed in a light tight holder.
4. A qualified radiographer trained to produce a satisfactory
exposure.
5. A person skilled in the interpretation of radiographs.

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 Radiographic Image
www.sajetc.com

Normal image

Radiographic image

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 Radiation Safety www.sajetc.com

Ionizing radiation is an extremely important NDT tool but it

can pose a hazard to human health. For this reason, special
precautions must be observed when using and working around
ionizing radiation. Complicating matters further is the fact that
Gamma and X-ray radiation are not detectable by the human
body. However, the risks can be minimized when the radiation
is handled and managed properly.

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 Advantages of Radiography www.sajetc.com
Testing
Information is presented pictorially.
 A permanent record is provided which may be viewed at a
time and place distant from the test.
Useful for thin sections.
Sensitivity declared on each film suitable for any material.

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 Limitations of Radiography www.sajetc.com

Testing
Possible health hazard.
 Need to direct the beam accurately for two-dimensional
defects.
 Film processing and viewing facilities are necessary
 Not suitable for automation.
 Not suitable for surface defects.

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