Material Science and Metallurgy: Yugesh

MATERIAL SCIENCE AND METALLURGY
“NON DESTRUCTIVE TESTING”
Branch : BE/MARINE ENGINEERING

Prepared by:
YUGESH
AKASH GOVIND
ALLON JONES
MURALIDARAN
NDT
NON-DESTRUCTIVE TESTING
• Non destructive testing(NDT) is one of
the important methods used for evolution
and quality control of metal components
• During testing, the metal component does
not get damaged
• These tests are used to locate or find out
the defects or flaws in the component
ADVANTAGES OF NDT
• The equipments are easy to handle
• Defects can be detected without damaging the
components
• Methods are quick and accurate
• Components can be sorted out on the basis of
electrical, magnetic or chemical properties
• Test results and other information can be
conveniently recorded on paper films, cassettes
and floppies
DIFFERENCE BETWEEN DESTRUCTIVE
AND NON DESTRUCTIVE TEST
NON DESTRUCTIVE TEST DESTRUCTIVE TEST
Used for finding out defects of Used for finding out the properties
materials of the material
Load is not applied on the material Load is applied on the material
No load applications, so no chance Due to load application, material

for material damage gets damaged
No requirement of special Special equipments are required
equipments
Non expensive Expensive
Less skill Skill is required
e.g: dye penetrate test, ultrasonic, e.g: tensile test, compression test,
radiography, etc hardness test, etc
BASIC ELEMENTS OF NDT METHOD
• SOURCE
• MODIFICATION
• DETECTION
• INDICATION
• INTERPRETATION
METHODS OF NDT
• Dye Penetrant Testing (DPT)
• Magnetic Particle Testing (MPT)
• Ultrasonic Testing (UT)
• Eddy Current Testing (ECT)
• Radiography Testing (RT)
DYE PENETRANT TEST
• Used for detect the surface cracks or defects
• One of the most widely used NDT methods
• Used to inspect almost any material
provided that its surface is not extremely
rough
• It is used for surface detection of forging,
casting, weld elements
PROCESS FOR DPT
• CLEANING
• DRYING OF
SURFACE
• APPLICATION
OF
PENETRATE
• REMOVAL OF
EXCESS OF
PENETRATE
• APPLICATION
OF
DEVELOPER
ADVANTAGES OF DPT
• 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 in expensive.
LIMITATIONS OF DPT
• Only surface breaking defects can be detected
• 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.
MAGNETIC PARTICLE TESTING
• This method is suitable for the detection of
surface and near surface discontinuities in
magnetic material , mainly ferrite steel and
iron
• METHODS OF MPT
• Dry method
• Wet method
PRINCIPLE OF MPT
• 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.
MPT IN GAS PIPE WELDING
Particles make a cluster at the welding joint for magnetic flux

leakage because of welding defects.
ADVANTAGES OF MPT
• Principally and relatively simple method
• Economical and easy to perform
• Portable for field testing
• Fast for production testing
• Reveal or disclose small surface flaws or
cracks which may be tight
LIMITATIONS OF MPT
• Material must be ferromagnetic
• Orientation and strength of magnetic field is
critical
• Detects surface and near-to-surface
discontinuities only
• Large currents are required
ULTRASONIC 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 piezo electrical transducer and is displayed on a screen.
PULSE-ECHO METHOD
TRANSMISSION METHOD
ADVANTAGES OF ULTRASONIC
TESTING
• 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
LIMITATIONS OF ULTRASONIC
TESTING
• 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.
ULTRASONIC MEASUREMENT
EDDY CURRENT TESTING(ECT)
• Used to detect surface flaws, to
measure thin walls from one surface
only
• To measure thin coating sand 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.
APPLICATION OF ECT
• Crack Detection
• Corrosion Monitoring
• Material Thickness Measurements
• Coating Thickness Measurements
• Conductivity Measurements
ADVANTAGES OF ECT
• 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
LIMITATIONS OF ECT
• Only conductive materials can be inspected

• Skill and training required is more extensive
than other techniques
• Surface finish and roughness may interfere
• Depth of penetration is limited.
RADIOGRAPHY
• Radiography Testing (RT), or
industrial radiography is 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.
RADIOGRAPHY TESTING
PROCESS
DIFFERENCE BETWEEN X RAY AND
GAMMA RAY RADIOGRAPHY
X RAYS GAMMA RAYS
Larger wavelength Shorter wavelength
Less penetration power High penetration power
Used for components having Used for more thickness components

thickness up to 62mm
Only one component can be examined Many components can be examined at
at a time a time
Equipment is larger in size Equipment is smaller in size
More intensity and faster Less intensity and slower

RADIOGRAPHY
LIMITATIONS OF
RADIOGRAPHY
• 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.
APPLICATION OF RADIOGRAPHY
• 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
RADIOGRAPHY
ULTRASONIC TESTING RADIOGRAPHY TESTING
Less flaw detection capabilities More flaw detection capabilities
Compared to radiography less operational More operational safety is required as the
safety is required radiations are harmful
Probe is used Probe is not used

Better accuracy and reliability Very fast method of testing
Operated manually Less or no manual work
Used for detection of internal defect, For detection of internal defects, porosity,
measurement of conductivity and crack casting, lack of fusion in welding, cracks,
depth measurement of geometry variation and
thickness of components
Ultrasonic
testing
Radiography
testing
CONCLUSION
• NDT is a new technology and system for
industrial inspection and testing
• Many developed countries uses this
technology because of its huge benefits
• Modern NDT methods will become just as an
important tool for risk based inspection
approaches and maintenance planning
• For this purpose every industry should have a
NDT division with NDT personnel

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MATERIAL SCIENCE AND METALLURGY

“NON DESTRUCTIVE TESTING”

Branch : BE/MARINE ENGINEERING

No load applications, so no chance Due to load application, material

Particles make a cluster at the welding joint for magnetic flux

• The operator can decide whether the test

• Only conductive materials can be inspected

Less penetration power High penetration power

Used for components having Used for more thickness components

More intensity and faster Less intensity and slower

• For detection of internal defects

Probe is used Probe is not used

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