Non Destructive Testing

Definition of Non Destructive Testing

Nondestructive testing (NDT) are noninvasive techniques to quantitatively measure some characteristic of an object. It is the method of 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

Commonly used NDT methods are:

Visual inspection Leak testing Acoustic emission testing Thermal inspection Radiographic technique Magnetic Particle Crack Detection Dye Penetrant Testing Ultrasonic Flaw Detection Eddy Current and Electro-magnetic Testing

Visual inspection
Visual Inspection typically means inspection using raw human senses and/or any nonspecialized inspection equipment The basic procedure used in this technique involves illumination of the test specimen using light, usually in the visible region. Important details can be collected during visual inspection which would be suitable for further analysis.

 It is carried out as a complementary method to all other NDT methods as it should precede or succeed all other examination. If the product is found unacceptable during visual examination itself, further inspection need not be carried out.

Visual inspection is selected for detecting following discontinuities:

Surface deposits Scaling Erosion Discoloration Oxidation bulging Missing parts Mechanical damage Dimensional conformance Gross defects visible on the surface Distortion of components during fabrication Corrosion on the surface

Basic Principles of Visual Testing

Visual examination is conducted when access allows the eye to be within 25 inches (610 mm) of the surface to be examined, and at an angle not less than 30 to the surface to be examined.

Different ways of visual testing:

a)Direct unaided visual testing. There is no interruption between the eye and the object. b) Direct aided visual testing : The nature of the image is not modified. Modification of the image is only allowed by : magnification with for example a mirror, a lens, an endoscope ;

c) Remote visual testing : The nature of the image is modified : for example the optical image is converted into an electronic image by a camera.

Optical aids used for visual inspection are:

Microscope Borescope Endoscope Flexiscope Telescope

Inspection using borescope

Borescopes:

Flexiscope:

Liquid Penetrant Testing

Penetrant inspection utilizes the natural accumulation of a fluid around the discontinuity to create a recognizable indication of a crack or other surface opening.

Inspection steps
1. Pre-cleaning: The test surface is cleaned to remove any dirt, paint, oil, grease or any loose scale that could either keep penetrant out of a defect, or cause irrelevant or false indications. Cleaning methods may include solvents, alkaline cleaning steps, vapour degreasing.

2. Application of Penetrant: The penetrant is then applied to the surface of the item being tested. The penetrant is allowed "dwell time" to soak into any flaws (generally 5 to 30 minutes). The dwell time mainly depends upon the penetrant being used, material being testing and the size of flaws sought. As expected, smaller flaws require a longer penetration time.

3. Excess Penetrant Removal: The removal method is controlled by the type of penetrant used. Water-washable, solventremovable, lipopphilic post-emulsifiable, or hydrophilic post-emulsifiable are the common choices. Emulsifiers represent the highest sensitivity level, and chemically interact with the oily penetrant to make it removable with a water spray.

 If excess penetrant is not properly removed, once the developer is applied, it may leave a background in the developed area that can mask indications or defects. In addition, this may also produce false indications severely hindering your ability to do a proper inspection.

4. Application of Developer: After excess penetrant has been removed a white developer is applied to the sample. Several developer types are available, including: non aqueous wet developer, dry powder, water suspendable, and water soluble. The developer draws penetrant from defects out onto the surface to form a visible indication, commonly known as bleed-out. Any areas that bleed-out can indicate the location, orientation and possible types of defects on the surface.

5. Inspection: The inspector will use visible light with adequate intensity for visible dye penetrant. Ultraviolet (UV-A) radiation of adequate intensity along with low ambient light levels for fluorescent penetrant examinations. 6. Post Cleaning: The test surface is often cleaned after inspection and recording of defects.

Main Uses of Liquid Penetrant Testing

Used to locate cracks, porosity, and other defects that break the surface of a material and have enough volume to trap and hold the penetrant material. Liquid penetrant testing is used to inspect large areas very efficiently and will work on most nonporous materials.

Images of Liquid Penetrant Testing

Main Advantages:
Large surface areas or large volumes of parts/materials can be inspected rapidly and at low cost. Parts with complex geometry are routinely inspected Indications are produced directly on surface of the part providing a visual image of the discontinuity. Equipment investment is minimal.

Disadvantages:
Detects only surface breaking defects. Surface preparation is critical as contaminants can mask defects. Requires a relatively smooth and nonporous surface. Post cleaning is necessary to remove chemicals.

 Requires multiple operations under controlled conditions. Chemical handling precautions are necessary.

Leak testing
A leak is a flow of material, either out of an orifice, or through a material (permeation). It is an admission or release of a material.

Images for bubble test

Advantages:
Bubbles pinpoint leak and give indication of size. Inexpensive Safe procedure Requires little operator training. Easy to use. Very sensitive and reliable Can be used even when there is no access to the opposite side.

Disadvantages:
Requires moderate pressures Leak size difficult to estimate Requires cleaning after use.

Helium mass spectrometer

A helium mass spectrometer is an instrument commonly used to detect and locate small leaks. It typically uses a vacuum chamber in which a sealed container filled with helium is placed. Helium leaks out of the container, and the rate of the leak is detected by a mass spectrometer.

Advantages:
Quantitative readout Most sensitive way to test evacuated tanks Clean & safe

Disadvantages
Expensive to buy and maintain Subject to damage from large leaks Requires skilled operators Requires frequent recalibration Not easily portable

Sniffer test:

Probe technique:

Advantages:
Low pressure required Quanitative readout No cleanup required High sensitivity when used to measure total leakage.

Disadvantages:
Expensive & often delicate equipment Operator dependent Slow (scanning speed should not be faster than one foot per minute) The detector can be easily damaged by leaks Requires frequent calibration Results in windy areas are often poor

Magnetic Particle Testing

Magnetic particle inspection (MPI) is a nondestructive testing (NDT) process for detecting surface and slightly subsurface discontinuities in ferro magnetic materials such as iron, nickel, cobalt, and some of their alloys.

Main uses:
Used to inspect ferromagnetic materials. Magnetic particle inspection can detect surface and near surface defects.

Magnetizing techniques:

Magnetic Particle Inspection is performed in four steps:

Surface preparation of component before testing. Initial demagnetization. Degreasing and cleaning. Magnetization of the component.

Types of electrical currents used:

Alternating current (AC) Direct current (DC, full wave DC) Half wave rectifier

Images for Magnetic Particle Testing

Advantages:
Large surface areas of complex parts can be inspected rapidly. Can detect surface and subsurface flaws. Surface preparation is less critical than it is in penetrant inspection. Magnetic particle indications are produced directly on the surface of the part and form an image of the discontinuity. Equipment costs are relatively low.

Disadvantages:
Only ferromagnetic materials can be inspected. Proper alignment of magnetic field and defect is critical. Large currents are needed for very large parts. Requires relatively smooth surface. Paint or other nonmagnetic coverings adversely affect sensitivity. Demagnetization and post cleaning is usually necessary.