2019. 03. 08.

Anyagtudomány és Technológia Tanszék

Introduction to Nondestructive Testing

Methods

Material Science
BMEGEMTMW01
01.03.2019

Introduction to NDT

• Nondestructive testing
• Nondestructive evaluation

• Why use NDT?

• All of our structural materials contain discontinuities

• Safe operation and reliability
• Quality Assurance management tool
• Information on repair criteria
• Lifetime prediction
• Mandatory by law

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 2019. 03. 08.

Introduction to NDT

• There is no universal test method!

• Conventional methods
• VT
• MPI
• PT
• UT
• RT
• ET
• ...

• Non-conventional methods
• PAUT
• TOFD
• ACFM
• …

Probability of Detection
POD

Flaw depth (mm)

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Discontinuity vs. defect

• Discontinuities always exist in the base material

Discontinuity vs. defect

• Discontinuities always exist in the base material

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Discontinuity vs. defect

• Discontinuities always exist in the base material

• But the probability of detection can be zero with the
recent methods
• With NDT methods discontinuities are determined

àEngineering Critical Assessment

àFracture mechanics New discipline:
àCritical size of discontinuity Structural Integrity
àDefect or not

Practical example

Storage tank inspection

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Practical example
• Wall thickness
measurements on the
shell courses
• In eight directions
• Determine minimum wall
thickness
• Shell load calculations
• Recommendation: repair
or not?

Practical example

Result
• Minimum wall thickness is not acceptable by international standard
• Excessive shell loads
• Reparation is mandatory

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Visual Testing

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Visual Testing

• Most basic and common inspection method.

• Only for surface open flaws
• Tools include fiberscopes, borescopes, magnifying
glasses and mirrors.
• Portable video inspection unit with zoom allows
inspection of large tanks and vessels, railroad tank cars,
sewer lines.
• Robotic crawlers permit observation in hazardous or
tight areas, such as air ducts, reactors, pipelines.

• Highly subjective, difficult to report

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Visual Testing

• Illumination of the test surface shall be 500 lux

minimum for general examinations and 1000 lux
minimum for critical work.
• Within 600mm of the surface to be examined. The
visual angle between plane of vision and surface being
tested shall not be less than 30°.
• Magnification aids may be employed for critical work
between 2X and 10X magnification.

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Visual Testing

http://pagacz.com.pl/oferowane-produkty/olympus/
https://www.ndt.org/rfp.asp?ObjectID=5600&category=Visual
%3A%3ARobotic+Cameras

https://www.indiamart.com/proddetail/sk
https://www.fiberscope.net/rigid-
ew-t-fillet-weld-gauge-14397938730.html
borescope.html
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Visual Testing - Application

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Visual Testing - Application

Effect of the angle of the light source

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Visual Testing - Application

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Visual Testing - Application

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Visual Testing - Application

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Visual Testing - Application

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Liquid Penetrant Testing

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Liquid Penetrant Testing

• Applicable for surface open flaws, cracks

• A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to
seep into surface breaking defects.
• The excess liquid is removed from the surface of the
part.
• A developer (powder) is applied to pull the trapped
penetrant out the defect and spread it on the surface
where it can be seen.
• Visual inspection is the final step in the process. The
penetrant used is often loaded with a fluorescent dye
and the inspection is done under UV light to increase
test sensitivity.

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Liquid Penetrant Testing

http://www.ndttechnologies.com/products/penetrant_testing.html

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Liquid Penetrant Testing

Surface tension • γgl: gas – liquid
• γsg: solid – gas
• γls: liquid – solid

ΣFx = γls - γsg- γgl cosθ = 0

ΣFy = γgl sinθ - A = 0

θ = 0° – fluid completely wets

0° < θ < 90° – fluid wets
Capillarity 90° < θ < 180° – fluid contracts
θ = 180° – fluid detaches

• Abovehead inspection
• Dwell time: To detect a crack of a
given size, the penetrant fluid
requires a lapse of time for
capillary action to draw the
penetrant into the flaws.
• Strong temperature dependency
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Liquid Penetrant Testing -

Application

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Liquid Penetrant Testing -

Application

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Liquid Penetrant Testing -

Application

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Liquid Penetrant Testing -

Application

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Magnetic Particle Testing

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Magnetic Particle Testing

• Only for ferromagnetic materials

• Sub-surface defects can be indicated
• The part is magnetized. Finely milled iron particles
coated with a dye pigment are then applied to the
specimen. These particles are attracted to magnetic
flux leakage fields and will cluster to form an indication
directly over the discontinuity. This indication can be
visually detected under proper lighting conditions.
• Demagnetization!

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Magnetic Particle Testing

Magnetic field
Flux leakage

Strong dependency
on the
Magnetic
flux
flux orientation!

Coil Insulator

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Magnetic Particle Testing -

Application

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Magnetic Particle Testing -

Application

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Magnetic Particle Testing -

Application

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Eddy Current Testing

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Eddy Current Testing

• Only qualitative
• For any kind of electrically conductive material testing
• For materials properties determination: hardness,
conductivity etc.
• For flaw detection: sub-surface cracks, discontinuities
• Low frequency applications: wall thickness
measurement
• Coating thickness meas.
• Calibration is very important

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Eddy Current Testing

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
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Eddy Current Testing

• Eddy currents are strongest at the surface of the

material and decrease in strength below the surface.
The depth changes with probe frequency, material
conductivity and permeability.

Standard Depth
of
Depth

Depth

Penetration
(Skin Depth)

1/e or 37 %
of surface density
Eddy Current Density Eddy Current Density
High Frequency Low Frequency
High Conductivity Low Conductivity
High Permeability Low Permeability

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Eddy Current Testing - Applications

http://www.directindustry.com/prod/olympus/product-17434-
1535661.html
https://www.indiamart.com/proddetail/usaf-general-purpose-eddy-
current-standard-block-1018-steel-15856740455.html 39

Eddy Current Testing - Applications

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Eddy Current Testing - Applications

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Eddy Current Testing - Applications

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Eddy Current Testing - Applications

R2 Maximum degree of corrosion:

R1 R3
3 4 5 6 7 8 9
2 10 10%
1 11

15 14 13 12
20%
R16 R4
30%
16 17 18 19 20
40%
25 24 23 22 21
50%
26 27 28 29 30 31
R15 R5 60%
36 35 34 33 32 70%

37 38 39 40 41 42 43 >70%

49 48 47 46 45 44 Hole Other

Not accessable area

R14 50 51 0 52 53 R6

59 58 57 56 55 54

60 61 62 63 64 65 66

71 70 69 68 67
R13 R7
72 73 74 75 76 77

82 81 80 79 78

83 84 85 86 87
R12 R8
91 90 89 88

92 102
93 101
94 95 96 97 98 99 100
R11 R9

R10

Corrosion Map Internal External

Corrosion Map Corrosion Map Note:
Internal and external corrosion values are added automatically. Color code shows maximum wall loss of the plate.
Owner: Drawing Number: Tank Number:
20% internal pitting

20% external pitting

Client num_063 xx
Name Signature Date
20% internal and external pitting
Inspector Corrosion map
40% wall loss
Controller of tank floor
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Eddy Current Testing - Applications

1450 660

720 80
240
500

380

R2 Maximum degree of corrosion:

R1 R3
3 4 5 6 7 8 9
2 10 10%
1 11

15 14 13 12
20%
R16 R4
30%
16 17 18 19 20
40%
1630

1325 24 23 22 21
50%
26 27 28 29 30 31
60%
750

R15 R5
36 35 34 33 32 70%

37 38 39 40 41 42 43 >70%

42045 Hole Other

280

49 48 47 46 44

Not accessable area

R14 50 51 2500 0 52 53 R6

59 58 4600 57 56 55 54

60 61 62 63 64 65 66
Maximum degree of corrosion: 1. Pitting RT 0,0 - 660,1630 Internal Pits (50%) on this area
71 702. 69
Pitting 68 RT 80,24067 Internal Pit (70%)
R13 R7
10% 3. Pitting RB76420,280 77 Internal Pit (60%)
72 73 74 75
20% 4. Pitting LT 0,0 - 720,500 Internal Pits (40%) on this area
82 81 80 79 78
5. Pitting LT 1450,380 Internal Pit (70%)
30%
83 84 6. 85
Pitting 86
RB 2500,0 -874600,750 Internal Pits (40%) on this area
40% R12 R8
91 90 89 88
No. Defect type Co-or dinates of defect Descr iption
50% 92 102
93 101
94 95 96 97 98 99 100
60% R11
Owner: R9 Drawing Number: Tank Number:

70% Client
R10 num_078 xx
>70% Corrosion Map Internal Name
External Signature Date
Corrosion Map Corrosion Map Note:
Inspector Internal and external corrosion values are added automatically. Color code shows maximum wall loss of the plate.
Hole Other
Controller Owner: Bottom Plate 13Drawing Number: Tank Number:
20% internal pitting
Not accessable area
20% external pitting
Client num_063 xx
Name Signature Date
20% internal and external pitting
Inspector Corrosion map
40% wall loss
Controller of tank floor
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Ultrasonic Testing

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Ultrasonic Testing

• High frequency sound waves are introduced into a

material and they are reflected back from surfaces or
flaws.
• Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound.
• Mostly for 2D flaw detection, weld inspcetion, wall
thickness measurement
• Quantitative results
• Developing area, new techniques

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Ultrasonic Testing

initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate

Oscilloscope, or flaw
detector screen

First back echo Crack Second back echo

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Ultrasonic Testing - Calibration

https://www.indiamart.com/proddetail/step-wedge-calibration-block-
for-ultrasonic-testing-16779061430.html

https://www.indiamart.com/proddetail/phased-array-
ultrasonic-testing-calibration-block-
15603111948.html

http://www.ajr-ndt.com/Products/v1-test-block.html

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Ultrasonic Testing – Angle probe

https://www.olympus-ims.com/en/ultrasonic-transducers/standard/

http://www.intrexkw.com/Home/OurServices/Non
-Destructive-Testing/Ultrasonic-Testing

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Ultrasonic Testing – Phased array

• Multiple transducers (4-128!), arbitrary inspection

positions, controlling delay time of each transducer
• This technique can be used to inspect more complex
geometries that are difficult and much slower to
inspect with single probes

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Ultrasonic Testing – Phased array

High knowledge of ultrasonic
inspection is needed for:
• Calibration
• Inspection
• Flaw size and location
determination

http://universityofultrasonics.com/training-
university-of-ultrasonics/phased-array-
ultrasonic-paut-training/pa-098-phased-
array-for-engineers-manager-end-users/

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Radiographic Testing

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Radiographic Testing

• The radiation used in radiography testing is a higher

energy (shorter wavelength, 10-9 – 10-12) version of the
electromagnetic waves that we see as visible light. The
radiation can come from an X-ray generator or a
radioactive source.

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Radiographic Testing

The part is placed between the radiation

source and a piece of film. The part will stop
some of the radiation. Thicker and more
dense area will stop more of the radiation.
The film darkness (density)
will vary with the amount
of radiation reaching the
film through the test
X-ray film object.
= less exposure
= more exposure

Top view of developed film • Weld inspection

• 3D flaws detection 54

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Radiographic Testing - Image

quality
http://apiexam.com/asme-v-radiology-part-2/
Accelerating voltage

Wire type image quality indicator

https://www.gemeasurement.com/sites/gemc.dev/files/indust
rial_radiography_image_forming_techniques_english_4.pdf
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Radiographic Testing - Isotopes

• Gamma ray radiation

• Types of isotopes:
• Co - 60
• Ir - 192
• Se - 75
• Panoramic images
• Safety!
https://www.nde-
ed.org/EducationResources/CommunityCollege/Radiography/EquipmentM
aterials/isotopesources.htm 56

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Radiographic Testing - Application

https://www.gemeasurement.com/sites/gemc.dev/files/industrial_radiography_image_forming_techniques_englis
h_4.pdf 57

Radiographic Testing - Digital

• As a result of incident X-ray or gamma ray radiation on the
storage phosphor, part of its electrons are excited and trapped
in a semi-stable, higher-energy state.
• This creates the latent image.
These trapped electrons can be released by
laser beam energy.
• This stimulation causes visible light
to be emitted, which can then be
captured by a PMT (Photo Multiplier Tube).

https://www.gemeasurement.com/sites/gemc.dev/files/industrial_radi
ography_image_forming_techniques_english_4.pdf 58

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Radiographic Testing - Digital

• The plate stores 4096 grey values

• Wide variety of thickness range
• Lower radiation dose is enough
• Lower exposure time
• Wall thickness can be measured digitally
• Documentation
• Results directly after exposure
• No darkroom, chemicals
• Digital optimization

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Radiographic Testing - Digital

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Brief summary

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Brief summary

• NDT definition, application

• Discontinuity vs defect
• Visual testing
• Liquid penetrant testing
• Magnetic particle testing
• Eddy curren testing
• Ultrasonic testing
• Radiographic testing

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References
• Dr. Békési László et al.: RONCSOLÁSMENTES ANYAGVIZSGÁLATI MÓDSZEREK
ALKALMAZÁSÁNAK TAPASZTALATAI
• Peter J Shull: Nondestructive evaluation
• Introduction to Nondestructive Testing by the Collaboration for NDT
Education
• Introduction to Eddy Current Testing by the Collaboration for NDT Education
• Fázisvezérelt technológia, Bodolai Tamás, Olympus, 2014
• Radiográfia, Fodor Olivér, 2018

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Thank you very much for your attention!

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