Unit 1-Complete Notes With MCQ
Unit 1-Complete Notes With MCQ
Unit 1-Complete Notes With MCQ
OVERVIEW OF NDT
Dr. J.CHANDRADASS
Associate Professor
SRMIST,
[email protected]
DEFINITION
Non-Destructive Testing may be defined as those testing methods in which the
material under test is not destroyed or to say the future usefulness of the material
under test is not impaired.
The terms
nondestructive examination (NDE),
nondestructive inspection (NDI), and
nondestructive evaluation (NDE) are also commonly used to describe this
technology.
Why NDT is needed?
An industrial product is designed to perform a certain function.
The user buys a product with every expectation that it performs the assigned
function well and gives trouble free service for a stipulated period of time.
Most of the machines and systems in the modern day work for example
power plants, chemical and other industrial plants, transport machines etc
are quite complex having thousands of components on which reliable
operation and smooth performance depends.
To ensure the reliability of such machines and the plant as a whole it is
important that each individual component is reliable and performs it s function
satisfactorily for an assigned period of time.
Knowledge of these defects with a view to detect and evaluate them and then minimizing them
in the product is essential to achieve improved or acceptable level of quality.
An improvement in the product quality increases its reliability and in turns the safety of the
machines and equipment, thus bringing economic returns to the user.
Therefore, a need to have method by which the defects in the products can be examined
without affecting their performance
Tests are not made on the objects directly Test are made directly on the object 100%
hence the correlation between the sample testing on actual components is possible
specimen used and objects need to be
proved
A single test may measure only one or a Many NDT methods can be applied on the
few of the properties same part and hence many or all
properties of interest can be measured
1. Visual inspection
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 object
Eddy current Testing
In ECT an alternating current (frequency 1 kHz-2 MHz) is made to flow in a coil
which in turn produces an alternating magnetic field around it.
The coil when brought close to the electrically conducting surface of a metallic
material to be inspected induces an eddy current flow in the material due to
electromagnetic induction. These eddy current are parallel to the coil winding.
The presence of any defect or discontinuity in the material disturbs the eddy
current flow. These eddy current in turn generate an alternating magnetic field
in opposite direction which may be detected either as a voltage across a
second coil or by the perturbation of the impedance of the original coil.
Eddy current testing is particularly well suited for detecting surface cracks Here
a small surface probe is scanned over the part surface in an attempt to detect a
crack.
Ultrasonics
High frequency sound waves are introduced into a material and they are
reflected back from surfaces or flaws.
The transfer of sound from the ultrasonic probe to the component requires a
coupling medium, which is usually water or gel.
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.
Casting Defect
The following are the major defects, which are likely to occur in sand
castings
Gas defects
Shrinkage cavities
Mold shift
Gas Defects
1. blowholes and
2. pinhole porosity.
These appear as rough spots and areas of excess metal, and are caused by
erosion of molding sand by the flowing metal. This is caused by the molding
sand not having enough strength and the molten metal flowing at high velocity.
The former can be taken care of by the proper choice of molding sand and the
latter can be overcome by the proper design of the gating system.
Metal penetration
When molten metal enters into the gaps between sand grains, the result is a
rough casting surface. This occurs because the sand is coarse or no mold wash
was applied on the surface of the mold. The coarser the sand grains more the
metal penetration.
Fusion
This is caused by the fusion of the sand grains with the molten metal, giving a
brittle, glassy appearance on the casting surface. The main reason for this is
that the clay or the sand particles are of lower refractoriness or that the pouring
temperature is too high.
Swell
Weld defect may be in the form of variations from the intended weld bead
shape, size and desired quality. Defects may be on the surface or inside the
weld metal. Certain defects such as cracks are never tolerated but other defects
may be acceptable within permissible limits. Welding defects may result into the
failure of components under service condition, leading to serious accidents and
causing the loss of property and sometimes also life.
Various welding defects can be classified into groups
such as cracks, porosity, solid inclusions,
lack of fusion and inadequate penetration,
imperfect shape and miscellaneous defects.
1. Cracks
Cracks may be of micro or macro size and may appear in the weld metal or
base metal or base metal and weld metal boundary. Different categories of
cracks are longitudinal cracks, transverse cracks or radiating/star cracks and
cracks in the weld crater. Cracks occur when localized stresses exceed the
ultimate tensile strength of material. These stresses are developed due to
shrinkage during solidification of weld metal.
Cracks may be developed
due to poor ductility of
base metal, high sulphur
and carbon contents, high
arc travel speeds i.e. fast
cooling rates, too concave
or convex weld bead and
Fig : Various Types of Cracks in Welds high hydrogen contents in
the weld metal.
2. Porosity
Porosity results when the gases are entrapped in the solidifying weld metal.
These gases are generated from the flux or coating constituents of the
electrode or shielding gases used during welding or from absorbed moisture in
the coating.
Rust, dust, oil and grease present on the surface of work pieces or on
electrodes are also source of gases during welding. Porosity may be easily
prevented if work pieces are properly cleaned from rust, dust, oil and grease.
During arc welding, flux either in the form of granules or coating after
melting, reacts with the molten weld metal removing oxides and other
impurities in the form of slag and it floats on the surface of weld metal
due to its low density. However, if the molten weld metal has high
viscosity or too low temperature or cools rapidly then the slag may
not be released from the weld pool and may cause inclusion.
Slag inclusion can be prevented if all the slag from the previously
deposited bead is removed, too high or too low welding currents are
avoided.
Visual inspection is probably the most widely used among all the non-
destructive tests. It is simple, easy to apply, quickly carried out and usually low
in cost.
A simple visual test can reveal gross surface defect thus leading to an
immediate rejection of the component and consequently saving much time and
money.
In this method direct visual and optically aided inspection is applied to the
surface of object to detect flaws and anomalies.
If significant flaws are detected during visual inspection then the part being
inspected can be rejected on that basis.
BASIC PRINCIPLE
The basic procedure used in visual NDT involves illumination of the test
specimen with light usually in the visible region.
The specimen is then examined with eye or by light sensitive device such as
photocells. The equipment used for visual inspection is extremely simple, but
adequate illumination is absolutely essential.
The human eye is the most frequently used tool for visual inspection. It can be
aided by lenses and magnifiers.
At places where direct vision is not possible boroscopes can be used. The
images can be observed under visible light or ultraviolet light may be used for
fluorescent materials.
Video and film cameras have also been employed for remote visual inspection,
infact liquid penetrant testing and magnetic particle testing are only more
advanced forms of visual inspection.
Defects which can be detected by unaided visual inspection
• The surface porosity, unfilled craters, contour of the weld beads and the
probable orientation of the interface between the fused weld bead and the
adjoining parent metal.
Microscope
Using the equation M=10/f a lens with a focal length of 5” has a magnification of
two or is said to be two power lens (2X).
The focal length of the simple magnifier and its working distance are
approximately the same. The field of view is the area seen through the magnifier.
Depth of field is the term used to indicate the distance a magnifier can be moved
towards or away from a subject remaining in good focus.
Minute defects and details of fine structure on a surface can be detected more
easily with the aid of microscope.
Optical microscope are used to evaluate with respect to shape and orientation of
cracks.
Borescopes
A borescope (Fig.) is a long, tubular optical device that illuminates and allows the
inspection of surfaces inside narrow tubes or difficult-to-reach chambers.
The tube, which can be rigid or flexible with a wide variety of lengths and
diameters, provides the necessary optical connection between the viewing end
and an objective lens at the distant, or distal, tip of the borescope.
By using a tube (normally flexible but also rigid) with a bundle of optical fibers.
By using a tube (normally flexible) with wiring that carries the image signal from a
charge-coupled device (CCD) imaging sensor at the distal tip
A rigid borescope with a lamp at the distal end. (b) A rigid borescope
with a light guide bundle in the shaft
Rigid Borescope
Rigid borescopes are generally limited to applications with a
straight-line path between the observer and the area to be observed.
The sizes range in lengths from 0.15 to 30 m (0.5 to 100 ft) and in diameters
from 0.9 to 70 mm (0.035 to 2.75 in.). Magnification is usually 3 to 4×, but
powers up to 50× are available.
The illumination system is either an incandescent lamp located at the distal tip
end (Fig. a) or a light guide bundle made from optical fibers (Fig. b) that
conduct light from an external source.
Some rigid borescopes have orbital scan (Fig. b), which involves the rotation
of the optical shaft for scanning purposes. Depending on the borescope
model, the amount of rotation can vary from 120 to 360°.
Some rigid borescopes also have movable prisms at the tip for scanning.
Rigid borescopes are available in a variety of models having significant
variations in the design of the shaft, the distal tip, and the illumination system.
Some of these design variations are described below.
Basic Design.
The rigid borescope typically has a series of achromatic relay lenses in the
optical tube. These lenses preserve the resolution of the image as it travels
from the objective lens to the eyepiece.
The lengths of miniborescopes are 110 and 170 mm (4.3 and 6.7 in.),
and the diameters range from 0.9 to 2.7 mm (0.035 to 0.105 in.).
The larger sizes have forward, side view, and forward-oblique views.
The 0.9 mm (0.035 in.) diam size has only a forward view.
Miniborescopes have an integral light guide bundle.
Hybrid borescopes
It utilize rod lenses combined with convex lenses to relay the image. The rod
lenses have fewer glass-air boundaries; this reduces scattering and allows for
a more compact optical guide.
Hybrid borescopes have lengths up to 990 mm (39 in.), with diameters ranging
from 5.5 to 12 mm (0.216 to 0.47 in.).
All hybrid borescopes have adjustable focusing of the objective lens and a
360° rotation for orbital scan.
The various viewing directions are forward, side, retrospective, and forward-
oblique.
Extendable borescopes
It allow the user to construct a longer baroscopic tube by joining extension
tubes.
Scopes with a light guide bundle have a shorter maximum length (about 8 m,
or 26 ft), but do allow smaller tube diameters (as small as 8 mm, or 0.3 in.).
• These devices are designed to provide sharp and clear images of parts and interior
surfaces that are normally impossible to inspect.
• A typical fiberscope (Fig.) consists of a light guide bundle, an image guide bundle, an
objective lens, interchangeable viewing heads, and remote controls for articulation of
the distal tip.
• Fiberscopes are available in diameters from 1.4 to 13 mm (0.055 to 0.5 in.) and in
lengths up to 12 m (40 ft). Special quartz fiberscopes are available in lengths up to
90 m (300 ft).
• The fibers used in the light guide bundle are generally .0254 mm (0.001 in.) in
diameter.
The second optical bundle, called the image guide, is used to carry the image
formed by the objective lens back to the eyepiece. The fibers in the image guide
must be precisely aligned so that they are in an identical relative position to each
other at their terminations for proper image resolution.
The diameter of the fibers in the image guide is another factor in obtaining good
image resolution. With smaller diameter fibers, a brighter image with better
resolution can be obtained by packing more fibers in the image guide.
With higher resolution, it is then possible to use an objective lens with a wider field
of view and also to magnify the image at the eyepiece. This allows better viewing of
objects at the periphery of the image. Image guide fibers range from 6.5 to 17 m
(255 to 670 in.).
A flexible fiberscope with a light source.
ENDOSCOPE
• The endoscope is much like a borescope except that it has a superior
optical system and a high intensity light source.
• Actually when the tip is about 4 mm from the surface being inspected
a magnification factor of about 10x is achieved.
• The process is carried out in two stages. First, a permanent record in the form of a
two dimensional interference pattern is obtained on a photographic plate by means
of a laser beam.
• The three dimensional image is then obtained from the two dimensional record again
using a laser. In this way a picture having a high definition and free from aberration
can be obtained without the use of a camera.
• Holography is used for the NDT of surfaces of highly complicated and precision
components without the disadvantage of having to use a high power microscope.