NDT TECHNIQUES

Agenda :
• Safety Moment
http://www.youtube.com/watch?v=aCx4MfxbOVA

• Introduction
• Presentation Overview
Inspection Means …. what ?
- Formal or official examination
- Physical process of determining compliance
- Examine carefully for accuracy with the
intent of verification
 DIFFERENT MATERIAL TESTING
METHODS
DESTRUCTIVE TESTING METHOD TO EVALUATE MATERIAL
PROPERTIES

HARDNESS TEST IMPACT TEST TENSION TEST

 NON DESTRUCTIVE TESTING
METHODS
THE PROCESS – Determines the Existence of

Flaws
Leak Detection

Discontinuities
Contamination

Dimensional Measurements
Imperfections

Without Impairing The Integrity or Function

 Types
 Working Principle
 Advantages
 Limitations
 TYPES OF NDT METHODS

Visual Testing ( VT )
Penetrant Testing ( PT )
Magnetic Particle Testing ( MPT )
Eddy Current Testing ( ED )
Ultrasonic Testing ( UT )
Radiography Testing ( RT )
REFERENCE CODE

ASME SECTION – V

General Requirements For NDT

Calibration Procedures

TEST Arrangement

Glossary of TERMS involved in each Methods

Div-1 & 2
ASME SECTION – VIII Div-

ACCEPTANCE CRITERIA / LEVEL

 VISUAL TESTING
 Used extensively to evaluate condition or quality.
 Easy to carry out, inexpensive & without special equipment.
 Requires good vision, good lighting and knowledge of what to look
for.
 Inspection can be enhanced by magnifying glasses, video image
scope, boroscopes etc.
 Can be applied when work in process, permitting corrections of
faults, gives indications of incorrect procedure.

LIMITATIONS
 Applicable to surface defects only
 Provides no permanent record
 Should always be the primary method
 LIQUID PENETRANT TESTING

1. ACTION
BASED ON - CAPILLARY ACTION.
2. PENETRANT IS DRAWN OUT OF CRACK BY STRONG TYPICAL TEST SAMPLE
CAPILLARY ACTION OF DEVELOPER. UNDER UV LIGHT

Penetrant is applied Excess dye is removed

Developer applied Visually inspected

 ADVANTAGES LIMITATIONS
1. Relatively simple 1. Only surface breaking defects can be
2. The method has high sensitivity to detected. Surface finish and roughness
small surface discontinuities or can affect inspection sensitivity.
defects. 2. Grinding cracks require longest
3. Large areas and large volumes of penetration time.
parts/materials can be inspected 3. The Penetrant used are flammable &
rapidly and at low cost. can cause skin irritation.
4. Applied to Metallic and nonmetallic, 4. Proper handling precaution is
magnetic and nonmagnetic, and essential.
conductive and nonconductive
materials 5. Post cleaning is necessary.
5. Indications are produced directly on 6. UV Light can cause sunburn and may
the surface of the part and constitute be injurious to eyes.
a visual representation of the flaw.
 MAGNETIC PARTICAL TESTING

1. Encircling an excited coil with an Circular magnetization created

alternating current of given frequency with prods

2. Inducing a flow of eddy current around the

material..
3. The flaw in the material passes through
the coil
4. It causes change in flow of eddy current.
5. Current get leaked
6. At leak point N - S poles formed producing
magnetism.
7. Test specimen attract sprinkled iron
powder.
8. Flaws get detected.
 ADVANTAGES LIMITATIONS
• Used for ferromagnetic materials, heat • Non magnetic materials can’t be tested.
treated cracks. • Demagnetization is must.
• Fillet weld cracks gives sharp • Electrical arching is a hazard as slip of
indications. prods may result in damaging the
• Indications occurred as straight, forked, surface of the part.
or curved.

• Normally used for finished machine

articles.
 EDDY CURRENT TESTING

• An electromagnetic technique.
• Used only on conductive materials.
• An energized coil is brought near to
surface of component to be inspected.
• Eddy current is induced.
• Current set up magnetic field to oppose
natural magnetic field.
• Current is disturbed in presence of flaws
• Impedance in the coil is altered.
• Change is measured and displayed in a
manner that indicates the type of flaw or
material condition.
ADVANTAGES DISADVANTAGES
• Sensitive to small cracks and other • Only conductive materials inspected
defects • Skill and training required is more
• Detects surface and near surface extensive than other techniques
defects • Surface finish and roughness may
interfere
• Equipment is very portable • Reference standards needed for
• Method can be used for much more setup
than flaw detection • Depth of penetration is limited
• Minimum part preparation is required
• Test probe does not need to contact
the part
• Inspects complex shapes and sizes of
conductive materials
 ULTRASONIC TESTING

A) Based on transmission of acoustic waves

into material under examination.
B) The Piezo electric quartz crystal as a
source.
C) Converts electrical pulse into mechanical
vibration or waves.
D) Waves travel across the specimen.
E) Reflect from flaws because of their
different acoustic nature.
F) The returning waves are reconverted to
electrical energy
G) And display a signal on a (CRT).
 FLAW DETECTION METHODS

THROUGH--TRANSMISSION
THROUGH

1. Two Transducers.

2. One as a transmitter & other as a

receiver.

3. Two transducers are located on opposite

sides of the test part..

PULSE ECHO

1. One transducer

2. Serve as a transmitter and receiver.

3. Test can be conducted even when there

is access to only one side.
ADVANTAGES
DISADVANTAGES
 It is sensitive to both surface and
subsurface discontinuities.  Surface must be accessible to
transmit ultrasound.
 The depth of penetration for flaw
detection or measurement is superior  Skill and training is more extensive
to other NDT methods. than with some other methods.
 Only single-sided access is needed  Materials that are rough, irregular in
when the pulse-echo technique is shape, very small, exceptionally thin
used. or not homogeneous are difficult to
inspect.
 It is high accuracy in determining
reflector position and estimating size  Cast iron and other coarse grained
and shape. materials are difficult to inspect due to
low sound transmission and high
 Minimal part preparation required. signal noise.
 Electronic equipment provides  Linear defects oriented parallel to the
instantaneous results. sound beam may go undetected.
 Established standards used to give  Reference standards are required for
reproducible and reliable results. both equipment calibration, and
 It has other uses such as thickness characterization of flaws.
measurements, in addition to flaw
detection.
 RADIOGRAPHY TESTING

I. Penetration and absorption capabilities of X - rays

& Gamma rays.
II. Used to test products such as welds, castings,
forgings and fabrications.
III. Passing through matter the amount of energy
absorbed at any point.
IV. Energy absorbed depends upon thickness &
density at that point.
V. When variation is detected it gets recorded on a
film.
VI. When film is processed latent image produced on
the film becomes a shadow picture.

CHARACTERISTIC OF RAYS

• They travel at the velocity of light. (~3 x 108

m/s)
• They travel in straight lines.
• Not affected by magnetic field.
• Expose photographic film. Penetration Ability
• They differ from light rays by their
Selection of source
As a general practice
• Upto 12mm thk use X rays.
• Upto 70mm thk use Cobalt 60
• Above 70mm thk either Cobalt 60 or IR 92

ADVANTAGES LIMITATIONS
Can be used with most of the materials. Specimens of complex geometry.
Provides permanent visual image. Safety consideration imposed by X and
Revels the internal nature of material. Gamma rays .
Discloses fabrication errors. Relatively expensive
Revels structural discontinuities Skill and trained person required
 WELD DEFECTS

Cold lap is a condition where the weld filler metal does not
properly fuse with the base metal or the previous weld pass
material. The arc does not melt the base metal sufficiently
and causes the slightly molten puddle to flow into base
material without bonding

Porosity is the result of gas entrapment in the solidifying metal.

Can take many shapes but often appears as dark round or
irregular spots. Sometimes porosity is elongated and may have
the appearance of having a tail. This is the result of gas
attempting to escape while the metal is still in a liquid state and
is called wormhole porosity .

Slag inclusions are nonmetallic solid material entrapped in

weld metal or between weld and base metal. In a radiograph,
dark, jagged asymmetrical shapes within the weld or along the
weld joint areas are indicative of slag inclusions.
Incomplete penetration (IP) or lack of penetration (LOP)
occurs when the weld metal fails to penetrate the joint. Lack
of penetration allows a natural stress riser from which a crack
may propagate. The appearance on a radiograph is a dark
area with well-defined, straight edges that follows the land or
root face down the center of the weldment .

Cracks can be detected in a radiograph only when they

are propagating in a direction that produces a change in
thickness that is parallel to the X-ray beam. Cracks will
appear as jagged and often very faint irregular lines.
Cracks can sometimes appear as "tails" on inclusions or
porosity.

Offset or mismatch - a condition where two pieces

being welded together are not properly aligned. The
radiographic image is a noticeable difference in density
between the two pieces. The difference in density is
caused by the difference in material thickness. The dark,
straight line is caused by failure of the weld metal to fuse
with the land area.
 NEW DEVELOPED NDE
TECHNIQUES
TOFD (Time Of Flight Diffraction)
- Kobe Steel has developed the new automatic UT technique using
TOFD (Time of Flight Diffraction) method.
- Useful for inspection of welds of heavy wall pressure vessels in
lieu of RT
- ASME Code Case 2235 permits automatic UT in lieu of RT.
- The technique consists of a separate ultrasonic transmitter and
receiver.
- After emission of a compressed wave from a transmitter, the first
signal to arrive at the receiver is lateral wave through upper surface.
In the absence of defects the second signal to arrive at the receiver
is the backwall echo.
- The diffracted signal generated at the upper tip of a defect will
arrive before the signal generated at the lower tip of a defect.
- With a time of flight of each flight path, the ultrasonic velocity and
the spatial relationships of the two probes, location and height of
defects can be very accurately calculated.

Features of TOFD :
1.High Probability of Flaw Detection
2.High Accuracy of Flaw Location Measurement
3.High Accuracy of Flaw Sizing in Length
4.Weld Integrity to be observed on CRT in Real Time as probes scan
5.All inspection Data to be Digitized and Stored so that the Data can
be Recalled and Processed for In-Service Inspection
TOFD (Time Of Flight Diffraction) VS Radiography

TOFD is superior in terms of the following compared with RT.

For RT - Set or Create temporary

RT room every time. Films shall
be protected always from any
direct exposure.
On the other hand TOFD can
apply at every place in the shop.
Lesser impact on the fabrication

Measurement Length (mm)

schedule.
Thickness (mm) Actual Length(mm)

Detection Rate of Defects Measurement accuracy by TOFD

 SELECTION CRITERIA

COST
TYPE & ORIGIN OF DISCONTINUITY

MANUFACTURING PROCESS

ACCESSIBILITY OF ARTICLE

LEVEL OF ACCEPTABILTY DESIRED

EQUIPMENT AVAILABILITY FOR TESTING

 ASME CODE REQUIREMENT –
ASME Section Div-1 & 2
Section VIII Div-

ASME SEc VIII Div.

ASME-VIII DIV 1-
page 138-170-232
2 NDE
THANK YOU