The document provides an overview of non-destructive testing including common methods like visual inspection, liquid penetrant, magnetic particle, ultrasonic, eddy current, and x-ray testing. It discusses applications of NDT in various industries like aircraft, pipelines, and bridges to inspect for flaws and ensure safety.
The document provides an overview of non-destructive testing including common methods like visual inspection, liquid penetrant, magnetic particle, ultrasonic, eddy current, and x-ray testing. It discusses applications of NDT in various industries like aircraft, pipelines, and bridges to inspect for flaws and ensure safety.
The document provides an overview of non-destructive testing including common methods like visual inspection, liquid penetrant, magnetic particle, ultrasonic, eddy current, and x-ray testing. It discusses applications of NDT in various industries like aircraft, pipelines, and bridges to inspect for flaws and ensure safety.
The document provides an overview of non-destructive testing including common methods like visual inspection, liquid penetrant, magnetic particle, ultrasonic, eddy current, and x-ray testing. It discusses applications of NDT in various industries like aircraft, pipelines, and bridges to inspect for flaws and ensure safety.
Testing The use of noninvasive techniques to determine the integrity of a material, component or structure or quantitatively measure some characteristic of an object. i.e. Inspect or measure without doing harm. Definition of NDT Methods of NDT
Visual What are Some Uses of NDE Methods? Flaw Detection and Evaluation Leak Detection Location Determination Dimensional Measurements Structure and Microstructure Characterization Estimation of Mechanical and Physical Properties Stress (Strain) and Dynamic Response Measurements Material Sorting and Chemical Composition Determination
Fluorescent penetrant indication When are NDE Methods Used? To assist in product development To screen or sort incoming materials To monitor, improve or control manufacturing processes To verify proper processing such as heat treating To verify proper assembly To inspect for in-service damage There are NDE application at almost any stage in the production or life cycle of a component. Six Most Common NDT Methods Visual Liquid Penetrant Magnetic Ultrasonic Eddy Current X-ray
Most basic and common inspection method.
Tools include fiberscopes, borescopes, magnifying glasses and mirrors. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Visual Inspection 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. Liquid Penetrant Inspection Magnetic Particle Inspection 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. Magnetic Particle Crack Indications Radiography The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source. High Electrical Potential Electrons - + X-ray Generator or Radioactive Source Creates Radiation Exposure Recording Device Radiation Penetrate the Sample Film Radiography Top view of developed film X-ray film 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. = more exposure = less exposure The film darkness (density) will vary with the amount of radiation reaching the film through the test object. Radiographic Images Conductive material Coil Coil's magnetic field Eddy currents Eddy current's magnetic field Eddy Current Testing Eddy Current Testing Eddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface in an attempt to detect a crack. 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. f plate crack 0 2 4 6 8 10 initial pulse crack echo back surface echo Oscilloscope, or flaw detector screen Ultrasonic Inspection (Pulse-Echo) Ultrasonic Imaging Gray scale image produced using the sound reflected from the front surface of the coin Gray scale image produced using the sound reflected from the back surface of the coin (inspected from heads side) High resolution images can be produced by plotting signal strength or time-of-flight using a computer- controlled scanning system. Common Application of NDT Inspection of Raw Products Inspection Following Secondary Processing In-Services Damage Inspection Inspection of Raw Products Forgings, Castings, Extrusions, etc. Machining Welding Grinding Heat treating Plating etc. Inspection Following Secondary Processing Cracking Corrosion Erosion/Wear Heat Damage etc. Inspection For In-Service Damage Power Plant Inspection Probe Signals produced by various amounts of corrosion thinning. Periodically, power plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage. Pipe with damage Wire Rope Inspection Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices. Storage Tank Inspection Robotic crawlers use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion. Cameras on long articulating arms are used to inspect underground storage tanks for damage.
Aircraft Inspection Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below. Jet Engine Inspection Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassembled. Fluorescent penetrant inspection is used to check many of the parts for cracking. Sioux City, Iowa, July 19, 1989 A defect that went undetected in an engine disk was responsible for the crash of United Flight 232. Crash of United Flight 232 Pressure Vessel Inspection The failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, the tanks are inspected using radiography and ultrasonic testing. Rail Inspection Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment. Bridge Inspection The US has 578,000 highway bridges. Corrosion, cracking and other damage can all affect a bridges performance. The collapse of the Silver Bridge in 1967 resulted in loss of 47 lives. Bridges get a visual inspection about every 2 years. Some bridges are fitted with acoustic emission sensors that listen for sounds of cracks growing.
NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used. Remote visual inspection using a robotic crawler. Radiography of weld joints. Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported. Pipeline Inspection Special Measurements Boeing employees in Philadelphia were given the privilege of evaluating the Liberty Bell for damage using NDT techniques. Eddy current methods were used to measure the electrical conductivity of the Bell's bronze casing at various points to evaluate its uniformity. RADIOGRAPHY Sub assembly Components: The sub assembly coach components fabricated by fillet welding are taken radiographs, where the load acting areas as prescribed by the relevant drawing and suspected weld area during visual inspection. MARKING OF RADIOGRAPHIC LOCATION, DIRECTION OF WELD BEAD AND PLACING OF PENETROMETER PLACING OF LOADED RADIOGRAPHIC FILM PLACING OF LEAD SHEET TO AVOID SCATTER RADIATION Sub-assembly Components T1 B1 T2 B2 T2 T1 B2 B1 RADIOGRAPHIC STANDARDS FOR EVALUATION OF WELD DEFECTS. 1. IIW Standard:
THERE ARE FIVE IIW STANDARDS
BLACK DEFECT FREE
BLUE VERY SLIGHT IMPERFECTIONS AS REGARDS HOMOGENITY IN THE FORM OF ONE OR MORE OF THE FOLLOWING DEFECT GAS CAVITY, SHRINKAGE CAVITY, SLAG INCLUTION AND UNDER CUT.
Two type of standards are generally used for evaluation 1. IIW standard 2. ASTM standard IIW RADIOGRAPHIC STANDARDS FOR EVALUATION OF WELD DEFECTS. GREEN SLIGHT IMPERFECTIONS AS REGARDS HOMOGENITY IN THE FORM OF ONE OR MORE OF THE FOLLOWING DEFECT GAS CAVITY, SHRINKAGE CAVITY, SLAG INCLUSION, UNDER CUT AND INCOMPLETE PENETRATION.
BROWN MARKED IMPERFECTIONS AS REGARDS HOMOGENITY IN THE FORM OF ONE OR MORE OF THE FOLLOWING DEFECT GAS CAVITY, SHRINKAGE CAVITY, SLAG INCLUSION, UNDER CUT, INCOMPLETE PENETRATION AND FUSION DEFECT. RADIOGRAPHIC STANDARDS FOR EVALUATION OF WELD DEFECTS. RED GROSS IMPERFECTIONS AS REGARDS HOMOGENITY IN THE FORM OF ONE OR MORE OF THE FOLLOWING DEFECT GAS CAVITY, SHRINKAGE CAVITY, SLAG INCLUTION, UNDER CUT, INCOMPLETE PENETRATION, FUSION DEFECT AND CRACK
IIW BLUE STANDARD IS FOLLOWED AT ICF WITH ACCEPTANCE CRITERIA TO ICF SPECIFICATION NO.ICF/M&C/SPEC/010
RADIOGRAPHIC STANDARDS FOR EVALUATION OF WELD DEFECTS. RCF is using ASTM Standards for Radiographic evaluation.
Specified Welding defects level as per ASTM E- 390 Vol-II
Shrinkage /Crack of any kind are not allowed Lack of Fusion is not allowed Incomplete Penetration is allowed up to level-II Burn through is not allowed Undercut is allowed upto level-IV Slag Inclusion is allowed up to Level-III Porosity Coarsed scattered Porosity is allowed upto level-II Fine scattered Porosity is allowed up to Level-IV
Cluster Porosity is allowed up to Level-III Elongated Porosity is not allowed
RADIOGRAPHIC STANDARDS FOR EVALUATION OF CAST DEFECTS Specified Casting defects level as per ASTM E- 446 The castings should be significantly free from harmful casting defects like :
Shrinkage /Crack Sand and Slag inclusions Gas porosity or blow holes etc
For More Information on NDT The Collaboration for NDT Education
www.ndt-ed.org The American Society for Nondestructive Testing
