The document discusses non-destructive testing methods. It focuses on penetrant inspection and magnetic particle inspection. Penetrant inspection uses liquid penetrants and developers to reveal surface defects through capillary action. Magnetic particle inspection uses magnetization and iron particles to detect subsurface flaws by visualizing disruptions in the magnetic field at defect locations. Both methods are useful for examining materials and components without damaging them.
The document discusses non-destructive testing methods. It focuses on penetrant inspection and magnetic particle inspection. Penetrant inspection uses liquid penetrants and developers to reveal surface defects through capillary action. Magnetic particle inspection uses magnetization and iron particles to detect subsurface flaws by visualizing disruptions in the magnetic field at defect locations. Both methods are useful for examining materials and components without damaging them.
The document discusses non-destructive testing methods. It focuses on penetrant inspection and magnetic particle inspection. Penetrant inspection uses liquid penetrants and developers to reveal surface defects through capillary action. Magnetic particle inspection uses magnetization and iron particles to detect subsurface flaws by visualizing disruptions in the magnetic field at defect locations. Both methods are useful for examining materials and components without damaging them.
The document discusses non-destructive testing methods. It focuses on penetrant inspection and magnetic particle inspection. Penetrant inspection uses liquid penetrants and developers to reveal surface defects through capillary action. Magnetic particle inspection uses magnetization and iron particles to detect subsurface flaws by visualizing disruptions in the magnetic field at defect locations. Both methods are useful for examining materials and components without damaging them.
such a way that allows material to be examinated without changing or destroying their usefulness NDT Methods • Penetrant Inspection • Magnetic Particle Inspection • Eddy Current Inspection • Ultrasonic Inspection • Radiographic Inspection
• Applicable to all non-porous, non-absorbing materials Penetrant Inspection • Penetrating fluid applied to component and drawn into defect by capillary action
• Penetrating fluid removed from component
surface (but not from defect) Penetrant Inspection •Developer applied to surface
•Penetrant drawn back out of the defect
by reverse capillary action Principle : Capillary Action • Interaction of adhesive forces(wetting side of the sides of the tubes) and cohesive forces(surface tension of the liquid) 1. PREPARATION AND PRE-CLEANING 2. PENETRANT APPLICATION
3. REMOVAL OF EXCESS PENETRANT
4. DEVELOPING 5. INSPECTION 6. POST TEST CLEANING What will happen if cleaning is not been done properly ?
•The penetrant is not be able to wet the surface
of the test object
•The penetrant is unable to enter a discontinuity
due to a blockage
•The bleed out of the penetrant from a discontinuity
is restricted CLEANING METHODS
MECHANICAL METHODS CHEMICAL METHODS
E.G BRUSHING,BLASTING E.G HOT SOLVING DEGREASING,ACID PICKLING System classification • PENETRANT • REMOVAL • DEVELOPERS • Colour • Solvent • Dry powder contrast • Water • Aqueous • Fluorescent washable • Non-Aqueous • Dual • Post emulsifiable TYPE OF PENETRANT
• COLOUR CONTRAST PENETRANT
• FLOURESENT PENETRANT
•DUAL PENETRANT APPLICATION OF PENETRANT
• DIPPING AND DRAINING
• SPRAYING • ELECTO-STATIC SPRAY • BRUSHING Qualities of penetrant • High surface tension • Good wetting ability • Specific gravity lower than 1 • Penetrant will not damaged the test piece • Non-toxic • High flash point • Low volatility • Visible in small quantities • Post -cleaning should be easy PENETRANT DESCRIPTION ADVANTAGES DISADVANTAGES REMOVAL
SOLVENT 1. CLEANED WITH A 1. PORTABILITY 1. EXPENSIVE
LINT FREE RAG 2. NO WATER SUPPLY REQUIRED 2. NOT SUITED TO BATCH INSPECTIONS
3. HAZARDOUS
WATER 1. CONTAIN 1. USEABLE ON ROUGH 1. EASY TO OVER WASHING
WASHING EMULSIFIER SURFACES 2. LEAST SENSITIVE METHOD 2. WASH BY 2. SUITABLE FOR BATCH COARSE WATER INSPECTION 3. REQUIRED WATER SOURCE
3. CHEAPER
POST 1. NEED TO APPLY 1. USED ON HIGH STRESS 1.EMULSIFICATION TIME IS
EMULSIFIEERS/ THE EMULSIFIER CRITICAL PARTS CRITICAL LIPOPHILIC 2. WATER SUPPLY ALSO REQUIRED
HYDROPHILLIC 1. ASLO KNOWN AS 1. MAIMUM PENETRATING ABILITY 1. NOT SUITED TO ROUGH
DETERGENTS SURFACE REMOVER 2. GREATER CONTROL OVER PENETRANT REMOVAL 2. MORE EXPENSIVE 2. WATER SUPPLY ALSO REQUIRED 3. EMULSIFICATION TIME NOT SO 3. MORE TIME CONSUMING CRITICAL
4. WIDE SHALLOW DEFECTS
ESSENTIAL FEATURES OF DEVELOPER • ABSORBENT TO DRAW PENETRANT OUT OF DEFECT
3. EASY TO REMOVE BUT DIFFICULT TO SEE IF PROPERLY APPLIED
4. FINE POWDERS CAN BE HAZARDOUS
SOLVENT 1. OFTEN BE CALLED NON-AQUEOS DEVELOPER
SUSPENDIBLE 2. IT IS A SUSPENSION OF INERT WHITE POWDER IN A VOLATILE SOLVENT
3. THE SOVENT EVAPORATES LEAVING A FINE WHITE BACKGROUND
4. MOST SENSITIVE
WATER 1. IT IS A WHITE POWDER AND THEN MIXED WITH WATER IN SUFFACTANT ADDED SUSPENDIBLE 2. NOT OFTEN BE USED
3. THE POWDER WILL DRAWS THE PENETRANT OUT OF DEFECT WHEN THE WATER EVAPORATES
4. USE AS IN CONCENTRATED IN COLOUR CONTRAST PENETRANT, THINNER FORM IN
FLOURESENT
WATER 1. SOLUTION OF SALTS IN FORMS OF FINE GRANULES WHICH DISSOLVED IN WATER
SOLUBLE 2. SUITABLY FOR FLUORESCENT PENETRANT Advantages of DPI • VERY SENSITIVE • CAN BE USED ON NON-FERROUS METALS, SOME PLASTICS AND GLASS • SMALL OBJECTS WITH COMPLEX GEOMETRY CAN BE INSPECTED • NO NEED POWER SUPPLY • NOT REQUIRED GREAT SKILLED • CAN BE APPLIED IN BATCHES Disadvantages of DPI • DEFECTS OPEN TO THE SURFACE ONLY CAN BE DETECTED
• SURFACE PREPARATION IS CRITICAL
• THE METHOD TAKES TIME
• MESSY
• INTERPRETATION SOMETIMES DIFFICULT
• DO NOT APPLIED TO PAINTED OBJECTS
• EFFLUENT PROBLEM WITH WASTE
Magnetic Particle Inspection Magnetic Particle Inspection • Test method for the detection of surface and sub-surface indications in ferromagnetic materials • Magnetic field induced in component • Defects disrupt the magnetic flux • Defects revealed by applying ferromagnetic particles PRINCIPLE OF MPI • MAGNETIZING THE SPECIMEN TO AN ADEQUATE FLUX DENSITY
• APPLYING FINE FERROMAGNETIC PARTICLES
OVER THE SURFACE OF THE SPECIMEN
• BEING ABLE TO SEE CLUSTERS OF THE
MAGNETIC PARTICLES THAT GATHER AT FLUX LEAKAGES AS AN INDICATION TO THE FLAW Principle of MPI(1) : Flux Leakage No Defect Defect
N S N S
Lines of flux follow the path of least resistance
PRINCIPLE OF MPI(2):FLUX LEAKAGE
• The magnetic flux lines IDEALLY at the
right angle(90°) to a flaw to give the best indication. • The minimum orientation of the flaws to the magnetic flux to be detected is 45 degree Magnetic Flux Leakage • A saturation of flux is introduced
N S Magnetic Flux Leakage • A saturation of flux is introduced • Flux forced into air by reductions in thickness
N S Magnetic Flux Leakage • A saturation of flux is introduced • Flux forced into air by reductions in thickness • Magnetic flux detected by sensors
Sensor
N S Magnetic Flux Leakage Affected by • Climatic conditions • Cleanliness • Surface condition Limitations • Coverage • Qualitative not Quantitative • Top side / Bottom side differentiation • PRECLEANING • MAGNETISATION • APPLYING THE DETECTING MEDIA • INSPECTION • DEMAGNETISATION • POST-TEST CLEANING PRE-CLEANING
•NOT BE SO THROUGHT AS FOR LIQUID
PENETRANT INSPECTION •MPI SHOULD NOT BE CARRIED OUT THROUGHT NON-MAGNETIC COATING THICKER THAN 50 MICROMETERS TYPE OF MAGNETIZATION CHARACTERESTICS DIRECTION . 1 PERMANENT MAGNET 1. PORTABLE, NO NEED ELECTRISITY LONGITUDINAL 2. NEED A GOOD CONTACT
2. ELECTRO MAGNETIC 1. PORTABLE, EASY TO USE, CHEAP LONGITUDINAL
2. OPERATED BY AC OR DC YOKE 3. AC DEMAGNETISATION
3. CURRENT FLOW PRODS 1. OPERATED BY AC CIRCULAR
2. CAN BE USED LARGE AND COMPLEX SHAPE 3. PROBLEM WITH ARCING
4.FLEXIBLE COIL 1. WRAPPING A CABLE THROUGH THE LONGITUDINAL
COMPONENTS AND PASSING A N AC OR DC CURRENT
5. FLEXIBLE CABLE 1. CABLE IS PLACED PARALLEL TO THE LONGITUDINAL
WELD, AC IS PASSED THROUGH THE CABLE
6. CURRENT FLOW 1. TEST BENCH CIRCULAR
2. COMPONENT IS HELD BETWEEN TWO CLAMPED 3. CURRENT IS PASSED THROUGH THE COMPONENT
7. THREADING BAR 1. TEST BEACH CIRCULAR
2. NONMAGNETIC CONDUCTOR IS PASSED THROUGH HOLLOW TUBES ON RING
8. MAGNETIC FLOW 1. SUITABLE FOR SHORT STUBBY LONGITUDINAL
COMPONENT 2. COMPONENT IS HELD BETWEEN TWO CLAMPED 3. MAGNETIC IS PASSED THROUGH CLAMPED DETECTING MEDIA • CAN BE INKS OR POWDER • MADE FROM HIGHLY PERMEABLE MATERIAL • FERRIC OXIDE IS USED FOR INKS,SUSPENDIBLE IN LIQUID,KEROSINE BASED OR WATER • POWDERS APPLICABLE TO SITE WORK SUCH AS WELD OR CASTING.CAN BE USED ON HOT COMPONENTS CONTROL CHECKS BLACK LIGHT CASTROL STRIPS/ PIE GAUGE
U.V LIGHT METER
FIELD INDICATOR
KETOS RING CENTRIFUGAL TUBES CONTROL CHECK DURATION REQUIREMENT CHECK LIST 1.25-3.5% NON-FLOURESENT DAILY INK SETTELEMENT 0.1-0.3 % FLOURESENT
FLOURESENT INK INTENSITY DAILY COMPARISON BETWEEN NEW
AND OLD ONE
COMPARISON BETWEEN NEW
CARRIER LIQUID CHECKED DAILY AND OLD ONE
CURRENT FLOW FACILITY DAILY DEPENDING ONPROCEDURE
MAGNETIC FLOW FACILITY DAILY DEPENDING ONPROCEDURE
TANK LEVEL DAILY DEPENDING ONPROCEDURE
UV LIGHT INTENSITY WEEKLY 0.8 MILIWATTS/ SQUARE CM
500 LUX BLACK INK
AMBIENT LIGHT INTENSITY WEEKLY 10 LUX FLOURESENT
U.V LIGHT LAMP MONTHLY SAFETY AND CLEANLINESS
Advantages of MPI • Will detect some sub-surface defects • Rapid and simple to understand • Pre-cleaning not as critical as with DPI • Will work through thin coatings • Cheap rugged equipment • Direct test method Disadvantages of MPI • Ferromagnetic materials only • Requirement to test in 2 directions • Demagnetisation may be required • Odd shaped parts difficult to test • Not suited to batch testing • Can damage the component under test Ultrasonic Inspection Principle • High frequency sound sound waves are introduced into a material • Interfaces between materials of differing acoustic properties reflect or transmit sound • Reflected sound is displayed on a CRT Defect Orientation 0 degree Probes
Screen
Depth Metal
Depth Defect Orientation Angle Probes
Range
Range Depth = Range x Cos (Probe angle) Defect Orientation
1 2 3 Advantages • Sensitive to cracks at various orientations • Portability • Safety • Able to penetrate thick sections • Measures depth and through wall extent Disadvantages • No permanent record (unless automated) • Not easily applied to complex geometries and rough surfaces. • Unsuited to course grained materials • Requires highly skilled and experienced technicians Radiographic Inspection • Electromagnetic radiation is imposed upon a test object • Radiation is transmitted to varying degrees dependant upon the density of the material through which it is travelling • Variations in transmission detected by photographic film or fluorescent screens • Applicable to metals,non-metals and composites Radiographic Inspection Radiation Source
Lower Higher density density
Specimen
Film Industrial radiography Electric Microwaves Waves Ultra Infra red violet TV
10-10 10-8 10-6 10-4 10-2 1cm 102 104 106 108
Wavelength Shorter Wavelength = Increased Energy
Shortening Wavelength X-Ray Production
TUNGSTEN
C TARGET U R R -ve +ve E N T FOCUSING CUP X-RAY X-RAY PRODUCTION • CATHODE • ANODE 1. PROCESS THAT MAKE THE 1. INCLINED TUNGSTEN TARGET ELECTRON BOILS OUT FROM EMBEDDED IN A LARGE LUMP THE HOT WIRE IS CALLED OF COPPER THERMIONIC EMISSION 2. USED AS A TARGET FOR THE 2. IT IS CONTROLLED BY THE ELECTRON TO HIT,AND THE MILIAMP CONTROL THAT IMPACT WILL PRODUCE X-RAYS SUPPLY CURRENT TO THE AND HEAT. CATHODE 3. VOLTAGE THAT SUPPLY TO THE 3. INCREASED THE CURRENT, WILL ANODE IS CONTROLED BY THE INCREASED THE INTENSITY OF kV CONTROL. THE ELECTRON STREAM AND HENCE THE RADIATION 4. THE HIGHER THE VOLTAGE ACROSS THE TUBE,THE HIGHER THE VELOCITY OF THE ELECTRONS AND THE GREATER THE PENETRATING POWER X-Ray Production Amperage
Increase Decrease
Increase filament Decrease filament
temperature temperature
Increase number of Decrease number of
electrons electrons
Increase amount Decrease amount of
of radiation radiation X-Ray Production Kilovoltage
Increase Decrease
Increase electron speed Decrease electron speed
Radiation wavelength Radiation wavelength
shortens increases
Increase penetration Decrease penetration
Factors Influencing Sensitivity Sensitivity - MEASURE OF ACCURANCY OF THE RADIOGRAPHY
Contrast Definition - LINE OF DEMARCATION - COMPARISON BETWEEN AREAS OF BETWEEN FILM DIFFERENT DENSITIES DENSITIES Factors Influencing Sensitivity Sensitivity
• CALCULATE USING PENETRAMETER OR IMAGE QUALITY INDICATION (IQI) Advantages of Radiography • Permanent record • Internal flaws • Can be used on most materials • Direct image of flaws • Real - time imaging Disadvantages of Radiography • Health hazard • Sensitive to defect orientation • Limited ability to detect fine cracks • Access to both sides required • Limited by material thickness • Skilled interpretation required • Relatively slow • High capital outlay and running costs Radioactive isotope • It is small,typically 1mm x 1.5 mm cylinders,that give off gamma rays • It occurs in nature and also in artificial isotopes • Artificial isotopes are created by bombarding an element with an excess of neutron in the nuclear reactor. • Example of nature isotopes are radium and uranium • Example of artificial isotopes are iridium 192 and cobalt 60 MEASUREMENT OF RADIOACTIVITY • THE BASIC UNIT IS CURIE • IN SI UNIT, IT IS MEASURED IN BECQUEREL • 1 CURIE = 3.7 X 1010 BECQUERELS • HALF LIFE OF AN ISOTOPE IS THE TIME IT TAKES FOR 1/2 OF THE ATOMS TO DECAY CALCULATE THE EXPOSURE TIME FOR GAMMA RADIOGRAPHY
• BY USING THE FORMULA BELOW ;
T = EF X D 2 I T = EXPOSURE TIME,SEC D = SOURCE TO FILM DISTANCE,IN I = INTENSITY OF THE SOURCE,CURIE EF = EXPOSURE FACTOR, REFER TO THE EXPOSURE CHART ISOTOPE CAMERA OR PROJECTOR
OPERATION OF A TYPICAL ISOTOPE CAMERA SAFE DISTANCE GIVEN BY THE FORMULA BELOW:
= CURIES X4.8X 1000 1/2
7.5 THIS GIVES DISTANCE IN METERS
• BARRIERS MUST BE ERECTED
BEYOND THE SAFE DISTANCE RADIOGRAPHIC FILM • IT HAS TWO TYPES BASICALLY: SLOW FILM - FINE GRAIN AND NEED MORE EXPOSURE FAST FILM - LARGE GRAINS AND NEED LESS EXPOSURE
• KNOWLEDGE OF FILM CAN HELPS THE RADIOGRAPHER
TO WORK OUT EXPOSURES WHEN CHANGING FILM BRANDS. E.G IN TABLE 5.3
• FILM ALSO SHOULD BE STORED IN EDGES IN COOL DRY
CONDITIONS AWAY FROM CHEMICALS AND RADIATION Radiographic Techniques • Single Wall Single Image(SWSI) • Double Wall Single Image(DWSI) • Double Wall Double Image(DWDI) Radiographic Techniques • Single Wall Single Image(SWSI)
Panoramic Radiographic Techniques • Single Wall Single Image(SWSI) • Double Wall Single Image(DWSI) Radiographic Techniques • Single Wall Single Image(SWSI) • Double Wall Single Image(DWSI) • Double Wall Double Image(DWDI) OFFSET
OFFSET RADIOGRAPHIC FILM
THREE LAYERS •PROTECTIVE LAYER • SILVER BROMIDE WILL EXPOSED AND TURN THE LAYER OF GELATIN PROTECTS THE FILM INTO BLACK EMULSION LAYER FROM SCRACTHES •THE IMAGE IS LATENT EXPOSED AND NO VISIBLE CHANGE •EMULSION LAYER IN FILM WOULD BE SUSPENDED IN IT THE SILVER NOTICEABLE UNTER BROMIDE.. DEVELOPMENT •TRANSPARENT POLYSESTER BASE OF RADIOGRAPHY DEVELOPER STOP BATH ALKALINE BASED . ACIDIC BASED 20°C -SWEELS THE EMULSION ,THUS •REMOVES ALL UNEXPOSED SILVER ALLOWING THE DEVELOPING AGENT TO GRAINS INTERACT WITH EXPOSED GRAINS •HARDENS THE EMULSION GELATIN -CHANGED THE EXPOSED SILVERS SALT TWICE CLEARING TIME TO BLACK METALLIC SILVER 5 TO 8 MINUTES 20°C
-ACIDIC BASED WARM,FILTERED, REDUCES SURFACES TENSION. -STOPS THE DEVELOPING CIRCULATING AIR ELIMINATES MOST ACTION AND NEUTRALIZE THE DRIES THE FILM WATER AND SPOTS ALKALINE DEVELOPER 30 TO 45 MIN 0.5 TO 1 MIN 1TO 2 MINUTES 20°C
DRYING WETTING FIXING
Advantages of Gamma over X rays • No electrical or water supplies needed • Equipment smaller and lighter-More portable • Equipment simpler and more robust • More easily accessed • Less scatter • Equipment initially less costly • Greater penetrating power Disadvantages of Gamma over X rays • Poorer quality radiographs • Exposure times can be longer • Sources need replacing • Radiation cannot be switched off • Poorer geometric unsharpness • Remote handling necessary Radiographic Image
