Non destructive testing

Non-Destructive testing is the use of noninvasive techniques to

determine the integrity of a material, component or structure or
quantitatively measure some characteristics of an object.
It is testing of material for surface or internal flaw, metallurgical
condition, without interfering in any way with the integrity of the
material or its suitability for service. i.e.Inspect or measure without
doing harm.It is a highly valuable technique that can save both money
and time in product evaluation, trouble shooting.It is very difficult to
weld or mold a solid object that has the risk of breaking in service, so
testing at manufacture and during use is often essential. During the
process of casting a metal object, for example, the metal may shrink
as it cools, and crack or introduce voids inside the structure. During
their service lives, many industrial components need regular
nondestructive tests to detect damage that may be difficult or
expensive to find by everyday
 Importance of NDT
1. NDT increases the safety and reliability of the product
during operation.
2. It decreases the cost of the product by reducing scrap and
conserving materials, labor and energy.
3. It enhances the reputation of the manufacturer as a producer of
quality goods. All of the above factors boost the sales of the
product whichbring more economical benefits for the
manufacturer.
4. NDT is also used widely for routine or periodic determination of
quality of the plants and structures during service.
5. This not only increases the safety of operation but also eliminates
any forced shut down of the plants.
 Methods of NDT
Ma
gne
tic
Aco Me
u stic asu
rem
ent
Mic s
rosc
opy
Visual

ultr
as oni
Magnetic particle cs
rren t
y Cu
d
Ed

Acoustic Emission
s
ray
X
 Common NDT Methods
1. Visual Testing (VT)
2. Atomic Emission Testing (AMT)
3. Dye Penetrant Testing (DPT)
4. Magnetic Particle Testing (MPT)
5. Ultrasonic Testing (UT)
6. Eddy Current Testing (ECT)
7. Radiography Testing (RT)
 Visual Testing
Visual testing is the most basic and common inspection
method involves in using of human eyes to look for
defects. But now it is done by the use special tools such as
video scopes, magnifying glasses, mirrors, or borescopes to
gain access and more closely inspect the subject area.
Visual Testing Equipment:

•Mirrors (especially small, angled mirrors),

•Magnifying glasses,
•Microscopes (optical and electron),
•Borescopes and fiber optic borescopes,
•Closed circuit television (CCTV) systems,
•Videoscope.
Acoustic Emission Testing
Acoustic Emission (AE) refers to the generation of transient elastic waves produced by a sudden
redistribution of stress in a material. When a structure is subjected to an external stimulus
(change in pressure, load, or temperature), localized sources trigger the release of energy, in the
form of stress waves, which propagate to the surface and are recorded by sensors. With the
right equipment and setup, motions on the order of picometers can be identified. Sources of
AE vary from natural events like earthquakes and rockbursts to the initiation and growth of
cracks, slip and dislocation movements, melting, twinning, and phase transformations in metals.
In composites, matrix cracking and fiber breakage and debonding contribute to acoustic
emissions. AE’s have also been measured and recorded in polymers, wood, and concrete, among
other materials.
Detection and analysis of AE signals can supply information regarding the origin and
importance of a discontinuity in a material. Because of the versatility of Acoustic Emission
Testing (AET), it has many industrial applications (e.g. assessing structural integrity, detecting
flaws, testing for leaks, or monitoring weld quality) and is used extensively as a research tool.
Acoustic Emission is unlike most other nondestructive testing (NDT) techniques in two regards.
The first difference pertains to the origin of the signal. Instead of supplying energy to the
object under examination, AET simply listens for the energy released by the object. AE tests are
often performed on structures while in operation, as this provides adequate loading for
propagating defects and triggering acoustic emissions.
The second difference is that AET deals with dynamic processes, or changes, in a material.
This is particularly meaningful because only active features (e.g. crack growth) are highlighted.
The ability to discern between developing and stagnant defects is significant event.
Advantages:
• Furthermore, AE testing usually provides an immediate indication relating to the
strength or risk of failure of a component.
• Other advantages of AET include fast and complete volumetric inspection using
multiple sensors, permanent sensor mounting for process control, and no need to
disassemble and clean a specimen.

Disadvantages:
• AE systems can only qualitatively gauge how much damage is contained in a
structure. In order to obtain quantitative results about size, depth, and overall
acceptability of a part, other NDT methods (often ultrasonic testing) are necessary.
• Another drawback of AE stems from loud service environments which contribute
extraneous noise to the signals. For successful applications, signal discrimination
and noise reduction are crucial.
• In AE system, it is possible for flaws to go undetected altogether if the loading is
not high enough to cause an acoustic
 Dye Penetrant Testing

This method is commonly used for detect the surface cracks or defects. Dye penetrant Testing
(DPT) is one of the most widely used nondestructive Testing (NDT) methods. DPT can be used to
inspect almost any material provided that its surface is not extremely rough.
Three liquids are used in this method.

1. Cleaner two surface cracks

2. Penetrant
3. Developer
At first the surface of the material that is to be tested is cleaned by a liquid. The liquid is called
cleaner.
Then a liquid with high surface wetting characteristics is applied to the surface of the part and
allowed time to seep into surface breaking defects. This liquid is called penetrant. After five or
ten minutes the excess penetrant is removed from the surface.
Then another liquid is applied to pull the trapped penetrant out the defect and spread it on the
surface where it can be seen. This liquid is called developer.
Aerosol spray can make penetrant materials very portable. Penetrant materials and associated
equipments are relatively inexpensive.
Visible dyes will show a sharp contrast between penetrant and developer making the
“bleedout” easy to see. Fluorescent dyes are viewed with an ultraviolet lamp, which makes the
“bleedout” fluoresce brightly reveling any material imperfections.
Advantages:
• This method has high sensitivity to small surface
discontinuities.
• Large areas and large volumes of parts/materials can be inspected
rapidly and at low cost.
• Indications are produced directly on the surface of the part and constitute a visual
representation of the flaw.

Limitations:
• Only surface breaking defects can be detected.
• Precleaning is critical since contaminants can mask defects.
• The inspector must have direct access to the surface being
inspected.
• Surface finish and roughness can affect inspection sensitivity.
• Post cleaning of acceptable parts or materials is required.
• Chemical handling and proper disposal is required.
 Magnetic Particle Testing

This method is suitable for the detection of surface and near surface discontinuities
in magnetic material mainly ferrite steel and iron. Magnetic particle Testing (MPT) is
a nondestructive testing method used for defect detection. MPT is fast and
relatively easy to apply, and material surface preparation is not as critical as it is for
some other NDT methods.

The process puts a magnetic field into the part. The piece can be magnetized by
direct or indirect magnetization.
• The first step in a magnetic particle inspection is to magnetize the component that
is to be inspected. If any defects on or near the surface are present, the defects
will create a leakage field. After the component has been magnetized, iron
particles, either in a dry or wet suspended form, are applied to the surface of the
magnetized part. The particles will be attracted and cluster at the flux leakage
fields, thus forming a visible indication that the inspector can detect.
• The inspection medium shall consist of finely divided Ferro- Magnetic particles,
which may be suspended in a suitable liquid medium (wet method)
• or used in dry powder form (dry method).
Advantages:
 It does not need very stringent pre-cleaning operation.
 It is the best method for the detection of surface and near to the surface
cracks in ferromagnetic materials.
 Fast and relatively simple NDT method.
 Generally inexpensive.
 Will work through thin coating.
 Highly portable NDT method.
 It is quicker.

Limitations:
 Material must be ferromagnetic.
 Orientation and strength of magnetic field is critical.
 Detects surface and near-to-surface discontinuities only.
 Large currents sometimes require
 Ultrasonic Testing
 Ultrasonic testing (UT) is a type of non-destructive testing
techniques based on the propagation of ultrasonic waves in the
object or material tested. In
most common UT applications, very short ultrasonic pulse-waves with
center frequencies ranging from 0.1- 15 MHz, and occasionally up to 50
MHz, are transmitted into materials to detect internal flaws or to
characterize materials.
 The conversion of electrical pulses to mechanical vibrations and the
conversion of returned mechanical vibrations back into electrical energy
is the basis for ultrasonic testing. The active element is the transducer as
it converts the electrical energy to mechanical vibrations, and vice versa.
This phenomena is known as piezoelectric effect.
 In ultrasonic testing, ultrasound transducer connected to a diagnostic
machine is passed over the object being inspected. The transducer is
typically separated from the test object by a couplant (such as oil) or by
water, as in immersion testing.
Ultrasound waves are generated by piezo-electric effect transducer,
which convert electric oscillation into mechanical vibration and vice-
versa.
 As the wave travels through the material, it may get reflected,
refracted, scattered or transmitted depending up on the condition
within in the material. From defective location, the wave get reflected
or attenuated.
The signals are picked up by the transducer and recorded for display
as time pulse-height pattern on a Cathode Ray Tube (CRT) screen.
Spacing between pulses and height of pulses are interpreted in terms
of relative location size of the flaw in material.
The distance to the flaw is calculated using the velocity formula of
distance upon time.
In the figure below, the reflected signal strength is displayed versus
the time from signal generation, when a echo was received. Signal
travel time can be directly related to the distance. From the signal,
information about the reflector location, size, orientation and other
features can sometimes be gained.
Advantages:
• Thickness and lengths up to 30 ft can be tested.
• Position, size and type of defect can be determined.
• Instant test results.
• Portable.
• Capable of being fully automated.
• Access to only one side necessary.

Limitations:
• The operator can decide whether the test piece is defective or not while the test is
in progress.
• Considerable degree of skill necessary to obtain the fullest
information from the test.
• Very thin sections can prove difficult.
 Eddy Current Testing
This method is widely used to detect surface flaws, to measure thin walls from one surface only, to
measure thin coatings and in some applications to measure depth. This method is applicable to electrically
conductive materials only. In this method eddy currents are produced in the product by bringing it close to
an alternating current carrying coil. The main applications of the eddy current technique are for the
detection of surface or subsurface flaws, conductivity measurements and coating thickness measurement.
Applications:
Crack Detection
Corrosion Monitoring

Material Thickness Measurements

Coating Thickness Measurements

Conductivity Measurements

Advantages:
Sensitive to small cracks and other defects
Detect surface and near surface defects

Inspection gives immediate results

Equipment is very portable

Method can be used for much more than flaw detection

Inspects complex shapes and sizes of conductive materials

Limitations:
Only conductive materials can be inspected.
Surface must be accessible to the probe.

Skill and training required is more extensive than other techniques.

Surface finish and roughness may interfere.

Depth of penetration is limited.

 • Radiography Techniques
• Radiographic Testing (RT), or industrial radiography, is a nondestructive
testing (NDT) method of inspecting materials for hidden flaws by using the
ability of short wavelength electromagnetic radiation (high energy photons)
to penetrate various materials.
• Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare
cases Cs-137) can be used as a source of photons This can see very
different things from X-rays, because neutrons can pass with ease through
lead and steel but are stopped by plastics, water and oils.
 Elements of Radiographic Testing
1. A source of penetrating radiation, such as an X-ray machine.
2. The object to be radiographed, such as a weldment.
3. A recording or viewing device, usually photographic (X-ray) film enclosed in a light
tight holder.
4. A qualified radiographer trained to produce a satisfactory
exposure.
5. A person skilled in the interpretation of radiographs.
Advantages:
• Information is presented pictorially.
• A permanent record is provided which may be viewed at a time and place
distant from the test.
• Useful for thin sections.
• Sensitivity declared on each film suitable for any material.
Limitations:
• Possible health hazard.
• Need to direct the beam accurately for two-dimensional defects.
• Film processing and viewing facilities are necessary
• Not suitable for automation.
• Not suitable for surface defects.
https://youtu.be/kZ7YfWW-rg0 2 min, NDT introduction
https://youtu.be/WoHiE5eGaD4 9 min comparison
https://youtu.be/X7F1xsCNyKo 3min, testing method and comparison
https://youtu.be/kL2koZRNcb0 7 min, liquid penetrant testing
https://youtu.be/qZC_uGt6B_8 7 min, magnetic method
https://youtu.be/4xulzkBOFKI 5 min thermography
https://youtu.be/ueFnrcdPVwk 2 min, AET
https://youtu.be/Lomf1NYd4O8 2 min, AET demo
https://youtu.be/cXpZWPxpwEQ 7 min, flaw detection, hindi
https://youtu.be/fXA6RVSr6Gg 7 min, liquid penetrant, hindi
https://youtu.be/TvTABJIgVeI 7 min, ultrasonic flaw detection, hindi
https://youtu.be/y22lZ_5WEHA 3 min, xray NDT
https://youtu.be/IcWjZbXiFkM 12 min, xray radiography
https://youtu.be/Iz0Njcc8Iqc 4 min, raidiography
https://youtu.be/W_z41QYczqE 2 min, radiography in hindi
https://youtu.be/0EDnhvehcjU 3 min, gamma radiography
https://youtu.be/N3a9vlIuRG0 12 min, complete radiography, hindi