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HSEYN KASIRGA
030040323
GROUP
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TABLE OF CONTENTS
I.
Introduction
1. Definitions
2. Purposes of Non-Destructive Testing
3. Classification of NDT Methods
a.
Visual Inspection
b.
Liquid (Dye) Penetrant Method
c.
Magnetic Particle Method
d.
Eddy Current Testing
e.
Ultrasonic Inspection
f.
Radiography
g.
Acoustic Inspection
II.
Experimental Procedure
1. Objective
2. Examination
a. Eddy Current Inspection
i. Equipments
ii. Experiment
b. Ultrasonic Inspection
i. Equipments
ii. Experiment
c. Liquid Penetrant Method
i. Equipments
ii. Experiment
d. Magnetic Particle Method
i. Equipments
ii. Experiment
III.
Data Analysis
1. Eddy Current Inspection
2. Ultrasonic Inspection
3. Liquid Penetrant Method
4. Magnetic Particle Method
IV.
Results
1. Eddy Current Inspection Experiment
2. Ultrasonic Inspection Experiment
3. Liquid Penetrant Method Experiment
4. Magnetic Particle Method Experiment
V.
Discussion
1. Advantages and Disadvantages of Each Method Performed
VI.
Conclusion
VII.
References
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I. INTRODUCTION
1. DEFINITIONS
Non-destructive testing, NDT (also called NDE, non-destructive evaluation, and
NDI, non-destructive inspection) is the testing performed on materials without destroying the
test objects and impairing its future usefulness. It is used for in-service inspection and for
condition monitoring of operating plant. It is also used for measurement of components and
spacing and for the measurement of physical properties such as hardness and internal stress.
The essential feature of NDT is that the test process itself produces no deleterious effects on
the material or structure under test; therefore it is vital for constructing and maintaining all
types of components and structures.
The subject of NDT has no clearly defined boundaries; it ranges from simple
techniques such as visual examination of surfaces, through the well-established methods of
radiography, ultrasonic testing, magnetic particle crack detection, to new and much
specialised methods. NDT methods can be adapted to automated production processes as well
as to the inspection of localised problem areas.
2. PURPOSES OF NON-DESTRUCTIVE TESTING
Since the 1920s, nondestructive testing has developed from a laboratory curiosity
to an indispensable tool of production. No longer is visual examination the principal means of
determining quality. Nondestructive tests in great variety are in worldwide use to detect
variations in structure, minute changes in surface finish, the presence of cracks or other
physical discontinuities, to measure the thickness of materials and coatings and to determine
other characteristics of industrial products. Modern non-destructive tests are used by
manufacturers to:
- ensure product integrity, and in turn, reliability
- avoid failures, prevent accidents and save human life
- make a profit for the user
- ensure customer satisfaction and maintain the manufacturer's reputation
- aid in better product design
- control manufacturing processes
- lower manufacturing costs
- maintain uniform quality level
- ensure operational readiness. (The American Society for NDT)
3. CLASSIFICATION OF NDT METHODS
There is much kind of non-destructive test methods performed on various
materials including metals, plastics, ceramics, composites, cermets, and coatings in order to
detect flaws, cracks, internal voids, surface cavities, defective welds and other defects inside
and on the surface of the materials.
There are some principal factors used to characterize the methods:
energy source or medium used to probe the test object (such as X-rays, ultrasonic
waves or thermal radiation)
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nature of the signals, image or signature resulting from interaction with the test object
(attenuation of X-rays or reflection of ultrasound, for example)
means of detecting or sensing resulting signals (photo emulsion, piezoelectric crystal
or inductance coil)
method of indicating or recording signals (meter deflection, oscilloscope trace or
radiograph)
basis for interpreting the results (direct or indirect indication, qualitative or
quantitative, and pertinent dependencies).
The objective of each test method is to provide information about the following
material parameters:
Discontinuities (such as cracks, voids, inclusions, delaminations)
Structure or microstructure (including crystalline structure, grain size, segregation,
misalignment)
Dimensions and metrology (thickness, diameter, gap size, discontinuity size)
Physical and mechanical properties (reflectivity, conductivity, elastic modulus, sonic
velocity)
Composition and chemical analysis (alloy identification, impurities, elemental
distributions)
Stress and dynamic response (residual stress, crack growth, wear, vibration)
Signature analysis (image content, frequency spectrum, field configuration).
(The American Society for NDT)
Although very special tests have been developed for specific applications,
following methods are universal NDT methods.
a. VISIUAL INSPECTION:
Visual inspection is the one NDT method used extensively to evaluate the
condition or quality of an item. It is easily carried out, inexpensive and usually doesn't require
special equipment. It is widely used for inspections of macroscopic surface flaws; welding
qualities, dimensional damages and changes, surface finish quality, delaminations, large
cracks, cavities, and dents etc.
The method requires good vision, good lighting and the knowledge of what to look
for. Visual inspection can be enhanced by various methods ranging from low power
magnifying glasses through to boroscopes. These devices can also be used with television
camera systems. Surface preparation can range from wiping with a cloth to blast cleaning and
treatment with chemicals to show the surface details.
Visual inspection can sometimes identify where a failure is most likely to occur
and identify when a failure has commenced. Visual inspection is often enhanced by other
surface methods of inspection, which can identify flaws that are not easily seen by the eye.
b. LIQUID (DYE) PENETRANT METHOD:
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used for the inspection of ferrous materials where magnetic-particle inspection is difficult to
apply. In some cases it can be used on non-metallic materials, too.
The ability of the liquid penetrant to be pulled into surface-breaking defects by
capillary action is employed in this technique to locate cracks, porosity, and other defects that
break the surface of a material and have enough volume to trap and hold the penetrant
material. Liquid penetrant testing is used to inspect large areas very efficiently and works on
most nonporous materials.
c. MAGNETIC PARTICLE METHOD:
Magnetic particle inspection is an NDT method that can be used to find surface,
near surface and layer flaws in ferromagnetic materials such as steel and iron by employing
the principle that magnetic flux will be distorted by the presence of a flaw in a manner that
will reveal its presence. The flaw (for example, a crack) is located from the "flux leakage"
following the application of fine iron particles to the area under examination. There are
variations in the way the magnetic field is applied, but they are all dependent on the above
principle.
The most common method of magnetic particle inspection uses finely divided iron
or magnetic iron oxide particles, held in suspension in a suitable liquid (often kerosene). This
fluid is referred to as carrier. The particles are often colored and usually coated with
fluorescent dyes that are made visible under a UV light. The suspension is sprayed or painted
over the magnetized specimen during magnetization with a direct current or with an
electromagnet, to localize areas where the magnetic field has protruded from the surface. The
magnetic particles are attracted by the surface field in the area of the defect and hold on to the
edges of the defect to reveal it as a build up of particles.
Surface irregularities and scratches can give misleading indications. Therefore it is
necessary to ensure careful preparation of the surface before magnetic particle testing is
undertaken.
d. EDDY CURRENT TESTING:
In this method high frequency sound waves are sent into a material by use of a
transducer. Ultrasonic very short pulse-waves of frequencies ranging from 0.5-15 MHz and
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occasionally up to 50 MHz are used. The sound waves travel through the material and are
received by the same transducer or a second transducer. The amount of energy transmitted or
received and the time the energy is received are analyzed to determine the presence of flaws.
Changes in material thickness and material properties can also be measured.
It is used to locate surface and subsurface defects in many materials including
metals, plastics, and wood. Ultrasonic inspection is also used to measure the thickness of
materials and otherwise characterize properties of material based on sound velocity and
attenuation measurements.
f.
RADIOGRAPHY:
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1 kHz and have been reported at frequencies up to 100 MHz. This method is used for the
detection of the subsurface flaws in the materials being good conductor o sound.
A commonly accepted definition for AE is a transient elastic waves within a
material due to localized stress release. Hence a source which generates one AE event is the
phenomenon which releases elastic energy into the material, which then propagates as an
elastic wave. AE events can also come quite rapidly when materials begin to fail, in which
case AE activity rates are studied as opposed to individual events. AE events that are
commonly studied include the extension of a fatigue crack, or fiber breakage in a composite
material among material failure processes. Examples of AE events generated from sources not
involving material failure include leakage, cavitations and impact.
Transducers are attached to the material in order to detect these waves. Most of
these sensors are in the frequency range of 20 kHz to 650 kHz. Some geophysical studies with
AE use much lower frequency sensors, while sensors in the MHz range are also available
commercially.
AE analysis is used successfully in a wide range of applications including:
detecting and locating faults in pressure vessels or leakage in storage tanks or pipe systems,
monitoring welding applications, corrosion processes, partial discharges from components
subjected to high voltage and the removal of protective coatings. Areas where research and
development of AE applications is currently being pursued, among others, are process
monitoring and global or local long-term monitoring of civil-engineering structures (e.g.,
bridges, pipelines, off-shore platforms, etc.). Another area where numerous AE applications
have been published is fiber-reinforced polymer-matrix composites, in particular glass-fibre
reinforced parts or structures. (e.g., fan blades). AE systems also have the capability of
detecting acoustic signals created by leaks.
The disadvantage of AE is that commercial AE systems can only estimate
qualitatively how much damage is in the material and approximately how long the
components will last. So, other NDE methods are still needed to do more thorough
examinations and provide quantitative results. Moreover, service environments are generally
very noisy, and the AE signals are usually very weak. Thus, signal discrimination and noise
reduction are very difficult, yet extremely important for successful AE applications.
(Nondestructive Testing Encyclopedia)
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b. ULTRASONIC INSPECTION:
i. Equipments:
For this experiment, a
USM-2
type
transducer
(pulser/receiver), an oscilloscope
for monitoring the changes, a
probe supporting to work at
frequency of 5MHz, and because
the inspected surface of the is not
flat a supporting fitting tool (shoe)
is used. To transmit the ultrasonic
waves from the transducer to the
test part, glycerin is used as
couplant. (See the Figure II.2.2.)
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Cleaner/Remover Spray
Developer Spray
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cleaned with a clean textile paying attention not to give some additional damage to the
surface. As the last step the yellow can, developer spray, is applied to the surface.
d. MAGNETIC PARTICLE INSPECTION:
i. Equipments:
For the experiment, a strong U shape magnet, a fluorescent magnetic spray, and
UV light is used. The magnet provides the necessary magnetic field, and the spray and light is
employed to higher the visibility of the flaws, cracks for the ease of the inspection.
ii. Experiment:
Because the surface of the part is examined, a clear surface is required for the
experiment. Therefore, the surface of the part is applied cleaner/remover spray or wiped with
a clean textile according to the surface quality of the part. The surface cleaned, fluorescent
spray is applied on the inspected surface of the part to make the defects more visible under
UV light. Then, according to the normal procedure of the experiment a magnetic field created
by a strong magnet should be used; however, the magnet of the laboratory was lost and could
not be found during experiment. Therefore, the experiment was continued without using a
magnet. After waited for a while for fluorescent to cover the surface, the surface is examined
under UV light.
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For inspection, the ability of liquid penetrant to infiltrate into surface defects,
capillary action is employed. This infiltrated penetrant is absorbed by developer with principle
of the atomic attraction forces, and they reacts with each other. As a result of this reaction,
there occurs some color differences on the different sections of the part. Two main colors are
observed on the surface: pink/red areas indicate for the surface defects such as cracks and
white areas indicates for the clear areas from any cracks.
3. MAGNETIC PARTICLE METHOD
When the magnet is placed on the surface of the part, there occur magnetic fluxes
around the part. If there is a discontinuity on the surface of the part, magnetic flux is broken
and a new polarization exists between the edges of the discontinuity. As a result of this
polarization, the edges of the discontinuity behaves like poles of a magnet and they attract
some iron particles of which clusters make the discontinuity more visible than the actual one.
The fluorescent magnetic spray and the UV light contribute to this inspection by improving
this visibility.
IV. RESULTS
1. EDDY CURRENT INSPECTION EXPERIMENT
Some cracks have been detected on the surface of the part and more of these
cracks were concentrated around the projections on the part, and sections close to the edges of
the part.
2. ULTRASONIC INSPECTION EXPERIMENT
Some cracks inspected in the part. One of them can be seen in the following figure.
(Figure IV.2.1)
Crack
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V. DISCUSSION
o
o
o
o
ii. Disadvantages:
b. ULTRASONIC INSPECTION
i. Advantages:
o
o
o
o
o
ii. Disadvantages:
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i. Advantages:
o Large surface areas or large volumes of parts/materials can be inspected rapidly and at
low cost.
o Parts with complex geometry are routinely inspected.
o Indications are produced directly on surface of the part providing a visual image of the
discontinuity.
o Equipment investment is minimal.
ii. Disadvantages:
i. Advantages:
Large surface areas of complex parts can be inspected rapidly.
Can detect surface and subsurface flaws.
Surface preparation is less critical than it is in penetrant inspection.
Magnetic particle indications are produced directly on the surface of the part and form
an image of the discontinuity.
o Equipment costs are relatively low.
o
o
o
o
ii. Disadvantages:
VI. CONCLUSION
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VI. REFERANCES
[1] American Society for Non-Destructive Testing, retrieved from http://www.asnt.org, on
October 31, 2006.
[2] Non-destructive Testing Encyclopaedia, by R. Diederichs and E. Ginzel
[3] The British Institute of Non-Destructive Testing, retrieved from http://www.bindt.org, on
November 1, 2006.
[4] Canadian Institute for NDT, retrieved from http://www.csndt.org/ndt.shtml, on
November 1, 2006.
[5] WIKIPEDIA, retrieved from http://en.wikipedia.org/, on November 1, 2006.
[6] Material Measurements Ltd, retrieved from http://www.material-measurements.co.uk/, on
November 3, 2006.
[7] CD International Technology, retrieved from http://www.cdint.com/definition.shtml, on
November 4, 2006.
[8] NDT Resource Centre, retrieved from http://www.ndt-ed.org/, on November 4, 2006.
[9] Material Testing Laboratory Manual, ITU, 2006.