Introduction of Non Destructive Test

Date : July 2008

NDT Introduction

► Nondestructive Testing
z The field of Nondestructive Testing (NDT) is a very broad, interdisciplinary
field that plays a critical role in assuring that structural components and
systems perform their function in a reliable and cost effective fashion.
z NDT technicians and engineers define and implement tests that locate and
characterize material conditions and flaws that might otherwise cause
reactors, boiler and pressure vessel to fail, pipelines to burst, ship to crack
and a variety of less visible, but equally troubling events.
z These tests are performed in a manner that does not affect the future
usefulness of the object or material. In other words, NDT allows parts and
materials to be inspected and measured without damaging them. Because
it allows inspection without interfering with a product's final use,
z NDT provides an excellent balance between quality control and cost-
effectiveness. Generally speaking, NDT applies to industrial inspections.
While technologies are used in NDT that are similar to those used in the
medical industry, typically nonliving objects are the subjects of the
inspections.

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NDT Introduction

► Nondestructive Evaluation

z Nondestructive Evaluation (NDE) is a term that is often used

interchangeably with NDT. However, technically, NDE is used to describe
measurements that are more quantitative in nature. For example, a NDE
method would not only locate a defect, but it would also be used to
measure something about that defect such as its size, shape, and
orientation.
z NDE may be used to determine material properties such as fracture
toughness, formability, and other physical characteristics. .

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NDT Introduction

► NDT/NDE Methods

z The number of NDT methods that can be used to inspect components and
make measurements is large and continues to grow.
z Researchers continue to find new ways of applying physics and other
scientific disciplines to develop better NDT methods. However, there are
six common NDT methods that are used most often.
z These methods are visual inspection, penetrant testing, magnetic particle
testing, electromagnetic or eddy current testing, radiography, and
ultrasonic testing. These methods and a few others are briefly described
below.

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NDT Introduction

► Visual and Optical Testing (VT)

z Visual inspection involves using an inspector's eyes to look for defects.

z The inspector may also use special tools such as magnifying glasses,
mirrors, or borescopes to gain access and more closely inspect the subject
area.
z Visual examiners follow procedures that range from simple to very complex.

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NDT Introduction

► Penetrant Testing (PT)

z Test objects are coated with visible or fluorescent dye solution.

z Excess dye is then removed from the surface, and a developer is applied.
z The developer acts as blotter, drawing trapped penetrant out of
imperfections open to the surface.
z With visible dyes, vivid color contrasts between the penetrant and
developer make "bleedout" easy to see.
z With fluorescent dyes, ultraviolet light is used to make the bleedout
fluoresce brightly, thus allowing imperfections to be readily seen. .

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Liquid Penetrant Testing (PT)

z The procedure should detail as a minimum the calibration equipment,
surface preparation, cleaning and drying prior to testing, temperature range,
type of penetrant, cleaner and developer used, penetrant application and
removal, penetration time, developer application and development time and
lighting conditions during testing.
z The surface to be examined should be clean and free from scale, oil,
grease, dirt or paint and should include the weld bead and base metal for
at least 10mm on each side of the weld, or the width of the heat affected
zone, whichever is greater.
z The temperature of parts examined should be typically between 5ºC and
50ºC, outside this temperature range special low/high temperature
penetrant and reference comparator blocks should be used.
z The penetration time should not be less than 10 minutes and in accordance
with the manufacturer’s specification. The development time should not be
less than 10 minutes and in accordance with the manufacturer’s
specification, normally between 10-30 minutes.

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NDT Introduction

► Magnetic Particle Testing (MT)

z This NDE method is accomplished by inducing a magnetic field in a

ferromagnetic material and then dusting the surface with iron particles
(either dry or suspended in liquid).
z Surface and near-surface imperfections distort the magnetic field and
concentrate iron particles near imperfections, previewing a visual indication
of the flaw. . .

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Magnetic particle testing (MT)

z The procedure should detail as a minimum the surface preparation,

magnetizing equipment, calibration methods, detection media and
application, viewing conditions and post demagnetization.
z The surface to be examined should be free from scale, weld spatter, oil,
grease, dirt or paint and should be clean and dry.
z When using current flow equipment with prods, care shall be taken to avoid
local damage to the material. Copper prod tips must not be used. The prod
tips should be lead, steel, aluminium or aluminium- copper braid.
z To ensure detection of discontinuities of any orientation, the welds are
magnetized in two directions approximately perpendicular to each other
with a maximum deviation of 30º. Adequate overlapping shall ensure
testing of the whole zone.
z Continuous wet particle method should be used as far as practicable.

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NDT Introduction

► Eddy Current Testing (ET)

z Electrical currents are generated in a conductive material by an induced

alternating magnetic field. The electrical currents are called eddy currents
because they flow in circles at and just below the surface of the material.
z Interruptions in the flow of eddy currents, caused by imperfections,
dimensional changes, or changes in the material's conductive and
permeability properties, can be detected with the proper equipment. .

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NDT Introduction

► Radiography Testing (RT)

z Radiography involves the use of penetrating gamma or X-radiation to

examine parts and products for imperfections.
z An X-ray generator or radioactive isotope is used as a source of radiation.
z Radiation is directed through a part and onto film or other imaging media.
z The resulting shadowgraph shows the dimensional features of the part.
z Possible imperfections are indicated as density changes on the film in the
same manner as a medical X-ray shows broken bones. .

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Radiographic testing (RT1)

z The procedure should detail as a minimum the type of radiation source,

considering the thickness to be radiographed, test arrangement and films
overlapping, type and position of image quality indicators (IQI), image
quality, film system and intensifying screens used if any, exposure
conditions, scattered radiation control, film processing, film density and
viewing conditions.
z Processed films should display hull no., frame no., weld boundary
indicators, Port/Starboard, location (or film serial number) and date as
radiographic image.
z The Classification Society may require to duplicate some radiographs in
order that some processed films are handed over to the Society together
with testing reports. Alternative method to duplicate the processed film can
be agreed with the Society.
z The type of source is selected by the shipbuilder in accordance with item
7.2 of ISO ..

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Radiographic testing (RT2)

z Single-wall exposure technique should be used as far as practicable.

z The image quality should be verified using an IQI (Image Quality Indicator)
in accordance with ISO 19232 or equivalent. In general the IQI is to be
placed on the source side of the weld examined. The minimum image
quality should be in accordance with Class A of ISO 17636 or equivalent,
as given in Table 2 for IQI’s of wire type placed on source side.
z When using IQI’s of wire type, the image of a wire is considered visible on
the film if a continuous length of at least 10mm is clearly visible in a section
of uniform optical density.
z The optical density of the radiographs should be selected by the
shipbuilder in accordance with Table 5 of ISO 17636.
z Traditional radiographic film may be replaced by digital radiographic
techniques where it can be shown, to the satisfaction of the classification
society, that the sensitivity of the digital image is better than or equal to the
image obtained with traditional radiographic film.

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Radiographic testing (RT3)

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NDT Introduction

► Ultrasonic Testing (UT)

z Ultrasonics use transmission of high-frequency sound waves into a

material to detect imperfections or to locate changes in material properties.
z The most commonly used ultrasonic testing technique is pulse echo,
wherein sound is introduced into a test object and reflections (echoes) are
returned to a receiver from internal imperfections or from the part's
geometrical surfaces.

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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Ultrasonic testing (UT1)

z The procedure should detail the equipment, type of probes (frequency,
angle of incidence), coupling media, type of reference blocks, method for
range and sensitivity setting, method for transfer corrections, scanning
technique, sizing technique and intervals for calibration checks during
testing.
z The equipment (instrument and probes) should be verified by the use of
appropriate standard calibration blocks at suitable time intervals.
z The range and sensitivity should be set prior to each testing and checked
at regular intervals as per the procedure and whenever needed.
z The scanning surfaces should be sufficiently clean and free from
irregularities like rust, loose scale, paint (excluding primer), weld spatter or
grooves which may interfere with probe coupling.
z The surface profile should be such to avoid loss of probe contact by
rocking.
z The scanning technique should be determined to allow the testing of the
entire volume of the weld bead and base metal for at least 10mm on each
side of the weld, or the width of the heat affected zone, whichever is
greater.
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IACS Rec. No. 20 - Non-destructive Testing of Ship Hull Steel Welds

► Ultrasonic testing (UT1)

z The probe frequency should be within the range 2 MHz to 5 MHz.
z The reference level for testing should be set using a Distance-Amplitude-
Corrected curve (DAC curve) for a series of 3mm diameter side-drilled
holes in a reference block or other methods like the Distance-Gain-Size
(DGS) system based on a disc shaped reflector provided the same
sensitivity is achieved. The reference block used should be made in a
material giving equivalent ultrasonic response to that of the material to be
tested.
z The indications with an echo height below 33% of DAC curve (DAC minus
10 dB) should be disregarded. The indications with an echo height equal to
or exceeding 33% of DAC curve (DAC plus 10 dB) should be evaluated.
z Base material in the scanning zone should be examined with a straight
beam technique to check the absence of imperfections which would
interfere with the angle beam technique, unless already demonstrated at a
previous fabrication stage.
z Angle beam technique should be used to search for longitudinal and
transverse weld discontinuities. An angle probe with an incident angle of
the sound wave equal to that of the weld preparation should be used as a
minimum .
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NDT Introduction

► Leakage Testing (LT)

z Several techniques are used to detect and locate leaks in pressure

containment parts, pressure vessels, and structures.
z Leaks can be detected by using electronic listening devices, pressure
gauge measurements, liquid and gas penetrant techniques, and/or a
simple soap-bubble test.

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