Non Destructive Testing

What is Nondestructive Testing

Non-destructive testing (NDT) is the testing of
material to detect internal and surface defects
or discontinuities using methods that do not
damage or destroy the material under test.
i.e. Inspect or measure without doing harm

Where is NDT used?

where we need to ensure the serviceability of
a specimen
where we cannot afford the cost of a failure of
the specimen because failure would be
financially unacceptable or cause harm to us
exist to prevent injury or death to the human
user of the tested item

Why we need NDT?

Generally, NDT is employed in various
industries for the following reasons;
i. To prevent accidents and save human lives
ii. To improve product reliability
iii. To give profit to the user by;
a.
b.
c.
d.
e.

Ensuring customer satisfaction

Helping in better product design
Controlling manufacturing processes
Lowering manufacturing processes
Maintaining a uniform quality level

When is NDT used?

NDT is used both before, during and after
construction
Using NDT "before or during construction"
prevents a substandard material or part from
wasting time and increasing scrap production
Using NDT after to monitor performance after
being service.

Basic Methods of NDT

Visual Testing (VT)
Penetrant Testing (PT or
DPI)
Magnetic Particle Testing
(MT or MPI)
Ultrasonic Testing (UT)
Radiographic Testing (RT)
Eddy Current Testing (ET)

Eddy
Eddy Current
Current
Testing
Testing
Visual
Visual
Testing
Testing

Other NDT methods;

Leak testing
Strain gauging
Acoustic emission
IR Thermography
Laser shearography

Visual Testing (VT)

It is the most cost effective method of inspection
Most basic and common inspection method
Visual Inspection requires little equipment, to
name a few;
Good eyesight & sufficient light
Welding Gauge
Pocket Rule, small steel rule
Inspection mirror
Square for checking straightness, alignment &
perpendicularity
Standards, codes & specification

Visual Inspection tools

Checking Weld Reinforcement

Inspection Mirror

Checking Fillet Weld Throat

Checking Fillet Weld Size

Checking Bevel Angle

Visual Inspection tools

Most basic and common
inspection method.
Tools include Lights,
Mirrors, fiberscopes,
borescopes, magnifying
glasses and CCTV.
Portable video inspection
unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air
ducts, reactors, pipelines.

Penetrant Testing (PT)

Basic Principles
Penetrant solution is applied to the
surface of a pre-cleaned component

Penetrant

Solid

The liquid is pulled into surfacebreaking defects by capillary action

Penetrant

After a period of time called the dwell

time has elapsed, excess penetrant is
carefully cleaned from the surface

Solid

 A developer is applied to pull the trapped

penetrant back to the surface where it spread out
and forms an indication

Developer

Solid

The indication is much easier to

see than the actual defect

Main Uses of PT
Used to locate cracks, porosity and other defects that is open to
the surface of a material.
i.e.
Fatigue cracks Porosity Pin holes in weld
Quench cracks Laps
Lack of fusion breaking
Grinding cracks Seams
the surface
Can be use to inspect almost any material provided that its
surface is not extremely rough or porous.
i.e. Metals, Glass, Ceramics, Rubber, Plastics

Advantages and Disadvantages

Advantages
Low operator skill
Large surface can be inspected rapidly and at low cost
Portable, simple, cheap and easy to interpret
Applicable to non ferrous material
Disadvantages
Detects only surface breaking defects
Surface preparation is critical as contaminant may
mask defect
Not applicable to porous material
Potential hazardous chemicals

Magnetic Particle Testing (MPI or MT)

Magnetic particle inspection is a
method of locating surface and
subsurface defects in
ferromagnetic materials

Basic Principles
A magnetic field is introduced in a
ferromagnetic
material.
The
magnetic lines of force travel
through the material, and exit and
reenter the material at the poles

 Defects such as cracks or voids cannot support as

much flux, and force some of the flux outside of the
part creating flux leakage
FLUX LEAKAGE

Magnetic particles distributed over the

component will be attracted to areas of
flux leakage and produces a visible
indication

Crack Indications

Electromagnetic Yoke

Main Uses of MT
Used to inspect ferromagnetic materials( those that can be
magnetized) for surface defects and those that are slightly
subsurface (near surface defects)
This method may be used to inspect plate edges prior to
welding, in process inspection of each weld pass, and to
inspect repair
It is good method for detecting surface crack of all sizes in
both weld and base metal, subsurface cracks, incomplete
fusion, undercut as well as defects on the repaired edges of
the base metal

Advantages and Disadvantages

Advantages
Pre-cleaning not as critical as PT
Can detect surface and subsurface defects
Relatively low equipment cost and simple equipment
Possible to inspect through thin coating
Disadvantages
Only ferromagnetic materials can be inspected
Requires relatively smooth surface
Proper alignment of magnetic field and defect is critical
Demagnetization is usually required

Ultrasonic Testing (UT)

Basic Principles
initial
pulse
crack
echo

back surface
echo

crack
0

10

plate

Oscilloscope, or
flaw detector
screen

A typical UT inspection consist of pulser/receiver,

transducer and display devices

Basic Principles
Driven by the pulser, the transducer (probe) generates a
high frequency ultrasonic (sound wave) energy and is
introduced and propagates through the material
When there is a discontinuity (such as crack) in the wave
path, part of the energy will be reflected back from the flaw
surface
The reflected wave signal is transformed into electrical
signal by the transducer and is displayed on the screen
From the signal, information about the flaw location, size,
orientation and other features can sometimes be gained

Main Uses of UT
Used to locate Internal and subsurface defects in
many material including metals, plastics and wood
It is also used to measure the thickness of material
Ultrasonic inspection has long been the preferred
method for nondestructive testing in welding
application
Ultrasonic scanning systems are used automated
data acquisitioning and imaging

Advantages and Disadvantages

Advantages
Can be used in ferrous and non ferrous material
Portable with instant result
Able to detect subsurface defects, measure depth &
through wall extent
Can easily detect lack of sidewall fusion in welds
Disadvantages
High operator skill level
Requires calibration and difficult to interpret
Not easily applied to complex geometry
Linear defects oriented parallel to the sound beam
may go undetected

Radiographic Testing (RT)

Basic Principles
Radiography is based on the ability of X-rays and
gamma rays to pass through metal and other material.
The object is placed is placed between radiation
source and a piece of film.
Radiation Source

Object

FILM

Basic Principles

X-ray film

The thickness and the density

of the part affects the amount
of radiation reaching the film
Thicker and more dense area
will stop more radiation to
reach the film
The film darkness (density)
will vary with the amount of
radiation reaching the film
= less exposure

Top view of developed film

= more exposure

Images of Porosity on weld

Images of Slag on weld

Main Uses of RT
Used to inspect almost any material for surface and
subsurface defects
Radiography can also be used to locate and measure
internal features of material
It can also be used to confirm the location of a hidden
parts in an assembly and to measure thickness of
materials

Advantages and Disadvantages

Advantages
Most material can be tested
Detects internal flaw & give permanent record
Ability to inspect complex shapes
Gives direct images of flaw
Disadvantages
Extensive operator & film interpretation training &
skill required
Access to both sides of the structure is usually
required
Orientation of the radiation beam to planar flaws is
critical
Relatively high capital cost
Radiation Hazard to personnel

Eddy Current Testing (ET)

Coils
magnetic field
Coil
Eddy Currents
magnetic field

Conductive
material
Eddy Currents

CRACK DETECTION

PROBE

PROBE

PROBE

FLAW
MATERIAL

PROBE

 Sub surface flaw

detection

Applications

Multi-layered aircraft
structures.
- Fuselage
- Wings
- Around Fasteners
Phase indicates flaw
depth
Magnitude indicates flaw
severity at depth

Inspect conducting materials

Detect surface and sub-surface discontinuities
Measure hardness and thickness of layer and
thin sheet

 Conductivity
measurement
Raw materials sorting
Manufacturing process
verification
Heat damage
Reference measurement

Limitations
Defect detection is limited to only few mm below surface
Does not indicate the shape of discontinuities