Module 10 - 1

Module 10

Visual
Inspection and
Other
NDE Methods
and
Symbols
A
W
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Module 10 - 2

Visual Inspection
Very cost effective
Limited to surface only
Requires

Training
Experience
Welding knowledge
Proper tools

Must be continuous, ongoing

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Module 10 - 3

Application of VT
Before welding
During welding
After welding

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Module 10 - 4

VT Before Welding
Review documents
Check welding procedures
Qualify/Certify welders, or check
certifications
Establish hold points
Develop inspection plan
Develop system for reject identification
Develop defect repair system

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VT Immediately Before
Welding

Module 10 - 5

Check
Check
Check
Check
Check
Check

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base and filler metals

welding equipment
weld preparations
joint fitup
weld joint cleanliness
preheat, if required

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Module 10 - 6

VT During Welding
Note welder skills
Check welding variables/procedure
compliance
Examine tacks and roots
Check backgouged surfaces
Check preheat temperatures
Check interpass temperatures
Check interpass cleaning

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Module 10 - 7

VT After Welding
Examine weld appearance
Check weld size and length
Check part dimensions
Monitor other NDE methods
Monitor postweld heat treating
Prepare inspection reports

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Module 10 - 8

Visual Inspection Tools

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Module 10 - 9

Prebending
and
Presetting
Pieces to
Allow for
Distortion
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Temperature
Measurements

Module 10 - 10

Required for:
Preheat
Interpass temperature limits
Post weld heat treatments

Typically achieved by:

Temperature sensitive crayons
Digital pyrometers

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Temperature-sensitive
Crayons

Module 10 - 11

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Module 10 - 12

Digital
Contact
Pyrometer

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Module 10 - 13

Fillet Weld Size

Convex or concave ??
Use correct template gage
Estimate between gage sizes
Measure to nearest 1/32 or 1/16
Measure smallest region

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Module 10 - 14

Measuring Fillet Size

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Module 10 - 15

Nondestructive Testing
Method of testing to evaluate
quality and not effect end-use
serviceability

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Elements of all NDE

Methods

Module 10 - 16

Source of probing energy

Discontinuities alter probing
energy
Detection of energy alteration
Indication of energy alteration
Recording and evaluating
indications

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Module 10 - 17

Common NDE Methods

Penetrant Magnetic Particle Radiographic Ultrasonic Eddy Current

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PT
MT
RT
UT
ET

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Module 10 - 18

Penetrant Testing
Surface discontinuities only
Relies on penetrant bleedout
Magnifies discontinuity size
Several methods

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Module 10 - 19

PT Types
Visible dye
Fluorescent dye

Three removal systems:

Solvent
Water
Emulsifiable

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Module 10 - 20

Clean the Surface

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Module 10 - 21

Apply Penetrant

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Module 10 - 22

Dwell Time
Varies with the nature of the job,
typically in the range of 2 to 20
minutes, or longer in special cases

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Module 10 - 23

Remove Excess Penetrant

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Module 10 - 24

Remove Excess Penetrant

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Module 10 - 25

Remove Excess Penetrant

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Module 10 - 26

Remove Excess Penetrant

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Module 10 - 27

Apply Developer
In
this
example,
spray can is too
close to the weld
surface, which can
lead to excessive
developer
on
surface. A distance
of 10-12 inches is
better.

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Module 10 - 28

Excessive Developer
Note runs caused
by excess
developer; this can
mask
discontinuities

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Module 10 - 29

Evaluate PT
Note porosity and
crack indications

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Module 10 - 30

Clean Part
Post inspection removal of developer
residues
may
be
required,
particularly if work piece is to be
weld repaired or painted.

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Module 10 - 31

PT Advantages
Relatively simple
All types of metals
Quite sensitive
Quite portable

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Module 10 - 32

PT Limitations
Somewhat slow
Limited to surface
Smooth surfaces required

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Module 10 - 33

PT Results
Sketches
Photographs
Lift off tapes

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Module 10 - 34

Magnetic Particle Testing

Parts are magnetized
Iron particle accumulation at flaw
Magnifies flaw size
Relatively quick process

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Module 10 - 35

Aspects of a Magnet
Magnetic flux (field)
North and south poles
Like sign poles repel
Opposite signs attract
Flux lines are parallel to each
other; do not cross

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Module 10 - 36

Magnetic Fields
Produced by two methods:
Permanent magnets
Electro magnets
Direct current
Alternating current
Half wave rectified AC

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Module 10 - 37

Permanent Magnet

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Module 10 - 38

Electromagnets
A current-carrying conductor
creates a magnetic flux around the
conductor and perpendicular to the
current flow.

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Module 10 - 39

Magnetic Field Around

Conductor

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Module 10 - 40

MT Principles
A flaw oriented transverse to
magnetic flux creates poles of
opposite signs at edges of flaw.
Very attractive to iron particles

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Module 10 - 41

Magnetic Particles
Iron based
Dry or wet
Types

Color dyed
Fluorescent

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Module 10 - 42

Longitudinal Magnetism

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Module 10 - 43

Circular Magnetism

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Module 10 - 44

MT Steps
Magnetize part
Apply iron particles
Evaluate accumulation
Clean part
Demagnetize part

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Module 10 - 45

MT Equipment
AC
AC
AC
AC
AC

/ DC bench units
yokes
/ DC yokes
/ DC prods
/ DC coils

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Module 10 - 46

Central Conductor Method

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Module 10 - 47

MT Method
--Yoke

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Module 10 - 48

MT Method
--Prods

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Module 10 - 49

MT Advantages
Rapid
Very sensitive
Low cost
Portable

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Module 10 - 50

MT Limitations
Magnetic materials only
Poor with thick coatings
Limited to surface, or near-surface
Demagnetization may be required

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Module 10 - 51

MT Results
Sketches
Photographs
Lift off tapes

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Module 10 - 52

Radiographic Testing

Based on the principle of

preferential radiation transmission
or absorption.

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X-Ray Machine (aimed

down)

Module 10 - 53

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Module 10 - 54

Radiation Absorption
Thicker, or higher density materials
absorb more radiation, resulting in
less transmission to the film.

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Module 10 - 55

Absorption vs Thickness

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Metal Densities

Module 10 - 56

Grams/cubic centimeter
Aluminum

2.70

Steel

7.87

Copper

8.96

Lead

11.34

Tungsten

19.30

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Module 10 - 57

Absorption vs Density

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Module 10 - 58

Radiation Types

Gamma radiation sources

Iridium 192
Cobalt 60
Cesium 137

X-Ray
Machine

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Module 10 - 59

RT Steps
Position radiation source
Position film behind object
Expose radiation
Develop film
Evaluate

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Module 10 - 60

Film Density Vs Flaws

Darker film zones:
Cracks, slag, porosity
Incomplete joint penetration
Lighter film zones:
Tungsten inclusions
Melt through, reinforcement

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Hole Type Image Quality

Indicators

Module 10 - 61

2T
hole
1T
hole
4T
hole

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Wire Type Image Quality

Indicators

Module 10 - 62

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Module 10 - 63

RT Equipment
Radiation source

Densitometer /
X-ray machine
film density
Gamma radiation
strips
source
Film processor
Radiation monitor

Film holders
IQIs

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Film viewers

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Module 10 - 64

Orientation of Source,
Plate, & Film

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Module 10 - 65

RT Advantages
Detects subsurface flaws
Used for all materials
Film is permanent record

If stored properly

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Module 10 - 66

RT Limitations
Radiation hazard
Requires access to both sides
Flaw orientation
Flaw types
Film interpretation

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Module 10 - 67

RT Results
Film
Video tape
Sketches

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Module 10 - 68

Ultrasonic Testing
Based on the propagation of sound
waves through materials, and the
reflected echo from density changes.

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Module 10 - 69

Piezoelectric Effect
Refers to materials which can convert
electrical energy to mechanical energy
and vice versa.

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Module 10 - 70

Principles of Sound
Sound travels within a given material at a
constant velocity, based in part, on material
density. Sound will not travel in a vacuum.
There are several types of sound waves:
Longitudinal (straight beam)
Shear (angle beam)
Others not pertinent to weld inspection

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Module 10 - 71

UT Equipment & Operation

Electronic base unit
Piezoelectric transducer
Calibration blocks

Couple probe to part with couplant

Carry out testing
Evaluate signals

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Module 10 - 72

UT Process

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Module 10 - 73

Longitudinal
Calibration

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UT Process - 1 of 2

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Module 10 - 74

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Module 10 - 75

UT Process - 2 of 2

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Module 10 - 76

Angle Beam
Testing of
Weld

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Module 10 - 77

Weld Testing - 1 of 2

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Module 10 - 78

Weld Testing - 2 of 2

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Module 10 - 79

UT Advantages
A true volumetric test
One side access
Very accurate
Deep penetration - 200
Critical flaws found
Equipment fully portable

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Module 10 - 80

UT Limitations
Highly skilled operator
Smooth surfaces
Groove welds > 1/4 thick

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Module 10 - 81

Eddy Current Testing

Based on the principle of eddy currents
being formed in conductive materials in
the presence of an AC coil and changes in
those eddy currents by material
changes.

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Module 10 - 82

Test
Coil

Induced Eddy
Currents

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Module 10 - 83

ET Uses
Flaw detection
Metal thickness
Coating thickness
Metal hardness
Heat treatment

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Module 10 - 84

ET CRT
Displays

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Module 10 - 85

ET Equipment
Base unit, CRT or meter
AC probe (coil)
Calibration standards

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Module 10 - 86

ET Advantages
No contact required with part
No couplant required
Readily Automated
Applicable to all metals

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Module 10 - 87

ET Limitations
Highly skilled operator
Too sensitive
Shallow penetration - 3/16
Calibration standards required
Requires surface cleanliness
Magnetic materials more difficult

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Module 10 - 88

NDE Symbols
Similar to weld symbols
Shorthand notation
Very useful
Combine with weld symbols

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Module 10 - 89

Standard Location of
Elements for NDE Symbols

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NDE Test Methods Abbreviations

1 of 2
Acoustic Emission

AET

Eddy Current

ET

Leak

LT

Magnetic Particle

MT

Neutron Radiography

NRT

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NDE Test Methods Abbreviations

2 of 2
Penetrant

PT

Proof

PRT

Radiography

RT

Ultrasonic

UT

Visual

VT

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Module 10 - 92

WIT Summary
Have covered much material in 3 days
Workbook and Sample Fundamentals
Exam are good guides to your grasp of
each Module, and may point towards
areas needing more study in Manual
Urge all to study these subjects in greater
depth as part of continuing education

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