NON DESTRUCTIVE

TESTING

By
A.GANESH
CMS / AWTI
NON DESTRUCTIVE TESTING
 NDT - Inspection of a material using non invasive
techniques to check its integrity. (i.e. Inspect or
measure without damaging the component)

Why NDT ?
 Ensuring integrity and reliability of a product.

 Testing components during service.

 Prevent failures, accidents & save human lives.

 To control manufacturing process – Economic

advantage.
NON DESTRUCTIVE TESTING
 Requirements for an NDT:

 A certified NDT inspector.

 Eye sight, Qualification, training, skill
 A well calibrated equipment.
 A qualified procedure.

 A standard CODE or Acceptance criteria.

 ASME BPVC, IBR, IS, ISO/EN
NON DESTRUCTIVE TESTING
 NDT METHODS

 Visual Inspection
 Penetrant test (PT / LPT/DPT)

 Magnetic particle test (MPT)

 Radiographic test (RT)

 Ultrasonic test (UT)

 Eddy current test (ET)

 Leakage test (LT)

 Accoustic Emission Test (AET)

 NDT - PROCESS
INDICATION

FALSE INDICATION TRUE INDICATION

NONRELEVANT INDICATION RELEVANT INDICATION

DISCONTINUITY

INTERPRETATION Judging

EVALUATION Code / std

REWORK

REJECT (DEFECT) ACCEPT

SCRAP
 PENETRANT TEST
 PT increases the “detectability” of small discontinuities
that the human eye might not be able to detect alone.
 Also called dye penetrant (DPT) or liquid penetrant(LPT)

 HISTORY: Oil & Whiting Method – early 1900s

 PRINCIPLE:
 “Capillary action” - phenomenon by which liquids can
enter into small openings.
 “Bleed out” – Bringing trapped liquid on the surface of
the component.
 The bleed out liquid is enhanced and seen in a
“contrast” background.
 HOW DOES PT WORK?
• A liquid with high surface wetting characteristics
is applied to the surface of a component under
test.
• The penetrant “penetrates” into surface breaking
discontinuities via capillary action.
• Excess penetrant is removed from the surface.
• A developer is applied to pull trapped penetrant
back to the surface.
• With good inspection
technique, visual
indications of any
discontinuities present
become apparent.
 WHAT MAKES PT WORK?
• Every step of the penetrant process is done to
promote capillary action.
• This is the phenomenon of a liquid rising or climbing
when confined to small openings due to surface
wetting properties of the liquid.

• Some examples:
Plants and trees draw water up from
the ground to their branches and
leaves to supply their nourishment.
The human body has miles of
capillaries that carry life sustaining
blood to our entire body.
 STEPS IN PENETRANT TEST

Application of Excess Application

Pre-cleaning penetrant
penetrant of developer
removal
DEVELOPING
DWELL TIME TIME
 BOUNDARIES OF PT?
WHAT CAN BE WHAT CANNOT BE
INSPECTED BY PT? INSPECTED BY PT?

Almost any material that • Components with rough surfaces,

has a relatively smooth, that trap and hold penetrant.
non-porous surface on • Porous ceramics.
which discontinuities or • Wood and other fibrous materials.
defects are suspected. • Plastic parts that absorb or react.
• Components with coatings that
prevent penetrants.
Defect indications
become less
distinguishable as
the background
“noise” level
increases.
 TYPES OF DISCONTINUITIES
DETECTED BY PT?
All defects that are
open to the surface.
– Rolled products--
cracks, seams,
laminations.
– Castings--cold shuts, hot
tears, porosity, blow
holes, shrinkage.
– Forgings– cracks, laps,
external bursts.
– Welds– cracks, porosity,
undercut, overlap, lack
of fusion, lack of
penetration.
CHOICES OF PENETRANT MATERIALS
Penetrant Type
I Fluorescent
II Visible

Method

A Water Washable
B Postemulsifiable - Lipophilic
C Solvent Removable
D Postemulsifiable - Hydrophilic
Developer Form
Dry Powder
Wet, Water Soluble
Wet, Water Suspendable
Wet, Non-Aqueous for type I
Wet, Non-Aqueous for type II
Specific application
PENETRANT SYSTEM
 Important penetrant properties:
 Wettability – adhesive, cohesive force
 Capillarity – contact angle, surface tension
 Fluidity – viscosity
 Retention & bleeding
 Stability
 Contrast – visible & fluorescent
CENTRE PIVOT PIN WITH
SURFACE CRACK
ADVANTAGES
• Relative ease of use.
• Can be used on a wide range of material types.
• Large areas or large volumes of parts/materials can be inspected
rapidly and at low cost.
• Parts with complex geometries are routinely inspected.
• Indications are produced directly on surface of the part providing a
visual image of the discontinuity.
• Initial equipment investment is low.
• Aerosol spray cans can make equipment very portable.
 LIMITATIONS
• Only detects surface breaking defects.
• Requires relatively smooth nonporous material.
• Precleaning is critical. Contaminants can mask defects.
• Chemical handling precautions necessary (toxicity, fire, waste).
• Metal smearing from machining, grinding and other operations
inhibits detection. In such case, materials may need to be etched
prior to inspection.
• Post cleaning is necessary to remove chemicals.
SUMMARY
 Principle: Capillary action and bleed out
 Procedure:
 Pre cleaning.
 Application of penetrant
 Dwell time
 Removal of excess penetrant.
 Application of developer
 Developing time.
 Penetrant types.
 Developer types.

 Advantages & Disadvantages.

MAGNETIC PARTICLE TEST
MAGNETIC PARTICLE TESTING
 Discontinuities open to the surface and just near to
the surface of ferromagnetic material can be
detected using MPT.

 PRINCIPLE:
Magnetic particles present in a magnetic field
are attracted towards the “flux leakage” caused by
a discontinuity present in a ferromagnetic material.
 MAGNETISM
Magnetism is the ability of matter Magnetic field lines:
to attract other matter to itself. • Form complete loops.
Objects that possess the property • Do not cross.
of magnetism are said to be • Follow the path of least
magnetic or magnetized and resistance.
magnetic lines of force can be • All have the same
found in and around the objects. strength.
A magnetic pole is a point where • Have a direction such that
the a magnetic line of force exits they cause poles to attract
or enters a material. or repel.

Magnetic lines of force Opposite poles attracting Similar poles repelling

around a bar magnet
FERROMAGNETIC MATERIALS
• A material is considered ferromagnetic if it can be
magnetized. Materials with a significant Iron, nickel or
cobalt content are generally ferromagnetic.
• Ferromagnetic materials are made up of many regions in
which the magnetic fields of atoms are aligned. These
regions are called magnetic domains.
• Magnetic domains point randomly in demagnetized
material, but can be aligned using electrical current or an
external magnetic field to magnetize the material.

S N
Demagnetized Magnetized
 HOW DOES MPI WORK?
A ferromagnetic test specimen is magnetized
with a strong magnetic field created by a
magnet or special equipment. If the specimen
has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through
the specimen and a leakage field will occur.
 HOW MPI WORKS?
Finely milled iron particles coated with a dye
pigment are applied to the test specimen. These
particles are attracted to leakage fields and will
cluster to form an indication directly over the
discontinuity. This indication can be visually
detected under proper lighting conditions.
 BASIC PROCEDURE
Basic steps involved:

1. Component pre-cleaning

2. Introduction of magnetic field

3. Application of magnetic media

4. Interpretation of magnetic particle

indications

5. Demagnetisation.
 PRE-CLEANING
Part’s surface should be clean and dry before
inspection
 When inspecting a test part with the magnetic
particle method it is essential for the particles to
have an unimpeded path for migration to both
strong and weak leakage fields alike.
Contaminants such as oil,
grease, or scale may not
only prevent particles from
being attracted to leakage
fields, they may also
interfere with interpretation
of indications.
INTRODUCTION OF THE MAGNETIC
FIELD
The required magnetic field can be introduced into a
component in a number of different ways.
1. Using a permanent magnet or an electromagnet that
contacts the test piece
2. Flowing an electrical current through the specimen
3. Flowing an electrical current through a coil of wire
around the part or through a central conductor running
near the part.
DIRECTION OF THE MAGNETIC FIELD
LONGITUDINAL MAGNETIC FIELD
CIRCULAR MAGNETIC FIELD

FLEMING’S RIGHT HAND RULE

• A longitudinal magnetic field has

magnetic lines of force that run parallel
to the long axis of the part.
• A circular magnetic field has magnetic
lines of force that run circumferentially
around the perimeter of a part.
IMPORTANCE OF MAGNETIC FIELD
DIRECTION
ORIENTATION OF THE DEFECT WITH THE Flux Leakage
MAGNETIC FIELD IS IMPORTANT.
An orientation of 45 to 90 degrees between the
magnetic field and the defect is necessary to
form an indication.

Since defects may No Flux Leakage

occur in various and
unknown directions,
each part is normally
magnetized in two
directions at right
angles to each other.
 PRODUCING A LONGITUDINAL
MAGNETIC FIELD USING A COIL

A longitudinal
magnetic field is
usually established by
placing the part near
the inside or a coil’s
annulus. This
produces magnetic
lines of force that are
parallel to the long
axis of the test part.
 CIRCULAR MAGNETIC FIELDS
Magnetic Field

Electric
Current

Circular magnetic fields are produced

by passing current through the part
or by placing the part in a strong
circular magnet field.
Head shot technique.
Prod technique.
Central conductor technique.
MAGNETIC PARTICLE MEDIA
Dry powder – dry method
With the dry method, the particles are
lightly dusted on to the surface.
The dry method is more portable.
Colour Contrast.

Wet method.
With the wet method, the part is flooded
with a solution carrying the particles.
The wet method is generally more
sensitive since the liquid carrier gives the
magnetic particles additional mobility.
Visible and Fluorescent type.
 CRANE HOOK WITH
SERVICE INDUCED CRACK

Fluorescent, Wet Particle Method

LACK OF FUSION IN SMAW WELD

Visible, Dry Powder

Method
HELICAL COILED SPRING
WITH A SEAM
 DEMAGNETIZATION
•Parts inspected by the magnetic particle
method may sometimes have an objectionable
residual magnetic field that may interfere
with subsequent manufacturing operations or
service of the component.
•Possible reasons for demagnetization include:
– May interfere with welding and/or
machining operations
– Can effect gauges that are sensitive to
magnetic fields if placed in close proximity.
– Abrasive particles may adhere to
components surface and cause and
increase in wear to engines components,
gears, bearings etc.
 DEMAGNETIZATION (CONT.)
• Demagnetization requires that the residual magnetic
field is reversed and reduced by the inspector.
• This process will scramble the magnetic domains
and reduce the strength of the residual field to an
acceptable level.
• METHODs:
• Taking the component away slowly from AC power.
• Step by step Reversing DC and passing through component.
• Raising temperature above curie point.(Heat treatment process)

Magnetized Demagnetized
 ADVANTAGES OF MPI
• Can detect both surface and sub-surface
defects.
• Can inspect parts with irregular shapes
easily.
• Precleaning of components is not as critical
as it is for some other inspection methods.
• Fast method of inspection and indications are
visible directly on the specimen surface.
• Considered low cost compared to many other
NDT methods.
• Is a very portable inspection method
especially when used with battery powered
equipment.
 LIMITATIONS OF MPI
•Cannot inspect non-ferrous materials .
•Inspection of large parts may require use of
equipment with special power requirements.
•Some parts may require removal of coating
or plating to achieve desired inspection
sensitivity.
•Limited subsurface discontinuity detection
capabilities. Maximum depth sensitivity is
approximately 6mm (under ideal conditions).
•Post cleaning, and post demagnetization is
often necessary.
•Alignment between magnetic flux and defect
is important
SUMMARY
 Principle: Flux leakage
 Ferromagnetic materials.
 Procedure:
 Pre cleaning
 Magnetic field
 Magnetic Particle (simultaneous / residual)
 Interpretation of indication
 Demagnetization.
 Magnetization types.
 Equipments.
 Demagnetization & its Importance.
 Advantages & Limitations.
 ULTRASONIC TESTING
 Propagation and echoing of ultrasonic waves
 Ultrasonic waves > 20,000Hz.

 Frequency used for testing: 0.15 – 50MHz.

 Frequency used in ICF: 2 – 2.5 MHz

 Ultrasonic waves generation by piezo electric

crystals. e.g: Quartz , PZT (Lead zirconate titanate)
 ULTRASONIC TESTING
 High frequency ultrasonic waves are introduced into
the material.
 They get reflected (echo) from surfaces and defects.

 Reflected sound energy is displayed versus time in a

CRT monitor.

initial
pulse

back surface crack

echo
crack
echo

0 2 4 6 8 10
 COMPONENTS OF
ULTRASONIC TESTING
 UT Equipment (CRT monitor and control unit)
 Transducer Probe (Normal, Angle)

 Couplant.

 Calibration block.

 Reference block.
APPLICATIONS OF UT IN RAILWAYS

 Bogie frame weldments, critical joints

 Axles and wheels

 Rails
 ULTRASONIC TESTING
 Merits:
 High penetration, sensitivity and accuracy.
 Capability of estimating size, orientation and shape
of the defect.
 Non hazardous, portable.
 Demerits:
 High skill & training required for operation.
 Difficult to inspect rough surface & irregular shapes.
 RADIOGRAPHIC TESTING
X – Ray:


Generated when high speed electrons are obstructed

with metallic targets.

Gamma Ray:
Produced during radioactive decay of elements.
Sources: Natural: U-235, Artificial: Ir-192, Co-60.
 RADIOGRAPHIC TESTING
 Electromagnetic radiation of certain wavelengths
penetrate materials and are absorbed differentially
by different materials.
 X-Ray or gamma radiation is used.

 The emergent radiation from the job is recorded

normally on a film.
 The film after processing is called a radiograph.

 Radiograph contains the shadow image of the

discontinuities.
RADIOGRAPHIC TESTING
 RADIOGRAPHIC TESTING
Preparing the sample

Exposure to radiation source

Developing the radiograph

Interpretation
RADIOGRAPHS OF
WELDMENTS
 WELD DISCONTINUITIES AS INDICATED
ON RADIOGRAPHIC FILM

Porosity as indicated by the dark Slag inclusion indicated by darker

areas in lighter denser weld metal less dense areas

Transverse cracks
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
 WELD DISCONTINUITIES AS INDICATED
ON RADIOGRAPHIC FILM

Incomplete fusion, less dense area Incomplete penetration in root pass

along edge of weld

Undercut as shown by less dense

areas along toe of cap pass
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
RADIOGRAPHIC TESTING
MERITS:
 Permanent readable record.

 Relatively easier interpretation.

DEMERITS:
 Thickness is limited depending upon source.

 More processing time.

 Radiation hazard.
 SUMMARY

 Visual Inspection
 Dye penetrant test – Capillary action

 Magnetic particle inspection – Flux leakage

 Ultrasonic testing – echo due to accoustic impedence

 Radiographic testing – Differential absorption of

radiation
SPECIFICATIONS FOR NDT OF WELDS
TEST IS ISO
Visual Inspection - ISO: 17637
Dye Penetrant Test IS:3658/66 ISO:3452-1
Magnetic particle test IS:5334/69 ISO:17638
Ultrasonic test IS:4260/69 ISO:17640

Radiographic test IS:1182/67 & ISO:17636

IS:4853/68
NDT Personnel IS:13805 ISO:9712
Qualification