General Introduction to NDT TWI

NDT Methods
Penetrant Inspection Magnetic Particle Inspection Eddy Current Inspection Ultrasonic Inspection Radiographic Inspection

Magnetic Flux Leakage Acoustic Emission

Liquid Penetrant Inspection

A.K.A. Dye Penetrant Inspection (DPI)
Penetrant Flaw Detection (PFD) Penetrant testing (PT)

Surface inspection method Applicable to all non-porous, non-absorbing materials

Penetrant Inspection
Penetrating fluid applied to component and drawn into defect by capillary action

Penetrating fluid removed from component surface (but not from defect)

Principle : Capillary Action

Interaction of adhesive and cohesive forces

Penetrant Inspection
Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface

Penetrant Inspection
Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface Penetrant drawn back out of the defect by reverse capillary action

Penetrant Inspection

System classification
PENETRANT Colour contrast Fluorescent Dual REMOVAL Solvent Water washable Post emulsifiable DEVELOPERS Dry powder Aqueous Non-Aqueous

Advantages of DPI
Applicable to non-ferromagnetic materials Able to test large parts with a portable kit Batch testing Applicable to small parts with complex geometry Simple,cheap easy to interpret Sensitivity

Disadvantages of DPI
Will only detect defects open to the surface Careful surface preparation required Not applicable to porous materials Temperature dependant Cannot retest indefinitely Compatibility of chemicals

Magnetic Particle Inspection

Test method for the detection of surface and sub-surface indications in ferromagnetic materials Magnetic field induced in component Defects disrupt the magnetic flux Defects revealed by applying ferromagnetic particles

Principle of MPI : Flux Leakage

No Defect Defect

Lines of flux follow the path of least resistance

Magnetic Particle Inspection

Advantages of MPI
Will detect some sub-surface defects Rapid and simple to understand Pre-cleaning not as critical as with DPI Will work through thin coatings Cheap rugged equipment Direct test method

Disadvantages of MPI
Ferromagnetic materials only Requirement to test in 2 directions Demagnetisation may be required Odd shaped parts difficult to test Not suited to batch testing Can damage the component under test

Magnetic Flux Leakage

A saturation of flux is introduced

Magnetic Flux Leakage

A saturation of flux is introduced Flux forced into air by reductions in thickness

Magnetic Flux Leakage

A saturation of flux is introduced Flux forced into air by reductions in thickness Magnetic flux detected by sensors

Sensor N S

Magnetic Flux Leakage

Affected by Climatic conditions Cleanliness Surface condition Limitations Coverage

Qualitative not Quantitative

Top side / Bottom side differentiation

Eddy Current Inspection

An alternating current is passed through a coil

Eddy Current Inspection

An alternating current is passed through a coil A.C. generates an alternating field

Eddy Current Inspection

An alternating current is passed through a coil A.C. generates an alternating field Alternating field generates eddy currents in conductors

Eddy Current Inspection

An alternating current is passed through a coil A.C. generates an alternating field Alternating field generates eddy currents in conductors Eddy currents generate opposing field which modifies current in coil

Eddy Current Inspection

Electrical currents induced in metals by alternating magnetic fields
The size of the current is affected by Electrical conductivity

Stand off distance

Flaws Permeability Specimen dimensions

Advantages of ET
Sensitive to surface defects Can detect through several layers Can detect through surface coatings Accurate conductivity measurements Can be automated Little pre-cleaning required Portability

Disadvantages of ET
Very susceptible to permeability changes Only on conductive materials Will not detect defects parallel to surface Not suitable for large areas and/or complex geometry's Signal interpretation required No permanent record (unless automated)

Ultrasonic Inspection
Principle
High frequency sound sound waves are introduced into a material Interfaces between materials of differing acoustic properties reflect or transmit sound Reflected sound is displayed on a CRT

Defect Orientation
0 degree Probes

Screen

Depth

Metal

Depth

Defect Orientation
Angle Probes

Range

Range
Depth = Range x Cos (Probe angle)

Defect Orientation
1 2 3

Advantages
Sensitive to cracks at various orientations Portability Safety Able to penetrate thick sections Measures depth and through wall extent

Disadvantages
No permanent record (unless automated) Not easily applied to complex geometries and rough surfaces. Unsuited to course grained materials Requires highly skilled and experienced technicians

Acoustic Emission
Transient stress waves from micro structural changes detected by sensors

Stress waves Stress

Radiographic Inspection
Electromagnetic radiation is imposed upon a test object Radiation is transmitted to varying degrees dependant upon the density of the material through which it is travelling Variations in transmission detected by photographic film or fluorescent screens Applicable to metals,non-metals and composites

Radiographic Inspection
Radiation Source

Lower density

Higher density

Specimen

Film

Radiographic Image

Advantages of Radiography
Permanent record Internal flaws Can be used on most materials Direct image of flaws Real - time imaging

Disadvantages of Radiography
Health hazard Sensitive to defect orientation Limited ability to detect fine cracks Access to both sides required Limited by material thickness Skilled interpretation required Relatively slow High capital outlay and running costs

The End
Any Questions Please ?

Vacuum Box Testing

Vacuum created within a perspex box Soapy liquid applied to surface

Vacuum Box Testing

Vacuum created within a perspex box Soapy liquid applied to surface Bubbles indicate through thickness defect