1.

Definition and importance of NDT

Non-destructive testing is the use of physical methods which will test materials,
components and assemblies for flaws in their structure without damaging their future
usefulness.
NDT is concerned with revealing flaws in the structure of a product. It, however, cannot predict
where flaws will develop due to the design itself.

All NDT methods have the following common characteristics:

(a) The application of a testing medium to the product to be tested.
(b) The changes in the testing medium due to the defects in the structure of the product.
(c) A means by which it detects these changes.
(d) Interpretation of these changes to obtain information about the flaws in the structure of the
product.

Importance of NDT
NDT plays an important role in the quality control of a product. It is used during all the
stages of manufacturing of a product. It is used to monitor the quality of the:
(a) Raw materials which are used in the construction of the product.
(b) Fabrication processes which are used to manufacture the product.
(c) Finished product before it is put into service.
Use of NDT during all stages of manufacturing results in the following benefits:
(a) It increases the safety and reliability of the product during operation.
(b) It decreases the cost of the product by reducing scrap and conserving materials, labour and
energy.
(c) It enhances the reputation of the manufacturer as producer of quality goods.
All of the above factors boost the sales of the product which bring more economical
benefits to the manufacturer.

Visual inspection is the simplest of all.

LPI
This method is being used since early 19th century

Liquid penetrant inspection is a method that is used to reveal

surface breaking flaws by bleedout of a colored or fluorescent dye
from the flaw. The technique is based on the ability of a liquid to
be drawn into a "clean" surface breaking flaw by capillary action.

Properties of liquid penetrants

2.2.1. Viscosity
Liquids have the ability to flow because molecules of the liquid can slide over each other.
The resistance of liquid to its flow is called viscosity Figure 2.2. In other words, viscosity of a
liquid is a measure of its internal resistance to flow.
The resistance to flow is because of the internal friction among the layers of molecules.
Liquids which flow very slowly like honey or glycerine, have high viscosities as compared to
ether and water having low viscosities.

Surface tension
Surface tension in a liquid is an example of cohesive force, where the molecules are
attracted to like molecules. The cohesive force tends to bind them together, having affinity for
each other. Two examples are water and mercury. When either of these liquids is spilled, they
tend to form spherical shapes, the cohesive force binding them together by surface tension.
Surface tension is one of the two most important properties which determines whether a
liquid makes a good penetrant but is not in itself the controlling factor. The term surface tension
can be described as force per unit length on an imaginary line drawn on the surface of a liquid.
The formation of penetrant indication on development is a reverse capillary action. The rise of
99
liquid in capillary tubes when dipped in it is due to surface tension and its wetting ability.

Capillarity
The capillary pressure is a function of the surface tension of the liquid and its ability to wet the
surface of the tube

8.0

EXAMINATION:

8.1

Dye Penetrant Inspection - Temperature Limitations:

The temperature of the penetrant materials and the surface of the part
should be between 50F and 100F for fluorescent water washable
penetrants and between 60F and 125F for visible penetrants.
8.2

Dye Penetrant Inspection - Penetrant Application:

a) Either immersion (dipping), flow-on, spray, or brushing technique is

used to apply the penetrant to the precleaned dry specimen.
b) The penetrant is applied evenly over the entire area.
c) Fillers shall be used on the upstream side of the air inlet when using
compressed air to apply penetrant.
8.3

Dye Penetrant Inspection - Dwell times:

a) Penetrant dwell times are critical and should be adjusted depending on

temperature and other conditions and may require qualification by
demonstration for specific applications.
b) Typical minimum penetration times are given in the Table-1.
c) Penetrant shall remain on the test surface for the entire dwell time
period.
d) Care shall be taken to prevent drying out of the applied penetrant and
additional penetrant must be applied to re-wet the surface.
Dye Penetrant Inspection - Typical Minimum Penetration Times
Material

Form

Type of Discontinuity

Water-Washable Penetration
Time*

Aluminium

Castings

Porosity, Cold Shuts

5 to 15 min

Aluminium

Extrusions,
Forgings

Laps

NR**

Aluminium

Welds

Lack of Fusion, Porosity

30

Aluminium

All

Cracks, Fatigue Cracks

30, not recommended for

fatigue crack

Magnesium

Castings

Porosity, Cold Shuts

15

Magnesium

Extrusions,
Forgings

Laps

not recommended

Magnesium

Welds

Lack of Fusion, Porosity

30

Magnesium

All

Cracks, Fatigue Cracks

30, not recommended for

fatigue crack

Steel

Castings

Porosity, Cold Shuts

30

Steel

Extrusions,
Forgings

Laps

not recommended

Steel

Welds

Lack of Fusion, Porosity

60

Steel

All

Cracks, Fatigue Cracks

30, not recommended for

fatigue crack

Brass & Bronze

Castings

Porosity, Cold Shuts

10

Brass & Bronze

Extrusions,
Forgings

Laps

not recommended

Brass & Bronze

Brazed Parts

Lack of Fusion, Porosity

15

Brass & Bronze

All

Cracks

30

Plastics

All

Cracks

5 to 30

Glass

All

Cracks

5 to 30

Carbide-tipped Tools

All

Lack of Fusion Porosity,

Craks

30

Titanium & High Temp

Alloys

All

All Metals

All

Brass & Bronze

8.4

not recommended
Stress or Inter-Granular
Corrosion

not recommended

Dye Penetrant Inspection - Excess Penetrant Removal:

After the elapse of penetrant dwell time, the excess penetrant is

removed by water spray. Water at 60F to 110F and a pressure
not exceeding 30 psi (210 KPa) is applied with droplet type sprayer
specifically designed for penetrant removal. The nozzle of sprayer is
held so that water strikes the surface of the specimen at an angle
of approximately 45 degrees. Care is to be taken to avoid overwashing, which causes washout of penetrant from discontinuities. Other
methods of referenced codes or specifications could also be used if applicable for the
test surface conditions.
8.5

Dye Penetrant Inspection - Drying:

The test surface must be dry prior to the application of non-aqueous

or dry developers. If water-based wet developer is used, it is
applied to still damp specimen immediately after the penetrant

removal wash. Excessive heat or too long a drying time tends to

bake the penetrant out of discontinuities.
8.6

Dye Penetrant Inspection - Developer Application:

When the drying process is complete, the specimen is ready for the
application of either dry or non-aqueous wet developer. When
water-based wet developer is used, it is applied by flooding the
surface to the wet specimen immediately after excess penetrant is
removed.
It is recommended to use aerosol cans, after agitation, typically for
weld inspection at various project-site works. Spray distance shall
be 10 to 12 from test surface. The test-areas must be cool
enough to prevent too repaid evaporation of the developer vehicle.
Dry developer is applied to the specimen by brushing with soft
brush, by use of a powder
gun, or by dipping the specimen in a
tank of the developer and removing excess powder with a low
pressure air flow.
An even thin coat/film of developer is preferred.
Applied developer shall not be removed from test surface.
8.7

Dye Penetrant Inspection:

8.7.1
The area under inspection shall be observed during
application of developer and at intervals during development time.
8.7.2
The recommended development time is between 7 and 30
minutes.
Development time begins directly after application of dry developer
and as soon as wet developer coating has dried on parts-surface.
8.7.3
Indications getting formed and formed at the test surface
(by the blotting action of developer) be noticed, analysed (relevant
indications be noted) under adequate lighting conditions.
8.7.4

Lighting Conditions:

a) Visible penetrant indications can be examined in either natural or

artificial light. Adequate illumination is required to ensure no loss in
the sensitivity of the examination. A minimum light intensity at the
examination site of 100 fc (1000 Lx) is recommended.

b) Examine fluorescent penetrant indications under black light in a

darkened area. Visible ambient light should not exceed 2 ft candles
(20 Lx). The measurement should be made with a suitable
photographic-type visible light meter on the surface being
examined.
Black Light Level Control - Black light intensity, minimum of 1000
W/cm2, should be measured on the surface being examined, with
a suitable black light meter. The black light wavelength shall be in
the range of 320 to 380 nm.
The intensity shall be checked at least once every 8 hours, or
whenever the work station is changed. Cracked or broken
ultraviolet (UV) filters should be replaced immediately. Defective
bulbs, which radiate UV energy, must be replaced before further
use. Since a drop in line voltage can cause decreased black light
output with consequent inconsistent performance, a constantvoltage transformer should be used when there is evidence of
voltage fluctuation.
Caution: Certain high-intensity black light may emit unacceptable
amounts of visible light, which will cause fluorescent indications to
disappear. Care should be taken to use only bulbs certified by the
supplier to be suitable for such examination purposes.
Note: The recommended minimum light intensity is intended for
general usage. For critical examination, higher intensity levels may
be required.
Black Light Warm Up - Allow the black light to warm up for a
minimum of 10 min prior to its use or measurement of the intensity
of the ultraviolet light emitted.
Visual Adaptation - The examiner should be in the darkened area for
at least 5 min before examining parts to allow the eyes to adapt to
the dark viewing.
Caution - Photochromic
examination.

lenses

shall

not

be

worn

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during