Module 10 - 1

Module 10
Visual
Inspection and
Other
NDE Methods
A
and Symbols
W
m e r i c a nS e l d i n g o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 VT Immediately Before Module 10 - 5

Welding
 Check base and filler metals
 Check welding equipment
 Check weld preparations
 Check joint fitup
 Check weld joint cleanliness
 Check preheat, if required

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 9

Prebending
and
Presetting
Pieces to
Allow for
Distortion

Am e r i c a n We l d i n g S o c i e t y
 Temperature Module 10 - 10

Measurements
 Required for:
– Preheat
– Interpass temperature limits
– Post weld heat treatments
 Typically achieved by:
– Temperature sensitive crayons
– Digital pyrometers

Am e r i c a n We l d i n g S o c i e t y
Temperature-sensitive Module 10 - 11

Crayons

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 12

Digital
Contact
Pyrometer

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 15

Nondestructive Testing

“Method of testing to evaluate

quality and not effect end-use
serviceability”

Am e r i c a n We l d i n g S o c i e t y
 Elements of all NDE Module 10 - 16

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

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 17

Common NDE Methods

 Penetrant - PT
 Magnetic Particle - MT
 Radiographic - RT
 Ultrasonic - UT
 Eddy Current - ET

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 18

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

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 24

Remove Excess Penetrant

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 25

Remove Excess Penetrant

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 Module 10 - 26

Remove Excess Penetrant

Am e r i c a n We l d i n g S o c i e t y
 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.

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 28

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

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 29

Evaluate PT
Note porosity and
crack indications

Am e r i c a n We l d i n g S o c i e t y
 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.

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 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”

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 41

Magnetic Particles
 Iron based
 Dry or wet
 Types
– Color dyed
– Fluorescent

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 Module 10 - 42

Longitudinal Magnetism

Am e r i c a n We l d i n g S o c i e t y
 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 / DC bench units
 AC yokes
 AC / DC yokes
 AC / DC prods
 AC / 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.”

Am e r i c a n We l d i n g S o c i e t y
X-Ray Machine (aimed Module 10 - 53

down)

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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

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
Hole Type Image Quality Module 10 - 61

Indicators

2T
hole
1T
hole
4T
hole

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Wire Type Image Quality Module 10 - 62

Indicators

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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 viewers
 Film holders
 IQI’s

Am e r i c a n We l d i n g S o c i e t y
 Module 10 - 64
Orientation of Source,
Plate, & Film

Am e r i c a n We l d i n g S o c i e t y
 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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 Module 10 - 74

UT Process - 1 of 2

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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.”

Am e r i c a n We l d i n g S o c i e t y
 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

Am e r i c a n We l d i n g S o c i e t y
 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 - Module 10 - 90

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 - Module 10 - 91

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

Am e r i c a n We l d i n g S o c i e t y