UNIT I - OVERVIEW OF NDT

Introduction

Non-destructive testing (NDT) is a testing and analysis technique used by industry to evaluate
the properties of a material, component, structure or system for characteristic differences or
welding defects and discontinuities without causing damage to the original part. NDT also
known as non-destructive examination (NDE), non-destructive inspection (NDI) and non-
destructive evaluation (NDE).

NDT uses science and math to make measurements and inspections. There is a large number of
different NDT methods used and they all use some form of energy to collect information. Some
of the more common methods used are electricity, magnetism, X-rays, and sound as the energy
form.

NDT methods are used to make sure that important parts on airplanes and automobiles and in
nuclear power plants are free of defects that could lead to an accident.

Difference between non destructive testing and destructive testing

Si.No. Destructive testing Non destructive testing

1 In destructive testing tests are carried out to Nondestructive testing is a wide group
the specimen's failure, in order to understand of analysis techniques used to
a specimen's performance or material evaluate the properties of a material,
behavior under different loads. component or system without causing
damage.

2 100% testing is not possible 100% testing is possible

3 Skilled operator is not required to perform The manual operation requires

testing experienced and skilled technicians.

4 Suitable for where production rate is mass Suitable for where small defects leads
quantity to accident

5 Internal defects cant be determined Surface and subsurface defects can be

determined

6 Cost of the equipment is not high Equipment cost is high

7 Equipment setup is not portable Equipment setup is portable and

carry-over where test to be performed
 8 Interpretation of results is easy Interpretation of results is difficult.

9 Ex. Tensile test, Bending Test, Brinell Test, Ex. Liquid penetration test,
etc.. Radiographic test, etc..

Advantages of NDT

● Less Waste. Since substances are not altered by NDT, they can continue to be used. That
means less wasted samples.
● Less Downtime. Using some methods, the materials can be tested even while in use,
which eliminates the need to shut down operations during testing.
● Accident Prevention. Non-Destructive Testing can help prevent accidents, which helps
reduce costs associated with repairs, replacement, and equipment loss and business shut
down.
● Identify Areas of Concern Before Failure. Components that fail can be costly to repair
or replace and may lead to an unexpected shutdown of the business or in some cases,
disasters. NDT can identify these areas of concern before they become a problem.
● Increased Product Reliability. Advanced and more comprehensive testing ensures
better products. Problems can be identified and fixed before the product goes to market,
and products that are already in use can be tested more frequently to ensure they continue
to perform as expected.
● Comprehensive Testing. Since this type of testing does not alter substances, every
component or product can be tested. There is no need for selective sampling, which tests
only a portion of the components. NDT techniques can also be applied at multiple stages
of development and construction, allowing manufacturers to identify and repair or replace
problem pieces before construction is complete, as well as after the product has been put
to use.
● It is a very sensitive method, capable of finding extremely fine flaws
● Small objects, with awkward shapes, can be inspected
● Equipment setup is portable easily carry-over where testing to be done

Disadvantages of NDT

● Preparation, before and after testing, can be time consuming.

● Sensitivity of inspection can sometimes be affected by the finish of a component.
● Operators should be certified to perform testing.
● Equipment setup is costly

Where To Use NDT Techniques

Non-Destructive Testing is used every day in industries all around us, ensuring our safety and
security.

NDT methods are used:

● In product evaluation.
● For troubleshooting
● For identifying areas of wear
● For assuring the safety and reliability of structures and component
● To find flaws or irregularities both on and under the surface of materials.

NDT is used in many industries, including:

● Engineering
● Air
● Space
● Rail
● Motor vehicles
● Utilities
● Power and energy companies
● Construction

Applications of Non-Destructive Testing

1. Bridges Inevitably, factors such as wear, exposure to the elements, and age of a bridge
will cause deterioration. Without proper maintenance, a bridge's structure can weaken,
and the consequences can be catastrophic. Non-destructive testing detects defects on
bridges before they could become a major problem.
2. Railroads Regular inspections also ensure that flaws are caught well before they could
pose a danger. Tragically, improper or lax maintenance on railroads has lead to
derailment. This is a reminder that proper, routine inspection is essential in the railroad
industry.
3. Storage Tanks Some storage tanks are stationary, while others are affixed to trucks for
transport. Storage tanks can hold water, petroleum, chemicals, natural gas, nuclear waste,
and much more. Like all structures, storage tanks can corrode or crack over time. An
unchecked flaw can lead to leakage which can incur major losses. Leakage can also be
highly dangerous if the materials enclosed in a tank are hazardous.
4. Aerospace Aircraft take a lot of stress from frequent landings and harsh environmental
conditions. Spacecraft must withstand rocket launches and the UV radiation of the sun.
At a cruising altitude of 35,000 feet in the sky, airplanes cannot afford to have major
 failures. That is why prevention through regular non-destructive testing on air and
spacecraft is vital.
5. Ships The rough waters of the ocean cause corrosion and wear on ships, so regular
maintenance and testing is crucial.
6. Pressure Tanks Pressure vessels store gases and liquids at a pressure different from our
atmosphere. This pressure difference means any flaw or crack in a vessel can cause
sudden pressure shifts that can cause an explosion. To avoid this, tanks are inspected
using radiography and ultrasonic testing.
7. Vehicles The automotive industry relies on regular non-destructive testing to ensure that
a car's parts meet safety standards.

Non-Destructive Testing Methods

● Visual Inspection (VI)
● Acoustic Emission Testing (AE)
● Electromagnetic Testing (ET)
● Ground Penetrating Radar (GPR)
● Laser Testing Methods (LM)
● Leak Testing (LT)
● Magnetic Flux Leakage (MFL)
● Ultrasonic Testing (UT)
● Liquid Penetrant Testing (PT)
● Radiographic testing (RT)

Visual Inspection (VT)

Visual inspection (VT) is the oldest and most widely used NDT method. This method involves
the visual observation of the surface of a test object to evaluate the presence of surface
discontinuities such as corrosion, misalignment of parts, physical damage and cracks. Visual
testing can be done by looking at the test piece directly, or by using optical instruments such as
magnifying glasses, mirrors, borescopes and computer-assisted viewing systems.

VT can be applied to inspect castings, forgings, machined components and welds and is used in
all branches of industry.

Advantages
● Low cost
● Portable equipment (if any)
● Immediate results
● Minimum special skills required
 ● Minimum part preparation

Limitations
● Only suitable for surfaces than can be viewed
● Usually only larger defects can be detected
● Scratches can be misinterpreted for cracks
● Quality of inspection influenced by surface condition, physical conditions, environmental
factors and physiological factors

Optical Aids Used for the Visual Inspection

Microscope: Magnifying devices and lighting aids can and are used to aid in the visual
inspection of objects and materials. These devices can be used to check for the presence of
foreign objects, corrosion and damage. With these kinds of devices it is useful to have a general
idea of where the defect may be located.

Borescope: A borescope is an optical device consisting of a rigid or flexible tube with an

eyepiece or display on one end, an objective lens or camera on the other linked together by an
optical or electrical system. Generally, the diameter of the borescope depends upon the diameter
of the hole or bore to be inspected. Rigid borescopes have the limitation that access to what is to
be viewed must be in a straight line. Ultrasonic inspection does not have this limitation.

Endoscope: An endoscope is much like a borescope except that it has superior optical systems
and uses a strong light source to aid it. Endoscopes are also unique in that objects remain in
focus from about 4mm on. Most people are familiar with the medical applications of this
technology.
Holography: Holography is the name given to the method of creating a three-dimensional image
of any given object. Holography is used in NDT to provide a record of the image of an entire
surface which can be compared to a defect-free surface.