NON-DESTRUCTIVE TESTING

Definition of NDT
The use of noninvasive
techniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure
without doing harm.

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Comparison Chart
DESTRUCTIVE TESTS NON-DESTRUCTIVE TESTS
1. Tests usually simulate one or more 1. Tests usually involve indirect
service conditions. Consequently, they measurements of properties of no direct
tend to measure serviceability directly significance in service. The correlation
and reliably. between these measurements and
serviceability must be proved by other
means.
2. Tests are usually quantitative 2. Tests are usually qualitative and
measurements of load for failure, rarely quantitative. They do not usually
significant distortion or damage, or life measure load for failure or life to failure,
to failure under given loading and even indirectly. They may, however,
environmental conditions. reveal damage or expose the
Consequently they may yield numerical mechanisms of failure.
data useful for design purposes or for
establishing standards or specifications.
DESTRUCTIVE TESTS NON-DESTRUCTIVE TESTS
3. The correlation between most 3. Skilled judgment and test or service
destructive test measurements and the experience are usually required to
material properties being measured interpret test indications. Where the
(particularly under simulated service essential correlation has not been
loading) is usually direct. Hence most proven, or where experience is limited,
observers may agree upon the results of observers may disagree in evaluating the
the test and their significance with significance of test indications.
respect to the serviceability of the
material or part.
4. Tests are not made on the objects 4. Tests are made directly upon the
actually used in service. Consequently objects to be used in service.
the correlation or similarity between Consequently there is no doubt that the
the objects tested and those used in tests were made on representative test
service must be proven by other means. objects.
5. Tests can be made on only a fraction 5. Tests can be made on every unit to be
of the production lot to be used in used in service, if economically
service. They may have little value justified. Consequently they may be
when the properties vary unpredictably used even when great differences from
from unit to unit. unit to unit occur in production lots.
DESTRUCTIVE TESTS NON-DESTRUCTIVE TESTS
6. Tests often cannot be made on 6. Tests may be made on the entire
Complete production parts. The tests are production part or in all critical regions
often limited to test bars cut from production of it. Consequently the evaluation
parts or from special material specimens applies to the part as a whole. Many
processed to simulate the properties of the critical sections of the part may be
parts to be used in service. examined simultaneously or sequentially
as convenient and expedient.
7.A single destructive test may measure 7. Many non-destructive tests, each sensitive
only one or a few of the properties that to different properties or regions of the
may be critical under service material or part, may be applied
conditions. simultaneously or in sequence.
In this way it is feasible to measure as many
different properties correlated with service
performance as desired.
8. Destructive tests are not usually 8. Non-destructive tests may often be applied
convenient to apply to parts in service. to in service parts or assemblies
Generally, service must be interrupted without interruption of service beyond normal
and the part permanently removed from maintenance or idle periods. They involve no
service. loss of serviceable parts.
DESTRUCTIVE TESTS NON-DESTRUCTIVE TESTS
9. Cumulative change over a period of 9. Non-destructive tests permit repeated
time cannot readily be measured on a checks of a given unit over a period of
single unit. If several units from the time. In this way, the rate of service
same lot or service are tested in damage, if detectable, and its correlation
succession over a period of time, it with service failure may be established
must be proven that the units were clearly.
initially similar. If the units are used in
service and removed after various
periods of time, it must be proven that
each was subject to similar conditions
of service, before valid data can be
obtained.
10. With parts of very high material or 10. Acceptable parts of very high
fabrication costs, the costs of replacing material or fabrication costs are not lost
the parts destroyed may be prohibitive. in non-destructive testing. Repeated
It may not be feasible to make an testing during production or service is
adequate number and variety of feasible when economically and
destructive tests. practically justified.
DESTRUCTIVE TESTS NON-DESTRUCTIVE TESTS
11. Many destructive tests require 11. Little or no specimen preparation is
extensive machining or other required for many forms of nondestructive
preparation of the test specimens. tests. Several forms of nondestructive
Often, massive precision-testing testing equipment are
machines are required. In consequence portable. Many are capable of rapid
the cost of destructive testing may be testing or sorting and in some cases may
very high, and the number of samples be made fully automatic. The cost of
that can be prepared and tested may non-destructive tests is less, in most
make severe demands upon the time of cases, both per object tested and for
highly skilled workers. overall testing, than the cost of adequate
destructive tests.
12. The time and man-hour 12. Most non-destructive test methods
requirements of many destructive tests are rapid and require far fewer manhours
are very high. Excessive production or actual hours than do typical
costs may be incurred if adequate and destructive tests. Consequently testing
extensive destructive tests are used as all the production units cost normally
the primary method of production less than, or comparable, to the costs of
quality control. inspecting destructively only a minor
percentage of the units in production lots.
Six Most Common NDT
Methods
1. Visual Testing (VT)
2. Dye Penetrant Testing (DPT)
3. Magnetic Particle Testing (MPT)
4. Ultrasonic Testing (UT)
5. Eddy Current Testing (ECT)
6. Radiography Testing (RT)

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Visual Testing

Visual testing is the most basic and common inspection method

involves in using of human eyes to look for defects. But now it is
done by the use special tools such as video scopes, magnifying
glasses, mirrors, or borescopes to gain access and more closely
inspect the subject area.

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Visual Testing Equipments:

• Mirrors (especially small, angled mirrors),

• Magnifying glasses,
• Microscopes (optical and electron),
• Borescopes and fiber optic borescopes,
• Closed circuit television (CCTV) systems,
• Videoscope.
Visual Testing Equipment’s

Fig: Videoscope Fig: Advanced Videoscope Fig: Borescopes

Fig. Microscope Fig: Magnifying glass

PENETRANT TESTING
 Introduction
• This module is intended to provide an introduction to the NDT method of
penetrant testing.
• Penetrant Testing, or PT, is a nondestructive
testing method that builds on the principle
of Visual Inspection.
• PT increases the “see ability” of small discontinuities that the human eye
might not be able to detect
alone.
How Does PT Work?
• In penetrant testing, 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 and other mechanisms.
• Excess penetrant is removed from the surface and a developer is
applied to
pull trapped penetrant back
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.
Basic Process of PT
1) Clean & Dry Component 4) Apply Developer
2) Apply Penetrant

5) Visual Inspection
3) Remove Excess

6) Post Clean Component

What Can Be Inspected Via PT?

Almost any material

that has a relatively
smooth, non-porous
surface on which
discontinuities or
defects are
suspected.
What Can NOT be Inspected Via PT?
• Components with rough surfaces,
such as sand castings, that trap
and hold penetrant.
• Porous ceramics
• Wood and other fibrous materials.
• Plastic parts that absorb or react
with the penetrant materials.
• Components with coatings that Defect indications
become less
prevent penetrants from entering distinguishable as
defects. the background
“noise” level
increases.
 What Types of Discontinuities Can Be
Detected Via 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
Visible Vs Fluorescent PT
• Inspection can be performed
using visible (or red dye) or
fluorescent penetrant
materials.
• Visible Pt is performed under
white light while fluorescent
PT must be performed using
Photo Courtesy of Contesco
an ultraviolet light in a
darkened area. All are all in
the level 1 sensitivity range.
• Fluorescent PT is more
sensitive than visible PT
because the eye is more
sensitive to a bright
indication on a dark
background. Sensitivity
ranges from 1 to 4.
Penetrant Removal Method
Penetrants are also classified by the method of removing
the excess penetrant.

• Solvent Removable penetrants are removed by wiping with a

cloth dampened with solvent.

• Water Washable penetrants are removed with a course spray

of water.

• Post-Emulsifiable penetrants are water-washable only after

they have reacted with an emulsifier solution..
Developers
• The role of the developer is to pull trapped
penetrant out of defects and to spread it
out on the surface so that it can be seen.
Also provides a light background to
increase contrast when visible penetrant is used.

• Developer materials are available in several different forms

/ Dry Powder
/ Wet, Water Suspendable
/ Wet, Water Soluble
/ Wet, Non-Aqueous
6 Steps of Penetrant Testing
1. Pre-Clean
2. Penetrant Application
3. Excess Penetrant Removal
4. Developer Application
5. Inspect/Evaluate
6. Post-clean
 Pre-cleaning – Step 1
• Parts must be free of dirt,
rust, scale, oil, grease, etc.
to perform a reliable
inspection.
• The cleaning process must
remove contaminants from
the surfaces of the part
and defects, and must not
plug any of the defects.

Pre-cleaning is the most

important step in the PT
process!!!
Penetrant Application
Many methods
– Step 2
of application
are possible
such as:
– Brushing
– Spraying
– Dipping/
Immersing
– Flow-on
– And more
Excess Penetrant Removal – Step 3
The removal technique depends upon the type of penetrant
used, as stated earlier…
– Solvent Removable
– Water Washable
– Post Emulsifiable
Developer Application – Step 4
The method of developer application is dependent on the
type of developer used. The primary methods for the
following main developer types will be covered in the
following slides.
– Dry
– Wet
– Nonaqueous Wet
Inspection/Evaluation – Step 5
In this step the inspector
evaluates the penetrant
indications against specified
accept/reject criteria and attempts
to determine the origin of the
indication.
Non-relevant weld geometry indications
The indications are judged to be
either relevant, non-relevant or
false.

Relevant crack indications from an

abusive drilling process
Inspection/Evaluation – Step 5
A very important step of
evaluation is to document
findings on an inspection
report form or other record
keeping form.
This may be supported with
drawings or photos of
indications, etc.
Post Clean – Step 6
The final step in the penetrant
inspection process is to thoroughly
clean the part that has been tested
to remove all penetrant processing
materials.
The residual materials could
possibly affect the performance of
the part or affect its visual appeal.
Penetrant Inspection Systems
Penetrant systems can be highly portable or stationary.

Image courtesy of Nebraska Army National Guard

Portable Penetrant System Stationary Penetrant System

Advantages of Penetrant Testing
• 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 of Penetrant Testing
• Only detects surface breaking defects.
• Requires relatively smooth nonporous material.
• Precleaning is critical. Contaminants can mask
defects.
• Requires multiple operations under controlled
conditions.
• Chemical handling precautions necessary (toxicity,
fire, waste).
• Metal smearing from machining, grinding and other
operations inhibits detection. Materials may need
to be etched prior to inspection.
• Post cleaning is necessary to remove chemicals.
 Summary

• Penetrant testing (PT) is one of the most widely used

nondestructive testing methods.
• Its popularity can be attributed to two main factors, which
are its relative ease of use and its flexibility.
• However, PT involves a number of processing steps that
must be closely control to achieve optimal sensitivity.
Thank You