CHAPTER 4

Non-Destructive Testing

Prepared by: Mdm Nurulhuda

Arifin
VISUAL INSPECTION
• Basic
Principle:
 Illumination of the test specimen with light
 Specimen examined with eye @ light
 Optical Aids:
1. Microscope – combination lens used to magnify image of
small object
2. Borescope – design to enable an observer to inspect inside a
narrow tube, pipe

3. Telescope – use to obtain magnified image of objects at considerable

distance from eye
• Information gained from VT:

1. General condition of components

2. Presence @ absence crack and position of crack
3. Surface porosity, contour of weld, adjoining parent metal
4. Result of VT may be great assist to others test
 4.2 Magnetic Particle Testing
How Does It Work?
 A ferromagnetic test specimen is magnetized with a strong
magnetic field created by a magnet or special equipment.
 If the specimen has a discontinuity, the discontinuity will interrupt
the magnetic field flowing through the specimen and a leakage
field will occur.
 Iron particles are applied to the test specimen.
 These particles are attracted to leakage fields and will form an
indication directly over the discontinuity.
 This indication can be visually detected under proper lighting
conditions.
 Magnetization Technique
1. Magnetization Using Direct Induction (Direct Magnetization)

 Current is passed directly through the

component.
 care must be taken to ensure that good
electrical contact and maintained between
the test equipment and the test
component.
 Improper contact  damage the
component or possible to overheat
components in areas of high resistance
2. Magnetization Using Indirect Induction
(Indirect Magnetization)

 using a strong external magnetic

field to establish a magnetic field within
the component.

 The use of permanent magnets is a

low cost method of establishing a
magnetic field.

 Limitation:
 lack of control of the field strength
 difficulty of placing and removing strong
permanent magnets from the component.
 Direction of the Magnetic Field

 Two general types of magnetic fields may be established

within the specimen.
2.longitudinal
1. circular

•A circular magnetic field •A longitudinal magnetic

field has magnetic lines of
has magnetic lines of force
force that run parallel to the
that run circumferentially
long axis of the part.
around a part.
 Importance of Magnetic Field
Direction

Flux Leakage

 the best detection of defects occurs when the

lines of magnetic force are established at
perpendicular to dimension of the defect.
 This orientation creates the largest disruption
of the magnetic field of the part.
 An orientation of 45 to 90 degrees between the
magnetic field and the defect is necessary to
form an indication. No Flux Leakage
 Basic Procedure MPI
1. Component pre-cleaning

2. Introduction of magnetic field

3. Application of magnetic media

4. Interpretation of magnetic particle

indications
1. Component pre-cleaning

The part’s surface should be clean and dry

before inspection.

2. Introduction of magnetic field

Using a permanent magnet or an electromagnet that contacts the
test piece
3. Application of magnetic media

Can be performed using either dry particles, or

particles suspended in a liquid

4. Interpretation of magnetic
particle indications
After applying the magnetic field,
indications that form must interpreted.

This process requires that the inspector

distinguish between relevant and non-
relevant indications
 Advantages / Disadvantage of
MPI
Advantages Disadvanta
genon-ferrous materials such as
1. Cannot inspect
1.Can detect both surface and near sub- aluminum, magnesium or most stainless steels.
surface defects.
2. Inspection of large parts may require
2. Can inspect parts with irregular shapes equipment with special power requirements.
easily.

3. Pre-cleaning of components is not as 3. Some parts may require removal of coating or

critical plating to achieve desired inspection sensitivity.

4. Fast method of inspection and indications 4. Limited subsurface discontinuity detection

are visible directly on the specimen surface. capabilities. Maximum depth sensitivity is
approximately 0.6”
5. Low cost compared to many other NDT
methods.
5. Post cleaning, and post demagnetization is
often necessary.
 4.3 Liquid Penetrant Testing
o A method used to reveal surface
discontinuities by bleed out of a
colored or fluorescent dye from
the flaw

o The technique is based on the

ability of a liquid to be drawn into
a "clean" surface discontinuity by
capillary action
o After a period of time (dwell
time) excess surface penetrant
is removed and a developer
applied

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 Step of DPI
1. Surface 3. Penetrant
2. Penetrant
Preparation Dwell
Application
Penetrant material is The penetrant is
applied by spraying, left on the
Surface must be surface for a
free of oil, brushing, or immersing
grease, water, or the part in sufficient time to
other a penetrant bath. allow as much
penetrant to be
contaminants drawn or to seep
that may prevent into a defect
penetrant from
entering flaws

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 4. Excess
Penetrant 5.Developer 6.Inspection
Removal Application
- Excess penetrant - Applied on sample to - Inspection is
must be removed draw penetrant trapped performed under
from the surface of in flaws back to the appropriate
the sample surface where it will be lighting to detect
- Step may involve visible. indications from
cleaning with a any flaws which
solvent, direct may be present.
rinsing with water

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 Advantages & Disadvantage
DPI
Advantages Disadvantages

1. High sensitivity (small discontinuities can be 1. Only surface breaking defects can be
detected) detected

2. Pre-cleaning is critical since

2. Few material limitations
contaminants can mask defects

3. Multiple process operations must be

3. Rapid inspection of large areas and volumes
performed and controlled

4. The inspector must have direct access to

4. Suitable for parts with complex shapes
the surface being inspected

5. Chemical handling and proper disposal

5. Low cost
is required

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Eddy Current Test
NDT methods that use the principal of “electromagnetism” as
the basis for conducting examinations

Eddy currents are created through a process called electromagnetic

induction
When alternating current is applied
to the conductor, such as copper
wire, a magnetic field develops in
and around the conductor

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 Factors the efficiency of eddy
current test

Test parameter:
1. Frequency
2. Type and geometry of test coil
 
Test object:
1. Electrical conductivity
2. Magnetic permeability
3. Dimension
4. Temperature

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  ITEM Eddy Current
1 Technique AC Current passing through a coil that
    is placed near the surface of the part
    to be inspected
     
2 function Crack detection
  Material thickness  measurements 
  Coating thickness measurements
  Conductivity measurements
   
3 advantages wide range condition
    info simple go/no go
    portable
    no consumables
    flexible probe
    total auto

4 metal ferrous/non ferrous

    iron casting
     
5 disadvantage restricted to :
    surface breaking
    slightly subsurface defect
   
6 principle electrical
Ultrasonic Test (VT)

Application UT:
1. Detect defect  voids, crack, inclusion, etc..
2. Measure thickness material
3. Study metallurgy structure of material
Fundamental Ultrasonic
Waves

 Allows energy to be transfer from one point to another at

some distance without any particle travel between two
Waves: points
 sound energy is transmitted through a solid material by
series of displacement that called as wave
 Principle Generation & Reception in
Ultrasonic

 All generation and detection of ultrasound involved the use of

transducer:
 generates the ultrasonic waves
 converts electrical energy to vibration energy
 Ultrasonic emitted by transducer enter top surface  continue
travel through plate
 Waves then reflected back to top surface  receive by transducer
 display on CRT
 Basic Ultrasonic Test System:

1. Pulse Echo Technique:

 Ultrasonic pulses are transmitted into a specimen.

 The ultrasound coming back to receiver after being reflected at any flaws or
back surface and displayed on a Cathode Ray Tube (CRT).
 Indications displayed on CRT are called as ‘Echoes’.
 The proportion of ultrasound that is reflected is highly depending on size of
reflecting surface with respect to incident beam.
Single Probe

Crystal probe will The reflected pulse will

Transmitter circuit will convert the electrical be converting to
feed the electrical pulse pulse into ultrasonic electrical pulse and
to crystal probe pulse and transmitted pulse will be displayed
into test piece on CRT screen
2. Through Transmission Technique:

 Two probes are used ( one for

transmitting ultrasonic waves & others
for receiving waves at other side)

 Receiving transducer aligned with

transmitting transducer to pick up sound
waves

 Suitable to inspect crack large

dimension than size probe
 Double Probe

Transmitter circuit feed

the electrical pulse to
crystal probe

Crystal probe convert the

electrical pulse into
ultrasonic pulse and
transmitted into test piece

The pulse will be detected

by another probe known as
receiver probe

Receiver probe will

convert ultrasonic pulse
into electrical pulse and
displayed on CRT.
MEASUREMENT TECHNIQUES

1. Normal Beam Inspection

Pulse-echo ultrasonic measurements can determine the
location of a discontinuity in a part  by accurately
measuring the time required

two-way transit time measured is divided by two to account

for the down-and-back travel path and multiplied by the
velocity of sound in the test material.
2. Crack Tip Diffraction

To identify length of a crack when:

1. geometry of the part is relatively

uncomplicated
2. orientation of a flaw is well known
4 Criteria for Successful Ultrasonic
Inspection.
1. Equipment and system are
suitable for specific application
2. Adequate reference /
standard block
3. Sufficiently trained and
experience operator
4. A clear definition of test
problem
 Couplant:
 A couplant is used between transducer face and test surface to
ensure sufficient sound transmission from transducer to test
surface.
 Good characteristic of couplant:
1. Easy to apply
2. Homogeneous and free of bubbles
3. Harmless to the test specimen and transducer
4. Able to wet both surface of test specimen and transducer
5. Has tendency to stay on test surface but it easy to remove
6. Has an acoustic impendence between transducer face and test specimen
• Advantages UT:

1. Penetration power allow examine thick material

2. High sensitivity
3. Harmless compare to radiography
4. Friendly user
5. Require access to only one surface

• Limitation UT:
1. Require trained inspector
2. Difficult to apply coarse grain material
3. Insensitive to detect parallel defect
4. Require couplant
5. Insensitive to detect very near to surface
4.6 Radiographic Testing
CONCEPT:
 X-ray is used to determine the
internal soundness of welds

 Based on the ability of X-rays &

gamma rays to pass through metal
and other materials

 All materials will absorb known

amounts of this radiant energy
Advantages & Disadvantage
Radiographic Test
Advantages Disadvantages

1. Eliminates disassembly
1. Radiation hazard
requirements

2. Trained operator

2. High sensitivity
3. Crack plane must parallel to
x-ray beam
 - END -

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