Non-Destructive

Testing (NDT)

By Group 6
What is NDT?
• Non-destructive testing is a wide group of analysis
techniques used in science and technology industry to
evaluate material, component or system without
causing damage.
• Other terms are: Non-Destructive Examination (NDE),
Non-Destructive Inspection (NDI), and Non-
Destructive Evaluation (NDE).
• NDT does not permanently alter the article being inspected, it is a
highly valuable technique that can save both money and time in
product evaluation, troubleshooting, and research.
• NDT does not directly measure mechanical properties but they are
used to locate defects or flaws in the component.
• Flaws reduce useful life of component resulting in premature failure
even with a sound design and proper selection of materials.
• To obtain high level of reliability, defect should be absent or at
minimum level.
• NDT is carried out periodically.
• Replacement of component before its premature failure to avoid
dangerous results.
 Applications of NDT
• NDT is commonly used in forensic engineering, mechanical
engineering, petroleum engineering, electrical engineering,
civil engineering, systems engineering, aeronautical
engineering, medicine, and art.
• Innovations in the field of nondestructive testing have had a
profound impact on medical imaging, including on echo
cardiography, medical ultrasonography, and digital
radiography.
Different types of NDT methods:
1. Dye Penetration Testing
2. Ultrasonic Testing
3. Magnetic Particle Testing
4. Radiography Testing
1. Dye Penetration Testing
• This non-destructive testing technique is particularly useful for finding
cracks, porosity, laps, seams, and other surface discontinuities in
castings, forgings, and weldments.
• Components may be ferrous, non-ferrous, plastic, glass, and ceramic.
Procedure:
1. Cleaning of surface. (By grease, oil, any other material)
2. Drying of surface.
3. Applying dye-penetrant on clean and dry surface. It is allowed to
penetrate in surface flaws. (Liquid Soluble Penetrant, Fluroscent)
4. Removing excess penetrant by soft and clean cotton.
5. Applying developer on the surface. This pulls out dye from flaws and
flaws are revealed by color of the dye. Instead of developer, fine
developing powder of talc powder can be sprinkled on the surface.
Water-Washable Fluorescent Liquid Penetrant Testing
Advantages Disadvantages
• Can be applied to any type of • Cleaning of components before
metals, non-metals, magnetic or and after testing to avoid
non-magnetic type. rusting.
• Results of the test can be • Only surface defects can be
interpreted easily. detected.
• Cost of test is very less as it does • Prone to misleading results in a
not require any instrument or case of components with surface
electronic display units. films or coatings.
• Simple to utilize and control.
2. Ultrasonic Testing
• Is a method of non-destructive testing that employs high-frequency
sound waves—typically above 20 kHz and often in the range of 0.5 to
15 MHz—to detect and characterize internal flaws, measure material
thickness, and assess structural integrity in industrial components.
• It is commonly applied in industries such as manufacturing,
aerospace, oil and gas, and construction.
Basic Principles
• Sound Wave Propagation: UT is based on the transmission of
ultrasonic waves into a material. A transducer, often made of
piezoelectric material, converts electrical pulses into ultrasonic waves,
which are introduced into the test object. When these waves
encounter interfaces (such as cracks, voids, or inclusions), part of the
energy is reflected back to the transducer.
• Detection Mechanism: The transducer also acts as a receiver,
detecting the reflected waves. By analyzing the time it takes for
echoes to return and their amplitude, inspectors can determine the
location, size, and nature of internal discontinuities.
• Couplant: A gel or liquid couplant is used between the transducer and
the test surface to facilitate efficient transmission of sound waves into
the material.
Ultrasonic Testing Modes:
• Pulse-Echo Method • Through-Transmission Method
A single transducer sends Separate transmitter and
and receives sound waves. receiver on opposite sides
Echoes from flaws or back of the object. Signal loss
walls are analyzed. indicates flaws.
An Ultrasonic Pulse-Echo Method to Detect Intern Ultrasonic test setup in through-transmission mode
al Defects in Epoxy Composite Insulation
Advantages Disadvantages
• Better detection of flaws • Due to manual operation, careful
situated deep in metal due to attention and highly skilled
superior penetrating power of operators are required.
ultrasonic waves. • Irregular shaped and rough parts
• High sensitivity, better accuracy are very difficult to examine.
and reliability. • Couplants are needed for
• Output of the test can be testing.
processed by computer which
lead to improved result
reliability.
 Magnetic Particle
Testing
• Also known as Magnetic Particle
Inspection (MPI)—is a non-destructive
testing (NDT) method used to detect
surface and near-surface defects in
ferromagnetic materials such as iron,
nickel, cobalt, and their alloys.
Principle:
• Magnetization: The component to be inspected is magnetized using equipment such as a
yoke or coil. The magnetic field can be applied using either alternating current (AC) or direct
current (DC), depending on the inspection requirements.

Yoke Coil
•MagneticFlux Leakage: When a
defect (e.g., crack or void) is present,
it disrupts the magnetic field, causing
it to "leak" out at the discontinuity.
This is called a magnetic flux leakage
field.

•Particle Application: Fine

ferromagnetic particles—either as
dry powder or suspended in a liquid
—are applied to the surface. These
particles are attracted to the areas of
flux leakage, forming visible
indications that reveal the presence,
location, and size of the defect.
Advantage & Disadvantage

Advantage Disadvantage


 Method is only applicable to
Sub-surface cracks can be
easily detected. only to ferromagnetic
materials.
 Almost any shaped and  Surface plating or paint coating
sized component can be affect the sensitivity of the
tested for defects. test.
 Highly sensitive method  After testing, demagnetization
detect small and shallow is a must.
surface cracks  Local heating and sparking is
possible during test hence
proper care must be taken.
4. Radiography Testing
• Is a method of non-destructive testing that uses ionizing radiation—
either X-rays or gamma rays—to inspect the internal structure of
materials and components. It is widely employed to detect internal
flaws such as cracks, voids, inclusions, and other discontinuities that
could compromise the integrity of critical industrial parts.
Basic Principle:
• The test object is placed between a radiation source and
a radiation-sensitive detector, such as film or a digital
sensor.
• X-rays or gamma rays penetrate the object; denser or
thicker areas absorb more radiation, reducing the
intensity reaching the detector.
• Differences in radiation absorption create a shadow
image (radiograph) on the detector, revealing internal
features and defects.
• The resulting image’s darkness (radiographic density)
varies with material thickness and composition—darker
areas indicate more radiation exposure, lighter areas
less.
 Advantages Disadvantages

• Non-Destructive • Radiation Safety

• Internal Inspection • Cost
• Wide Applicability • Complex Interpretation
• Time Consuming
FERROUS
METALS
Composition, Uses and
Characteristics
 What are ferrous
definiti metals?
key properties
on
⚬Ferrous metals are materials that
primarily contain iron. These metals ⚬Strength
are often magnetic and are known for ⚬Durability
their strength and durability, making ⚬Magnetic Qualities
them ideal for construction and
industrial use.
⚬Susceptible to rust and corrosion
unless alloyed or treated.
Example of Ferrous
Metals
Steel
⚬ primarily composed of iron and carbon with
other elements added to achieve specific
properties.
⚬ It is known for its strength, durability, and
versatility.
⚬ making it one of the most widely used
materials in construction, manufacturing, and
engineering.
Example of Ferrous
Metals
Cast
resistance,
iron
⚬ It is known for its excellent hardness, wear
and ability to withstand high
compression loads.
⚬ It is a ferrous metal that contains iron as its primary
component along with 2-4% carbon and varying
amounts of silicon.
⚬ Cast iron is typically brittle, but its thermal
conductivity makes it ideal for applications like
cookware, engine blocks, pipes, and machinery parts.
 Example of Ferrous
Metals
Carbon
⚬ It is an alloy of iron and carbon and typically containing up to 2%
carbon.
Steel
⚬ Classified into three categories :
1. Low-carbon steel - Soft, malleable, and commonly used for
products like pipes and sheets.
2. Medium-carbon steel - Strong and versatile, often used in
mechanical parts and gears.
3. High-carbon steel - Hard and wear-resistant, ideal for cutting
tools and springs.
 Application
Industrial Use Everyday Items Infrastructure
⚬Construction ⚬Kitchen Utensils
⚬Bridges
⚬Machinery ⚬Transportation
⚬Buildings
⚬Tools Components
 Advantages and
Limitations
Advantage Limitation
s
⚬Strength and Durability
s
⚬Prone to Corrosion
⚬Brittleness
⚬Cost-Effectiveness
⚬Heavy Weight
⚬Magnetic Properties
⚬Energy-Intensive Processing
⚬Versatility
⚬Recyclability
 Protecting Ferrous
Methods : Metals
⚬Alloying
⚬Coating
⚬Regular Maintenance
 Non-Ferrous
Metals
Definition Characteristics Examples

Malasarte, Lovely
 DEFINITION CHARACTERISTICS

Non-Ferrous metals are metal  Corrosion Resistance

is that do not have any iron in  Lightweight
them at all. This means that it  Malleability and Ductility
is not attracted to a magnet  Conductivity
and they do not rust in the  Non-magnetic
same way when exposed to
moisture.  Alloying Potential
 Lower Melting Points
 Examples of Non Ferrous Metals
Aluminum

It tends to be light in color although it can be polished

to a mirror like appearance. It is very light in weight.
Used: cooking foil, window frames, expensive bicycles
Melting Point: 660 degrees Celsius
Copper
Is a ductile and malleable metal. It is often red/brown
in color. It is very good conductor of heat and
electricity.
Used: wires, electric components, cookware,
coverings
Melting Point: 1084 degrees Celsius
Zinc
Is very resistant to corrosion from moisture.
However, zinc is a very weak metal and is
used mainly for coating steel.
Used: coatings, screws, steel buckets, for
galvanizing steel
Melting Point: 419 degrees Celsius

Tin
Is a very ductile and malleable material. It is
resistant to corrosion from moisture. Bright
silver color in appearance.
Used: coating of food cans, beer cans,
whistles, soldering
Melting Point: 231 degrees Celsius
Lead
Is a soft and malleable metal. Counted as one of
the heavy metals. Bluish-white in color after being
freshly cut, but soon tarnishes to a dull grayish
color when exposed to air.
Used: roof flashing, batteries,
Melting Point: 327 degrees Celsius
Silver
a soft, white, lustrous transition metal, it has the
highest electrical conductivity of any element and
the highest thermal conductivity of any metal.
Used: jewelry, currency coin, sports trophy,
mirrors
Melting Point: 961 degrees Celsius
Gold
Is a dense, soft, shiny, malleable, and
ductile metal. Pure gold has a bright
yellow color and luster traditionally
considered attractive, which it
maintains without oxidizing in air or
water.
Used: jewelry, computers as a
conductor
Melting Point: 1337 degrees Celsius
Thank you!