NON DESTRUCTIVE

TESTING
NDT - general name for all
methods which permit testing /
inspection of materials / parts
without impairing its future
usefulness

TYPES OF DEFECTS
inherent defects - present during initial
production of raw materials
z processing defects - resulted from the
manufacturing process
z service defects - occurred during the
operation
z

Examples of causes of defects

Blowholes - gas trapped during
solidification process
z Segregation - during solidification of
alloy
z Scale - oxide formation on the surface of
a metal heated to high temperature
z Stress - residual stress after cold
working or rapid cooling
z

Cracks
quenching / hardening cracks - rapid
volume change
z tempering cracks - rapid heating
z shrinkage cracks - rapid cooling
z grinding cracks - friction heating
z also caused by residual stress,
collapsed blowholes, improper rolling,
sharp edge of dies etc. etc.
z

TEST METHODS
visual
z pressure and leak
test
z penetrant
z thermal
z radiography
z acoustic
z magnetic
z

electrical /
electrostatic
z electromagnetic
induction - eddy
current
z optical holography
z electron probe
z etc.etc
z

Visual Testing
most widely used
z experienced inspector knows where are
likely cracks , orientation of cracks
relative to various zones in the weld,
surface porosity, weld penetration,
potential weakness such as sharp
notches or misalignment
z

Pressure and Leak Test

common form is hydrostatic test
z hydrostatic test often required for
pressure vessels, pipes, valves.
z normally pressurised to 1.5 or 2 times
the working pressure
z for sensitive leak test, radioactive
material, halogen or helium gases are
used
z

Penetrant
extension of visual inspection
z for detection of surface flaws
z two kinds ; dye penetrant and
fluorescent penetrants
z

Basic steps of dye penetrant

testing
z
z
z
z
z

clean the surface

apply penetrant
remove excess penetrant
apply developer
inspect / interpretation

penetrant seep
into flaw

developer draws
penetrant onto
surface

Magnetic particle testing

for locating surface & subsurface
discontinuities in ferromagnetic
materials
z leakage current occurs at the
discontinuities / surface flaws when
magnetized
z fine particles collect at the leakage sites
z

Magnetic particle testing

Ultrasonic testing
use beams of high frequency sound
waves to probe the material
z internal flaws and locations can be
determined by analyzing reflected sound
waves
z

Ultrasonic testing

Ultrasonic testing - limitations

z
z
z
z

Complex shapes
can be difficult
Small coverage
area
Highly trained
personnel
Rough surfaces
may cause
problems

Radiography
z
z
z
z
z
z
z
z

Similar to medical
Costly method, expensive
equipment
Different angles needed
Thin cracks may be missed
Costly
Highly trained personnel
Radiaiton hazard
Complex shapes / can give
problems

Eddy current testing

Eddy current induced when electrically

conductive material close to alternating
magnetic field
Eddy current generates magnetic field which
interact with original magnetic filed

Eddy current testing

z
z
z
z
z
z
z
z

Detect both surface & near

surface irregularities
Close contact not needed
Can be automated
No clean up
Low cost equipment
Response can be sensitive
interpretation difficult
Depth of penetration limited
Need to maintain constant
distance between coil and
specimen for good result