Manufacturing Laboratory-I (ME207) Report

Date of submission: 13/10/2021 Name: Md Athar Hassan

Group: G10 Entry No: 2019MEB1278

Experiment No -08
Tittle of the Experiment
Identification of defects by Non-destructive testing

Objective of the Experiment

 To learn the principles and basics of non-destructive testing methods and how they
work.
 To learn how to calibrate ultrasound testing equipments for actual measurement.
 To identify defects by using the dye penetrant test and ultrasonic testing methods.
 To learn about the different types, benefits of different non-destructive testing
procedures in order to be able to choose the optimal approach for a certain material.

Material and apparatus used in the Experiment

 For Dye penetration testing-
 Cleaner/remover spray - It is used to clean the part's surface and remove any extra
residue.
 Liquid penetrant spray - It penetrates surface flaws like as cracks and splits.
 Developer spray - It reacts with the infiltrated liquid penetrant.
 Work piece, tissue paper - to clean and dry the surface.

 For Ultrasonic Testing-

 Flat probe (pulser/receiver),
 Ultrasonic testing display - for monitoring the changes in peak to detect defect.
 Oil is used as couplant.
 standard mild steel specimen, aluminium specimen

 For Magnetic Particle Test-

 Electromagnetic Yoke - provides the necessary magnetic field
 Magnetic fluorescent particles
 Bar of ferromagnetic material as a work piece
 UV torch-is employed to higher the visibility of the flaws, cracks for the ease of the
inspection.
 Wet magnetic particles(mix 11gm of fluorescent magnetic particles with 500gm of
water).

Procedure of the Experiment

 For Dye penetration testing-
 Firstly we clear the surface from dirt, dust, or other contaminants, which is done with a
special chemical (cleaner spray) and after apply spray we clean the work piece with
the tissue paper..
 Then we apply liquid penetrant spray to the part's inspected surface, and waited
about 10 minutes for the infiltration of the liquid penetrant to the defects.
 The surplus penetrant on the surface is then washed with a water or a clean cloth.
 Then we apply developer spray, and leave the work piece for 15 min , after 15
minutes we observed the red spotted colour on the defected or crack position.

 For Ultrasonic Testing-

 Firstly calibrate the US testing unit using the standard mild steel specimen and
aluminium. On the display unit set mode as T-R, angle zero degree, set the velocity
 5920m/s for mild steel and 6300m/s for aluminium and adjust the range higher than
the depth of the specimen.
 Then take the work piece, and we use a couplant between the probe and the tool, to
convey the ultrasonic waves and prevent any cavities from interfering with the
transmission.
 The probe is then placed into the tool's corresponding space at a specific angle and
moved across the surface to detect any discontinuities. If there are no defects, a high
peak is formed; if defects are found, short peaks are formed, and we can see their
corresponding D values on the display to check at what height from the surface,
cracks are found.

 For Magnetic Particle Test-

 Firstly, we sprayed the work piece with cleaner/remover spray or wiped it with a tissue
paper.
 Then, on the inspected surface of the work piece, we used wet magnetic spray to
make the faults more evident under UV light.
 The electromagnetic yoke is then attached to the work piece and turned on.
 After waiting a while, we noticed that magnetic fluorescent particles accumulated at
the defect portions on the work piece's surface when we see with a UV torch.

Result and Observation

 Dye penetration testing-
We observed the red spotted colour on the defected or crack position.

 Ultrasonic Testing-
We observed if there are no defects, a high peak is formed; if defects are found, short
peaks are formed, and we can see their corresponding D values on the display at what
height from the surface, cracks are found.

 But in this testing we can not detect the defects with the axis parallel to the direction
of the sound signal using UST this is the major drawbacks.

 Magnetic Particle Test-

We observed that magnetic fluorescent particles accumulated at the defect portions on
the work piece's surface when we see with a UV torch.
Assignment Question/Aswers-

Ans. Using US testing, we can detect faults in all three examples of ceramic, composite,
and metal. It's straightforward in metals, as demonstrated in the experiment. In the case
of ceramics, a special couplant is required (which is water mostly). It's difficult to test
composites because they're made up of different layers with different sound speeds, but
we can do so by calibrating the test accordingly. For example, we can make any layer
material the 'base' material and assume the length of the other layers based on this layer
so that sound travels at the same speed and takes the same amount of time in all the
layers. We can now convert the distances from our hypothetical scenario to the real case
because we know the actual composition of the composite.

Q2. State any two advantages and limitation of magnetic particle test.
Ans. Advantages of Magnetic Particle Testing Techniques:
 Relatively safe method, Portability,less training requirements and a relatively low cost
 With ease, inspects irregular shapes
Disadvantages of Magnetic Particle Testing:
 In some cases, it's necessary to de-magnetize.
 The material or component under test must be ferromagnetic.

Q3. State any two characteristics/properties of good penetrant and good developer in
case of dye penetrant test.
Ans. Two characteristics/properties of good penetrant are as:-
 Very low viscosity and low surface tension, so that it can penetrates into the surfaces
easily.
 Remain in the defect but remove easily from the surface.
Two characteristics/properties of good developer in case of dye penetrant test are as:-
 To accomplish soaking action, they must be absorptive. It should have a fine texture,
but not too fine, as this would cover imperfections.
 After the test is finished, it must be easily removed. It must be non-irritating and non-
toxic.

Learning from the Experiment

 Understood the concepts of penetrant testing, ultrasonic testing and magnetic particle
testing.
 I am able to understand in which material for which test should be done.
 How to use UST to determine the defect's location.

Safety concern
 We must wear gloves throughout the experiment to prevent from the harmful effects
of toxic spray.
 Inside the workshop, your sole focus should be on executing your job safely, thus no
cell phones, music players, or other distractions are permitted.
 In the workshop, wear fully covered, rubber soled shoes within the workshop instead
of walking barefoot (or with slippers/sandals, etc.).