Me367 Non-Destructive Testing Module-1 (As Per Apj Ktu Syllabus)

SUKESH O P/ APME/JECC 1
ME367 NON-DESTRUCTIVE TESTING

MODULE-1(AS PER APJ KTU SYLLABUS)
10/16/2018 Sukesh O P, AP-ME , JECC
ME357 Non-Destructive Testing
2
Introduction to NDT- Visual Inspection- Liquid

Penetrant Inspection- Magnetic Particle
Inspection- Ultrasonic Testing- Radiography
Testing- Eddy Current Testing.
SUKESH O P/ APME/JECC 10/16/2018

MODULE-1
3
Introduction to NDT, Comparison between destructive and

NDT, Importance of NDT, Scope of NDT, difficulties of
NDT, future progress in NDT, economics aspects of NDT.
Visual Inspection - tools, applications and limitations -
Fundamentals of visual testing: vision, lighting, material
attributes, environmental factors. visual perception, direct
and indirect methods mirrors, magnifiers, boroscopes, fibro
scopes, closed circuit television, light sources special
lighting, a systems, computer enhanced system.

Why are metals tested ?
 Ensure quality
 Test properties
 Prevent failure in use
 Make informed choices in using materials
Factor of Safety is the ratio comparing the actual

stress on a material and the safe useable stress.
Two forms of testing
 Mechanical tests – the material may be physically
tested to destruction. Will normally specify a value
for properties such as strength, hardness, toughness,
etc.
 Non-destructive tests (NDT) – samples or finished

articles are tested before being used.
DESTRUCTIVE TESTING
6
 In destructive testing, tests are carried out to the

specimen’s failure, in order to understand a specimen’s
structural performance or material behavior under
different loads.
 Stress testing
 Tensile test
 Compressive test
 Impact testing
 Hardness testing
 Torsion test
 Shear test
 Creep test
 Fatigue test

HARDNESS TESTING
Hardness is the ability to withstand indentation or
scratches
Types :-
 Brinellhardness test
 Vickers hardness test
 Rockwell hardness tests

Hardness testing machine
 The indenter is pressed

into the metal
 Softer materials leave
a deeper indentation
Impact Tests
 Toughness of metals is the ability to withstand
impact.
 Types :-
 Izodtest
 Charpy impact test
Tensile Testing
 Uses an extensometer to apply measured force to

an test specimen. The amount of extension can be
measured and graphed.
 Variables such as strain, stress, elasticity, tensile

strength, ductility and shear strength can be gauged.
 Test specimens can be round or flat.

UTM
12

Shear and
Bending test
13
Torsion test

Non Destructive Testing
Nondestructive testing (NDT) has been defined as

comprising those test methods used to examine an
object, material or system without impairing its
future usefulness. The term is generally applied to
nonmedical investigations of material integrity .
NON-DESTRUCTIVE TESTING- Introduction
15
 Non destructive testing(NDT) is one of the important

methods used for evolution and quality control of
metal components
 During testing, the metal component does not get
damaged.
 NDT plays a crucial role in everyday life and is
necessary to assure safety and reliability.
 Typical examples are found in aircraft, spacecraft
(shuttle), motor vehicles, pipelines, bridges, trains,
power stations, refineries, buildings and oil platforms
which are all inspected using NDT.
NON-DESTRUCTIVE TESTING- Introduction
16
 Non Destructive Testing involves techniques based on application of physical

principles employed for purpose of determining characteristics of materials or
components and for detecting and assessing inhomogeneity and harmful defects
without changing the usefulness of materials or components.
 The methods used may be simple or intricate.
 It plays a vast role in quality control of finished product.
 Skilled judgments and experience is required while performing NDT.

Characteristics of NDT
 Applied directly to the  Can be performed on

product parts that are in service
 Tested parts are not  Low time consumption
damaged  Low labour cost
 Various tests can be
performed on the same
product
 Specimen preparation
not required
Types of defects
1. Inherent defect: are formed during the initial
production of raw material. Ex: Porosity, cavity, voids etc
2. Processing defect: are formed during the processing

of component. Ex: surface and subsurface cracks developing due to
mechanical and thermal processing like grinding, heat treatment etc.,
3. Service defects : are formed during operating cycle
of component. Ex: surface and subsurface cracks due to fatigue, stress
corrosion, hydrogen embrittlement, pitting etc
NON-DESTRUCTIVE TESTING- Industrial Use
19
 Inspection of Raw Products – Forgings, Castings, Extrusions.

 Inspection following Secondary Processing – Machining, Welding, Grinding,
Heat Treatment, Plating.
 Inspection for In-Service Damage – Cracking, Corrosion, Erosion/Wear, Heat
Damage.

20
Special equipment's are No requirement of special

required equipments
IMPORTANCE of Non-Destructive Testing
21
NDT is used typically for the following reasons:

 Accident prevention and to reduce costs
 To improve product reliability
 To determine acceptance to a given requirement
 To give information on repair criteria.

SCOPE of Non-destructive Testing
22
These are NDE application at almost any stage in the

production or life cycle of a component.
 To assist in product development
 To screen or sort incoming materials
 To monitor, improve or control manufacturing

processes
 To verify proper processing such as heat treating
 To verify proper assembly
 To inspect for in-service damage

ADVANTAGES of Non-Destructive Testing
23
 The equipment's are easy to handle

 Defects can be detected without damaging the
components
 Methods are quick and accurate
 Saves time in product evaluation
 Surface defects and inside defects can be easily
evaluated.
 Improves the quality of production
 Portable mode of inspection
DIFFICULTIES of Non-Destructive Testing
24
 Lack of skilled operators.

 Radiation hazards.
 Power source required.
 High cost of equipment.
 Surface must be clean and smooth.
 Demagnetization may be needed.

FUTURE PROGRESS in Non-Destructive Testing
25
 There are two general trends within the NDT community that are influencing
development and both centre around the operator. On the one hand,
instrumentation is being developed to reduce the operator's involvement as much as
possible through automating functions and computerizing results. On the other side
there are significant efforts to quantify or standardize the human element through
training and qualification.
 Second in importance is an increasing demand from users for more precision, more
reliability and more speed. As users become more dependent on NDT results, to
support extended component life and lower factors of safety, this pressure will
increase. Finally the need for specialist technicians as well as applications specialists
will grow to cope with the many opportunities being presented.
 There is a new factor coming into NDT, which seems likely to bring major
modifications to most NDT methods. This is the use of computer techniques, using
small computers. Apart from the obvious, rather trivial uses to simplify calculations, it
is now possible to collect, store and process vast quantities of digital data at very
high speeds.
Types of Non-Destructive Testing
26
Visual Liquid Penetrant Magnetic Particle

Examination Testing Testing
Eddy Current Ultrasonic

Testing Radiography
Testing

NDT Methods
1. Visual Inspection
2. Liquid penetrant method(Dye penetrant
testing)
3. Ultrasonic Inspection
4. Radiography methods
 X-ray radiography & fluoroscopy
 γ- ray radiography (gamma ray radiography)
5. Eddy current testing
6. Magnetic particle testing
APPLICATIONS of NDT
28
Power Plant Inspection Heat Exchanger Tubes
Wire Rope Inspection

Storage Tank Inspection
Aircraft Inspection
Jet Engine Inspection
Rail Line Inspection
Bridge Inspection
Pipe Line Inspection
Pressure Vessel Inspection NDT Method Used : Eddy
Current
APPLICATIONS of NDT
29
Power Plant Inspection Cable Wires

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Magnetic
Particle
APPLICATIONS of NDT
30
Power Plant Inspection Storage Tank Body

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Ultrasound

APPLICATIONS of NDT
31
Power Plant Inspection Thin Outer Body of
Aircraft
Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Eddy
Current
APPLICATIONS of NDT
32
Power Plant Inspection Innumerous Engine
Parts
Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Fluorescent
Penetrant
APPLICATIONS of NDT
33
Power Plant Inspection Railway Tracks

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Magnetic
Particle
APPLICATIONS of NDT
34
Power Plant Inspection Bridge Cables

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used : Acoustic
Emission
APPLICATIONS of NDT
35
Power Plant Inspection Inner Surface of Pipes

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used :
Radiography
APPLICATIONS of NDT
36
Power Plant Inspection Pressure Vessels

Aircraft Inspection
Bridge Inspection
Pressure Vessel Inspection NDT Method Used :
Radiography
Reliability
37
Properties Liquid Magnetic Eddy Radiograph Ultrasonic
Penetrant Particle Current y
Materials ALL Magnetic Conducting ALL ALL

Applicable
Detection Surface Surface, Surface, Volumetric Volumetric

Capability Sub-surface Sub-surface
Depth Sizing NO NO YES YES YES

Orientation NO NO YES YES YES
Evaluation
Major Factors affecting Reliability :

 Size of Defect
 type of NDT used
 Inspection Environment
 Quality of Equipment
 Capability of Operator. SUKESH O P/ APME/JECC 10/16/2018
Market of NDT
38
 Non Destructive Testing Market is estimated to grow at a CAGR of 3.5%

to reach the worth $1720.96 Million by 2020.
 Major Revenue Generating Regions – U. S. and Europe.
 Latin America and Asia-Pacific are emerging markets.
 Brazil, India and China have immense growth potential for NDT.

39
THANK YOU

40

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SUKESH O P/ APME/JECC 1

ME367 NON-DESTRUCTIVE TESTING

Introduction to NDT- Visual Inspection- Liquid

SUKESH O P/ APME/JECC 10/16/2018

Introduction to NDT, Comparison between destructive and

SUKESH O P/ APME/JECC 10/16/2018

Factor of Safety is the ratio comparing the actual

 Non-destructive tests (NDT) – samples or finished

 In destructive testing, tests are carried out to the

SUKESH O P/ APME/JECC 10/16/2018

 Rockwell hardness tests

 The indenter is pressed

 Uses an extensometer to apply measured force to

 Variables such as strain, stress, elasticity, tensile

 Test specimens can be round or flat.

SUKESH O P/ APME/JECC 10/16/2018

SUKESH O P/ APME/JECC 10/16/2018

Nondestructive testing (NDT) has been defined as

 Non destructive testing(NDT) is one of the important

 Non Destructive Testing involves techniques based on application of physical

SUKESH O P/ APME/JECC 10/16/2018

 Applied directly to the  Can be performed on

2. Processing defect: are formed during the processing

 Inspection of Raw Products – Forgings, Castings, Extrusions.

SUKESH O P/ APME/JECC 10/16/2018

Special equipment's are No requirement of special

NDT is used typically for the following reasons:

 To improve product reliability

 To determine acceptance to a given requirement

 To give information on repair criteria.

SUKESH O P/ APME/JECC 10/16/2018

These are NDE application at almost any stage in the

 To screen or sort incoming materials

 To monitor, improve or control manufacturing

 To verify proper assembly

 To inspect for in-service damage

SUKESH O P/ APME/JECC 10/16/2018

 The equipment's are easy to handle

 Lack of skilled operators.

SUKESH O P/ APME/JECC 10/16/2018

Visual Liquid Penetrant Magnetic Particle

Eddy Current Ultrasonic

SUKESH O P/ APME/JECC 10/16/2018

Wire Rope Inspection

Wire Rope Inspection

Wire Rope Inspection

SUKESH O P/ APME/JECC 10/16/2018

Wire Rope Inspection

Wire Rope Inspection

Wire Rope Inspection

Wire Rope Inspection

Materials ALL Magnetic Conducting ALL ALL

Detection Surface Surface, Surface, Volumetric Volumetric

Depth Sizing NO NO YES YES YES

Major Factors affecting Reliability :

 Non Destructive Testing Market is estimated to grow at a CAGR of 3.5%

SUKESH O P/ APME/JECC 10/16/2018

SUKESH O P/ APME/JECC 10/16/2018

SUKESH O P/ APME/JECC 10/16/2018

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