Non-Destructive Testing

By Er. Kabita Ojha

 Testing
⚫ Testing is the process of evaulating a system or its
components to find whether it satisfies the specified
requirements or not.
•Types of Testing
•Destructive Testing
•Chiesel Test, hardness, tensile teat ect.

•Non-Destructive Testing
•Visual inspection, MPT, Eddy Current etc.

•Semi/Partial Destructive Testing

•Torque Test, Biological Microspic Test etc.
Non-Destructive Tesing
⚫ It is a testing and analysis technique used by industry
to evaluate the properties of a material, component,
structure or system without causing damage to the
original part.
⚫ It refers to an array of inspection methods that allow
inspectors to evaluate and collect data about a
material, system, or component without permanently
altering or without damaging it.
⚫ NDT may also be called NDE (non-destructive
examination or evaluation)or NDI (non-destructive
inspection)
⚫ For Example: inspecting weak points in a boiler used at an oil
refinery
⚫ An expecting mother getting an ultrasound to check on the
health of her baby would be considered an NDT use case, as
would getting an X-ray or MRI
⚫ Here are the eight most commonly used NDT techniques:
⚫ Visual NDT (VT)
⚫ Ultrasonic NDT (UT)
⚫ Radiography NDT (RT)
⚫ Eddy Current NDT (ET)
⚫ Magnetic Particle NDT (MT)
⚫ Acoustic Emission NDT (AE)
⚫ Dye Penetrant NDT (PT)
⚫ Leak Testing (LT)
⚫
Advantages of Non-Destructive Testing:

⚫ Savings. NDT is more appealing than destructive testing

because it allows the material or object being examined
to survive the examination unharmed, thus saving money
and resources.
⚫ Safety. NDT is also appealing because almost all NDT
techniques (except radiographic testing) are harmless to
people.
⚫ Efficiency. NDT methods allow for the thorough and
relatively quick evaluation of assets, which can be crucial
for ensuring continued safety and performance on a job
site.
⚫ Accuracy. NDT methods have been proven accurate
and predictable, both qualities you want when it
comes to maintenance procedures meant to ensure the
safety of personnel and the longevity of equipment.
 Visual Testing
⚫ Visual Non-Destructive Testing is the act of collecting
visual data on the status of a material to detect presence of
surface discontinuties.
⚫ Visual Testing is the most basic way to examine a material
or object without altering it in any way.
⚫ Inspection process may be done using behaviours like
looking, feeling, listening, smelling, twisting, shaking etc.
⚫ This testing is based on the principle of illumination of the
test specimen with the light, usually in the visible region.
⚫ It also requires the proper eyesight of the tester.
⚫ The surface of the test specimen should be adequately
cleaned before inspection.
Types of Visual Inspection
1) Unaided visual inspection
⚫ It is also known as direct visual inspection.
⚫ Inspection can be done without using optical aids.

2) Aided visual inspection

⚫ It is also known as indirect visual inspection.
⚫ Optical aids are used such as magnifying glasses,
mirrors, microscope.
⚫ It permits visibility to areas which are not accessible to
human eye.
Advantages of Visual Testing:
⚫ Low cost
⚫ Easy and quick inspection methos
⚫ Perform on almost all materials

Limitations:
⚫ Using unadded visual inspection only large discontinuties
are identified.
⚫ Limited to detection of any surface discontinuities.
⚫ Skilled labour is required.
⚫ Result depends upon eye resolution of inspectior.
Applications of Visual Inspections:
⚫ To check the misalignment of parts
⚫ To check leakage or abnormal operation
⚫ To check corrosion, errosion, cracks and surface
defects.
 Ultrasonic Testing (UT)
⚫ Ultrasonic Non-Destructive Testing is the process
of transmitting high-frequency sound waves into a
material in order to identify changes in the material’s
properties.
⚫ Ultrasonic Testing uses sound waves(frequency>20 KHz)
to detect defects or imperfections on the surface of a
material created.
⚫ Ultrasonic Testing can be conducted on a wide variety of
material forms including casting, forgings, welds and
composites.
⚫ By this methos, surface and internal discontinuties such as
laps, seams, cracks, voids, holes, and lack of bond can be
accuately evaluated from one side.
Ultrasonic Testing (UT)
⚫ For Ultrasonic testing, there is a probe (transducer), which
convert electrical signal into sound wave and sound wave
into electrical signal.
⚫ Probe works as emitter as well as receiver by emitting and
receiving radiation signal.
⚫ At first, electric signal is given to the probe and it converts
electrical signal into sound wave.
⚫ This sound wave is strikes above the surface of the pipe and
then travelled throughout the pipe until it reflects back to
the surface.
⚫ Initial pulse is observed on the screen which is also known
as transmission pulse.
⚫ If there is no cracks, back echo is observed on the screen
which has same amplitude as initial pulse.
⚫ The surface of the test piece should be throughly cleaned and
smooth before testing.
⚫ Before transmitting ultrasonic waves, an oil film is provided
between the probe and the casting surface.
⚫ Then, ultrasonic wave is introduced into the metal and the
time interval between the transmission of the outgoing and
reception of incoming signals are measures with a cathode
ray oscilloscope (CRO).
⚫ As the wave is sent from the transmitter probe it strikes the
upper surface of the casting and makes a sharp peak or echo
at left hand side of CRO screen.
⚫ In case a defect exists in between top and bottom casting
surfaces, most of the beam striking this defect will get
reflected from the defect.
⚫ The reflected signal reach the receiver probe and
indicate a echo on the CRO screen before the echo
given by the wave striking far end of the casting and
returning.
⚫ Quantitive assessment of defects can be made on the
basis of use of comparison.
Applications:
⚫ Rail Roads, water or oil pipes, shafts, aircraft parts
⚫ Extended and forged aluminium parts, cracks, internal
discontinuties
⚫ Certain types of welds are also inspected by this
method
Advantages:
⚫ high speed of opertaion & low cost
⚫ more sensitive than radiography
⚫ big casting can be symmetrically scanned for initial
defection of major defects.
⚫ fast and reliable method of non-destructive
inspection.
Disadvantages:
⚫ This method is sensitive to surface roughness
⚫ The interpretation of oscilliography may not be easy in
complex castings.
 Radiography Testing (RT)
⚫ Radiography Non-Destructive Testing is the act of using
gamma or X-radiation on materials to identify
imperfections.
⚫ Radiography Testing directs radiation from a radioactive
isotope or an X-ray generator through the material being
tested and onto a film or some other kind of detector.
⚫ The readings from the detector create a shadowgraph,
which reveals the underlying aspects of the inspected
material.
⚫ Radiography Testing can uncover aspects of a material that
can be hard to detect with the naked eye, such as
alterations to its density.
Radiography Testing (RT)
Radiography Testing (RT)
⚫ These test are used to detect defects such as blow
holes, cracks, shrinkage cavities and slag inclusions.
Procedure:
⚫ In X-ray radiography, the portion of the casting where
defects are suspected is exposed to X-rays emitted
from the X-ray tube.
⚫ A cassette containing X-ray film is placed behind and
in contact with the casting perpendicular to the ray.
⚫ During exposure, X rays penetrate the casting and thus
affect the X-ray film.
⚫ It posses less density than the sound metal of the
casting, they transmit X-rays better than the sound
metal does, therefore film appears to be more dark
where defects are in line.
 Eddy Current (Electromagnetic)
Testing (ET):
⚫ Eddy Current Non-Destructive Testing is a type of
electromagnetic testing that uses measurements of the
strength of electrical currents (also called eddy currents)
in a magnetic field surrounding a material in order to
make determinations about the material, which may
include the locations of defects.
⚫ To conduct Eddy Current Testing, inspectors examine the
flow of eddy currents in the magnetic field surrounding a
conductive material to identify interruptions caused by
defects or imperfections in the material.
Eddy Current Testing
⚫ First, we supply AC current to the coil, then magnetic field is
induced around the coil.
⚫ When the induced magnetic field is near to the workpiece,
secondary magnetic field is generated which is known as
Eddy Magnetic Field.
⚫ Due to this Eddy Magnetic Field, eddy current is generated
on the surface of the workpiece.
⚫ If there is any defect on the surface of the workpiece. then
generated eddy current is changed. While changing eddy
current, eddy magnetic field is also changed.
⚫ Further changed is shown on primary magnetic field, which
changes the supplied AC current. (phase or amplitude of AC)
⚫ Due to change in eddy current AC current changed which is
shown on dispaly.
Application of Eddy Current Testing:
⚫ To check the casting defect, forging defect etc.
⚫ Used for surface inspection and tubing inspections.
⚫ Used to detect flaws in induction furnace

Factors Affecting Eddy Current Testing:

1) Material Properties: Alloy Composition, Heat
Treatment, Surface Conditions
2) Part Dimension/Geometry: Thickness, Distance from
Other Conductor, Specimen Ecentricity
Magnetic Particle Testing
⚫ Magnetic Particle Non-Destructive Testing is the act of
identifying imperfections in a material by examining
disruptions in the flow of the magnetic field within the
material.
⚫ To use Magnetic Particle Inspection, inspectors first
induce a magnetic field in a material that is highly
susceptible to magnetization.
⚫ After inducing the magnetic field, the surface of the
material is then covered with iron particles, which
reveal disruptions in the flow of the magnetic field.
⚫ These disruptions create visual indicators for the
locations of imperfections within the material.
Magnetic Particle Testing
⚫ This is one of the non-destructive testing method.
⚫ It is used for checking cracks mainly in welding joints
which are not visible to the nacked eyes.
⚫ It is used for ferromagnetic materials like: Iron, Nickel,
Cobalt & other alloys.
⚫ Components:
1. Magnetic Field Supply
2. Ferrous Particle Powder
Magnetic Particle Testing
⚫ First, magnetic field lines are passed through the pipe
from south to north pole, these field lines are moves
parallel to each other without any distruption.
⚫ If there is crack on the pipe surface, the direction of
magnetic field lines changes due to crack.
⚫ The ferrous particle powder is applied on the pipe
surface and then magnetic field lines are passed
through the pipe.
⚫ These particles are accumulated in the crack where
magnetic field attract ferrous materials.
 Acoustic Emission Testing (AE)
⚫ Acoustic Emission Non-Destructive Testing is the act of using
acoustic emissions to identify possible defects and
imperfections in a material due to pressure, temperature, load
etc.
⚫ This testing method is used in different structure such as
metals, composites, wood, fiberglass, ceramics, plastics,
polymer, concrete etc.
⚫ Intensity, location, and arrival time can be examined to reveal
information about possible defects within the material.
⚫ The elastic waves generated by a material subjected to an
external stimulus like pressure, load, temperature, which
propagate to the surface and are recorded by sensor.
Acoustic Emission Testing (AE)
⚫ AE has been used on structures including pressure
vessels, fire bottles, gas wells, nuclear weapons, solar
collectors etc.
⚫ When a crack or some deformation occurs in the
material, it results in a rapid release of energy,
transmitting in the form of an elastic wave, called
Acoustic Emission (AE).
⚫ AE frequencies are usually in the range of 150-300 kHz,
which is above the frequency of audible sound.
⚫ Through analyzing the characteristics of background
noise, the cracked sound pulses are separated accurately
from the originally continuous signal.
Applications:
⚫ Used for LPG tank, Storage tank
⚫ Used for Bridges, rail way track
⚫ Used for underground tank, water pipeline etc.
Advantages:
⚫ Realtime detection of component failure
⚫ Highly accurate results
⚫ Early warning of crack growth
⚫ Economical and sensitive
⚫ Exact location of defect can be found with the help of
sensors.
Disadvantages:
⚫ High initial cost
⚫ Difficult for outdoor use (due to distance between
monitor and signal)
⚫ Requires skilled person to operate and understant
signals.
 Dye Penetrate Testing (DPT)
⚫ It is a non-destructive testing method that builds on the
principle of Visual Inspection.
⚫ It help to find out small discountinuties that the human eye
might not be able to detect alone.
⚫ In this testing, liquid with high surface wetting
characteristics is applied to the surface of a components
under test.
⚫ The penetrant "penetrates" into surface breaking
discountinuities via capillary action and other mechanism.
⚫ Excess penetrant is removed from the surface and a
developer is applied to pull trapped penetrant back the
surface.
Dye Penetrate Testing
⚫ With good inspection techniques, visual indications of any
discontinities present become apparent.
Process of PT:
1) Clean & Dry Component
2) Apply Penetrant
3) Remove Excess Penetrant
4) Apply Developer
5) Visual Inspection
⚫ Almost any material that has a relatively smooth, non-porous
surface on which discontinuties or defects are suspected.
⚫ For regular dyes, the color shows in the contrast between the
penetrant and the developer.
LEAK TESTING (LT)
⚫ Leak Non-Destructive Testing refers to the process of
studying leaks in a vessel or structure in order to
identify defects in it.
⚫ Inspectors can detect leaks within a vessel using
measurements taken with a pressure gauge,
soap-bubble tests, or electronic listening devices,
among others.
⚫ The purpose of leak testing are to ensure reliability
and serviceability of components and to prevent
premature failure of systems containing fluids under
pressure or vacuum.
Two principle methods are used for leak testing:
⚫ Vacuum Method
⚫ Overpressure Method

Leak Testing is divided into:

⚫ Leak Detection
⚫ Leak Location
⚫ Leakage Measurement