6000 STEEL

6000. 6500. Construction Testingg and

• 6130 ‐ Design Data, Principles and Tools
Examination ‐
6100 &
6200 • 6140 ‐ Codes and Standards 6510. Nondestructive Testing Methods
• 6200 ‐ Material
• Definition of NDT
• 6310 ‐ Members and Components
6300
• 6320 ‐ Connections, Joints and Details • Methods of NDT
• 6330 ‐ Frames andd Assembles
bl ¾ Visuall
• 6410 ‐ AISC Specifications for Structural Joints ¾ Liquid Penetrant
6400
• 6420 ‐ AISC 303 Code
C d off St
Standard
d dP Practice
ti ¾ Magnetic
• 6430 ‐ AWS D1.1 Structural Welding Code ¾ Ultrasonic
6500 • 6510 ‐ Nondestructive Testing Methods ¾ Eddy Current
• 6520 ‐ AWS D1.1 Structural Welding Code Tests
¾ X‐ray
6600 • 6610 ‐ Steel Construction
• 6620/6630 ‐ NUREG‐0800 / RG 1.94 • Usage of NDT
BMA Engineering, Inc. – 6000 1 BMA Engineering, Inc. – 6000 2

Definition of NDT What are Some Uses of NDE Methods?

The use of noninvasive • Flaw Detection and Evaluation
techniques to determine • Leak Detection
the integrity of a material,
component or structure • Location Determination
or • Dimensional Measurements
Fluorescent penetrant indication
quantitatively measure • Structure and Microstructure Characterization
some characteristic of
• Estimation of Mechanical and Physical Properties
an object.
• Stress ((Strain)) and Dynamic
y Response
p
Measurements
i.e. Inspect or measure without doing harm.
• Material Sorting and Chemical Composition
BMA Engineering, Inc. – 6000 3
Determination
BMA Engineering, Inc. – 6000 4
 When are NDE Methods Used? Nondestructive Testing
There are NDE application at almost any stage in
• Advantages
d
the production or life cycle of a component
– Can test in‐service structures
– To
T assist
i t in
i productd t development
d l t – Evaluate surface and
– To screen or sort incoming materials internal conditions
– To monitor, improve or control – Cost efficient
manufacturing processes • Disadvantages
– To verify proper processing such as heat – Reliability (measurements are made indirectly)
treating – Qualitative
– To verify proper assembly – Requires a skilled professional for interpretation of
results
– To
T iinspectt ffor in‐service
i i damage
d
BMA Engineering, Inc. – 6000 5 BMA Engineering, Inc. – 6000 6

Destructive Testing Methods of NDT

• Advantages
d
– Reliable (direct measurements)
Visua
– Quantitative
l
– Directly relates to material properties
• Disadvantages
– Cannot test in‐service structures
– Requires a model
• Costly & Time Consuming
– Multiple tests are sometimes
required

BMA Engineering, Inc. – 6000 7 BMA Engineering, Inc. – 6000 8

 Six Most Common NDT Methods Visual Inspection
Most basic and common
• Visual inspection method
method.
• Liquid Penetrant
• Magnetic Tools include fiberscopes,
• Ult
Ultrasonic
i borescopes, magnifying
borescopes
• Eddy Current glasses and mirrors.
• X ray
X-ray
Portable video inspection
unit with zoom allows
i
inspection
i off llarge tanks
k
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air ducts,
reactors, pipelines.
BMA Engineering, Inc. – 6000 9 BMA Engineering, Inc. – 6000 10

Liquid
q Penetrant Inspection
p Liquid Penetration
• A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to
seep into surface breaking defects
defects.
• The excess liquid is removed from the surface of Process:
the part.
• Clean surface
• A developer (powder) is applied to pull the
trapped penetrant out the defect and spread it on • Apply liquid penetrant
the surface where it can be seen.
• Visual inspection is the final step in the process. • Remove excess penetrant
The penetrant used is often loaded with a
fl orescent d
fluorescent dye
e and the inspection is done under
nder • Apply developer
UV light to increase test sensitivity.
• Inspect
• Post‐cleaning

BMA Engineering, Inc. – 6000 11 BMA Engineering, Inc. – 6000 12

 Magnetic Particle Inspection Magnetic Particle
The part is magnetized. Finely milled iron particles coated with a dye Process:
pigment are then applied to the specimen. These particles are attracted to
magnetic flux leakage fields and will cluster to form an indication directly • Magnetize surface
over the discontinuity.
discontinuity This indication can be visually detected under proper
lighting conditions. – Discontinuities create a
magnetic
g flux
• Sprinkle magnetic particles
• Inspect

BMA Engineering, Inc. – 6000 13 BMA Engineering, Inc. – 6000 14

Magnetic Particle Crack Indications Radiography

g p y
The radiation used in radiography testing
is a higher energy (shorter wavelength)
High
g Electrical Potential
version of the electromagnetic waves that
we
see as visible light. The radiation can Electrons
come from an X-ray
X ray generator or a + -
radioactive source.
X-ray Generator
or Radioactive
Source Creates
Radiation

Radiation
Penetrate
the Sample

Exposure Recording Device

BMA Engineering, Inc. – 6000 15 BMA Engineering, Inc. – 6000 16

 Fil Radiography
Film R di h Ultrasonic
The part is placed between the radiation
source and a piece of film. The part will
stop some of the radiation. Thicker and
more dense area will stop more of the
radiation.
The film darkness
(density) will vary with
the amount of radiation
X-ray film reaching the film through
the test object.
object
= less exposure
= more exposure
Top view of developed film
BMA Engineering, Inc. – 6000 17 BMA Engineering, Inc. – 6000 18

Radiographic Images Eddyy Current Testingg

Coil's
C il'
Coil magnetic field

Eddy current's
g
magnetic field
Eddy
currents

Conductive
material
BMA Engineering, Inc. – 6000 19 BMA Engineering, Inc. – 6000 20
 Eddyy Current Testingg Ultrasonic Inspection
p (Pulse‐Echo)
Eddy current testing is particularly well suited for detecting surface cracks High frequency sound waves are introduced into a material
but can also be used to make electrical conductivity and coating thickness and they are reflected back from surfaces or flaws.
measurements. Here a smallll surface
f probe
b is scanned d over the
h part surface
f
in an attempt to detect a crack. Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound
sound. f

initial
pulse

back surface
echo
crack
echo

crack
0 2 4 6 8 10 plate

Oscilloscope, or flaw
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detector screen
BMA Engineering, Inc. – 6000 22

Ultrasonic Imaging
High
Hi h resolution
l ti iimages can b be produced
d dbby plotting
l tti signal
i l Usage: Inspection of Raw Products
strength or time-of-flight using a computer-controlled
scanning system
system.
• Forgings,
• Castings,
• Extrusions,
• etc.

Gray scale image produced using Gray scale image produced using the
the sound reflected from the front sound reflected from the back surface of
surface of the coin the coin (inspected from “heads” side) BMA Engineering, Inc. – 6000 24
BMA Engineering, Inc. – 6000 23
 Usage:
g Inspection
p Followingg Usage: Inspection For
Secondary Processing In‐Service Damage
• Machining
• Welding
• Crackingg
• Grinding
• Heat treating • Corrosion
• Plating • Erosion/Wear
• etc. • Heat Damage
• etc.

BMA Engineering, Inc. – 6000 25 BMA Engineering, Inc. – 6000 26

Usage: Power Plant Inspection Usage:

g Storage
g Tank Inspection
p
Robotic crawlers use
Periodically, power plants are ultrasound to inspect
shutdown for inspection.
inspection the
h walls
ll off llarge
Inspectors feed eddy current above ground tanks
probes into heat exchanger tubes g of thinning
for signs g
t check
to h k ffor corrosion
i damage.
d due to corrosion.

Cameras on
Pipe with damage Prob longg
e articulating
Signals produced
by various arms are used
amounts of
corrosion thinning.
to inspect
underground
storage tanks
for damage.
damage

BMA Engineering, Inc. – 6000 27 BMA Engineering, Inc. – 6000 28

 Usage:
g Pressure Vessel Inspection
p Usage:
g Pipeline
p Inspection
p
The failure of a pressure vessel NDT is used to inspect pipelines to
can result in the rapid release of a prevent leaks that could damage the
environment. Visual inspection,
p ,
large amount of energy
energy. To protect radiography and electromagnetic
against this dangerous event, the testing are some of the NDT
tanks are inspected using methods used.
radiography
di h and d ultrasonic
lt i ttesting.
ti

Remote visual inspection

using a robotic crawler.

Magnetic flux leakage inspection

inspection.
This device, known as a pig, is
placed in the pipeline and collects
data on the condition of the pipe as
it iis pushed
h d along
l b
by whatever
h t iis
being transported.
Radiography of weld joints.
BMA Engineering, Inc. – 6000 29 BMA Engineering, Inc. – 6000 30

6500. Construction Testing and

E
Examination
i i ‐ 6000 STEEL
6000.
• 6130 ‐ Design Data, Principles and Tools
6510 Nondestructive Testing Methods
6510. 6100 &
6200 • 6140 ‐ Codes and Standards
Objective and Scope Met • 6200 ‐ Material
• Definition of NDT • 6310 ‐ Members and Components
6300
• Methods of NDT • 6320 ‐ Connections, Joints and Details
• 6330 ‐ Frames andd Assembles
bl
¾ Visual
• 6410 ‐ AISC Specifications for Structural Joints
¾ Liquid
q Penetrant 6400
• 6420 ‐ AISC 303 Code
C d off St
Standard
d dP Practice
ti
¾ Magnetic • 6430 ‐ AWS D1.1 Structural Welding Code
¾ Ultrasonic 6500 • 6510 ‐ Nondestructive Testing Methods
¾ Eddy Current • 6520 ‐ AWS D1.1 Structural Welding Code Tests
¾XX‐ray
ray 6600 • 6610 ‐ Steel Construction
• Usage of NDT • 6620/6630 ‐ NUREG‐0800 / RG 1.94
BMA Engineering, Inc. – 6000 31 BMA Engineering, Inc. – 6000 32
 6500. Construction Testingg and Weldability
• Capacity to be welded into a specific structure that has certain
Examination ‐ properties and characteristics and will satisfactorily meet service
requirements
6520. AWS D1.1 Structural Welding Code
• Thorough knowledge of the phase diagram is essential
• Destructive Test for Welds
• Factors such as strength, toughness, ductility, notch sensitivity, elastic
• Nondestructive Test for Welds modulus, specific heat, melting point, thermal expansion, surface
tension characteristics of the molten metal, corrosion resistance.
– Dye Penetrate Testing
– Magnetic Particle Testing Testing Welded Joints
– Radiographic Testing of Groove Welds in Butt Joints • Quality of the welding joint is established by welded joint
– Ultrasonic
l Testing off Groove Welds
ld
• Each technique has capabilities ,limitations and sensitivity reliability
– Acoustic & Pressure Testing and requirement for special equipment and operator skill
skill.

BMA Engineering, Inc. – 6000 33 BMA Engineering, Inc. – 6000 34

Destructive Techniques Destructive Techniques

Tension Test :
• Longitudinal and transverse tension tests are performed
TTwo types
t off specimens
i for
f tension‐
t i
• Stress strain curves are obtained shear testing of welded joints.

Tension‐Shear
i h Test
• Specifically prepared to simulate actual welded joints and procedures.
• Specimen subjected to tension and shear strength of the weld metal

Bend test :
• Determines ductility and strength of welded joints.
• The welded specimen is bend around a fixture
• The specimens are tested in three‐point transverse bending
• These tests help to determine the relative ductility and strength of (a) Wrap‐around bend test method.
the welded joints (b) Three‐point
Th i bending
b di off welded
ld d specimens.
i

BMA Engineering, Inc. – 6000 35 BMA Engineering, Inc. – 6000 36

 Other destructive testing Testing of Spot Welds
• FFracture Toughness
T h Test:
T
• Corrosion and creep tests
• Testingg of spot
p welds
• Tension‐Hear
• Cross‐tension
• T it
Twist
• Peel

Non Destructive testing

Non‐Destructive
• Often weld structures need to be tested Non‐Destructively
• Non‐Destructive testing are :
• Visual
• Radiographic
• Magnetic‐particle
• Liquid‐penetrant
• Ultrasonic (a) Tension‐shear test for spot welds. (b) Cross‐Tension test. (c) Twist test. (d) Peel test

BMA Engineering, Inc. – 6000 37 BMA Engineering, Inc. – 6000 38

TENSILE BEND TESTING

Material is sectioned • Shows

andd edges
d rounded
d d Physical condition of the weld
of to prevent
cracking.
ki Determine welds efficiency
• Tensile strength
Punch marks are made
• Ductility
to see elongation.
• Fusion and penetration

BMA Engineering, Inc. – 6000 39 BMA Engineering, Inc. – 6000 40

 BEND TEST Root bend
O
• Bend
B d through
h h 180
• the specimen should be a minimum of 30mm wide
• The fulcrums diameter is 3x thickness of the plate
• The bottom rollers have a distance of the diameter of
the former + 2.2 times the thickness of the plate
• Upper and lower surfaces ground or filed flat and
edges rounded off.
• the tests should be one against the root ‐another
against the face ,and in some cases a side bend.

BMA Engineering, Inc. – 6000 41 BMA Engineering, Inc. – 6000 42

FACE BEND
IMPACT
• CHARPY AND IZOD
• Gives the toughness and shock loading of the
material and weld at varying temperatures
with a notch such as under cut
• The measurement is the energy required to to
break a specimen with a given notch
o
• 2mm depth at a 45 bevel or a “U”
U notch.
notch

BMA Engineering, Inc. – 6000 43 BMA Engineering, Inc. – 6000 44

 CHARPY

TEST MACHINE

BMA Engineering, Inc. – 6000 45 BMA Engineering, Inc. – 6000 46

VICKERS HARDNESS
HARDNESS TESTS.
• This
hi gives
i the
h metalsl ability
bili to show
h resistance
i
to indentation which show it’s resistance to
wear and abrasion.
• The tests are
– Brinell
– Rockwell
– Vickers diamond pyramid
– Scleroscope

BMA Engineering, Inc. – 6000 47 BMA Engineering, Inc. – 6000 48

 DYE PENETRANTS
DYE PENETRANTS
• These are an aid to visual inspection

• Will onlyy find surface defects

• Use correct type

BMA Engineering, Inc. – 6000 49 BMA Engineering, Inc. – 6000 50

Dye Penetrant Test

DYE PENETRANTS
• Types
– Red
– Flouresant

• CAUTION
– Oil based • Dye penetrant testing locates minute surface cracks and porosity
– Water washable • Dye types that may be used include:
ƒ Color contrast dye ‐ which shows up under ordinary light
ƒ Fluorescent dye – which shows up under black light
• The dye is normally applied by spraying it directly on the weld
BMA Engineering, Inc. – 6000 51 BMA Engineering, Inc. – 6000 (AISC & NISD 2000) 52
 Magnetic Particle Inspection
MAGNETIC PARTICLE
• Mainly for surface
defects
• Some sub surface
d f
defects can b
be ffound
d
• Only ferrous metal

• Magnetic particle inspection uses powdered magnetic particles to indicate defects in

magnetic materials
• A magnetic field is induced in the part
• The magnetic powder is attracted to and outlines cracks within the material
(AISC & NISD 2000)
BMA Engineering, Inc. – 6000 53 BMA Engineering, Inc. – 6000 54

Radiographic Inspection

RADIOGRAPHIC
X‐RAY
GAMMA RAY
Electro magnetic
g
radiation of short
duration
Both of these methods
are a danger to • Radiographic inspection,
inspection or X‐ray,
X ray can also be used to detect flaws inside welds
health • Invisible rays penetrate the metal and reveal flaws on an x‐ray film or fluorescent
screen (above)
• This is the most costly of the inspection methods
BMA Engineering, Inc. – 6000 55 BMA Engineering, Inc. – 6000 (AISC & NISD 2000) 56
 X‐ RAY X‐ RAY

BMA Engineering, Inc. – 6000 57 BMA Engineering, Inc. – 6000 58

X‐RAY VIEWER
Pictures taken are
viewed
i d as negatives
i
will only give flat
image not in three
dimensional
darkened area must
be used for viewingg

BMA Engineering, Inc. – 6000 59 BMA Engineering, Inc. – 6000 60

 ULTRASONIC TESTING ULTRA SONIC Device

This uses high pitched

sound d
The sound will not pass
through an air gap so
bounces back and is
picked up on a receiver
The reader is a
oscilloscope

BMA Engineering, Inc. – 6000 61 BMA Engineering, Inc. – 6000 62

Ultrasonic Inspection

• Ultrasonic inspection can be used to detect flaws inside welds

• High frequency sound waves are directed into the metal with a probe held at a specific
angle
• The flaws reflect some energy back to the probe
• Flaws show up as indications on a screen (above) and are subject to interpretation by
an inspector
BMA Engineering, Inc. – 6000 63 BMA Engineering, Inc. – 6000 (AISC & NISD 2000) 64
 ACOUSTICS
APPLICATION OF A LOAD
• Used to test pressure vessels
Striking with a rounded
object
bj • Pipe lines
• The item for testing is filled with water or oil it
Ringing tone if no defect i then
is h pressurised i d using
i a pump
• A safetyy valve is set 1.5 to 2 times below the
Tone changes when working pressure.
object is cracked

BMA Engineering, Inc. – 6000 65 BMA Engineering, Inc. – 6000 66

PRESSURE TEST

BMA Engineering, Inc. – 6000 67 BMA Engineering, Inc. – 6000 68

 6500. Construction Testing and
Examination ‐
6520 AWS D1.1
6520. D1 1 Structural Welding Code
Objective and Scope Met
• Destructive Test for Welds
• Nondestructive Test for Welds
– Dye Penetrate Testing
– Magnetic
M ti P
Particle
ti l TTesting
ti
– Radiographic Testing of Groove Welds in Butt
Joints
– Ultrasonic Testing of Groove Welds
– Acoustic & Pressure Testing
BMA Engineering, Inc. – 6000 69