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Destructive vs. Non-Destructive Testing

 Mechanical methods are used
for qualification or random
sampling only because they
must destroy a portion of a
Non-Destructive Examination of Welds welded assembly to provide
results (i.e., destructive)

 Nondestructive methods on the other hand provide

assessment of weld quality without altering or
damaging the specimen being tested

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NDT vs. NDE Five Common NDT Methods:

 NDT – Non-Destructive Testing  RT – Radiographic Testing
Volumetric
Inspection
 NDE – Non-Destructive Examination or…  UT – Ultrasonic Testing

 NDE – Non-Destructive Evaluation  MT – Magnetic Particle Testing

o These terms essentially all mean the same thing and are
Surface
 PT – Liquid Penetrant Testing Inspection
used inter-changeably in the industry

 VT – Visual Testing or Inspection

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Introduction to RT - Video Radiographic Testing – Basic Set-up

Radiation Film in Holder

Source

Slag Inclusions in Developed Film

Weld
http://www.youtube.com/watch?v=VscasN8jgf
o&list=UUVbLbc7goDa6FxauaveyUHA&index=6

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X-Rays vs. Gamma Rays

Radiographic Film Interpretation  The radiation used for radiography is electromagnetic radiation of
a shorter wavelength than visible light and ultraviolet radiation

 X-rays come from a high-

voltage electrical camera
Radiation turns the film dark – the more radiation that gets through, the
darker the film
These dark lines indicate more radiation has passed through slag  Gamma-rays come from
inclusions instead of metal at edges of root pass radioactive isotopes (e.g.
Iridium192)

Weld Reinforcement

Base Metal
Iridium
These changes in density, indicate the relative Pellet
Thickness X-Ray Camera
thickness of the metal
Gamma Camera

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Advantages of X-Ray Technology
 X-ray machines can have
their power adjusted to
match the thickness of the
metal being inspected
 X-ray machines can be safer
because the radiation source
is turned off electrically
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Control of X-Ray Power
 To radiograph thicker material, the voltage
applied to the X-ray camera is increased and
will cause a decrease in X-ray wavelength and
more penetrating power for the thicker material
 Sample Voltages for X-raying steel:
• 1/8 inch = 75 kV
• 1/2 inch = 150 kV
• 1 inch = 200 kV
• 2 inch = 300 kV
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Advantages of Gamma Ray Technology
 The radiation from the X-ray camera,
is focused in one direction and
requires electricity
 In contrast, a Gamma camera does not
require electricity so it is portable and is
capable of panoramic exposures for piping
and boiler welds
Welding Quality & Inspection
Gamma Ray Sources
 A Gamma Ray Source for radiography is an unstable
isotope that gives off radiation as it decays
 When not in use, the radioactive capsule is wound
back inside a special containment camera lined with
lead or depleted uranium
 Radiation is monitored with a Geiger Counter
Protection Methods:
• Time
• Distance
• Shielding
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Gamma Ray Sources: Radiographic Film Quality

Iridium 192 vs. Cobalt 60  Radiographs should only be considered if
they are of suitable quality based on:
Characteristic Iridium192 Cobalt60 1. Contrast Poor Contrast
Good Contrast Good Contrast
2. Definition
Applications 0.25 – 3.5 inch steel 1 – 7 inch steel

44 lb of depleted 500 lb of depleted

Camera Weight Specimen Poor Definition Good Definition
uranium uranium

Half Life 74 days 5.4 years

 Factors affecting these two items in taking a
suitable radiograph are:
1 inch concrete 2.7 inch concrete
Half Value Layer a) A small source of radiation
0.2 inch lead 1 inch lead
b) A long source-to-film distance
c) A short film-to-specimen distance

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Radiographic Image Quality Indicators Introduction to UT - Video

 A "Penetrameter" is also called an Image
Quality Indicator and should appear on the
radiograph to verify it is of adequate quality
ISO Wire Type
ASTM Sheet
Type

 These holes represent artificial defects

that must appear on the film image for it
http://www.youtube.com/watch?v=41i0ciqqYYM
to be considered acceptable

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Front Surface Back Surface

Basic Principles of UT (0") (4")
Ultrasonic Couplant
Calibration of CRT to 5
inches – multiple 1" 2" 3" 4" 5"  An oil or gel couplant is necessary between
echoes on calibration the transducer and specimen to adequately
block
transfer sound energy
Defect (3")
When high frequency
sound is sent through
the weld, defects
reflect signals back
early resulting in
signal on the CRT
between the front &
back surface 4"
1 inch calibration block

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Interpreting UT Signals Locating Discontinuity Depth with UT

 If no defects are present, there won't be a reflection signal
on the CRT, only a signal from the transmitted sound
 Defects will cause a signal on the CRT based on the
distance to the defect
 By moving the transducer around to look at defect
signals from different directions, a technician can verify
size and depth of a defect
 This is done based calculations knowing sound angles
and thicknesses

Defects can have

distance and depth (a Defects can have
+ b) located for repair distance and depth (a
excavation, based on + b) located for repair
a excavation, based on
calculations a
calculations

b
b

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Ultrasonic Thickness Gauge Ultrasonic Thickness Gauge

 Ultrasonic testing can do an accurate job in
dimensional thickness measurement by placing the
transducer on one side of the specimen only
 This can be accurate to one thousandths of an inch
and is beneficial for applications like checking the wall
thickness of piping transporting corrosive materials
where access to 2 sides to use calipers or a
micrometer is not possible

Pipe Elbow
Erosion/Corrosion

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Automated Ultrasonic Inspection

Advantages & Disadvantages of UT

Advantages Disadvantages

Can locate very small defects Very time consuming

Requires highly trained

Can be portable
inspectors
Can find all surface and sub- Pre and Post-Cleaning is
surface defects required
Defect size and depth can be Permanent record difficult to
determined obtain
Phased Array
Ultrasonic Inspection

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Four Basic Steps in MT:

Introduction to MT - Video
1. Magnetize the test piece area
2. Apply magnetic particles (in powder form)
3. Inspect for defects
4. Demagnetize & clean

http://www.youtube.com/watch?v=N1emHJD
0-1E&list=UUVbLbc7goDa6FxauaveyUHA

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Basic Principles of MT Basic Principles of MT:

 When magnetized, the magnetic lines of force travel  The iron particles sprinkled on
through the ferro-magnetic material the surface are only attracted
to areas of flux leakage
 If there is a disruption in the magnetic field from a causing a buildup that can be
defect, the lines of force bend around the defect easily seen

 This will find defects on the

surface and to a depth of
approximately ¼ inch deep

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Limitations of the MT Method Field Methods of MT

 Yoke Method (magnetic
1. The material can only test "ferro-magnetic"
horseshoe) - current not
metals (not aluminum and most stainless steels)
passed through specimen
2. The defect must be within ¼" of the specimen
surface
3. The defect must be aligned approximately
perpendicular to the magnetic field (defects  Prod Method - current
parallel to the direction of the lines of force will be passed through specimen
missed)

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Field Methods of MT MT – Yoke Method

 The Yoke method provides
 Yoke Method (magnetic
horseshoe) – produces
these benefits in
linear lines of force comparison to the Prods
method:
• No danger of burn marks on
part as no current is passed
through specimen
 Prod Method – produces • The yoke is normally much
circular lines of force lighter in weight in
comparison to the heavy
cables required from high
amperages using prods

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Other Methods of MT Magnetic Particle Wet Bench

 Circumferential Field
• Sometimes called "head shot"
• Detects longitudinal defects

 Longitudinal Field
• Sometimes called "coil shot"
• Detects transverse defects

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Visible MT with a White

MT Methods: Contrast Paint AC vs. DC MT Methods
 AC current provides better results detecting
UV or ‘Black’ surface defects but has no sub-surface
Light for
Fluorescent MT
capability

Visible MT with
Florescent MT with Contrasting Particles
Contrasting Particles

 DC current provides capability to detect

defects to a depth of approximately ¼ inch
below the surface of the specimen
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Properties of the Magnetic Particles Introduction to PT - Video

Application Bulb
 The particles need to be highly
"permeable" meaning easy to
magnetize
 They should have low retentivity
meaning low residual magnetism
when the magnetic force is
removed
 They are available in various
colours to provide colour contrast
as well as being available as wet
fluorescent spray
http://www.youtube.com/watch?v=QpU5JyhN
Particulate attracted to
VgQ&list=UUVbLbc7goDa6FxauaveyUHA
magnet under paper

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Materials Required for Basic PT Six Steps in Basic PT:

1. Clean and dry specimen
1. Cleaner – used to 1
thoroughly clean
2. Apply penetrant 2
specimens prior to
inspection and for doing
post-inspection clean-up 3. After "dwell time" (typically
15 mins.), remove excess
2. Penetrant – a penetrant from surface
penetrating oil usually 3
dyed red to be "pulled"
into defects
4. Apply developer 4
3. Developer – this white 5. Inspect for "bleedout"
powder-type coating indications
acts as a blotter to help
draw out pentrant and 6. Post-clean specimen to 5
provides colour contrast remove residue
for visibility
6

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Relevant vs. Non-Relevant PT Indications Relevant vs. Non-Relevant PT Indications

 Weld defects open to the surface will have a  Can You Spot and
dark red "bleedout" indication as a signal of a Relevant and Non-
possible defect Relevant Indications?

 Lighter coloured pink indications should

normally be disregarded as non-relevant from
inadequate cleaning
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PT: Visible vs. Fluorescent Dye Comparing MT to PT

 Non-fluorescent
Also called "Dye Penetrant“
Liquid Penetrant Testing Magnetic Particle Testing

 Fluorescent Usually very portable Requires electricity

Bleed-out from defects
Although this type
Finds defects open to surface Finds surface and slightly sub-
improves the ability to only surface defects
find small defects, it
Can only be used on "ferro-
also requires a Can be used on all metals
magnetic" metals
darkened inspection Better able to locate small
area and a black light May miss very small defects
defects

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RT & PT: Repair Welding Pneumatic (Leak) Testing

 Penetrant Testing is often used prior to repair welding  Pneumatic leak testing is often conducted on low-
of defects found with another NDT process pressure storage tanks, vessels, fittings, and lines
 E.g. - without ensuring excavation has completely
removed a crack, there is a chance the crack may return  Low pressure air is typically used (e.g., under 5psi
and grow even through the repair weld or 35KPa) --- pressure relief valves are required
to prevent over-pressure and explosions
Repair
CrackedWeld
Defect Excavation
Weld

 Penetrant Testing can verify the excavation has gone to

the bottom of the defect prior to repair welding

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Pneumatic (Leak) Testing Leak Testing

 A leak detection fluid (e.g., soapy water solution)  Other variations of leak testing include:
is applied to weld seams and mechanical fittings
and it is inspected for bubbles o Immersion Testing

 Pressure losses from the vessel are also o Helium Leak Testing
monitored.
o Vacuum Box Testing

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Visual Inspection: VT Canadian Inspector/Technician Qualifications:

 Visual Inspection is an  RT – Radiographic Testing

NDT method used in
Canadian General
virtually all welding
 UT – Ultrasonic Testing Standards Board
operations (CGSB) standards
 VT should always be NR-CAN is the
 MT – Magnetic Particle Testing Certifying Agency
performed before
other methods
 PT – Liquid Penetrant Testing
 VT starts before Standard
welding and continues CSA W178.2
during welding  VT – Visual Inspection (of welds) CWB is the
Certifying Agency

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