MPE012-NON-DESTRUCTIVE EVALUATION

UNIT I
NON-DESTRUCTIVE TESTING: AN INTRODUCTION, VISUAL INSPECTION
& LIQUID PENETRANT TESTING

G.Selvakumar, Asst. Prof (SG)

Department of Mechanical Engineering
National Engineering College, K.R. Nagar -628 503, TN, India
Reach me at: kural_selva@rediffmail.com

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 Visual Inspection
The human eye is one of mankinds most fascinating tools
and is capable of assessing many visual characteristics
and identifying various types of discontinuities.

Basic Principle:

Illumination of the test specimen with light, usually in the

visible region.

The specimen is examined with eye or by light sensitive

devices such as photocells.
Eye:
Most valuable NDT tool.
Eye most sensitive to yellow green light (5560 A)
Adequate lighting (about 800-1000 lux) is prime importance.
Human inspector is not allowed to work not more than 2 Hrs on continuous
basis to avoid errors due to decrease in visual reliability and discrimination.

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The lux (symbol: lx) is the SI unit of illuminance and luminous emittance,
measuring luminous flux per unit area. It is equal to one lumen per square
metre. [Wikipedia]

Example:
Moonless, overcast night sky = 104 lux
Full moon on a clear night = 0.271.0 lux
Sunrise or sunset on a clear day = 400 lux

Defects which can be detected by unaided visual inspection:

Presence or absence of oxide film or corrosive product on the

surface

In welding Presence or absence of cracks, orientation of the

cracks, unfilled caters, weld beads etc., ( Size of discontinuity
Approximately 0.25 inches and larger can be measured by unaided
eye)

Potential sources of mechanical weaknesses such as Notches,

misalignments etc., 3
 An Inspector at Tinker Air Force Base Gets a
Visual Inspection of a Torpedo Tube
Magnified View of an Engines High-Pressure
Aboard a Navy Attack Submarine (Photo
Turbine Area with a New Digital Fiber-Optic
Courtesy of the Department of Defense;
Borescope. (Photo Courtesy of US Air Force;
Photo Taken by JO3 Corwin Colbert, USN)
Photo taken by Margo Wright) [The AMMTIAC
[The AMMTIAC Quarterly, Volume 1, Number 3]
Quarterly, Volume 1, Number 3]

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Optical Aids used for Visual Inspection
Optical instruments in visual inspection is beneficial and in
recommended to:

(a) Magnify defects that cannot be detected by the naked eye.

(b) Permit visual checks of areas not accessible to the unaided
eye.

Optical Aids:
(a)Microscope
(b) Borescope
(c)Endoscope
(d) Flexible Fiber-Optic Borescope (Flexiscope)
(e) Telescope
(f) Holography
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 Microscope
A microscope is an instrument used to see objects that are too small for the
naked eye. The science of investigating small objects using such an instrument
is called Microscopy. Microscopic means invisible to the eye unless aided by a
microscope. [wikipedia]

Types of -scope:
optical microscope which
uses light to image the
sample

Electron microscope (both

the transmission electron
microscope and the
scanning electron
microscope)

Transmission electron
microscope (TEM): passes
electrons through the
sample, analogous to basic
optical microscopy.
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 Case Study:1
(Corner error measurement using optical microscope)

Job profile with corner angles.

Corner error measurement for aggressive

and low parameters setting for a = 47 mm,
h = 23mm and =30. CE: corner error.
Measured with the aid of an OLYMPUS
make, STM6 model measuring microscope
[ selvakumar et.al (2012), J Engineering
Manufacture, 226(10), Pp.16941704]

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 Case Study:2 - SEM

SEM Picture of Al5083 alloy specimen SEM Picture of Al5083 alloy specimen
before Machining (Magnification : 1000x) machined with single pass WEDM
(Magnification : 1000x)

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 Borescope
[PAUL E. Mix, INTRODUCTION TO NONDESTRUCTIVE TESTING A Training Guide- Second Edition ]

Borescopes are optical instruments

designed for remote viewing of objects.

Because of the variety of applications

and multitude of inspection needs,
borescopes are manufactured in rigid,
extended, flexible, and micro designs.

In general, the diameter of the

borescope determines the size of the
minimum opening into which it can be
inserted.

The borescopes three main optical components are

the objective lens system, the relay lens system,
and the eyepiece, which determine its
magnification.

Rigid and micro-style

borescopes for jet engine
inspection.
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 Borescope
The objective lens is located at the end of the borescope and it acts similar to a
camera lens. It forms the primary image of an object on the back of the lens.

Relay lenses reform or relay the primary image every few inches along the length of
the borescope. In long borescopes, several relay lenses are used.

The last set of relay lenses produce the final image at the eyepiece of the borescope.
The eyepiece lens enables the human eye to see the final image formed.

Each of these three components produces a magnificationthe total magnification is

the product of each magnification in accordance with Equation shown below.

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 Borescope
Many companies now offer a complete,
standalone video information
processing system. Features of these
closed-circuit television (CCTV)
systems include defect image
measuring capability, computerized
video enhancement, alphanumeric
keyboard for data identification, high-
resolution display and recording,
hardcopy documentation, and audio
recording. The high-resolution video
camera used with this system can be
attached to virtually any borescope,
fiberscope, periscope, or telescope.
This system is said to be ideal for
applications involving long inspection
video-borescope periods, multiple operator viewing, or
cases where complete documentation is
required.
Borescope enables to inspect the inside of an narrow tube, bore or chamber.
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 Endoscope
[ Baldev raj et al., Practical non- destructive testing, 3rd Edition, Narosa Publishing House]

Endoscope is like a borescope.

But it has a superior optical
system and high intensity light
source.

Unique feature of this is that

objects are continuously in
focus from about 4mm to
infinity.

The no focusing feature of this

endoscope makes it much
easier to use than a borescope.

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Flexible Fiber-Optic Borescope (Flexiscope)
Flexible borescopes can be used for quality
assurance applications, preventative
maintenance, general inspection and various
other shop floor and viewing of hard to
reach/see spots.

Specification:

4.0 mm / 6.0 mm/ 8.0 mm Stainless Steel Braided

Probe

2-way (4 way is also available), 90 degree, tip

articulation

Working Length: 110cm /160cm

12,000/ 20,000 pixel fiber optic image bundle 2 way Articulating

Flexible Borescope
Specialized light post
(Fiberscope)
Universal focusable eyepiece 13
 Flexiscope [wikipedia]
A flexible borescope (fiberscope) includes a bundle of optical fibers which divide the
image into pixels.

It can be used to access cavities which are around a bend, such as a combustion chamber
or "burner can", in order to view the condition of the compressed air inlets, turbine blades
and seals without disassembling the engine.

Flexible borescopes suffer from pixelation and pixel crosstalk due to the fiber image guide.

Image quality varies widely among different models of flexible borescopes depending on
the number of fibers and construction used in the fiber image guide.

Some high end borescopes offer a "visual grid" on image captures to assist in evaluating
the size of any area with a problem.

For flexible borescopes, articulation mechanism components, range of articulation, field of

view and angles of view of the objective lens are also important.

Fiber content in the flexible relay is also critical to provide the highest possible resolution
to the viewer.

The ability to control the light at the end of the insertion tube allows the borescope user to
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make adjustments that can greatly improve the clarity of video or still images.
 Telescope
[ Baldev raj et al., Practical non- destructive testing, 3rd Edition, Narosa Publishing House]

Used to obtain magnified images of

objects at considerable distance from
the eye.

It consists of 2 lenses called objective

and eye piece.

It can be used in conjunction with

periscope for viewing a concealed
surface. But, Closed Circuit Television
(CCTV) is also used for this purpose.

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 periscope
A periscope is an
instrument for observation
from a concealed position.
In its simplest form it
consists of an outer case
with mirrors at each end
set parallel to each other at
a 45-degree angle. This
form of periscope, with the
addition of two simple
lenses, served for
observation purposes in
the trenches during World
War I. Military personnel
also use periscopes in periscope
some gun turrets and in
armoured vehicles.
[Wikipedia]
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 Holography
[ Baldev raj et al., Practical non- destructive testing, 3rd Edition, Narosa Publishing House]

A method of obtaining an accurate 3D image of a given object.

( It involves the use of a laser, interference, diffraction, light intensity
recording and suitable illumination of the recording.)

This process is carried out in 2 stages.

1. A permanent record in the form of 2 Dimensional

interference pattern is obtained on a photographic plate by
means of laser beam. (LASER - Light Amplification of
Stimulated Emission Radiation)

2. The 3 Dimensional image is then obtained from the

2D record again using a laser.

In this way, a picture having a high definition and free

from aberrations can be obtained without the use of a camera.
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 Holography
[PAUL E. Mix, INTRODUCTION TO NONDESTRUCTIVE TESTING A Training Guide- Second Edition]

Beam splitter divides the beam into an object beam and reference beam.

The object beam illuminates the object and the reference beam is projected
directly on the film or CCD (charge-coupled device) camera.

The object and reference beams are adjusted so that they are in-phase and the
same length from the beam splitter to film or CCD camera.
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 Holography
The beams can be independently
directed, expanded, or collimated by
mirrors and lenses in each beam.

The reference beam reilluminates the

processed film (or CCD camera) and
the light is diffracted into the exact
waveforms that had been originally
reflected by the object.

The holographic image of the projected object contains all the visual information
of the original object.

When this image is superimposed on the object, real-time holography is

produced.

Any differences between the image of original object and present object can be
immediately seen.

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 Holography
[ Baldev raj et al., Practical non- destructive testing, 3rd Edition, Narosa Publishing House]

Holography is used for the NDT of surfaces

of highly complicated and precision
components without the disadvantages of
having to use a high power microscope.

In a simple operation, a hologram can

provide a record of the image of an entire
surface which can be readily compared with
that of a standard defect free surface.

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 Holography
Advantages of Holography: [PAUL E. Mix, INTRODUCTION TO
NONDESTRUCTIVE TESTING A Training Guide- Second Edition]

Non-contacting measurement. In many cases, there

are no surface preparation or marking requirements.

Full-field view. Whether the measurement is macro-

or microscopic, the full-field view of the area of
interest can be examined and measured.

No consumables. Unlike other NDT methods, no

penetrants, marking materials, or coatings are
required.

Real-time measurements are possible.

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 Holography
Applications: [PAUL E. Mix, INTRODUCTION TO NONDESTRUCTIVE TESTING A
Training Guide- Second Edition]

Determining the vibration modes and characteristics of rotating

objects such as wheels, gears, and early disk drives.

Determining mechanical deformation in structural materials.

Determining the integrity of bonds and laminations in composite

materials.

Determining mechanical stress-strain and thermal stress-strain

relationships in a multitude of materials.

The detection of cracks in steel channel bolt holes, ceramics at high

temperature, concrete, glass tubes and plates, railroad wheels,
pressure vessels, welded steel plates, and honeycomb panels.
Improved laser systems are used for many of these same
applications today.
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 Assignments...!!?
1. Write a brief story on evolution of Microscope.
2. How does a microscope works?
3. What do you mean by Magnification of a
Microscope?
4. What is SEM? How does it works?
5. What is Transmission electron microscope
(TEM)?
6. Define : (a) interference (b) diffraction.
7. Why Laser is employed in Holography?

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Thank You

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