NON DESTRUCTIVE TESTING

NDT - general name for all methods which permit testing / inspection of materials / parts without impairing its future usefulness

TYPES OF DEFECTS
inherent defects - present during initial production of raw materials processing defects - resulted from the manufacturing process service defects - occurred during the operation

Examples of causes of defects

Blowholes - gas trapped during solidification process Segregation - during solidification of alloy Scale - oxide formation on the surface of a metal heated to high temperature Stress - residual stress after cold working or rapid cooling

Cracks
quenching / hardening cracks - rapid volume change tempering cracks - rapid heating shrinkage cracks - rapid cooling grinding cracks - friction heating also caused by residual stress, collapsed blowholes, improper rolling, sharp edge of dies etc. etc.

TEST METHODS
visual pressure and leak test penetrant thermal radiography acoustic magnetic electrical / electrostatic electromagnetic induction - eddy current optical holography electron probe etc.etc

Visual Testing
most widely used experienced inspector knows where are likely cracks , orientation of cracks relative to various zones in the weld, surface porosity, weld penetration, potential weakness such as sharp notches or misalignment

Pressure and Leak Test

common form is hydrostatic test hydrostatic test often required for pressure vessels, pipes, valves. normally pressurised to 1.5 or 2 times the working pressure for sensitive leak test, radioactive material, halogen or helium gases are used

Penetrant
extension of visual inspection for detection of surface flaws two kinds ; dye penetrant and fluorescent penetrants

Basic steps of dye penetrant testing

clean the surface apply penetrant remove excess penetrant apply developer inspect / interpretation

penetrant seep into flaw

developer draws penetrant onto surface

Magnetic particle testing

for locating surface & subsurface discontinuities in ferromagnetic materials leakage current occurs at the discontinuities / surface flaws when magnetized fine particles collect at the leakage sites

Magnetic particle testing

Ultrasonic testing
use beams of high frequency sound waves to probe the material internal flaws and locations can be determined by analyzing reflected sound waves

Ultrasonic testing

Ultrasonic testing - limitations

Complex shapes can be difficult Small coverage area Highly trained personnel Rough surfaces may cause problems

Radiography
Similar to medical Costly method, expensive equipment Different angles needed Thin cracks may be missed Costly Highly trained personnel Radiaiton hazard Complex shapes / can give problems

Eddy current testing

Eddy current induced when electrically conductive material close to alternating magnetic field Eddy current generates magnetic field which interact with original magnetic filed

Eddy current testing

Detect both surface & near surface irregularities Close contact not needed Can be automated No clean up Low cost equipment Response can be sensitive interpretation difficult Depth of penetration limited Need to maintain constant distance between coil and specimen for good result