TWI

Nondestructive Tests
Prepared by: Mostafa Mohammed Ahmed Aref

Introduction
We use Non Destructive Testing (NDT) when we wish to assess the integrity of a structure without destroying it Types of NDT used are: Dye penetrant inspection (PT)

Magnetic particle inspection (MT)

Radiographic inspection (RT) Ultrasonic inspection (UT)

Dye penetrant inspection (PT)

Introduction
Surface breaking defects only detected Penetrant applied to the component and drawn into the defects by capillary action

Applicable to all non- porous materials.

Procedure

Procedure
First the work must be cleaned thoroughly, then a penetrant is applied for a specified time Once the contact time has elapsed, the penetrant is removed and a developer is then applied

Any penetrant that has been drawn into a crack by capillary action will be drawn out into the developer
Two types of penetrants are: 1) Colour contrast 2) Fluorescent Penetrant

Method

Apply Penetrant

Clean then apply Developer

Result

PENETRANT (PT)

APPLICATIONS
Surface discontinuities:
Cracks, porosity, seams, laps, leaks.

COMMENTS
Messy; need good ventilation.

PENETRANT (PT)

ADVANTAGES
Inexpensive; easy to apply; more sensitive than visual alone; use on most materials; rapid; portable.

LIMITATIONS
Surface only; not useful on hot, dirty, painted, or very rough surfaces. Requires some technique.

Magnetic particle inspection (MT)

Introduction
Surface and slight sub-surface detection Relies on magnetization of component being tested Ferro-magnetic materials only can be tested Methods of applying a magnetic field, yoke, permanent magnet and prods. Any defect which interrupts the magnetic field, will create a leakage field, which attracts the particles

Method
Electro-magnet (yoke) DC or AC Collection of ink particles due to leakage field Crack like indication Prods DC or AC

Crack like indication

Procedure
First the work must be cleaned and a whitener applied for contrast. A magnetic flux is then applied by permanent magnet, electro magnet, or straight current A magnetic ink is applied which will concentrate in areas of flux leakage, as those caused by flaws The weld length must be crossed at 90 by the magnetic field The types of magnetic media used are: 1) Wet ink 2) Dry powder 3) Fluorescent ink

Method
Contrast paint Magnet & Ink Result

MAGNETIC PARTICLE (MT)

APPLICATIONS
Surface and near surface discontinuities:
Cracks, voids, porosity, inclusions, seams, laps.

COMMENTS
Messy. Can cause defects.

MAGNETIC PARTICLE (MT)

ADVANTAGES
Low cost; fast; more sensitive to tight cracks than PT; can do near subsurface; portable.

LIMITATIONS
Material must be ferromagnetic; surface must be clean; part may be demagnetized; alignment of field is important. Requires operator technique.

Radiographic inspection (RT)

Introduction
Radiation is transmitted to varying degrees dependant upon the density of the material through which it is travelling Thinner areas and materials of a less density show as darker areas on the radiograph Thicker areas and materials of a greater density show as lighter areas on a radiograph

Applicable to metals, non-metals and composites

Procedure
A film is placed inside a cassette between lead screens. It is then placed to the rear of the object to be radiographed A radiographic source, is exposed to the work and film for a pre-calculated time Any imperfections in line with the beam of radiation will be shown on the film after exposure and development

The 2 types of radiation used in industrial radiography:

1) 2) X rays (from Cathode Ray Tube) Gamma rays (from a Radioactive Isotope)

Method
Source Radiation beam Image quality indicator

Radiographic film

Test specimen

Method
Source Radiation beam Image quality indicator

Test specimen

Radiographic film with latent image after exposure

RADIOGRAPHY (RT)

APPLICATIONS
Subsurface discontinuities:
Cracks, voids, inclusions, thickness variation, lack of fusion, incomplete penetration, corrosion, missing components, composition>

COMMENTS
One of the most frequently used methods.

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RADIOGRAPHY (RT)

ADVANTAGES
Easily understood permanent record; usually moderate cost; can be portable; applicable to a wide range of materials.

LIMITATIONS
Cannot detect laminations; radiation hazard and regulations; access to both sides can be high cost; requires trained operators.

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Ultrasonic inspection (UT)

Introduction
This detection method uses high frequency sound waves, typically above 2MHz to pass through a material A probe is used which contains a piezo electric crystal to transmit and receive ultrasonic pulses and display the signals on a cathode ray tube or digital display The actual display relates to the time taken for the ultrasonic pulses to travel the distance to the interface and back An interface could be the back of a plate material or a defect

Procedure

First the work must be cleaned thoroughly, then a couplant is applied to increase sound transmission

A probe is then applied with the correct angle for the weld preparation and sound waves are transmitted
Any imperfections will rebound the sound waves causing a signal to occur on the cathode ray tube

Method
Apply Couplant Sound wave
CRT display

Result

Signal rebounded from Lack of fusion

Method
initial pulse defect echo Back wall echo

Material Thk defect

10

20

30

40

50

Compression Probe

CRT Display

ULTRASONIC (UT)

APPLICATIONS
Surface and deep subsurface discontinuities:
Cracks, laminations, porosity, lack of fusion, inclusions, thickness.

COMMENTS
Need good standards. Frequently used method.

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ULTRASONIC (UT)

ADVANTAGES
Rapid if automated but manual is slow; applicable to very thick specimens; can give location and size of discontinuity; good sensitivity; inspect from one side; portable.

LIMITATIONS
Couplant required; thin complex shapes are difficult; orientation of discontinuity important; very operator-dependent.

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