Assignment 1

Subject Name: Non Destructive

Testing
Subject code: MTPE 14
Name: Sapthagirivasan R T
Roll No: 112120056
Non Destructive Testing in Automobile Industry

➢ Introduction on NDT (Non Destructive Testing):

Non destructive testing (NDT) is broad group of techniques for analysing, used in science and
technology sector to assess the defects, flaws, irregularities and properties of a material,
component, or system without causing damage or comprising their functionality because of
which huge amount of money is saved. The primary goal of non-destructive testing is to ensure
the reliability, safety, and integrity of structures. Non-Destructive Testing (NDT) Techniques
or Methodologies allow the investigator to carry out examinations without compromising the
integrity of the engineering specimen under observation while providing an elaborate view of
the surface and structural discontinuities and obstructions. These techniques are crucial for
quality control, maintenance, and safety assessments throughout the life cycle of a product or
structure. Due to these reasons NDT is especially valuable in industries where the failure of
components could have severe consequences, such as in the case of aircraft, pipelines, bridges,
nuclear facilities, and pressure vessels and it saves as a lot of money and time in product
evaluation, troubleshooting and research.

➢ NDT in Automotive Industry:

Nowadays, automobiles serve diverse practical needs and contribute to our desire for extended
journeys, road trips, adventures, and exploration. Motor vehicles have significantly simplified
our lives by facilitating long-distance travel, commuting, and transporting children to school.
The extensive testing that modern cars undergo before, during, and after production, as well as
the often-overlooked non-destructive testing (NDT) procedure, are aspects rarely
acknowledged. We tend to overlook the rigorous testing and safety assurances provided by
contemporary cars.
NDT proves to be a critical tool in the automotive sector, serving essential roles in quality
control, product design, engineering, research and development, manufacturing, and
maintenance of automobiles. In the automotive and automotive supply industry, where the
demands on components, its quality and its reliability are increasingly stringent, the need for
advanced non-destructive testing (NDT) methods is paramount. Defects must be eliminated,
Zero defect quality is the goal, especially for components operating close to their physical load-
limits or in safety relevant positions. Control of dimensional tolerances and the dimensional
measurement of complex geometries with high resolution up to sub-µm is a prerequisite.
Sometimes there is a need for in-line testing of all manufactured components (100%-testing).
In-line testing also allows for process control and thus reduces waste production. Moreover,
the industry's high throughput and short production cycles, lasting only a few seconds and The
application of virtual simulations, employing finite element modelling principles, can now be
made more accessible through premarket testing utilizing advanced non-destructive
procedures. By employing this non-destructive testing approach, manufacturers can evaluate
diverse real-world scenarios, thereby improving the accuracy and predictability of automotive
safety systems and component performance, these qualities emphasize the importance of NDT
that aligns seamlessly with the rapid pace of the production cycle because NDT aids the new
product development in a much faster pace with rapid optimisation of production processes.
Its applications encompass a variety of non-invasive inspection techniques aimed at evaluating
material properties and identifying potential damage, such as corrosion or cracks. Through
these methods, the automotive industry can ensure the reliability and safety of its products
without compromising the integrity of the materials under examination.
By utilizing non-destructive monitoring methods, the automotive industry can effectively
identify defects within different materials and components, and can approximate how much a
vehicle's components will wear and fail during manufacture and testing. This involves testing
the internal structure of materials and observing their responses to various stimuli like heat,
sound, light, and electricity. Importantly, this is achieved without causing any damage to the
object under inspection. The continuous development of electronic and computer technology
further contributes to the evolution of non-destructive testing, allowing for the extraction of
valuable information about the type, characteristics, number, size, and location of defects.
Ultimately, these automobile components must be assembled and subjected to testing. Prior to
the assembly of a car, each individual part undergoes thorough testing, and additional tests are
conducted after the assembly process is completed.
In this context, the integration of production and quality measurement techniques plays a
crucial role in providing customers with more economical and reliable automotive products.
The seamless incorporation of NDT into the production process not only ensures the stringent
requirements of defect elimination and dimensional accuracy but also contributes to the overall
efficiency and reliability of the automotive manufacturing sector.

➢ Role of NDT in evaluating features during the development of a

vehicle:
Non-Destructive Testing (NDT) plays a crucial role in evaluating features during the
development of a vehicle. Some key features that can be tested through NDT includes:

1. Weld Quality Assessment: NDT techniques like ultrasonic testing (UT) and radiographic
testing (RT) can be employed to ensure the integrity of welded joints, which are critical for
vehicle structural stability.

2. Material Integrity: Ultrasonic and magnetic particle testing are useful for detecting defects
or inconsistencies in materials, ensuring that the components used in the vehicle meet the
required standards for strength and durability.

3. Surface Crack Detection: Techniques such as dye penetrant testing and eddy current testing
are effective in identifying surface cracks or flaws in components, preventing potential failure
points that could compromise safety.
4. Corrosion Inspection: Ultrasonic and radiographic methods can be applied to assess the
extent of corrosion in metal structures, helping to prevent structural weaknesses that might
compromise safety over time.

5. Composite Material Testing: For vehicles incorporating composite materials, methods like
ultrasonic testing and thermography can be used to assess the quality and structural integrity
of these materials without causing damage.

6. Bolt and Fastener Inspection: Ultrasonic testing is valuable for evaluating the tightness
and integrity of bolts and fasteners, ensuring that critical components remain securely attached.

7. Brake System Evaluation: Ultrasonic and radiographic testing can be employed to examine
the internal components of brake systems, identifying potential issues that may affect braking
performance and overall vehicle safety.

8. Quality Control of Cast Components: Radiographic and ultrasonic testing are effective in
inspecting cast components for defects or irregularities that could compromise their strength
and safety.

9. Assembly Verification: NDT methods help verify the proper assembly of components,
ensuring that all parts are correctly fitted and secured to prevent safety hazards caused by
assembly errors.

10. Structural Integrity: Radiographic and ultrasonic testing can be used to assess the overall
structural integrity of critical components such as chassis, frame, and suspension systems,
ensuring they meet safety standards.
By incorporating NDT techniques to evaluate these features, manufacturers can enhance the
reliability and safety of vehicles during the development process.

➢ In Automotive industry NDT is primarily used for:

(i) Detection of material defects:
While numerous testing methods exist, only a handful are genuinely applicable to assess
automotive components. Optical interferometry achieves by far the highest resolution.
However, optical techniques can only monitor surfaces or coatings. In contrast, the best
penetration depth (except for some highly absorbing materials such as Pb or Pt) combined with
a high resolution is usually gained by X-ray CT. In between these extremes, we find eddy
current measurements for the detection of near-surface defects.

Fig 1

Fig 1: Classification and comparison of X-ray CT, ultrasonic testing, eddy current and optical
measurement techniques (denoted as non-interferometrical optics and white light
interferometry) according to penetrating depth, detectable defect location and spatial
resolution.

(ii)Dimensional measurements:
While numerous testing methods exist, only a handful are genuinely applicable to assess
automotive components. Figure 2 shows the classification of the above mentioned techniques
in figure 1, with respect to dimensional measurements. Here, the emphasis is on the
measurement of geometrical parameters.

Fig 2
(iii)Researching new technologies:
Research and development teams have the option to employ non-destructive testing for the
evaluation of different innovative concepts or approaches. This could involve examining a
component following its production using recently configured fabrication equipment or
scrutinizing a novel material blend utilized in a particular part. These assessments provide
comprehensive insights that extend beyond simple pass-fail evaluations.

➢ Various NDT techniques used in automotive industry:

1. Magnetic particle inspection methods:
The magnetic particle inspection techniques are predominantly utilized for identifying surface
imperfections in components. When a ferromagnetic material undergoes magnetization and
surface cracking occurs, a specific leakage magnetic field is generated on the component's
surface. This magnetic field leakage is then detected by a magnet-sensitive element, providing
information on the characteristics of various defects. Unlike other inspection methods, this
approach doesn't necessitate cleaning of the component, resulting in relatively high inspection
efficiency. It is capable of effectively detecting surface defects such as cracks and rust.
Importantly, the magnetic particle inspection method is not constrained by component size and
can be applied to components of diverse shapes and parts, streamlining the inspection process.

Fig 3:The image depicts Magnetic particle inspection

2.Eddy current detection methods:

Utilizing the principles of electromagnetic induction, the eddy current detection method is
employed to assess the physical and structural imperfections of diverse materials through the
generation of differential amplitude and phase eddy currents within alternating magnetic fields.
This technique is particularly adept at identifying surface and near-surface defects in metallic
materials. Notably, the inspection process does not necessitate direct contact between the
component and the inspection probe, thereby meeting the criteria for high-speed and automated
inspection. Eddy current inspection is applicable not only to ferromagnetic materials but also
to non-ferromagnetic ones, and it does not require the tested material to possess a specific
electrical conductivity. Consequently, it can be utilized for inspecting a wide range of materials.
Despite these advantages, the method poses challenges in processing due to the generation of
high-frequency excitation signals during the detection process. In the automotive industry, it
finds extensive use in inspecting components such as detector valves, ring seats, and ball pins.

Fig 4: The image depicts eddy current testing method

3.Radiation detection methods:
The radiation irradiation approach is now the most used non-destructive testing technique. The
technique is based on the idea that various materials absorb and attenuate light in different
ways, which allows for variation in the negative's darkness, which may be used to identify
material defects. It is employed in the automotive sector for the purpose of inspecting welded
and cast parts. Wheel hubs and camshafts, for instance, are examined.

Fig 5: The image depicts X-Ray radiography and Gamma Ray radiography which are types of
radiation detection methods.
4. Laser holographic detection methods:
A technique called laser holography makes use of this technology to find flaws both inside and
on the external surface of a component. Different external stresses cause different deformations
in components, and there is a relationship between the deformations and internal faults in the
component. Through the use of various loading techniques, such as fluid pressure loading and
thermal loading, the surface of the component is slightly deformed by the holographic
interference method. The shape of the light wave before and after loading is compared, and the
internal defect of the component is identified based on the change in the interference fringe of
the light wave.

Fig 6:The above image depicts how laser holographic testing

5.Penetration testing methods :
A Penetration method is a type of surface examination technique, that is capable of identifying
both metallic and non-metallic materials. By using fluorescent or colouring permeation fluid,
one can directly observe the material surface of open defects by applying the fluid and allowing
it to penetrate into the material's surface defects through the capillary action of the liquid. This
allows for the amplification of the surface defect image. Typically, the penetration testing
method is used as an auxiliary inspection technique. Examples of such testing techniques are
vehicle maintenance and component performance testing.
Fig 7:Image depicts how Dye penetration testing method

6. Ultrasound methods:
Ultrasonic inspection relies on the transmission properties of ultrasound waves in various
materials to accurately pinpoint internal defects within the material. Since ultrasound waves
experience greater attenuation in air, maintaining a clean surface is essential during component
inspection. This ensures effective introduction of sound waves into the interior of the examined
object through a designated coupling material. In contrast to traditional ultrasonic inspection
methods, this approach involves the generation of ultrasonic waves in the material through
electromagnetic or laser stimulation. Notably, this method eliminates the need for coupling
material, making it particularly suitable for examining components like crankshafts, half-
shafts, and tappets.

Fig 8:Image depicts how ultrasonic testing works

7.Thermography:
Thermography as a method to enhance product quality and reduce production costs. Although
effective, the disadvantage lies in its limited industrial implementation. Infrared thermography
involves measuring and mapping surface temperatures, typically utilizing thermal imaging
cameras. Flash thermography is particularly successful in imaging composite parts, allowing
visualization of defects such as missing rovings, fuzzballs, and fiber orientations. The method
is also capable of detecting defects in cured parts like delaminations, dry spots, porosity, or
disbondings. An infrared thermographic scanning system, usable day or night, detects
electromagnetic radiation emitted by objects based on temperature differences. Radiometers
capture these radiations, and imagers convert them into electrical signals using an infrared
detector.
Fig 9: Image depicts thermography works

➢ Application of NDT Technology in Automotive Industry:

Different NDT methods are employed to test various components of automobiles.
Here are examples of how NDT is applied in the automotive industry for testing
different components:
1. Engine Block Testing through Ultrasonic Testing(UT):
Ultrasonic Testing is commonly used to inspect engine blocks for internal defects such as
cracks, porosity, and inclusions. In this method, high-frequency sound waves are transmitted
through the material, and the echoes are analyzed to detect any irregularities. For engine blocks,
UT helps ensure that there are no hidden flaws that could compromise the structural integrity
and performance of the engine.

2. Weld Inspection in Chassis through Radiographic Testing (RT):

Radiographic Testing is utilized to inspect welded joints in chassis components. X-rays or
gamma rays are directed through the weld, and the resulting image allows inspectors to identify
defects such as incomplete penetration, porosity, or cracks. This ensures the structural integrity
of the chassis, which is crucial for vehicle safety.

3. Wheel Hub and Axle Inspection through Magnetic Particle Testing (MPT):
Magnetic Particle Testing is often employed to inspect critical components like wheel hubs and
axles for surface and near-surface defects. In this method, magnetic particles are applied to the
surface, and any magnetic flux leakage caused by defects is detected using specialized
equipment. MPT is effective for identifying cracks, weld defects, and other discontinuities in
ferromagnetic materials.

4.Brake System Inspection through Visual Inspection(VI), Ultrasonic Testing(UT):

Component Tested: Brake components (discs, calipers)
Visual inspection is commonly used for the overall assessment of brake components. Ultrasonic
Testing can be employed to check the thickness of brake discs and detect any hidden defects.
This ensures that the braking system meets safety standards and performs effectively.

5. Aluminium Body Panel Inspection through Eddy Current Testing (ECT):

Eddy Current Testing is suitable for inspecting conductive materials like aluminum. It can
detect surface cracks, corrosion, and variations in thickness. In the automotive industry, ECT
is often used to ensure the quality of aluminum body panels, which are lightweight and
corrosion-resistant but may still be susceptible to defects.

6. Crankshaft Testing through Magnetic Particle Testing (MPT):

Magnetic Particle Testing is applied to inspect the crankshaft for surface and near-surface
defects, such as cracks and fissures. A magnetic field is induced in the crankshaft, and magnetic
particles are applied to the surface. Any magnetic flux leakage caused by defects is readily
visible under UV light, allowing for precise defect detection without damaging the crankshaft.

7. Transmission Gear Inspection through Liquid Penetrant Testing (LPT):

Liquid Penetrant Testing is effective for identifying surface-breaking defects in transmission
gears. A liquid penetrant is applied to the gear surface, and after a specified dwell time, excess
penetrant is removed. A developer is then applied, drawing the penetrant out of any surface
defects and making them visible. This method helps ensure the integrity of the gears and
prevents potential failures.

8. Suspension System Inspection through Ultrasonic Testing (UT):

Ultrasonic Testing is used to inspect critical suspension components for internal defects. UT
can detect flaws such as weld defects, inclusions, and material inconsistencies within the
control arms or tie rods. Ensuring the structural integrity of these components is essential for
maintaining vehicle stability and safety during operation.

9. Fuel Tank Examination through Radiographic Testing (RT):

Radiographic Testing is employed to examine the welds and internal structure of fuel tanks.
This method allows for the detection of weld defects, porosity, and other internal irregularities
that could compromise the integrity of the tank. RT ensures that the fuel containment system is
free from defects that could lead to leakage or failure.

10. Airbag Inflator Inspection through Acoustic Emission Testing (AET):

Acoustic Emission Testing is utilized to monitor the structural integrity of airbag inflators. AE
detects the release of stress waves or acoustic emissions from the inflator during pressure
changes. This method is sensitive to the initiation and growth of defects, providing early
detection of potential issues and ensuring the reliability of the safety-critical airbag system.

11. Piston and Cylinder Bore Inspection through Eddy Current Testing (ECT):
Eddy Current Testing is suitable for inspecting the surface of pistons and cylinder bores for
defects such as cracks, wear, and variations in material properties. ECT uses electromagnetic
induction to detect changes in conductivity or permeability, allowing it to identify surface
irregularities without direct contact with the component.

12. Exhaust System Examination through Ultrasonic Testing (UT):

Visual inspection is often used for the external assessment of exhaust components, checking
for corrosion, weld quality, and physical damage. UT is applied to assess the thickness of
exhaust pipes and to detect internal defects such as corrosion or blockages. Ensuring the
integrity of the exhaust system is crucial for emissions control and overall vehicle performance.

13.Electrical Wiring and Connectors through Infrared Thermography (IRT):

Infrared Thermography is used to inspect electrical components for overheating and potential
electrical faults. An infrared camera captures thermal images, allowing technicians to identify
hotspots indicative of resistance, loose connections, or other electrical issues. This method is
especially useful for detecting problems in wiring and connectors that could lead to electrical
failures.

14. Plastic Components in Interiors through X-ray Computed Tomography (CT):

X-ray Computed Tomography is employed for detailed inspections of plastic components in
the vehicle interior. It provides cross-sectional images, revealing internal structures, voids, or
defects that may not be visible externally. CT is valuable for assessing the quality and structural
integrity of complex plastic parts.
15. Cooling System Inspection through Pressure Testing, Visual Inspection:
Pressure testing is commonly used to assess the integrity of the cooling system. Components
like radiators and hoses are pressurized with air or water, and any leaks or weaknesses in the
system are identified. Visual inspection complements this by allowing inspectors to visually
identify issues such as corrosion, physical damage, or loose connections.

16. Electronic Control Units (ECUs) and Circuit Boards through X-ray Inspection,
Automated Optical Inspection (AOI):
X-ray Inspection is used for detailed examination of electronic components, revealing solder
joint quality, component placement, and potential defects within ECUs and circuit boards. AOI
employs cameras and image recognition algorithms to inspect circuit boards for visual defects,
ensuring the reliability of electronic systems in the vehicle.

The above specific examples illustrate how different NDT methods are tailored to the unique
characteristics and requirements of various automotive components. The selection of the
appropriate NDT technique depends on factors such as material composition, component
geometry, and the types of defects expected in each specific application.

➢ Overcoming Challenges in NDT application in industry:

The successful implementation of Non-Destructive Testing (NDT) in automotive plants,
emphasizing the importance of considering plant management's perspective. To overcome
roadblocks, solutions must address real problems known to the management and align with
plant realities, including cost considerations and production rates. The need to minimize costs,
particularly inspection costs, and reduce interference with production flow is highlighted. The
integration of automation and intelligence into inspection instruments is crucial to achieve
precision, reduce fatigue, and minimize human error.
Quicker inspection methods, such as machine vision, non-contact ultrasound, resonance
testing, and infrared thermography, are introduced to minimize production interference. The
paragraph also proposes a shift in the approach to inspections, suggesting that inspections can
be used not only to find defects but also to reduce the production of faulty products. This
involves abandoning the traditional "Go/No-Go" indication in favor of quantitative inspection
as a trend indicator, allowing for timely corrective action.
The ultimate integration of NDT into production is described as in-situ process control, where
inspections are incorporated directly into production machinery to ensure 100 percent
satisfactory outcomes in real-time. However, it is acknowledged that in-situ inspection systems
may not always align with plant realities, and their suitability depends on the relationship
between process complexity and instrumentation cost. For high-volume operations like spot
welding, automated, on-line, post-process inspection is suggested as a more practical solution
to minimize dependence on trained personnel and interference with production flow. This
scenario involves inspecting subassemblies after all welding operations are completed, using
automated tests to flag unsatisfactory welds and provide timely feedback.

➢ Opportunities:
Even a technology for inspection that meets the previously mentioned criteria encounters an
additional obstacle: resistance to change from the existing practices. The plant may be
comfortable with its current methods, even if they lead to waste and inefficiencies, simply
because they have been followed for many years. The plant might demand unrealistic or
outdated standards from NDT. Issues like a lack of floor space for new instrumentation or
inadequate procedures for result logging and tracking can hinder even the most dedicated
efforts.
Hence, the most promising chances for expanding NDT in the automotive industry align with
the introduction of new materials and processes. The continuous pursuit of safer and more fuel-
efficient vehicles prompts the introduction of new materials, and new processes aim to reduce
costs, improve quality, and facilitate the use of these materials. In this context, arguments based
on tradition become less relevant. With the absence of established production lines, prejudices,
and procedures, the introduction of new materials and processes brings forth new challenges,
to which NDT provides solutions.
New materials in consideration or currently introduced include advanced high-strength steels,
aluminium, magnesium, and composites, each introducing unique complexities. Emerging
joining processes like self-piercing rivets, laser welding, friction stir welding, and ultrasonic
welding pose challenges. Adhesive bonding raises issues related to component mix, placement,
and cure. Modern die castings exhibit previously unseen flaws. Traditional paint systems face
competition from wet-on-wet and powder processes, as well as film laminates. The
introduction of new products, such as hybrid and fuel-cell vehicles, brings forth fresh
challenges and, consequently, new opportunities for NDT in addressing these issues.

➢ Conclusion:
Implementing NDT in the automotive sector poses challenges due to high production rates and
intense competition. Obstacles include the expenses associated with inspection instrumentation
and personnel, the need to maximize production flow, and resistance to change from established
practices. Advancements can be achieved by embracing automation, utilizing intelligent
instrumentation, and leveraging quantitative measurements as indicators of trends to minimize
or eliminate defective products. Emerging opportunities in NDT are arising from the
combination of continuous improvements in NDT technology and the rapid introduction of
new materials and processes in the automotive industry.