Non Destructive Testing Objective

When this presentation has been completed you

will have a greater understanding of and
recognise various NDT methods and their
differences ,capabilities and why one particular
method may be chosen based on the advantages
Non-Destructive Testing and disadvantages over other methods. Why we
choose or don’t choose a particular method for a
Section 5 certain material and the potential risks in safety
and production issues.

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Non-Destructive Testing Non-Destructive Testing

A welding inspector should have a working Surface crack detection

knowledge of NDT methods and their  Liquid penetrant (PT or dye-penetrant).
applications, advantages and  Magnetic particle inspection (MT or MPI).
disadvantages.
Volumetric inspection
Four basic NDT methods  Ultrasonics (UT).
1. Magnetic particle inspection (MT).  Radiography (RT).
2. Dye penetrant inspection (PT). Each technique has advantages and
3. Radiographic inspection (RT). disadvantages with respect to:
4. Ultrasonic inspection (UT).  Technical capability and cost.
Note: The choice of NDT techniques is based on
consideration of these advantages and disadvantages.

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Penetrant Testing

Main features:
 Detection of surface breaking defects only.
 This test method uses the forces of capillary
action.
Penetrant Testing (PT)  Applicable on any material type, as long they are
non porous.
 Penetrants are available in many different types:
 Water washable contrast.
 Solvent removable contrast.
 Water washable fluorescent.
 Solvent removable fluorescent.
 Post-emulsifiable fluorescent.

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 Penetrant Testing Penetrant Testing

Step 1: Pre-cleaning Step 2: Apply penetrant

 Ensure surface is very clean normally with the use of a  After the application, the penetrant is normally left on
solvent. the components surface for approximately 15-20
minutes (dwell time).
 The penetrant enters any defects that may be present
by capillary action.

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Penetrant Testing Penetrant Testing

Step 3: Clean off penetrant Step 3: Apply developer

 The penetrant is removed after sufficient penetration  After the penetrant has be cleaned sufficiently, a thin
time (dwell time). layer of developer is applied.
 Care must be taken not to wash any penetrant out off  The developer acts as a contrast against the penetrant
any defects present. and allows for reverse capillary action to take place.

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Penetrant Testing Penetrant Testing

Step 4: Inspection/development time Fluorescent penetrant

 Inspection should take place immediately after the Bleed out viewed under
developer has been applied. a UV-A light source
 any defects present will show as a bleed out during
development time.
 After full inspection has been carried out post cleaning
is generally required.

Bleed out viewed

under white light Colour contrast Penetrant

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5-2
 Penetrant Testing Penetrant Testing

Advantages Disadvantages Comparison with magnetic particle inspection

 Simple to use.  Surface breaking defect
 Inexpensive. only. Advantages
 Quick results.  Little indication of  Easy to interpret results.
 Can be used on any non- depths.  No power requirements.
porous material.  Penetrant may
 Portability. contaminate component.
 Relatively little training required.
 Low operator skill  Surface preparation  Can use on all materials.
required. critical.
 Post cleaning required. Disadvantages
 Potentially hazardous  Good surface finish needed.
chemicals.  Relatively slow.
 Can not test unlimited
 Chemicals - health and safety issue.
times.
 Temperature dependant.

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Any Questions

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Magnetic Particle Testing (MT)

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Magnetic Particle Testing Magnetic Particle Testing

Main features: Collection

 Surface and slight sub-surface detection. of ink
 Relies on magnetization of component being tested. particles
 Only ferro-magnetic materials can be tested. due to
 A magnetic field is introduced into a specimen being leakage
tested. field
 Methods of applying a magnetic field, yoke,
permanent magnet, prods and flexible cables. Electro-magnet (yoke) DC or AC
 Fine particles of iron powder are applied to the test
area.
 Any defect which interrupts the magnetic field, will
create a leakage field, which attracts the particles.
 Any defect will show up as either a dark indication or
in the case of fluorescent particles under UV-A light a
Prods DC or AC
green/yellow indication.

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 Magnetic Particle Testing Magnetic Particle Testing

A crack like
indication

Alternatively to contrast inks, fluorescent inks may be

used for greater sensitivity. These inks require a UV-A
light source and a darkened viewing area to inspect
the component.

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Magnetic Particle Testing Magnetic Particle Testing

Typical sequence of operations to inspect a Advantages Disadvantages

weld  Simple to use.  Surface or slight
 Clean area to be tested.  Inexpensive. sub-surface
 Apply contrast paint.  Rapid results. detection only.
 Apply magnetisism to the component.  Little surface  Magnetic materials
 Apply ferro-magnetic ink to the component preparation required. only.
during magnatising.  No indication of
 Possible to inspect
 Iterpret the test area. through thin defects depths.
 Post clean and de-magnatise if required. coatings.  Only suitable for
linear defects.
 Detection is required
in two directions.

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Magnetic Particle Testing

Comparison with penetrant testing

Advantages
Any Questions

?
 Much quicker than PT.
 Instant results.
 Can detect near-surface imperfections (by current
flow technique).
 Less surface preparation needed.
Disadvantages
 Only suitable for ferromagnetic materials.
 Electrical power for most techniques.
 May need to de-magnetise (machine components).

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 Ultrasonic Testing

Main features:
 Surface and sub-surface detection.
 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
Ultrasonic Testing (UT) 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.
 For ultrasound to enter a material a couplant must be
introduced between the probe and specimen.

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Ultrasonic Testing Ultrasonic Testing

Pulse echo Digital Defect Back wall

signals A UT Set, Initial pulse echo echo
scan
display

Material Thk
defect

0 10 20 30 40 50

Compression probe Checking the material Thickness Compression probe CRT Display

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Ultrasonic Testing Ultrasonic Testing

UT set
A scan Initial pulse
display
Defect echo
defect 0 10 20 30 40 50

½ Skip CRT Display

initial pulse

defect echo
defect 0 10 20 30 40 50
Angle probe
Full Skip CRT Display

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5-5
 Ultrasonic Testing Ultrasonic Testing

Advantages Disadvantages Comparison with radiography

 Rapid results.  Trained and skilled
 Both surface and sub- operator required. Advantages
surface detection.  Requires high operator  Good for planar defects.
 Safe. skill.
 Good for thick sections.
 Capable of measuring the  Good surface finish
depth of defects. required.  Instant results.
 May be battery powered.  Defect identification.  Can use on complex joints.
 Portable.  Couplant may  Can automate.
contaminate.
 Very portable.
 No permanent record.
 Calibration required.
 No safety problems (parallel working is
 Ferritic Material (mostly).
possible).
 Low capital and running costs.

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Ultrasonic Testing

Comparison with radiography

Disadvantages
Any Questions

?
 No permanent record (with standard
equipment).
 Not suitable for very thin joints <8mm.
 Reliant on operator interpretation.
 Not good for sizing porosity.
 Good/smooth surface profile needed.
 Not suitable for coarse grain materials (eg,
castings).
 Ferritic materials (with standard equipment).

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Radiographic Testing

The principles of radiography

 X or Gamma radiation is imposed upon a test
object.
 Radiation is transmitted to varying degrees
dependant upon the density of the material
Radiographic Testing (RT)
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.

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 Radiographic Testing Radiographic Testing

Source

Image quality indicator

Radiation beam

X–rays Gamma rays

Electrically generated. Generated by the decay Test specimen
of unstable atoms. Radiographic film

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Radiographic Testing Radiographic Testing

Source Density - relates to the degree of darkness.

Image quality indicator
Radiation beam

Densitometer

Test specimen Contrast - relates to the degree of difference.

Definition - relates to the degree of sharpness.
Sensitivity - relates to the overall quality of the radiograph.
Radiographic film with latent image after exposure

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Radiographic Sensitivity Radiographic Sensitivity

Step/hole type IQI

7FE12

Wire type IQI

Step/Hole type IQI Wire type IQI

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5-7
 Radiographic Techniques Single Wall Single Image (SWSI)

Single Wall Single Image (SWSI)

 Film inside, source outside.

Single Wall Single Image (SWSI) panoramic

 Film outside, source inside (internal exposure).
Film
Double Wall Single Image (DWSI)
 Film outside, source outside (external
exposure). Film

Double Wall Double Image (DWDI)

 Film outside, source outside (elliptical
IQI’s should be placed source side
exposure).

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Single Wall Single Image Panoramic Double Wall Single Image (DWSI)

Film
Film
 IQI’s are placed on the film side.
 IQI’s are placed on the film side.  Source outside film outside (multiple exposure).
 Source inside film outside (single exposure).  This technique is intended for pipe diameters over 100mm.

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Double Wall Single Image (DWSI) Double Wall Single Image (DWSI)

Identification
 Unique identification.
 IQI placing.
 Pitch marks indicating EN W10

readable film length.

A B

ID MR11

Radiograph
Radiograph

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5-8
 Double Wall Double Image (DWDI) Double Wall Double Image (DWDI)

Identification
 Unique identification. 4 3
 IQI placing.
EN W10
 Pitch marks indicating
readable film length.

Film 1 2
 IQI’s are placed on the source or film side.
ID MR12
 Source outside film outside (multiple exposure).
 A minimum of two exposures.
 This technique is intended for pipe diameters less than Shot A Radiograph
100mm.

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Double Wall Double Image (DWDI) Radiography

Penetrating power

4 3 Question: What determines the penetrating power

of an X-ray?
 The kilo-voltage applied (between anode and
cathode).

Question: What determines the penetrating power

of a gamma ray?
1 2  The type of isotope (the wavelength of the gamma
rays).
Elliptical radiograph

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Radiography Radiographic Testing

Gamma sources Advantages Disadvantages

 Permanent record.  Expensive consumables.
Isotope Typical thickness range  Little surface  Bulky equipment.
 Iridium 192 10 to 50 mm (mostly used) preparation.  Harmful radiation.
 Cobalt 60 > 50mm  Defect identification.  Defect require significant
 No material type depth in relation to the
 Ytterbium < 10mm
limitation. radiation beam (not good
 Thulium < 10mm  Not so reliant upon for planar defects).
 Caesium < 10mm operator skill.  Slow results.
 Thin materials.  Very little indication of
depths.
 Access to both sides
required.

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5-9
 Radiographic Testing Radiographic Testing

Comparison with ultrasonic examination Comparison with ultrasonic examination

Advantages Disadvantages
 Good for non-planar defects.  Health and safety hazard.
 Good for thin sections.  Not good for thick sections.
 Gives permanent record.  High capital and relatively high running costs.
 Easier for 2nd party interpretation.  Not good for planar defects.
 Can use on all material types.  X-ray sets not very portable.
 High productivity.  Requires access to both sides of weld.
 Direct image of imperfections.  Frequent replacement of gamma source needed
(half life).

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Any Questions

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