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%20TESTING.htm
Nondestructive Testing(NDT)
Nondestructive testing (NDT), also called nondestructive examination
(NDE) and nondestructive inspection (NDI), is testing that does not
destroy the test object.NDT is very important for industry for constructing
and maintaining all types of components,equipments and structures. To
detect different defects such as cracks(sub surface or surface) and
corrosion, there are different methods of testing available, such as X-ray
(where cracks show up on the film) and Ultrasound (where cracks show up
as an echo blip on the screen).Magnetic particle test,Die penetrant
test(DPT),Eddy current test etc.
While destructive testing usually provides a more reliable assessment of
the state of the test object, destruction of the test object usually makes
this type of test more costly to the test object's owner than
nondestructive testing and it is also not possible to carrout destructive
test in running plant.
The need for NDT
It is very difficult to weld or mold a solid object that has the risk of
breaking in service, so testing at manufacture and during operation/use is
often essential. During the process of casting a metal object, for example,
the metal may shrink as it cools, and crack or introduce voids inside the
structure. Even the best welders (and welding machines) do not make
100% perfect welds. Some typical weld defects that need to be found and
repaired are lack of fusion of the weld to the metal and porous bubbles
inside the weld, both of which could cause a structure to break or a
pipeline to rupture.
During their service lives, many industrial components need regular
nondestructive tests to detect damage that may be difficult or expensive
to find by everyday methods. For example:
this can the remove the penetrant from the flaws. This process must be
performed under controlled conditions so that all penetrant on the surface
is removed (background noise), but penetrant trapped in real defects
remains in place.
Application of Developer:
After excess penetrant has been removed a white developer is applied to
the sample. Several developer types are available, including: non-aqueous
wet developer, dry powder, water suspendible, and water soluble. Choice
of developer is governed by penetrant compatibility (one can't use watersoluble or suspedible developer with water-washable penetrant), and by
inspection conditions. When using non-aqueous wet developer (NAWD) or
dry powder the sample must be dried prior to application, while soluble
and suspendible developers are applied with the part still wet from the
previous step. NAWD is commercially available in aerosol spray cans, and
may employ acetone ,isopropl alchol or a propellant that is a combination
of the two. Developer should form a thin, even coating on the surface.
The developer draws penetrant from defects out onto the surface to form
a visible indication, a process similar to the action of blotting paper. Any
colored stains indicate the positions and types of defects on the surface
under inspection.
Inspection:
The inspector will use visible light with adequate intensity (100 footcandles is typical) for visible dye penetrant. Ultraviolet (UV-A) radiation of
adequate intensity (1,000 micro-watts per centimeter squared is
common), along with low ambient light levels (less than 2 foot-candles) for
fluorescent penetrant examinations. Inspection of the test surface should
take place after a 10 minute development time. This time delay allows the
blotting action to occur. The inspector may observe the sample for
indication formation when using visible dye, but this should not be done
when using fluorescent penetrant. Also of concern, if one waits too long
after development the indications may "bleed out" such that
interpretation is hindered.
Radiographic testing
Radiographic Testing (RT) is a nondestructive testing (NDT) method of
inspecting materials for hidden flaws by using the ability of short
wavelength electromagnetic radiation to penetrate various materials,
basically it is emmision of photons. Either an X-ray machine or a
radioactive source can be used as a source of photons
Since the amount of radiation emerging from the opposite side of the
material can be detected and measured, variations in this amount (or
intensity) of radiation are used to determine thickness or composition of
an indication of the flaws existence, this flux leakage is caused by the flaw
in the ferromagnetic material for which is being tested.
The testing devices are portable, provide immediate feedback, and do not
need to contact the item in question. Recently tomographic notion of ECT
has been explored see for example:
Magnetic-particle inspection
Magnetic particle inspection processes are non destructive methods for
the detection of defects in ferrous materials. They make use of an
externally applied magnetic field or DC current through the material, and
the principle that the magnetic susceptibility of a defect is markedly
poorer (the magnetic resistence is greater) than that of the surrounding
material.
The presence of a surface or near surface flaw (void) in the material
causes distortion in the magnetic flux through it, which in turn causes
leakage of the magnetic fields at the flaw. This deformation of the
magnetic field is not limited to the immediate locality of the defect but
extends for a considerable distance; even through the surface and into the
air if the magnetism is intense enough. Thus the size of the distortion is
much larger than that of the defect and is made visible at the surface of
the part by means of the tiny particles that are attracted to the leakage
fields.
The most common method of magnetic particle inspection uses finely
divided iron or magnetic iron oxide particles, held in suspension in a
suitable liquid (often kerosene). This fluid is referred to as carrier. The
particles are often colored and usually coated with fluorescent dyes that
are made visible with a hand-held ultraviolet (UV) light. The suspension is
sprayed or painted over the magnetized specimen during magnetization
with a direct current or with an electromagnet, to localize areas where the
magnetic field has protruded from the surface. The magnetic particles are
attracted by the surface field in the area of the defect and hold on to the
edges of the defect to reveal it as a build up of particles.
This inspection can be applied to raw material in a steel mill (billets or
slabs), in the early stages of manufacturing (forgings, castings), or most
commonly to machined parts before they are put into service. It is also
very commonly used for inspecting structural parts (e.g., landing gear)
that have been in-service for some time to find fatigue cracks.
Usually tested pieces needs to be demagnetizated by a degaussing tool
before use.
It is a quite economic non destructive test because it is easy to do and
much faster than ultrasonic testing and penetrant testing.
E 408, Standard Test Methods for Total Normal Emittance of Surfaces Using
Inspection-Meter Techniques.
E 426, Standard Practice for Electromagnetic (Eddy-Current) Examination of
Seamless and Welded Tubular Products, Austenitic Stainless Steel and Similar Alloys.
E 427, Standard Practice for Testing for Leaks Using the Halogen Leak Detector
(Alkali-Ion Diode).
E 428, Standard Practice for Fabrication and Control of Steel Reference Blocks Used
in Ultrasonic Examination.
E 431, Standard Guide to Interpretation of Radiographs of Semiconductors and
Related Devices.
E 432, Standard Guide for Selection of a Leak Testing Method.
E 433, Standard Reference Photographs for Liquid Penetrant Inspection.
E 446, Standard Reference Radiographs for Steel Castings Up to 2 in. (51 mm) in
Thickness.
E 479, Standard Guide for Preparation of a Leak Testing Specification.
E 493, Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector
in the Inside-Out Testing Mode.
E 494, Standard Practice for Measuring Ultrasonic Velocity in Materials.
E 498, Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector
or Residual Gas Analyzer in the Tracer Probe Mode.
E 499, Standard Test Methods for Leaks Using the Mass Spectrometer Leak Detector
in the Detector Probe Mode.
E 505, Standard Reference Radiographs for Inspection of Aluminum and Magnesium
Die Castings.
E 515, Standard Test Method for Leaks Using Bubble Emission Techniques.
E 543, Standard Practice for Agencies Performing Nondestructive Testing.
E 545, Standard Test Method for Determining Image Quality in Direct Thermal
Neutron Radiographic Examination.
E 566, Standard Practice for Electromagnetic (Eddy-Current) Sorting of Ferrous
Metals.
E 569, Standard Practice for Acoustic Emission Monitoring of Structures During
Controlled Stimulation.
E 570, Standard Practice for Flux Leakage Examination of Ferromagnetic Steel
Tubular Products.
E 571, Standard Practice for Electromagnetic (Eddy-Current) Examination of Nickel
and Nickel Alloy Tubular Products.
E 587, Standard Practice for Ultrasonic Angle-Beam Examination by the Contact
Method.
E 588, Standard Practice for Detection of Large Inclusions in Bearing Quality Steel
by the Ultrasonic Method.
E 592, Standard Guide to Obtainable ASTM Equivalent Penetrameter Sensitivity for
Radiography of Steel Plates 1/4 to 2 in. (6 to 51 mm) Thick with X-Rays and 1 to 6
in. (25 to 152 mm) Thick with Cobalt-60.
E 650, Standard Guide for Mounting Piezoelectric Acoustic Emission Sensors.
E 664, Standard Practice for the Measurement of the Apparent Attenuation of
Longitudinal Ultrasonic Waves by Immersion Method.
E 689, Standard Reference Radiographs for Ductile Iron Castings.
E 690, Standard Practice for In Situ Electromagnetic (Eddy-Current) Examination of
Nonmagnetic Heat Exchanger Tubes.