~Unsa.L aA!};Jn.

I:Jsau-uoN

SI uO!};Jas

uO!};JadsUI ~u!Pla M. S SIM.

TWI
rllfll. _ THE WELDING INSTITUTE

Non-Destructive Testing:
NDT or Non Destructive Testing may be used as a means to evaluate the quality of a
component by assessing its internal and/or external integrity, but without destroying it.

There are many methods of NDT some of which require a very high level of skill both in
application and analysis and therefore NDT operators for these methods require a high
degree of training and experience to apply them successfully.

The four principle methods ofNDT used are: .

1) Penetrant testing

2) Magneticparticle testing

3) Ultrasonictesting

4) Radiographic testing

A welding inspector should have a general working knowledge of all these NDT
methods, their applications, advantages and disadvantages.

NDT operators are examined to establish their level of skill, which is dependant on their
knowledge and experience, in the same way as welders and welding inspectors are
examined and tested to establish their level of skill.

Various examination schemes exist for this purpose throughout the world. In the UK the
CSWIP and PCN examination schemes are those that are recognised most widely.

A good NDT operator has both knowledge and experience, however some of the above
techniques are more reliant on these factors than others.

Welding Inspection of Steels WIS 5 15.1 TWI WORLD CENTRE FOR

Section 15 Non-Destructive Testing MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWl Ltd mOl TECHNOLOGY

TWI
V/l!JI. _ THE WELDING INSTITUTE

Penetrant Testing
Basic Procedure

1) The component must be thoroughly cleaned and have a smooth surface finish

2) Penetrant is applied and allowed to dwell for a specified time. (Contact time)

3) Once the dwell or contact time has elapsed, the excess penetrant is removed by
wiping with a clean lint free cloth, fmally wiped with a soft paper towel moistened
with liquid solvent. (Solvent wipe)

4) The developer is then applied, and any penetrant that has been drawn into any
defect by capillary action will be now be drawn out by reverse capillary action

5) A close inspection is made to observe any indications (bleed out) in the developer

6) Post cleaning and protection

Method (Colour contrast, solvent removable)

1) Apply Penetrant 2) Clean then apply Developer 3) Result

,r
Advantage Disadvantages
1) Low operator skill level 1) Careful surface preparation

2) Used on non-ferromagnetic 2) Surface breaking flaws only

3) Low cost 3) Not used on porous material

4) Simple, cheap and easy to interpret 4) No permanent record

5) Portability 5) Hazardous chemicals

Welding Inspection of Steels WIS 5 15.2
Section 15 Non-Destructive Testing
TWI WORLD CENTRE FOR
MATERIALS JOINING
Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY
TWI
V/lDI. _ THE WELDING INSTITUTE

Magnetic Particle Testing

Basic Procedure

1) Test method for the detection of surface and sub-surface defects in ferromagnetic
materials

2) Magnetic field induced in component.

(Permanent magnet, electromagnet (Y6 Yoke) or current flow (prods)

3) Defects disrupt the magnetic flux

4) Defects revealed by applying ferromagnetic particles.

(Background contrast paint may be required)

Method

1) Apply contrast paint 2) Apply magnet & ink 3) Result

Advantage Disadvantages

1) Pre-cleaning not as critical as with DPI 1) Ferromagnetic materials only

2) Will detect some sub-surface defects 2) Demagnetisation may be

required

3) Relatively low cost 3) Direct current flow may

produce Arc strikes

4) Simple equipment 4) No permanent record

5) Possible to inspect through thin coatings 5) Required to test in 2 directions

Welding Inspection of Steels WIS 5 15.3

Section 15 Non-Destructive Testing
TWI WORLD CENTRE FOR
MATERIALS JOINING
Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY
TWI
VIlOI. _ THE WELDING INSTITUTE

Ultrasonic Testing
Basic Procedure

1) Component must be thoroughly cleaned; this may involve light grinding to remove
any spatter, pitting etc in order to obtain a smooth surface

2) Couplant is then applied to the test surface. (water, oil, grease etc.)
This enables the ultrasound to be transmitted fTom the probe into the component
under test

3) A range of angled probes are used to examine the weld root region and fusion faces.
(Ultrasound must strike the fusion faces or any discontinuities present in the weld at
90° in order to obtain the best reflection of ultrasound back to the probe for display
on the cathode ray tube)

Method

1) Apply Couplant 2) Apply sound wave 3) Result

Signal rebound from the

lack of sidewall fusion

Portable
Able
Advantage
No
Can major
Ferrous &with
to detect
easily instant
and
safety
detect
Non results
sizeofsub-surface
-requirements
lack
ferrous sidewall
alloys defects
fusion3)
4)
5)
1)
2) Disadvantages
1) High operator skill level

Difficult to interpret

Requires calibration

No pennanent record.
(Unless automated)

Not easily applied to complex

geometry

WeJding Inspection ofSteeJs WIS 5 15.4

Section 15 Non-Destructive Testing TWI WORLD CENTRE FOR
MATERIALS JOINING
Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY
TWI
V/lOL THE WELDING INSTITUTE

Radiographic Testing
Basic Procedure

1) X or Gamma radiation is imposed upon a test object

2) Radiation is transmitted in varying degrees dependant upon the density of the

material through which it is travelling

3) Variations in transmission detected by photographic film, or fluorescent screens.

(Film placed between lead screens then placed inside a cassette)

4) An IQI (image quality indicator) should always be placed on top of the

specimen to record the sensitivity of the radiograph

Method

i
a) Load film cassette b) Exposure to radiation c) Developed graph

Radioactivesource -

Devel0d]
graph ,~ >I \=
'~

• •
I
Permanent
Most record
Detectsmaterials
internal can be tested
flaws 1)
2)
3)
Advantage
1)
Disadvantages
Skilled interpretation required

Access to both sides required

Sensitive to defect orientation

(possible to miss planar flaws)

4) Gives a direct image of flaws 4) Health hazard

5) Fluoroscopy can give real time imaging 5) High capital cost

Welding Inspection of Steels WIS 5 15.5

Section 15 Non-Destructive Testing TWI WORLD CENTRE FOR
MATERIALS JOINING
Rev 09-09-06 Copyright © 2006 TWI Ltd mOl TECHNOLOGY
TWI
roOI. _ THE WELDING INSTITUTE

Summary of Non Destructive Testing:

tested.
Yokes.
All
Wet
and Colour
Permanent
materials
materials.
& Dry
X-ray
Un-favoured
grained
magnets Low
No
All
small can
sidewall
can Gamma
lack
Permanent
be
Advantages
Surface/Sub
sources
inks.
Application
Portable
for
structured
and be
fusion
of
tested
Disadvantages
straight
more
Requires
straight
surfaces
A wide
No
High
Relatively
safety
non
Simple
Can
Gamma cost of
with
large
operator
diameter,
porous
assess defects
sidewall
record
surface
instant
easily
Extremely skill
current
safety
Difficult
Surface
variety
Cannot
Highly
Fe may
permanent
process of
find
messy
calibration
flaws
be
toof
requirements
low
equipment
ray fusion**
results
flaws
results
level
lack
requirements
tested
interpret
generally
magnetic
operator
clean
De-magnetise costmaterials
only
record
metals
the
skill
after
material
or
penetration
is very technique
line of Can cause arc strikes using
identify
material
inlevel
pipe
portable only
use
Discipline
Welds/Castings.

** To identify planar or 2 dimensional defects such as lack of side wall fusion, or cracks
etc, the orientation of the radiation beam must be in line with the orientation of the defect
as shown below, hence if the radiation source is at the centre of the weld then no
indication of lack of side wall fusion may be shown on the radiograph.

Lack of
sidewall fusion

Film

Radiation beam

Welding Inspection of Steels WIS 5 15.6 TWI WORLD CENTRE FOR

Section 15 Non-Destructive Testing MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd VOl TECHNOLOGY

TWI
VDOI. _ THE WELDING INSTITUTE

WIS 5 Section 15 Exercises:

1) List 5 advantages and 5 disadvantages of each NDT discipline?

Discipline 345 Advantages12354

Disadvantages

2) Briefly state the major limitation of the Radiographic NDT process in terms
of the orientation and practical observation of internal planar imperfections?

3) Complete the basic procedure for the Penetrant testinf! method of NDT?
1. The component must be thorou2hlv cleaned with a smooth surface finish
2. --------------------------
3. -------------------------
4.

5. --------------------------
6.

Welding Inspection of Steels WIS 5 15.7

Section 15 Non-Destructive Testing
TWI WORLD CENTRE FOR
MATERIALS JOINING

Rev 09-09-06 Copyright © 2006 TWI Ltd rzlOI TECHNOLOGY