Non Destructive Testing

Different stages of a Product Life Cycle:

Idea generation

Screening of ideas, evaluation and final choice

Concept development and testing Business analysis Product and Marketing mix development Market testing, feed back and corrections, if any Commercialization Repair, Maintenance and Overhaul

Product Development is Expensive and Time Consuming

Drivers for Product Sustainability in market:

Low cost (both initial and maintenance) High reliability Longevity or Life Technology sustenance
Vendor end Useful life of product Customer end

Failure rate and hence the performance and life of a product depends upon defects inherent and/or produced during its usage

Innovative methods needed to improve Life and Reliability

Where do defects come from?

Input raw materials
Forgings
Castings Extrusions

Fabricated Parts Machining (Turning, Milling, EDM)

Joining (Welding, Brazing, Soldering, Riveting) Special processes (Heat Treatment, Plating, Anodizing)

Sub-assemblies/Assemblies
Damage during assembly Improper use of of Jigs and Fixtures Improper handling

In service damage
Wear, Corrosion, Erosion Fatigue, Cracking

Heat related damage

Accidents Improper usage

Control defects to improve Life and Reliability

UA232 : July 19, 1989

Ideal case : Zero defect, virtually impractical Practical case : Predictable performance and life in presence of flaw

Undetected flaw may result in catastrophic failure

Non Destructive Evaluation (NDE):

Def: The use of non-invasive techniques to determine the integrity of a material / Component / Structure or Quantitatively measure some characteristic of an object without damaging the material / Component / Structure

NDE assesses integrity of a system without destroying it

Destructive vs Non-Destructive Evaluations

Destructive
Measurements are direct, reliable, quantitative Results are easy to interpret Sample taken from product, represents entire product In-service testing not possible

Non- Destructive
Measurements are indirect & reliability to be verified Test results are qualitative 100% testing of actual product In-service testing possible

Repeated tests not possible on same specimen

Specimen preparation is expensive

Repeated tests over a period of time on the same part

Less expensive

Time taken for testing is more

Only a few properties can be measured Product is destroyed during test

Time taken is less

Multiple properties can be evaluated Does not call for shutting down in some cases

NDE retains the integrity of product while evaluating it

Terms associated with NDE:

Non Destructive Testing (NDT) Non Destructive Inspection (NDI)

Non Destructive Examination (NDEX)

Exit conditions of NDE:

Size, Shape and Location of flaw(s)

Next steps after NDE:

Disposition to Accept / Re-work / Reject the object

Early detection of flaw saves cost and effort on product

Application of NDE in industry:

Screen incoming materials Monitor / Control / Improve manufacturing processes Verify effectiveness of process. E.g., Heat Treatment Verify correctness of assembly Inspect in-service damage

Defects generally evaluated by NDE:

Casting defects (Pores, Cracks, shrinkage..)

Forging defects (Seams, Cracks, inclusions..)

Rolling defects (Laminations, Cracks..) Welding defects (Pores, Cracks, lack of fusion..)

Types of flaws generally encountered:

Volumetric (3-D, e.g., pores, shrinkage, slag inclusion..) Planar (2-D, e.g., seams, cracks..)

NDE finds use in every stage of product development

Selection of NDE methods:

Criteria:
Clear understanding of the problem Suitable method for a given situation

Available calibration or acceptance tests

Generally used methods:

Flaw detection and evaluation Leak detection and evaluation Metrology and evaluation Location determination and evaluation Microstructure characterization Estimation of mechanical and physical properties Signature analysis Chemical composition determination

Specific NDE method for specific application

Flaw detection and evaluation

Flaw detection is the most important part of NDE. Detection becomes easier if the inspector has some knowledge of the particular item under inspection and its usage. Generally there are six common flaw detection methods: Visual Liquid penetrant Magnetic particle Ultrasonic Eddy current Radiography

Complimentary methods may be used for confirmation of result

Visual Inspection
Most common and basic method Accessories include mirrors, magnifying glass, borescopes, fiberscopes etc. Portable video inspection unit with zoom allows inspection of large tanks and vessels etc. Robotic units permit observation in hazardous or tight areas, such as ducts, reactors, pipelines.

Visual inspection for quick checks

Liquid Penetrant Inspection

A liquid with high surface wetting characteristics is applied to the surface of the part and allowed time to seep into surface breaking defects.

The excess liquid is removed from the surface of the part.

A developer (powder) is applied to pull the trapped penetrant out the defect and spread it on the surface where it can be seen. Visual inspection is the final step in the process. The penetrant used is often loaded with a fluorescent dye and the inspection is done under UV light to increase test sensitivity.

Red dye / Fluorescent penetrant provides immediate indication of surface flaws

Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be visually detected under proper lighting conditions.

This method is applicable to Ferromagnetic materials only

Ultrasonic Inspection
High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound.

initial pulse back surface echo

U/s Transducer

crack echo

crack
0 2 4
Time

Flaw

10

plate

Oscilloscope, or flaw detector screen

Wide range of materials and thicknesses can be tested by U/s method

Eddy Current Testing

Coil

Presence of a flaw in test object distorts the interference pattern between main magnetic field and that induced by eddy current which can be interpreted with the use of a calibration block. Applicable to surface and sub-surface flaws Only electrically conductive materials can be inspected

Coils magnetic field

Eddy currents magnetic field

Conductive material Eddy Currents

Sensitive technique applicable to conductive materials

Radiographic Inspection
A source of radiation, test object and recording medium are required. X-Ray and Gamma Ray are generally used as sources Radiation protection required for operation Radiation is differentially absorbed by the test object and the resulting exit radiation pattern is recorded and interpreted +
Electrons

High Electrical Potential

X-ray Generator or Radioactive Source Creates Radiation

Radiation Penetrate the Sample

Exposure Recording Device

Radiation protection needed during Radiography