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7/29/2019 19. Non Destructive Testing
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Copyright 2004, TWI Ltd World Centre for Materials Joining Technology
TWICSWIP 3.1
WIS 5WELDING INSPECTION
NDT.
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Surface Testing
Dye Penetrant Inspection
Magnetic Particle InspectionEddy Current Inspection
.
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Volumetric Inspection
Ultrasonic Inspection
Radiographic Inspection.
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Dye Penetrant Inspection
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Liquid Penetrant Inspection
Surface inspection method
Applicable to all non-porous,non-absorbing materials
A.K.A. Dye Penetrant Inspection (DPI)
Penetrant Flaw Detection (PFD)
Penetrant Testing (PT)
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Penetrant Inspection
Penetrating fluid appliedto surface of component
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Penetrant Inspection
Penetrating fluid enters defectby means of capillary action
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Excess penetrantremoved from surface
Penetrant Inspection
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Developer applied tosurface
Penetrant Inspection
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Development time forindications to appear onsurface
Penetrant Inspection
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System classification
Type of penetrantMethod of penetrant removalType of developer
Penetrant Inspection
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Advantages of Penetrant Inspection
Applicable to non-ferromagnetic materials
Able to test large parts with portable kit
Suitable for batch testing
May not require electricity or water
Applicable to small parts with complexgeometry
Simple, cheap and easy to interpret
Sensitivity
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Disadvantages of Penetrant Inspection
Will only detect defects open to thesurface
Requires careful surface preparation
Not applicable to porous surfaces
Temperature dependant
Cannot retest indefinitely
Compatibility of chemicals
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System Classification - Penetrant
Colour contrast
Fluorescent
Dual
Penetrant Inspection
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System Classification - Removal
Solvent
Water washable
Post emulsifiable
Penetrant Inspection
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System Classification - Development
Dry powder
Aqueous
Non aqueous (solvent based)
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Fluorescent v Colour Contrast
Fluorescent more sensitive
Less operator fatigue with fluorescent
More difficulty in monitoring excesspenetrant removal
Requires UV-A lamps, with subduedbackground lighting for fluorescent
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Magnetic Particle Inspection
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Magnetism Materials will strongly attract pieces
of iron to themselves
Phenomenon discovered in theancient Greek city of Magnesia
Magnets utilised in navigation
Oersted discovered the link betweenelectricity and magnetism
Faraday revealed that electrical andmagnetic energy could beinterchanged
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Magnetic Particle Inspection
Test method for the detection of surfaceand sub-surface indications in
ferromagnetic materials Magnetic field induced in component
Defects disrupt the magnetic flux
Defects revealed by applyingferromagnetic particles
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Principle of MPI : Flux Leakage
N S SN
No Defect Defect
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Permeability of Material
Paramagnetic:Weakly attracted by magnets
Examples: Aluminium,Tungsten
Diamagnetic:Slightly repelled by magnetsExamples Gold,Copper and Water
Ferromagnetic:Strongly attractedExamples Iron,Cobalt and Nickel
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Magnets
N
Lines of force / Lines of flux
S
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Electromagnetism
A current flows through a conductorand sets up a magnetic field around it
Field is at 90o to the direction of theelectrical current
Directionof currentflow
Direction of magnetic field
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Depth below surface
SN SN
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Defect Orientation
Defect at 90 degrees to flux : maximum
indication
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Defect Orientation
>45 Degrees to Flux: Acceptableindication
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Defect Orientation
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Equipment
Permanent Magnet
Electromagnets
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Longitudinal field between poles
Defects detected at 90 degrees to poles
Permanent Magnet
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Advantages No power supply
No electrical contactproblems
Inexpensive
No damage to testpiece
Lightweight
Disadvantages Direct field only
Deteriorate over time
No control over fieldstrength
Poles attract detectingmedia
Tiring to use
Permanent Magnet
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Electromagnetism
A current flows through a conductorand sets up a magnetic field around it
Field is at 90o to the direction of theelectrical current
Directionof currentflow
Direction of magnetic field
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Coil Magnetisation
Changes circular field into longitudinal
Increases the strength of the field
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Electromagnets
Soft iron laminates within a coil.
Defects detected at 90 degrees to poles
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Electromagnets
Advantages AC,DC or rectified
Controllable field
strength No harm to test piece
Can be used todemagnetise
Easily removed
Disadvantages Power supply required
Longitudinal field only
Carry mains supply Poles attract particles
Legs must have areacontact
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Demagnetisation
Required if
Rotating parts
Components to be welded,machined orelectroplated
Aircraft parts
Removal of residual magnetisation
Check for removal with Field strengthmeter (magnetometer)
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Eddy Current Inspection
Coil Coilsmagnetic
fieldEddy
currents
Eddy
currentsmagnetic
fieldsConductive
material
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Eddy Current Inspection
An alternating current
is passed through a coil
A.C. generates analternating field
Alternating fieldgenerates eddy currentsin conductors
Eddy currents generateopposing field whichmodifies current in coil
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Eddy Current Inspection
Electrical currents induced in metalsby alternating magnetic fields
The size of the current is affected by:-
Electrical conductivity
Stand off distance
Flaws
Permeability
Specimen dimensions
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Advantages
Sensitive to surface defects
Can detect through several layersCan detect through surface coatings
Accurate conductivity measurements
Can be automatedLittle pre-cleaning required
Portability
Eddy Current Inspection
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DisadvantagesVery susceptible to permeability changes
Only works on conductive materials
Will not detect defects parallel to the surface
Not suitable for large areas and /or complex geometry
Signal interpretation required
No permanent record (unless automated)
Eddy Current Inspection
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Ultrasonic Inspection
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Acoustic Spectrum
Human
16Hz - 20kHz
Ultrasonic Range
+ 20kHz
Testing
0.5MHz - 50MHz
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There are three Principlewaveforms used in ultrasonicinspections
Compression
Shear
Surface
Principle waveforms in ultrasonic
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Compression waves
Vibration and propagation in the samedirection
Travel in solids, liquids and gases
Propagation
Particle vibration
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Surface Waves
Elliptical vibration
Velocity 8% less than shear
Penetrate one wavelength deep
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Sound travelling through a material
Velocity varies according to the material
Compression waves
Steel 5960m/sec
Water 1490m/sec
Air 344m/sec
Copper 4700m/sec
Shear waves
Steel 3245m/sec
Water NA
Air NA
Copper 2330m/sec
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Probe Design
Probe housing
Transducer
Electrical connections
Damping
Wear shoe
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Probe Design
Shear Wave
DampingTransducer
Perspex wedgeShear wave
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Pulse Echo Testing
Single probe sends and receives sound
Gives an indication of defect depth anddimensions
Not fail safe
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Sound travels throughthe steel block at5.9Km/sec.
The returning sound
vibrates the crystal,which produces anelectrical pulse which isamplified and is shownon the cathode ray
tube.
Pulse Echo Testing
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If a large defect ispresent all thesound will be
returned to theprobe.
The signal on theCRT can show the
depth of thedefect.
Pulse Echo Testing
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If a smaller defectis present some ofthe sound will be
returned to theprobe, some willcontinue to theback wall.
Note the reductionin size of the defectsignal
Pulse Echo Testing
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Defects parallel to the surface will reflect sound back to
the probeDefects at an angle to the surface will reflect thesound at an angle
The signal will not appear on the CRT
Pulse Echo Testing
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Angle probes used to reflect soundoff inclined defects
Pulse Echo Testing
l h i
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Angle probes used to testwelds
Pulse Echo Testing
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Through Transmission Testing
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Through Transmission Testing
Immersion Testing
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Immersion Testing
Waterpathdistance
Water path distance
Front surface Back surface
T i i ith R fl ti
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Transmission with Reflection
T R
i i i h fl i
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Transmission with Reflection
T R
Ti f Fli ht Diff ti
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Time of Flight Diffraction
Ti f Fli ht Diff ti
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Time of Flight Diffraction
Ti f Fli ht Diff ti (TOFD)
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Time of Flight Diffraction (TOFD)
Ti f Fli ht Diff ti (TOFD)
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The echo amplitude is displayed as grey for zero, black formaximum negative and white for maximum positivesignals
D-scan is made up of dozens of
A-scans set side by sideTop of defect
Time of Flight Diffraction (TOFD)
Ti f Fli ht Diff ti (TOFD)
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AdvantagesDoes not depend on defect orientation
Defect height can be exactly determined
Inspection results are immediately available
Permanent print is available
Higher test speed means costs are less
Time of Flight Diffraction (TOFD)
Ti f Fli ht Diff ti (TOFD)
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Disadvantages
The weld must be reasonably accessiblefrom both sides
There is a dead zone for defect detectionclose to the surfaces
Is more a sizing tool than a detecting tool
Time of Flight Diffraction (TOFD)
Radiographic Inspection
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Radiographic Inspection
Radiographic Inspection
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Radiographic Inspection
X or Gamma radiation is imposed upona test object
Radiation is transmitted to varyingdegrees dependant upon the density ofthe material through which it istravelling
Variations in transmission detected by
photographic film or fluorescent screens
Applicable to metals,non-metals andcomposites
Radiographic Inspection
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Radiographic Inspection
Lowerdensity
Higherdensity
Radiographic Inspection
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Radiograph of weld showing:-
Crack
Slag
Lack of fusion
Porosity
Undercut
Radiographic Inspection
Radiographic Inspection
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Advantages Permanent record
Internal flaws
Can be used on most materials
Direct image of flaws
Real - time imaging
Radiographic Inspection
Radiographic Inspection
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Disadvantages
Health hazard
Sensitive to defect orientation
Limited ability to detect fine cracksAccess to both sides required
Limited by material thickness
Skilled interpretation required Relatively slow
High capital outlay and running costs
Radiographic Inspection
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Electromagnetic Spectrum
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Electromagnetic Spectrum
TV
Microwaves
Infra
red
Ultra
violet
Industrialradiography ElectricWaves
X-Ray Production
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X-Ray Production
+ve-ve
X-ray tube isevacuated to create avacuum
Disadvantages of Gamma over X rays
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Disadvantages of Gamma over X rays
Poorer quality radiographs
Exposure times can be longer
Sources need replacing
Radiation cannot be switched off
Poorer geometric unsharpness
Remote handling necessary
Radiographic Techniques
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Radiographic Techniques
Single Wall Single Image(SWSI)
Double Wall Single Image(DWSI)
Double Wall Double Image(DWDI)
Advantages of Gamma over X rays
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Advantages of Gamma over X rays
No electrical or water supplies neededEquipment smaller and lighter-More portable
Equipment simpler and more robust
More easily accessed
Less scatter
Equipment initially less costly
Greater penetrating power
Radiographic Technique
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Radiographic Technique
Single wall, single image (SWSI)
Panoramic
Radiographic Technique
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Double wall, single image (DWSI)
Double wall, double image (DWDI)
Radiographic Technique
Radiographic Technique
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DWSI DWDI
Radiographic Technique
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