UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING
MECHANICAL AND PRODUCTION ENGINEERING DEPARTEMENT
NDT ASSIGNMENT
MECH 2001Y MECHANICS OF MATERIALS AND
MANUFACTURING PROCESSES







10/04/14
BUNDHUN AADIL 1015672
MECHANICAL LEVEL 4
Contents
Introduction ............................................................................................................................................ 3
Advantages of NDT: ............................................................................................................................ 3
Methods of NDT testing ...................................................................................................................... 4
Visual Inspection ..................................................................................................................................... 4
Liquid-Penetrant Inspection ................................................................................................................... 5
Magnetic-Particle inspection .................................................................................................................. 6
Eddy-current inspection .......................................................................................................................... 8
Radiographic inspection .......................................................................................................................... 9
Ultrasonic Inspection ............................................................................................................................ 10
Thermal Inspection ............................................................................................................................... 11
Conclusion ............................................................................................................................................. 12
References ............................................................................................................................................ 12











Introduction

Non-destructive testing inspection usually implies a process for finding defects in such a manner that
product integrity and surface texture remain unchanged. The application of NDT process is involved
in various field of engineering from mass productive system to maintenance of machine. In recent
years, the word defective and defect have often been interpreted as meaning unfit for service, and
their use is declining in favour of terms such as flaw, imperfection, discontinuity and non-
conformance.
[1]
Generally, NDT is normally carried out in one of the following circumstances:
1. As a control check and an aid to the monitoring of quality during manufacture. In this case
NDT is used to check the maintenance of required quality levels during manufacture. The
presence of manufacturing imperfections and defects may be detected with regard to
assessment of their characteristics and severity.
2. During in service inspection. In the case NDT methods are used in order to detect any
physical deterioration in a component or structure that might occur under service conditions.
NDT methods are most usually employed to detect cracking, or crack propagation from
existing defects. Such cracking is commonly associated with some form of fatigue.
3. Critical defect assessment. This use of NDT normally involves an in-depth examination of
known defects in a structure in order to provide detailed information for fitness for purpose
assessments and fracture mechanics calculations.



Advantages of NDT:
1. May reveal failure mechanism.
2. Can be done on entire production, defective parts can be removed instantaneously.
3. May be performed on parts in service.
4. Little or no specimen preparation is required.
5. Different tests can be applied and repeated to the same item simultaneously.
6. Little or no specimen preparation is required.
7. Equipment is often portable for use in field.


Methods of NDT testing
The methods generally used for non-destructive testing are as follows:
Visual Inspection.
[2]

Hardness Testing.
Liquid-Penetrant Inspection.
Magnetic-Particle Inspection.
Eddy current Inspection.
Electromagnetic Sorting on Testing.
Radiographic Inspection.
Inspection by Neutron Radiography.
Ultrasonic Inspection.
Inspection by Optical Holography.
Acoustic-Emission Inspection.
Microwave Inspection.
Leak testing.
Rapid Identification of Metals and Alloys.
Thermal Inspection.
Spark testing of Ferrous Alloys.
Chemical Spot Testing.
The most widely used NDT methods in engineering industry are in bold characters. In this article we
will define the main methods employed and their steps to achieve results.

Visual Inspection
This method is widely used in automotive industry where vehicles undergo this inspection as final
stage before being marketed. The inspection is carried out in a good illumination chamber, basically
this chamber consists of white fluorescent light built and arranged in a manner to facilitate visual
inspection. Vehicles, with some kind of defects, are resent in the production line for proper repair.
This method is done for only surface analysis.
Liquid-Penetrant Inspection
Penetrant testing aims to increase the visible contrast between the defects and the background by
treating the whole component with a searching liquid of high penetrating power (i.e. low velocity).
[2]

In this method, fluids are applied to the surfaces of the part and allowed to penetrate into surface
cracks, seams, and pores. The condition for usage of this method is the lower limit of the crack must
be as such to allow Penetrant to fully enter and the upper limit must be sufficiently large for cleaning
stage. The Penetrant can seep into cracks as small as 0.1m in width.
[3]
Searching liquid is such that
it must be clearly visible to inspectors. To enhance the vision, Penetrants used are of fluorescent type
with ultraviolet light detection and visible type using dyes (usually red in colour) which appear as
bright outlines on the surface.
Fig 1 Sequence of operations in penetrant testing

1. Component preparation
Anything that would prevent or absorb penetrant must be removed, for example grease, dust,
scale, rust, water or coating. Liquid or vapour degreasing in organic solvent is effective in
removing oil and grease, while acid pickling will remove scale and rust. Then the component
is made to dry in a dryer.
2. Application of penetrant
For the treatment of surface with penetrant, is done by either dipping into searching liquid or
spraying. Then the component is left to soak and dry. The drying time is usually 20-30min
depending on the type of manufacturing process.
[2]

3. Removal of excess penetrant
Normally penetrant are removed by water but if the penetrant is of post-emulsifiale, it is
treated in an emulsifying stage before wash. It is important that excess penetrant is completely
removed, since any residue will give false indication of the presence of flaw.
4. Drying
Component passed into a dryer.
5. Developing
A developing agent is applied, to allow the penetrant to seep back to the surface and to spread
to the edges of openings, thus magnifying the size of defects.
About 20mins are usually allowed for development of the surface.
6. Inspection
For fluorescent penetrant, this stage takes action in a UV chamber. A good intensity of light is
needed for proper inspection for other developer.

This method can be used to detect a variety of surface defects. The equipment is simple and easy to
use, can be portable, and is less costly to operate than that of other methods. However, this method
can only detect defects that are open to the surface.
Practical example: An example came from a seminar last year 2013 from CEB; liquid penetrant
technique is practiced in hydraulic blades and hot gas removal fan (ID fan). Hydraulic blades are
susceptible to high speed debris that collides on propulsion and eventually give rise to small surface
cracks. To maintain the speed and consequently the shaft speed constant (as a result power), a proper
maintenance schedule for this blade is done at CEB. Also same procedure is respected for the hot gas
removal fan.



Magnetic-Particle inspection
This method utilises small ferro-magnetic particles to reveal the defect from the component.
Magnetic-particle testing detects cracks and flaws from surface and sub-surface of component. The
line of flux produced by the component is used to find defects. The defect under the surface produces
an uneven form of the flux line as seen from the figure below. But note that the deformation in flux
lines must be such that it crosses the surface limits for detection otherwise nothing will be detected.


Fig 2 shows the flux lines and its distortion on flaws

Note: The component must be strictly cleaned and demagnetised prior to testing.
Sequence of operation:
Magnetisation
The component under test can be magnetised either by connecting wires like poles for passage of
current or wrapping a coil around the component with current passing into the coil. The former
method give rise to magnetic field in circular motion and the latter give rise to magnetic field in
longitudinal form. Both method of magnetisation can be used to find defect on the longitudinal or
lateral plane.
Applying magnetic particles on the surface of the component
Magnetic particles (e.g. Fe
3
O
4
) are mixed in a carrier medium usually kerosene and the work is dipped
into it. The magnetic particles are usually of fluorescent type which enables detection of flaws by UV
light. Then inspection is done.
Demagnetisation
Once a component has been magnetised it tends to retain some magnetic field that have adverse effect
if the component is machined or assembled into machine. Machine this component results into swarf
collection resulting into tool damage and during assembly it can upset other nearby components.
Demagnetising is done by moving the magnetising coil away from the specimen or by gradually
reducing the current flowing through it.

Application
The principal industrial uses of magnetic particle inspection are final inspection, receiving inspection,
in-process inspection and quality control, maintenance and overhaul in the transportation industries,
plants and machinery maintenance and inspection of large components.

Eddy-current inspection
This method is based on electromagnetic induction. The component is placed in an electric coil in
which alternating current flows at frequencies from 60 Hz to 6 MHz depending on component size.
Eddy current is produced by this alternative magnetic field. Any crack or flaws distort the direction of
eddy current. A searching coil carrying ac is moved over the surface of the component under test and
any change in the electrical properties of the coil is assumed to indicate the presence of flaws. Defect
can be detected under a depth limited to 13mm.
[3]
In the non-ferrous wrought metal industries, eddy-
current testing is the most widely used non-destructive testing technique.
Note: This technique is still in a research phase in a way that it can also identify properties and
composition of the metal.
Figure 3 shows the changes in eddy-current flow caused by a defect in a workpiece





Radiographic inspection
This method consists of two types of analysis:
I. X-Ray analysis
II. Gamma Ray analysis
Radiography inspection is used to detect internal flaws such as cracks and porosity. For X-ray, the
principle involved is difference in density; the metal surrounding the defect is denser and, hence,
shows up as lighter than the flaws on an X-ray film. The film is placed at the back of the component
and after radiation it is examined in a light intensity. Light dense region is examined carefully and if
rejected if non-compliant. X-ray radiography can be used to examine engineering structures,
components and devices.
Gamma Ray inspection is used to inspect thick sections otherwise it would require the use of very
large X-ray sets. A radioactive isotope is exposed to a position of the work. The work may be large
pipes or weld that has to be inspected for crack that may propagate to produce leakage. All this
depend on the structure and accessibility of the pipe. All the procedures are designed as per standards
for safety of people and environment. Like X-ray, film is examined to detect any flaws in the weld.
Figure 4 shows the positioning of gamma film prior to clearance of pipe
[4]





Ultrasonic Inspection
Ultrasonic is the general subject of sound whose frequency is above the upper pitch limit of the
human ear. Ultrasound is used to test engineering materials for cracks and defects, and to measure
material thickness. The ultrasonic wave sent to the workpiece is reflected back to the piezo with little
distortion and if defects present, part of the wave is reflected back according to its position. Ultrasonic
waves are generated by a transducer. The transducer can both be used for transmission and reception.
A coupling medium (gel) is used to prevent any hard attenuation when transmitted from transducer to
the surface of the specimen.
There are 2 ways for Flaw detection:
I. Pulse-reflection method
II. Transmission method
In pulse reflection method, waves are transmitted into the component under test and the time which
elapses between the transmission signal and the return of the reflected echo from the back wall of the
component. If any defect is present on half way of the ultrasonic wave, the wave is partly reflected to
the transducer while the other wave struck the back wall. The defect echo gives the inspector the
position of the defect with respect to the back wall. Note that there is only one transducer and
consequently make is easier and more rapid compared to the other detection.
Figure 5 illustrates the reflection method

In transmission method, a continuous beam is used. The ultrasonic beam passes from the transmitter
into the workpiece and then to the receiver.
Two peaks appear on the cathode ray oscilloscope; one shows a peak with roughly no attenuation and
the other one shows an attenuated peak.


Figure 6 illustrates the transmission method of ultrasonic flaw detection

Application:
Steel plate and flat bar from 5mm to 30mm thick can be checked for laminations, seams, rolling
cracks and inclusion. This method is widely used to check for casting defects and welding inspection.
Ultrasonic inspection is used for quality control and material inspection in all major industries, this
includes electrical and electronic-component manufacturing; production of steel, aluminium and
titanium; and fabrication of structures such as air frames, pressure vessels, ships, bridges, motor
vehicles, machinery and jet engines.
[1]


Thermal Inspection
Thermal inspection involves using contact and non-contact type heat sensing devices to determine
temperature changes. Defects in the workpiece cause a change in temperature.
In thermographic inspection, materials such as heat sensitive paints and papers, liquid crystals, and
other coatings are applied to the surface. Any changes in their colour or appearance indicate defects.
The most common method of non-contacting thermographic inspection uses infrared detectors,
scanning microscopes and cameras, which have high response time and sensitivities.
Thermometric inspection utilizes devices such as thermocouples, etc...
Applications: usually used to detect any imperfection in temperature in boiler or machines. Also used
to detect leakage
Conclusion
To conclude NDT testing is used for its rapidness and effectiveness compared to destructive testing.
NDT techniques such as visual, liquid penetrant, magnetic, ultrasound and eddy current gives out
results in less than 2 hour. To differentiate between these methods, is the power to which it detects
flaws. For surface or sub-surface defects testing, this can be inserted in the line production itself
where defective components can be removed promptly. However internal flaws cannot be detected in
line production as this will cost a lot of time and money to company. Internal flaws detection are
usually used while performing maintenance schedule.



References
[1] ENGINEERING METROLOGY: 6
th
edition, I.C. GUPTA B.Sc. Engg. M.I.E. Prod E Pg769sec17.1.
[2] THE STRUCTURE, PROPERTIES AND HEAT TREATMENT OF METALS, D.J.D. and L.A.O.
pg 171 sec 11.2.
[3] MANUFACTURING ENGINEERING TECHNOLOGY: 4
th
EDITION, Serope Kalpakjian and Steven
R. Schmid.
[4] EN ISO 17636-1, NON-DESTRUCTIVE TESTING OF WELDS- RADIOGRAPHIC TESTING-PART1:
X- AND GAMMA-RAY TECHNIQUES WITH FILM, January 2013.