MEC 281

MATERIALS SCIENCE

CHAPTER 6
NON-DESTRUCTIVE
TESTING
Rasdi bin Deraman
Fakulti Kejuruteraan Mekanikal
UiTM Pulau Pinang
9.1 PRINCIPLES AN APPLICATION
OF NDT

Non-destructive tests (NDT) are

inspection methods which are usually
used to search for the presence of
defects in components, without causing
any effects on the properties of the
components. The type of defects
detectable are cracks, porosity, voids,
inclusions, etc.
9.1 PRINCIPLES AND APPLICATION
OF NDT (Cont….)
Modern NDT is used by manufacturers to:
ensure product integrity and reliability;
prevent failure, accidents and saving lives;
make profit for users; ensure customer
satisfaction; aid in better product design;
control manufacturing process; lower
manufacturing costs; maintain uniform
quality level; ensure operational readiness.
9.1 PRINCIPLES AND APPLICATION
OF NDT (Cont….)
Non-Destructive testing is the collective
name given to testing processes applied
to components or structures to
interrogate their integrity, in such a way
as to not prevent the component or
structure from being used.
It can also be used for Condition
Monitoring, by interrogating
components or structures that have
been in service to determine their
suitability to retain in service (e.g. Oil
Storage Tank Wall Thickness
measurement, Aircraft Wheel inspection
after each 12 months service or 1000
9.2 CLASSIFICATION OF NDT

Non-Destructive Testing can be performed by

numerous techniques. The classification of NDT
that most commonly applied techniques today are:

1. Liquid Penetrant Inspection

2. Magnetic Particles Inspection
3. X-Ray Radiographic
4. Ultrasonic Flaw Detection Methods
5. Eddy Current Inspection
9.2.1 Liquid Penetrant Testing

Discontinuities such as crack that

penetrate to the surface can be
detected by liquid penetration
inspection.

• two kinds: dye penetrant and

fluorescent penetrants
 Liquid Penetrant Testing (Cont..)
The technique is based on the
ability of a liquid to be drawn into a
"clean" surface breaking flaw by
capillary action.
Penetration Fluorescent
penetrant on
surface seeps
into the crack.
Liquid Penetrant Testing (Cont..)
Emulsifies is applied to the
penetrant. Emulsifier mixes with
penetrant on the surface, but
penetrant in the crack is not
emulsified. Emulsifier makes the
mixture washable .
Emulsification
Emulsifier and
penetrant

Penetrant only
 Liquid Penetrant Testing (Cont..)
Water spray removes the emulsified
penetrant. Water removes the surface
film as well.

Rinse

water

Penetrant only
 Liquid Penetrant Testing (Cont..)
A developer is applied to pull the
trapped penetrant out the defect and
spread it on the surface where it can be
seen.
Development

developer

Penetrant
Liquid Penetrant Testing (Cont..)
Black light causes the penetrant to
glow in dark.

Inspection
Black Light

Developer

Penetrant
 Liquid Penetrant Testing (Cont..)
• Typical application:

Example of materials : all

metal, glass, casting,
forging, machined parts
9.9.2 Magnetic Particles Inspection

Magnetic particle inspection is a

method that can be used to find
surface and near surface flaws in
ferromagnetic materials such as
steel and iron.
Magnetic Particles Inspection (Cont…)
A magnetic field is included in the material to be
tested producing lines of flux. If a discontinuity
is present in the material, the reduction in the
magnetic permeability of the material due to the
discontinuity changes the flux density of the
magnetic field. Leakage Field at a Crack in a Bar
Magnet is shown in figure below.
Magnetic Particles Inspection (Cont…)

The iron particles can be applied dry or

wet; suspended in a liquid, colored or
fluorescent. While magnetic particle
inspection is primarily used to find
surface breaking flaws, it can also be
used to locate sub-surface flaws. But
it's effectiveness quickly diminishes
depending on the flaw depth and type.
Magnetic Particles Inspection (Cont…)

Surface irregularities and scratches

can give misleading indications.
Therefore it is necessary to ensure
careful preparation of the surface
before magnetic particle testing is
undertaken.
 Advantages and limitation
Advantages
• Simplicity of operation and application
• Complex shapes can be tested
• Detect small fine crack
• Low cost

Disadvatages
• Restricted to ferromagnetic materials
• Restricted to surface or near surface flaws
• Required cleaning process
• Need more than two magnetization in order to
inspect complex shape.
9.2.3 X-Ray Radiographic

This technique utilizes the ability of x-ray

and gamma ray (short wave length
electromagnetic rays) that are capable of
going through relatively large thickness
of metal. This method involves the
differences in density between the solid
and the region that contains internal
defect.
 Film Radiography

The part is placed between the

radiation source and a piece of
film.

X-ray film

= less exposure
= more exposure
Top view of developed film
 •The results of inspection are recorded on
the film as darker and lighter images. The
region that contains defect has lower density
compare to free defect region and absorbs less
of the radiation. Thus defects appear as darker
area on film.
9.2.4 Ultrasonic Flaw Detection Methods

This method utilizes high frequency sound

wave, which is produced by
piezoelectric materials such as quartz or
barium titanate.

The rate of wave

transmitted through
the material is
depended on the
modulus of elasticity
and the density of the
material.
Ultrasonic Flaw Detection Methods (Cont…)
• We can measure the distance/depth
for flaw in the sample by measuring
the echo distance from the initial
f

initial
pulse

back surface
echo
crack
echo

crack
0 2 4 6 8 10 plate
Oscilloscope, or flaw
detector screen
Ultrasonic Flaw Detection Methods (Cont…)
As the sound enters the surface of the material
to be tested, it is reflected to the crystal where
it is converted back to electrical pulse. This
impulse is amplified and shown as
indication/pip/echo on the screen of the
oscilloscope.

The 1st interface will show one

indication/pip/echo. When sound wave reaches
the opposite side surface of material, it is
reflected back and shows as another
indication/ pip/ echo on the screen farther to
the 1st indication /pip/echo .
 The distance between these two
indication/echo is a measure of the thickness of
the component to be tested.

If the thickness of the

certain portion is less
than the original/
initial thickness, it
shows that a
discontinuity lies
within the material
and even tell us the
depth of the
discontinuity
below the surface.
 6.2.5 EDDY CURRENT INSPECTION
NDT by eddy current methods
involves inducing electric currents in a
test piece and measuring the changes
produced in those currents by
discontinuities or other physical
differences in the test piece.
It is used to check welds in
magnetic and nonmagnetic materials
and is particularly useful in testing bars,
fillets, welded pipe, and tubes.
The frequency may vary from 50 Hz
to 1 MHz, depending on the type and
thickness of material current methods.
Principles of Operations
Eddy currents are induced in a test article
when an alternating current is applied to a
test coil (probe). The alternating current in
the coil induces an alternating magnetic
field in the article which causes eddy
currents to flow in the article.
 EDDY CURRENT INSPECTION (Cont…)

• When an energized coil is brought near to the

surface of a metal or conducting component, eddy
current set up a magnetic field that tend to oppose
the original magnetic field. The impedance of coil
in close proximity to the specimen is affected by
the presence of the induced eddy currents in the
specimen
 EDDY CURRENT INSPECTION (Cont…)

• when the eddy currents in the specimen are

distorted by the presence of the flaws or
material variations, the impedance in the coil
is altered. This changes is measured and
displayed in a manner that indicates the types
of flaw or material condition
 EDDY CURRENT INSPECTION (Cont…)

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
EDDY CURRENT INSPECTION (Cont…)
EDDY CURRENT INSPECTION (Cont…)
EDDY CURRENT INSPECTION (Cont…)
EDDY CURRENT INSPECTION (Cont…)
EDDY CURRENT INSPECTION (Cont…)
EDDY CURRENT INSPECTION (Cont…)
 EDDY CURRENT INSPECTION (Cont…)

Eddy current testing is particularly well suited for

detecting surface cracks but can also be used to make
electrical conductivity and coating thickness
measurements. Here a small surface probe is scanned
over the part surface in an attempt to detect a crack.
• Application

– Detect defect under coated material

– Detect defect that are so small
– To check welds
– Application inside tube such as in
heat exchanger
– Detect surface crack, pit,
subsurface crack, corrosion inner
surface
Non-Destructive
Testing
(NDT)
TQ