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(NDT)
INTRODUCTION
Metallurgy and Materials Engineering
University of Indonesia
Definition
A term used collectively to denote a
variety of inspection, testing, and
measurement process that elicit
information about the characteristic
of an object without damaging it or
impairing its ability to perform its
intended function.
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NDE (NDT, NDI, NDEx)
testing, inspection, and examination
looking at/through; measuring
something about an object
to determine: some characteristic of
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9 Areas
flaw detection and evaluation
leak detection and evaluation
metrology
evaluation
structure and microstructure
characterization
….. (see next page)
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9 Areas
….. (see previous page)
estimation of mechanical and
physical properties
stress (strain) and dynamic
response
(signature analysis)
(chemical composition
determination)
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Flaw Detection and Evaluation
6 primary factors involved
in selecting an NDE method(s):
be evaluated
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Flaws Definitions
Discontinuity - Any change of property which
can be detected by means of NDI.
(Discontinuities may be natural features of a
component, eg. a bolt hole, or undesirable
features such as cracks.)
Flaw - An undesirable discontinuity. (Flaws may
be acceptable, eg. an acceptably small non-
metallic inclusion, or unacceptable as will
usually be the case with a crack.)
Defect - A flaw, the nature or size of which
renders a material or component unserviceable
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TYPES OF DEFECTS
Inherent defects - present during
initial production of raw materials
processing defects - resulted from
the manufacturing process
Service defects - occurred during the
operation
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Examples of causes of defects
Blowholes - gas trapped during
solidification process
Segregation - during solidification of
alloy
Scale - oxide formation on the
surface of a metal heated to high
temperature
Stress - residual stress after cold
working or rapid cooling
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Cracks
quenching / hardening cracks - rapid
volume change
tempering cracks - rapid heating
shrinkage cracks - rapid cooling
grinding cracks - friction heating
also caused by residual stress,
collapsed blowholes, improper
rolling, sharp edge of dies etc. etc
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5 Basic Elements
Source (probe medium)
Modification (changing as the result of
variations or discontinuities)
Detection (determining the changes)
Indication (indicating or recording the
signals)
Interpretation (interpreting the
indications)
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Indications
Indication - That which indicates a the presence of
a discontinuity. Indications may be developed
directly on the component being inspected, eg.
penetrant and magnetic particle indications, or on a
separate test instrument eg. in the form of
deflections in a CRT trace, deflections of a pointer
on a meter, or on a separate recording medium, eg.
a radiograph or chart recording
False Indication - An indication arising from an
unintended source
Non-relevant Indication - An indication of a
discontinuity which is not of the nature of that
sought
Relevant Indication - An indication of significance to
the purpose of the inspection
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Methods of NDE
VISUAL TESTING (VT)
LIQUID PENETRANT TESTING (LT)
MAGNETIC PARTICLE TESTING (MT)
EDDY CURRENT TESTING (ET)
ULTRASONIC TESTING (UT)
RADIOGRAPHIC TESTING (RT)
Acoustic Emissions Testing (AE)
Neutron Radiographic Testing (NRT)
Strain measurement (SM)
Thermographic, etc
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Visual Inspection
Used to :
Magnify defects which can not be
detected by the unaided eye
Assist in the inspection of defects
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Equipments
Magnifying Glass
Magnifying Mirror
Microscope
Borescope
• endoscopes or endoprobes
Flexible Fiber Optic Borescope
• working lengths are normally 60 to 365 cm
with diameters from 3 to 12.5 mm
Video Imagescope
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Borescope
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Visual acuity
"Non-destructive Testing Personnel Qualification and Certification",
which is:
• At least one eye: Capable of reading the letters of an Ortho-Rater 8 or
Jaegar #2 Chart at 12 inches.
• Personnel shall be capable of distinguishing and differentiating
between colours used in the process involved
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Liquid Penetrant
Inspection
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Methods
Penetrant is drawn into crack by
capillarity action. Water spray
removes penetrants from surface
(but not from crack). Developer acts
like a blotter to draw penetrant out
of crack.
If fluorescent penetrant used, black
light causes penetrant to glow in
dark
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Objective
surface opening due to cracks,
porosity, seams, laps, fold, small
discontinuities, etc
Use to :
• Monitoring production technique
• Find and isolating the flaws, before
other processes continue
• Quality cross check for finishing product
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Applications
magnetic and non magnetic
materials.
homogeneous, not porous.
castings, forgings, machined parts,
and cutting tools, field inspections;
turbine blades for surface cracks or
porosity
Limitations:
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Principles
Cohesive and adhesive action
Molecular arrangements at a
liquid-wall interface. (a) The
contact angle, θ, as shown,
between the liquid and the wall
is less than 90o, and the
surface of the wall is wetted.
(b) Cohesive forces between
like molecules are greater than
the adhesive forces between
unlike molecules. In this case,
the surface of the wall is not
wetted and the liquid is in the
form of separate droplets
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Principles
2 LV cos
h
rg
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Principles
Height, h that liquid penetrates in a crack :
Depends on the capillarity force due to the
surface tension
Requires a contact angle less than 90
0
liquid
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Materials
U.S. Military Specification MIL-I-25135E
• Penetrant Systems :
Type I - Fluorescent dye
Type II - Visible dye
Type III - Visible and fluorescent dye (dual mode)
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Operations
1. Surface preparation. The surface must be free
of oil, grease, water, or other containing flaws.
Penetrant inspection should be scheduled prior
to the mechanical operations such as grit or
vapor blasting, which have a tendency to smear
the surface of parts, thus closing the defects.
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Operations
3. Penetrant dwell. The penetrant is left on the
surface for a sufficient time to allow penetration
into flaws. The time involved is based on
experience.
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Operations
5. Developer application. Developer may be
applied by dusting (dry powdered) or immersion
or spray (water developers) applications. Non
aqueous wet developers may be applied by
spray only. The developer should then be
allowed to dwell on the part surface for
sufficient time (usually’ 10 mm minimum) to
permit it to draw penetrant out of any surface
flaws to form visible indications of such flaws.
Longer times may be necessary for tight cracks.
6. inspection. Inspection is then performed under
appropriate lighting to detect any flaws which
may be present.
7. Clean surface.
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Operations
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Post Emulsifier
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Multistation Processing Unit
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Test Methods
Designation Method Symbol
Fluorescent Water-washable FA
penetrant testing Post-emulsifiable FB
Solvent-removable FC
Dye Penetrant Water-washable VA
testing Solvent-removable VC
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Penetrating methods
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Penetrating time
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Dwell times
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Indications
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Flaws Types
Continuous Lines : Cracks are observed generally as jagged
lines; cold shuts appear as smooth, narrow straight lines;
forging laps appear as smooth wavy lines; scratches tend to
be shallow.
Broken Lines : Continuous lines become partially closed by
working, such as grinding, peening, forging, or machining,
resulting in a discontinuous line.
Small Round Holes : These are typical of general porosity,
gas holes, pin holes, or very large grains.
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Effect of mechanical surface
preparation
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False indications
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Detecting fine cracks
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Glossary of Terms
black light. Electromagnetic radiation in the near-ultraviolet range of
wavelength (330 to 390 nm).
developer. A material applied to the specimen surface to accelerate bleed
out and to enhance the contrast of indications.
Aqueous. A suspension of developer particles in water.
Dry. A fine free-flowing powder.
Liquid film. A suspension of developer particles in a solvent which leaves a
resinous film on the surface after drying.
Soluble. A developer completely soluble in its carrier.
Solvent. Developer particles suspended in a non-aqueous vehicle prior to
application.
developing time. The time between the application of the developer and
the examination of the part.
dwell time. The time that the penetrant or emulsifier is in contact with
the specimen surface, including the time required for application and to
drain (see Fig. 4.2).
emulsification time (emulsifier dwell time). The time that an
emulsifier remains on the specimen to combine with the surface penetrant
prior to removal.
emulsifier. A liquid that interacts with an oily substance making it water
washable.
hydrophilic. Having a strong affinity for water. Substance that is
attracted to a water phase rather than to air in an air-water
interphase (e.g., —OH).
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Glossary of Terms
hydrophilic emulsifier. A water-based liquid that interacts with the
penetrant oil rendering it water washable.
lipophilic. A fat-liking molecular group (e.g., CH3) that has affinity for
hydrocarbons.
lipophilic emulsifier. An oil-based liquid that interacts with the penetrant
oil rendering it water washable.
lyophilic. Solid-liquid mixture with surface active molecules containing
several molecular groups with both affinities and repulsions for the liquid
phase; “solvent loving” (opposite of lyophobic).
lyophobic. “Solvent-hating” (opposite of lyophilic).
penetrant. A liquid that is applied to the surface of a part so that it
penetrates surface- breaking defects.
• Dual purpose. Produces both fluorescent and color contrast visible
indications.
• Fluorescent. Emits visible radiation when excited by black light.
• Solvent-removable. Traces removable by wiping with a material lightly
moistened with solvent remover.
• Visible. Characterized by an intense color, usually red.
• Water-washable. With a built-in emulsifier.
Post emulsifications penetrant. Requires the application of a separate
emulsifier to render the excess surface penetrant water washable.
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