Probe Placement For Several Weld Configuration

Probe Placement for several weld
configuration

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Main uses of UT
Used to locate surface and subsurface defects in
many materials including metals, plastics, and wood.
Ultrasonic inspection is also used to measure the
thickness of materials and otherwise characterize
properties of material based on sound velocity and
attenuation measurements.
Advantages of UT
It is sensitive to both surface and subsurface discontinuities.
The depth of penetration for flaw detection or measurement is

superior to other NDT methods.
Only single-sided access is needed when the pulse-echo technique is

used.
It is high accuracy in determining reflector position and estimating

size and shape.
Minimal part preparation required.
Electronic equipment provides instantaneous results.
Detailed images can be produced with automated systems.
It has other uses such as thickness measurements, in addition to flaw

detection.
Disadvantages of UT
Surface must be accessible to transmit ultrasound.
Skill and training is more extensive than with some other methods.
It normally requires a coupling medium to promote transfer of sound

energy into test specimen.
Materials that are rough, irregular in shape, very small, exceptionally

thin or not homogeneous are difficult to inspect.
Cast iron and other coarse grained materials are difficult to inspect due
to low sound transmission and high signal noise.
Linear defects oriented parallel to the sound beam may go undetected.
Reference standards are required for both equipment calibration, and

characterization of flaws.
Magnetic Particle Testing

This NDT method is accomplished by inducing a
magnetic field in a ferromagnetic material and then
dusting the surface with iron particles (either dry or
suspended in liquid). Surface and near-surface flaws
produce magnetic poles or distort the magnetic field
in such a way that the iron particles are attracted and
concentrated. This produces a visible indication of
defect on the surface of the material.
Magnetization
There are basically two types of magnetic field:
1.
Longitudinal Magnetic field.
2.
Circular Magnetic Field.
Magnetization
1.
Longitudinal Magnetization : When the length of a

component is several time larger than its diameter, a
longitudinal magnetic field can be established in the
component. The component is often placed
longitudinally in the concentrated magnetic field that
fills the center of a coil or solenoid. This
magnetization technique is often referred to as a "coil
shot."
Yoke for Longitudinal Magnetization
Magnetization
2. Circular
Magnetization : when current is passed

through a solid conductor, a magnetic field forms in
and around the conductor. The following statements
can be made about the distribution and intensity of
the magnetic field.
The field strength varies from zero at the center of

the component to a maximum at the surface.
The field strength at the surface of the conductor

decreases as the radius of the conductor increases
when the current strength is held constant.
(However, a larger conductor is capable of carrying
more current.)
Magnetization
The field strength outside the conductor is directly

proportional to the current strength. Inside the
conductor the field strength is dependent on the
current strength, magnetic permeability of the
material.
The field strength outside the conductor decreases

with distance from the conductor.
Magnetic Fields
Circular Magnetic Field for
Longitudinal Defects.
Longitudinal
Magnetic field for
Circular Defects.
Prods for Circular Magnetization
Examples of Magnetic Particle Indication
Indications of Cracks
Before and after inspection pictures of cracks

emanating from a hole

Indication of a crack in a saw blade

Indication
of cracks running between

attachment holes in a hinge

Indication
of cracks originating at a
fastener hole

Magnetic
particle wet fluorescent indication

of a cracks in a drive shaft

Magnetic
particle wet fluorescent indication of

a crack in a bearing
Main uses of MT
Used to inspect ferromagnetic materials (those that
can be magnetized) for defects that result in a
transition in the magnetic permeability of a material.
Magnetic particle inspection can detect surface and
near surface defects.
Advantages of MT
Large
surface areas of complex parts can be

inspected rapidly.
Can
detect surface and subsurface flaws.
Surface
preparation is less critical than it is in

penetrant inspection.
Magnetic
particle indications are produced
directly on the surface of the part and form an

image of the discontinuity.
Equipment
costs are relatively low.
Disadvantages of MT
Only ferromagnetic materials can be inspected.
Proper alignment of magnetic field and defect is critical.
Large currents are needed for very large parts.
Requires relatively smooth surface.
Paint or other nonmagnetic coverings adversely affect

sensitivity.
Demagnetization and post cleaning is usually

necessary.
Penetrant Testing
Penetrant solution is applied to
the surface of a precleaned
component. The liquid is pulled
into surface-breaking defects by
capillary action. Excess
penetrant material is carefully
cleaned from the surface. A
developer is applied to pull the
trapped penetrant back to the
surface where it is spread out
and forms an indication. The
indication is much easier to see
than the actual defect.
Steps of Penetrant Testing

1. Surface Preparation: One of the most critical
steps of a liquid penetrant inspection is the
surface preparation. The surface must be free of
oil, grease, water, or other contaminants that may
prevent penetrant from entering flaws. The
sample may also require etching if mechanical
operations such as machining, sanding, or grit
blasting have been performed. These and other
mechanical operations can smear the surface of
the sample, thus closing the defects.

2. Penetrant Application: Once the surface has been thoroughly
cleaned and dried, the penetrant material is applied by

spraying, brushing, or immersing the parts in a penetrant
bath.

3. Penetrant Dwell: The penetrant is left on the surface for a
sufficient time to allow as much penetrant as possible to be

drawn from or to seep into a defect. Penetrant dwell time is the
total time that the penetrant is in contact with the part surface.
Dwell times are usually recommended by the penetrant
producers or required by the specification being followed. The
times vary depending on the application, penetrant materials
used, the material, the form of the material being inspected, and
the type of defect being inspected. Minimum dwell times
typically range from 5 to 60 minutes. Generally, there is no
harm in using a longer penetrant dwell time as long as the
penetrant is not allowed to dry. The ideal dwell time is often
determined by experimentation and is often very specific to a
particular application.

4. Excess Penetrant Removal: This is a most delicate
part of the inspection procedure because the excess
penetrant must be removed from the surface of the
sample while removing as little penetrant as
possible from defects. Depending on the penetrant
system used, this step may involve cleaning with a
solvent, direct rinsing with water, or first treated with
an emulsifier and then rinsing with water .

5. Developer Application: A thin layer of developer is
then applied to the sample to draw penetrant
trapped in flaws back to the surface where it will be
visible. Developers come in a variety of forms that
may be applied by dusting (dry powdered), dipping,
or spraying (wet developers).

6. Indication Development: The developer is allowed to
stand on the part surface for a period of time sufficient

to permit the extraction of the trapped penetrant out of
any surface flaws. This development time is usually a
minimum of 10 minutes and significantly longer times
may be necessary for tight cracks.

7. Inspection: Inspection is then performed under
appropriate lighting to detect indications from any
flaws which may be present.
8. Clean Surface: The final step in the process is to

thoroughly clean the part surface to remove the
developer from the parts that were found to be
acceptable.
Main uses of Penetrant Testing

Used to locate cracks, porosity, and other defects
that break the surface of a material and have
enough volume to trap and hold the penetrant
material. Liquid penetrant testing is used to inspect
large areas very efficiently and will work on most
nonporous materials.
Advantages of Penetrant Testing
Large surface areas or large volumes of

parts/materials can be inspected rapidly and at low
cost.
Parts with complex geometry are routinely

inspected.
Indications are produced directly on surface of the

part providing a visual image of the discontinuity.
Equipment investment is minimal.
Disadvantages of Penetrant Testing
Detects only surface breaking defects.
Surface preparation is critical as contaminants can

mask defects.
Requires a relatively smooth and nonporous surface.
Post cleaning is necessary to remove chemicals.
Requires multiple operations under controlled

conditions.
Chemical handling precautions are necessary (toxicity,

fire, waste).
Radiography Testing
The radiation used in radiography testing is a higher
energy (shorter wavelength) version of the
electromagnetic waves that we
see as visible light. The radiation can come from an
X-ray generator or a radioactive source.
Radiography Testing
High Electrical Potential
Electrons
+
X-ray Generator or Radioactive Source Creates

Radiation
Radiation
Penetrate
the
Sample
Exposure Recording Device
Radiography Testing
RT involves the use of penetrating gamma- or Xradiation to examine material's and product's defects
and internal features. An X-ray machine or
radioactive isotope is used as a source of radiation.
Radiation is directed through a part and onto film or
other media. The resulting shadowgraph shows the
internal features and soundness of the part. Material
thickness and density changes are indicated as
lighter or darker areas on the film.
Radiography Testing
X-ray film
Top view of developed film
X-rays are used to produce

images of objects using film or
other detector that is sensitive
to radiation. The test object is
placed between the radiation
source and detector. The
thickness and the density of
the material that X-rays must
penetrate affects the amount
of radiation reaching the
detector.
Radiography Testing
This variation in radiation produces an image on the
detector that often shows internal features of the test
object.The part is placed between the radiation
source and a piece of film. The part will stop some
of the radiation. Thicker and more dense area will
stop more of the radiation.
Main Uses of RT
Used to inspect almost any material for surface and
subsurface defects. X-rays can also be used to
locates and measures internal features, confirm the
location of hidden parts in an assembly.
Advantages of RT
Can be used to inspect virtually all materials.
Detects surface and subsurface defects.
Ability to inspect complex shapes and multi-layered

structures without disassembly.
Minimum part preparation is required.
Disadvantages of RT
Extensive operator training and skill required.
Access to both sides of the structure is usually required.
Orientation of the radiation beam to non-volumetric

defects is critical.
Field inspection of thick section can be time consuming.
Relatively expensive equipment investment is required.
Possible radiation hazard for personnel.
Eddy Current Testing

Alternating electrical current is passed through a coil
producing a magnetic field. When the coil is placed
near a conductive material, the changing magnetic
field induces current flow in the material. These
currents travel in closed loops and are called eddy
currents. Eddy currents produce their own magnetic
field that can be measured and used to find flaws
and characterize conductivity, permeability, and
dimensional features.
Eddy Current Testing
Coil
Coil's
magnetic field
Eddy current's
magnetic field
Eddy
currents
Conductive
material
Main Uses of Eddy Current Testing

Used to detect surface and near-surface flaws in
conductive materials, such as the metals. Eddy
current inspection is also used to sort materials
based on electrical conductivity and magnetic
permeability, and measures the thickness of thin
sheets of metal and nonconductive coatings such
as paint.
Advantages of Eddy Current Testing
Detects surface and near surface defects.
Test probe does not need to contact the part.
Method can be used for more than flaw detection.
Minimum part preparation is required.
Disadvantages of Eddy Current Testing
Only conductive materials can be inspected.
Ferromagnetic materials require special treatment to

address magnetic permeability.
Depth of penetration is limited.
Flaws that lie parallel to the inspection probe coil winding

direction can go undetected.
Skill and training required is more extensive than other

techniques.
Surface finish and roughness may interfere.
Reference standards are needed for setup.
Non-Destructive Testing Method & Application

Flaw type
Surfac
e
Cracks
&
Flaws
SubSurface
Cracks
&
Flaws
Internal
Flaws
&
Disconti
nuities
Lack of
bond
Of lock
of
Fusion
Ferrous
Components
&
Finished
M.T.
U.T.
E.T.
R.T.
U.T.
U.T.
Non-ferrous
Components
Finished
P.T.
U.T.
E.T.
R.T.
U.T.
M.T.
U.T.
R.T.
U.T.
R.T.
U.T.
R.T.
U.T.
Material
Aircraft
Ferrous
Components
Aircraft
Non-Ferrous
R.T.
M.T.
E.T.
R.T.
P.T.
NonMetallic
Inclusions
Slag,
porosity
Material
Quality
Laminations,
Thickness
Measureme
nt
M.T.
U.T.
U.T.
U.T.
E.T.
U.T.
U.T.
M.T.
U.T.
U.T.
U.T.
P.T.
U.T.

Flaw type
Material
Ferrous
Forgings &
Stampings
Ferrous raw
Materials &
Rolled
products
Ferrous tube
&
pipe
Surfac
e
Cracks
&
Flaws
SubSurfac
e
Crack
s&
Flaws
Internal
Flaws
&
Discont
inuities
M.T.
M.T.
U.T.
R.T.
U.T.
R.T.
U.T.
U.T.
M.T.
U.T.
U.T.
M.T.
U.T.
U.T.
M.T.
U.T.
U.T.
M.T.
U.T.
U.T.
M.T.
M.T.
E.T.
Lack of
bond
Of lock
of
Fusion
U.T.
Non-Metallic
InclusionsSlag,
porosity
Materia
l
Quality
Laminations
,
Thickness
Measureme
nt

Flaw type
Material
Ferrous
welds
Steel
castings
Surface
Cracks
&
Flaws
M.T.
U.T.
P.T.
M.T.
Iron castings
M.T.
Non-Ferrous
Components
&
Materials
P.T.
E.T.
SubSurfa
ce
Crack
s&
Flaws
Internal
Flaws
&
Discont
inuities
U.T.
R.T.
U.T.
M.T.
U.T.
U.T.
E.T.
Lack
of
bond
Or
lack of
Fusio
n
Material
Quality
Laminations
,
Thickness
Measureme
nt
R.T.
U.T.
U.T.
R.T.
U.T.
R.T.
U.T.
U.T.
U.T.
R.T.
U.T.
R.T.
U.T.
R.T.
U.T.
NonMetallic
InclusionsSlag,
porosity
U.T.
P.T.
U.T.
U.T.
U.T.
U.T.
NDT Facility at L&T Hazira

1. Ultrasonic Testing
Sr.no.
Model
Make
Key Features
USM 25 S
Krautkramer
Recording and printing facility upto

200 nos of A-Scan displays
USD 15X
Krautkramer
Output for permanent recording
SS-130/230
Sonatest
Multiple DAC and echo dynamics

determinations
ISONIC
UDS 3.3
Sonotron
Recording and printing of B & C scan,

end view, TOFD and probe
characteristic determination .
EX 10/100
EEC
Printing of freeze wave form
USK 6/7
Krautkramer
More gain reserve and more

resolving power

2. Radiography Testing.
S.No
M/c
Description
Capacity
Quantity
Key Features
1.
LINAC/Mtsubi
shi
12.5MeV
Radiation thickness up to 500mm

with micro seconds
2.
X-Ray :
Seifert
India Ltd.
450KeV
High sensitivity. Using in control

rods (cd sandwich), for lower thick
and nuclear jobs.
3.
4.
5.
6.
Gamma ray/
Tech ops
AGFA
GEVERT
200KeV
Co.60
Ir.192
Auto
Processor
1
2NO.
Radiation thickness
thickness.
2NO.
Radiation thickness up to 3
thickness
Reduce cycle time, optimum
quality, easy to service, low
chemical consumption
2NO.
up
to

3. Penetrant Testing.
Pre-Cleaner
Penetrant
Excess Penetrant
Remover
AcetoneCommercial
Grade
PP-15
PC-21
PP-110
PC-120
Thane
AcetoneCommercial
Grade
FLAWGUIDE
Penetrant-NP
FLAWGUIDE
Cleaner-NP
FLAWGUIDE
Developer-NP
Magnaflux
AcetoneCommercial
Grade
SPOTCHECK
SKL-I
SKC-I
SPOTCHECK
SKD-S2
Manufacturer
P-Met,
Vadodra
Pradeep,
Developer
PD-31&31A
PD-130&
PD-130 A
Questions & Answers
Thank You

Probe Placement For Several Weld Configuration

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What are the main NDT methods discussed in the document?

What are the main NDT methods discussed in the document?

What are some advantages and disadvantages of ultrasonic testing mentioned?

What are some advantages and disadvantages of ultrasonic testing mentioned?

Probe Placement for several weld