APPLICATION OF NDT IN RLA

By

S.Gunasekar
Senior Engineer
Welding research institute
BHEL , Tiruchy
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Basic NDT methods used for RLA

PENETRANT TESTING (PT)
MAGNETIC PARTICLE TESTING (MT)
RADIOGRAPHIC TESTING (RT)
ULTRASONIC TESTING (UT)
EDDY CURRENT TESTING (ECT)

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PENETRANT TESTING
Basic principle : Capillary action
Application :
To find defect present open to surface
Applicable to non porous metallic materials
Ferrous and non ferrous
Non-metallic materials like fully densified
ceramics
Non porous plastics and glass.
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Penetrant testing steps

Pre cleaning.
Application of penetrant.
Dwell time
Removing excess penetrant.
Apply developer.
Dwell time.
Inspection.
Post cleaning.
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FLOURESCENT

VISIBLE

Visible under UV light only

Visible under normal light

Comparatively High sensitivity

Comparatively Low sensitivity

Yellow green in color

Bright red or magenta in color

Min light intensity

1000 w/sq.cm

Min light intensity

100fc (1000 lx)

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 Advantage:
Reliable
Easy to interpret
Low operator skill is sufficient

Limitation :
Only surface defects can be identified
Cannot be used for porous material
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MAGNETIC PARTICLE TESTING

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MAGNETIC PARTICLE TESTING

Principle : Magnetic flux leakage
Application :
Ferro magnetic materials
To find defects present in surface and subsurface of the job

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N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

N
N
N
N
N
N
N
N

S
S
S
S
S
S
S
S

Magnetic Materials(Domain aligned)

S
N
N

S
N

S
N
N
S
S

S N
S
S
S S S

N
N
S

S
N

N
N
S

N
N

N
N

S
N
N

S
N

N
S
N

N
S

N
S

N
N

S
S

S
S

Ferromagnetic Materials (random domains)

S
S
S
S
S
S

N
N
N
N
N
N

S
S
S
S
S
S

N
N
N
N
N
N

S
S
S
S
S
S

S
S
S
S
S
S

N
N
N
N
N
N

N
N
N
N
N
N

Breaking of magnets leads to two magnets

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S
S
S
S
S
S

N
N
N
N
N
N

S
S
S
S
S
S

N
N
N
N
N
N

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YOKE METHOD- LONGITUDINAL MAGNETISATION

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PROD METHOD CIRCULAR MAGNETIZATION

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Pie gauge

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Crane Hook with

Service Induced Crack

Fluorescent, Wet Particle Method

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Drive Shaft with

Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

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Threaded Shaft with

Service Induced Crack

Fluorescent, Wet Particle Method

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Large Bolt with

Service Induced Crack

Fluorescent, Wet Particle Method

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Radiographic testing

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RADIOGRAPHIC TESTING

Principle of Radiographic Testing

Differential

Factors

absorption of ionizing radiation.

causing differential absorption :

- Atomic number
- Density
- Thickness

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RADIOGRAPHIC TESTING

Radiation source

Job

Recording medium
(Film)

Film after developing

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RADIOGRAPHIC TESTING

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RADIOGRAPHIC TESTING

Film Density
Density = log (I0 / I t)
I0 - Initial intensity
I t - Transmitted intensity

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RADIOGRAPHIC TESTING

Radiation source
X

Ray :
High speed electron stopped by target.

Gamma

Ray :

Emitted by disintegrating nuclei of

radioactive isotopes.

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RADIOGRAPHIC TESTING

X-Rays

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RADIOGRAPHIC TESTING

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RADIOGRAPHIC TESTING

X Ray

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RADIOGRAPHIC TESTING

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RADIOGRAPHIC TESTING

GAMMA RAY

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RADIOGRAPHIC TESTING

Camera for Gamma ray source

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RADIOGRAPHIC TESTING

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RADIOGRAPHIC TESTING

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RADIOGRAPHIC TESTING

Exposure chart

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RADIOGRAPHIC TESTING

Incomplete penetration / LOP

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RADIOGRAPHIC TESTING

Incomplete penetration / LOP

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RADIOGRAPHIC TESTING

Lack of fusion

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RADIOGRAPHIC TESTING

Lack of fusion

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RADIOGRAPHIC TESTING

Porosity

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RADIOGRAPHIC TESTING

Porosity

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RADIOGRAPHIC TESTING

Cluster porosity

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ULTRASONIC TESTING

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What is Sound ?
Mechanical vibration of particles
Needs a medium to travel
Sound is classified based on frequency as
Frequency range Hz

Description

Example

0 - 20

Infrasound

Earth quake

20 - 20000

Audible sound

Speech, music

> 20000

Ultrasound

Bat, Quartz crystal

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Basic concepts of sound

Distance travelled
Velocity = ----------------------------Time taken

Distance travelled is proportional to time taken

( Velocity of sound is constant, in a material )
If time taken is known distance travelled by sound wave in a
material can be calculated.

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Amplitude

Probe

X/2
0

10

Time or Distance

X
X/2

Equipment Display

Calibration
block

Job

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CRT Display

Amplitude

Probe

Specimen
X
X = Time taken by ultrasound to travel to and fro in material
= Metal path distance

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Time or
Distance

Top View

Side View

Half S.D
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Full S.D

Cap width/2

Interpretation

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Eddy Current
Principle : Based on the principle of electromagnetic induction.
Application :
To detect surface and sub surface defects
Inspection in conducting material

Test Probe
Eddy Currents

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Eddy Current Testing

Coil's
magnetic field

Coil

Eddy current's
magnetic field
Eddy
currents
Conductive
material
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EDDY CURRENT TESTING

ADVANTAGES

Sensitive to small cracks and other defects

Detects surface and near surface defects
Inspection gives immediate results
Test probe does not need to contact the part

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EDDY CURRENT TESTING

LIMITATIONS

Only conductive materials can be inspected

Surface finish and roughness may interfere
Depth of penetration is limited
Flaws such as de laminations that lie parallel to
the probe coil winding and probe scan direction
are undetectable.

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Thank You
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