Introduction To NDT. BY: Omid HEIDARY

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1 Introduction To NDT BY: Omid HEIDARY

2 NDT Methods Penetrant Testing Magnetic Particle Testing Eddy Current Testing Ultrasonic Testing Radiographic Testing Acoustic Emission Infrared Testing Visual Testing Other methods

3 NDT Which method is the best? Depends on many factors and conditions

4 NDT Industries involved with NDT: Oil and Gas Metal Manufacturing Construction Composite Manufacturing Metal Fabrication Inspection and Testing Chemical Research and Development Aerospace Training and Certification Power Generation Transportation Medical Electronic

5 Penetrant Testing Also known as Dye Penetrant Inspection (DPI) Penetrant Flaw Detection (PFD) Liquid Penetrant Inspection (LPI) Surface Testing method For detecting surface breaking defects (opened to surface) Applicable to all materials -except for excessively porous (absorbing) materials

6 Basic Steps Pre-cleaning Penetrant application Removal of excess penetrant Application of Developer Inspection Post-cleaning

7 Penetrant Testing Penetrating fluid (penetrant) applied to component Immersion Brushing Aerosol Spraying Electrostatic

8 Advantages of PT Applicable to non-ferromagnetics Able to test large parts with a portable kit Batch testing Applicable to small parts with complex geometry Simple,cheap easy to interpret Sensitivity

9 Disadvantages of PT Will only detect defects open to the surface Careful surface preparation required Not applicable to porous materials Temperature dependant Cannot retest indefinitely Compatibility of chemicals

10 Magnetic Particle Testing

11 Magnetic Particle Testing Test method for the detection of surface and sub-surface defects in ferromagnetic materials

12 Equipment

13 Depth below surface N S N S

14 Ultrasonic Testing

15 Principle High frequency sound sound waves are introduced into a material Reflected sound gives information on the material under test and signals displayed on a CRT Ultrasonic Testing

16 What is Sound? A mechanical vibration The vibrations create Pressure Waves Sound travels faster in more elastic materials Number of pressure waves per second is the Frequency Speed of travel is the Sound velocity

17 Sound at an Interface Sound will be either transmitted across or reflected back Reflected Interface How much is reflected and transmitted depends upon the relative acoustic impedance of the 2 materials Transmitted acoustic impedance Z V

18 Air Large Acoustic Impedance Ratio Steel Steel Large Acoustic Impedance Ratio Air Steel Steel Aluminum Steel No Acoustic Impedance Difference Small Acoustic Impedance Difference

19 Snell s Law C If the angle of Incident is increased the angle of refraction also increases Perspex Up to a point where the Compression Wave is at 90 from the Normal Steel 90 This happens at the FIRST CRITICAL ANGLE C S

20 Probes

21 Compression / Longitudinal Vibration and propagation in the same direction / parallel Travel in solids, liquids and gases Particle vibration Propagation

22 Shear / Transverse Vibration at right angles / perpendicular to direction of propagation Travel in solids only Velocity 1/2 compression (same material) Particle vibration Propagation

23 Ultrasonic Displays A scan The CRT (Cathode Ray Tube) display The Horizontal axis : Represents time base / beam path length / distance / depth The Vertical axis : Represent the amount of sound energy returned to the crystal

24 Ultrasonic Inspection initial pulse defect echo Back wall echo defect Material Thk Compression Probe CRT Display

25 mm The depth of the defect can be read with reference to the marker on the screen

26 Thickness / depth measurement The closer the reflector to the surface, the signal will be more to the left of the screen C B A The thickness is read from the screen B C The THINNER the material the less distance the sound travel A

27 Scanning Procedure Parent Material 0 degree both sides To maximum range for angle probes Full skip distance for 60 or 70 probes

28 Weld Root Scanning Procedure Half skip from both sides For PCN exams : 70 degree probe at half skip from both sides

29 Scanning Procedure Weld Fusion Faces Half to full skip from both sides A probe which strikes fusion faces at 90 degrees Probe angle = 90 - (1/2 Root angle)

30 Defect Orientation ONLY DEFECTS HAVING A SUITABLY ORIENTATED REFLECTING SURFACE CAN BE DETECTED BY PULSE ECHO METHODS!! Orientation favourable, sound reflected back to point of origin Orientation unfavourable, sound not reflected back to point of origin

31 B scan Ultrasonic Displays The End View Display B

32 C scan Ultrasonic Displays The Plan View Display C

33 D scan Ultrasonic Displays The Side View Display D

34 Advantages of UT Sensitive to cracks at various orientations Portability Safety Able to penetrate thick sections Measures depth and through wall extent

35 Disadvantages No permanent record (unless automated) Not easily applied to complex geometries and rough surfaces. Unsuited to course grained materials Requires highly skilled and experienced technicians

36 Radiographic Testing

37 Radiographic Testing Electromagnetic radiation is imposed upon a test object Radiation is transmitted to varying degrees dependant upon the density of the material through which it is travelling Variations in transmission detected by photographic film or fluorescent screens Applicable to metals,non-metals and composites

38 Shorter Wavelength = Increased Energy Shortening Wavelength

39 Electromagnetic Spectrum Industrial radiography Ultra violet Infra red Microwaves TV Electric Waves cm Wavelength

40 Relative Intensity Mev. Wavelengths Co to1.3 Mev Yb to 0.2 Mev Ir to 0.47 Mev Long Wavelength l Short Gamma line spectrum (discrete energies), the wave length is not of a fixed nature. A number of frequencies will be emitted for most sources.

41 Radiographic Sensitivity 7FE12 Step / Hole type IQI Wire type IQI

42 Radiographic Inspection Source Radiation beam Image quality indicator Radiographic film Test specimen

43 The basis of radiography Source High dense discontinuity Low dense discontinuity Lighter region on radiograph Film Darker region on radiograph

44 The basis of radiography Source Thin part Thick part Film Lighter Region on radiograph Darker region on radiograph

45 Radioactive isotope It is small,typically 1mm x 1.5 mm cylinders,that give off gamma rays It occurs in nature and also in artificial isotopes Artificial isotopes are created by bombarding an element with an excess of neutron in the nuclear reactor. Example of nature isotopes are radium and uranium Example of artificial isotopes are iridium 192 and cobalt 60

46 MEASUREMENT OF RADIOACTIVITY THE BASIC UNIT IS CURIE IN SI UNIT, IT IS MEASURED IN BECQUEREL 1 CURIE = 3.7 X BECQUERELS HALF LIFE OF AN ISOTOPE IS THE TIME IT TAKES FOR 1/2 OF THE ATOMS TO DECAY

47 RADIOGRAPHIC FILM IT HAS TWO TYPES SLOW FILM -FINE GRAIN AND NEED MORE EXPOSURE FAST FILM - LARGE GRAINS AND NEED LESS EXPOSURE KNOWLEDGE OF FILM CAN HELPS THE RADIOGRAPHER TO WORK OUT EXPOSURES WHEN CHANGING FILM BRANDS. E.G IN TABLE 5.3 FILM ALSO SHOULD BE STORED IN EDGES, IN COOL DRY CONDITIONS AND AWAY FROM CHEMICALS OR RADIATION

48 Radiographic Techniques

49 Single Wall Single Image SWSI Film Film IQI s should be placed source side

50 Single Wall Single Image Panoramic SWSI panoramic Film IQI s are placed on the film side Source inside film outside (single exposure)

51 Double Wall single Image DWSI Film IQI s are placed on the film side Source outside film outside (multiple exposure) This technique is intended for pipe diameters over 100mm

52 Double Wall Double Image DWDI Film IQI s are placed on the source or film side Source outside film outside (multiple exposure) A minimum of two exposures This technique is intended for pipe diameters less than 100mm

53 Radiographic Film Emulsion AgBr Supercoat Subbing Base Emulsion AgBr Subbing Supercoat

54 Developer Stop bath PROCESSING FILM Running water MANUAL SYSTERM

55 Advantages of Radiography Permanent record Detection of Internal flaws Can be used on most materials Direct image of flaws Real - time imaging

56 Disadvantages of Radiography Health hazard Sensitive to defect orientation Limited ability to detect fine cracks Access to both sides required Limited by material thickness Skilled interpretation required Relatively slow High capital outlay and running costs

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