ME367 NON-DESTRUCTIVE TESTING MODULE-1 Sukesh O P, AP-ME, JECC 10/16/2018 SUKESH O P/ APME/JECC 1

ME357 Non-Destructive Testing 10/16/2018 SUKESH O P/ APME/JECC 2 Introduction to NDT- Visual Inspection- Liquid Penetrant Inspection- Magnetic Particle Inspection- Ultrasonic Testing- Radiography Testing- Eddy Current Testing.

MODULE-1 10/16/2018 SUKESH O P/ APME/JECC 3 Introduction to NDT, Comparison between destructive and NDT, Importance of NDT, Scope of NDT, difficulties of NDT, future progress in NDT, economics aspects of NDT. Visual Inspection - tools, applications and limitations - Fundamentals of visual testing: vision, lighting, material attributes, environmental factors. visual perception, direct and indirect methods mirrors, magnifiers, boroscopes, fibro scopes, closed circuit television, light sources special lighting, a systems, computer enhanced system.

Why are metals tested ?  Ensure quality  Test properties  Prevent failure in use  Make informed choices in using materials Factor of Safety is the ratio comparing the actual stress on a material and the safe useable stress.

Two forms of testing  Mechanical tests – the material may be physically tested to destruction. Will normally specify a value for properties such as strength, hardness, toughness, etc.  Non-destructive tests (NDT) – samples or finished articles are tested before being used.

DESTRUCTIVE TESTING 10/16/2018 SUKESH O P/ APME/JECC 6  In destructive testing, tests are carried out to the specimen’s failure, in order to understand a specimen’s structural performance or material behavior under different loads.  Stress testing Tensile test Compressive test  Impact testing  Hardness testing  Torsion test  Shear test  Creep test  Fatigue test

HARDNESS TESTING Hardness is the ability to withstand indentation or scratches Types :-  Brinell hardness test  Vickers hardness test  Rockwell hardness tests

Hardness testing machine  The indenter is pressed into the metal  Softer materials leave a deeper indentation

Impact Tests  Toughness of metals is the ability to withstand impact.  Types :-  Izod test  Charpy impact test

Tensile Testing  Uses an extensometer to apply measured force to an test specimen. The amount of extension can be measured and graphed.  Variables such as strain, stress, elasticity, tensile strength, ductility and shear strength can be gauged.  Test specimens can be round or flat.

UTM 10/16/2018 SUKESH O P/ APME/JECC 12

Shear and Bending test 10/16/2018 SUKESH O P/ APME/JECC 13 Torsion test

Non Destructive Testing Nondestructive testing (NDT) has been defined as comprising those test methods used to examine an object, material or system without impairing its future usefulness. The term is generally applied to nonmedical investigations of material integrity.

NON-DESTRUCTIVE TESTING- Introduction  Non destructive testing(NDT) is one of the important methods used for evolution and quality control of metal components  During testing, the metal component does not get damaged.  NDT plays a crucial role in everyday life and is necessary to assure safety and reliability.  Typical examples are found in aircraft, spacecraft (shuttle), motor vehicles, pipelines, bridges, trains, power stations, refineries, buildings and oil platforms which are all inspected using NDT. 10/16/2018 SUKESH O P/ APME/JECC 15

NON-DESTRUCTIVE TESTING- Introduction  Non Destructive Testing involves techniques based on application of physical principles employed for purpose of determining characteristics of materials or components and for detecting and assessing inhomogeneity and harmful defects without changing the usefulness of materials or components.  The methods used may be simple or intricate.  It plays a vast role in quality control of finished product.  Skilled judgments and experience is required while performing NDT. SUKESH O P/ APME/JECC 10/16/

Characteristics of NDT  Applied directly to the product  Tested parts are not damaged  Various tests can be performed on the same product  Specimen preparation not required  Can be performed on parts that are in service  Low time consumption  Low labour cost

Types of defects 1. Inherent defect: are formed during the initial production of raw material. Ex: Porosity, cavity, voids etc 2. Processing defect: are formed during the processing of component. Ex: surface and subsurface cracks developing due to mechanical and thermal processing like grinding, heat treatment etc., 3. Service defects : are formed during operating cycle of component. Ex: surface and subsurface cracks due to fatigue, stress corrosion, hydrogen embrittlement, pitting etc

NON-DESTRUCTIVE TESTING- Industrial Use  Inspection of Raw Products – Forgings, Castings, Extrusions.  Inspection following Secondary Processing – Machining, Welding, Grinding, Heat Treatment, Plating.  Inspection for In-Service Damage – Cracking, Corrosion, Erosion/Wear, Heat Damage. SUKESH O P/ APME/JECC 10/16/

10/16/2018 SUKESH O P/ APME/JECC 20 Special equipment's are required No requirement of special equipments

IMPORTANCE of Non-Destructive Testing 10/16/2018 SUKESH O P/ APME/JECC 21 NDT is used typically for the following reasons:  Accident prevention and to reduce costs  To improve product reliability  To determine acceptance to a given requirement  To give information on repair criteria.

SCOPE of Non-destructive Testing These are NDE application at almost any stage in the production or life cycle of a component.  To assist in product development  To screen or sort incoming materials  To monitor, improve or control manufacturing processes  To verify proper processing such as heat treating  To verify proper assembly  To inspect for in-service damage 10/16/2018 SUKESH O P/ APME/JECC 22

ADVANTAGES of Non-Destructive Testing  The equipment's are easy to handle  Defects can be detected without damaging the components  Methods are quick and accurate  Saves time in product evaluation  Surface defects and inside defects can be easily evaluated.  Improves the quality of production  Portable mode of inspection 10/16/2018 SUKESH O P/ APME/JECC 23

DIFFICULTIES of Non-Destructive Testing 10/16/2018 SUKESH O P/ APME/JECC 24  Lack of skilled operators.  Radiation hazards.  Power source required.  High cost of equipment.  Surface must be clean and smooth.  Demagnetization may be needed.

FUTURE PROGRESS in Non-Destructive Testing 10/16/2018 SUKESH O P/ APME/JECC 25  There are two general trends within the NDT community that are influencing development and both centre around the operator. On the one hand, instrumentation is being developed to reduce the operator's involvement as much as possible through automating functions and computerizing results. On the other side there are significant efforts to quantify or standardize the human element through training and qualification.  Second in importance is an increasing demand from users for more precision, more reliability and more speed. As users become more dependent on NDT results, to support extended component life and lower factors of safety, this pressure will increase. Finally the need for specialist technicians as well as applications specialists will grow to cope with the many opportunities being presented.  There is a new factor coming into NDT, which seems likely to bring major modifications to most NDT methods. This is the use of computer techniques, using small computers. Apart from the obvious, rather trivial uses to simplify calculations, it is now possible to collect, store and process vast quantities of digital data at very high speeds.

Types of Non-Destructive Testing Visual Examination Liquid Penetrant Testing Magnetic Particle Testing Eddy Current Testing Radiography Ultrasonic Testing SUKESH O P/ APME/JECC 10/16/

NDT Methods 1. Visual Inspection 2. Liquid penetrant method(Dye penetrant testing) 3. Ultrasonic Inspection 4. Radiography methods X-ray radiography & fluoroscopy γ - ray radiography (gamma ray radiography) 5. Eddy current testing 6. Magnetic particle testing

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Eddy Current Heat Exchanger Tubes SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Magnetic Particle Cable Wires SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Ultrasound Storage Tank Body SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Eddy Current Thin Outer Body of Aircraft SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Fluorescent Penetrant Innumerous Engine Parts SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Magnetic Particle Railway Tracks SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Acoustic Emission Bridge Cables SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Radiography Inner Surface of Pipes SUKESH O P/ APME/JECC 10/16/

APPLICATIONS of NDT Power Plant Inspection Wire Rope Inspection Storage Tank Inspection Aircraft Inspection Jet Engine Inspection Rail Line Inspection Bridge Inspection Pipe Line Inspection Pressure Vessel Inspection NDT Method Used : Radiography Pressure Vessels SUKESH O P/ APME/JECC 10/16/

Reliability Major Factors affecting Reliability :  Size of Defect  type of NDT used  Inspection Environment  Quality of Equipment  Capability of Operator. SUKESH O P/ APME/JECC 10/16/

Market of NDT  Non Destructive Testing Market is estimated to grow at a CAGR of 3.5% to reach the worth $ Million by  Major Revenue Generating Regions – U. S. and Europe.  Latin America and Asia-Pacific are emerging markets.  Brazil, India and China have immense growth potential for NDT. SUKESH O P/ APME/JECC 10/16/

THANK YOU SUKESH O P/ APME/JECC 10/16/

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