IntroductiontoNondestructiveTestingForIPPS Agenda IntroductiontoNDTOverviewofSevenMostCommonNDTMethodsApplications Theuseofnondestructivetechniquestodeterminetheintegrityofamaterial component orstructure Toinspectormeasurewithoutdoingharm DefinitionofNDT MethodsofNDT VisualMagneticParticleX rayLiquidPenetrantUltrasonicEddyCurrentChemicalComposition WhatareSomeUsesofNDTMethods FlawDetectionandEvaluationLeakDetectionLocationDeterminationDimensionalMeasurementsEstimationofMechanicalandPhysicalProperties Fluorescentpenetrantindication WhenareNDTMethodsUsed ToassistinproductdevelopmentToscreenorsortincomingmaterials Tomonitor improveorcontrolmanufacturingprocesses ToverifyproperprocessingsuchasheattreatingToverifyproperassemblyToinspectforin servicedamage ThereareNDTapplicationatalmostanystageintheproductionorlifecycleofacomponent SevenMostCommonNDTMethods VisualLiquidPenetrantMagneticParticleX rayEddyCurrentUltrasonicChemicalComposition Mostbasicandcommoninspectionmethod Toolsincludefiberscopes borescopes magnifyingglassesandmirrors Roboticcrawlerspermitobservationinhazardousortightareas suchasairducts reactors pipelines Portablevideoinspectionunitwithzoomallowsinspectionoflargetanksandvessels railroadtankcars sewerlines VisualInspection Aliquiddyeisappliedtothesurfaceofthepartandallowedtimetoseepintosurfacebreakingdefects Theexcessliquidisremovedfromthesurfaceofthepart Adeveloper powder isappliedtopullthetrappedpenetrantoutthedefectandspreaditonthesurfacewhereitcanbeseen Visualinspectionisthefinalstepintheprocess ThepenetrantusedisoftenloadedwithafluorescentdyeandtheinspectionisdoneunderUVlighttoincreasetestsensitivity LiquidPenetrantInspection MagneticParticleInspection Thepartismagnetized Finelymilledironparticlescoatedwithadyepigmentarethenappliedtothespecimen Theseparticlesareattractedtomagneticfluxleakagefieldsandwillclustertoformanindicationdirectlyoverthediscontinuity Thisindicationcanbevisuallydetectedunderproperlightingconditions MagneticParticleCrackIndications Radiography Theradiationusedinradiographytestingisahigherenergy shorterwavelength versionoftheelectromagneticwavesthatweseeasvisiblelight TheradiationcancomefromanX raygeneratororaradioactivesource FilmRadiography Topviewofdevelopedfilm X rayfilm Thefilmdarkness density willvarywiththeamountofradiationreachingthefilmthroughthetestobject RadiographicImages Conductivematerial Coil EddyCurrentTesting EddyCurrentTesting Eddycurrenttestingisparticularlywellsuitedfordetectingsurfacecracksbutcanalsobeusedtomakeelectricalconductivityandcoatingthicknessmeasurements Hereasmallsurfaceprobeisscannedoverthepartsurfaceinanattempttodetectacrack Highfrequencysoundwavesareintroducedintoamaterialandtheyarereflectedbackfromsurfacesorflaws Reflectedsoundenergyisdisplayedversustime andinspectorcanvisualizeacrosssectionofthespecimenshowingthedepthoffeaturesthatreflectsound f plate crack initialpulse crackecho backsurfaceecho Oscilloscope orflawdetectorscreen UltrasonicInspection Pulse Echo ChemicalCompositionorPositiveMaterialIdentification PMI Opticalemissionsystems OES alsocalledarc spark usesanarcorasparktovaporizethesample excitingtheatomsandionsintoemissionofradiation Thisemittedradiationthenpassesthroughanopticalfiberandisdispersedintoitsspectralcomponents Aphoto multipliertube PMT measurestherangeofwavelengthsemittedx rayfluorescence XRF usesX raysemittedfromanX raytubeoraradioisotopetoexcitetheatomsofthesamplematerial Anelectronisejected causingasecondtofallintoitsvoidandenergyisreleased Adetectorwithintheinstrumentusestheenergyleveltodeterminetheelement CommonApplicationofNDT InspectionofRawMaterialInspectionFollowingSecondaryProcessingIn ServicesDamageInspection InspectionofRawProducts ForgingsCastingsExtrusionsPlate MachiningWeldingGrindingHeattreatingPlating InspectionFollowingSecondaryProcessing CrackingCorrosionErosion WearHeatDamage InspectionForIn ServiceDamage PowerPlantInspection Signalsproducedbyvariousamountsofcorrosionthinning Periodically powerplantsareshutdownforinspection Inspectorsfeededdycurrentprobesintoheatexchangertubestocheckforcorrosiondamage WireRopeInspection Electromagneticdevicesandvisualinspectionsareusedtofindbrokenwiresandotherdamagetothewireropethatisusedinchairlifts cranesandotherliftingdevices StorageTankInspection Roboticcrawlersuseultrasoundtoinspectthewallsoflargeabovegroundtanksforsignsofthinningduetocorrosion Camerasonlongarticulatingarmsareusedtoinspectundergroundstoragetanksfordamage AircraftInspection Nondestructivetestingisusedextensivelyduringthemanufacturingofaircraft NDTisalsousedtofindcracksandcorrosiondamageduringoperationoftheaircraft Afatiguecrackthatstartedatthesiteofalightningstrikeisshownbelow JetEngineInspection Aircraftenginesareoverhauledafterbeinginserviceforaperiodoftime Theyarecompletelydisassembled cleaned inspectedandthenreassembled Fluorescentpenetrantinspectionisusedtocheckmanyofthepartsforcracking SiouxCity Iowa July19 1989 AdefectthatwentundetectedinanenginediskwasresponsibleforthecrashofUnite