SlideShare a Scribd company logo
PRESENTED BY
MOHAMMED ABDUL SHAFEEQ
(M.TECH)
NEED AND DEFINITION
• An industrial product is designed to perform a certain
function
• The user buys it with an expectation that it will perform
the assigned function well and it gives a trouble-free
service for a reasonable period of time
• The level of guarantee or certainity with which a trouble-
free service can be provided by any product may be
termed as its degree of reliability
• The reliability of a machine having a number of
components depends upon the reliability factors of all the
individual components
Continued……
 Reliability comes through improving the quality or quality
level of the products
 A good quality product can therefore be termed as one
which performs it’s assigned function for a reasonable
length of time
 The products which fails to meet this criterion ,their
breakdown occurs unpredictably and earlier than a
specified time called as bad quality products
 The improvement of product quality to bring it to a
reasonable quality level is important in many ways
 It leads to increase in reliability of products and the
safety of machines and equipment
Continued………
 It results in bringing economic returns to the
manufacturer by increasing his production,reducing
scrap levels
 It leads him to enhance his reputation as a producer of
quality goods and hence boosting his sales
 There is therefore a need to have methods by which the
defects in products can be determined without effecting
their serviceability
 A wide variety of test schemes exist,some destructive and
some non-destructive
 Strictly speaking,Non-destructive testing has no clearly
defined boundaries
Continued……
 According to ASTM,Non-destructive testing is the development
and applications of technical methods to examine the material
of components
 That should be in the way such that it do not impair future
usefulness,serviceability in the process of detecting and
locating the discontinuities
 Non-destructive testing plays an important role in the quality
control not only of the finished products,but also of the half
finished products and raw materials
 Non-destructive testing(NDT) is the process of
inspecting,testing materials for discontinuities with out
destroying the serviceability of the part or system
 In other words,when the inspection or test is completed the
part can still be used
Continued……
The destructive tests are often used to determine the
physical properties of materials such as impact
resistance,ductility, ultimate tensile strength…etc
 The non-destructive tests are often used to
determine molecular properties such as
discontinuities,material characteristics..etc
TYPES OF NDT
The most important NDT methods are given below
1.Visual and optical testing
2.Liquid penetrant testing
3.Ultrasonic testing
4.Magnetic particle inspection
5.Eddy current testing
6.Radio graphy
7.Leak testing
• For any product that we want to inspect through NDT, its
internal region is divided into three types, namely
1.Surface region
2.Sub-surface region
3.Interior region
It is shown in the figure below
• The type of test is to be performed is decided on the
basis of the location of the defect
• For surface opening defects, Liquid penetrate test
(LPT) is most commonly used
• For surface defects,Magnetic particle test(MPT)
Ultrasonic test(UT),Radiography test(RT),Eddy
current test(ECT) are used
• For sub-surface defects,MPT,UT,RT,ECT are used
• For interior defects,UT,RT are used
CATEGORIES OF NDT
All the major NDT methods are placed into two
categories,they are
1.ACTIVE TECHNIQUES
2.PASSIVE TECHNIQUES
Continued…..
The active techniques are those where a test medium
is applied to the test specimen and a response is
expected if a flaw is present
The response is then detected by some means and
recorded
Magnetic particle testing,ultra sonic testing, and
radiography fall into this category
Continued…..
Passive techniques are those that monitor the item
during either a typical load environment or a proof
cycle and attempt to determine the presence of defect
This is through some reaction of a specimen
Acoustic emission,Noise analysis,leak testing,visual
examination,and some residual magnetic techniques
are in this classification
VISUAL AND OPTICAL
TESTING(VT)
Visual inspection involves using an inspector’s eyes
to look for defects
 The inspector may also use special tools such as
magnifying glasses,mirrors,borescopes to gain access
and more closely inspect the subject area
 Visual examiners follow procedures that range from
simple to very complex
LIQUID PENETRANT
TESTING
Test objects are coated with visible or flouroscent dye
solution
 Excess dye is then removed from the surface,and a
developer is applied
 The developer acts as a blotter,drawing trapped
penetrant out of imperfections open to the surface
 With visible dyes,colour contrasts between the
penetrant and developer make “bleed out” easy to see
 With flouroscent dyes,Ultra violet light is used to
make the bleedout flouroscence brightly,thus
allowing imperfections to be readily seen
Basic processing steps of
Liquid penetrate testing
1.SURFACE PREPARATION:
The surface must be free of oil,grease,water or other
contaminents
The sample may also require etching if mechanical
operations such as machining,sanding have been
performed
These and other mechanical operations can have
metal over the flaw opening and prevent the
penetrant from entering
Continued………
2.PENETRANT APPLICATION:
• Once the surface has been thoroughly cleaned and
dried,the penetrant material is applied by
spraying,brushing,or immersing the part in a
penetrant bath
Continued……..
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
• The times vary depending upon the application,penetrant
materials used,the material,the form of the material being
inspected,type of defect being inspected for
• Minimum dwell time typically ranges 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
Continued…….
4.EXCESS PENETRANT REMOVAL:
• This is the 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 treating the part with an emulsifier and then
rinsing with water
Continued…….
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)
Continued………
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
• Significantly,longer times may be necessary for tight
cracks
Continued……..
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 this process is to thoroughly clean
the part surface to remove the developer from the
parts that were found to be acceptable
ADVANTAGES OF LIQUID
PENETRATE TESTING:
• This method is highly sensitive to the small surface
discontinuities
• This method has few material limitations i.e. almost all type
of materials can be inspected
• Large areas and large volumes of parts can be inspected
rapidly and at low cost
• Parts with complex geometric shapes are routinely inspected
• Indications are produced directly on the surface of the part
and constitute a visual representation of flaw
• Aerosol spray cans make penetrant materials very portable
• Penetrant materials and associated equipment are relatively
in expensive.
DISADVANTAGES OF LIQUID
PENETRATE TESTING
Only surface breaking defects can be detected
Only materials with a relatively non-porous surface
can be inspected
Precleaning is critical since contaminants can mask
defects
Must have direct access to the surface being
inspected
Surface finish and roughness can affect inspection
sensitivity
Post cleaning of tested materials is required
Chemical handling and proper disposal is required
ULTRA SONIC TESTING
Ultra sonic testing uses high frequency sound energy
to conduct examinations and make measurements
The most commonly used ultrasonic testing
technique is pulse echo,where sound is introduced
into a test object
The reflections(echoes) are returned to a receiver
from internal imperfections
• A typical UT inspection system consists of several
functional units,such as pulse/receiver, transducer,
and display devices
• A pulser/receiver is an electronic device that can
produce high voltage electrical pulses
• Driven by the pulser,the transducer generates high
frequency ultra sonic energy
• The sound energy is introduced and propogates
through the materials in the form of waves
• When there is a discontinuity (such as crack) in the
wave path,part of energy will be reflected back from
the flaw surface
Continued…….
• The reflected wave signal is transformed into an
electrical signal by the transducer and is displayed
on the screen
• The reflected signal strength is displayed versus the
time from signal generation to when an echo was
received
• Signal travel time can be directly related to the
distance that the signal travelled
• From the signal, information about the reflector
location,size,orientation and other features can
sometimes be gained
ADVANTAGES OF UT
• It is sensitive to both surface and sub-surface
discontinuities
• The depth of penetration for flaw detection or
measurement is superior
• Only single-sided access is needed
• Minimal part preparation is required
• Instantaneous results
• It has other uses,such as thickness measurement,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
• Materials that are rough,irregular in shape,very small
exceptionally thin,or not homogeneous are difficult to
inspect
• Linear defects oriented parallel to the sound beam
may go undetected
• Reference standards are required for both equipment
calibration and the characterization of flaws
EDDY CURRENT INSPECTION
(ECI)
• Electrical currents are generated in a conductive
material by an induced alternating magnetic field
• The electrical currents are called as Eddy currents
because they flow in circles at and just below the
surface of the material
• Interruptions in the flow of Eddy currents,caused by
imperfections,dimensional changes,or changes in
material’s conductive and permeability properties.
• It can be detected by proper equipment
Continued……..
BASIC PRINCIPLE:
• Eddy currents are created through a process called
electro magnetic induction
• When an alternating current is applied to the
conductor,such as copper wire,a magnetic field
develops in and around the conductor
• This magnetic field expands as the alternating
current rises to maximum and collapses as the
current is reduced to zero
• If another electrical conductor is brought into the
close proximity to this changing magnetic
field,current will be induced in this second conductor
• Eddy currents are induced electrical currents that
flow in a circular path
ADVANTAGES OF ECI:
• Sensitive to small cracks and other defects
• Detects surface and near surface defects
• Inspection gives immediate results
• Equipment is very portable
• Method can be used for much more than flaw
detection
• Minimum part preparation is required
• Inspects complex shapes and sizes of conductive
materials
DISADVANTAGES OF ECI:
• Only conductive materials can be inspected
• Skill and training required is more extensive than the
other techniques
• Surface finish and roughness may interfere
• Reference standards needed for setup
• Depth of penetration is limited
RADIOGRAPHY(RT)
Radiography involves the use of penetrating gamma
or X-radiation to examine parts and products for
imperfections
An X-ray generator or radio active isotope is used as
a source of radiation
Radiation is directed through a part and onto film or
other imaging media
The resulting shadowgraph shows the dimensional
features of the part
Possible imperfections are indicated as density
changes on the film in the same manner as medical
X-ray shows the broken bones
Continued……
Defective areas such as porosity,cracks,weld
undercut,usually show up darker on the film except
for defects such as excess weld metal,spatter..etc
ADVANTAGES:
• Detects surface and sub-surface defects
• Can be used on a wide variety of materials
• Provides permanent record of the inspection
DISADVANTAGES:
• Safety precautions are required for sage use of
radiation
• Access to both sides of the specimen required
• Orientation of the sample is critical
• Bulky and expensive machinery is required
LEAK TESTING(LT)
• Several techniques are used to detect and locate
leaks in pressure contaminant parts,pressure vessels
and structures
Leaks can be detected by using
• Electronic listening devices
• Pressure gauge measurements
• Liquid and gas penetrant techniques
• A simple soap bubble test
MAGNETIC PARTICLE
INSPECTION(MPI)
• Magnetic particle inspection is fast and relatively
easy to apply and part surface preparation is not as
critical as other NDT methods
• These characteristics make MPI one of the most
widely utilized non-destructive testing methods
• This method is used to inspect a variety of products
such as castings,forgings,and weldments
• Many different industries use magnetic particle
inspection for discovering surface and sub-surface
discontinuities
• Some examples of the industries use this technique
are structural steel,automotive,petrochemical,power
generation,and aerospace industries
HISTORY OF MPI:
Magnetism is the ability of matter to attract other
matter to itself
The ancient greeks were the first to discover this
phenomenon in a mineral they named magnetite.
Later on Bergmann, Becquerel and faraday
discovered that all matter including liquids and gases
were effected by magnetism
The earliest known use of Magnetism to inspect an
object took place as early as 1868
Carron Barrels were checked for defects by
magnetizing the barrel then sliding a magnetic
compass along the barrel’s length
Continued……..
• These early inspectors were able to locate flaws in the
barrels by monitoring the needle of the compass
• This was a form of non-destructive-testing but the
term was not commonly used untill sometime after
world war-1
• In the early 1920’s,William hoke realized that
magnetic particles(coloured metal shavings)could be
used with magnetism as a means of locating defects
• Hoke discovered that a surface or sub-surface flaw in
a magnetized material caused the magnetic field to
distort and extend beyond the part
• This discovery was brought to his attention in the
machine shop
Continued……..
 He noticed that the metallic grindings from hard steel
parts(held by a magnetic chuck while being ground) formed
patterns on the face of the parts
 They corresponded to the cracks in the surface
 Applying a fine ferro magnetic powder to the parts caused a
build up of powder over flaws and formed a visible indication
 In the early 1930’s,magnetic particle inspection was quickly
replacing the oil-and-whiting method(an early form of the
liquid penetrant inspection)
 It is the method of choice by the railroad industry to inspect
steam engine boilers,wheels,axles and tracks
 Today,the MPI inspection method is used extensively to check
for flaws in a large variety of manufactured materials and
components
BASIC CONCEPTS OF
MAGNETISM
MAGNETIC FIELD: It simply describes a volume of
space where there is a change in energy within that
volume.This change can be detected and measured
MAGNETIC POLE:The location where a magnetic
field can be detected exiting or entering a material is
called a magnetic pole
POLE:The point in a bar magnet where the maximum
magnetic force exists is called pole
DIPOLE:The existence of two unlike poles in a single
material is called dipole
NORTH POLE:The pole in a bar magnet where the
lines of force exits is called north pole
Continued……..
SOUTH POLE:The pole in a bar magnet where the
lines of force enters is called south pole
MAGNETIC FLUX:Magnetic flux is the imaginary
lines of force associated with the defined area.It’s
units are weber
MAGNETIC FLUX DENSITY:The number of magnetic
lines of force cutting through a plane of a given area
at a right angle is known as the magnetic flux
density(B). It has tesla as it’s unit
MAGNETIC PERMEABILITY:The degree of magneti-
zation of a substance in a given magnetic field
It is defined as the ratio of magnetic flux density(B)
to magnetic field strength(H)
Continued…….
It is defined in other words as the ability of the
material to allow the magnetic line of force to pass
through it
MAGNETIC SUSCEPTIBILITY:It is a dimensionless
proportionality constant that indicates the degree of
magnetization of a material in response to applied
magnetic field.
It is denoted by “X”
PROPERTIES OF MAGNETIC LINES OF FORCE:
• The magnetic lines seek the path of least resistance
between opposite magnetic poles.In a single bar
magnet they attempt to form closed loop from pole to
pole
Continued…….
They never cross one another
They all have the same strength
Their density decreases(they spread out)when they
move from an area of higher permeability to an area
of lower permeability
Their density decreases with increasing distance from
the poles
They are considered to have direction as if
flowing,though no actual movement occurs.they flow
from the south pole to the north pole within the
material and north pole to south pole in air
TYPES OF MAGNETIC
MATERIALS
Magnetic materials are divided into three types based
up on their behaviour in the magnetic field,they are
Dia magnetic material
Para magnetic material
Ferro magnetic material
DIA MAGNETIC MATERIAL:
• Materials have a weak and negative susceptibility to
magnetic fields
• They are slightly repelled by a magnetic field and
does not retain the magnetic properties when the
external field is removed
• Examples:copper,silver,gold
Continued…….
PARAMAGNETIC MATERIALS:
• Materials have a small and positive susceptibility to
magnetic fields
• These materials are slightly attracted by a magnetic
field
• These materials does not retain magnetic properties
when the external field is removed
• Examples:magnesium,molybdenum,lithium,..etc
FERROMAGNETIC MATERIALS:
• Materials have a large and positive susceptibility to
an external magnetic field
• They exhibit a strong attraction to magnetic fields
and are able to retain their magnetic properties after
the external field is removed
Continued……….
 Ferro magnetic materials get their magnetic
properties not only because their atoms carry a
magnetic moment,but also because the material is
made up of small regions known as magnetic
domains
 In non-magnetized state,the domains are nearly
randomly organized and in magnetized state,the
domains are alligned as shown in figure
Example:iron,cobalt,nickel
PRINCIPLE INVOLVED UNDER
ELECTRO MAGNETIC
MAGNETIZATION:
Electric field is always accompanied with magnetic
field
The flemings rules tell how the electric field and
magnetic field accompanied with each other
Fleming gives two rules—1.Fleming’s left hand rule
2.Fleming’s right hand rule
FLEMING’S LEFT HAND RULE:
• It is used for electric motors
• The left hand is held with the thumb,index finger,and
middle finger mutually at right angles
• The fore finger represents the direction of the
magnetic field(north to south)
Continued……….
The middle finger represents the direction of the
conventional current(from positive to negative)
The thumb represents the direction of force or
resultant motion
Continued……..
FLEMING’S RIGHT HAND RULE:
• It is used for generators
• It shows the direction of induced current flow when a
conductor moves in magnetic field
• The right hand is held with the thumb,fore
finger,middle finger mutually perpendicular to each
other
• The thumb represents the direction of motion of the
conductor
• The fore finger represents the direction of magnetic
field (north to south)
• The middle finger represents the direction of induced
current(positive to negative)
Continued………
Whenever a current carrying conductor comes under
magnetic field naturally,there will be force acting on
the conductor,In this situation,the relationship
between magnetic field,current,force will be explained
by fleming’s left hand rule
Whenever the current carrying conductor is forcefully
brought under magnetic field,the relationship
between magnetic field,induced current,force will be
given by fleming’s right hand rule
HYSTERESIS LOOP
By studying this hysteresis loop,we can learn about
the magnetic properties of the material
This loop shows relationship between the induced
magnetic flux density(B)and the magnetizing force(H)
The loop is generated by measuring the magnetic flux
(B) of a ferromagnetic material while the magnetizing
force(H) is changed
Continued………
RETENTIVITY:It is a material’s ability to retain a
certain amount of residual magnetic field when the
magnetizing force is removed after achieving
saturation
COERCIVE FORCE:The amount of reverse magnetic
field which must be applied to a magnetic material to
make the magnetic flux return to zero
Relative to the other material,the materials with
the wide hysteresis loop has:
• Lower permeability
• Higher retentivity
• Higher coercivity
• Higher reluctance
• Higher residual magnetism
Continued……
The material with the narrower loop has:
• Higher permeability
• Lower retentivity
• Lower coercivity
• Lower reluctance
• Lower residual magnetism
• In magnetic particle inspection,the level of residual
magnetism is important
• Residual magnetic fields are effected by the
permeability, which can be related to the carbon
content and alloying of the material
• A component with high carbon content will have low
permeability and will retain more magnetic flux than
a material with low carbon content
BASIC PRINCIPLE OF MPI
 The main principle behind this magnetic particle
inspection is MAGNETIC FLUX LEAKAGE
 If we break the bar magnet into the centre will result
two bar magnets with north and south poles on each
end of the magnets
 If the magnet is just cracked but not broken into two
pieces,a north and south pole will form at each edge
of the crack
 The magnetic field exits the north pole and re-enters
the south pole.
 The magnetic fields spreads out when it encounter
the small air gap created by the crack because the air
cannot support as much magnetic field per unit
volume as magnet can
Continued…….
When the field spreads out,it appears to leak out of
the material and,thus,it is called a flux leakage field
If iron particles are sprinkled on a cracked
magnet,the particles will be attracted and cluster not
only at the poles at the ends of the magnet but also
at the poles at the edges of the crack
This cluster of particles is much easier to see than
the actual crack and this is the basis for MPI.
PROCESS TO CONDUCT MPI:
The entire process is carried out in 8 steps,they are:
1.Surface preparation
2.Surface cleaning
3.Magnetize the test specimen
4.Magnetic particle application
5.Excess magnetic particle removal
6.Indication,identification and marking
7.De-magnetization
8.Report writing and evaluation
Continued……
 Surface preparation: Surface should be prepared in
such a way it should be useful for testing by this
method.Grinding operation should be done to obtain
the surface neatly
 Surface cleaning: As in liquid penetration
test,surface should be cleaned neatly such that no
impurities should be present on the surface
Solvent remover should be used for cleaning the
surface
• Magnetization of specimen: Two general types of
magnetic fields are introduced into the specimen.they
are:
1.Longitudinal magnetization
2.Circular magnetization
Continued……..
A longitudinal magnetic field has magnetic lines of
force that run parallel to the long axis of the part
A Circular magnetic field has magnetic lines of force
that run circumferentially around the perimeter of
the part
Methods of magnetization:There are two methods
of magnetization, they are
1.Direct magnetization
2.Indirect magnetization
Direct magnetization:Current is directly passed
through the component.This is done through
i)Head shot method
ii)Prod method
Continued……
Indirect magnetization: It is accomplished by using a
strong external magnetic field to establish a magnetic
field within the component.This is done through
1.Electromagnetic yoke method
2.Central conductor method
HEAD SHOT METHOD PROD METHOD
Continued…..
YOKE METHOD CENTRAL CONDUCTOR
METHOD
Continued…….
MAGNETIC PARTICLE APPLICATION:
Two types of magnetic particles are applied, they are
1.Dry particles
2.Wet particles
• Dry particles are generally used for inspection on
rough surfaces
• Wet inspections are generally considered as best for
detecting very small discontinuities on smooth
surfaces
• Black contrast and white contrasts are used for
identifying discontinuities in wet particle method
Continued……
DRY PARTICLES
WET PARTICLES
Continued…….
EXCESS PARTICLE REMOVAL: Excess particles
should be removed for clear identification of defects
INDICATION,IDENTIFICATION AND MARKING:
1.The direction of magnetic field is identified by using
pie guage
2.Field indicator,hall-effect meter are used to measure
the strength of the magnetic field
3.Defects are identified and they are marked
FIELD INDICATOR
Continued…..
PIE GUAGE
HALL EFFECT METER
Continued……
• DEMAGNETIZATION:De-magnetization is commonly
done in two ways
1.Hammering
2.Reverse magnetization
• REPORT WRITING AND EVALUATION:
A report is made based on the results obtained after
conducting the test.
Based on that report, the product will be judged whether it
will be useful for future use or not
This is the entire process of MPI
ADVANTAGES OF MPI:
Easy to handle equipment
Longitudinal magnetization machines are portable
It is not limited by the size and shape of the
specimen being tested.small tanks to large cranes
can be inspected using this method
Cost is inexpensive when compared to UT and RT
DISADVANTAGES:
• It can be applied to only ferro-magnetic materials
• More consumption of electricity
• We can identify only surface and sub-surface defects
• Safety is needed
ANALYSIS OF MY MPT TEST
 WORK PIECE:Work piece is the weldment of two
mild steel plates of dimensions 250mm X 120mm X
12 mm each.
 Weldment is a V-butt joint joined with solid metal arc
welding process
MY WORKPIECE
Continued…….
• METHOD OF MAGNETIZATION:The method I used
is Electromagnetic yoke method with direct current
• Reason to adopt this method is yoke is portable and
is applicable here as a laboratory purpose
• Prod machine serves the same purpose but with the
high voltage of 2000V which can be used only for the
inspection of huge components in industry
• As the weight of work piece is 7 kgs, AC cannot be
used because AC can bear only upto 4.5 kgs where
as DC can hold 18 kgs
Continued……..
Continued……..
 CALIBRATION:Calibration is performed in order to
check the performance of the electromagnetic yoke
machine.
 It is conducted on the ASTM test block which
consists of holes at standard distances and depths
 Correct indication of defects in the block is the
indication that the electromagnetic yoke is in perfect
condition
 The calibration is done….the yoke used here is in
perfect condition
Continued…..
• YOKE CALIBRATION AND LIMITATIONS:
• LIFTING CAPACITY:
FOR AC-4.5 KG
FOR DC-18.1KG
• SENSITIVITY CHECK:
AC-1MM
DC-5MM
• Can check defects upto depth of 6 mm
theoretically….
MY REPORT:
TRANSVERSE CRACKS
SPATTERS
WELD DEFECTS FOUND USING DRY MAGNETIC PARTICLES
UNDERCUT
CONCLUSION:
• SPATTERS: Occurred due to disturbance in the
molten weld pool during the transfer of wire into the
weld,typically caused by voltage being too low or
amperage being too high
• UNDERCUT: Occurred because of melting of parent
metal because of high arc during welding and so the
fusion of weld is improper at the toe of the weld
• CRACKS:The crack here in the weld is found
because of difference in travel speed or
current.Also,pressure applied on electrode during
welding may be the cause for the formation of crack
Continued……
EVALUATION:
• Sputters can be removed by careful grinding on the
surface but undercut and crack here obtained cannot
be rectified
• If it is in the industry as the components are huge
castings they are grounded to the depth of defect and
the crack is filled by welding
• Applications of high stresses results in more
cracks.More the number of defects,ability of the
material to with stand loads is less
• In the weld portion,if cracks or undercuts are found,
then the component is not considered for further use
REFERENCES:
 TYPES OF WELD:
http://mechanicalinventions.blogspot.in/2014/10/differ
ent-types-of-welding-defects.html
 TYPES OF JOINTS:
http://www.ateliersbg.com/news/the-5-types-of-basic-
welding- joints.aspx
 TYPES OF WELDING:
http://engineeringhut.blogspot.in/2010/11/welding-
and-its-classification.html
 BASICS OF NDT: https://www.nde-
ed.org/EducationResources/CommunityCollege/MagPa
rticle/TestingPractices/Dry%20Particle.htm
 MPT:
http://mech.vub.ac.be/teaching/info/Damage_testing_
prevention_and_detection_in_aeronautics/PDF/magne
tic.pdf
Non destructive testing of materials
THANK YOU

More Related Content

PPTX
Presentation on Dye Penetrant Testing
PPT
Introduction to NDT and Visual Inspection
PPT
Presentation on non destructive testing
PPT
Non Destructive Testing
PPT
Non Destructive Testing Of Materials
PPTX
Non Destructive Testing
PPTX
Nondestructive Testing (NDT)
PDF
Introduction to Non Destructive Testing
Presentation on Dye Penetrant Testing
Introduction to NDT and Visual Inspection
Presentation on non destructive testing
Non Destructive Testing
Non Destructive Testing Of Materials
Non Destructive Testing
Nondestructive Testing (NDT)
Introduction to Non Destructive Testing

What's hot (20)

PPTX
Non destructive testing ppt
PPTX
Dye penetrant inspection .....NDT
PPTX
LIQUID PENETRANT INSPECTION
PPTX
Ultrasonic testing
PPT
non destructive testing
PPTX
Non-destructive Testing
PDF
Penetrant testing
PPTX
Presentation on ndt
PDF
Non Destructive Testing (NDT)
PPTX
non-destructive testing ppt
PPTX
Ultasonic testing
PDF
Non destructive testing basics
PDF
Thermographic Nondestructive Testing (NDT)
PPTX
L9 visual inspection
PPTX
Ndt visual inspection
PPT
NDT presentation
PPTX
Liquid penetrant testing
PDF
Liquid Penetrant Inspection (LPI)- NDT
PPT
Acoustic Emission (AE) Testing
PPTX
VISUAL INSPECTION.pptx
Non destructive testing ppt
Dye penetrant inspection .....NDT
LIQUID PENETRANT INSPECTION
Ultrasonic testing
non destructive testing
Non-destructive Testing
Penetrant testing
Presentation on ndt
Non Destructive Testing (NDT)
non-destructive testing ppt
Ultasonic testing
Non destructive testing basics
Thermographic Nondestructive Testing (NDT)
L9 visual inspection
Ndt visual inspection
NDT presentation
Liquid penetrant testing
Liquid Penetrant Inspection (LPI)- NDT
Acoustic Emission (AE) Testing
VISUAL INSPECTION.pptx
Ad

Similar to Non destructive testing of materials (20)

PPTX
Non destructive testing]
PPTX
OML 751 UNIT 3.pptx
PPTX
Non Destructive Testing methods
PDF
NDT Method.pdf
PPTX
ndt grp8..pptx
PDF
NON DESTRUCTIVE TESTING
PPTX
liquid penetrant test and ultrasonic test
PPTX
Nondestructive test
PPT
Introduction to Non-Destructive Testings
PPTX
Non destructive testing
PPTX
Basic NDT Training. Phased Array Ultrasonic
PPTX
Non destructive evaluation
PDF
Non destructive testing (ndt)
PPT
Presentation on Non Destructive Testing.
DOCX
Non destructive testing
PPTX
Destructive & Non Destructive Testing Of Materials
PPTX
DT N NDT.pptx non destructive methods on ce
PPTX
LIQUID PENETRANT AND MAGNETIC PARTICLE INSPECTION
Non destructive testing]
OML 751 UNIT 3.pptx
Non Destructive Testing methods
NDT Method.pdf
ndt grp8..pptx
NON DESTRUCTIVE TESTING
liquid penetrant test and ultrasonic test
Nondestructive test
Introduction to Non-Destructive Testings
Non destructive testing
Basic NDT Training. Phased Array Ultrasonic
Non destructive evaluation
Non destructive testing (ndt)
Presentation on Non Destructive Testing.
Non destructive testing
Destructive & Non Destructive Testing Of Materials
DT N NDT.pptx non destructive methods on ce
LIQUID PENETRANT AND MAGNETIC PARTICLE INSPECTION
Ad

Recently uploaded (20)

PPTX
web development for engineering and engineering
PPTX
Construction Project Organization Group 2.pptx
PPT
Project quality management in manufacturing
PPTX
Geodesy 1.pptx...............................................
PPTX
UNIT-1 - COAL BASED THERMAL POWER PLANTS
PPTX
Sustainable Sites - Green Building Construction
PPTX
MET 305 2019 SCHEME MODULE 2 COMPLETE.pptx
PDF
Automation-in-Manufacturing-Chapter-Introduction.pdf
PDF
Unit I ESSENTIAL OF DIGITAL MARKETING.pdf
PDF
Digital Logic Computer Design lecture notes
PDF
Well-logging-methods_new................
PDF
R24 SURVEYING LAB MANUAL for civil enggi
PDF
TFEC-4-2020-Design-Guide-for-Timber-Roof-Trusses.pdf
PPTX
Foundation to blockchain - A guide to Blockchain Tech
PPTX
Infosys Presentation by1.Riyan Bagwan 2.Samadhan Naiknavare 3.Gaurav Shinde 4...
PDF
The CXO Playbook 2025 – Future-Ready Strategies for C-Suite Leaders Cerebrai...
PPT
Mechanical Engineering MATERIALS Selection
PPTX
bas. eng. economics group 4 presentation 1.pptx
PPTX
CYBER-CRIMES AND SECURITY A guide to understanding
PDF
Mitigating Risks through Effective Management for Enhancing Organizational Pe...
web development for engineering and engineering
Construction Project Organization Group 2.pptx
Project quality management in manufacturing
Geodesy 1.pptx...............................................
UNIT-1 - COAL BASED THERMAL POWER PLANTS
Sustainable Sites - Green Building Construction
MET 305 2019 SCHEME MODULE 2 COMPLETE.pptx
Automation-in-Manufacturing-Chapter-Introduction.pdf
Unit I ESSENTIAL OF DIGITAL MARKETING.pdf
Digital Logic Computer Design lecture notes
Well-logging-methods_new................
R24 SURVEYING LAB MANUAL for civil enggi
TFEC-4-2020-Design-Guide-for-Timber-Roof-Trusses.pdf
Foundation to blockchain - A guide to Blockchain Tech
Infosys Presentation by1.Riyan Bagwan 2.Samadhan Naiknavare 3.Gaurav Shinde 4...
The CXO Playbook 2025 – Future-Ready Strategies for C-Suite Leaders Cerebrai...
Mechanical Engineering MATERIALS Selection
bas. eng. economics group 4 presentation 1.pptx
CYBER-CRIMES AND SECURITY A guide to understanding
Mitigating Risks through Effective Management for Enhancing Organizational Pe...

Non destructive testing of materials

  • 1. PRESENTED BY MOHAMMED ABDUL SHAFEEQ (M.TECH)
  • 2. NEED AND DEFINITION • An industrial product is designed to perform a certain function • The user buys it with an expectation that it will perform the assigned function well and it gives a trouble-free service for a reasonable period of time • The level of guarantee or certainity with which a trouble- free service can be provided by any product may be termed as its degree of reliability • The reliability of a machine having a number of components depends upon the reliability factors of all the individual components
  • 3. Continued……  Reliability comes through improving the quality or quality level of the products  A good quality product can therefore be termed as one which performs it’s assigned function for a reasonable length of time  The products which fails to meet this criterion ,their breakdown occurs unpredictably and earlier than a specified time called as bad quality products  The improvement of product quality to bring it to a reasonable quality level is important in many ways  It leads to increase in reliability of products and the safety of machines and equipment
  • 4. Continued………  It results in bringing economic returns to the manufacturer by increasing his production,reducing scrap levels  It leads him to enhance his reputation as a producer of quality goods and hence boosting his sales  There is therefore a need to have methods by which the defects in products can be determined without effecting their serviceability  A wide variety of test schemes exist,some destructive and some non-destructive  Strictly speaking,Non-destructive testing has no clearly defined boundaries
  • 5. Continued……  According to ASTM,Non-destructive testing is the development and applications of technical methods to examine the material of components  That should be in the way such that it do not impair future usefulness,serviceability in the process of detecting and locating the discontinuities  Non-destructive testing plays an important role in the quality control not only of the finished products,but also of the half finished products and raw materials  Non-destructive testing(NDT) is the process of inspecting,testing materials for discontinuities with out destroying the serviceability of the part or system  In other words,when the inspection or test is completed the part can still be used
  • 6. Continued…… The destructive tests are often used to determine the physical properties of materials such as impact resistance,ductility, ultimate tensile strength…etc  The non-destructive tests are often used to determine molecular properties such as discontinuities,material characteristics..etc
  • 7. TYPES OF NDT The most important NDT methods are given below 1.Visual and optical testing 2.Liquid penetrant testing 3.Ultrasonic testing 4.Magnetic particle inspection 5.Eddy current testing 6.Radio graphy 7.Leak testing
  • 8. • For any product that we want to inspect through NDT, its internal region is divided into three types, namely 1.Surface region 2.Sub-surface region 3.Interior region It is shown in the figure below
  • 9. • The type of test is to be performed is decided on the basis of the location of the defect • For surface opening defects, Liquid penetrate test (LPT) is most commonly used • For surface defects,Magnetic particle test(MPT) Ultrasonic test(UT),Radiography test(RT),Eddy current test(ECT) are used • For sub-surface defects,MPT,UT,RT,ECT are used • For interior defects,UT,RT are used
  • 10. CATEGORIES OF NDT All the major NDT methods are placed into two categories,they are 1.ACTIVE TECHNIQUES 2.PASSIVE TECHNIQUES
  • 11. Continued….. The active techniques are those where a test medium is applied to the test specimen and a response is expected if a flaw is present The response is then detected by some means and recorded Magnetic particle testing,ultra sonic testing, and radiography fall into this category
  • 12. Continued….. Passive techniques are those that monitor the item during either a typical load environment or a proof cycle and attempt to determine the presence of defect This is through some reaction of a specimen Acoustic emission,Noise analysis,leak testing,visual examination,and some residual magnetic techniques are in this classification
  • 13. VISUAL AND OPTICAL TESTING(VT) Visual inspection involves using an inspector’s eyes to look for defects  The inspector may also use special tools such as magnifying glasses,mirrors,borescopes to gain access and more closely inspect the subject area  Visual examiners follow procedures that range from simple to very complex
  • 14. LIQUID PENETRANT TESTING Test objects are coated with visible or flouroscent dye solution  Excess dye is then removed from the surface,and a developer is applied  The developer acts as a blotter,drawing trapped penetrant out of imperfections open to the surface  With visible dyes,colour contrasts between the penetrant and developer make “bleed out” easy to see  With flouroscent dyes,Ultra violet light is used to make the bleedout flouroscence brightly,thus allowing imperfections to be readily seen
  • 15. Basic processing steps of Liquid penetrate testing 1.SURFACE PREPARATION: The surface must be free of oil,grease,water or other contaminents The sample may also require etching if mechanical operations such as machining,sanding have been performed These and other mechanical operations can have metal over the flaw opening and prevent the penetrant from entering
  • 16. Continued……… 2.PENETRANT APPLICATION: • Once the surface has been thoroughly cleaned and dried,the penetrant material is applied by spraying,brushing,or immersing the part in a penetrant bath
  • 17. Continued…….. 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 • The times vary depending upon the application,penetrant materials used,the material,the form of the material being inspected,type of defect being inspected for • Minimum dwell time typically ranges 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
  • 18. Continued……. 4.EXCESS PENETRANT REMOVAL: • This is the 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 treating the part with an emulsifier and then rinsing with water
  • 19. Continued……. 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)
  • 20. Continued……… 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 • Significantly,longer times may be necessary for tight cracks
  • 21. Continued…….. 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 this process is to thoroughly clean the part surface to remove the developer from the parts that were found to be acceptable
  • 22. ADVANTAGES OF LIQUID PENETRATE TESTING: • This method is highly sensitive to the small surface discontinuities • This method has few material limitations i.e. almost all type of materials can be inspected • Large areas and large volumes of parts can be inspected rapidly and at low cost • Parts with complex geometric shapes are routinely inspected • Indications are produced directly on the surface of the part and constitute a visual representation of flaw • Aerosol spray cans make penetrant materials very portable • Penetrant materials and associated equipment are relatively in expensive.
  • 23. DISADVANTAGES OF LIQUID PENETRATE TESTING Only surface breaking defects can be detected Only materials with a relatively non-porous surface can be inspected Precleaning is critical since contaminants can mask defects Must have direct access to the surface being inspected Surface finish and roughness can affect inspection sensitivity Post cleaning of tested materials is required Chemical handling and proper disposal is required
  • 24. ULTRA SONIC TESTING Ultra sonic testing uses high frequency sound energy to conduct examinations and make measurements The most commonly used ultrasonic testing technique is pulse echo,where sound is introduced into a test object The reflections(echoes) are returned to a receiver from internal imperfections
  • 25. • A typical UT inspection system consists of several functional units,such as pulse/receiver, transducer, and display devices • A pulser/receiver is an electronic device that can produce high voltage electrical pulses • Driven by the pulser,the transducer generates high frequency ultra sonic energy • The sound energy is introduced and propogates through the materials in the form of waves • When there is a discontinuity (such as crack) in the wave path,part of energy will be reflected back from the flaw surface
  • 26. Continued……. • The reflected wave signal is transformed into an electrical signal by the transducer and is displayed on the screen • The reflected signal strength is displayed versus the time from signal generation to when an echo was received • Signal travel time can be directly related to the distance that the signal travelled • From the signal, information about the reflector location,size,orientation and other features can sometimes be gained
  • 27. ADVANTAGES OF UT • It is sensitive to both surface and sub-surface discontinuities • The depth of penetration for flaw detection or measurement is superior • Only single-sided access is needed • Minimal part preparation is required • Instantaneous results • It has other uses,such as thickness measurement,in addition to flaw detection
  • 28. DISADVANTAGES OF UT • Surface must be accessible to transmit ultrasound • Skill and training is more extensive than with some other methods • Materials that are rough,irregular in shape,very small exceptionally thin,or not homogeneous are difficult to inspect • Linear defects oriented parallel to the sound beam may go undetected • Reference standards are required for both equipment calibration and the characterization of flaws
  • 29. EDDY CURRENT INSPECTION (ECI) • Electrical currents are generated in a conductive material by an induced alternating magnetic field • The electrical currents are called as Eddy currents because they flow in circles at and just below the surface of the material • Interruptions in the flow of Eddy currents,caused by imperfections,dimensional changes,or changes in material’s conductive and permeability properties. • It can be detected by proper equipment
  • 30. Continued…….. BASIC PRINCIPLE: • Eddy currents are created through a process called electro magnetic induction • When an alternating current is applied to the conductor,such as copper wire,a magnetic field develops in and around the conductor • This magnetic field expands as the alternating current rises to maximum and collapses as the current is reduced to zero
  • 31. • If another electrical conductor is brought into the close proximity to this changing magnetic field,current will be induced in this second conductor • Eddy currents are induced electrical currents that flow in a circular path
  • 32. ADVANTAGES OF ECI: • Sensitive to small cracks and other defects • Detects surface and near surface defects • Inspection gives immediate results • Equipment is very portable • Method can be used for much more than flaw detection • Minimum part preparation is required • Inspects complex shapes and sizes of conductive materials
  • 33. DISADVANTAGES OF ECI: • Only conductive materials can be inspected • Skill and training required is more extensive than the other techniques • Surface finish and roughness may interfere • Reference standards needed for setup • Depth of penetration is limited
  • 34. RADIOGRAPHY(RT) Radiography involves the use of penetrating gamma or X-radiation to examine parts and products for imperfections An X-ray generator or radio active isotope is used as a source of radiation Radiation is directed through a part and onto film or other imaging media The resulting shadowgraph shows the dimensional features of the part Possible imperfections are indicated as density changes on the film in the same manner as medical X-ray shows the broken bones
  • 35. Continued…… Defective areas such as porosity,cracks,weld undercut,usually show up darker on the film except for defects such as excess weld metal,spatter..etc ADVANTAGES: • Detects surface and sub-surface defects • Can be used on a wide variety of materials • Provides permanent record of the inspection DISADVANTAGES: • Safety precautions are required for sage use of radiation • Access to both sides of the specimen required • Orientation of the sample is critical • Bulky and expensive machinery is required
  • 36. LEAK TESTING(LT) • Several techniques are used to detect and locate leaks in pressure contaminant parts,pressure vessels and structures Leaks can be detected by using • Electronic listening devices • Pressure gauge measurements • Liquid and gas penetrant techniques • A simple soap bubble test
  • 37. MAGNETIC PARTICLE INSPECTION(MPI) • Magnetic particle inspection is fast and relatively easy to apply and part surface preparation is not as critical as other NDT methods • These characteristics make MPI one of the most widely utilized non-destructive testing methods • This method is used to inspect a variety of products such as castings,forgings,and weldments • Many different industries use magnetic particle inspection for discovering surface and sub-surface discontinuities • Some examples of the industries use this technique are structural steel,automotive,petrochemical,power generation,and aerospace industries
  • 38. HISTORY OF MPI: Magnetism is the ability of matter to attract other matter to itself The ancient greeks were the first to discover this phenomenon in a mineral they named magnetite. Later on Bergmann, Becquerel and faraday discovered that all matter including liquids and gases were effected by magnetism The earliest known use of Magnetism to inspect an object took place as early as 1868 Carron Barrels were checked for defects by magnetizing the barrel then sliding a magnetic compass along the barrel’s length
  • 39. Continued…….. • These early inspectors were able to locate flaws in the barrels by monitoring the needle of the compass • This was a form of non-destructive-testing but the term was not commonly used untill sometime after world war-1 • In the early 1920’s,William hoke realized that magnetic particles(coloured metal shavings)could be used with magnetism as a means of locating defects • Hoke discovered that a surface or sub-surface flaw in a magnetized material caused the magnetic field to distort and extend beyond the part • This discovery was brought to his attention in the machine shop
  • 40. Continued……..  He noticed that the metallic grindings from hard steel parts(held by a magnetic chuck while being ground) formed patterns on the face of the parts  They corresponded to the cracks in the surface  Applying a fine ferro magnetic powder to the parts caused a build up of powder over flaws and formed a visible indication  In the early 1930’s,magnetic particle inspection was quickly replacing the oil-and-whiting method(an early form of the liquid penetrant inspection)  It is the method of choice by the railroad industry to inspect steam engine boilers,wheels,axles and tracks  Today,the MPI inspection method is used extensively to check for flaws in a large variety of manufactured materials and components
  • 41. BASIC CONCEPTS OF MAGNETISM MAGNETIC FIELD: It simply describes a volume of space where there is a change in energy within that volume.This change can be detected and measured MAGNETIC POLE:The location where a magnetic field can be detected exiting or entering a material is called a magnetic pole POLE:The point in a bar magnet where the maximum magnetic force exists is called pole DIPOLE:The existence of two unlike poles in a single material is called dipole NORTH POLE:The pole in a bar magnet where the lines of force exits is called north pole
  • 42. Continued…….. SOUTH POLE:The pole in a bar magnet where the lines of force enters is called south pole MAGNETIC FLUX:Magnetic flux is the imaginary lines of force associated with the defined area.It’s units are weber MAGNETIC FLUX DENSITY:The number of magnetic lines of force cutting through a plane of a given area at a right angle is known as the magnetic flux density(B). It has tesla as it’s unit MAGNETIC PERMEABILITY:The degree of magneti- zation of a substance in a given magnetic field It is defined as the ratio of magnetic flux density(B) to magnetic field strength(H)
  • 43. Continued……. It is defined in other words as the ability of the material to allow the magnetic line of force to pass through it MAGNETIC SUSCEPTIBILITY:It is a dimensionless proportionality constant that indicates the degree of magnetization of a material in response to applied magnetic field. It is denoted by “X” PROPERTIES OF MAGNETIC LINES OF FORCE: • The magnetic lines seek the path of least resistance between opposite magnetic poles.In a single bar magnet they attempt to form closed loop from pole to pole
  • 44. Continued……. They never cross one another They all have the same strength Their density decreases(they spread out)when they move from an area of higher permeability to an area of lower permeability Their density decreases with increasing distance from the poles They are considered to have direction as if flowing,though no actual movement occurs.they flow from the south pole to the north pole within the material and north pole to south pole in air
  • 45. TYPES OF MAGNETIC MATERIALS Magnetic materials are divided into three types based up on their behaviour in the magnetic field,they are Dia magnetic material Para magnetic material Ferro magnetic material DIA MAGNETIC MATERIAL: • Materials have a weak and negative susceptibility to magnetic fields • They are slightly repelled by a magnetic field and does not retain the magnetic properties when the external field is removed • Examples:copper,silver,gold
  • 46. Continued……. PARAMAGNETIC MATERIALS: • Materials have a small and positive susceptibility to magnetic fields • These materials are slightly attracted by a magnetic field • These materials does not retain magnetic properties when the external field is removed • Examples:magnesium,molybdenum,lithium,..etc FERROMAGNETIC MATERIALS: • Materials have a large and positive susceptibility to an external magnetic field • They exhibit a strong attraction to magnetic fields and are able to retain their magnetic properties after the external field is removed
  • 47. Continued……….  Ferro magnetic materials get their magnetic properties not only because their atoms carry a magnetic moment,but also because the material is made up of small regions known as magnetic domains  In non-magnetized state,the domains are nearly randomly organized and in magnetized state,the domains are alligned as shown in figure Example:iron,cobalt,nickel
  • 48. PRINCIPLE INVOLVED UNDER ELECTRO MAGNETIC MAGNETIZATION: Electric field is always accompanied with magnetic field The flemings rules tell how the electric field and magnetic field accompanied with each other Fleming gives two rules—1.Fleming’s left hand rule 2.Fleming’s right hand rule FLEMING’S LEFT HAND RULE: • It is used for electric motors • The left hand is held with the thumb,index finger,and middle finger mutually at right angles • The fore finger represents the direction of the magnetic field(north to south)
  • 49. Continued………. The middle finger represents the direction of the conventional current(from positive to negative) The thumb represents the direction of force or resultant motion
  • 50. Continued…….. FLEMING’S RIGHT HAND RULE: • It is used for generators • It shows the direction of induced current flow when a conductor moves in magnetic field • The right hand is held with the thumb,fore finger,middle finger mutually perpendicular to each other • The thumb represents the direction of motion of the conductor • The fore finger represents the direction of magnetic field (north to south) • The middle finger represents the direction of induced current(positive to negative)
  • 51. Continued……… Whenever a current carrying conductor comes under magnetic field naturally,there will be force acting on the conductor,In this situation,the relationship between magnetic field,current,force will be explained by fleming’s left hand rule Whenever the current carrying conductor is forcefully brought under magnetic field,the relationship between magnetic field,induced current,force will be given by fleming’s right hand rule
  • 52. HYSTERESIS LOOP By studying this hysteresis loop,we can learn about the magnetic properties of the material This loop shows relationship between the induced magnetic flux density(B)and the magnetizing force(H) The loop is generated by measuring the magnetic flux (B) of a ferromagnetic material while the magnetizing force(H) is changed
  • 53. Continued……… RETENTIVITY:It is a material’s ability to retain a certain amount of residual magnetic field when the magnetizing force is removed after achieving saturation COERCIVE FORCE:The amount of reverse magnetic field which must be applied to a magnetic material to make the magnetic flux return to zero Relative to the other material,the materials with the wide hysteresis loop has: • Lower permeability • Higher retentivity • Higher coercivity • Higher reluctance • Higher residual magnetism
  • 54. Continued…… The material with the narrower loop has: • Higher permeability • Lower retentivity • Lower coercivity • Lower reluctance • Lower residual magnetism • In magnetic particle inspection,the level of residual magnetism is important • Residual magnetic fields are effected by the permeability, which can be related to the carbon content and alloying of the material • A component with high carbon content will have low permeability and will retain more magnetic flux than a material with low carbon content
  • 55. BASIC PRINCIPLE OF MPI  The main principle behind this magnetic particle inspection is MAGNETIC FLUX LEAKAGE  If we break the bar magnet into the centre will result two bar magnets with north and south poles on each end of the magnets  If the magnet is just cracked but not broken into two pieces,a north and south pole will form at each edge of the crack  The magnetic field exits the north pole and re-enters the south pole.  The magnetic fields spreads out when it encounter the small air gap created by the crack because the air cannot support as much magnetic field per unit volume as magnet can
  • 56. Continued……. When the field spreads out,it appears to leak out of the material and,thus,it is called a flux leakage field If iron particles are sprinkled on a cracked magnet,the particles will be attracted and cluster not only at the poles at the ends of the magnet but also at the poles at the edges of the crack This cluster of particles is much easier to see than the actual crack and this is the basis for MPI.
  • 57. PROCESS TO CONDUCT MPI: The entire process is carried out in 8 steps,they are: 1.Surface preparation 2.Surface cleaning 3.Magnetize the test specimen 4.Magnetic particle application 5.Excess magnetic particle removal 6.Indication,identification and marking 7.De-magnetization 8.Report writing and evaluation
  • 58. Continued……  Surface preparation: Surface should be prepared in such a way it should be useful for testing by this method.Grinding operation should be done to obtain the surface neatly  Surface cleaning: As in liquid penetration test,surface should be cleaned neatly such that no impurities should be present on the surface Solvent remover should be used for cleaning the surface • Magnetization of specimen: Two general types of magnetic fields are introduced into the specimen.they are: 1.Longitudinal magnetization 2.Circular magnetization
  • 59. Continued…….. A longitudinal magnetic field has magnetic lines of force that run parallel to the long axis of the part A Circular magnetic field has magnetic lines of force that run circumferentially around the perimeter of the part Methods of magnetization:There are two methods of magnetization, they are 1.Direct magnetization 2.Indirect magnetization Direct magnetization:Current is directly passed through the component.This is done through i)Head shot method ii)Prod method
  • 60. Continued…… Indirect magnetization: It is accomplished by using a strong external magnetic field to establish a magnetic field within the component.This is done through 1.Electromagnetic yoke method 2.Central conductor method HEAD SHOT METHOD PROD METHOD
  • 62. Continued……. MAGNETIC PARTICLE APPLICATION: Two types of magnetic particles are applied, they are 1.Dry particles 2.Wet particles • Dry particles are generally used for inspection on rough surfaces • Wet inspections are generally considered as best for detecting very small discontinuities on smooth surfaces • Black contrast and white contrasts are used for identifying discontinuities in wet particle method
  • 64. Continued……. EXCESS PARTICLE REMOVAL: Excess particles should be removed for clear identification of defects INDICATION,IDENTIFICATION AND MARKING: 1.The direction of magnetic field is identified by using pie guage 2.Field indicator,hall-effect meter are used to measure the strength of the magnetic field 3.Defects are identified and they are marked FIELD INDICATOR
  • 66. Continued…… • DEMAGNETIZATION:De-magnetization is commonly done in two ways 1.Hammering 2.Reverse magnetization • REPORT WRITING AND EVALUATION: A report is made based on the results obtained after conducting the test. Based on that report, the product will be judged whether it will be useful for future use or not This is the entire process of MPI
  • 67. ADVANTAGES OF MPI: Easy to handle equipment Longitudinal magnetization machines are portable It is not limited by the size and shape of the specimen being tested.small tanks to large cranes can be inspected using this method Cost is inexpensive when compared to UT and RT DISADVANTAGES: • It can be applied to only ferro-magnetic materials • More consumption of electricity • We can identify only surface and sub-surface defects • Safety is needed
  • 68. ANALYSIS OF MY MPT TEST  WORK PIECE:Work piece is the weldment of two mild steel plates of dimensions 250mm X 120mm X 12 mm each.  Weldment is a V-butt joint joined with solid metal arc welding process MY WORKPIECE
  • 69. Continued……. • METHOD OF MAGNETIZATION:The method I used is Electromagnetic yoke method with direct current • Reason to adopt this method is yoke is portable and is applicable here as a laboratory purpose • Prod machine serves the same purpose but with the high voltage of 2000V which can be used only for the inspection of huge components in industry • As the weight of work piece is 7 kgs, AC cannot be used because AC can bear only upto 4.5 kgs where as DC can hold 18 kgs
  • 71. Continued……..  CALIBRATION:Calibration is performed in order to check the performance of the electromagnetic yoke machine.  It is conducted on the ASTM test block which consists of holes at standard distances and depths  Correct indication of defects in the block is the indication that the electromagnetic yoke is in perfect condition  The calibration is done….the yoke used here is in perfect condition
  • 72. Continued….. • YOKE CALIBRATION AND LIMITATIONS: • LIFTING CAPACITY: FOR AC-4.5 KG FOR DC-18.1KG • SENSITIVITY CHECK: AC-1MM DC-5MM • Can check defects upto depth of 6 mm theoretically….
  • 75. WELD DEFECTS FOUND USING DRY MAGNETIC PARTICLES UNDERCUT
  • 76. CONCLUSION: • SPATTERS: Occurred due to disturbance in the molten weld pool during the transfer of wire into the weld,typically caused by voltage being too low or amperage being too high • UNDERCUT: Occurred because of melting of parent metal because of high arc during welding and so the fusion of weld is improper at the toe of the weld • CRACKS:The crack here in the weld is found because of difference in travel speed or current.Also,pressure applied on electrode during welding may be the cause for the formation of crack
  • 77. Continued…… EVALUATION: • Sputters can be removed by careful grinding on the surface but undercut and crack here obtained cannot be rectified • If it is in the industry as the components are huge castings they are grounded to the depth of defect and the crack is filled by welding • Applications of high stresses results in more cracks.More the number of defects,ability of the material to with stand loads is less • In the weld portion,if cracks or undercuts are found, then the component is not considered for further use
  • 78. REFERENCES:  TYPES OF WELD: http://mechanicalinventions.blogspot.in/2014/10/differ ent-types-of-welding-defects.html  TYPES OF JOINTS: http://www.ateliersbg.com/news/the-5-types-of-basic- welding- joints.aspx  TYPES OF WELDING: http://engineeringhut.blogspot.in/2010/11/welding- and-its-classification.html  BASICS OF NDT: https://www.nde- ed.org/EducationResources/CommunityCollege/MagPa rticle/TestingPractices/Dry%20Particle.htm  MPT: http://mech.vub.ac.be/teaching/info/Damage_testing_ prevention_and_detection_in_aeronautics/PDF/magne tic.pdf