NDT REPORT

1. A
SEMINAR REPORT
ON
NON DESTRUCTIVE TESTING
SUBMITTED BY
Jamshed Alam
B.TECH (M.E.)3RD
YEAR
SEMINAR INCHARGE SEMINAR GUIDE
Mr. PRABHAKAR GUPTA Mr. PRABHAKAR GUPTA
Ass. Prof. Ass. Prof.
DEPARTMENT OF MECHANICAL ENGINEERING
MOHAMMAD ALI JAUHAR UNIVERSITY RAMPUR (UP)

2. ACKNOWLEDGEMENT
I wish to express my gratitude and heartful thanks to my seminar
In-charge and guide Mr. PrabhakarGupta departmentof mechanical
engineering , MAJU, Rampur , for their constructive and helpful
suggestions and guidance. I am really thankful for their support and
inspiration throughout the making of this report. I am also duly
acknowledged for their continuous Encouragement which has been
motivating force in moulding the seminar report. I am immensely grateful
and indebted to them for believing in me throughout the course of study.
Immense thanks to the department of mechanical engineering for
Helping me in innumerable ways. My most humble regards to my
parents for extending full co-operation. I am very thankful for to almighty
GOD who is source of energy within me.
JAMSHED ALAM
Roll No. 1601050007
B.TECH3RD
YEAR
(M.E.)
MOHAMMAD ALI JAUHAR UNIVERSITY
RAMPUR (U.P.)

3. MOHAMMAD ALI JAUHAR UNIVERSITY
(Established Under UP Act NO. 19.6.2006)
JauharNagar , Post-siganKhera, Rampur (U.P.)
Phone No: 0595-2328786,
Website – www.jauhar university.edu.in
Email- vcmajuiv@live.com
CERTIFICATE
This is to certify that Jamshed Alam a student of B.Tech, 3rd
year,
Mechanical engineering has delivered his seminar on Non
destructive testing as partial fulfilling as per of requirement of M.A.J.
University.
During the collectionof material and preparation of project he was
found to be very good.
I wish him all the success in future endeavours.
Mr.Shailendra Kumar Neeraj Mr. Prabhakar Gupta
Co-Ordinator (A.P.)
Department of Mechanical Engineering

4. CONTENT
S.NO. TITLE
1. Introduction
2. What is NDT
3. Applications
4. Objectives
5. Types
6. Liquid penetrant method
7. Advantages
8. Ultrasonic flaw detection
9. Radiography
10. References
INTRODUCTION

5. Non-destructive testing (NDT) is a wide group of analysis techniques used
in science and industry to evaluate the properties of a material,
componentorsystem without causing damage.The terms Nondestructive
examination (NDE), Nondestructive inspection(NDI), and Nondestructive
evaluation (NDE) are also commonly used to describe this technology.
Because NDT does not permanently alter the article being inspected,it is
a highly-valuable technique that can save both moneyand time in product
evaluation, troubleshooting, and research.
Non-destructive Testing is one part of the function of Quality Control and
is Complementary to other long established methods. By definition non-
destructive testing is the testing of materials, for surface or internal flaws
or metallurgical condition, without interfering in any way with the integrity
of the material or its suitability for service.
Serving the equipment, supply, and repair needs of Non destructive
Testing (NDT) professionals in diverse industries for over 40 years. Our
sales representatives and customer care team are veteran NDT
professionals who can help you solve tough inspection problems. They
are backed up by a logistics team that is focused ontimely and accurate
order fulfillment. We truly value your business and know you have many
choices when it comes to your NDT needs.

6. The technique can be applied on a sampling basis for individual
investigation ormay be used for100%checking of materialina production
quality control system. Whilst being a high technology concept,evolution
of the equipment has made it robust enough for application in any
industrial environment at any stage of manufacture - from steelmaking to
site inspection of components already in service.
A certain degree of skill is required to apply the techniques properly in
order to obtain the maximum amount of information concerning the
product, with consequent feed back to the production facility. Non-
destructive Testing is not just a method forrejecting substandard material;
it is also an assurance that the supposedly good is good. The technique
uses a variety of principles; there is no single method around which a
black box may be built to satisfy all requirements in all circumstances.
What follows is a brief descriptionof the methods mostcommonlyused in
industry, together with details of typical applications, functions and
advantages.
The methods Covered are:
• Radiography
• Magnetic Particle Crack Detection
• Dye Penetrate Testing
• Ultrasonic Flaw Detection
• Eddy Current and Electro-magnetic Testing

7. WHAT IS NDT?
NDT stands fornon-destructive testing.In otherwords it is a way of testing
without destroying. This means that the component- the casting, weld or
forging, can continue to be used and that the non destructive testing
method has done no harm. In today's world where new materials are being
developed, older materials and bonding methods are being subjected to
higher pressures and loads, NDT ensures that materials can continue to
operate to their highest capacity with the assurance that they will not fail
within predetermined time limits.
NDT can be used to ensure the quality right from raw material stage
through fabrication and processing to pre-service and in-service
inspection .Apart from ensuring the structural integrity, quality and
reliability of components and plants, today NDT finds extensive

8. applications for condition monitoring, residual life assessment, energy
audit, etc.

9. COMMON APPLICATION OF NDT
 Inspection of Raw Products
 Inspection Following SecondaryProcessing
 In-Services Damage Inspection

10. OBJECTIVES
 To ensure operational readiness
 To maintain uniform quality level;
 To lower manufacturing costs;
 To control manufacturing processes;
 To aid in better product design
 To ensure customer satisfaction and maintain the manufacturer's
reputation;
 To make a profit for the user;

11.  To evaluate the physical and mechanical properties of materials
 To ensure product integrity, and in turn, reliability;
 To detect internal or surface flaws
 To measure the dimensions of materials
 To ensure product integrity, and in turn, reliability;
 To detect internal or surface flaws
 To measure the dimensions of materials
TYPES
 Visual Inspection
 Liquid penetrant method
 Ultrasonic Inspection
 Radiography methods
a. X-ray radiography & fluoroscopy
b. γ- ray radiography
 Eddy current testing
 Magnetic particle testing
 Thermography

12. VISUAL INSPECTION
Visualinspection is one of the mostcommonand mostpowerful
means of non-destructive testing. Visual testing requires adequate
illumination of the test surface and propereye-sight of the tester.
To be most effective visual inspection does however, merit special
attention because it requires training (knowledge of productand
process,anticipated service conditions,acceptance criteria, record
keeping, for example) and it has its own range of equipmentand
instrumentation. It is also a fact that all defectsfound by other NDT
methods ultimately must be substantiated by visual inspection.VT
can be classified as Directvisualtesting, Remote visual
testing and Translucentvisualtesting. The most commonNDT
methods MT and PT are indeed simply scientific ways of
enhancing the indication to make it more visible. Often the
equipmentneeded is simple for internal inspection, light lens
systems such as bore scopesallow remote surfaces to be
examined. More sophisticated devices of this nature using fibre

13. optics permit the introduction of the device into very small access
holes
and channels. Most of these systems provide for the attachment of
. a camera to permit permanent recording.
Trinity NDT material testing facility contains light meters, welding
gauges, magnifiers, lenses, other measuring instruments and
equipments for precise control of surface quality. Our NDT
inspectors, engineers and technicians are qualified to NDT Level I,
II as perwritten practice prepared according to ASNT recommended
practice SNT-TC-1A and in-house ASNT NDT Level IIIs for
providing inspection and consulting services.
EQUIPMENT : Visual and Optical tests are carried out in aircraft
maintenance with following equipment:
i) Magnifying Glass - Generally consists of a single lens for
lower power magnification and double or multiple lenses for
higher magnification.
ii)Magnifying Mirror - This one is a concave reflective surface,
such as a dental mirror may be used to view restricted areas
of aircraft not accessible with a magnifying glass.
iii) Microscope -It is a multiple element magnifier, providing
very high power magnification, is used for the inspection of
parts removed from the aircraft. Some portable units are also
used to evaluate suspected indications found on the aircraft.
iv) Borescope - Borescope is a precision optical instrument
with builtin illumination. Borescopes sometimes called
'endoscopes' or 'endoprobes', which consists with superior

14. optical systems and high intensity light sources, some
broescopes provides magnification option, zoom controls or
accessories.
v) Flexible Fibre Optic Borescope - Permits manipulation of
the instrument around camers and through passages with
severaldirectionalchanges.Wovenstainless steelsheathings
protects the image relay bundle during repeated flexing and
manoeuvring. The working lengths are normally 60 to 365 cm
with diameters from 3 to 12.5 min.
vi) Video Imagescope - The video Imagescope is similar to a
Fibrescope with the exception that video camera and its
connections have replaced the image bundle and a TV
monitor has replaced the eyepiece. This image may be
magnified for precise viewing. The field of vision is up to 90
degree and probe tip has four way articulation. Presently the
smallest diameter is 9.5 mm with working length up to 100
feet.

15. APPLICATIONS :
 Detection of surface defects or
structural damage in all
materials.
 Optical instruments are used for
visual checks of internal areas
and for deep holes and bores of
aircraft structure, landing gears
etc.
 Widely used to monitor engine
components, such as, turbine
wheels and nozzles,
compressor vanes and blades
combustion cans without
opening the engine.
 'Borescopes', 'fibrescopes' and
'video imagescopes' are most
important optical aids in remote
- visual inspection,which area is
normally inaccessible.
KEY POINTS :
 Simple to use in areas where other methods are impractical.
 Accessibility required.
 Reliability depends upon the experience of the operator.

16. LIQUID PENETRANT METHOD
PRINCIPLE
A liquid penetrant is applied at the surface of the specimen.The penetrant
is drawn by the surface flaws due to capillary action and this is
subsequently revealed by a developer, in addition with visual inspection.

17. PROCEDURE
 Cleaning the surface
 Application of the penetrant
 Removal of excess penetrant
 Developing
 Inspection
APPLICATIONS
 Turbine rotor discs & blades
 Aircraft wheels, castings, forged components, welded assemblies
 Automotive parts – pistons, cylinders, etc.
 Bogie frames of railway locomotives & rolling stock
 Electrical ceramic parts – spark plug insulators, glass-to-metal
seals, etc.
 Moulded plastic parts
ADVANTAGES & LIMITATIONS OF LIQUID PENETRANT METHOD
ADVANTAGES
 Simple & inexpensive
 Versatile & portable
 Applicable to ferrous,non-ferrous,non-magnetic & complexshaped
materials which are non-porous & of any dimension
 Detects cracks, seams, lack of bonding, etc.

18. LIMITATIONS
 Detect surface flaws
 Non-porous surface for material
 Surface cleaning before & after inspection
 Deformed surfaces & surface coatings prevent detection
ULTRASONIC FLAW DETECTION
PRINCIPLE
Whenever there is a change in the medium, the ultrasonic waves are
reflected. Thus, from the intensity of the reflected echoes, the flaws are
detected without destroying the material.

19. APPLICATIONS
 Quality control & material inspection
 Detection of failure of rail rolling stock axes, pressure columns,
earthmoving equipments, mill rolls, mixing equipments, etc.
 Measurement of metal section thickness
 Thickness measurements – refinery & chemical processing
equipments, submarine hulls, aircraft sections, pressure vessels,
etc.
 Inspect pipe & plate welds
 Inspect pins, bolts & shafts for cracks
 Detect internal corrosion
ADVANTAGES & LIMITATIONS
ADVANTAGES
 Sensitive to surface & subsurface discontinuities
 Superior depth of penetration for flaw detection
 High accuracy – position, size & shape of defect
 Minimal part preparation
 Instantaneous result
 Automated detailed images
 Non hazardous
 Portable

20. LIMITATIONS
 Surface accessibility for ultrasonic transmission
 Highly skilled & trained manpower
 Irregular, rough, coarse grained or non homogenous parts, linear
defects oriented parallel to the beam cannot be inspected – low
transmission & high noise
 Coupling medium required
 Reference standards – equipment calibration & flaw
characterization
RADIOGRAPHY
1. X-RAY RADIOGRAPHY
PRINCIPLE
X-rays are passed through the specimen under inspection and it is
differentially absorbed by the specimen. The transmitted x-rays are
received by the photographic film and the film is developed.The dark and
light shadows reveal the defects present in the specimen and hence the
defects are defected.

21. i. X-RAY RADIOGRAPHY – Displacement Method
PRINCIPLE
X-rays are exposed over the specimen by keeping the x-ray source at
position ‘A’ and then at ‘B’ by displacing the source through a certain
distance. The images are recorded at positions ‘A’ and ‘B’. From the
displacements of the x-ray tube and the images, the exact position of the
defect can be determined.

22. MERITS & DEMERITS
MERITS
 X-ray displacementmethod merits material suitability used on
castings and weldings .
 Determination of thickness used on uneven surfaces.
 Time consumptionis less.
 Permanent record.
DEMERITS
 Expensive.
 Developmenttime consumptionlarge.
 Skilled & trained personnelrequired.
 Tissue damage due to radiations

23. X-RAY FLUOROSCOPY
PRINCIPLE
X-rays are passed through the specimen and is made to fall on a
fluorescentscreen.With respectto the defects in the specimen,there will
be a variation in intensity.

24. MERITS & DEMERITS
MERITS
 No need of washing and developing films
 Low cost
 Image viewed immediately on screen
 Time consumption is less
 Movement of defects detected (real time images)
 Permanent record can be made
DEMERITS
 Poor resolution
 Low image contrast
 Electronic image intensifier required for increasing the contrast
DIFFERENCES
RADIOGRAPHY
 Image developed on photographic film
 High resolution & contrast
 Immediate image cannot be obtained.
 X-ray energy is converted into chemical energy.
 Expensive
 Time consumption is high.
FLUOROSCOPY
 Image is developedon fluorescentscreen.
 Fair resolution and low contrast.

25.  Immediate image can be viewed through the monitor.
 X-ray energy is converted into visible light.
 Inexpensive.
 Time consumptionis low
EDDY CURRENT INSPECTION
PRINCIPLES
Eddy current inspection is one of several NDT methods that use the
principal of electromagnetism” as the basis for conducting examinations.
Several other methods such as Remote Field Testing (RFT), Flux
Leakage and Barkhausen Noise also use this principle.
Eddy currents are created through a process called electromagnetic
induction. When alternating current is applied to the conductor, such as
copperwire, 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 electricalconductor
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. They get their name from
“eddies” that are formed when a liquid or gas flows in a circular path
around obstacles when conditions are right.

26. One of the major advantages of eddycurrent as an NDT toolis the variety
of inspections and measurements that can be performed. In the proper
circumstances, eddy currents can be used for:
 Crack detection
 Material thickness measurements
 Coating thickness measurements
 Conductivity measurements for:
o Material identification
o Heat damage detection
o Case depth determination
o Heat treatment monitoring
ADVANTAGES
 Sensitive to small cracks and other defects
 Detects surface and near surface defects
 Inspectiongives immediate results
 Equipmentis very portable

27.  Method can be used for much more than flaw detection
 Minimum part preparation is required
 Test probe does not need to contact the part
 Inspects complexshapes and sizes of conductive materials
LIMITATIONS
 Only conductive materials can be inspected
 Surface must be accessible to the probe
 Skill and training required is more extensive than other
techniques
 Surface finish and and roughness may interfere
 Referencestandards needed forsetup
 Depth of penetration is limited
 Flaws such as delaminations that lie parallel to the probe coil
winding and probe scan direction are undetectable

28. MAGNETIC PARTICLE TESTING (MPT/MT)
Magnetic particle testing or MPT is a nondestructive testing method for
locating surface and near surface discontinuities in ferromagnetic
materials. It depends for its operation on the fact that when the material
or part under testis magnetized,discontinuities that lie in a cause leakage
field to the direction of the magnetic field will cause a leakage field to be
formed at and above the surface of the part. The presence of this leakage
field, and therefore the presence of the discontinuity, is detected by the
use of finely divided ferromagnetic particle applied overthe surface,some
of the particle being gathered and held by the leakage field. This
magnetically held collectionof particle forms anoutline of the discontinuity
and generally indicates its location, size, shape and extent. Magnetic
particles are applied over a surface as dry particles, or as wet particle in
a liquid.
Ferromagnetic materials include most of the iron, nickel and cobaltalloys.
These materials lose their ferromagnetic properties above acharacteristic
temperature called the Curie point which is approximately 760◦ C for most
of the ferromagnetic material.

29. APPLICATIONS
The principal industrial uses of magnetic article testing are final inspection,
receiving inspection, in process inspection and quality control,
maintenance and overhaul in the transportation industries, plant and
machinery maintenance and inspection of large components.
LIMITATIONS
Thin coatings of paint and other non-magnetic coverings,such as plating;
adversely affect sensitivity of magnetic particle inspection. Other
limitations are:
 Magnetic particle inspection methods will work only on
ferromagnetic materials.
 For best results, the magnetic field must be in a direction that will
intercept the principle plane of the discontinuity. Sometimes this
requires two or more sequential inspections. With different
magnetizations.
 Demagnetization following magnetic particle testing is often
necessary.
 Post cleaning to remove remnants of the magnetic particle clinging
to the surface may be required after testing and demagnetization.
 Exceedingly large currents sometimes are required for very large
parts.
 Care is necessary to avoid local heating and burning of finished
parts or surface at the points of electric contact.
 Although magnetic particle indications are easily seen, experience
and skill in interpreting their significance are needed.

30. THERMOGRAPHY NON-DESTRUCTIVE TESTING (NDT)
Every object releases thermal radiation which is invisible to the
human eye. This radiation is measured by the infrared camera, and
is displayed visually in different nuance of colours. At TÜV
Rheinland, infrared cameras with the latest technology are used.
Thus, measurements on buildings of various sizes can be
conducted almost anywhere. The concluding report includes the
evaluation of the thermograms, the documentation of the building's
thermal status as well as the analyses and evaluation of the data.
PRODUCT TESTING
TÜV Rheinland is the leading and the mostcompetentproviderof product
testing and certifications for the worldwide marketplace. In the laboratory
and in real life, in highly industrialized and in developing countries, our
TÜV Rheinland specialists certify safety and quality to the needs of
producers and consumers alike. TÜV Rheinland offers safetytesting and
certification services for products commonly encountered in modern life
such as home appliances, audio/video products, medical products,
textiles, telecommunication equipment to name a few. Offering global
compliance solutions such as EMC, cTUVus (NRTL) and International
Approvals for any country of destination, TÜV Rheinland’s global network
helps customers gain global access more effectively and efficiently.

31. APPLICATIONS
Construction and Real Estate Information
Security
Education and Personnel Services
Industrial Facilities and Machinery Management
Systems
Materials Testing and Inspection Product
Testing

32. IMPORTANCE 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 lab our cost .
WHAT ARE SOME COMMON DEFECTS?
 Porosity
 Undercutting
 Rollover or “Cold Lap”
 Slag inclusion
 Poor penetration
 Voids
 Hydrogen Embrittlement

33. CONCLUSION
NDT can save and/or avoid costs in millions of dollars forfacilities that use
its methods. There are proven NDT technologies to do this, from
conventional to more advanced ones that are esentially based on the
conventional ones. Their required training requirements and proper
application are paramount for realizing ever-increasing benefits.
Non Destructive Testing (NDT) is a technique for damage assessment,
disaster prediction and quality control, to detect the defects without
affecting the internal structure. This thesis presents and proposes some
novel techniques for weld flaw classification from industrial radiography
for improving the safety of nuclear power plant, petrochemical industries
etc using image processing and clustering techniques. Six differentnovel
approaches are conducted and documented in this thesis for the
classification of the weld defect along with a broad literature survey of
various techniques conducted bynumerous researchers inthis field.Weld
defect classification in radiographic images using Fuzzy C-Means
clustering and Zernike moments, PCA and K-Means clustering based
weld defect identification from radiographic images, Weld defect
recognition in radiography based on Projection Profile and RST invariant
by using LVQ, Detection using Image reconstruction by Simultaneous
Algebraic ReconstructionTechnique (SART),An efficientfast processing
Adaptive Median filter based on enhanced Dijkstra’s 3-way partitioning is
developed in this thesis, Weld flaw identification from radiographic weld
images using Radon Transform and improved Fuzzy C-Means clustering.
This thesis presents novel approaches for the improvement of automatic
classification and judgement of discontinuities or defects in welding. The
result shows that these above techniques are robust and provide a good
detection rate for different types of weld flaws. The future scope of this

34. researchwork lies in the field of pre-processing,segmentationand feature
extraction. The segmentation and feature extraction techniques like
Watershed, Hough Transform and Zernike Moments respectively are
mathematically and computationally complex due to the morphological
operations, parametric plane conversions and orthogonal projections
respectively,thereby consuming more execution time. So there is always
a future scope for making the image enhancement, segmentation and
feature extraction techniques simpler and more effective by reducing
computational complexity which will help in faster and more accurate
recognition of weld defects from radiographic images.
REFERENCES
1. ASNT-Nondestructive Testing Handbook -Vol - Ten - 1996
2. ASNT-Nondestructive Testing Handbook - Vol - Nine - 1996.
3. B. Hull & V.John - Nondestructive Testing (1998),Macmillan,
UK
4. Chris Hobbs & Ron Smith - Beneath the Surface, British
Airways Technical Journal.
5. P. G Lorenz- The Science of Remote Visual Inspection,
1990.
6. NDT Standard Practice Manual - McDonnel Douglas
Corporation (Revision -3), 1996.