Dr.A.

SubjenderReddy

Non Destructive Testing Methods

Evaluation of capabilities and competence of

NDT Laboratory.

2-2-1137/8/1

New Nallakunta

Hyderabad-500044

India
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1.0 Non destructive Testing- An over view
Non destructive Methods are used for testing of various types of materials such as rocks,
soils, metals, woo, plastic, cast materials. The non destructive methods are relatively simple
to perform and in certain instances, for example, when investigation width and depth of
cracks in concrete, the NDT methods are the only ones that can provide reasonable answer.

1.1 The non destructive methods include acoustic emission, electromagnetic, gamma and X-
radiography and gagging, ultrasonic examination, leak testing, liquid penetration
examination, magnetic particle examination and other methods.

1.2 The non destructive methods should satisfy the following criteria:
 The methods should facilitate testing in the field and the laboratory.
 The test equipment should be portable and, with few expectations, is based on the
principle used in testing methods.

1.3 When a material is examined, the NDT produces an indication that is subjected to
interpretation as false, non-relevant or relevant. If it has been interpreted as relevant, the
necessary subsequent evaluation will results in the decision to accept or reject the material.

2. NDT methods:

Based on measuring physical properties, the NDT methods are categorized into various
methods. The following is the brief description of the different NDT methods.

2.1 Acoustic emission methods:

2.1.1. The acoustic method is based on the principle of measuring the transient elastic waves
generated by the rapid release of energy from localized deformations in material at points
being stressed beyond their elastic limit.
2.1.2. The method is applied to determine the quality of the materials, which include
 study the initiation and growth of cracks and other deformations
 determining elastic moduli of material and pavement systems
 Monitoring of large structural members and locating origin of cracking and zones of
maximum deformation.
 Evaluation of loading levels of structures.

2.2 Electromagnetic Method:

2

2.2.1. The non destructive magnetic method of testing is based on inducing test object with eddy
Page

currents flow. Changes in the flow caused by the variations in the specimen are reflected
into nearby devices for subsequent analysis by suitable instrumentation and techniques.
2.2.2. Various types of electromagnetic methods are in use such as microwave absorption
technique, high frequency penetration technique.
2.2.3. The electromagnetic methods are commonly used for testing of materials to obtain
information regarding the quality of materials.
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2.3. Ultrasonic Method.

2.3.1. The ultrasonic method is based on introducing ultrasonic waves into, through or onto
surface of the object being examined and examining various attributes of material from
effects on the ultrasonic waves.
2.3.2. There are different types of ultrasonic measuring techniques such as mechanical pulse
velocity, resonance frequency, immersion testing and pulse echo method.
2.3.3. These methods are normally applied to
 Evaluation of flaws
 Structural integrity studies
 Quality studies such as uniformity, strength etc

2.4. Electrical Methods.

2.4.1. Electrical method is based on the principle that a material under the test offers resistance to
the passage of current when the later is to pass through it.
2.4.2. There are various electrical measuring techniques, which include electro chemical potentials,
equi-potential, charged body, induced polarization method.
2.4.3. Electrochemical potential is used for
 Corrosion studies
 Protection studies of underground and under water metallic structures.
2.4.4. Electrical resistivity methods are applied to
 determine resistivity of materials
 Moisture content of materials
 Thickness of concrete material and slabs.

2.5 Gamma and X-Radiography

2.5.1. These methods use penetrating ionizing radiation of gamma and X-rays to display images
for the detection of discontinuities or to ensure integrity of the part. The incident radiation
of gamma and X-ray may transfer or scatter its energy and these processes are related to the
characteristics of the materials.
2.5.2. Gamma ray spectrometry method can be used on the surfaces, rock outcrops/surfaces,
mine workings, trenches, pits and boreholes as well as in laboratory. While X-radiography
produces images of the objects, the gamma ray spectrometry provide information
commonly used for determination of material properties such as density, porosity,
permeability, water saturation etc and also for elemental analysis.

2.6. Neutron Radiography.

2.6.1. Neutron radiography is the process of making image of internal details of an object by the
selective attenuation of neutron beam by the object. When the material is bombarded with
the neutrons the emitted gamma rays or thermal neutrons recorded.

2.6.2. Various measurement methods are in use such as neutron-neutron, neutron-gamma, pulsed
neutron, neutron activation, neutron scattering, neutron resonance etc.
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2.6.3. The neutron radiography method is commonly applied for
 corrosivity studies
 determine material properties such as density
 Determine salinity and porosity of insitu formations.

2.7. Magnetic Particle Examination.

2.7.1. This non destructive testing method utilizes magnetic leakage fields and suitable indicating
materials to disclose surface and near surface discontinuity indications.
2.7.2. This method is mainly applied to ferromagnetic products and non-metallic intrusions, for
determining quality of material. It measures the leakage in magnetic flux caused by the
surface or near surface discontinuities.

2.8. Leak Detection Method.

2.8.1. The method utilizes pressure changes, bubbles, or a passage of tracer fluid through a
pressure boundary etc for the detection of various types of leakage.
2.8.2. The method is applied to detect the leaks in closed systems.

2.9. Liquid Penetrant Examination.

2.9.1. This type of testing method uses suitable liquids that penetrate discontinuities open to the
surface of the solid materials and, after appropriate treatment, indicate the presence of the
discontinuities.
2.9.2. This NDT method is commonly used to determine the surface openings of the materials.

2.10. Purpose of NDT.

The NDT of materials are commonly carried out for the following reasons.
 Production control and precision measurements
 Quality control studies at site and laboratory.

2.11 NDT of Materials.

 The NDT is conducted on various types of materials such as metals, glass, ceramics,
plastic, rubber, wood etc.
 Rock and soil samples
 Construction material such as concrete, bricks, and other cast and composite material
 On site structures such as buildings, bridges, pavements etc
 Semi finished and other products within manufacturing process.

3.0 Quality Analysis.

3.1. The quality analysis of materials by NDT methods include:

 Detection and evaluation of defects such as cracks, voids, fractures, compositional
defects
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 Determination f uniformity of materials
 Establishing acceptance criteria for quality of materials
 Monitoring structural integrity such as
- detection of internal/external changes due to nearby activities
- foundation movements, vibrations
- corrosion monitoring on bridges and other structures on site

3.2 Testing of concrete.

As far as concrete and other building materials are concerned, the NDT is used for
 Determination of flexural and compression strength
 Quality of concrete including
- setting characteristics
- aggregate properties
- mix properties
- water cement ratio content
- maturity of concrete
- durability under freezes, thaw conditions.
 durability under aggressive environments such as sulphate attack and acidic
waters
 chemical composition of concrete
 determination of quality and service of existing structures and concrete pavements under
repeated loads.

4.0. Establishment of NDT Laboratory.

4.1. Evaluation of capability of laboratory.

4.1.1. The capability of laboratory to properly perform designated examination is evaluated from
the essential characteristics pertaining to the-
 organization
 personnel
 facilities
 quality control system of the agency
4.1.2. Systematic assessment of competence of the laboratory is required. It includes:
 determining whether the laboratory has adequate capacity and capability to fulfill
contractual requirements.
 Determining whether the laboratory has adequate control system
 determining whether the facilities comply with its own written policies to practices or
both
 guideline and practices to meet specific requirement of the projects/contract

4.2. Documentation.
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The following information concerning the establishment of NDT laboratory shall be
reviewed and documented.

4.2.1. Services
 Types of services provided by the agency
 Types examination performed
 Types of users of the agency’s services.
4.2.2. NDT equipment.
 NDT equipment details
 Testing methods available/approved
 Types of NDT performed.
4.2.3. NDT Personnel
 number of employees and levels of certified NDT personnel
 practices and procedures for the personnel certification
 training programs and qualification examination for NDT personnel

4.3. Methods of NDT.

The capabilities of NDT laboratory shall include, but not limited to, one or more of the
following methods.
 Magnetic particle
 Penetrant
 Radiographic/fluoroscopic
 Ultrasonic
 Eddy current
 Leaky testing.

4.4. Performing NDT.

4.4.1 The NDT laboratory should ensure that

 The laboratory shall perform examination for which it is adequately equipped and
staffed.
 The employees shall perform only examinations for which they are adequately qualified
 All the equipment are calibrated and personnel are certified in accordance with the
applicable specifications
 All examinations are performed in accordance with the specified standards or quality
control criteria or both.

5.0 Procedure Manuals

5.1. The NDT laboratory shall have prepared written procedures/manuals for the type of work
which it is responsible /contracted.
5.2. The manuals shall be of sufficient details to provide complete guidance for the use of NDT
personnel.
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5.3. The laboratory shall prepare the quality control manuals in compliance with the
departments’ QA/QC procedures.
5.4. Procedures for staff criteria.

6.0. Equipment for NDT.

The laboratory responsible for non destructive testing of materials should be equipped with,
or have to access to at least the equipment listed for the applicable process.
6.1. Radiography equipment

6.1.1 The instrument source shall have sufficient energy and intensity to examine materials in
accordance of the required specification. Either X-ray or gammas ray is used, unless,
otherwise specified.
6.1.2 The instruments operations parameters such as voltage, amplitude range must be must be
adequate to penetrate the thickness of the material to be evaluated and produce acceptable
film densities.
6.1.3 The recording medium shall be capable of recording or displaying images of the sensitivity
and contrast required by the applicable specification.
6.1.4 Facilities for processing data must be available.

6.2. Ultrasonic equipment.

6.2.1 The instrument must include all accessories

6.2.2 It must be capable of generating pulsed ultrasonic energy over an adequate frequency range
to ensure proper examination in accordance. with applicable governing specification.
6.2.3 The ultrasonic unit shall include a pulsed circuit, receiver circuit, CRT display.
6.2.4 The reference standards must be in accordance with authority furnished standards or
specifications or both.

6.3. Neutron Radiography Equipment

6.3.1. The source such as thermal neutrons, scattered neutrons, gamma rays etc shall be sufficient
to provide clear images of the objects in area of interest.
6.3.2. The source shall be capable of producing specified radiographic quality in a timely exposure.
6.3.3. Safety and monitoring of equipment consistence with good practice current regulations shall
be available.
6.3.4. Recording medium shall meet the requirement of the specifications.
6.3.5. Processing equipment shall be adequate to ensure the quality intent of the applicable
specifications is maintained.
6.3.6. Suitable facilities must be available to handle film processing.

6.4. Leak Testing Equipment.

6.4.1. For helium testing, mass spectrometer is required.
6.4.2. For radioisotope leak testing, a tracer gas pressurization system and detectors are required.
6.4.3. Halogen leak testing requires a standard probe type halogen leak detectors.
6.4.4. Bubble leak testing requires baths for heating detector fluids to specified temperature.
6.4.5. Reference standards are required.
6.5. Electromagnetic equipment. GeoSolutionsIndia

6.5.1. The apparatus shall be capable of inducing electromagnetic field and detect changes in
electric and magnetic characteristics of specimen.
6.5.2. Shall have conductivity standards for direct comparison with traceability, and laboratory
developed standards for specified tests.
6.5.3. Shall have calibration standards for uniform thickness measurements.

6.6. Magnetic Particle Equipment.

6.6.1 The equipment shall be capable of inducing magnetic field of sufficient density.
6.6.2 Coils, probes, clamps, pads are used to magnetize the part or section of the part.
6.6.3 The apparatus shall have suitable switches to control different amperages.
6.6.4 Dry or wet magnetic particles may be applied.
6.6.5 Equipment for demagnetization shall be capable of demagnetize to the extent specified in
specifications.

6.7 Leak Penetrant equipment.

6.7.1. The equipment shall be capable of apply Penetrant, wash surface part, dry the part, apply
developer.
6.7.2. Equipment may consist of either immersion dip tanks or spray apparatus or brushing.

7.0 Use of NDT Methods.

A typical NDT laboratory performs non destructive testing for various purposes.

7.1 X-ray and gamma Radiography

 can be applied to casting, forging, weldments and assembles.
 detects internal discontinuities such as cracks, voids, cavities, porosity
 portable and permanent record

7.2. Neutron Radiography.

 Detects presence, absence or mis-location of components are variation of suitable
composition.
 Detection of corrosion
 High sensitivity and permanent records.

7.3. Liquid Penetrant Examinations.

 Detects cracks, laps, porosity, seams
 Used for testing of casting, forging, weldments, metallic and non-metallic components.

7.4 Eddy current examination.

 measures changes in electrical and magnetic properties caused surface and near surface
discontinuities.
 Detect cracks, seams, voids, variations in alloy composition and heat treatment.
 Used for testing of materials such as bars, rods, wire, tubing, local regions of sheet metal
and also for alloy sorting and thickness gagging.
7.5. Microwave examination. GeoSolutionsIndia
 Measures anomalies in complex dielectric coefficient.
 Surface anomalies in conductive materials
 Detects surface bands, disbanded voids, moist content, thickness measurements
 Used for testing of materials such as glass, fiber-resin structure, plastics, and ceramics

7.6 Magnetic Particle/Leak detection examination.

 Detects surface and near surface cracks, laps, voids, and non-metallic inclusions.
 Method can be applied to ferromagnetic products such a weldments, castings, forging
and extrusions and other basic steel products.

7.7 Ultrasonic Examination.

 Detects cracks, voids, porosity, laminations, delamination, and inclusions
 Can be applied to weldments, plates, tubes, casting, forging, extrusions, thickness
gagging.

7.8. Ultrasonic holography.

 Used for evaluation of discontinuities detected by other methods
 Examination of limited regions of structures in the images.
7.9. Ionic examination.
 Detects disbands, delaminating cracks, honeycomb, small parts

7.10 Infrared Testing.

 Measures surface temperatures, anomalies in thermal conductivity or surface
emmissivity or both
 detects voids, or disbands in non metallic, used for location of hot cold spots in
thermally active assemblies

7.11 Strain gage.

 used for stress-strain analysis of most materials

7.12 Optical Holography.

 detects disbands, delaminating plastic deformation
 testing materials include honeycomb, composite structures, tyres, precision parts such as
bearing elements

7.13 Leak detection

 detects leaks in closed system
 used in vacuum systems, gas and liquid storage vessels, piping

7.14 Acoustic emission.

 detects structural anomalies, leaks, delaminating, fiber structure and matrix failure in
composite materials
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 used in crack detection and location during proof testing, crack propagation, composite
structures, rotating equipment.
8.0 Quality control system for NDT Laboratory.
 There are general requirements to be satisfied for the establishment and maintenance of
quality control system for agencies engaged in NDT.
 The procedure of quality control system for a NDT laboratory shall be included for
calibration, standardization, reference samples, inspection plans.
 The basic requirements for QCS encompass the following areas, all of which shall be
documented: quality policy statement, planning and administration, organization, human
resources, physical resources and quality control.

8.1 Quality policy.

 The quality policy of NDT laboratory should be in compliance with organizational
quality system.
 In addition, wherever relevant, the quality objects and control systems, planning can be
implemented for additional needs.
 The laboratory shall have quality manuals describing quality requirements of each
product, method or test, where appropriate.
 Periodical audit of the quality control system shall be made.
8.2 NDT Personnel.
 The NDT laboratory shall have personnel qualified in accordance with a recognized
personnel qualification practice or standard
 A training program shall be maintained for the staff.

8.3 Equipment maintenance.

 An inventory of equipment used to perform NDT shall the equipment details and uses
 Properties of the equipment subject to the standardization and calibration reference to
recognized calibration procedures
 Frequency of calibration and sensitivity
 Written procedures for each NDT service provided.
8.4 QA/QC
QA/QC of NDT laboratory shall include the following:
 Procedures for ensuring accuracy of measurement of product and processes to specified
requirements
 Establishing a calibration system to ensure traceability
 Documentation of calibration system
 Document control to ensure all examinations are in accordance with the instructions,
procedures, or other specifications
 Preparation of quality records to allow traceability; records on working instructions such
as applicable standards, checks, tests etc; records of examination conducted
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 Process control to ensure that all required operations are performed in the specified
manner and sequence
 Special process control including periodic verification of accuracy, variability of
equipment
 Continuous quality improvements to maintain satisfactory performance levels
 Preventive action to identify and eliminate the cause of loosing control or changes in the
process.
 Quality control system may be integrated as a subsystem of a larger parent’s system.

9.0 Summary.

9.1 There are minimum requirements to be satisfied by the laboratory in order to perform non
destructive examination

9.2 Establishing NDT laboratory requires the review and documentation of the following
information
 types of users and their needs
 types of methods and equipment required
 facilities of the laboratory to perform NDT

9.3 For performing NDT, the following are the requirements from which the capabilities and
competence are evaluated.

9.3.1 For performing NDT the following are requirements from which
 facilities of the laboratory to perform NDT
 types methods and equipment required
 procedures for maintenance and calibration of equipment
 written procedures for each test, each equipment and type
 procedures to ensure quality in performing examination
 analysis of data for continuous quality improvement to meet customers’ requirement.
 capabilities types of users and their needs,