Module 10 - 1

Module 10

Visual Inspection and Other NDE Methods and Symbols

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Module 10 - 2

Visual Inspection
Very cost effective Limited to surface only Requires

Training Experience Welding knowledge Proper tools

Must be continuous, ongoing

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Module 10 - 3

Application of VT
Before welding During welding After welding

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Module 10 - 4

VT Before Welding
Review documents Check welding procedures Qualify/Certify welders, or check certifications Establish hold points Develop inspection plan Develop system for reject identification Develop defect repair system

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Module 10 - 5

VT Immediately Before Welding

Check base and filler metals Check welding equipment Check weld preparations Check joint fitup Check weld joint cleanliness Check preheat, if required

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Module 10 - 6

VT During Welding
Note welder skills Check welding variables/procedure compliance Examine tacks and roots Check backgouged surfaces Check preheat temperatures Check interpass temperatures Check interpass cleaning

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Module 10 - 7

VT After Welding
Examine weld appearance Check weld size and length Check part dimensions Monitor other NDE methods Monitor postweld heat treating Prepare inspection reports

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Module 10 - 8

Visual Inspection Tools

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Module 10 - 9

Prebending and Presetting Pieces to Allow for Distortion

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Module 10 - 10

Temperature Measurements

Required for:
Preheat Interpass temperature limits Post weld heat treatments

Typically achieved by:

Temperature sensitive crayons Digital pyrometers

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Module 10 - 11

Temperature-sensitive Crayons

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Module 10 - 12

Digital Contact Pyrometer

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Module 10 - 13

Fillet Weld Size

Convex or concave ?? Use correct template gage Estimate between gage sizes Measure to nearest 1/32 or 1/16 Measure smallest region

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Module 10 - 14

Measuring Fillet Size

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Module 10 - 15

Nondestructive Testing
Method of testing to evaluate quality and not effect end-use serviceability

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Module 10 - 16

Elements of all NDE Methods

Source of probing energy Discontinuities alter probing energy Detection of energy alteration Indication of energy alteration Recording and evaluating indications

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Module 10 - 17

Common NDE Methods

Penetrant Magnetic Particle Radiographic Ultrasonic Eddy Current

PT MT RT UT ET

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Module 10 - 18

Penetrant Testing
Surface discontinuities only Relies on penetrant bleedout Magnifies discontinuity size Several methods

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Module 10 - 19

PT Types
Visible dye Fluorescent dye

Three removal systems: Solvent Water Emulsifiable

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Module 10 - 20

Clean the Surface

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Module 10 - 21

Apply Penetrant

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Module 10 - 22

Dwell Time
Varies with the nature of the job, typically in the range of 2 to 20 minutes, or longer in special cases

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Module 10 - 23

Remove Excess Penetrant

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Module 10 - 24

Remove Excess Penetrant

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Module 10 - 25

Remove Excess Penetrant

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Module 10 - 26

Remove Excess Penetrant

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Module 10 - 27

Apply Developer
In this example, spray can is too close to the weld surface, which can lead to excessive developer on surface. A distance of 10-12 inches is better.

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Module 10 - 28

Excessive Developer
Note runs caused by excess developer; this can mask discontinuities

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Module 10 - 29

Evaluate PT
Note porosity and crack indications

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Module 10 - 30

Clean Part
Post inspection removal of developer residues may be required, particularly if work piece is to be weld repaired or painted.

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Module 10 - 31

PT Advantages
Relatively simple All types of metals Quite sensitive Quite portable

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Module 10 - 32

PT Limitations
Somewhat slow Limited to surface Smooth surfaces required

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Module 10 - 33

PT Results
Sketches Photographs Lift off tapes

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Module 10 - 34

Magnetic Particle Testing

Parts are magnetized Iron particle accumulation at flaw Magnifies flaw size Relatively quick process

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Module 10 - 35

Aspects of a Magnet
Magnetic flux (field) North and south poles Like sign poles repel Opposite signs attract Flux lines are parallel to each other; do not cross

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Module 10 - 36

Magnetic Fields
Produced by two methods: Permanent magnets Electro magnets
Direct current Alternating current Half wave rectified AC

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Module 10 - 37

Permanent Magnet

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Module 10 - 38

Electromagnets
A current-carrying conductor creates a magnetic flux around the conductor and perpendicular to the current flow.

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Module 10 - 39

Magnetic Field Around Conductor

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Module 10 - 40

MT Principles
A flaw oriented transverse to magnetic flux creates poles of opposite signs at edges of flaw. Very attractive to iron particles

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Module 10 - 41

Magnetic Particles
Iron based Dry or wet Types

Color dyed Fluorescent

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Module 10 - 42

Longitudinal Magnetism

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Module 10 - 43

Circular Magnetism

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Module 10 - 44

MT Steps
Magnetize part Apply iron particles Evaluate accumulation Clean part Demagnetize part

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Module 10 - 45

MT Equipment
AC / DC bench units AC yokes AC / DC yokes AC / DC prods AC / DC coils

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Module 10 - 46

Central Conductor Method

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Module 10 - 47

MT Method --Yoke

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Module 10 - 48

MT Method --Prods

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Module 10 - 49

MT Advantages
Rapid Very sensitive Low cost Portable

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Module 10 - 50

MT Limitations
Magnetic materials only Poor with thick coatings Limited to surface, or near-surface Demagnetization may be required

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Module 10 - 51

MT Results
Sketches Photographs Lift off tapes

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Module 10 - 52

Radiographic Testing

Based on the principle of preferential radiation transmission or absorption.

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Module 10 - 53

X-Ray Machine (aimed down)

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Module 10 - 54

Radiation Absorption
Thicker, or higher density materials absorb more radiation, resulting in less transmission to the film.

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Module 10 - 55

Absorption vs Thickness

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Metal Densities
Grams/cubic centimeter
Aluminum Steel Copper Lead Tungsten 2.70 7.87 8.96 11.34 19.30

Module 10 - 56

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Module 10 - 57

Absorption vs Density

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Module 10 - 58

Radiation Types

Gamma radiation sources

Iridium 192 Cobalt 60 Cesium 137

X-Ray
Machine

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Module 10 - 59

RT Steps
Position radiation source Position film behind object Expose radiation Develop film Evaluate

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Module 10 - 60

Film Density Vs Flaws

Darker film zones: Cracks, slag, porosity Incomplete joint penetration Lighter film zones: Tungsten inclusions Melt through, reinforcement

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Hole Type Image Quality Indicators

Module 10 - 61

2 T hole 1 T hole 4 T hole

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Module 10 - 62

Wire Type Image Quality Indicators

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Module 10 - 63

RT Equipment

Radiation source
X-ray machine Gamma radiation source

Densitometer / film density strips Film processor

Radiation monitor Film holders IQIs

Film viewers

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Orientation of Source, Plate, & Film

Module 10 - 64

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Module 10 - 65

RT Advantages
Detects subsurface flaws Used for all materials Film is permanent record

If stored properly

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Module 10 - 66

RT Limitations
Radiation hazard Requires access to both sides Flaw orientation Flaw types Film interpretation

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Module 10 - 67

RT Results
Film Video tape Sketches

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Module 10 - 68

Ultrasonic Testing
Based on the propagation of sound waves through materials, and the reflected echo from density changes.

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Module 10 - 69

Piezoelectric Effect
Refers to materials which can convert electrical energy to mechanical energy and vice versa.

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Module 10 - 70

Principles of Sound
Sound travels within a given material at a constant velocity, based in part, on material density. Sound will not travel in a vacuum. There are several types of sound waves: Longitudinal (straight beam) Shear (angle beam) Others not pertinent to weld inspection

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Module 10 - 71

UT Equipment & Operation

Electronic base unit Piezoelectric transducer Calibration blocks

Couple probe to part with couplant Carry out testing Evaluate signals

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Module 10 - 72

UT Process

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Module 10 - 73

Longitudinal Calibration

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UT Process - 1 of 2

Module 10 - 74

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Module 10 - 75

UT Process - 2 of 2

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Module 10 - 76

Angle Beam Testing of Weld

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Module 10 - 77

Weld Testing - 1 of 2

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Module 10 - 78

Weld Testing - 2 of 2

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Module 10 - 79

UT Advantages
A true volumetric test One side access Very accurate Deep penetration - 200 Critical flaws found Equipment fully portable

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Module 10 - 80

UT Limitations
Highly skilled operator Smooth surfaces Groove welds > 1/4 thick

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Module 10 - 81

Eddy Current Testing

Based on the principle of eddy currents being formed in conductive materials in the presence of an AC coil and changes in those eddy currents by material changes.

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Module 10 - 82

Test Coil

Induced Eddy Currents

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Module 10 - 83

ET Uses
Flaw detection Metal thickness Coating thickness Metal hardness Heat treatment

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Module 10 - 84

ET CRT Displays

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Module 10 - 85

ET Equipment
Base unit, CRT or meter AC probe (coil) Calibration standards

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Module 10 - 86

ET Advantages
No contact required with part No couplant required Readily Automated Applicable to all metals

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Module 10 - 87

ET Limitations
Highly skilled operator Too sensitive Shallow penetration - 3/16 Calibration standards required Requires surface cleanliness Magnetic materials more difficult

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Module 10 - 88

NDE Symbols
Similar to weld symbols Shorthand notation Very useful Combine with weld symbols

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Standard Location of Elements for NDE Symbols

Module 10 - 89

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NDE Test Methods - Abbreviations 1 of 2

Acoustic Emission Eddy Current Leak Magnetic Particle Neutron Radiography AET ET LT MT NRT

Module 10 - 90

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NDE Test Methods - Abbreviations 2 of 2

Penetrant Proof Radiography Ultrasonic Visual PT PRT RT UT VT

Module 10 - 91

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Module 10 - 92

WIT Summary
Have covered much material in 3 days Workbook and Sample Fundamentals Exam are good guides to your grasp of each Module, and may point towards areas needing more study in Manual Urge all to study these subjects in greater depth as part of continuing education

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