1.

OVERVIEW OF NON DESTRUCTIVE

TESTING (NDT)

1.1 Definition
Non Destructive Testing may be defined as testing methods in which the
material subjected to testing related to characteristics, inhomogeneity and
harmful defects doesn’t undergo destruction or loss of
functionality/usefulness for which it was intended for.

NDT is often referred to as Non Destructive Inspection (NDI) or Non

Destructive Evaluation (NDE).

1.2 NDT Versus Mechanical Testing

A broad comparison of conventional mechanical testing and NDT is as
follows:

Table 1: Comparison of NDT Vs Mechanical Testing

Non Destructive Testing

Sl No Mechanical Testing
(NDT)

1 No Destruction of Specimen Destruction of Specimen

2 Specimen can be used after test Specimen cannot be used

Testing of specimens during Testing of specimens during

3
service is possible service is not possible
Multiple tests can be performed Generally Single test can be
4
on the same specimen performed on a specimen
5 Tests can be performed directly Tests are performed on specimens
on the product having same maeterial
Non Destructive Testing & Evaluation 5

Non Destructive Testing

Sl No Mechanical Testing
(NDT)
characteristics as product

6 Repeated Testing is possible Repeated Testing is not possible

Test Measurements should be

7 Test Measurements are reliable
validated
Test measurements are generally
Test Measurements are
8 indirectly obtained by proper
generally directly obtained
interpretation
Information obtained are not
9 Information obtained are precise
precise

10 Data obtained are qualitative Data obtained are quantitative

Testing is generally operator Testing is generally equipment

11
dependent dependent

1.3 Overview of Non Destructive Testing Methods for

the Detection of Manufacturing defects as well as
material characterization
Although there are a number of testing methods, the following are the
important Non Destructive Testing methods:

(1) Visual Inspection

(2) Liquid Penetrant Testing

(3) Magnetic Particle Testing

 (4) Thermography

(5) Eddy Current Testing

(6) Ultrasonic Testing

(7) Acoustic Emission Testing

(8) Radiography Testing

Non Destructive testing methods find wide applications which are not
limited to testing alone. They are employed for thickness measurement,
identification of materials and chemical composition etc.

Some of the applications of these testing techniques are as follows:

(1) Thickness Measurement – Using ultrasonic testing quick and

accurate measurement of thickness of materials can be obtained.
Thickness can also be measured by radiation absorption methods
and eddy current principle.

(2) Indentification/Classification of materials – Some of the tests

like eddy current, spark test, ultrasonic test, sluphur printing, spot
test etc can be effectively applied to determine the lay up order in
composites, presence of fillers etc.

(3) Chemical composition evaluation – Spectrochemical analysis is

widely used for evaluating chemical composition of material.

(4) Surface characteristics may be obtained using nuclear scattering

method

(5) Stress Concentration & Critically loaded areas may be

determined using Moire method and photoelasticity techniques
Non Destructive Testing & Evaluation 7

(6) Mechanical properties like modulus of elasticity, residual

stresses may be evaluated using ultrasonic testing

(7) In-service embrittlement and deformation of materials can be

checked using acoustic emission techniques.

(8) Ultimate strength, fatigue strength, strength of bonding etc.

Can be evaluated by eddy current testing.

1.4 Relative Merits and limitations

Merits

• Tests are performed on the actual object/product instead of sample

specimen

• Tested parts retain their original property thereby making them

usable after testing or evaluation

• If required every part from a small batch or large portion of a given

material can be examined

• Tests can be conducted when the parts are in service

• Internal as well as surface conditions may be examined

• Different NDT methods can be applied on the same part

• Some of the NDT methods are portable and hence equipments can
be carried to locations of interest in large structures like aircraft
and bridges.

• Most test methods provide results quickly

• Very less preparation required

Limitations:

• Results are operator dependent.

• Skilled judgement and considerable experience is requried to

effectively interpret indications from test

• Measurements are indirect and hence requires verification of

reliability

• Some testing methods do not provide permanent record of tests.

• Some testing methods are very expensive

1.5 Various physical characteristics of materials and

their applications in NDT
Non Destructive Testing & Evaluation 9

2. VISUAL INSPECTION

2.1 Introduction
Visual inspection is a widely used Non Destructive Testing method which
is very simple. Whenever inspection of a material is needed, the very first
inspection will be with the eyes. But for a proper examination of the
material adequate illumination is required. How the material is viewed for
the inspection determines the type of visual inspection method.

Visual inspection can be broadly classified into

(i) Unaided Visual Inspection

(ii) Aided Visual Inspection

2.2 Unaided Visual Inspection

Trained and experienced human ‘eye’ is the most valuable asset in visual
inspection. Visual Inspection performed with naked eyes without the aid of
optical instruments can be termed as unaided visual inspection.

Human eye is sensitive to only light of certain wavelengths. Under ordinary

light conditions, human eye is most sensitive to yellow green light. Long
exposure to lights may make the inspector difficult to judge the material.
Hence care must be taken to provide sufficient rest in between inspections.

Unadided Visual Inspection may be employed for the following detections:

• Potential sources for failure like sharp edges, very thin sections,
misaligned holes etc.
 • Presence of Corrosion, dirt, grease layer on the surface of the
material

• Presence or absence of visible cracks, location and orientation of

such cracks in welded joints

• Orientation of weld beads

• Surface porosity and unfilled craters

2.3 Aided Visual Inspection

Visual Inspection done with the aid of optical instruments may be termed
as aided visual inspection. Instrumental aids provide access to remote
locations and also magnify defects that are not clearly visible to naked eye.

The following instruments can be used for aided visual inspection:

1. Microscope/Magnifying glass:

Whenever magnification of defects on the surface is required, microscopes

or magnifying glasses may be used. Microscopes can be used only when
the object of inspection is very small. Magnifying glasses can be used only
at those locations that are accessible.

Placing the lens at proper distance away from the object will provide an
enlarged view of the defect area. Enlarged view will help in evaluating
shape and orientation of the cracks and defects.

2. Telescope

Telescope, like microscope and magnifying glasses provides an enlarged

view of the object under observation. But they are used when distant
inaccessbile surface needs to be examined.
Non Destructive Testing & Evaluation 11

3. Borescope

Borescopes are long tubular circular devices which contain a source of

illumination at object lens end.

The tubes come in wide variety of lengths and diameters. They are
generally used for examination of inner surfaces of long narrow tubes or
circular cylinders. General construction of a borescope is as shown in fig
2.1

Fig 2.1: Borescope

The light source illuminating the object passes light to the observer through
complex arrangement of lenses, thus providing better image of the object.
The image becomes less bright when the distance increases due to loss of
light.

4. Flexiscope

Flexiscope are Flexible Fibre Optic Borescope that are used when
examination of interior surfaces of tubes and cylinders having turns are
required. Flexiscope permits maneuvering of object end through passages
with several directional changes. Image relay bundle is protected by woven
steel sheathing. General construction of a fibrescope is shown in Fig 2.2
 Fig 2.2: Flexiscope

5. Videoscope

Videoscope are similar to borescope but has image sensors and high
intensity light source. Image sensors housed at the distant end of the
videoscope relays the image back to the observer through internal wiring.
This allows for a far superior image quality in comparison to borescope or
flexiscope. Videoscopes have provision to record videos or still images.

6. Holography

Optical holography is an imaging method, which records the amplitude and

phase of light reflected from an object as an interferometric pattern on film.
This allows for the full 3-Dimensional image of the object to be
reconstructed.

The interference pattern contours on holographic film provide data

regarding stress states. Data of surface and sub surface defects can be
obtained. Also information regarding vibration modes, mechanical
properties and residual stresses can be obtained.