THIRD EDITION. Practical. Non-Destructive Testing. Baldev Raj T. Jayakumar M. Thavasimuthu. Alpha Science International Ltd. Oxford, U. K.
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1 THIRD EDITION Practical Non-Destructive Testing Baldev Raj T. Jayakumar M. Thavasimuthu CD Alpha Science International Ltd. Oxford, U. K.
2 Contents Foreword Preface to the Third Edition Preface to the First Edition CHAPTER 1. Non-Destructive Testing: An Introduction CHAPTER 2. Visual Inspection 2.1 Basic Principle The Eye Defects which can be detected by unaided visual inspection Optical Aids Used for Visual Inspection Microscope Borescope Endoscope Flexible fibre-optic Borescope (Flexiscope) Telescope Holography Applications 7 CHAPTER 3. Liquid Penetrant Testing 3.1 Physical Principles Procedure for Penetrant Testing Cleaning Penetrant application Removal of excess penetrant Application of developer Inspection and evaluation Penetrant Testing Materials JJ Penetrants Cleaners and emujsitiers Developers Special requirements Test blocks 12 v vii i.x 1 4 8
3 xii Contents _ 3.4 Penetrant Testing Methods Water washable method / Post-emulsifiable method / Solvent removable method /4 3.5 Sensitivity Applications and Limitations Standards Typical Examples 16 CHAPTER 4. Magnetic Particle Testing 4.1 Magnetism-Basic Definitions and Principle of MPT Principle of MPT Magnetizing Techniques Magnetization using a magnet Magnetization using an electromagnet Contact current flow method Using the threading bar The coil Induced current flow Procedure Used for Testing a Cümponent Equipment Used for MPT Sensitivity Limitations Standards Typical Examples 30 CHAPTER 5. Eddy Current Testing 5.1 Principles Instrumentation für ECT Techniques High sensitivity techniques Inspection of heal exchanger tubes by single frequency ECT system Multifrequency ECT High frequency ECT D or phased array ECT InspectiQn offerromagnetic materials Sensitivity Advanced Eddy Current Test Methods Magneto-optic/eddy current imaging (MOl) Pulsed eddy current testing Low frequency eddy current lesting SQUID based eddy current testing Applications Limitations Standards 62 CHAPTER 6. Radiography 6.1 Basic Principle
4 Contents xiii 6.2 Eleetromagnetie Radiation Sourees X-ray souree Produetion of X-rays High energy X-ray souree Gamma ray sources Properties of X- and gamma rays Radiation Attenuation in the Speeimen Effeet of Radiation on Film L Film ionisation Inherent unsharpness Radiographie Imaging GeometrieaJ faetors Radiographie film Intensifying sereens Film density Radiographie sensitivity Penetrameter Determining radiographie exposure lnspeetion Teehniques Single wall single image teehnique Double wall penetration teehnique Latitude teehnique Special teehniques Applieations of Radiographie Inspeetion Limitations Typical Examples Real Time Radiography Mierofoeal Radiography Advantages and limitations of mierofoeal radiography, Applieations Safety in Industrial Radiography Radiation units Limits for radiation exposure Methods for exposure eontrol Radiation monitoring Standards Neutron Radiography Prineiples of neutron radiography Neutron sources Moderator and eollimator Neutron deteetion Applieations ofneutron radiography 91 CHAPTER 7. Ultrasonic Testing 7.1 Basie Properties of Sound Beam Sound waves Veloeity"ofultrasoniewaves Aeoustie impedanee Behaviour of ultrasonic waves 96 93
5 xiv Contents' _ 7.2 Ultrasonic Transducers Characteristics of ultrasonic beam Attenualion Inspection Methods Normal incident pulse-echo inspection Normal incident through-transmission testing Angle beam pulse-echo testing Criteria for probe selection Flaw sensitivity Beam divergence Penetration and resolution Techniques for Nonnal Beam Inspection Fatigue cracks IncJusions, slag, porosity, and large grain structure Thickness measurement: corrosion deteclion Intergranular cracks: hydrogen attack Techniques for Angle Beam Inspection Pipe inspeclion Flaw Characterisation Techniques Ultrasonic Flaw Detection Equipment Modes of Display A-scan B-scan C-scan Immersion Testing Applications of Ultrasonic Testing Advantages Limitations Standards Mechanical Impedance Analysis Technique Introduction and basic principle I I I Measurement of variations in mechanical impedance I Applications and limitations JJ5 CHAPTER 8. Acoustic Emission Testing 8.1 Principle of AET Technique Instrumentation Sensitivity Applications Standards Structural Integrity Assessment Hydro testing of a Horten sphere / Acoustic Emission Technique for Leak Defection Leak defection in an end shield of a PHWR /23 CHAPTER 9. Thermography 9.1 Basic Principles
6 Contents xv 9.2 Oetectors and Equipment Techniques Applications Thermal imagining for eondition monitoring of industrial eomponent Codes and Standards 131 CHAPTER 10. In situ Metallographie Examination Approach to the Selection of Site for Metallographie Examination Replication Process Significance of Microstructural Observation Oecision Making Applications 13) 10.6 Codes and Standards Typieal Case-Studies for assessment of components by IN-SITU Metallography Assessment of degration of a heavy water plant eomponent 136 CHAPTER 11. Leak Testing 11.1 Measurement of Leakage Leak Testing Methods Leak Oetection Bubble testing Helium leak deteetor Standards 143 CHAPTER 12. Comparison and Seleetion of NDT Methods 12.1 Oefects in Materials Metallurgieal proeess and defeets 146 Casting defects 146 Forging and roljing defects 148 Extrusion defects 149 Drawing defects 150 Welding defects 150 Grinding cracks 153 Heat treating cracks Defeets introdueed during service 154 Cause of material failures Types of material failures Selection of the NOT Method Visual testing (VT) Liquid penetrant testing Magnetic particle testing Eddy eurrent testing Radiographie testing (RT) Ultrasonic testing (UT) Aeoustie emission testing (AET) Thermography Summary Selection of Instrumentation Visual testing
7 xvi Contents Liquid penetrant testing Magnetic particle testing Eddy current testing Radiography testing Ultrasonic testing Acoustic emission testing Thermography Summary 169 CHAPTER 13. ProbabiJity of Detection Concepts in NDT Introduction ProbabiIity of Detection (POD): The Approach TypicaI Methodology for Establishing POD Role of POD Concepts During Design and Operation 176 CHAPTER 14. Statistical Methods for Quality Control Probability Basic concepts Prabability sampie space and tlaw si~e distribution Effect of inspection on f1aw size distribution Statistical Methods Basic principles Contra1 charts Basic princip1es of acceptance samp1ing inspection Sampling plans Taguchi Concepts in Quality Control Basic concepts Total Quality Management Quality Deming's philosophy Concept of total quality management Key ingredients of total quality management Summary 195 CHAPTER 15. Codes, Standards, Specification and Procedures Code Standards International and national standards Industry standards Government and military standards Industry practices Company standards Specification Procedures Indian National Standards for NDT International Standards far NDT ISO standards for quality systems Conclusion 202 GENERAL REFERENCES 203 INDEX 206
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