Nondestructive Testing Methods - Training Workbook

37 Pages·2009·3.676 MB·37\37

Nondestructive
Testing Methods
Training Workbook
EW-512-6
Written by
the Staff of Hobart Institute
of Welding Technology
Additional copies can be obtained from:
Hobart Institute of Welding Technology
400 Trade Square East
Troy, Ohio 45373
www.welding.org
[phone]
© 2009. Hobart Institute of Welding Technology, 400 Trade Square East, Troy, Ohio, U.S.A.
All rights reserved.
Printed in the United States of America.
ISBN: 978-1-936058-23-5
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
iii
TABLE OF CONTENTS
TOPIC PAGE
Glossary of Welding Terms v
Introduction to Nondestructive Testing Methods 1
Principles of Visual Testing 7
Principles of Penetrant Testing 13
Principles of Magnetic Particle Testing 19
Principles of Ultrasonic Testing 25
Principles of Radiographic Testing 30
iv
TOPIC 1
INTRODUCTION TO NONDESTRUCTIVE TESTING
OBJECTIVE
To be able to define and identify the purpose for nondestructive testing and the symbols used to indicate
INTRODUCTION
This section includes an overview of nondestruc-
tive testing, its purpose, the basic principles in-
volved with the most common types, giving a de-
scription of the symbols used to indicate methods
of inspection.
Visual Testing

Nondestructive testing is an evaluation process in
which no damage occurs to completed welds or
to the surrounding structure provided the proper
procedures are followed. It is used to qualify pro-
cedures, welders, and to monitor the quality of
production welding.
Penetrant Testing
Nondestructive testing, whether in the shop or
field, can be used for detecting small discontinui-
ties and defects quickly and effectively. The most
common methods for nondestructive testing are:
Visual
Penetrant
Magnetic particle
Ultrasonic
Radiographic
Magnetic Particle Testing
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
1
When choosing an inspection method, take into
consideration the advantages and limitations of the
method.
Ultrasonic Testing
The sensitivity of each method reflects its ability to
respond to a discontinuity’s size, shape and loca-
tion. Visual inspection is limited to discontinuities
exposed to the surface. Radiographic inspection
could be used to detect discontinuities on or below
the surface. The method to employ is based largely
on the degree of quality required for the weldment.
For example, to verify quality, visual or magnetic
particle inspection may be all that is required for low
pressure piping, whereas high pressure piping may
require radiographic testing.
Radiographic Testing
Cooperation between design, welding, and quality
engineers is required to determine which testing
methods to use in order to meet the testing require-
ments of the weldment.
Once the decision is made, it becomes the quality
assurance engineer’s responsibility to provide the
qualified inspector with the details of the inspection
requirements, so the weld can be inspected cor-
rectly.
Magnetic Particle Testing
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
2
PT
PN-17 PT
GTAW 114 45 1114
4 45 Methods of indicating inspection type will be nec-
eMsseatrhyo dwsh eonf innodnicdaetsintrgu citnivsep etcetsiotinng t yisp er ewqiulli rbede.
Tnheisc eiss sgaernye wrahlelyn dnoonned eosnt reunctgivinee teersitningg d irsa rweqinugirse db.y
thTeh iuss eis ogf ennoenrdaellsyt rduocntiev eo tne setinnggi nseyemribnogl sd aranwd iwngrist-
tebny pthroec uesdeu roefs n. ondestructive testing symbols and
written procedures.
111
4
II. NONDESTRUCTIVE TEST
SIYI.M BNOOLSNDESTRUCTIVE TEST
SYMBOLS
Nondestructive testing symbols are standardized
MT 6
mNuocnhd leiksetr uthceti vsey tmesbtoinlsg ussyemdb foolsr wareel dsitnagn.d aAr driezfeedr-
emncuec hlin elik ies uthseed s iynm thbeo lssa musee md afonnr ewr ealsd iwnegl.d i nAg
sryemfebroelns,c ea nlidn eis isa su sloendg inas t hnee cseasmsaer ym faonr naedrd ainsg
inwfoerlmdinagtio sny.mbols, and is as long as necessary for
adding information.
RT 25%
An arrow is used to direct the information to the de-
sired location. It can be placed at either end of the
reAfne raernrcoew liinse u, speodin ttoin gd iruepc to trh deo iwnfno,r mona teioitnh etor sthidee
wdheesriere wde loldcsa atioren .t o I tb cea pnl abcee pdl.aced at either end of
the reference line, pointing up or down, on either
side where welds are to be placed.
Other side
Arrow side
The side of the joint the arrow points to is referred
Other side Arrow side
toT haes sthidee “ oafr rtohwe jsoiidnet ”t.h e T ahrero owp ppoosinittes stoid ies rise fcearrleledd
thtoe a“ost htheer “saidrreo”w. Ist iidse i”m. pTohreta onpt pboesciateu sseid iet sisp ceaclilfieeds
wthhiec h“o sthideer soifd teh”e. Iwt iesl dimedpo jortiannt ti sb etoc abues ien ist psepcetceidfie.s
which side of the welded joint is to be inspected.
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
3
©2009, Hobart Institute of Welding Technology EW 512-6 Nondestructive Testing Methods
3
TThhee ssyymmbboollss uussee iinniittiiaallss ttoo iinnddiiccaattee tthhee tetesstt
VT mmeetthhoodd ttoo bbee uusseedd.. T Thheeyy a arere::
PT VVTT == vvisisuuaal l tteessttiningg
PPTT == ppeenneettrraanntt tteessttiningg
MMTT == mmaaggnneetticic ppaarrtticiclele tteessttiningg
UUTT == uultltrraassoonnicic tteessttiningg
RRTT == rraaddioioggrraapphhicic tteessttiningg
Other side
Other side
Arrow side WWhheenn tthhee tteesstt ssyymmbbooll iiss loloccaatteedd bbeellooww ththee
Arrow side
rreeffeerreennccee lliinnee,, iitt ssiiggnniififieess tthhaatt iinnssppeeccttiioonn iiss ttoo bbee
Arrow side Other side Arrow side ppeerrffoorrmmeedd oonn tthhee aarrrrooww ssididee oof ft hthee j ojoinint.t . WWhheenn
ppllaacceedd aabboovvee tthhee lliinnee,, iitt iinnddiiccaatteess tthhee ininssppeeccttioionn
Other side iiss ttoo bbee ppeerrffoorrmmeedd oonn tthhee ootthheerr ssiiddee..
Other side
Arrow side
Arrow side
Other
side
TThhee tteesstt ssyymmbbooll ccaann bbee ppllaacceedd oonn bbootthh ssiiddeess ooff
RT + PT
tthhee rreeffeerreennccee lliinnee ttoo iinnddiiccaattee tthhaatt eeaacchh ssiiddee ooff t thhee
RT wweelldd iiss ttoo bbee iinnssppeecctteedd..
TThhee ssyymmbbooll iiss cceenntteerreedd bbeettwweeeenn aa bbrreeaakk iinn tthhee
UT rreeffeerreennccee lliinnee wwhheenn iitt ddooeessnn’’tt mmaatttteerr oonn wwhhicichh
ssiiddee tthhee iinnssppeeccttiioonn iiss ttoo bbee ppeerfroformrmeedd. . IInn aalll l
ccaasseess,, tthhee iinnssppeeccttiioonn iiss ffoorr 110000%% ooff tthhee wweeldld
uunnlleessss ootthheerrwwiissee nnootteedd..
DDeettaaiillss,, ssuucchh aass tteessttiinngg pprroocceedduurreess,, ssppeecciifificcaattioionn,,
pprroocceesssseess, , oorr ootthheerr ppeerrttiinneenntt ininffoorrmmaattiioonn aarree
A-12
RT ssoommeettiimmeess ppllaacceedd aatt tthhee eenndd ooff tthhee rreeffeerreennccee l ilninee
iinnssiiddee aa ““ttaaiill bbrraacckkeett””..
WWhheenn lleessss tthhaatt 110000%% ooff tthhee lleennggtthh iiss ttoo bbee
MT 6
iinnssppeecctteedd,, iitt ccaann bbee ssppeecciififieedd bbyy aa sseeccttiioonn lelennggtthh
oorr ppeerrcceennttaaggee llooccaatteedd ttoo tthhee rriigghhtt ooff tthhee ssyymmbbool.l.
TThhee rreeqquuiirreedd sseeccttiioonnss oorr aarreeaass aarree uussuuaalllyly
ssppeecciififieedd iinn tthhee wwrritittetenn pprorocceedduureress. . WWhheenn nnoo
ppeerrcceennttaaggeess aarree nnootteedd,, 110000%% ooff tthhee wweelldd iiss ttoo
RT 25% bbee cchheecckkeedd..
©© 22001009. , HHoobbaarrtt IInnssttiittuutete o of fW Weeldldinign gT eTcehcnhonloogloyg y EEWW 551122--66 NNoonnddeesstrturucctitviev eT eTsetsitnign gM Metehtohdosd s
4
4
TThhTeeh eaa llall llaa arroorouuunnnddd tteteesssttt sssyyymmmbbbooolll iiisss uuussseeeddd wwwhhheeennn t htthhee ei n-
iinnssspppeeeccctttiiiooonnn iiisss tttooo bbbeee pppeeerrrfffooorrrmmmeeeddd cccooommmpppllleeettteeelllyyy aaarrrooouuunnnddd a
aa wwweeellldddeeeddd jjjoooiiinnnttt...
TThhTeeh enn uunmmubbmeebrr e oorff toteefs stttesss tttoos bbteoe ppbeeerr ffoporermmrfeoedrdm iisse diinn ddisiic ctitneedddi ciinnte d
ppaainrree pnnatthhreeesnsiitssh..e TTshihsee. ssTyyhmmeb bsooyll msshhbooowwl nns h hhoeewrreen ss hppeeecrceiififi esesps e ffoocuuifirre s
MMTT
aappfoppulliicrc aaattpiioopnnlissc aootffi o mmnasag gonnfe emttiicac gppnaaerrtttiiicccl leep aiinnrtssicppleeecc ittniioosnnp..ection.
((44))
Multiple reference lines are nondestructive test
33 symbols combined with other nondestructive or
MMwuullettiilppdllieen grr eesffyeemrreebnnocclees . lliiTnnheeess oaarrrdeee nrn ooinnn ddweehssittcrruuhc ctotiivpveee r tateetissottn s
ssyyammnbdbo otlelsss tccsoo ammrebb iipnneeerddf o wwrmiitthhe doo ittshh eeinrrd nnicootennddd eebssytt rrtuuhccett iiovvered eoorrr of
RRTT ++ PPTT 22
wwetehllddeii nnliggn esssyy.mm Tbbhooells sfi.. r sTTt hhoeep oeorrrdadeteiorr niinn i sww hthhiicechh c ooloppseeerrsaattt iiotoonn ssth e
RRTT
aannaddrr otteewss.ttss aarree ppeerrffoorrmmeedd iiss iinnddiicctteedd bbyy tthhee oorrddeerr
ooff tthhee lliinneess.. TThhee fifirrsstt ooppeerraattiioonn iiss tthhee cclloosseesstt ttoo
11
tthhee aarrrrooww..
This multiple reference line shows a single
TThhViigss r ommouuvllettii ppwlleee lrdree fwfeeirrtehen nmcceee ltlli inntheer ossuhhgoohww stso aab ess iinninggsllepee VVct--e d
VVTT ggrrooonoo vvtheee ww aeerllrddo www iistthhid mme eewlltitt htthh arroo cuuoggmhh bttooin babetei o iinnns soppfee vccitsteeudda loo annn d
TT2288
VVTT ++ RRTT tthhreea daairrorrgoorwwa psshiiddicee t ewwsiittthihn gaa mccoeomtmhbobidinnsaa.t tiiVooinns uooaff l vviniisssuupaaellc atainondnd is
rraapddeiioorfggorrraamppehhdiicc ottnee ssthttiineng go tmmheeertt hhsooidddess... I n VVspiisseuucaatlil o iinnn ssdppeeetacctitliisoo nna re
iiss l oppceearrfftooerrdmm ieendd p ooronnc ttehhdeeu ooretthh Tee-rr2 ss8ii.ddee.. IInnssppeeccttiioonn ddeettaaiillss
aarree llooccaatteedd iinn pprroocceedduurree TT--2288..
TThhTeeh eee nneggniingneieneeerreiinnrgign gss ttaasftffaf fccfa acnna pnpr ropovrvoiiddveeid ieinn ffioonrrfmmoraamttiiaootnnio ffnoo rrf or
wwewelleddliidnniggn gaa nnaddn diinn ssinppseepccettiicootnnio nuu ssuiinnsggin sgsy ysmmybbmoobllsso laasn naddn ndno ontteeosste s
oonno ntthh teeh eee nneggniignnieeneeerreiinnrgign gdd rrdaarwwaiwinngignssg..s.
KKnnKoonwwolwleelddeggdeeg eoo ffo ttfhh eteh ettee sstettiisnntggin gmm eemtthheoothddossd,, spp,r roopccroeecddeuudrreeussre,, s,
aannaddn tdthh eeth sseyy msmybbmoobll eoellle eemmleeemnnttessn,, tccsaa, nnc eaennna aebbnlleea byylooeuu y ttooo u bb eetotttt eebrre t-
uunnteddree urrssnttdaaennrdds ttathhniisds tcchooismm cmmooomnnm lloaannn gglauunaagggueea gaaenn dda nhhdee lhlppe lttpoo to
mmmaaiiannittnaatiianni nhh iihggihhgeehrre qqr uuqaaulliaittylyi t aya tta lloto wlwoewerre ccro ocssott.s.t.
LLeennggtthh ooff sseeccttiioonn
NNuummbbeerr ooff tteessttss ttoo bbee tteesstteedd
RReeffeerreennccee lliinnee ((NN)) TTeesstt iinn ffiieelldd
((
((
TTaaiill OtherOthersideside sidessides LL TTsseeyyssmmtt--bbaaoollll--llaarroouunndd
TT
((
SoSorrpp ooeettcchhiiffeeiiccrr aarrteteiiooffeennrreennccee ((ArrowArrowOtherOther BothBoth
AArrrrooww
BBaassiicc tteessttiinngg ssyymmbbooll
©©22©00 002990,,1 HH0oo. b bHaaorrtbt aIInnrtss ttIniittsuutttiteeu ooteff WWof eeWllddeiilnndggin TTgee Tccehhcnnhoonllooolggoyyg y EEWW 55E11W225--661 2 NN-6oo nnNddoeenssdtterrusutccrttuiivcvetei v TTeee sTstteiinsntggin MMg eMettehhtoohddosdss
555
TOPIC 1
REVIEW QUESTIONS
1. Define the purpose of nondestructive testing:
_______________________________________________________________________________________
_______________________________________________________________________________________
_______________________________________________________________________________________
2. Where are nondestructive symbols placed?
_______________________________________________________________________________________
_______________________________________________________________________________________
3. List the common methods of nondestructive testing:
_______________________________________________________________________________________
_______________________________________________________________________________________
4. How long should the reference line of a nondestructive test symbol be?
_______________________________________________________________________________________
_______________________________________________________________________________________
5. An arrow is used to direct the information to:
_______________________________________________________________________________________
_______________________________________________________________________________________
6. The side of the joint the arrow points to is called the:
_______________________________________________________________________________________
_______________________________________________________________________________________
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
6
TOPIC 2
PRINCIPLES OF VISUAL TESTING
OBJECTIVE
To be able to identify the basic principles and applications of visual testing.
INTRODUCTION
Visual testing is the most popular and widely
used nondestructive testing method. It consists
of examining weld and overall weldments and
comparing the evaluation to a set of standards.
When correctly applied, it is an effective method of
quality control insuring conformance to a procedure
and allowing errors to be corrected. This leads to
production of a higher quality weldment at reduced
costs.
Visual inspection practice requires the inspector to
be familiar with all duties which apply to inspection,
such as:
• Learning to read blueprints
• Having a knowledge of welding
• Processes specification
• Procedures and workmanship standards
The inspector must be capable of making:
• Responsible judgments
• Accurately recording data
• Writing concise reports
Even though visual testing is the simplest method
of performing inspections, detailed written procedures
are needed to ensure proper application of the
inspection.
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
7
PREWELD INSPECTION
To perform preweld inspection, an inspector be-
comes familiar with all aspects of the job, such as:
• Material specification
• Bill of materials
• Welding procedures
When completely familiar with all the written de-
tails, the inspector compares the dimensions of
all the parts, checking dimensions to engineering
drawings, and verifying tolerances of parts to en-
sure proper final fit-up of the weldment.
The inspector examines the joint preparation and
surface conditions of the materials for proper
cleaning and lack of flaws. Poor fit-up, contaminat-
ed base metal surfaces, improper equipment, and
incorrect settings can lead to weld discontinuities
or defects.
If backing is specified, it should be in accordance
with the job specifications and be correctly and
securely fastened. The tack welds become part
of the finished weld and should meet the same
soundness requirements.
Preweld inspection should include examining
the equipment to insure it is in proper operating
condition.
© 2010. Hobart Institute of Welding Technology EW512-6 Nondestructive Testing Methods
8