MAGNETIC PARTICLE INSPECTION

                 This test is generally used to locate cracks and surface defects in a wide range of products. But in particular, it is employed to detect fatigue cracks at points of local high tensile strengths. The name "Magnaflux" is commonly associated with this process. This method is a relatively simple and easy technique. It is almost free from any restriction as to size, shape, composition and heat treatment of ferromagnetic substance.

              This method is restricted to magnetic materials e.g., iron, cobalt, nickel. etc. This test is based on the principle that if there is flaw in the magnetic material through which a magnetic field is allowed to pass, the lines of magnetic force or flux will be distorted near the flaw and lines of magnetic flux will be uniform for magnetic materials which are defect free.

             This test is performed by magnetising the substance and the immersing the test piece in a bath of kerosene oil containing iron oxide powder. One can also use the coloured power. If a crack or void lies across the path of the magnetic flux, each side of the crack or void becomes a magnetic pole which attracts iron powder. The accumulation of iron dust on the crack portion of the sample reveal the crack. This test can detect both internal and external defects. One can detect the cracks caused by quenching fatigue failure in welding, blow holes in castings and grinding operations by this method.

ULTRASONIC TESTING

                       The sound waves whose frequency is above the upper pitch limit of the human ear are called Ultrasonics. Ultrasonic testing and inspection is one of the most useful non-destructive methods in metal testing. Rail roads, water pipes, boilers, air craft parts of forged materials, etc., are tested for cracks, inclusions or other internal discontinuities.

                      Ultrasonic waves are usually generated by the piezoelectric effect which converts electrical energy to mechanical energy. A quartz crystal is used for the purpose.

• The surface of casting to be inspected by ultrasonics is made fairly smooth by machining otherwise ultasonic waves can't be efficiently transmitted from the probe into the casting. Before transmitting ultrasonic waves, an oil or water film is provided between the probe and the casting surface; this ensures proper contact between them and better transmission of waves from the probe into the surface of the object to be tested.
• For carrying out the operation, ultrasonic wave is introduced into the metal and the time intervals between transmission of the outgoing and reception of incoming signals are measured with a cathode ray oscilloscope (CRO). The time base of CRO is so adjusted that the full width of the trace represents the section being examined.
• As the wave is sent from the transmitter, if the test piece is free from cracks, or flawless, then it reflects ultrasonic waves without distortion. If there are any flaws in the specimen, the time taken by the ultrasonic waves will be less as the reflection of these waves will be from flaw points and not from the bottom of the specimen. Cathode ray oscilloscope (CRO) is used to receive the sound signals,whose time base circuit is connected to it. Knowing the time interval between the transmission of the sound pulse and the reception of the echo signal, we can calculate the depth of the crack.

ADVANTAGES : 

1. It involves low cost and high speed of operation.
2. This method is more sensitive than radiography.
3. Big castings can be symmetrically scanned for initial detection of major defects.
4. Depth of penetration for flaw detection or measurement is superior to the other methods.
5. Only single sided access is required.
6. It provides flaw distance information.
7. The minimum flaw size which can be detected is equals to about 0.1% of the distance from the probe to the detect.

DISADVANTAGES :

1. This method of inspection is sensitive to surface roughness.
2. Thin parts may be difficult to inspect.
3. Linear defects oriented parallel to the sound beam can go undetected.
4. Reference standards are often needed.

LIQUID PENETRATION TEST

                    This test is employed for detection of small defects which are very small to detect with naked eye. This test is used to detect surface cracks or flaws in non-ferrous metals. The test specimen is first thoroughly cleaned and dried before the test. A liquid penetrant is applied to the surface; This test employs a visible colour-contrast dye penetrant technique for the detection of open surface flaws in metallic and non-metallic objects. The penetrants are applied by spraying, dipping or brushing over the surface of material to be inspected. The excess penetrant is then washed or cleaned. Absorbent powder is then applied to absorb the penetrants in the cracks, voids which reveals the flaws. This test reveals flaws such as shrinkage cracks, porosity, fatigue cracks, grinding cracks, forging cracks, seams, heat treatment cracks and leaks etc., on casting, welding, machined parts, cutting tools, pipes and tubes.

                  If the fluorescent penetrant is used the developed surface must be examined under ultra violet light to see the presence of defects. This technique is used for non-porous and non-absorbent materials. Care may be taken to clean the surface so that it is free from dust, scale, etc, to have better results. penetrants are highly toxic and flammable and hence proper precautions should be taken both during use and of storage of penetrants.

              Liquid penetrant tests are simple, versatile, portable and inexpensive. The results are easy to interpret but only surface faults can be detected. If a permanent record is required a photograph or videotape or inspectors report may be kept. The use of laser scanners and digital control allows this process to be used as a mass production technique.

ELECTRICAL METHOD

                   The electrical method consist in measuring the electrical resistance of the material and then to note the variation in the electrical resistance. The variation is co-related to the physical defect. A number of electrical methods have been employed in non-destructive inspection and testing of machinery and wide variety of metallic material and parts for dimensional inaccuracies and physical defects.

                   A crack detector operates on the principle that if a crack occurs anywhere within the piece it interfaces with the flow of electric current through the metal, increasing its overall resistance. This holds true regardless of the shape of piece. Operation of the instrument consists of accurately measuring the electrical resistance of some critical machine part between two definitely established contact points, usually chosen at extreme opposite ends and of repeating the measurement at regular intervals. When successive measurements show the increase in resistance at a progressive rate, a fatigue fracture is beginning to propagate and the part should be removed from the surface.

ADVANTAGES:

1. Detects surface and near surface defects.
2. Test probe doesn't need to contact the part.
3. Method can be used for more than flaw detection.
4. Minimum part preparation is required. 

 DIS ADVANTAGES:

• Only conductive materials can be inspected.
• Ferromagnetic materials require special treatment to address magnetic permeability.
• Depth of penetration is limited.
• Flaws that lie parallel to the inspection probe coil winding direction can go undetected.
• Surface finish and roughness may interfere.
• Reference standards are needed for setup.

DAMPING

                    As the Measurement of damping can give information on the origin of defect such as forming of quenching cracks. For Example, an increase in damping was found in steel specimen which had been quenched. It is possible to determine the position of a crack in a cylindrical piece. When a solid specimen vibrates, its free oscillations decay when isolated from their environment. Some of the energy is always convert into heat. The various mechanisms by which this transfer of energy occurs are collectively termed as internal friction.