Class 8 NDE PDF

Purpose of Inspection
Non-Destructive
Evaluation
(NDE)
In-service structures
Safety or not
NDE is the only

method to inspect
without damage to
structures.
Advantage of NDE
Selection of appropriate repairment and
retrofitting method
Life prediction by fracture mechanics
Periodic inspection schedule
Chitoshi Miki
Department of Civil Engineering
Tokyo Institute of Technology
Types of NDE Methods
Visual Test (VT)
2 main types for different types of cracks
Preliminary inspection of structures
Surface-breaking cracks
VT
PT
MT
ET
UT
:
:
:
:
:
Visual Testing
Dye Penetrant Testing
Magnetic Particle Testing
Eddy Current Testing
Ultrasonic Testing
Embedded cracks
UT
RT
10X magnification
eyes
crack
difficulty in detection because they are

invisible!!
: Ultrasonic Testing
: Radiographic Testing
3
Magnetic Particle Test (MT)
MT Application at Sites
Equipments
Magnetic
crack
Fatigue
Test
Magnetic flux on specimen

surface is induced by
magnetic field
Magnet
Black Light
Magnetic flux
Magnet powder
light
Testing
Magnet
powder
crack
Leakage at crack
Magnetic flux
specimen
5
Dye Penetrant Test (PT)
PT Application at Sites
Theory
1. Fill the penetrant on specimen
surface
2. Clean specimen surface

(eliminate excessive penetrant)
Penetrant in
cracks only
penetrant
crack
4. Penetrant leaks to film layer

resulting in image of crack
3. Fill the film layer on specimen

crack
Eddy Current Test (ET)
ET Application at Sites
Theory
Equipment
Exciting current
coil
Signal measurement
Eddy current
at specimen surface
If there is cracks or defects, signals will change

9
Ultrasonic Test (UT)

Probe
Transmit the X-ray to the specimen and the film

defect
Radiation source
Sound wave
Types of probes
X-ray beam
Angle-beam probe:
45, 60, 65, and 70
crack
specimen
Film- fuji, kodak
Quality control of welds in shops

Maintenance inspection in sites
A-Scan:
Normal-beam Observe the flaw echo via

probe
CRT display
amplitude
Radiographic Test (RT)
10
Flaw echo
time
defect
11
12
UT Application at Sites
Research Works on NDE

Topics
Manual UT (MUT)
Detection of surface-breaking fatigue cracks
Chitoshi Miki, Makoto Fukazawa, Masahiko Katoh, and Hisao Ohune: Journal of Structural
Eng./Earthquake Eng., JSCENo.386/I-8pp. 329-3371987.10. (in Japanese)
Automatic UT (AUT)
Effects of paint films on detectability of

cracks by NDI methods
Makoto Fukazawa, Hisao Ohune, Masahiko Katoh and Chitoshi Miki: Journal of Structural
Detection of embedded fatigue cracks
Jiro Tajima, Munehiro Fukui, Chitoshi Miki and Makoto Fukazawa: Journal of Structural
Current development of ultrasonic testing

systems (2001~2004)
13
14
Surface-Breaking Fatigue Cracks
Topics
Fatigue cracks initiated at toes of fillet welds
1.
2.
3.
4.
5.

MT
PT
ET
RT
UT
Which is the most

promising method ?

systems (2001~2004)
How is the resolution

of the method?
15
Specimens and Inspection Methods
16
Fracture Surfaces and Results
Specimens with fatigue cracks
Type B
Fatigue cracks were introduced by 3points bending test.

l (length)
Type A
surface
Type B
a
(depth)
Fracture surface
Results
PT
Inspection methods
MT
Length of cracks
MT, PT, ET
Cracks
Depth of cracks
UT
17
18
Specimen A
Specimen B
MT
Min. detectable size

< 5mm
Estimated length (mm)
Overestimate
a
(depth)
Accuracy ratio = Estimated / Actual

Ratio > 1 Overestimate
< 1 Underestimate

Actual length (mm)
Actual length (mm)
crack
= 6mm
Undetectable
Min. depth = 1 mm
l (length)
surface
ET
Min. depth < 0.5 mm
Slightly
overestimate
PT
MT
= 10mm
Accuracy ratio
a
(depth)
crack
ET
Min. depth = 2.5 mm

Accuracy ratio
l (length)
Minimum Detectable Crack Depths

Effects of
undercut
Accuracy ratio
surface
Actual length (mm)
Length Estimation Results
Actual depth (mm)
Underestimate
PT
Actual depth (mm)
19
Estimation of Crack Depths by UT
Actual depth (mm)
20
Results of UT
Tip-echo method
Specimen A
Actual depth (mm)
crack
b
a
Amplitude
Specimen B
Undetectable
Tip echo + Corner echo

Good estimation
Corner echo
a= 2.5 mm
Only corner echo could not estimate
a= 1.0 mm
Tip echo
Estimated depth (mm)
Distance
Cracks could not be

detected
21
Summary
22
Minimum detectable sizes of defects by NDI methods
Topics
For MT, ET, PT
<
<

For UT

systems (2001~2004)
23
24
Paint Films
Specimens with Paint Films
Most of steel bridge members are coated with paint.

Paint films prevent steel bridges from weathering corrosion.
Load
t = 10mm
Before removal of
paint
After removal of
paint
VT, ET, MT, PT, UT
How does it affect the inspection ?

25
Inspection Results VT (I)
Total
Thickness
=100 m
Actual length (mm)
Painting Process
26
VT (Through paint)
Min. detectable
size
= 4mm
5 Layers
Discontinuities of paint films are

the sign of presence of cracks
Easy to detect
27
Inspection Results VT (II)
Inspection Results ET
Before and after the removal of paint films

Paint
Non-Paint

Paint
= Correct Judgment
= Misjudgment
After removal
28
Non-Paint
= Correct Judgment
= Misjudgment
No sign of cracks
Detectability largely decreases
Almost no effects
Low reliability
29
30
Actual length (mm)
Inspection Results PT (I)
Inspection Results PT (II)

Paint
PT (After removing paint)
Non-Paint
= Correct Judgment
= Misjudgment
After removal of paint films

Slight amount of penetrant
leaks into the cracks
Min. detectable
size
= 6mm
Low color contrast
Underestimate the length of cracks
Detectability decreases
Min. size = 6 mm
31
Inspection Results MT (I)
32
Inspection Results MT (II)
Actual length (mm)

Paint
MT (After removing paint)
Non-Paint
= Correct Judgment
= Misjudgment
Min. size = 2 mm
Min. detectable
size
After the removal
Error = 1 mm
Detectability increases
= 2mm
The most reliable methods

33
Inspection Results UT (I)
34
Inspection Results UT (II)
Inspection procedure

Actual length (mm)
Paint
Non-Paint
= Correct Judgment
= Misjudgment
No large effects
Overestimate the length of cracks

35
36
Summary
Detectable crack length limit
Topics


systems (2001~2004)
37
Specimens with Artificial Defects
38
Procedure for Introducing Defects
JIS-SM58Q
Blowhole-like defects
locations of defects
Totally 11 defects
11 10
Hole
drilling
2 1
Load
Load
3
Apply fatigue test to this specimen until cracks reach surface
4-6
Apply UT and RT
An artificial blow hole
39
Testing Procedure UT
B
Inspection Results
Compare with actual size
Blow Hole Echo
Echo Height
40
Crack
Upper Tip
Echo
Lower Tip
Echo
C-5
C-6
A-9
Estim
eted size
Size
Estimated
by UT [m m ]
19.3
6.2
5.9
Actual Size
[mm ]
19.1
6.3
5.9
Distance
AB C
Good agreement
Weld line
High accuracy of crack size estimation

41
42
Relation of Crack Width and Height

Results detected by UT
Fracture Surfaces
Width ,W (mm)
Width and height are

almost the same
Cracks propagate with

circular shape
w
crack
H
Height ,H (mm)
Cracks have circular

shape.
defect
43
Width of Cracks by RT and UT
44
Summary
UT is better than RT in terms of
accurate estimation of crack sizes.
Width by RT, mm
Good agreement with crack

size >= 12mm
RT:
Underestimate cracks with size 8
12 mm
Recently UT become the most used

method for inspection.
RT:
Cracks with size less than 8mm
could not be detected.
Not dangerous to human

Faster than RT
Width by UT, mm
Cheaper than RT
45
Drawbacks of UT
1. Presentation of results
amplitude
UT lacks reliability and objectivity

in the result presentation.
46
Recent Development of UT
2. Detection of 3D defects
Multi-channel array probes
Linear Tandem Array Probe
Difficult to detect waves reflected

by planar defects
A-Scan
Miki et al. (1999)
Planar Tandem Array Probe
Incident
wave
Flaw echo
Miki et al. (2002)

15mm
time
To
improve
Visualization of defects
To
improve
25mm
48mm
25mm
Undetectable
3D defect
reflected wave
defect
Angle-beam
probes: 70
254mm
Planar Pitch-Catch Array Probe

Miki et al. (2003)
Defect cannot
be detected !!
Angle-beam
probes: 65
129mm
Normal-beam
probes
New type of probes

47
13mm
59mm
48
Ultrasonic Inspection System
Visualization System
Synthetic Aperture Focusing Technique (SAFT)
Personal computer
Recorded wave signals
High-speed
switching system
Selectable
Image of defects
probe
Pulse generator
Array probe
Reliability increased
Actual defects
Advantages of this system

Compact and portable appropriate for in-service inspection
Very fast All wave signals are recorded within 5 seconds
All wave signal can be recorded at sampling frequency of 60 MHz,
which is large enough for defect evaluation.
Three dimensions
Multi-channel array probes
Our target
49
Detection by Linear Tandem Array Probe
Detection by Planar Tandem Array Probe
Cruciform joint
Weld defect in cruciform joint
Setup
probe
3
50
Linear tandem array probe
Cruciform Joint
25mm
8mm
Incomplete
penetration
Image result
Top view
50 mm
probe
High objectivity
8.3mm
40 mm
Geometry
1.5 mm
Side view
Very accurate results
Image of incomplete
penetration
6 mm
50 mm
Incomplete penetration
51
Detection by Planar Tandem Array Probe
52
Detection by Planar Pitch-Catch Array Probe

Steel bridge frame pier
Geometry (unit: mm)
Probe front
Accurate
information in
3D
122
specimen
Shape and size

of defect can be
obtained
Probe
Designed defect
SAFT images
incomplete
Co l
beam
High objectivity
Beam width
Y
322
column
Thickness 22mm
um
n
SAFT images
Beam
t/2
incomplete
t/2
X
53
54

Probe

SAFT results
Inspection at intersection of
incomplete penetrations
Y = 20
Inspection area
SAFT results
SAFT image
X = -20
SAFT images
present at location
of incomplete
penetrations.
Images show accurate

results in shape and
location
SAFT image
55
56
Thank you
57
10

Class 8 NDE PDF

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Purpose of Inspection

NDE is the only

Types of NDE Methods

Visual Test (VT)

2 main types for different types of cracks

Preliminary inspection of structures

difficulty in detection because they are

Magnetic Particle Test (MT)

Magnetic flux on specimen

Dye Penetrant Test (PT)

2. Clean specimen surface

4. Penetrant leaks to film layer

3. Fill the film layer on specimen

Eddy Current Test (ET)

If there is cracks or defects, signals will change

Ultrasonic Test (UT)

Transmit the X-ray to the specimen and the film

Quality control of welds in shops

Normal-beam Observe the flaw echo via

Radiographic Test (RT)

Research Works on NDE

Detection of surface-breaking fatigue cracks

Effects of paint films on detectability of

Detection of embedded fatigue cracks

Current development of ultrasonic testing

Research Works on NDE

Surface-Breaking Fatigue Cracks

Fatigue cracks initiated at toes of fillet welds

Detection of surface-breaking fatigue cracks

Effects of paint films on detectability of

Detection of embedded fatigue cracks

Which is the most

Current development of ultrasonic testing

How is the resolution

Specimens and Inspection Methods

Fracture Surfaces and Results

Specimens with fatigue cracks

Fatigue cracks were introduced by 3points bending test.

Min. detectable size

Accuracy ratio = Estimated / Actual

Min. detectable size

Actual length (mm)

Actual length (mm)

Min. depth < 0.5 mm

Min. detectable size

Min. depth = 2.5 mm

Minimum Detectable Crack Depths

Actual length (mm)

Length Estimation Results

Actual depth (mm)

Actual depth (mm)

Estimation of Crack Depths by UT

Actual depth (mm)

Actual depth (mm)

Tip echo + Corner echo

Estimated depth (mm)

Cracks could not be

Research Works on NDE

Minimum detectable sizes of defects by NDI methods

For MT, ET, PT

Detection of surface-breaking fatigue cracks

Effects of paint films on detectability of

Detection of embedded fatigue cracks