JNDE September 2016

HIGHLIGHTS

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contents 1 4 7 19 30

61 72

90 94

LETTERS - President Talk - Managing Editor Talk - Chief Editor Talk ISNT CORNER - About ISNT - Awards & Awardees / Sponsors CHAPTER SPACE - Chapter Chairmen & Secretary - Chapter News - Chapter Focus - CHENNAI FACE TO FACE Dr.Avinash Sonawane – AERB, Mumbai TECHNICAL PAPERS - Landscape Report Demonstrates Importance of NDT to The UK Economy-BINDT Special Paper - Magnetic Pulse Welding of Dissimilar Materials for Automotive Applications - An Industrial Vision System For Sub Surface Visualization Of Structural Steel Sample Using Digitized Frequency Modulated Thermal Wave Imaging: A Numerical Study - Single Sided NMR for NDE of GFRP – Rubber Interface - Damage Characterization of Ti-6Al-4V Titanium Alloy under Monotonic and Cyclic Loading Conditions BACK TO BASICS - Basic Principles and Industrial applications–Magnetic Particle Inspection - Codes & Standards for Magnetic Particle Testing - Basic Principles - Dye Penetrant Testing - Codes & Standards for Dye Penetrant Testing ARTICLES - Certification of Consumables in Liquid Penetrant Testing and Magnetic Particle Testing – An Overview - The Journey of Magnetic Particle Testing In Bharat Forge.

- Physical Principles, Properties And Dynamic Characteristics Of Penetrant Processing Materials

SEPTEMBER 2016 Volume 14 - Issue 6

JNDE EDITORIAL Team Managing Editor : Mr. Rajul Parikh Chief Editor : Dr. Krishnan Balasubramaniam Editorial Team : Ms. M.Menaka Dr. Sarmishtha Palit Mr. Paritosh Nanekar Mr. Arumugam Dr. Prabhu Rajagopal Mr. Bikash Ghose Mr. Diwakar Joshi Dr. Ravibabu Mulaveesala Dr. Debasish Mishra Dr. M.T. Shyamsunder JNDE Executive : Ms.Rachna Jhaveri ON THE

COVER Page

WHAT'S NEW Product Gallery EVENTS - Indian / International Events Calendar 2016 - Dr. N. Kondal Rao Memorial Award - Brief Report on Student’s Seminar "Behind the Teacher's Desk" (BTTD - 2016) - Refresher Course on Radiation Safety for Radiation Professionals, Radiology Professionals, QA, QC & Non Radiation Personnel - A Brief Report on WCNDT 2016 - Upcoming Event - NDE 2016

101 NGC/NCB - A Brief

- Meeting Schedule / Updates

102 TRAINING

- Qualification of NDT Personnel - Training & Exam Schedule

106 SPECIAL FEATURE - NDE Patents - WORD SEARCH

108 ADVERTISER'S INDEX

This cover photo image signifies the Magnetic Particle Inspection & Dye / Liquid Penetrant Testing methods to detect cracks.

Image Courtesy : Marine Inspection Service Pvt. Ltd., Australia.

OBJECTIVE – This Journal of Non Destructive Testing & Evaluation (JNDE) is published quarterly by the Indian Society for Non Destructive Testing (ISNT) for promoting NDT Science & Technology. The objective of this journal is to provide a forum for dissemination of knowledge in NDE & related fields. Papers will be accepted on the basis of their contribution to the growth of NDE Science & Technology.

The Journal is for private circulation to members only. All rights reserved throughout the world. Reproduction in any manner is prohibited. Views expressed in the Journal are those of the authors' alone.

PUBLISHED BY:-Mr. Rajul P. Parikh Managing Editor – JNDE, Hon. General Secretary - Indian Society for Non Destructive Testing. (ISNT) Modules 60 & 61, Readymade Garment Complex. SIDCO Industrial Estate, Guindy, Chennai – 600 032.

Phone: 044-2250 0412 / 4203 8175. Email:isntheadoffice@gmail.com FOR SUBSCRIPTION, ADVERTISEMENT & OTHER INQUIRIES CONTACT:Ms.Rachna Jhaveri - JNDE Executive. No.8, 2nd Floor, Jyoti Wire House, Near Kolsite, Off. Veera Desai Road, Andheri (W), Mumbai – 400 053. INDIA. Phone:022-61503839 Email : isnt.jnde@gmail.com. Printed at VRK Printing House, Chennai

LETTERS

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Surface & Sub surface methods of Non Destructive Testing & evaluation are key to many QC/QA requirements in various industries. These NDT methods have proven to be most reliable for detection of surface & near surface discontinuities and are used to inspect finished products as well as critical components in-process during production and R & D. The materials inspected include metals, composites, plastics, coated surfaces, glass etc.

Whatever are the market dynamics, Non Destructive Testing industry continues to grow. The demand for all the methods of surface NDT testing is rapidly becoming mandatory for safety of critical components used in most of the core sector industries such as Power, Aerospace, Automotive, Oil & gas, defence etc. All these NDT methods help to verify weld quality & corrosion damage in service to confirm structural integrity of the component without compromising it’s ability to perform in service. Although these NDT methods are time proven & well accepted, there is general lack of understanding of the basic principles & hence the cases of misuse.

The purpose of NDE journal is intended to further the progress of NDT science. The issues of such scientific journals are always read with great seriousness and as such the scientific articles in this journal contains articles which are peer reviewed to ensure scientific validity. The issue also contains articles and information which can be of useful to NDT professionals & NDT community at large.

NDE journal is, now, made available online on ISNT website which will help all interested readers to read, download, and/or print articles at no cost. My sincere congratulations to Managing Editor Mr. Rajul Parikh and Chief Editor Dr. Krishnan Balasubramanian and entire team involved in to bring out this Sept '16 issue. I am sure that all the readers will definitely appreciate their great efforts.

MANAGING EDITOR Talk

Mr. D.J.Varde President-ISNT president@isnt.org.in

Another issue, another intriguing topic!! JNDE September issue focuses on probably the most simple & most widely practiced NDT techniques of “Magnetic Particle Inspection & Dye Penetrant Testing”.

This issue enthralls you as it journeys from the basic principles, characteristics & properties, industrial applications & certification of consumables of Magnetic Particle Inspection & Dye Penetrant Testing to an intriguing journey of more than 50 years of Magnetic Particle Testing technique as used at M/s Bharat Forge, Pune.

We are excited to bring excerpts from a talk with Dr. Avinash Sonawane, Head Radiology Safety Division, AERB, Mumbai, further in Face to Face Section. Readers can stay updated with the events calendar & a brief report on recent events, courses to be conducted in near future & introducing a puzzle to be solved in the MPI technique.

JNDE September is our third edition of the new look format & has so much more to offer in this issue, that you will wish to retain it for future reference. Once again encouraging & calling our readers to share an insight on this journal. We have taken an initiative in introducing our ISNT Team in ISNT Corner, to connect to people you communicate with.

Keep Reading. Stay Connected!

CHIEF EDITOR Talk

Rajul Parikh Managing Editor-JNDE secretary@isnt.org.in

Greetings from the Editor-in-Chief’s desk. I am happy to see many positive reactions to the new look version of our journal. I encourage all researchers and practitioners to kindly contribute technical and industry application articles to this journal. This year’s ISNT conference will be held in Trivandrum and the ISNT Trivandrum Chapter is gearing for a grand event. I request all potential speakers to urgently submit your abstracts and all participants to register as early as possible in order to help organisers plan this event in advance. I look forward to seeing you all at NDE 2016 in Trivandrum.

Krishnan Balasubramaniam Editor in Chief balas@iitm.ac.in www.isnt.org.in

Journal of Non Destructive Testing & Evaluation

September 2016

LETTERS

PRESIDENT Talk

ABOUT ISNT

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| ABOUT ISNT

About ISNT Indian Society For Non Destructive Testing (ISNT) was formed on 21st April 1989 by merger of two societies namely Non Destructive Testing Society of India registered in Calcutta in July 1972 and Non Destructive Inspection Engineering registered at Madras in March 1981. It is a non-profit organization and is registered under the Tamil Nadu Societies, Registration Act, 1975 (Tamil Nadu Act 27 of 1975) Regd. No.49 of 1981.

The Indian Society for Non-destructive Testing (ISNT) is the society for NDT professionals and practitioners which offers invaluable resources, information and linkages for industrial quality development and professional development to its members. The objective of the Society is to promote the awareness of NDT Science and Technology through education, research and exchange of technical information within the country and internationally to its members and other professionals using NDT. The family of ISNT has more than 6000 strong members. It is a diverse and dynamic family of professionals representing NDT technicians, scientists, engineers, researchers, manufacturers and academicians – all dedicated to improve product safety and reliability. These specialists represent virtually every industry and discipline that may benefit from NDT technology.

ISNT holds periodic seminars and workshops on topics relating to NDT methods and applications, as well as exhibitions displaying cutting edge NDT products and services.

ISNT has 19 chapters spread all over the country with headquarters at Chennai. In addition to the above, we have two wings – •

National Certification Board The National Certification Board has been formed for the training and certification of NDT professionals in India and has been periodically conducting Level-I and Level-II courses through ISNT chapters. NCB-ISNT has been recognized by ASNT as the NSO in India and has been periodically conducting Level III ASNT exams right from 1986. NCB-ISNT plays key role in international harmonization of training and certification.

•

QUNEST – Quality through Non-Destructive Evaluation Science and Technology The QUNEST has been formed to : a)Identify NDE issues and thrust areas; b) Foster NDE Science and Technology nationally with international inputs; c) Continuing Education and d) Enhance international standing and make ISNT a global player.

ISNT keeps the members informed about technological advances, new products, certification and training and international linkages.

MEET THE ISNT TEAM

A. SUBRAMANIAN

K. VENKATESWARLU

K. SHAVEETHA

S. EABEN RUTH

RACHNA JHAVERI

ACCOUNTS OFFICER & IN-CHARGE OF ISNT HO In ISNT since 2-1-2012.

Has vast knowledge and experience in Accounts, Taxation & Administration Matters. Managing day to day functioning of Head Office, matters connected with statutory compliance, co-ordinates with ISNT chapters and ISNT Chapters and ISNT Office bearers, arrangements for Meetings, guiding HO Staff in their respective area of work.

In ISNT since 1-11 2010.

In-charge of work connected with Accounts, Preparation of MIS, Payment of Statutory dues maintenance of Accounting Records, Preparation of Monthly Income & Expenditure Statement and matters connected with ISNT Membership.

In ISNT since 23-3-2011.

In-charge of work connected with Training and Certification conducted by NCB-ISNT as per the instruction of NCB Office Bearers.

Takes care of general correspondences and other administration matters of Head Office.

Assisting of Office in charge in regular matters.

In ISNT since 4-82014.

Coordinate with JNDE Executive, Correspondence with Subscribers and other institution in connection with JNDE Journal.

Assisting accounts in-charge in matters connected with preparation of Vouchers, Receipts, Tabulation of Service Tax, Data Entry in Tally and other work assigned from time to time. JNDE EXECUTIVE

In ISNT since 17-8-2015.

In charge of sourcing, handling advertisements, Invoicing, payments follow up. Coordinating payments & JNDE related matter with Head Office.

Correspond & coordinate with Editors/ Authors/ Chapters for write ups & managing contents.

Laying out, designing cover page, proof reading, taking for final print.

September 2016

Journal of Non Destructive Testing & Evaluation

www.isnt.org.in

CHAPTER SPACE

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Shri D.S Kushwah Chairman –ISNT, Ahmedabad Chapter, NDT Services, 1st Floor, Motilal Estate, Bhairavnath Road Maninagar, Ahmedabad: 380028 (Off): 079-25431845 dskushwah@vsnl.net / deepak@ndtservices.co.in Shri Rajeev Vaghmare Hon. Secretary- ISNT Ahmedabad Chapter, C/o. Modsonic Instruments Mfg.co. Pvt. Ltd., Plot No.33, Phase III, GIDC Industrial Estate, Naroda, Ahmedabad - 382 330 (Off): 079 - 22811217 modsonic@modsonic.com Shri Vijayaraghavan Chairman– ISNT-Bangalore Chapter No.303, Rr Takht, 37 Bupasandra Main Road Sanjayanagar Extension, Bangalore - 560 094 Cell:0'9980255932 pvrvan@gmail.com Shri Shashidhar P. Pallaki Hon. Secretary,ISNT-Bangalore Chapter CEO, Pallakki NDT Excellence Center No-411, A, 4th Phase, Peenya Industrial Area Banaglore - 560058 Cell:0'9448060717 pallakki@pallakkindt.com sonaspectionndt@yahoo.co.in Dr. Krishnan Balasubramaniam Chairman, ISNT Chennai Chapter Dean & Professor of Mechanical Engineering, Head of Centre for Non Destructive Evaluation, "MEMH/MDS 301, Department of Mechanical Engineering" Indian Institute of Technology (IITM), Chennai – 600 036 Ph.044 – 22574662 / Cell: 0' 9840200369 balas@iitm.ac.in Shri R. Vivek Hon. Secretary, ISNT-Chennai Chapter Managing Partner, Electro-Magfield Controls & Services, "Plot No.165, Women’s Industrial Park, Sidco Industrial Estate," Vellanur, Kattur Village, Chennai – 600 062 (O) 26366013 / 14/17, Mobile No: 9840023015 emcs@vsnl.net / r_vivekh@yahoo.com / vivek@electromagfield.com Shri Dayaram Gupta Chairman – ISNT Delhi Chapter Cell: 0'9891841907 Shri T. Kamaraj Hon. Secretary, ISNT, Delhi Chapter 799-Pocket - V, Mayur Vihar Phase - I, Delhi – 110091 Cell: 9810364515 isntdelhi@gmail.com /inicondt@yahoo.com Shri P. Mohan Chairman, ISNT Hyderabad Chapter Metsonic Engineers ( P ) Ltd No, 63, Ishaq colony, Wellington Road, Secunderabad, Telangana - 500015 Ph: 9490167000, Fax: 040-27840585 metsonic.engineers@gmail.com Shri M. Venkata Reddy Hon. Secretary, ISNT Hyderabad Chapter Scientist, NDE Division, Defence R&D Laboratory Kanchanbagh, Hyderabad, Telangana, PIN: 500058 Ph: 040-24583940, Cell: 9440472195 mallu.venkatareddy@gmail.com Dr. Amitava Mitra Chairman, ISNT-Jamshedpur Chapter Head, BDM Division CSIR - National Metallurgical Laboratory, Jamshedpur - 831 007 Ph. No. 0657-2345205; Cell: 0'9430717376 amitra@nmlindia.org www.isnt.org.in

Shri Tarun Kumar Das Hon. Secretary, ISNT- Jamshedpur Chapter Sr. Sct., MST Division, CSIR - National Metallurgical Laboratory, Jamshedpur - 831 007 Ph.No.0657-2345076 / Cell:0'9955465980 tkdas@nmlindia.org Shri B. Anandapadmanaban Chairman, ISNT Kalpakkam Chapter, Associate Director, QA-FRFCF & Head, QAD, IGCAR, Kalpakkam - 603 102 Ph: 044-27480071; Cell: 9443881190 bap@igcar.gov.in / anandabala@ymail.com Shri G. Kempulraj Hon. Secretary, ISNT Kalpakkam Chapter Head, Central Workshop Division IGCAR, Kalpakkam-603102 Ph: 044-27480072/27488600; Cell: 9444061792 kempul@igcar.gov.in Shri C.K. Soman Chairman –ISNT –Kochi Chapter, Dy. General Manager (P&U) Bharat Petroleum Corp. Ltd. (Kochi Refinery) PO Ambalamugal 682 302, Ernakulam, Kochi Ph : Off -0484-2821104 Cell:0'9495001014 somanck@bharatpetroleum.in Shri V. Sathyan Hon. Secretary -ISNT Kochi Chapter, SM (Project) Bharat Petroleum Corp. Ltd. (Kochi Refinery) PO Ambalamugal 682 302, Ernakulam, Kochi 0484-2822109 (O) Cell:0'9446086345 sathyanv@bharatpetroleum.in Shri Dipankar Gautam Chairman, ISNT- Kolkata Chapter AB 121, Salt Lake, Kolkata – 700 064 Ph. No. 033 23581072 Cell: 98048 13030 / 98302 03223 dgautam1956@gmail.com / dipankargautam@yahoo.co.in Shri Sreebash Chandra Saha Hon. Secretary, ISNT- Kolkata Chapter 123, Ramlal Agarwala Lane, Meghdoot Apartment, BLOCK A, FLAT NO. 2B, Kolkata – 700 050 Ph. No. 033 2531 6584 Cell: 98300 21818 replndt@cal.vsnl.net.in Shri Ambresh Bahl Chairman, ISNT- Kota Chapter CE(QA), RR Site, NPCIL, PO - Anushakti, Via - Kota (Raj) - 323 307 Ph.01475 - 242164; Cell:0'9413351764 abahl@npcil.co.in Shri A. Varshney Cell:0'9413358365 abhishekvarshney@npcil.co.in Shri Hemant Madhukar Chairman, ISNT- Mumbai Chapter Metal Analysis & Services Pvt. Ltd. 219, Busa Industrial Estate, UdyogBhavan, TokerseyJivraj Road, Sewri, Mumbai- 400 015 Ph. No. 022-2413 0813/ 2413 1160 Cell: 98191 43936 / 98206 38249 Metalanalysis1997@gmail.com Shri Samir K. Choksi Hon. Secretary, ISNT - Mumbai Chapter Choksi Imaging Ltd., 4 & 5, Western India House, Sir P. M. Road, Fort, Mumbai- 400 001 Ph. No. 022-2610 1113 / Cell : 0'9821011113 Choksiindia@yahoo.co.in Shri Jeevan Ghime Chairman, ISNT-Nagpur Chapter M/s. Becquerel Industries Pvt. Ltd. 33, Rushikesh Modern Co-op. Hsg. Society Ingole Nagar, Wardha Road, Nagpur - 440005 Cell: 0'9822565879 jeevan@biplndt.com

Shri Parag W. Pathak Hon. Secretary, ISNT - Nagpur Chapter M/s. NDT Solutions Saket - Pruthvi Appt.

Plot No-. A+ B, Second Floor, Surendra Nagar, Nagpur - 440015 Cell: 0' 7709047371 paragwpathak@yahoo.com Shri M. S. Shendkar Chairman , ISNT Pune Chapter Sonal Industrial Services, Sr. no. 415/1B, Manimangal Society, B-103, Near Siddharth motors, Kasarwadi, Pune-411034.

Cell: 91-9822546332. (O- (020) 46761580) sisndt@yahoo.com / chairman@isntpune.org.in Shri Uday B. Kale Hon. Secretary, ISNT Pune Chapter KUB Quality Services, Plot No 55, Scheme No- 4 Sector 21, Yamunanagar, Nigdi, Pune- 411044 Cell: 91-9822246543. (O- (020) 27661491) anay2000@gmail.com / secretary@isntpune.org.in Shri V Ranganathan Chairman –ISNT, Sriharikota Chapter Chief General Manager, Solid Propellant Plant, SDSC – SHAR, Sriharikota – 524124 Ph:- 08623-225525, / Res: 251503 Fax: 08623-5625 Cell: 0' 9490471915 vranga@shar.gov.in Shri B Karthikeyan Hon. Secretary – ISNT- Sriharikota Chapter Sci/Eng. NDT/SPROB, SDSC – SHAR, Sriharikota – 524124 Ph:- 08623-223076,223382 / Res: 242119 karthikeyan.b@shar.gov.in Shri Elangovan Mudliyar Chairman - ISNT, Tarapur Chapter Shri D B Sathe Hon. Secretary-ISNT, Tarapur Chapter Shri. Mathivanan Chairman, ISNT -Trichy Chapter, General Manager/Quality, New Quality Bldg, HPBP, BHEL, Trichy, Tamilnadu, PIN-620014 Cell: 0’9442649140 gmathi@bheltry.co.in Shri V. Deepesh Hon. Secretary, ISNT -Trichy Chapter, Deputy Manager/NDTL, Bldg-I, HPBP, BHEL, Trichy, Tamilnadu, PIN-620014 Ph.-0431-2575427; Cell: 0’9489054004 secyisnttry@gmail.com Shri G. Levin Chairman-ISNT- Trivandrum Chapter Group Director, PRG/PRSO, TERLS AREA VSSC, ISRO P.O, Trivandrum-695022 Ph:0471-256-3621/3854 / Fax:0471-2562060 Cell : 0’9496050075 g_levin@vssc.gov.in / gopal_levin@yahoo.com Shri Shanmughavel Hon. Secretary, ISNT- Trivandrum Chapter SCI/ENGR SE, QCM/QCG/MME, RFF AREA VSSC, ISRO P.O., Trivandrum - 695022 Ph. No. 0471-2562690 Cell: 0’9249562486 a_shanmugavel@vssc.gov.in / isnttvm@gmail.com Ms. Hemal Mehta Chairman - ISNT-Vadodara Chapter 3, Uday Park, Near M Cube Mall, Jetalpur Road, Vadodara-390 007, Gujarat Cell: 0'9825042087 mehtapmet@gmail.com Shri Jaidev Patel Hon. Secretary, ISNT - Vadodara Chapter 11/A Sudarshan Society, Manjaipur, Near Jain Temple, Vadodara-390 011, Gujarat Cell: 0'9376255166 jaidev@tcradvanced.com / jaipatel74@rediffmail.com Journal of Non Destructive Testing & Evaluation

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CHAPTER Chairmen & Secretary

CHAPTER NEWS

MUMBAI – 20.06.2016 TO 09.07.2016 General NDT course conducted from 20th June to 24th June 2016 for ONGC Engineers. Shri L. M. Tolani was the course Director and faculties were Shri L.Venkatraman, Shri A.S.Tapase, Shri Ashok Trivedi, Shri R S Vaghasiya, Shri Paritosh Nanekar, Shri Arvind Bhide and Shri L. M. Tolani. Two sessions of practical demonstration of NDE were conducted by M/s NDTS India (P)

Ltd., and M/s Institute of Testing Technology.

15 participants were attended the course.

RT Level- II Course & Exam for ONGC Engineers from 26-30, September 2016 and Examination on 1st October 2016. Shri Amar Pathare is Course coordinator .

EC Meeting was conducted on 9th July 2016 at ISNT, Mumbai Chapter.

ISNT, Mumbai AGM on 17th September 2016 at CAPERS Banquet, Sakinaka, Andheri (East).

NDT COURSE CONDUCTED AT ISNT, MUMBAI CHAPTER

BANGALORE – 28.02.16 TO 05.05.16 22.07.16 – 23.07.16 - ISNT Bengalooru Chapter conducted workshop on 'AEROSPACE NDE' at The Rialto Hotel, Ananda Rao Circle, Bengalooru.

Inaugural address was given by Deputy Director General of Civil Aviation, Sri. Shanmugam.

40 candidates sponsored by organisations Boeing, GTRE,HAL, Tata Advanced materials, Wipro Aerospace, Honeywell, Titan Aerospace, Snecma, Hampsons, Quest Aerospace, L&T Aerospace, Service providers & Equipment manufacturers participated.

Sessions were handled by Deputy Director General of Civil Aviation. Sri. Shanmugam, Joint Director General of Aircraft Quality Assurance.

Inaugural address by Sri. Shanmugam.

Deputy Director General of Civil Aviation presenting 'Model of Tejas Aircraft' as Memento

During the vote of thanks, participants gave excellent feed back about the workshop.

The workshop was convened by Sri. P. Vijayaraghavan. Chairman ISNT, Bengalooru chapter.

Sri. Mathivannan, Squadron Leader Ramakrishna, Sri. S.V. Suresh GM (HAL), Smt. Roopa Rajesh, GM (Axiscades Technologies), Sri. Vijayaraghavan.P (ex.HAL), Sri. Ganapathi Sharma (HAL) & Sri. Santosh Narayan, Aero consultant. www.isnt.org.in

Aerospace NDE Workshop - Candidates Journal of Non Destructive Testing & Evaluation

September 2016

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CHAPTER NEWS

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CHAPTER NEWS

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COURSES CONDUCTED FROM MAY TO JULY 2016 1. Radiographic Testing Level-II (IS-13805 /SNT-TC-1A) course and examination was held on 18th May 2016 to 28th May 2016. Number of candidates attended the course and examination was ten.

Mr.S.Subramanian was the Course Director and Mr.R.Sreedaran was the examiner.

Faculties were Mr.B.Ram Prakash, Mr.R.Subbaratnam, Dr.V.Meenakshi Sundaram, Mr.M.Manimohan, Mr.J.Shanmugam, Mr.P.Anandan, Mr.E.Sathya Srinivasan, Practical session was handled by Mr.M.S.Viswanathan and Mr.N.Vasudevan.

2. Surface NDT (MT & PT) Level-II (IS-13805 / SNT-TC-1A) course and examination was held on 16th June 2016 to 25th June 2016.

Number of candidates attended the course was 12 and examination was 14. Mr.E.Sathya Srinivasan was the course director and Mr.C.Srinivasan was the examiner. Faculties were Mr.M.Suresh, Mr.J.Shanmugam, Mr.B.Ram Prakash, Mr.M.Manimohan, Mr.S.R.Ravindran, Mr.S.Sundararaman, Mr.E.Sathya srinivasan, Practical session was handled by Mr.R.Vivek, Mr. M.S.Viswanathan and Mr.S.Velumani.

3. Leak Testing Level-II (SNT-TC-1A) course was held from 27th June 2016 to 3rd July 2016. Number of candidates attended the course and examination was 11.

Mr.S.R.Ravindran was the course director and Mr.T.Gurunathan was the examiner.

Faculties were Mr.P.Palaniappan, Mr.Loganathan & Mr.R.Subbaratnam.

4. Visual Testing Level-II (IS-13805 / SNT-TC1A) course and examination was held on 11th July 2016 to 16th July 2016. Number of candidates attended the course and examination was 10. Mr.R.Chandran was the Course Director and Mr.E.Sathya Srinivasan was the Examiner. Faculties

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were Mr.R.Chandran, Mr.R.Subbaratnam, Mr.Manimohan, Mr.S.Velumani and Practical session was handled by Mr.A.R.Parthasarathy and Mr.S.Velumani.

5. In-house program on Visual Testing Level-II (IS 13805) course and examination was held on 19th July 2016 to 23rd July 2016 at M/s.

NPCIL, Kudankulam. Number of candidates attending the course and examination were 26. Mr.R.Chandran was the examiner.

Faculties were Mr.R.Subbaratnam, Mr.Sathya Srinivasan and Mr.S.Velumani.

MEETINGS CONDUCTED DURING MAY TO JULY 2016 1. Executive committee meeting was held on 1st June 2016.

2. Executive Committee meeting was held on 26th July 2016.

3. Annual General Body Meeting was held on 30.07.2016 at ISNT, Conference Hall, 70 members attended the meeting. Returning Officer Dr.G.S.Kandasamy announced the New Executive Committee Members for the year 2016-2017. Mr.R.Vivek has been elected at Hon.Secretary for the year 2016-2017. Mementos were given to all the members present. Outgoing Secretary Mr.S.R.Ravindran were honoured during AGM proceedings.

CHAPTER COURSES TO BE CONDUCTED i.

Ultrasonic Testing Level-II (IS:13805 / SNTTC-1A) from 3rd August 2016 to 13th August 2016.

ii. In-house training at PT Level-II (IS 13805) from 16th August 2016 to 20th August 2016 at KKNPP, NPCIL. iii. Radiographic Testing Level-II (IS:13805 / SNT-TC-1A) from 14th September 2016 to 24th September 2016.

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CHENNAI – 18.05.16 TO 26.07.16

CHAPTER NEWS

Technical Lecture : Shri C P Chandrasekaran, Principal Consultant from Total Quality Management International delivered evening lecture arranged by ISNT Pune chapter on "Introduction to Recent Upgradation in ISO 9001" on 3rd August 2016 at Hotel Ambassador, Pune. The technical lecture emphasized the major changes in ISO 9001-2015 and was well received by large audience.

About 45 members attended the lecture.

Other Activities : 1. NDT Awareness Workshop for KIT College of Engineering, Kolhapur was conducted on 5th and 6th August 2016. This workshop was attended by about 120 students studying in Mechanical Engineering.

The faculties from ISNT Pune Chapter were Mr. B B Mate (MT and Course Director), Mr. Sunil Gophan (UT), Mr. B K Pangare (RT) & Mr. Kalesh Nerurkar (PT) 2. Executive committee met 3 times during this period.

7th EC meeting on 11th June 2016 8th EC meeting on 20th July 2016 9th EC meeting on 20th August 2016

TRIVANDRUM – 01.12.15 TO 29.02.16

M.R. Kurup Memorial lecture delivered by Shri. M.C. Dathan, Former Director, VSSC

05/06/16 NGC meeting: Chairman & secretary attended the meeting and updated on the status of NDE 2016 08/06/16 EC meeting: Discussed about AGM preparation 15/06/16 LOC meeting: 4th meeting of LOC NDE 2016 held 25/06/16 EC meeting: AGM reports finalized & approved www.isnt.org.in

AGM of ISNT Trivandrum chapter on 09.07.16

09.07.16 AGM: AGM of our chapter was held and 56 members attended along with their family.

20.07.16 LOC meeting: 5th meeting of LOC NDE 2016 held to review the preparation for NDE 2016.

M.R. Kurup Memorial lecture delivered by AGM of ISNT Trivandrum chapter on Shri. M.C. Dathan, Former Director, VSSC 09.07.16 on 09.07.16 Journal of Non Destructive Testing & Evaluation

September 2016

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PUNE – 01.06.16 TO 31.08.16 ISNT Level II Leak Testing Course was organised

by ISNT Pune Chapter. There were total 17 participants from various industry. This was the first certification course after ISNT Pune Chapter got the accreditation from NCB, ISNT. Total 16 participants were eligible for examination. The course duration was from 19th June to 26th June 2016.

The course faculty members were Mr. Chintamani M Khade (Faculty/Course Director) & Mr. B B Mate (Faculty) Examination was conducted on 27th June 2016.

The examiners were Mr. Jayaprakash Hiremath (Regional Controller, West) and Mr. Prashant Khatavkar.

NDT Awareness Course was arranged for AKER Solutions on 14th July 2016. This awareness program was for the employees working in the Engineering, Planning, Design, Project Department. About 32 participants attended the Theory and Practical Demonstration covering RT, PT, MT and UT methods.

The faculties from ISNT Pune Chapter were Mr. B B Mate (RT and PT), Mr. Uday B Kale (UT and MT), Mr. R Sankarlal (Course Coordinator)

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CHAPTER NEWS

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programmes and making mid course corrections whenever it becomes necessary.

The chapter has to its credit pioneering many novel programs. They are as below.

1. Platform for progress – Case Study program 2. Best Operator Award in UT 3. Conducting workshops at University and colleges as early as 1998.

4. MOU with Anna University signed.

5. First Chapter to have one of its members nominated to the University Academic Council.

6. The chapter is primarily responsible for including Non Destructive Testing as an elective subject in the curricula of the graduate engineering student.

7. This chapter was instrumental in bringing together international societies and signing various MOU’s with them during NDE 2002.

NDE 2002 seminar transcended to the next level by the participation of top notch NDT experts from worldwide like Dr. Claudia V. Kropas-Hughes, NDE research leader, Wright Patterson Air Force Base - one of the key persons in USA in the matters of NDT and evaluation, to deliver the keynote address.

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CHAPTER FOCUS : CHENNAI Chennai chapter of ISNT, after the merger of Non Destructive Testing Society of India and Indian Institute of Non-Destructive Inspection Engineering, commenced its operations on April 21, 1989 with a grand re-opening ceremony at Hotel Taj Connemara.

Though IINDIE had an office at Nungambakkam, Madras after the merger, the office space was designated as the Head office of ISNT. Hence the chapter was operating from the head office with a table donated by an esteemed member of Chennai Chapter of ISNT. True to the tradition of IINDIE, ISNT CC focused its attention on training and certification right from the word ‘GO’. Initially the training courses were conducted at rental halls and hotels. The overwhelming response prompted the chapter to hire a flat at the same building during 1997.

The hard work put in by the office bearers and the faculties resulted in the creation of a brand name in the field of NDT Training. The success of the training program propelled the EC and then office bearers to embark upon procuring a flat to facilitate training. With the help of Mr.Thambithurai the present office space measuring 1026 sq.feet at Readymade Garment Complex, Guindy Industrial Estate was procured and inaugurated on 29th February 2004.

ACTIVITIES Presently the 763 members strong is marching ahead by continuing its core function of training and certification, acclaimed by corporate and public sector organizations all over the country. The chapter has in its proud possession an array of specimens with natural discontinuities to initiate the students into the field of interpretation. The chapter has accumulated sufficient number of equipments and accessories to impart practical training to the participants along with manuals prepared by our faculties. The methodology adopted has created enormous awareness in the industries culminating in conducting many in-house programmes. Such successes have propelled the chapter to embark upon hitherto unchartered path of conducting training & certification programmes in VT, LT & ET. It will not be out of place to mention that this is the only chapter accredited by NCB since 2009.

MILESTONES ACHIEVED Chennai chapter has conducted NDE Seminars during 1991, 2002, 2011 and has been awarded to conduct the NDE for the year 2017.

This growth is well neigh impossible without the think tank of the Chapter, The EC meeting, conducted every month and charting out the

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CHAPTER NEWS

INAUGURATION OF ISNT, CHENNAI CHAPTER OFFICE DURING 2004

BEST CHAPTER AWARDS FOR THE YEAR 2006

ACCREDITATION CERTIFICATE GIVEN BY NCB www.isnt.org.in

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8. Celebration of ISNT day, wherein the family of the members are invited and listen to a universally interested topic. The unique function also facilitates the faculty members, examiners, equipment supporters and the awardees of special prizes.

With multifarious activities as mentioned above it is no wonder that the chapter was selected as the Best Chapter, 5 times in the past 19 years.

FUTURE PLANS The event that this chapter is looking forward to is NDE 2017. The chapter is very eager to conduct the seminar in a very grand manner and is looking forward to the cooperation and participation of all the chapters and members of ISNT. We invite you to visit http://nde2017. com/ for information regarding this event.

ACCREDITATIONS Life Time Achievement Award was awarded to six members of the chapter (Mr.A.Srinivasulu, Mr.K.Viswanathan, Mr.Deenadayalu, Mr.R.Sampath, Mr.G.Ramachandran & Dr.O.Prabhakar).

Many Chennai Chapter members have been awarded other awards of Society, to its credit.

Thus it is for all to see the growth of a seed sown three decades back into a huge fruit bearing tree serving the humanity as a whole by spreading awareness about NDT and be instrumental in ensuring a safe society.

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FACE TO FACE

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FACE TO FACE

DR.AVINASH SONAWANE

Head, Radiological Safety Division and External Relations Officer, Atomic Energy Regulatory Board. (AERB) Dr. Avinash U. Sonawane is associated with the Radiological Safety Division (RSD) of the Atomic Energy Regulatory Board (AERB) since 1987.

AERB lays down radiation safety standards & enforces the regulatory provisions for radiation protection in handling radiation sources ( i.e. radioactive material and radiation generating equipment). Dr. Sonawane has qualified Level-III examination of Indian Society of Non Destructive Testing (ISNT). He has been honored by ISNT, Mumbai Chapter with NDT Achievement Award2013 for Training/Education. He is a member of the Technical Committee of the National Accreditation Board for Hospitals & Healthcare Providers (NABH) and has been empanelled as NABH Assessor for Medical Imaging Services (MIS). He has been designated as the national Point of Contact on safety and security of radiation sources in International Atomic Energy Agency (IAEA), Vienna.

How did you take up the subject of Radiation Safety & pursued it to get a doctorate degree in the subject?

Radiation safety is a very interesting, challenging & dynamic field mainly because of new radiation www.isnt.org.in

technologies coming up rapidly in the market for the benefit of the society. So, it is essential to ensure radiological safety while handling radiation sources. You may be aware that use of ionsing radiation is increasing in almost every field such as healthcare, industrial, agriculture, research and teaching. Today the radiation technology is playing vital role for the benefits of farmers of the country to preserve food and allied products.

Let me share with you my interest in the field of regulation and radiation protection. In 198990 as a designated Radiation Safety Officer (RSO) in one of the industrial intuition, I was asked to plan radiography of a boiler which had a small man-hole for entry /exit & we had to take radiographs of several boiler pipe joints.

The exposure time was few seconds. So, the task was to enter the manhole, position the source and film over the pipe, expose the source and then immediately come out through man-hole, which was virtually not feasible to complete in few seconds. The operator had no alternative but to get some time exposed inside the boiler while carrying out radiography. This was disturbing to me as RSO. I observed on earlier occasions that the awareness about radiation hazards and necessary safety measures to be observed was very poor among the radiography Journal of Non Destructive Testing & Evaluation

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personnel. Trainee radiographers, who mainly operates the radiography devices were little familiar about radiation safety requirements. In some instances, even RSOs, site-in-charges and radiographers were not so aware about radiation safety regulations. Hence, I was motivated to pursue this subject and instill sense of radiation safety amongst these radiography personnel who in many cases do not have the benefit of proper education.

With regard to my research studies on radiation protection of patients in diagnostic radiology, I would like to share with you that moment in my life which triggered me to undertake these studies. My father was suffering from serious illness & was asked to undergo a pelvic X-ray. Though, he was unable to move & walk, he somehow went through the x-ray test. But after a while, he was asked to repeat the X-Ray. He was in unbearable pain so it was extremely difficult for him to get up & position himself for the repeat test. Since, I was aware of the fact that he would receive additional about 710 mGy radiation dose during repeat test and therefore I protested it. I also observed that even radiologists had not much knowledge on the health effects of ionizing radiation and safety precautions for due adherence.

i.e. from nuclear power plants, nuclear fuel cycle facilities and radiation facilities where radiation sources are handled.

“AERB's main mission is to ensure that use of ionising radiation does not cause undue risk to the health of the people and the environment.

AERB is the legal apex authority for enforcing the regulations” You are responsible to provide clarifications on various types of radiation safety issues and concerns faced by various stakeholders and also as External Relations Officer of AERB, you are required to prepare and provide information relating to several parliament issues/questions on this subject as well as to public, media, international atomic energy agency & radiation field practitioners, it is a 24/7 job, how do you manage all of that?

“Radiation Safety is a very interesting, challenging & dynamic subject because of new radiation technologies coming up in the market for the benefit of the society”

I do manage all these functions with my sincere efforts and obviously guidance from the management of AERB. In this context, I must give credit to my staff members who proactively support me in carrying out my regulatory functions even after office hours and on holidays.

It is true that various regulatory issues are to be dealt with after peer assessment and by keeping future implications such as study of emerging radiation technologies in industrial and medical field, human resource development and training, adoption of new radiation protection standards, expediting timely disposal of disused sources, spreading more awareness about safety regulations and safety practices etc. We do have suitable regulatory mechanism and expertise to overcome such issues in an efficient way.

While dealing with such special issues, we always involve specialists from other organizations, academic institutions, research organizations and various concern government ministries/ inter-ministries co-ordinations.

In brief, please tell us about AERB, its role & vision.

What is eLORA? How does one practice it?

Such real experiences made me choose the subject of radiation protection and regulation and of course this is the most essential field that people must know. Because of my interest in Radiation Safety & Regulation, I joined the Atomic Energy Regulatory Board in 1987 - the most appropriate organization for my future professional goals.

AERB was established by president of India in 1983. It was constituted with a very focused mission of preventing/minimizing undue risk to the health of people & environment while using ionizing radiation. Chairman AERB is the legal apex authority for enforcing the radiation safety regulations. AERB regulates all types of radiation and nuclear facilities in the country, September 2016

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The accelerated growth in the application of ionising radiation technology has posed tremendous tasks to AERB for regulating all these facilities to ensure safety and security of radiation sources effectively and efficiently. In order to meet the challenge, AERB took initiative of implementing a state of art web-based system, www.isnt.org.in

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I am also happy to inform that eLORA system has won the SKOCH Smart Governance Award 2015 during SKOCH Summit towards transformative governance in recognition of successful implementation of eLORA “eLORA is a web based, efficient and transparent regulatory system which ensures maximum governance and minimum government�

In the field of NDT, who all are covered & are obliged to be registered under the eLORA? The agencies / institutions possessing radiation source(s) for industrial radiography purposes, the suppliers of radiography exposure devices / sources, the contract awarding agencies, the radiography personnel are the stakeholders in e-LORA in respect of industrial radiography practice.

As on the date, 551 industrial radiography institutions are operational in eLORA and there are 3577 radiographer personnel, which include 1389 Site in Charges, 2188 certified radiographers and 800 RSOs, are registered in eLORA. How do you rate the awareness & safety compliance, within the NDT R practitioners?

It has been noted in the recent years that there www.isnt.org.in

is reduction in number of incidents reported from industrial radiography practice. Overall compliance with regulatory provisions by NDT institutions is satisfactory but needs further effectiveness in implementation of certain safety requirements such as adequate number of certified radiography personnel, availability of calibrated radiation survey instruments/ pocket dosimeters and importantly adequate security measures for radiography sources.

For creating the awareness on safety requirements, AERB organized several awareness programs and participated in various workshops, conferences & published advertisements in newspapers. Our website too has safety directives & clips to create awareness on radiation safety practices. We always take support of other industrial organizations/ associations like ISNT, NANSO for disseminating safety information.

General perception is that AERB is a policeman, to be feared & a hindrance to their work, how do you plan to change the mindset & make RT practitioners voluntarily adopt safe practices?

I do not agree to this. AERB is a high level scientific regulatory organization, having qualified & recognized expertise in fields like engineering, radiological and environmental science to name a few. If we observe any noncompliance, we scientifically review from the radiological consequences view point and whether the non-compliance has resulted into degradation of overall safety status and safety culture of institution. Based on such assessment, appropriate enforcement actions are taken.

We follow sequential steps in the enforcement of actions such as issuing a notice to licensee, providing opportunity for personal hearing and then enforcement of appropriate action.

Requirements for ensuring safe handling of radiation sources is the responsibility of employer and licensee & they should respect the same for sincere implementation as these requirements are for their own safety as well as safety of occupational workers and the public.

What is the role of AERB in training practitioners? Can ISNT play a role in this?

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e-LORA (e-Licensing of Radiation Applications) through automation of regulatory processes associated with the use of ionising radiation.

This is AERBs initiative towards the minimum government and maximum governance. The objective of the project is to enhance efficiency and transparency in the regulatory processes of AERB. The process is simplified for obtaining regulatory consents from AERB for radiation facilities as well as stakeholders. eLORA is useful particularly to stakeholders and they can view the status of the application on a 24 x 7 basis. The eLORA system facilitates fast and transparent regulatory services to all stakeholders of AERB by online submission of applications. With the development of eLORA , the response from utility and AERB has significantly improved.

The major achievement is the quantum jump in registration of medical x ray equipment.

More importantly, eLORA has proper inventory management of radiation sources in the country. eLORA system is now in fully operational phase since December 31, 2015.

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which requires specific qualification and training for a person to become radiation professional. Training courses for radiographer (RT-1) and Radiological Safety Officers (RT-2) are conducted by Bhabha Atomic Research Centre.

Minimum education qualification and Syllabus for these courses are laid down by AERB and in this regard, in 2012, AERB issued the standard syllabus for training courses on radiological safety. In view of the increased demand for radiation professionals, RT-1 courses have been outsourced to other agencies. Currently five such agencies are conducting RT-1 training courses.

Examination and specialized lectures in these courses are conducted by a joint team of experts from BARC & AERB. Qualified and experienced professional of ISNT play an important role in these courses by sharing their expertise as lecturer. You may be knowing that ISNT, Trichy chapter organizes such course (RT-1) with collaboration of BHEL. Trichy and other ISNT chapters can also carry out an assessment to meet the demand of these courses in future.

“Industrial radiography is a specialized profession which requires specific qualification and training for a person to become radiation professional.”

When there are incidences involving compromised safety, what is your advice to the NDT practitioners & the management of the organization, in handling the situation?

All the NDT agencies should have the attitude for safety as priority which results in “doing the best job, not the fastest job”. I have always noticed that radiography personnel work under pressure, it may be from NDT organization or work contractors & quality assurance agencies.

I also sympathize with the NDT personnel who do experience very uncomfortable work environment. They have to work in wee hours or in open field, due to which concentration on job gets affected which increases chances of occurrence of unusual incidences. My advice to them is that whenever a source in under unsafe or insecure condition, or is misplaced, one must inform employer, RSO and AERB immediately and at least within 24 hours, so that further actions can be initiated in time by involving other concerned agencies for handling the incident. Information about causes of incident, September 2016

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preventive measures and lessons learn must be disseminated among radiography personnel.

“All NDT agencies should have safety as their priority. Thereby, doing their job at it's best & not fastest.”

What are the basic safe practices one must adopt while performing RT? In the field of radiography today, a very stateof- the- art equipment are being operated with robust safety interlocks, source position indicators, multi-purpose key etc. While in earlier time (before 1990) , manually operated radiography devices were being used, due to which some skin burn incidences were reported. Today, institutions like the Board of Radiation and Isotope Technology, Department of Atomic Energy and companies like Electronic Engineering Co., are suppliers of remotely operated radiography devices.

It is very essential that proper radiation survey meters (RSM) must be used by radiography personnel to confirm whether source is in exposed position and importantly whether it has been retrieved back to its original shielded condition. This is because, several incidents have been reported due to non-utilization of appropriate RSMs. It is also important to ensure that TLD badges are used by radiography personnel and trainee radiographers. I am sure that the adherence with standard operating procedure for carrying out radiography work and the respectful implementation of safety requirements will ensure almost zero incident in industrial radiography practice.

I advice that a copy of AERB Safety Code on Industrial Radiography and other safety guidelines must be made available to all the radiography personnel. This is the responsibility of every NDT institution.

What are the other major applications of radiation in industry?

Nucleonic control systems (i.e. nucleonic gauges) are being extensively used in almost all types of industries for online measurement and monitoring of various physical process parameters such as thickness, level, density etc. and also as an elemental analyzer. NCS incorporates radioactive sources of few millwww.isnt.org.in

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The Application of radiation are also being used to assess wear and tear of piston rings and gears in engine and its prevention by suitable lubricant studies. Alloys are frequently subjected to different treatments such as age hardening, annealing, quenching and cold rolling. Radiation sources are used to find the effect on such treatments. The phenomenon of self-diffusion in metals, i.e. movement of atom of metal within crystal lattice. Hence, ionizing radiation is a powerful tool for solution of numerous problems in industry.

Finally what is your message to the NDT community?

NDT institutions, no doubt plays an important role in ensuring quality engineering in the development of country. NDT is indeed a technique to be appreciated where no industrial process is disturbed /altered & quality of steel structures/castings is ensured. Several NDT applications in the country are based on use of radioactive sources. In case of other developed countries, NDT applications based on radioactive sources are gradually replaced by X-Ray equipment, as it is a controlled source of radiation where one can energize the machine whenever required & de-energize once the job is done. We should therefore put our efforts in bringing more x-ray equipment in NDT field and gradually phase out the NDT methods using radiation sources. Therefore, we must adopt new built-in-safety radiation technologies & accordingly generate skilled manpower to ensure safe operations. Never compromise radiation safety while performing NDT tests using radiation.

My message to NDT community is that spread

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awareness about safe operations of ionizing radiation based NDT equipment and organize refresher courses for NDT personnel to keep pace with advance technologies in the field “We must adopt new built-in-safety radiation technologies & accordingly generate skilled manpower to ensure safe operations .“ AERB's challenges / regulatory concerns on overall application of radiation technology.

My main concern is for radiographers and trainee radiographers to whom we should conduct separate periodic refresher safety training courses to make them aware about radiation hazards and safe operating procedures.

ISNT again can play an important role in doing this. As a regulator, my expectation is obviously 100% implementation of safety regulations

by NDT originations to ensure radiation safety of occupational workers, people and the environment. It is indeed a challenge to ensure that safety culture is established among radiography personnel and this culture is implemented and then sustained all the times

by NDT institutions. Remember, development and publication of the radiation safety documents alone cannot ensure the safety but its effective implementation needs inculcation of safety culture among the minds of operating personnel.

Other challenges in general are the further development of regulation to deal with advance emerging radiation technology in applications of radiation in medicine and industry; sustaining continuity in ensuring human resource development programme. For all these issues, the regulatory measures have already been contemplated and are being enforced to deal with effectively.

“As a regulator, my expectation is obviously 100% implementation of safety regulations by NDT originations to ensure radiation safety of occupational workers, people and the environment.”

Dr. Avinash Sonawane as interviewed by Rajul Parikh, Rachna Jhaveri & Saji Janardhanan.

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curie strength and also operates based on X-rays.

The on-line density of industrial products is measured and monitored by Cesium 137 source. I suggest that ISNT can play important role in publishing articles and disseminating information on safe installation and use of NCS in view of their increasing applications in industry

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Let's Hear from You What's New covers Technical Talk, Technical Papers / Articles, Press Releases & New Product Information related to NDT Community. JNDE invites you to write in and send your contributions / submissions to isnt.jnde@gmail.com at least 2 months before Publishing date of JNDE.

TECHNICAL PAPERS

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Landscape Report demonstrates importance of NDT to the UK economy - A special paper Mrs. Rosalyn Behan

Marketing & PR Assistant The British Institute of Non-Destructive Testing Newton Building, St George’s Avenue Northampton NN2 6JB, UK

The recently published 2014 report ‘A landscape for the future of NDT in the UK economy’ identifies the fundamental opportunities and challenges for the NDT community in the UK, and it prescribes several key enabling actions as part of its detailed vision for the future needs of the NDT industry over the coming 20 years (the 20-year vision), in order to encourage economic growth and increase the public’s awareness of and safety through NDT. The enabling actions detailed in the report are expected to assist in the avoidance of a spectrum of obstacles the NDT sector may face if preventative actions are not put into place. The required actions are detailed in four primary sections: new business engagement, people, technology and research and development (R&D). Each of these elements plays a major role in the fight to secure a brighter future for the NDT industry.

Although the need to increase awareness of the NDT and CM industries has been apparent for some time, the idea for the Landscape report was raised about three years ago. Steve Lavender MBE (Co-Managing Director at Lavender International Ltd and former BINDT President) had a series of meetings, early in his presidency in 2012, with his MP, Angela Smith, who arranged a BINDT visit to Portcullis House, where the contingent met MPs from a committee of science and industry. They suggested that BINDT should obtain more quantitative information about the NDT industry in order to appreciate the strategic importance of NDT for the UK economy.

Meanwhile the UK Research Centre for NonDestructive Evaluation (RCNDE) made an attempt to engage with the Technology Strategy Board (TSB) to develop a more cohesive technology transfer plan.

The TSB then started to raise questions about the scale of the NDT community and business impact in September 2016

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order to understand the priorities for investment in the field – including factors such as how much of the economy depends on NDT, what NDT means to the gross national product, how many people are employed and so on.

This prompted the formation of an NDT Working Group, comprising experts from the NDT industry along with RCNDE, the Materials Knowledge Transfer Network (KTN) and National Physical Laboratory’s (NPL)Product Verification Programme.

This Group compiled the Landscape report, based on a series of sector reports produced in 2012, to highlight the prospects for the NDT industry in the UK over the next 20 years, improve awareness of the fundamental role that NDT plays within the UK infrastructure and to overcome the barriers that are holding back future developments that advance the use of NDT as a proactive asset management tool, as opposed to a reaction to a failure or disaster.

The NDT Working Group selected Tony Dunhill –BINDT immediate Past President – as Chair and a cross-sector workshop was arranged by the Materials KTN to identify the opportunities and barriers for NDT to help set the objectives for the Landscape report.

KTNs are one of the TSB’s key tools for facilitating the UK’s innovation communities to connect, collaborate and find out about new opportunities in key research and technology sectors[1]. It was clear that there were often difficulties in getting the latest developments in NDT out of universities and in to use. Robin Young, a member of the Materials KTNadvisory board and technology expert for the Materials KTN transport sector at the time of the report, suggested that NDT become a topic that the Materials KTN should address. Robin says: “I always felt that NDT was underrepresented in the portfolio

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of activities that the Materials KTNwas working with. I was aware of how well-matched the NDT themes are with the strategic agenda of the TSB. I felt that it was the right time to raise awareness in the community and this report was an important part of that process.”The need to be able to demonstrate the national importance of NDT and how it underpins many different sectors and technologies, as well as finding a way to help secure funding (especially from the government’sDepartment for Business Innovation and Skills(BIS)) for technology transfer activities,were all agreed as priority issues,as was the need to gain more information on how the NDT community fits overall within the UK economy.

Common strategic issues Within the Landscape report is a section highlightingthe main sectors within the NDT industry– the sector review. The data on these pages are provided for the insurance, aerospace, rail, marine, civil infrastructure, power, oil & gas, advanced manufacturing and defence sectors.To obtain this information, a survey was produced for representatives from each sector to complete.

Obtaining quantitative data proved to be one of the most challenging tasks for the group – for example, there was no national register for NDT qualifications.

“It suddenly became apparent that there were a lot of things we didn’t know, like how many inspectors there are in the various sectors,because there are numerous qualification schemes, such as PCN, ASNT, CSWIP, company schemes and the like,” declaresTony Dunhill. The working group found that the figures for the actual UK market size were also difficult to quantify. Tony continues:“It is quite hard to get numbers for the actual market size of the NDT industry in the UK itself. We can make qualitative assessments but NDT is performed in most tiers of a supply chain, which may be global, making UK numbers difficult to uncover. NDT does, however, underpin all the sectors surveyed, with parts being inspected many times during their service lives.” Despite the difficulties in finding the correct information, it became obvious from the data that was collected that there were many common strategic issues across the different sectors as far as NDT requirements were concerned and, although there were some variations in detail due to the diverse range of sectors under examination,

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the overall drive was the same –training and research & development.

The training of new NDT inspectors is a clear example of how the key enabling actions detailed in the Landscape report are intended to work. In the UK, training and certification in NDT is seen as the international gold standard. This great achievement is, however, currently being overshadowed by an ageing workforce (many of whom are nearing retirement age) and limited external awareness of the significance of NDT in respect of economic growth and public safety.“The main barriers are a lack of awareness of what is possible and that is accentuated by a shortage of people who are skilled both technically and have a commercial instinct as well,” says Robin Young. Training an NDT inspector can be expensive and thus of particular concern for some organisations. It is, therefore, of paramount importance to raise the profile of NDT throughout the education system by building schemes to encourage enrolment on new programmes, such as apprenticeships, industrial placements and engineering doctorates, in order to resolve the skills shortage currently being faced in NDT, and in turn increase the knowledge and awareness of those who may have previously been oblivious to the existence of NDT. “I will challenge anybody to come across anyone in NDT who was told to ‘go into NDT’.

I think virtually everybody working in the NDT industry today has stumbled across it – this needs to change,”adds Tony Dunhill.

By developing training provisions and facilitating schemes to increase recruitment of professional NDT personnel,the profile of NDT will be raised and strengthened, enablingnew, high-technology capabilities to be addressed with a new generation of NDT inspectors. Tony Dunhill offers the following advice to any personcontemplating a career in NDT, whether considering a change of direction mid-career or leaving compulsory education: “NDT is a career that uses every type of physics you can imagine. Magnetics, heat, light, sound; I can point you to a place that uses them all. There is even a place for the use of radioactive gas, which I wouldn’t recommend –but it is a technique! So, if you have a remote interest in science and you are interested in doing slightly daring stuff, then this may well be the right career for you. It requires a whole range of skills and so, even if you are not academically gifted, there is still plenty of opportunity.”

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As new material, designs and operating conditions are developed within the UK infrastructure, there is a marked need for new NDT solutions.Traditional NDT methods can be time consuming and labour intensive so the demand is for faster and more automated systems. To support this the decision by the Engineering and Physical Sciences Research Council (EPSRC) to launch RCNDE in 2003 has helped to rebuild the UK research base into a world-leading resource to deliver the advances needed.

The Landscape report details how more of UK business can benefit from NDT by establishing a PR programme –for example preparing and advertising case studies to demonstrate the successful use of NDT and promoting the benefits of increasing the use of NDT.Keith Newton, Director of RCNDE and co-editor of the Landscape report, says: “For me, one of the most important things is the assembly of business case studies to demonstrate the successful use of NDT to those areas of the economy thatcurrently don’t think too much about NDT. This doesn’t need a lot of investment, it is more a case of consuming people’s time to write up the case studies.”

Technology Transfer However, one of the biggest and most costly barriers to getting new technology through to industry is the technology transfer process. “Technology transfer often requires major investment for validation, commercial prototypes and so on that will require samples, access to facilities and plant for trials,”claims Keith Newton. “It can be very expensive (often more expensive than the research itself), which only prolongs the process of validating techniques to move them into a commercial state.”

The slow-moving validation stage is described in the Landscape report using the classic example of the ultrasonic time-of-flight diffraction (TOFD) technique developed in 1985, which took over 20 years to become mainstream. The report speaks of seeking more ‘imaginative routes for funding’ in order to expose new commercial opportunities and to eliminate the risk from the transfer of new technologies. “Because it is expensive, small companies can’t afford to do it. We are trying to get more systematic approaches to funding validation.

One of the outcomes of the Landscape report is the need for a national defects library to help significantly lower the costs, as well as shared-cost projects. There has also been some talk of looking for September 2016

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capital investment for a major structural integrity NDT centre, which would include things such as validation.” The main need for the Landscape report was to help to set the scene for any new funding opportunities. The fact it has been written by a cross-sector group will enhance its validity.

The further maintenance and development of the level of the UK NDT capability and investment is fundamental in delivering new technology to meet the future industry challenges outlined in the 20year vision of the report. In order to accomplish this, NDT requires recognition for the scope of its influence. “It is a world market,” says Tony. “Most of the large companies who rely on NDT have a very clear view as to what their NDT requirements are going to be in five, 10 and 20 years’ time. We have written that down as a vision of the future and have provided that to our academic collaborators.

They are working on material that meets what we need. This kind of collaboration is quite rare, so many diverse industries actually having the same requirements. If we can get good technologies into companies in the UK to inspect what our companies want, all the other companies in the world will want the same thing.”

A clear example of what Tony speaks of emerged from the Hatfield rail crash case,one of several rail disasters that changed the face of safety in Britain’s rail infrastructure through NDT. On 17 October 2000, a passenger train (travelling northbound from London) de-railed just south of Hatfield.

Four passengers were killed and around 70 were injured. The two main causes of the accident were later revealed as ‘rolling contact fatigue’ and ‘head cracking’ (defined as multiple surfacebreaking cracks on the gauge corner and rail-head) [2].The recommendations following the crash investigation,carried out by HSE and the British Transport Police (BTP), included the evaluation of other methods for the non-destructive testing of rail (for example eddy current) and the need for increased technical and managerial competence for all employees with a responsibility for any aspect of track maintenance[3].

An explanation of the positive effect that NDT has had on the UK rail system since 1998 is detailed in the Landscape report. By utilising NDT techniques (in this case ultrasonic testing) as an asset management tool, the break rate on the UK rail network has been

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significantly reduced from around 900 per year (prior to the Hatfield incident) to an encouraging 125 per year in 2012[4].Tony speaks of the value that the application of suitable NDT has on the rail system and the world market: “It is so rare to have the data of how many cracks are actually there. Network Rail knew that in 1998 they had 952 cracks. By putting an NDT inspection in place, they started clearing the cracks from the rails. Over time, the inspections improved, enabling the detection of smaller cracks.

Since then, they’ve gone even further and so now this figure has been greatly reduced. The other beautiful part is that they realised that they could license this management process out to others; it wasn’t buried in Network Rail. The Indian railway network (to name just one) is now using the same management process. So, not only has Network Rail improved the UK’s rail system and made our lives safer but it has also improved other global systems.

That’s an attractive and morally responsiblebusiness model.”

detailed how NDT impacts on that competence.There wasn’t one that we didn’t have some influence on. I feel that really demonstrates how enabling NDT is.

It’s not a ‘thing’ in its own right, but it enables many other entities.”

The Landscape report draws the conclusion that the UK NDT industry and R&D base is already well positioned,butcapable of delivering much more value to the economy in the UK and on a more global scale if it can be stimulated with cross-sector investment aimed at addressing improvements in technology transfer rates, increasing business performance and growth and better recognitionof the value of risk reduction through theapplication of advanced NDT. For more information and to view the full report visit http://www.bindt.org/downloads/MaterialsKTN-Future-of-NDT-in-UK-economy.pdf [1]

Technology Strategy Board, ‘Knowledge Transfer Networks’, 2014. Available: https://www.innovateuk. org/-/knowledge-transfer-networks. Last accessed 25th June 2014.

[2]

A Doherty, S Clark, R Care and M Dembosky, ‘Why Rails Crack?’,2005. Available: http://www.ingenia.org.uk/ ingenia/articles.aspx?Index=318. Last accessed 17 June 2014.

3

Health and Safety Executive,‘Hatfield Derailment Investigation’,2002.

Available: http://www. railwaysarchive.co.uk/documents/HSE_Hatf_IntRep003. pdf. Last accessed 17June 2014.

The next level The priority recommendations and key enabling actions established from the Landscape report are the driving force behind the future of NDT. “We need to look for ways of working together to help the common agenda,” suggests Robin Young.

As the engineering infrastructure ages and more complex systems are developed, the need for more dexterous NDT methods will grow; the speed at which these methods can be implemented must increase considerably and, consequently, an increased need for an up-skilled and new generation of NDT professionals will be imminent. “These are the things that are needed to take NDT forward to the next level, covering areas such as training, research, technology transfer and raising the profile of NDT with companies who don’t think about NDT already,”adds Keith Newton.

The TSB has developed 22 key competencies with the aim to ensure that high-value manufacturing (HVM) is a key driver of UK economic success.

The set of 22 competencies is grouped around five strategic themes and during the compilation of the Landscape report it was discovered that NDT had an invaluable impact on all of them. “This was the most surprising thing we found during our research,” says Tony Dunhill. “In the appendix, we have written a paragraph for each of the competencies and then www.isnt.org.in

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[4]

Harris,‘KTN report’, p8,2014.

Notes for editors About BINDT

The British Institute of Non-Destructive Testing (BINDT) is a UK-based professional engineering institution working to promote the advancement of the science and practice of non-destructive testing (NDT), condition monitoring (CM), diagnostic engineering and all other materials and quality testing disciplines. Internationally recognised, it is concerned with the education, training and certification of its members and all those engaged in NDT and CM and through its publications and annual conferences and events it disseminates news of the latest advances in the science and practice of the subjects. For further information about the Institute and its activities, visit http://www.bindt.org

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What are NDT and CM? Non-destructive testing is the branch of engineering concerned with all methods of detecting and evaluating flaws in materials. Flaws can affect the serviceability of a material or structure, so NDT is important in guaranteeing safe operation as well as in quality control and assessing plant life. The flaws may be cracks or inclusions in welds and castings or variations in structural properties, which can lead to a loss of strength or failure in service. The essential feature of NDT is that the test process itself produces no deleterious effects on the material or structure under test. The subject of NDT has no clearly defined boundaries; it ranges from simple techniques such as the visual examination of surfaces, through the well-established methods of radiography, ultrasonic testing and magnetic particle crack detection,

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to new and very specialised methods such as the measurement of Barkhausen noise and positron annihilation spectroscopy.

Condition monitoring (CM) aims to ensure plant efficiency, productivity and reliability by monitoring and analysing the wear of operating machinery and components to provide an early warning of impending failure, thereby reducing costly plant shutdown. Condition monitoring originally used mainly vibration and tribology analysis techniques but now encompasses new fields such as thermal imaging, acoustic emission and other non-destructive techniques. The diagnostic and prognostic elements, in addition to increasingly sophisticated signal processing, is using trends from repeated measurements in time intervals of days and weeks.

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1

Kudiyarsan S and 2Arungalai Vendan S

Technical Group, Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI), Kalpakkam.

Industrial Automation and Instrumentation Division, School of Electrical Engineering, VIT University, Vellore Email: kudiyarasan@rediffmail.com 1 2

ABSTRACT Several intricacies are encountered during welding of dissimilar metals such as aluminum and copper together.

The joining of copper to aluminum is inevitable for certain application in the electrical industry due to good conductivity and response offered by copper, aluminum for weight reduction. Whilst in the majority of cases, aluminum and copper can be joined by adhesive bonding, mechanical fastening, fusion welding and solid-phase welding techniques. Several intricacies are encountered during welding of dissimilar metals such as aluminum and copper together. Parts made of aluminum and copper joints are suggested for reducing the weight of automobiles to enhance fuel efficiency. This promotes greater demand for joining these two dissimilar materials in different shapes. Magnetic pulse welding has technically sound phenomenon that enables its applicability in joining dissimilar conductive materials. In this process, a high intensity current flowing through a coil near an electrically conductive material generates an intense magnetic field that induces eddy currents in the flyer.

The electromotive force developed gives rise to a current whose magnetic field opposes the original change in magnetic flux. Through this study the feasibility of MPW for joining dissimilar conductive materials are well established.

Index Terms:- Magnetic Pulse Welding (MPW), Magnetic Flux, Eddy current, Welding of aluminum, Electromagnetic force.

I. INTRODUCTION he Magnetic Pulse Welding (MPW) is solid-state joining process employed for similar and dissimilar conductive metals viz., aluminum, brass, or copper to steel, titanium, stainless, aluminum, magnesium copper and most other metals. MPW system comprises a power supply, bank of capacitors, a high-speed switching system and a coil (Fig.1). The parts to be joined are inserted into the coil. The capacitor bank is charged and the high-speed switch is activated. A strong magnetic flux is created around the coil when the current is applied and as a result eddy currents are formed in the parts. The eddy currents oppose the magnetic field in the coil and an opposing force is generated [1]. This force drives the materials together at a tremendous high rate of speed and creates an explosive type of weld (see Fig 2).

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Fig 1

: Magnetic Pulse Welding Power Supply Set Up with capacitor bank.

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MAGNETIC PULSE WELDING OF DISSIMILAR MATERIALS FOR AUTOMOTIVE APPLICATIONS

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Fig 2

: MPW Principle

It’s imperative for the parts undergoing plastic deformation to possess good electrical conductivity which enables lesser energy consumption [2]. For more conductive metals such as aluminum and copper, the less energy is required to achieve a weld.

Owing to the impact velocity and pressure, the inner material must have sufficient structural strength to withstand the impact without deformation [3]. It is essential to maintain higher security level and special safety precautions [4] due to the high current intensity and voltage. MPW welding is associated with reduced formation of these intermetallic phases 5, 6 . The experimental results and welding characteristics for several samples such as AlAl [8], and Al-Fe [9] are reported in the available literatures. However, Al-Cu tubular combination which has greater demand in automobile industries has been less reported with respect to MPW process.

Moreover, the metallurgical characterization and non-destructive tests on MPW specimens in the available literatures are scanty. Hence, in this study, an attempt is being made to weld Al-Cu tubular components with the dimensions of inlet value in automobile industries using MPW process.

Further, mechanical testing and metallurgical characterizations are being carried out.

II. EXPERIMENTAL PRIOR AND PROCEDURES The specimens employed in this study are Al (Driver) and Cu (Flyer). The MPW equipment that is used in this study has a maximum charging energy of 10 kJ. An outer Al pipe was machined to be 0.6 mm thick, 90 mm long, and 10 mm in diameter. An inner Cu rod with an 8 mm diameter was employed.

For the pipe joint, the gap between the Al and Cu was 1mm. The specimens are ground using emery paper to remove marks sustained during machining.

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Fig. 3

: MPW Specimen with Cut Cross Section and inner weld view

First, the voltage had to be charged according to the welding conditions. Then welding is carried out by electromagnetic force from discharged current through a working coil which develops a repulsive force between the induced currents flowing parallel and in the opposite direction in the tube. Fig 3 shows few typical samples after welding has been performed.

It may be observed that there is a reduction in diameter in the area of the weld. After welding, the work pieces are cross sectioned and prepared for examination by standard metallographic procedures such as mechanical polishing down to 1-micrometer grit and light chemical etching. The samples were then examined by optical and scanning electron microscopy. Microanalysis by wavelength dispersive spectroscopy was utilized to evaluate the local distribution of alloying elements at the joint and its vicinity.

The cut cross section of the specimen in Fig. 3 indicates good bonding with visual inspections. The inner weld view exhibits a defect free weld with good bonding nature. Besides, it is clearly noticed that there are no deformations or cracks in the weld portion.

III. RESULTS AND DISCUSSION The welded specimens are subjected to destructive and non destructive tests to evaluate its quality and strength. Metallurgical characterizations are performed to analyze the bond integrity and examined for presences of intermetallic phases.

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III. a. TENSILE TEST

Welded samples are tested on a standard tensile testing machine at a test rate of 5 mm/min. In all cases, failure occurred in the region away from the weld area. The tensile results emphasizes that ductile failure of a welded Al-Cu Rod/Pipe occurs at a distant from the weld. There is no failure on the weld interface.

III. b. METALLOGRAPHY TEST

Welded samples were examined under optical microscope after etching and polishing then the bonding of two materials was verified with magnification ranging from 10X to 100X and observed that there is no imperfections and defects noticed and integrity of both the materials is intact.

III. c. RADIOGRAPHY TEST

Radiography tests are performed for investigating the presence of pore /cluster of pores if any and also to examine the effectiveness of the fused dissimilar joints. X-ray mode with 50Kv and 3mA source is used for this study. The exposure time was about 90 seconds and ASME Sec V is the standard being used (No particular standard given in literatures).

Fig. 4 (a) and 4 (b) shows the sample subjected to radiography tests.

The results of the radiography suggest that the quality is good and free from impurities/pores.

Further, it illustrates good fusion in many samples.

However, in few more samples, the response appears to indicate lack of fusion. It is important to note the fact that, radiography is not a suitable technique for solid state bonds as the thin line of interlayer’s formed at the weldment are not identified generally by x-ray.

III. d. MICRO-STRUCTURAL ANALYSIS

Microstructures of the cross sections of different AlCu welds are presented in Fig. 5.

Fig. 4 (a) : Copper Specimen Subjected to Radiography.

Fig. 5(a) Microstructure of Al/Cu MPW weld sample.

Fig. 4 (b) : A l / C u W e l d m e n t S p e c i m e n S u b j e c t e d t o Radiography.

Fig 5(b) Microstructure of Al/Cu MPW weld sample

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Weld quality appears to vary prominently along the interface from start to end for all welds in this configuration. Generally, the start and end zones of the welds exhibited no or only limited bonding.

In contrast, the centre portion of the welds showed greater bond integrity. The inadequacy in bonding at the corners of the weld zone is a typical feature of MPW cylindrical parts and according to literature is not critical for many applications [11, 12].

Nevertheless, the non bonded/ improperly bonded corner sections can act as a very strong notch pointing at the weld, which would be undesirable and unfavorable for cyclic load or corrosive environment.

The wave pattern by the side of the interface significantly depends on sample geometry and to a negligible degree on the process parameters (Fig. 5 (a) & 5 (b)). Substantial utility of copper cylinders and relatively low pulse energies inhibited the wave formation. Contrary, applying hollow copper cylinders and high pulse energies pronounced waves are visible, especially in the middle section of the welds. This geometrical influence is in accordance with findings in 11 . It is imperative to note that the wave formation process is not mandatory for a good bonding. It is furthermore worth mentioning that to some extent wave formation could also be observed in regions without bonding. Circumventing the formation of intermetallic phases at the welding interface is impossible. The extent of interface depends on the process parameters and is fairly connected with the structure of the interface.

If the interface shows a wavy appearance, the intermetallics mainly concentrate in so called “melt pockets�, which are mostly located at the crests of the waves (Fig. 5a). If EMP produces a wave less

Fig. 6

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: SEM image of Al/Cu welded specimen

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interface, the intermetallic phases form a film of varying thickness (Fig. 5b). It is pointed out that the phase film appears to be interrupted by regions without any intermetallics. For a thickness below 5 microns the intermetallics contain rarely any cracks, voids or pores.

III. e. SCANNING ELECTRON MICROSCOPY (SEM)

The SEM investigations present more information on bonding and phase formations. The SEM of the Al-Cu welded specimen is shown in Fig. 6. It may be noted that the dearth of any diffusion layers leads to the postulation that local melting is mainly involved in the phase formation and bonding process along the interface.

As for low pulse energies the intermetallic phases consist primarily of aluminum, it is deduced that solely aluminum but not copper was molten during low energy MPW. Al-rich phases are formed under strong non equilibrium conditions. From the sharp and stepwise transition in chemical composition between the two parent metals and the formed intermetallic phases it is in accordance with Carpenter and Wittman [13] who deduced that solid state diffusion is not involved as active bonding mechanism in the process of MPW aluminum to copper.

Owing to short bonding time and the finite rates of solid-state phase transformations, there is prospectus that a thin layer on the low-melting point material fused and alloyed with the more refractory copper. Rapid melting and solidification explain the formation of intermetallic phases.

IV CONCLUSION Magnetic Pulse Welding of aluminum and copper generates enough heat at the interface to enhance plenty of mass transfer for the precipitation of intermetallic phases. However, the relative amounts of these phases remained small compared to fusion welding processes because the observed transition region is narrow and discontinuous. The type and chemical composition of the created intermetallics depend on the pulse parameters chosen. This behavior is endorsed to different temperature-time system of the process leading to varying amounts of melting of the two base materials. To impound detrimental effects on the mechanical properties of the joints the thickness of the formed intermetallics

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should not exceed few microns. Above a critical thickness the intermetallics are prone to cracking and spallation.

REFERENCES [1]

Pulsar Ltd.: Magnetic Pulse Welding Solutions, Pulsar Ltd. Raanana, Israel, 2006. http://www.pulsar.co.il/ systems/?did=30 5.9.2009.

[2]

Glouschenkov, V.A., Grechnikov, F.V., Mayshev, B.S.PulseMagnetic Processing Technology when making parts units of Aerospace Engineering. Journal de Physique IV. (1997) Vol. 7, Colloque C3, Suplement of Physic Journal 111. pp.

C3-45 to C3-48.

[3]

4

Weber, Austin. The Cold Welding Process is being used for more and more high-volume applications. Assembly Magazine, (2002).

Neugebauer, R., Loeschmann, F., Putz, M., Koch, T Laux, G.. A production oriented approach in electromagnetic forming of metal sheets. 2nd International Conference on High Speed forming, Dortmund, Germany (2006), pp. 143153.

[5]

Shribman, V. Magnetic Pulse Welding of Automotive HVAC Parts. Pulsar - Magnetic Pulse Solutions, (2007) pp. 1-31.

[6]

Aizawa, T.,Lee, Kwang-Jin, Kumai, Shinji, Arai, Takashi.

Interfacial microstructure and strength of steel/aluminum

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alloy lap joint fabricated by magnetic pressure seam welding. Materials Science & Engineering A, (2007) Vol. 471, pp. 95-101.

[7]

I. Masumoto, K. Tamaki and M. Kojima: Journal of the Japan Welding Society, No. 1, 49 (1980), p.29.

[8]

T. Aizawa and M. yoshizawa: Proc. 7th Symposium Of Japan Welding Society, Kobe, Japan (2001), p. 205.

[9]

2010 1st International Conference on Energy, Power and Control (EPC-IQ), College of Engineering, University of Basrah, Basrah, Iraq, November 30 - December 2, 2010

[10] Ben-Artzy, A.; Stern, A.; Frage, N. ; Shribman, V.; Sadot, O.: Wave formation mechanism in magnetic pulse welding.

International Journal of Impact Engineering 37, 2010, p.

397-404.

[11] Marya, M.; Marya, S.; Priem, D.:On the characteristics of electromagnetic welds between aluminum and other metals and alloys, Welding in the world, 49, 2005, pp 7484 12 Carpenter, S. H.; Wittman, R. H.: Explosive Welding. Annu.

Reviews Mater. Sci. 1975.5, 1975, p. 177-199.

[13] Tsujino,J and Ueoka, T, “Ultrasonic butt welding of aluminum, anticorrosive aluminum and copper plate specimens,� Ultrasonics Symposium, 1988. Proceedings., IEEE 1988, vol. A247, pp. 529-551, April 1955.

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An Industrial Vision System For Sub Surface Visualization Of Structural Steel Sample Using Digitized Frequency Modulated Thermal Wave Imaging: A Numerical Study Siddiqui Juned A1, Dua Geetika2, Arora Vanita2, Ghali Venkata Subbarao3, M Amarnath1 and Mulaveesala Ravibabu1*

1InfraRed Imaging Laboratory (IRIL), Pandit Dwarka Prasad Mishra Indian Institute of Information Technology, Design and Manufacturing Jabalpur, Jabalpur, India 2 InfraRed Imaging Laboratory (IRIL), Indian Institute of Technology Ropar, Department of Electrical Engineering, Ropar, India 3 K L University, Green Fields, Vaddeswaram, Guntur (Dist.), Andhra Pradesh, India-522 502 *ravibabucareiitd@yahoo.co.in

ABSTRACT Non-stationary thermal wave imaging techniques have proved to be an indispensable approach for nondestructive testing and evaluation of solids. This work emphasizes on digitized frequency modulated thermal wave imaging for characterization of steel specimen having inclusions. Multi-transform techniques have been implemented onto the captured thermal response to visualize sub-surface inclusions and further compared by taking signal to noise ratio into consideration.

Keywords: Finite element analysis, Hilbert Transform, Non-stationary thermal wave imaging, Signal to noise ratio (SNR).

Introduction Non-destructive testing and evaluation (NDT&E) of material using infrared thermography (IRT) enables quick and reliable analysis, without impairing its physical, chemical or mechanical properties.

Industrial IRT can be broadly classified into two approaches, namely passive and active [1-5]. In passive approach the test specimen and its subsurface inclusions naturally exhibit different thermal contrast at ambient temperature whereas in case of active approach, an external stimulus is necessary to induce significant thermal contrast. Depending on the external stimulus, different approaches of active thermography have been developed, such as pulse thermography (PT) [1], lock-in thermography (LT) [3], pulse phase thermography (PPT) [4]. The active approach finds numerous applications in thermal NDT (TNDT). Active IRT is widely used to retrieve the

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information regarding thermo-physical properties or NDT&E of materials. Recently introduced nonstationary thermal wave imaging methods [5-11] mainly, frequency modulated thermal wave imaging (FMTWI) and its digitized version (DFMTWI) [6,7] plays a vital role in testing and evaluation by overcoming the problems associated with the conventional methods (PT, LT and PPT) such as high peak power requirements of pulse based techniques and long experimentation time of modulated LT [11].

In FMTWI the incident heat flux is varied by driving the heat sources with a linear frequency modulated signal (in up chirp form), which causes a similar frequency modulated surface heating over the sample. This helps to introduce desired band of frequencies with significant magnitude into the test sample which improves the test resolution.

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In contrast to FMTWI, modulation of the heat sources is much easier in DFMTWI. Furthermore, in DFMTWI we can probe more energy into the sample by introducing harmonics along with the desired band of frequencies which may improve the depth resolution for near surface defects. This paper highlights the capability of DFMTWI technique in visualizing inclusions present in modeled structural steel sample. Further, Multi-transform techniques have been implemented and compared by taking signal to noise ratio (SNR) into consideration [11].

Modeling, Simulation & Data Analysis In this work a 3D finite element analysis (FEA) has been carried out on a steel sample using COMSOL Multiphysics. The mild steel sample with four inclusions {Calcium Oxide (CaO), Magnesium Oxide (MgO), Aluminium Oxide (Al2O3) and Air} (shown in Fig. 1) has been modeled with a finer mesh using 3D tetrahedral elements.

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The FEA was carried out by imposing a DFM heat flux over the surface of the test object and the surface thermal response has been captured at a frequency of 25 Hz. The simulations were carried out under adiabatic boundary conditions, with the sample at an ambient temperature of 300 K. The sample properties and the introduced inclusions are as given in Table 1.

The simulated data has been further processed for the detection of inclusions. This is carried out by constructing phase images obtained from the time domain matched filter approach and the conventional frequency domain analysis as follows: Time Domain Matched Filter Approach. In time domain analysis, time domain phase image is constructed from the circular convolution of the in-phase as well as quadrature-phase of the chosen reference signal with that of the captured temporal thermal response. It is given as [10,12]: (1) where sgn(f) is the signum function and Ref(f) and P(f) are the Fourier transforms of the reference thermal signal ref(t) and the captured thermal response p(t), IFFT and * denote the inverse Fourier transform and complex conjugate operators, respectively. The quadrature of the reference temperature response is obtained using Hilbert Transform (HT) and the frequency response is obtained through Discrete Fourier Transform (DFT).

Fig. 1

: Layout of the modeled mild steel sample with inclusions. (a) Calcium Oxide (CaO), (b). Magnesium Oxide (MgO), (c) Aluminium Oxide (Al2O3) and (d).

Air

Table: 1 Sample Properties

However, the time domain correlation coefficient (CC) image is obtained from the circular convolution between the chosen reference signal and the captured temporal thermal response given as follows [10,12]: (2)

Material Thermal Property

CaO

MgO

Al2O3

Air

Mild steel

Density (Kg/m3)

3350

3580

3975

1.225

7850

Thermal Conductivity (W/m-K)

15

36

30.3

0.024

60.5

Specific Heat (J/Kg-K)

749

960

880

1010

434

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Fig. 2

: The processing approach adopted for construction of pulse compressed correlation co-efficient and phase contrast images [10,12].

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The procedure is schematically represented in Fig.2.

Frequency Domain Analysis. The frequency domain phase image is computed as follows: Suppose p(n) is a temporal temperature data captured at a predefined rate obtained for a given pixel (i,j) in the field of view, then its Fourier transform P(f) is given as [4-6]: (3) where Real(f) and Imag(f) are the real and imaginary components of P(f) respectively.

Further, the phase can be computed as follows [4-6]: (4)

Results and Discussion The present work highlights the capability of DFMTWI approach in visualizing the inclusions present in a structural mild steel sample. In this approach, the test specimen is allowed to undergo a known controlled digital modulated thermal stimulation sweeping their fundamental frequency range from 0.01Hz to 0.1 Hz in 100 s, and the corresponding thermal response of the surface is captured. The temporal mean raise in captured thermal response is removed using a first-order data fitting. Post processing multi-transform (frequency and time domain) techniques have been implemented onto zero mean thermal response and the results obtained are shown in Fig.3. The conventional frequency domain image is shown in Fig. 3. (a), whereas the time domain phase image is shown in Fig. 3. (b). The time domain correlation coefficient image is shown in Fig. 3(c). Results obtained clearly shows that materials with different thermal properties gives different thermal contrast, therefore can be easily utilized for identification of sub-surface feature characteristic and its properties.

Further, Thermal contrasts have been quantified in terms of the materials SNR as computed using: (5)

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Fig. 3

: Results obtained for DFMTWI technique for frequency and time domain transform techniques (a). frequency domain phase image. (b). time domain phase image. (c). time domain correlation coefficient image.

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SNRs have been computed for different inclusions in the mild steel sample for images obtained with different analysis methods as presented in Table 2.

Table 2 Signal to Noise Ratio TRANSFORM TECHNIQUE

SNR in Decibels (dB) for different inclusions CaO (a)

MgO (b) Al2O3 (c)

Air (d)

FFT Phase

60.2195

43.0183

56.5514

62.8375

Time Domain Correlation

76.6976

60.2347

68.0149

82.6174

Time Domain Phase

76.0767

61.5548

70.0866

77.4733

[4]

X. Maldague and S. Marinetti, “Pulse Phase Infrared Thermography,” Review of Scientific Instruments, 74 (1 II), pp. 417-419, 2003.

[5]

R. Mulaveesala and S. Tuli, “Theory of frequency modulated thermal wave imaging for nondestructive subsurface defect detection,” Applied Physics Letters, 89 (19), art.no.

191913, 2006.

[6]

R. Mulaveesala, P. Pal and S. Tuli, “ Interface study of bonded wafers by digitized linear frequency modulated thermal wave imaging,” Sensors and Actuators, A: Physical, 128 (1), pp. 209-216, 2006.

[7]

R. Mulaveesala and S. Tuli, “Digitized frequency modulated thermal wave imaging for nondestructive testing,” Materials Evaluation, 63 (10), pp. 1046-1050, 2005.

[8]

R. Mulaveesala, J. S. Vaddi and P. Singh, “Pulse compression approach to infrared nondestructive characterization,” Review of Scientific Instruments, 79 (9), art.no. 094901, 2008.

[9]

V. S. Ghali, N. Jonnalagadda and R. Mulaveesala, “Threedimensional pulse compression for infrared nondestructive testing,” IEEE Sensors Journal, 9(7), pp. 832-833, 2009.

Conclusion The proposed work highlights the capability of DFMTWI technique to visualize different inclusions present in the test object. Various multi transform techniques have been introduced in time and frequency domain and comparisons have been made among them by taking SNR into consideration. Results clearly show that the time domain approaches are superior to that of frequency domain approache.

References [1]

X.P.V. Maldague, “Theory and Practice of Infrared Thermography for Nondestructive Testing,” Wiley, New York, 2001

[2]

D. P. Almond and S. K. Lau, “Defect sizing by transient thermography I: An analytical treatment,” Journal of Physics D: Applied Physics, 27 (5), pp. 1063-1069, 1994.

[3]

G. Busse, “Optoacoustic phase angle measurement for probing a metal,” Applied Physics Letters, 35 (10), pp. 759760, 1979.

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[10] N. Tabatabaei, A. Mandelis and B.T. Amaechi, “Thermophotonic radar imaging: An emissivitynormalized modality with advantages over phase lock-in thermograph, ” Applied Physics Letters, 98 (16), art.no.

163706, 2011.

[11] V. S. Ghali and R. Mulaveesala, “Comparative data processing approaches for thermal wave imaging techniques for non-destructive testing,” Sensing and Imaging, 12 (1-2), pp. 15-33, 2011.

[12] G. Dua and and R. Mulaveesala, “Applications of Barker coded infrared imaging method for characterisation of glass fibre reinforced plastic materials,” Electronics Letters, 49 (17), pp. 1071-1073, 2013.

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Single Sided NMR for NDE of GFRP – Rubber Interface K.Srinivas, N.Durga Rani and B.V.S.R.Murthy

DoCMP & NDE, Advanced Systems Laboratory, Kanchanbagh PO, Hyderabad-500058 Email: vasu72@gmail.com

ABSTRACT Glass fibre reinforced composite structures are being widely used for various applications in industry. Rubber insulation is used for protecting glass fibre reinforced composite structures (GFRP) from corrosive environments.

GFRP – rubber interface is crucial for the final applications as degradation will lead to catastrophic failure of the composite structure. The quality of the interface depends on the chemical bond between the GFRP and rubber. Due to environment effects the interface may dis-bond over period of time due to chemical degradation of cross links between rubber and GFRP. Nuclear magnetic resonance (NMR) is an advanced NDE technique to study chemical nature of the materials. Solid state NMR relaxometry studies of composite structures are widely used for studying the interfaces non-destructively. In this paper we report single sided inspection of GFRP – rubber interface using proton single sided NMR.GFRP samples with rubber insulation are studied from single side and their chemical signatures are mapped. Dis-bonds are detected as decrease in proton density due to chemical degradation of cross links between GFRP and rubber. Results are elaborated in the paper.

Key words: GFRP, Composite, Rubber, NMR, NDE, Dis-bond.

Introduction Composite materials consisting of fibre reinforcement in polymer matrix are widely used for many industrial applications including aerospace, automotive, marine, and petrochemical and construction industries. Composite structures are fabricated with multiple interfaces in multi layered configuration for specific applications in industries.

Such composite materials exist in a variety of forms having differing materials. Out of many engineered composite materials Glass fibre reinforced polymer (GFRP) composite structures in combination with elastomeric materials are widely used in industrial applications including wind mill blades and oil pipe lines 1,2 . GFRP composite structures are reported to be affected by the presence of moisture and corrosive environments. In such applications the GFRP composite structure is protected by the insulation later (elastomer) which is adhesively bonded to the bare composite structure. Ageing and degradation mechanism of interface caused due to many factors such as temperature, chemical environment and loading conditions on rubber 3 .

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Characterizing such composite interfaces with in multilayered composite structure is by characterizing individual materials before they are combined followed by characterizing the interface alone under various environmental conditions. Interface may widely differ from the individual constituent materials in the multilayered composite. In case of multi layered glass fibre reinforced composite and rubber structure, the interface of adhesively bonded rubber with composite is crucial. The basic parameters that affect the interface include chemical composition of the adhesive and the depth of the interface. Other than these, factors such as process variables, contaminants and exposure to environmental conditions also affect the bonded interfaces. Several advanced NDE techniques are available for studying physio-chemical nature of the bonded interfaces. Nuclear magnetic resonance (NMR) technique is reported to be an advanced NDE tool for characterizing the bonded interface 4 .

Nuclear magnetic resonance (NMR) is one of the advanced and very popular non-invasive methods to probe molecular level properties of many

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materials including advanced composites such as fibre reinforced polymer matrix composites 5 . In standard NMR instruments, a solid state sample is placed inside a homogeneous DC magnetic field (usually superconducting magnets having high magnetic field strength) which influences the protons inside the nuclei to align in the direction of the external magnetic field (Bo). In addition to this, RF magnetic field (B1) at frequency equivalent to the resonance magnetic field is applied for creating perturbation in the proton spins 6 .

Low resolution solid state NMR methods have become popular for their low cost and easy applications to various materials including elastomers and polymer composites. Low frequency NMR equipments use permanent magnets for magnetization and can be used for evaluating materials through relaxometry studies. Low frequency NMR has been reported a useful tool for evaluating microstructure and molecular dynamics of elastomers 6 . Low frequency single sided NMR systems are available as portable NMR systems for various industrial applications for studying chemical nature of materials nondestructively 7, 8 .

In order to cross check degradation of the interface, chemical nature of the bonded interface is monitored using Nuclear Magnetic Resonance (NMR) technique.

Single sided low frequency NMR has been established as a qualitative tool to access the degradation and chemical nature of the elastomeric materials 9 .

Profile NMR-MOUSE which is provided with a high precision lift and mobile spectrometer were extensively used for studying elastomeric materials.

In this technique, sample is tested non-destructively from outside by estimating relaxation times at each location along the depth of the sample. Using a precise stepper motor assembly magnetic field is positioned inside the material at different depths to see the chemical nature of the interface. During profile NMR relaxation experiments spin-lattice (T1) and spin- spin (T2) relaxation times of elastomeric materials are recorded for studying the chemical changes in rubber and polymers. The present paper reports the use of a single sided low frequency (12.88 MHz) portable NMR system for non-destructive evaluation of GFRP-rubber bonded interface.

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Experimental Description of Profile NMR and test sample:

The Mobile Universal Surface Explorer (MOUSE) probes are portable single sided NMR systems designed for applications where sample cannot be inserted into the magnets 10 . These systems were developed by Prof Bernhard Blumich’s group in Aachen, Germany. The system is based on the principle of inside-out NMR where the sample is outside the magnet. These systems are provided with stepper motor for precise lifting of magnets to magnetize the region of interest inside the sample.

For the present studies, we have used commercially available proton solid state NMR system (Model PM 25, Make: Magritek,) with 12.88 MHz rf frequency.

The profile NMR-MOUSE (PM25) is a portable open NMR sensor equipped with a permanent magnet (Bo equivalent to 0.3T) geometry that generates a highly uniform gradient perpendicular to the scanning surface outside the magnets. Figure 1 shows solid state proton single sided portable NMR system (PM25) used for the present work. A flat sensitive volume is excited and detected by a surface RF coil (frequency 12.88 MHz) placed on top of the magnet at a position that defines the maximum penetration depth into the sample 9, 10 . By repositioning the sensitive slice across the object, this scanner produces one-dimensional profiles of the sample with a spatial resolution of 30 m. Saturation recovery and CarrPurcell-Meiboom-Gill (CPMG) pulse sequences were used for determining the T1 and T2 relaxation times respectively 5 . This paper reports results from experiments performed with CPMG pulse sequence at pre-defined position programmed using PROSPA software. The sensor excites a sensitive volume at a fixed distance from the magnet surface as per the program by mechanically moving the sensor the

Figure 1 shows photograph of profile NMR system with sample on the top.

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sensitive volume is stepped through the sample and the CPMG sequence is then applied at each position with an echo-time of 60 s. Then signal from each position is plotted as amplitude versus depth plot to generate depth profile of the sample.

Initially, Glass Epoxy (GE) laminate of 100X100 mm size and 3 mm has been taken over which hydroxyl terminated poly-butadiene based adhesive is used for bonding rocasin rubber (thickness 2 mm). Rocasin rubber is a co-polymer of poly-butadiene and poly acrylo-nitrile. This rubber is well known insulation material used in various industrial applications. In order to bond rubber with Glass epoxy composite material adhesive with hydroxyl-terminated polybutadiene is used. Description and formulation of adhesive material is beyond the scope of the paper.

A uniform coating layer of adhesive of thickness 500 microns is used for bonding rubber material.

Figure 2 below shows multilayered configuration of test sample for solid sate NMR inspection. Inspection is done from Glass epoxy side so that NMR system initially probes glass epoxy followed by adhesiverubber interface and rubber materials. After initial curing at 60oC for 1 hr bond quality inspection was carried out using single sided NMR system described above. Degradation of the rubber and adhesive interface is monitored by heating the sample to higher temperature. The bonded sample is heated to 60 C, 80 C, 100 C, 150 C and 200 C using a hot air oven. After each temperature the sample is taken out and tested for degradation in the bonded interface.

presence of higher proton density due to the hydroxyl terminated poly-butadiene adhesive used for binding the rubber. Profile also shows presence of rubber whose signal intensity values are lower than that of adhesive. The signal from rubber is observed until the entire thickness of the rubber is scanned. Beyond 5.5 mm depth i.e. beyond rubber thickness of 2 mm the signal value fall to baseline indicating absence of protons beyond the rubber material. To know the nature of the adhesiverubber interface T2 (spin-spin) relaxation data is obtained by taking the sensitive slice to the depth corresponding to the interface at 3.5 mm. By placing the sensitive slice at the depth where the adhesiverubber interface is strong, experiments were performed using CPMG pulse sequence. After 2048 scans free induction decay data is taken and fitted to bi-exponential curve to obtain the relaxation times of various polymer species present at the interface.

It is also observed that at 150oC there is distinct dip in the profile data indicating degradation of interface of adhesive-rubber. At 200oC the adhesive has completely degraded and de-bond is created between GFRP-rubber.

Figure 4 shows free induction decay (FID) data obtained for adhesive-rubber interface at various temperatures. The FID data at each of the temperature is bi-exponentially fitted to obtain spinspin relaxation times. It is observed that multiple relaxation times obtained in bi-exponential fit indicate presence of proton species from adhesive material and cross linked polymer of adhesive and

Figure 2 shows configuration of multilayered composite sample with bonded interface for testing

Results and discussion CPMG sequence is used for obtaining data at each of the depth during profile experiments. From the CPMGfast data normalized peak integral value is plotted as a function of depth 9, 10 . Figure 3 shows normalized peak integral value of Glass epoxy sample bonded with rocasin rubber as a function of depth (in microns) at different temperatures. Depth profile data shows no signature of Glass epoxy sample whereas adhesive-rocasin rubber interface show steep increase in amplitude at the depth corresponding of 3 mm (3000 microns). Indicating

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Figure 3 shows 1D depth profile data of GFRP-Rubber bonded with hydroxyl terminated poly-butadiene adhesive.

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Figure 4 shows free induction decay curve of the adhesiverubber interface at various temperatures.

rubber interface. Higher normalized peak value at the adhesive-rubber interface indicates strong bonding between rubber and GFRP material. From the bi-exponential fit spin-spin relaxation times were calculated and classified as T2short and T2 long.

The shorter spin –spin relaxation time (T2short) indicate highly cross-linked interface which is stiffer and hence lower relaxation time compared to polymer species which are free. Table 1 below shows T2short and T2long data of adhesive –rubber interface at various temperatures. From the T2short and T2long data percentage of amorphous and crystalline phases in the adhesive bond interface is calculated using equation 1 given below: (1) Where: Ashort: Constant of T2short Along: Constant of T2long

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From the table 1 it can be seen that with increasing temperature T2 relaxation times were observed to decrease indicating increasing crystalline in the interface. This may be due to further polymerization of adhesive material leading to stiffness and contraction. As it is well known that with increasing cross link density the polymer segmental motion gets restricted leading to decrease in T2 relaxation times 6 . In this case stiff interface is observed beyond 100oC. Contraction in adhesive material leads to phase separation and debond. It is also observed that beyond 150oC, a defect (dis-bond) appeared in the profile data between GFRP and rubber (see figure 3) due to degradation of the interface. At 200oC there is further decrease in the T2 values and increase in crystalline percentage (see table 1). A increasing de-bond thickness is observed in the profile data at 200oC (see figure 3). The degradation of the adhesive is due to increasing polymerization within the adhesive material further solidifying the polymer leading to contraction and debonding at the interface 3 .

Conclusions Single sided NMR relaxometry studies at low magnetic fields has been identified as a new NDE tool for studying thermal aging of adhesive bonded interfaces in polymer composite materials. Solid state single sided proton NMR is observed to differentiate chemical signatures of hydroxyl terminated polybutadiene adhesive and rubber in a multilayer composite sample. The spin–spin relaxation of adhesive-rubber interface has been identified to be distinct from adhesive and rubber. By monitoring spin-spin relaxation times of the bonded interface the chemical degradation can be identified during

Table 1 Spin-spin relaxation data of adhesive-rubber interface S.No.

Temperature ( C)

Along

T2long (ms)

Ashort

T2short (ms)

% Crystalline

% Amorphous

1

60

0.62

7.98

0.70

0.041

46

53

2

80

0.84

5.22

0.53

0.039

61

38

3

100

0.87

3.22

0.38

0.026

69

30

4

150

0.91

2.12

0.11

0.011

89

10

5

200

0.99

0.99

0.009

0.00021

92

8

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bond quality inspection. Single–sided proton NMR has been observed to be useful insitu inspection tool for bond quality of adhesively bonded interfaces.

5

P.T. Callaghan, “Principles of Nuclear Magnetic Resonance Microscopy,” Claredon Press: Oxford, 1993.

6

K. Saalwachter, “Chain dynamics in elastomers as investigated by proton NMR”, Macromolecules, vol. 39, pp. 3291-3303, 2006.

7

B. Bl cmich, NMR Imaging of Materials, Oxford University Press: Oxford, 1992.

8

R. Dykstra, R T. Callaghan. D. Eccles and M. Hunter, “Portable NMR systems for Non Destructive Testing”, Non-destructive testing Australia, vol. 1, pp 15-18, 2005

9

F Casanova, J Perlo, B Blumich: Single sided NMR, SpringerVerlag, Berlin 2011, ISBN 978-3-642-16306-7

References 1

S.K Mazumdar,: Composites manufacturing: materials, product, and process engineering, CRC press 2002. ISBN 0-8493-0585-3

2

P.K.Mallick,.:Fiber-reinforced composites : materials, manufacturing, and design, Taylor & Francis Group, USA2008, ISBN-13: 978-0-8493-4205-9

3

A.E. Somers, T.J. Bastow, M.I. Burgar, M. Forsyth, A.J. Hill: “Quantifying rubber degradation using NMR”, Poly Degrad.

Stab, Vol. 70 pp 31-37, 2000.

4

J K Kim,: Engineered interfaces in fibre reinforced composites, Elsevier Publications 1998, ISBN 0-08042695-6

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10 R Dykstra, M Adams , P.T.Callaghan, A Coy, C.D.Eccles, M W Hunter, T Southern, R L Ward “ A portable Nuclear Magnetic Resonance Sensor System” Sensors and Transducers , Vol. 90, pp 255-266 , 2008.

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Jalaj Kumar*@, B Nagaraja Kowmudi*, Vikas Kumar* Marat Tyunin#, Alexey Soldatenkova# and L.R. Botvina#

*Defence Metallurgical Research Laboratory (DMRL), Hyderabad, India #Institute of Materials Engineering and Technology (IMET), Moscow, Russia @ Corresponding author: Jalaj@dmrl.drdo.in, Phone: +9124586469, Fax: +9124340266

ABSTRACT Stages of damage accumulation process in specimens from Ti-64 alloy at monotonic and fatigue loadings were studied by means of replicas, acoustic emission and ultrasound attenuation methods. Acoustic emission method was used to characterize the damage accumulation process at various stages of loading in real time mode. Acoustic emission sources recorded during the loading of the specimens were located and the cumulative amplitude distributions of acoustic signals were estimated. It was established that cumulative distributions of micro cracks and acoustic emission signals of damage accumulation are well described by a b-value parameters.

Keywords: Acoustic emission; b-value; liner and non-linear ultrasonics; replica

Introduction Life assessment of aeroengine components is a complex multidisciplinary task involving diverse expertise such as Metallurgical and Mechanical characterization of materials, Fracture Mechanics, Solid Mechanics, Numerical Modeling, and Non Destructive Evaluation (NDE). The three broad design philosophies commonly employed in quantifying the service life of critical systems are Safe-Life, Damage Tolerance (DT), and Continuum Damage Mechanics (CDM). CDM is an emerging computational tool for the life assessment and design of aeroengine components wherein, the final fracture event is predicted by quantifying the degradation of the component with the usage as a function of the evolving damage in the component [1-4]. Components in complex systems such as aeroengines are simultaneously exposed to several loads involving monotonic, creep, mechanical and thermal fatigue, and corrosion. The cumulative effect of these loads on the evolution of damage in critical components is matter of serious concern, with significant ramification on their design, operation, www.isnt.org.in

and life-cycle cost. The knowledge of damage evolution during loading on components could be used for condition based monitoring of aeroengines.

The characterization of microstructure, mechanical properties, deformation, damage initiation and growth by Non-Destructive Evaluation (NDE) is vital for assessing the performance of components.

A variety of NDE techniques have been developed for the assessment of ductile, creep and fatigue damage [5-10]. Among these techniques, Acoustic emission (AE) [11-16] can be used for online damage assessment while, linear [17-23] and non-linear ultrasonic [24-30] techniques and replica technique 31-33 can be used offline damage assessment.

Compressor blades are one of the most safety and performance critical components in an aeroengine.

Their failure can cause an irreparable loss of engine and the aircraft as well. The health monitoring of these blades is of extreme importance to minimize, if not eliminate, all possible causes of damage. In this study, damage evolution in Ti-6Al-4V alloy currently being used in compressor blades of aeroengine has been investigated using AE, UT, NLU and replica Journal of Non Destructive Testing & Evaluation

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Damage Characterization of Ti-6Al-4V Titanium Alloy under Monotonic and Cyclic Loading Conditions

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techniques along with the current state of their applications. An attempt has also been made to correlate AE data with replica using b-value concept to characterize multi-scale damage.

Acoustic Signature Analysis Damage Characterization

based

In different areas of science and engineering, scaling laws are used to describe the relationships between certain variables. These laws are based on self-similarity i.e. phenomenon reproduces itself on different time and or space scales [34-37]. The fracture process is multistage and involves the stages of nucleation, accumulation and growth of defects, formation of main crack, and the final fracture. Among the stages, the final fracture has been extensively studied using fracture mechanics concepts. The stage of multiple or distributed fracture, when the accumulation and growth of different-scale defects occur, is the least understood because it typically requires the use of sophisticated techniques for the evaluation of defects of various kinds [38]. The fracture process involves various length and time scales, with simultaneous processes and complex interactions [39]. This multi scale complex phenomenon has been studied using fractals [40], renormalization group theory [41], percolation, self-organized criticality [42]. The best known approach among them is b-value approach, developed for seismic activity by GutenbergRichter law [43] and applied for metals based on self similarity approach. The b-value parameter is determined as a slope of cumulative distribution curve of the number of seismic events (Ns) on their energy (E), or the magnitude equal to the logarithm of this energy. Above-mentioned characteristics related to each other by the Gutenberg - Richter equation: Log E=CS–bS•M

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(2)

logNC = Cc – bclog L

(3)

The validity of these relations for metallic materials was shown for the first time in 46-48 . Authors used the method of acoustic emission and optical microscopy to assess the size of the plastic zone and the distribution of microcracks within the plastic zone. These studies were carried out to study the interrelation between the damage parameters and the characteristics of acoustic emission. It was established that the decrease of b value both for acoustic emission and for microcrack distribution observed when approaching the stage of macrocrack initiation and it could be used for estimating damage evolution [39,47-48] and as a criterion of approach of critical event - material fracture.

The main goal of this paper is establishing common peculiarities preceding critical event observed by various methods and characterizing mechanical and physical behavior of material in Ti-64 titanium alloy under monotonic and cyclic loadings using AE, UT, NLU and replica techniques.

Material

The material used in the present study is Ti-6Al-4V titanium alloy. The nominal chemical composition of the titanium alloy is listed in Table 1. The titanium alloy was initially forged and rolled at 950oC followed by annealing at 700oC for 2 h and then cooled in air.

The microstructure of the alloy (Figure1) shows typical mill-annealed features. The microstructure shows equiaxed primary alpha grains surrounded by residual beta phase. The microstructure also shows slight grain flow along the rolling direction.

(1)

Where, NS is a number of acoustic emission events with energy not less than E, CS – constant, M – seismic magnitude. The amplitude of AE signal (A) measured in decibels and considered as an analogue of magnitude of seismic events. As was shown in studies [43-45] carried out on rock specimens, the relations similar to (1) connects the number of AE signals (NAE) with their amplitude (A) and also the number of microcracks or faults in rocks (NC) and their length (L):

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logNAE = CAE–bAElogA,

Fig. 1

: Mill annealed microstructure of Ti-6Al-4V alloy

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Table 1 Nominal chemical composition of the Ti-6Al-4V alloy (in wt.%) Al

V

Fe

N

O

C

H

6.2 3.96 < 0.20 < 0.01 < 0.3 <0.05 < 0.003

Ti Bal

Experimentation 3.1 Specimen Design

Generally, cylindrical specimens are used for cyclic loading conditions as per ASTM E-8 and E-647 respectively. However, it is not possible to accommodate NDT (AE, UT, NLU) sensors with flat bottom onto the gauge length of these specimens for online and offline damage measurements.

To overcome this difficult, a new specimen with flat gauge length was optimized using AUTOCAD software for monotonic loading as shown in Figure 2. However, this design was further modified with reduced cross section in the gauge area to avoid fracture in the grip area by reducing stress concentration in that area as shown in Figure 3.

Fig. 2

: Specimen design for online monotonic damage measurement

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3.2 Monotonic Loading

Tensile testing was performed at the rate of 0.5 mm/ min on INSTRON-3352 screw driven test system.

One specimen was strained till final with capture of AE data and replica, while one specimen was stopped after UTS point. One more specimen was interrupted just after yield point to take replica and the same was further loaded till fracture with in-situ AE signals being captured.

3.3 Fatigue Loading

Low Cycle Fatigue (LCF) tests were conducted under strain-controlled mode on INSTRON-8500 servohydraulic fatigue test system. Tests were carried out under total strain amplitudes (± 1.0 %) condition.

One sample was tested till fracture while one sample was interrupted at mid life.

3.4 Acoustic Emission Testing

During testing, the acoustic emission (AE) signals were recorded by means of four-channel system InterUnis A-Line 32D in the frequency range of 50-500 kHz using piezoelectric detector that have resonance at frequency of 150 kHz. The amplitude threshold was set equal to 32 dB. The number of AE signals (NAE) and acoustic activity (dNAE/dt) were estimated. In addition, the bAE values were assessed, i.e. the slope in the relation between the total number and amplitude of AE signals. For this purpose, the graphs of the cumulative number distribution of AE amplitudes were plotted in the coordinate axes SNAE – A, where SNAE – the cumulative number of AE signals with amplitude not less than given one, A – the signal amplitude in dB. AE sensors were located onto the gauge length of the specimens.

The bAE values were determined from the following relation: 20.lgSNAE = C–bAE.A (4) Time dependence of b value was plotted using special software based on Python programming language.

3.5 Linear Ultrasonic Measurements

Propagation velocity(J) and attenuation factor, a, of longitudinal ultrasound waves were measured by means of flaw detector “EPOCH-4”. All the measurements were made at room temperature at frequency of 10 MHz. Fig. 3

: Specimen design for online cyclic damage measurement

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The values of υ and a are calculated according following equations: Journal of Non Destructive Testing & Evaluation

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2l J = ---t’

(5)

where l – specimen thickness, t – time of ultrasound wave propagation; (6) where A1 and A2–two successive amplitudes of a signal.

Specimen thickness was measured by a digital Vernier caliper. Measurement accuracy of ultrasound wave velocity and attenuation factor is 5 % and 10 %, respectively.

3.6 Non-linear Ultrasonic Measurements

The non-linear ultrasonic measurements were performed on a computer-controlled transmitter– receiver (Model RAM-5000, M/s. RITEC, USA), generating Sine waves with an adjustable number of cycles at a single frequency, was used to drive the transducer. The experimental setup is as shown in Figure 4. When an ultrasonic wave propagates through a material, a strong nonlinear effect will be generated due to the nonlinear elastic properties of that material. Therefore, the damage to the material can be evaluated by measuring the nonlinearity of the ultrasonic wave propagated through the target material. Nonlinear measurements use the phenomenon of harmonic generation. A longitudinal ultrasonic wave of finite amplitude tone burst of amplitude Ao at frequency wo is launched on one side of the specimen under examination. If Ao is sufficiently large, the wave detected on the other side of the specimen will contain many harmonic components, i.e. the detected wave possesses a component of amplitude A1 at the fundamental frequency wo, a component of amplitude A2 at the

second harmonic frequency 2wo, etc. As a measure of nonlinearity, the parameter b is defined as a combination of the second and third-order elastic moduli Cij and Cklm. For instance, b = 3 + (C111/C11) for longitudinal waves in an isotropic material.

The parameter b can also be expressed in terms of amplitudes A1 and A2 of the fundamental and second harmonic displacements.

(7) where v is the ultrasonic phase velocity, z the specimen thickness and wo the fundamental frequency. Eq.(1) implies that |b| may be determined by measuring A1 and A2 of the fundamental and second harmonic displacements in a harmonic generation experiment. In the present study, a 5 MHz ultrasonic transducer ( 6 dB bandwidth of 2–8 MHz) with a diameter of 8.8 mm was used as a transmitting probe. A 10 MHz broadband ultrasonic transducer used as a receiver.

3.7 Replica Technique

In order to study plastic zones, the silicon replicas were removed from the polished lateral surface of a specimen. The replicas were analyzed with optical microscopes Olympus GX 51 and Neophot 21 equipped with a video camera. Microcrack distributions were assessed using digital image analyzing program.

Results and Discussions 4.1 Monotonic Loading Acoustic Emission

The plots of the tensile damage vs the acoustic activity (dNAE/dt) is shown in the Figure 5. Figure 6, 7 and 8 show the plots of acoustic activity (dNAE/dt) vs b value under tensile loading. The time dependence of bAE (Figure 6) exhibits intervals of decreasing and increasing b values. This parameter decreases after yield point of specimen before the onset of macrocrack initiation stage. This means that the b value can be used as the criteria of localization of fracture Table 2 b-values for different specimens

Fig. 4

: Experimental setup of Nonlinear Ultrasonic Technique

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bAE

NAE

Specimen 1

1.21

17642

Specimen 2

0.95

748

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Fig. 5

: Tensile curve vs. AE activity

Fig. 7

: AE activity and b-value during preload to yield

Fig. 6

: AE activity and b-value

Fig. 8

: AE activity and b-value during tensile after preload

Fig. 9

: Attenuation value at different locations in gauge length for specimen 1 (60s) and specimen 2 (600 s)

process, and its decrease can be a result of change in the mechanism of fracture, which might be due to the transition from the stage of micro-cracks nucleation to the stage of coalescence of microcracks [39]. Table 2 shows b values for specimen 1 (preloaded to yield point) and specimen 3 (strained till final fracture).

Ultrasonic Measurements

The variation of attenuation factor along the gauge length is plotted in the Figure 9 for specimen1 and specimen 2. The attenuation difference for specimen 2 is more than specimen 1 as due to microcrack nucleation and growth this sample is more damaged than specimen1, which is in the elastic region. From these results we can conclude that attenuation measurement is very effective tool for the damage www.isnt.org.in

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measurement in the Ti-6Al-4V titanium alloy under tensile loading.

Replica Technique

The replicas obtained on the polished surface of specimens at different stages of loading (Figure 10) are shown in Figure 11-12. The investigations were carried out with flat gauge length specimens under conditions of static loading. The replicas (Figure 12) allowed the study of microcracks patterns in the zone at each stage of the process. After tests, the replicas were analyzed using an optical microscope equipped with digital video camera, and the obtained patterns of multiple fractures were processed by the image analysis program. The maximal number of microcracks measured on each sample depended on the degree of damage of the material at the each

stage of loading. For one typical point i.e. replica no.5, the results of measurements were used for plotting cumulative curves of the distribution of microcracks by length in the following coordinates: total number of microcracks (N) with the length greater and equal to the current length versus current length of microcracks (L) as shown in Figure 13. At the initial stage of loading, numerous deformation bands have been observed, with no evidence of microcracks. The b-value vs. crack length has shown an exponential decay (Figure 13). As reported in literature [48], at this stage, cracks nucleate independently at a constant rate, depending on the level of applied stress. This implies that the crack accumulation process can be conceived as steady state, which gives uniform distribution of crack.

Fig. 10 : Tensile diagram with points of interruption for replica removal

Fig. 11 : Micro-cracks and slip bands pattern on different stages of loading: replica No.4

Fig. 12 : Micro-cracks and slip bands pattern on different stages of loading: replica No.5

Fig. 13 : Micro-cracks distribution on replica No.5

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4.2 Fatigue Loading Acoustic Emission

Two AE sensors were placed on the LCF specimen to capture the acoustic emission data using PAC, system. The sensors operate in the range of 150-750 kHz. Different AE parameters such as amplitude, hits, energy and events were capture in both time and length scale. The mechanical response is shown in Figure 14. The AE data is shown in Figure 15 and Figure 16 for full life and half life specimens. From Figure 15 a and Figure 16 a, it can be observed that in the initial period of loading low amplitude signals are observed, while at near final fracture high amplitude of signals observed. This infers to the fact that plastic deformation is dominant in the initial period, whereas micro-cracking and macro-crack propagation observed in the final fracture region. The amplitude vs location graphs (Figure 15b and Figure 16 b) clearly points out that most of the deformation and cracking is concentrated only in the middle of

( a)

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the gauge length thus highlighting the importance of AE technique for crack location identification. It is to be noted that for tensile loading the amplitudelocation plots have shown distributed pattern all over the gauge length as shown in Figure 16c. This clearly shows that the damage and deformation is much more localized for LCF specimen than tensile specimen.

Linear Ultrasonic Measurements

Figure 17 shows the variation of linear ultrasonic velocity with the number of cycles of fatigue and Figure 18 shows the variation shows the variation of the attenuation with number of cycles of fatigue.

The results show that the attenuation difference is more significant than the linear ultrasonic velocity measurement for estimating the damage of the low cycle fatigue loaded specimens. The percentage change in the attenuation coefficient is 180 , which is higher than the percentage change in the linear ultrasonic velocity (15 %). Hence for the damage

( b)

Fig. 14 : Low cycle fatigue test output (a) Hysteresis loop (b) CSR curve

( a)

( b)

Fig. 15 : AE output for LCF specimen (till fracture) (a) Amplitude (dB) vs. Time plot; (b) Amplitude (dB) vs. Location plot (b) Amplitude (dB) vs. Location plot

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( a)

( b)

Fig. 16 : AE output for LCF specimen (till midlife) : Amplitude vs. Time plot (b) Amplitude vs. location plot

( c)

Fig. 16c : AE output for tensile specimen : Amplitude vs. location plot

measurement of Ti-6Al-4V titanium alloy under low cycle fatigue loading using linear ultrasonic wave, attenuation coefficient proves to be better damage quantifying parameter as compared to linear ultrasonic velocity change.

Nonlinear ultrasonic measurements

The nonlinear ultrasonic damage parameter ‘b’ was measured by using a computer-controlled transmitter–receiver (Model RAM-5000, M/s. RITEC) with a 5 MHz probe as a transmitter and10 MHz probe as receiver. The nonlinear parameter is the

Fig. 17 : Variation of linear ultrasonic velocity with number of fatigue cycles

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effective technique for quantification of damage for low cycle fatigue loaded samples. Figure 19 shows the variation of ‘b’in the guage length of the virgin sample.

The plot shows that there is not much variation in the ‘b’in the guage length before low cycle fatigue loading. Figure 20 and 21 shows the variation of ‘b’ in the guage length of the samples which have undergone low cycle fatigue loading for 600 and 1000 cycles. The damage parameter ‘b’ is increasing from the grip region to the fracture region, this shows that

Fig. 18 : Variation of attenuation coefficient with number of fatigue cycles

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Fig. 19 : Variation of nonlinear parameter beta with the location in the gauge length for virgin material

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Fig. 20 : Variation of nonlinear parameter beta with the location in the gauge length for 600 cycles

due to presence of more cracks with less ineraction among them as against in tensile specimen [38,43].

Fig. 21 : Variation of nonlinear parameter beta with the location in the gauge length for 1000 cycles

the fracture region at the centre is more damaged.

The ultrasonic measurements proves to be one of the best technique for damage characterization of the low cycle fatigue loaded Ti-6Al-4V titanium alloy specimens. Similar increasing trends in beta parameters have been observed by other researchers for aluminum alloys [25, 49].

The applicabilty and limitations of each NDT technique used in the present study is summarised in the Table 3. It can be observed that acoustic emission is the best techniue for online damage monitoring specially for volumetric damages. The well established linear ultrasonic technique is best technique till date for volumteric damage assessment.

However, this technique can be used only offline with excellent surface finished specimens and componenets. The non-liner ultrasonic technique is grwoing very fast and may beome an standard techniue for damage assessment in near future, specialy for offline sub-surface damage assessemnt.

The replica technique continue to be useful in its limited domain of application.With the correlation of replicas with other techniques such as acoustic emission is going to increase its applicability for damage assessment at specimen and component level.

Replica Technique

The replicas of fractured specimens of Ti-6Al-4V titanium alloy which have been undergone low cycle fatigue loading are shown in the Figure 22.

The figure shows the distribution of the microcracks and the crack branching from the main crack. Figure 23 shows the microcrack distribution assessed by using digital image analyzing program. The replica technique is very effective technique for capturing the damage in the microcracks on the surface of the specimens. The power law dependence of cumulative counts on amplitude is reported to be

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Table - 3 M ISSING in document file

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Fig. 22 : Replica of fractured specimens and b-values

Fig. 23 : Microcrack distribution on fractured specimen

Conclusions Stages of damage accumulation process in specimens from Ti-64 alloy at monotonic and fatigue loadings were studied by means of replicas, acoustic emission and ultrasound attenuation methods on specially designed specimens.

Acoustic emission method was used to characterize the damage accumulation process at various stages of loading in real time mode. Acoustic emission sources recorded during the loading of the specimens were located and the cumulative amplitude distributions of acoustic signals were estimated.

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The b value parameter can be used as the criteria of localization of fracture process, and its decrease can be as a result of change in the mechanism of fracture, which might be due to the transition from the stage of micro-cracks nucleation to the stage of coalescence of micro-cracks.

The low cycle fatigue damage was found more localised than tensile damage. It was established that cumulative distributions of micro cracks and acoustic emission signals of damage accumulation are well described by a b-value parameters.

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TECHNICAL PAPER

For the damage measurement of Ti-6Al-4V titanium alloy under low cycle fatigue loading using linear ultrasonic wave, attenuation coefficient proves to be better damage quantifying parameter as compared to linear ultrasonic velocity change.

The beta parameter using NLU has also been able to successfully capture the damage process in the material under low cycle fatigue loading condition.

Acknowledgements The authors acknowledge the constant encouragement and support from Director, DMRL, India and Director, IMET, Russia for this work. The support and funding from DST, India and RAS, Russia is also acknowledged. Useful technical discussions with Dr. R. Sunder, Biss R&D Centre, Bangalore, India is also acknowledged.

References [1]

Allix O, Dragon A and Hild F (2002), Continuum Damage Mechanics of Materials and Structures, Elsevier Science Ltd., New York.

[2]

Roemer M and Kacprzynski G J in Proc. Advanced Diagnostics and Prognostics for Gas Turbine Engine Risk Assessment, IGTI/ASME Turbo Expo, Munich (2000), Germany.

[3]

Fatemi A and Yang L, Int. J. Fatigue, 20 (1998) p. 9.

[4]

Yang X, Li, Jin Z, and Wang T, Int. J. Fatigue, 19(1997), p 687.

[5]

A. Venugopal Rao, Jalaj Kumar and Vikas Kumar in Proc. National Seminar on New vistas in Aviation and Aerospace,Institution of Engineers, Jaipur- 13-14, Nov 2010.

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[12] F. Kaumann, T. Bidlingmaier, G. Dehm, A. Wanner, and H. Clemens. Intermetallics 8:823–830(2000).

[13] S. Mashino, Y. Mashimo, T. Horiya, M. Shiwa, and T. Kishi.

Mater. Sci. and Engg. A 213:66 (1996).

[14] R. Botten, X. Wu, D. Hu, and M. H. Loretto. Acta Mat. 49:1687 (2001).

[15] F. McBangonluri, E. Akpan, C. Mercer, W. Shen, and W. O. Soboyejo. Mater. Sci. and Engg. A 405:111 (2005).

[16] Jalaj Kumar, Sony Punnose, C. K. Mukhopadhyay, T. Jayakumar & Vikas Kumar. Res. N D E, 23:1, 17-31 (2012).

[17] Morishita T, Hirao M, Fukuoka H. Journal of the Society of Materials Science (Japan) 1990;39:1037–42.

[18] JeongH, Kim D-H.MaterialsScienceandEngineeringA2002;3 37:82–7.

19 Szela z ek J,MackiewiczS,Kowalewski L. NDT&EInternational 2009;42:150–6.

[20] Raj B, Moorthy V, Jayakumar T, Bhanu Sankara Rao K. International Materials Reviews 2003;48(5):273–325.

[21] Ohtani T, Ogi H, HiraoM. In: Proceedings of the 16th WCNDT, Montreal, 2004.

[22] Stamm H. European Journal of Nondestructive Testing 1992;1(4):169–78.

[23] Gyekenyesi AL, Kautz HE, Shannon RE. Journal of Materials Engineering and Performance 2002;11(2):205–10.

[24] Balasubramaniam K., Valluri J. S., and Prakash R. V., Materials Characterisation (2011).

[25] Jayarao V. V. S., Elankumaran K., Raghu V P., and Balasubramaniam K., (2008). Journal of Applied Physics, 104, 1 [26] Kommareddy V., Ramaswamy S., Ganesan B., Oruganti R., Bala R. and Shyamsunder MT, (2006), ECNDT - Fr.1.5.478.

[27] Kyung Y. J., (2009), , International Journal of Precision Engineering and Manufacturing Vol. 10, No. 1, pp. 123135.

[6]

A. Venugopal Rao, Jalaj Kumar and Vikas Kumar, Minerals & Metals Review, XXXV (4) (2009) p. 28.

[7]

Jalaj Kumar, S. Baby and Vikas Kumar, Materials Science and Engineering A, Vol. 496, Issues 1-2, Nov. 2008, pp. 303– 307.

[8]

Jalaj Kumar, S. Punnose and Vikas Kumar - Materials Science and Technology, 2011, Vol. 27, No

[29] Bermes C., Jin-Yeon K., Qu J. and Jacobs L. J. (2007), , Applied Physics Letters 90, 021901

[9]

Jalaj Kumar, S. Baby, M. Mahesh Kumar, T Jaykumar and Vikas Kumar , J Nondestruct Eval (2009) 28: 85–90

[30] Cantrell J. H., (2006), Philosophical Magazine, Vol.86, No. 11, 1539–1554.

[10] Jalaj Kumar, K. Prasad and Vikas Kumar, Fatigue and Fracture of Engineering Materials and Structures, 34, 131138

[31] Neubauer B, Wedel U. Advances in life prediction methods.

New York: ASME; 1983 pp. 307–313.

[11] B. Raj and T. Jayakumar. Acoustic Emission: Current Practices and Future Directions, ASTM STP1077, American Soc. for Testing and Materials, Philadelphia, PA (1990).

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[28] Herrmann J., Kim J., Jacobs. L. J., Qu J., Littles J. W. and Savage M. F., (2006), Journal of Applied Physics 99, 124913

[32] Loh NL. British Journal of NDT 1989;31(8):437–9 [33] G. Sposito et al. NDT&E International 43 (2010) 555–567 [34] R.o. ritche, int. j. fract (2005) 132: 197-203.

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[35] Barenblatt G I (1996) Scaling, self-similairity and intermediate asymptotics. Cambridge University Press, Cambridge, UK. [36] Barenblatt GI (2003) Scaling, Cambridge University Press, Cambridge, UK. [37] Barenblatt G I and Botvina L R 1983 Izv. AN USSR (in Russian)MSS 2 88-92.

[38] M.R. Tyutin, L.R. Botvian, N.A. Zharkova, T.B. Petersen And J.A. Hudson, Strength, Fracture And Complexity 3 (2005) 73-80.

[39] A. Carpinteri, G. Lacidogna And S. Puzzi, Physical Meseomechaincs, 11, 5-6 (2008) 260-271.

[40] A. Carpinteri, Mech. Mat. 18 (1994) 89.

[41] A. Carpinteri, Int. J. Solids Struct, 31 (1994) 291.

[42] G. Calaelli, Di. Tolla And A. Petri, Phy. Review Letter, 77 (1996) 2503.

[43] Scholz C.N. The mechanics of earthquakes and faulting.

Cambridge: Cambridge University Press. 2002. P. 470 C. [44] Smith W.D. , Nature, 1981. V. 289. P. 333-341.

[45] Smirnov V.B., Ponomarev A.V., Zavialov A.D. , Physics of the earth, 1995. N1. p.38-58. (in Russian) [46] Botvina L.R., Petersen T.B. Proc. of the ECF13: Fracture Mechanics: Applications and Challenges, 6-9 September, 2000 San Sebastian, Spain, CD, paper N 235, p. 1-5.

[47] M. Tyutin And L. Botvina, 15th Int. Conf. Strength Mat. (Icsma-15), J. Phy: Conference Series 240 (2010) 012035.

[48] Petersen T.B., J. of Exp. and Tech. Physica Lett. 21 (1995) No 2, pp. 74-79.

[49] Karthik T. N., Elankumaran K., and Balasubramaniam K., (2007), Applied Physics Letters 91, 134103.

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Sudhir Phansalkar BE-Metallurgy Consultant in Metallurgy, NDT, Failure analysis.- Quest Services

Introduction Magnetic Particle Inspection commonly known as MPI or MT is one of the ancient methods for detecting surface and near surface flaws in ferromagnetic materials like steels and cast irons in all forms of products like bars, billets, tubes, castings, forgings, finished products, wrought products, welded products as well as all heat treated conditions. Only exception of ferrous materials is the Austenitic Stainless steel which cannot be inspected by this method along with other commonly used nonferrous materials like Aluminum, copper and their alloys.

Advantages and Limitations As compared to PT and VT which are also commonly used NDT methods for detecting surface flaws, MT has a lot of advantages. It can detect surface as well as subsurface flaws. It can detect flaws on surface covered with coatings like plating/painting (with certain limitations).

It can detect the flaws filled up with corrosion products making it very useful for in service inspection to detect stress corrosion and fatigue, cracks etc. Equipment can be portable or stationary. Some of equipment can be battery operated or can operate without power also.

Different sensitivity levels can be achieved by varying the test parameters.

Most common limitation of the method is that it suitable only for ferromagnetic materials.

Further it can only detect the discontinuity having Depth : width ratio more than 5:1 and is oriented perpendicular or angled up to 45 to the direction of magnetic field. For fully finished component &/or component made from high carbon/alloy steel or heat treated components, direct induction methods must be judiciously used for the danger of sparking at the contact

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points which may damage the surface finish or deteriorate the properties or generate cracks.

Principle of testing: When a part made of ferromagnetic material is magnetized either by direct induction (by passing current directly through the component) or by indirect induction (by keeping the part in magnetic field), magnetic field is generated in the part. If there is any discontinuity on or near surface where magnetic field is strong and in favorable direction as described in (II) above, lines of force cannot pass through the discontinuity and hence some lines of force complete their path by traveling through the air and again enter into the part.

This is called leakage flux. If magnetic powder is sprinkled on the surface, powder gets attracted to the leakage field creating the indication which will be of same shape of discontinuity but with large magnification. The size and Detectability of indication will depend on many factors like type of material, value and type of current used, direction of magnetization, type and method of application of magnetic medium, lighting condition etc.

Testing process Actual process comprises of six steps as below: 1.

2.

3.

4.

5.

6.

Pre-cleaning Magnetization Application of magnetic medium Inspection Demagnetization Post cleaning

Magnetization, Application of magnetic medium and Inspection are the essential steps for all MPI. But other three steps may or may not be required depending on parts, part configuration, material application, stage of manufacture and so on.

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MAGNETIC PARTICLE INSPECTION

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Step 2 magnetization and step 3 Application of medium will decide which technique is being applied. If both steps are done simultaneously, it is called ‘Continuous Method’ which is most commonly used because of high sensitivity, can be used for both hard and soft magnetic materials with using any type of current AC or DC. If these steps are done one after another i.e. first Magnetization and then application of medium, it is called “Residual Method” which is limited to use only for Hard Magnetic material. Operator should be well aware of use of these techniques as many times even though “continuous method” is specified, operator is inadvertently using “residual method” because of his unawareness.

Methods of Magnetization: Depending on desired direction of magnetization and if current is passed through the component or not there are basic five methods of magnetization: 1.1

Head Shot: Direct induction method to create circular magnetic field to detect Longitudinal crack.

1.2

Prod: Direct induction method to create circular magnetic field to detect flaws in Any direction by orienting prod contact points. Flaws are seen only in aligned to or 45 to prod joining line.

1.3

Central conductor: Indirect induction method to create circular magnetic field in Surrounding component to detect longitudinal crack on ID or OD of the Component and radial cracks on end surfaces.

1.4

Coil: Indirect induction method to create longitudinal magnetic field in Component kept in coil to detect circular or transverse cracks in component.

1.5

Yoke: Indirect induction method to create longitudinal field in the component to detect cracks in any direction by orienting

Demagnetization required or not will be decided on below factors: a. If residual will affect next manufacturing process b. If residual field will affect the functioning of part when put in use. c. If residual field is sufficiently strong to affect as above d. What is the next operation after MPI. Head Shot

Coil Shot Technique

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Prod Technique

Yoke Technique

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the yoke positions. Cracks are seen only aligned perpendicular to or within 45 to the line joining yoke point.

1.8

Magnetic medium: This is basically magnetic powder with suitable size, shape and distribution to suit the application and having high permeability and low retentivity. Powder can be applied either in dry condition or wet wherein powder is mixed in definite proportion either in water or oil. Powder can also be either fluorescent or non-fluorescent (visible).

Powder used for wet application is finer than that used for dry method and shows high mobility having high sensitivity for fine surface defects. Hence more suitable for complex finished component and detecting fatigue and stress corrosion cracks. Dry powder is more suitable for subsurface defects.

1.9

Inspection light: Type of light depends on which powder is being used. Fluorescent powder need the use of black light with minimum intensity of 1000 w/sqcm on inspection surface and has distinct advantage of high contrast. This inspection shall be carried out in darkness. Visible powders have different colors like red, black, grey to improve the contrast and to be inspected in normal day light or white light.

Demagnetization: Demagnetization can be done by using Separate demagnetizing coil or using a Demagnetizing cycle on machine (when such facility is available on machine. In either case, two actions shall be done on component- Reverse the field and reduce the field. Such cycles shall be applied in sufficient numbers in continuously decreasing order so that at the end residual field will be near to zero and within acceptable limit which is normally 5 Gauss (max).

Variables in MPI 1.6

Direction of Magnetization: Magnetization shall be done perpendicular to the expected direction of flaws. This can be achieved by selecting proper method of magnetization &/or proper orientation of equipment (prod/Yoke) on component.

1.7

Current: Any of AC, DC or HWDC current can be used for magnetization.

Alternating current (AC) is commonly available, has skin effect and highest powder mobility and is more suitable to detect fine surface discontinuities and also for complex jobs. Hence it is commonly used for finished parts.

Direct current (DC) has more penetration, least powder mobility and so more commonly used for raw material and semi-finished parts.

Half Wave Direct current (HWDC) has good combination of penetration and powder mobility and very widely used for MPI of raw material, forgings, castings, semi-finished parts, Weldment.

Values of current shall be selected to achieve the required degree of magnetization as defined in procedure or as decided by using known artificial/natural flawed specimen.

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Routine verification: Following verifications are necessary to ensure that MPI process is followed correctly: 1.10 Concentration and quality of bath: Special pear shaped glass tube is used for this test. It is recommended to use this test at least at the start of each shift or as defined in procedure depending on numbers of jobs inspected, itâ&#x20AC;&#x2122;s criticality and surface quality. Concentration shall be maintained as defined in procedure which shall be in line with manufacturerâ&#x20AC;&#x2122;s recommendations. Generally it shall be 0.1 to 0.5 ml/100ml for fluorescent and 1.2 to 2.4 ml/100ml for visible powder.

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Pie Gauge

Shims

1.11 Light intensity: Black light intensity, white light intensity and backround white light intensity in darkened area are the regular checks required to be done as per recommended procedures.

1.12 Adequacy of magnetic field: Direction and strength of magnetic field can be tested directly by using Hall effect probe meter.

1.13 General testing of adequacy of method: All above parameters are important for getting proper results of MPI. But all these parameters can be tested together i.e. in combination by using artificial flawed specimen like pie gauge, shims, MTU blocks .. etc. These artificial flawed specimen shall be kept on a component which is under test on most difficult area for magnetization e.g . not inside the coil but farthest distance from the coil which is under inspection.

MTU Block

material, forgings/castings/fabricated parts, finished machined items before assembly, failure investigations, in service inspection of pipes, tanks/pressure vessels/rails/engine parts etc.

It is widely used in industries like steel mills, forge shops, foundry, auto and auto-ancillaries, piping industries, fabrication shops etc.

Visible Method

Advances in MPI

Application of MPI

Automation for MPI in mass production industries is now a day is very common to reduce manpower requirement and improving reliability of technique. Actual inspection is still manual. Various Poka-Yokes are installed in machines e.g. To ensure proper flow of current, proper flow of medium etc. Black light with high intensities and longer life are available for improving sensitivity. Multidirectional magnetizing special purpose machines are available for testing complex jobs all over in all directions.

MPI is commonly used for testing ferrous materials in form of billets, bars, tubes as raw

MPI still remains a very important NDT method for testing surface flaws on ferrous materials.

Fluorescent Method

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ISO CODE & SPECIFICATIONS 1 ISO 17638:2003 Non-destructive testing of welds -- Magnetic particle testing 2

ISO 108935:2011

Non-destructive testing of steel tubes -- Part 5: Magnetic particle inspection of seamless and welded ferromagnetic steel tubes for the detection of surface imperfections

3

ISO 3059:2012

Non-destructive testing -- Penetrant testing and magnetic particle testing - Viewing conditions

4

ISO 23278:2015 Non-destructive testing of welds -- Magnetic particle testing -- Acceptance levels

5

ISO 99341:2015

Non-destructive testing -- Magnetic particle testing -- Part 1: General principles

6

ISO 99342:2015

Non-destructive testing -Magnetic particle testing -- Part 2: Detection media

7

ISO 99343:2015

Non-destructive testing -Magnetic particle testing -- Part 3: Equipment

8

ISO 12707:2016 Non-destructive testing -Magnetic particle testing -- Vocabulary

9

ISO 6933:1986

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Railway rolling stock material -- Magnetic particle acceptance testing

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ASTM CODE SPECIFICATIONS 1 ASTM D6577 Standard Guide for Testing - 15 Industrial Protective Coatings 2 ASTM A340 - Standard Terminology of 16 Symbols and Definitions Relating to Magnetic Testing 3 ASTM E709 Standard Guide for 15 Magnetic Particle Testing 4 ASTM New Practice for Magnetic WK41198 Particle Testing for General Industry 5 ASTM E1444 / Standard Practice for E1444M - 16e1 Magnetic Particle Testing 6 ASTM A275 / Standard Practice A275M - 15 for Magnetic Particle Examination of Steel Forgings 7 ASTM E3022- Standard Practice for 15 Measurement of Emission Characteristics and Requirements for LED UV-A Lamps Used in Fluorescent Penetrant and Magnetic Particle Testing 8 ASTM A966 / Standard Practice A966M - 15 for Magnetic Particle Examination of Steel Forgings Using Alternating Current 9 ASTM E2297 Standard Guide for Use - 15 of UV-A and Visible Light Sources and Meters used in the Liquid Penetrant and Magnetic Particle Methods 10 ASTM Revision of E1444 / E1444M WK51692 - 12 Standard Practice for Magnetic Particle Testing

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INDIAN STANDARDS 1

IS 3415 : 1998

2

IS 3703 : 2004

3

IS 5334 : 2003

4

IS 6410 : 1991

5

IS 6752 : 1991

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Glossary of terms used in magnetic particle flaw detection.

Recommended Practice for Magnetic Particle Flaw Detection.

Magnetic Particle Flaw Detection of Welds - Code of Practice.

Specification for magnetic flaw detection inks and powders.

Code of practice for magnetic particle flaw detection of ferrous pipes and tubes.

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IS 7743 : 2006

Recommended Practice for Magnetic Particle Testing and Inspection of Steel Forgings.

7 IS 10543 : 1983 Method for dry powder magnetic particle testing.

8 IS 12147 : 1987 Recommended practice for wet magnetic particle examination.

9 IS 15539 : 2004 Recommended Practice for Magnetic Particle Examination of Steam Turbine Rotor Blades.

ASME SEC V STANDARDS 1

SE 709

Standard guide for Magnetic Particle Testing

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KALESH NERURKAR PRADEEP NDT PRODUCTS PVT. LTD

INTRODUCTION LIQUID PENETRANT TESTING or PT is a basic nondestructive testing technique to detect discontinuities that are open to the surfaces of solid and particularly nonporous materials.

Indications of a wide variety of flaw sizes can be found regardless of the configuration of the work piece and the orientation of the flaw.

It is widely used to detect discontinuities of wrought and cast products of both ferrous and nonferrous metals, ceramics, parts produced by powder metallurgy, plastics and glass. The typical discontinuities that can be detected by liquid penetrant testing are shrinkage cracks, hot tears, cold shuts, folds and micro shrinkage pores in castings, laps and forging cracks in forgings, crater cracks, cracks in heat affected zone and center bead cracks, porosity in welds, laminations in sheets, grinding cracks in machined components, quench cracks in heat treated steel and service induced discontinuities such as stress corrosion cracks and fatigue cracks.

PRINCIPLE Liquid penetrants seep into open to surface discontinuities by capillary action. The excess penetrant on the surface is removed and only the penetrant in the discontinuity remains. After the developer is applied the penetrant inside the discontinuity bleeds out due to blotting action of the developer. The coloured penetrant produces a indication on white background of the developer. Hence due to colour contrast the indications of small and fine discontinuities become prominently visible to human eye.

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PROCEDURE TESTING

FOR

LIQUID

PENETRANT

Liquid penetrant testing requires at least six essential steps as follows: 1. Surface Preparation: All surfaces of the component to be inspected must be thoroughly cleaned and completely dry before being subjected to penetrant inspection. Components should be free from dirt, rust, oil, grease, scale etc. for reliable inspection. The cleaning process must remove contaminants from the surface of the component and must not mask any defects or discontinuities. The surfaces can be cleaned by any suitable process involving mechanical, chemical or solvent cleaning.

2. Penetrant application: Once the work piece is clean and dry, the penetrant is applied so that it forms a continuous film on the surface of the component. Penetrant can be applied by any suitable process like brushing, spraying, dipping or by flow on process. The penetrant must remain on the component for some specified time so that the penetrant can enter the discontinuities.

This time is known as Dwell Time. Dwell time depends on type of penetrant, temperature, material type and surface finish and is often determined by experimentation.

3. Removal of Excess Penetrant : Excess penetrant is removed by wiping with a clean dry cloth. Cloth dampened with solvent is used to remove the remaining penetrant from surface. This is normally done in the case of solvent clean type penetrants. This

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LIQUID PENETRANT TESTING â&#x20AC;&#x201C; BASIC PRINCIPLES

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is necessary to eliminate background effect during inspection. The removal method depends on the type of penetrant used. In case of Water Washable Penetrant excess penetrant is removed by coarse spray of water jet. Post emulsifiable penetrants require the use of emulsifiers which may be lipophilic or hydrophilic. Proper removal of excess surface penetrant is important for reliable and good results. Over removal of penetrant must be strictly avoided.

4. Developer Application: The component is dried either before or directly after application of the developer depending on the type of the developer to be used. It is advisable that the developer should be applied by spraying by an aerosol can so that it provides a thin uniform coating and also provides a white background or contrast. Developer provides a blotting effect due to which the penetrant bleeds out of discontinuity. Thus a red indication is obtained on white background in case of visible penetrant.

5. Inspection : After the indication is properly developed, the surface is inspected visually.

Visible penetrant inspection is performed in good lighting environment of sufficient intensity. Fluorescent penetrant inspection is performed in a dark environment using black (ultraviolet) light. The ambient white light should be minimum so that the florescence brilliantly under black light.

The indications obtained are inspected and evaluated against acceptance/ rejection criteria. These are documented in the form of records.

6. Post Cleaning: The final step in liquid penetrant testing is to thoroughly clean the component to remove all the residual penetrant testing materials on the surface.

The presence of residual materials may affect the further processing operations.

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MATERIALS TESTING

IN

LIQUID

PENETRANT

Penetrants - There penetrants are broadly classified as Fluorescent ( type I) and Visible (type II) These two types of penetrants are further classified as per their method of use i.e. water washable (method A), postemulsifiable lipophilic (method B) and postemulsifiable hydrophilic (method D), and solvent removable (method C). l ifier - Emulsifiers are liquids which make postemulsifiable penetrants water washable. With the use of emulsifiers the excess postemulsifiable penetrant on the surface of the component to be tested can be removed. There are two methods used in postemulsifiable lipophilic method (Method B) and postemulsifiable hydrophilic method (Method D).

Cleaners - Cleaners act as solvents to remove the excess penetrant on the surface of the component. Excess penetrant on the surface is removed by wiping the surface with lintfree cloth slightly dampened with cleaner.

Care should be taken while wiping so that the penetrant in the discontinuities is not removed.

Developers - The purpose of a developer is to bleed the penetrant out from the discontinuity by its blotting action. When it is sprayed as a thin uniform layer it draws out the penetrant from the discontinuity and spreads it on the surface thus enhancing the visibility of the discontinuity. It provides contrast in the case of visible penetrants and increases brightness intensity of indications in fluorescent penetrants. Developers are further classified as per the form in which they are used namely dry developer (form A), water soluble (form B), water suspendible (form C) and non aqueous wet developer (form D).

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ADVANTAGES OF PENETRANT TESTING: 1. Relative ease of use.

2. Can be used for wide range of materials.

3. Large areas or volumes of parts can be inspected economically and rapidly.

4. Aerosol spray cans can be carried to remote locations. Hence the equipment is portable.

5. Parts with complex geometries can be routinely inspected.

6. Indications are provided directly on the surface of the component, so no other equipment is required to visualise and analyse the image.

LIMITATIONS OF PENETRANT TESTING: • •

Only defects open to surface can be revealed.

Requires relatively smooth and non porous surface.

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ISO CODE & SPECIFICATIONS IS 12889 - NON-DESTRUCTIVE TESTING PERFORMANCE EVALUATION OF LIQUID PENETRANTS IS 3658 - CODE OF PRACTICE FOR LIQUID PENETRANT FLAW DETECTION IS 11732 : ACCEPTANCE STANDARDS FOR LIQUID PENETRANT INSPECTION OF STEEL CASTING ASTM A903/A903M STANDARD SPECIFICATION FOR STEEL CASTINGS, SURFACE ACCEPTANCE STANDARDS, MAGNETIC PARTICLE AND LIQUID PENETRANT INSPECTION ASTM E433: REFERENCE PHOTOGRAPHS FOR LIQUID PENETRANT INSPECTION ASTM E165: STANDARD TEST METHOD FOR LIQUID PENETRANT EXAMINATION

•

Pre cleaning is very important otherwise the contaminants can hide the defects.

ASTM E270 - STANDARD DEFINITIONS OF TERMS RELATING TO LIQUID PENETRANT EXAMINATION

•

Testing should be done in well ventilated area. Chemical handling precautions are necessary.

ASTM E 1135 : TEST METHOD FOR COMPARING THE BRIGHTNESS OF FLUORESCENT PENETRANTS

•

Post cleaning is necessary.

ASTM E1208 : PRACTICE FOR FLUORESCENT LIQUID PENETRANT TESTING USING THE LIPOPHILIC POST-EMULSIFICATION PROCESS

LIQUID PENETRANT TESTING - INDUSTRIAL APPLICATIONS Liquid Penetrant testing has wide applications in industries. In aerospace industries it is used for testing aircraft structural elements manufactured from light alloys (aluminium, aluminium-lithium, titanium) and composite materials, rotating parts of gas turbines, blades and rotors, undercarriage structures (landing gears), bearings, etc.

It is extensively used for testing components for nuclear applications, boiler and pressure vessels, automobile manufacturing for forged and machined components.

It has wide applications for in service inspection of stress corrosion and fatigue cracks.

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ASTM E1209 : STANDARD TEST METHODS FOR FLUORESCENT LIQUID PENETRANT EXAMINATION USING THE WATER-WASHABLE PROCESS ASTM E1210 : STANDARD TEST METHODS FOR FLUORESCENT LIQUID PENETRANT TESTING USING THE HYDROPHILIC POSTEMULSIFICATION PROCESS ASTM E1219: PRACTICE FOR FLUORESCENT LIQUID PENETRANT TESTING USING THE SOLVENT-REMOVABLE PROCESS ASTM E1220: STANDARD TEST METHODS FOR VISIBLE PENETRANT TESTING USING SOLVENT-REMOVABLE PROCESS

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| BACK TO BASICS

ASTM E1417 : STANDARD PRACTICE FOR LIQUID PENETRANT EXAMINATION ASTM E1418 : STANDARD TEST METHODS FOR VISIBLE PENETRANT TESTING USING THE WATER-WASHABLE PROCESS ASTM E2297 : GUIDE FOR USE OF UV-A AND VISIBLE LIGHT SOURCES AND METERS USED IN THE LIQUID PENETRANT AND MAGNETIC PARTICLE METHODS ASME Sec V, Article 6: LIQUID PENETRANT EXAMINATION ASME SE-165 : STANDARD TEST METHOD FOR LIQUID PENETRANT EXAMINATION MIL-I-25135 : THIS SPECIFICATION COVERS MATERIALS USED IN THE LIQUID PENETRANT INSPECTION OF METAL AND NONPOROUS, NONMETAL PARTS FOR MATERIAL DISCONTINUITIES OPEN TO THE SURFACE. MIL-STD-1907 : THIS STANDARD DESCRIBES THE DISCONTINUITY LIMITS ALLOWED UNDER FOUR QUALITY LEVEL CLASSIFICATIONS FOR PENETRANT INSPECTED AND THREE QUALITY LEVEL CLASSIFICATIONS FOR MAGNETIC PARTICLE INSPECTION. THE MATERIALS MAY BE FORGINGS, CASTINGS, TUBES, SHEETS, BARS, ETC. FABRICATION STAGES MAY BE MACHINED, UN MACHINED, WELDED, OR UN WELDED PARTS/MATERIALS. ISO 3059: NON-DESTRUCTIVE TESTING PENETRATION TESTING AND MAGNETIC PARTICLE TESTING - VIEWING CONDITIONS, REFERENCE TEST BLOCKS

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Journal of Non Destructive Testing & Evaluation

ISO 3452 : NON-DESTRUCTIVE TESTING. PENETRANT TESTING. PART 1 TO 6 . GENERAL PRINCIPLES, TESTING OF PENETRANT MATERIALS, PENETRANT TESTING, EQUIPMENT, PENETRANT TESTING AT TEMPERATURES HIGHER THAN 50 C AND PENETRANT TESTING AT TEMPERATURES LOWER THAN 10 C ISO 3453: NON-DESTRUCTIVE TESTING-LIQUID PENETRANT INSPECTION -- MEANS OF VERIFICATION ISO 3879 - WELDED JOINTS - RECOMMENDED PRACTICE FOR LIQUID PENETRANT TESTING: ISO 4987 - STEEL CASTINGS PENETRANT INSPECTION

LIQUID

ISO 9583 - NON-DESTRUCTIVE TESTING LIQUID PENETRANT INSPECTION OF METALLIC SURGICAL IMPLANTS ISO 9916 - ALUMINIUM ALLOY AND MAGNESIUM ALLOY CASTINGS - LIQUID PENETRANT INSPECTION ISO 10893: NON-DESTRUCTIVE TESTING OF STEEL TUBES. LIQUID PENETRANT INSPECTION OF SEAMLESS AND WELDED STEEL TUBES FOR THE DETECTION OF SURFACE IMPERFECTIONS. ISO 12706: NON-DESTRUCTIVE TESTING -DEFINES TECHNICAL TERMS RELATING TO PENETRANT TESTING. ISO 12095 - SEAMLESS AND WELDED STEEL TUBES FOR PRESSURE PURPOSES - LIQUID PENETRANT TESTING ISO 23277 -NON-DESTRUCTIVE TESTING OF WELDS - PENETRANT TESTING OF WELDS ACCEPTANCE LEVELS

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BACK TO BASICS

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September 2016

ARTCILES

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CERTIFICATION OF CONSUMABLES IN LIQUID PENETRANT TESTING AND MAGNETIC PARTICLE TESTING – AN OVERVIEW Mrs. V.A.Datar M.Sc., ASNT Level III (MT & PT) Director, FerroChem NDT Systems Pvt. Ltd., Pune – 411 004

ABSTRACT Non-destructive testing plays a very important role in all Engineering Industries including Inservice Inspection. The success of NDE depends on right procedure, right person and right machine consumables.

The consumables used in Surface NDE like Liquid Penetrant Testing and Magnetic Particle Testing, need certification, as per different Codes and Standards. The end user relies only on certificate review for the correct choice of consumables.This paper enlightens on how these consumables are certified for Liquid Penetrant Testing and Magnetic Particle Testing Methods.

Dye Penetrant Testing is one of the very preliminary Testing methods in NDT. The process is very simple, easy to use, economical and reliable.

An author of a book which was published about 50 years back, had stated in preface that when he started working on Dye Penetrant Testing Method, he was wondering how long this process will last, looking at its simple and basic nature. He, however, confirmed that even after working for more than 15 years, he found that the process was still in demand and expressed his confidence that this will continue to be in demand for many years.

We are experiencing the correctness of the expression of the author today.

Dye Penetrant Testing has, in fact, become more universal and more and more people are adopting it for testing work. The actual users of Dye Penetrants are not necessarily aware about the composition and required properties of the chemicals. They depend on the specified characteristics as per the standards. However, for getting confirmation of many characteristics, they require assurance from the manufacturer of the products in form of Test Certificate.

Above statement applies to Magnetic Particle Testing also.

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The responsibility of a manufacturer is not only towards manufacturing a suitable product, but is also to provide a test Certificate for user. Many times this is mandatory requirement of Codes, Standards and Specifications. The American Society for Mechanical Engineers (ASME) Section V NonDestructive Testing Article 6, Mandatory Appendix II 690 states:

II-690 DOCUMENTATION Certifications obtained on penetrant materials shall include the penetrant manufacturers’ batch numbers and the test results obtained in accordance with II-640. These records shall be maintained as required by the referencing Code Section.

We will discuss, in brief, in the following lines on what should be the contents of an ideal Test Certificate which accompanies supplied product.

Dye Penetrant Testing is a process which demands skillful use of products by a user who understands the principle of Testing thoroughly. The product will prove not suitable for use if not used properly and may result in not getting the required end results including sensitivity.

It is therefore obligatory on the part of the manufacturer to assure that the product has all necessary qualities required for crack detection.

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In fact, when manufacturer manufactures product for a particular purpose, he forms his own quality Test parameters, taking into consideration the requirements of applicable Codes & Standards. He also considers the expectations from the product from the point of view of ideal performance.

1.

Many international standards have now emerged, which describe the proper / the most suitable method of using Dye Penetrants. The standards specify quality parameters which control the performance of the product to ensure that the desired end results are obtained.

E.g. The Sulphur Halide Estimation requirement as per code is given below:

2.

The end user has his own limitations and specific circumstances / conditions under which he wishes to carry out the testing. The end user will expect that the product will survive or overcome the limitations which are unavoidable during the use. The end user will explain the limitations to manufacturer before procuring the product.

3.

Many times, there is involvement of a Consultant / Third Party Inspector, who is appointed to help the end user about the choice and the quality of the product he needs for testing work. The Consultant / Third Party Inspector, expects that the certificate mentions, certain parameters, which will help him to assess the required quality of the product.

T-640 MISCELLANEOUS REQUIREMENTS T-641 CONTROL OF CONTAMINANTS The user of this Article shall obtain certification of contaminant content for all liquid penetrant materials used on nickel base alloys, austenitic or duplex stainless steels, and titanium. These certifications shall include the penetrant manufacturers’ batch numbers and the test results obtained in accordance with Mandatory Appendix II of this Article. These records shall be maintained as required by the referencing Code Section.

II-640 REQUIREMENTS II-641 NICKEL BASE ALLOYS

Ideally, a Test Certificate should be such that it will have all information required which is demanded by the aforesaid four objectives.

When examining nickel base alloys, all penetrant materials shall be analyzed individually for sulfur content in accordance with SE-165, Annex 4.

Alternatively, the material may be decomposed in accordance with SD-129 and analyzed in accordance with SD-516. The sulfur content shall not exceed 1 by weight.

Generally, a certificate is defined as a written or printed or soft statement of facts that may be used as a proof. It guarantees the quality or value of the product.

II-642 AUSTENITIC OR DUPLEX STAINLESS

In the table given below, we have listed

STEEL AND TITANIUM

In column 1, Quality Test Parameters of Red, Solvent Removable Dye Penetrant,

When examining austenitic or duplex stainless steel and titanium, all penetrant materials shall be analyzed individually for halogens content in accordance with SE-165, Annex 4. Alternatively, the material may be decomposed and analyzed in accordance with SD-808 or SE-165, Annex 2 for chlorine and SE-165, Annex 3 for fluorine. The total halogens content shall not exceed 1 by weight.

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To clarify further, we would take an example of what should be an ideal Test Certificate of Red,Solvent Removable Dye Penetrant.

In columns 2,& 3,values of Test results are mentioned.

In column 4, ‘ ’ marks are shown parameters relevant to or demanded by user .

In column 5, ‘ ’ marks show which parameters are to be included in the certificate.

In column 6, reference standard names are mentioned.

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| ARTICLES Quality Test Parameters for Red, Solvent Removable Dye Penetrant

Quality Test Sr. Parameters of No. Red,Solvent Removable Dye Penetrant 1 2 3 4 5 6 7 8

1 Lot number Quantity Manufacturing Date Expiry Date Color in Day Light Colorimetry Meniscus Test Photograph No. 1 Drop on Filter Paper

9

Color Contrast against Developer

10

Color stability by Meniscus Test Wettability Photograph No. 2 Surface Tension by Stalagnometer ‘Bead’ Formation Kinematic Viscosity

11 12 13 14 15 16 17 18

Drying Test on ‘Tile’ Photograph No. 3 Drying test on Meniscus Kit Flash Point

19

Temperature Stability Corrosion

20 21

pH Halides by weight

22

Sulfur by weight

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Requirements of an fact rer 2

Red O.D. min. 0.60 Max. 4mm diameter

Standard / Consultant

User

3

4

ertificate

5

Name of standard 6 ASME Sec. V Article 6

Red, Orange, Purple

AMS 2644

Nominal value +/-10

1) AMS 2644 2) ISO3452-2 NPCIL

No ‘ring formation’ after 2 hrs.

No ‘ring formation’, spot same as reference sample Uniform spot after 2 hrs.

Continuous film for two hours 130-140 drops No ‘bead’ formation Nominal value Max. 5 cSt at 38 C Must flow freely After 2 hours Uniform spot After 2 hours Nominal Value Min. 93 C Between -10 to 55 C

Must flow After 2 hours

freely

1) Min. 93 C 2) Nominal value +/-5 C -18 to 66 C

No pitting, etching, No corrosion For 2 hours oxidation in 48 hrs. at 50 C 7 to 10 Maximum 10,000 ppm 1) Less than 200 ppm 2) 0.001 to 5 (i.e.10 to 50,000ppm) 3) less than 1 ( i.e. 10,000 ppm) Maximum 10,000 ppm 1) Less than 200 ppm 2) 0.1 to 5 (i.e. 1 to 50,000ppm) 3) less than 1 (i.e.10,000ppm)

1)AMS 2644 2) ISO 3452-2 AMS 2644 ISO 3452-2 1. ISO 3452-2 2. ASTM E-165 3. ASME sec.

V article 6 ISO 3452-2 ASTM E-165 ASME sec.V article 6

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Quality Test Sr. Parameters of No. Red,Solvent Removable Dye Penetrant 23

24 25 26 27 28

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Requirements of an fact rer

1 2 Sensitivity on known On 50 Ni-Cr panel crack specimen 100 cracks as Photograph No. 4 shown In reference photograph Dwell Time As recommended in ASTM E-165 Developer As per manufacturerâ&#x20AC;&#x2122;s Compatibility standard Solvent Remover As per Manufacturerâ&#x20AC;&#x2122;s Compatibility standard Specific Gravity Nominal 0.90 to 1 Storage Stability Maximum 2 years

Standard / Consultant 3 Min. 80 cracks on 30/50 panel Recommended manufacturer

ertificate

User 4

5

by

Name of standard 6 ISO 3452-2

ASTM E-165

Nominal value +/-5 Minimum 1 year

ISO 3452-2 AMS 2644

Quality Test Parameters for Wet application Magnetic Powder (Oil Based) for visual Inspection: Sr. No

Quality Test Parameters

1

Requirements an fact rer

2

Standard / Consultant

User

3

4

ertificate

Name of Standard

5

6

Properties 1

Lot number

2

Quantity

3

Manufacturing Date

4

Expiry Date

5

Form

6

R e c o m m e n d e d Paste / powder : 10 As per manufacturers Concentration of to 20 gm per ltr recommendation oil Liquid Conc. : 10 to 20 ml per ltr.

1)ASTM E-709 & Article 25

Color

1)ASME sec.V Article 7

7

Paste / powder/ liquid concentrate

Black and Red

1) Different than examination surface 2) Stated by supplier

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2)ASME Sec.V

2) ISO 9934-2

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Sr. No

Quality Test Parameters

Requirements an fact rer

1 8

Standard / Consultant

User

3

4

2

Settling volume in 1.2 to 2.4 ml 100ml centrifuge tube after 60 min.

1.2 to 2.4 ml

ertificate

Name of Standard

5

6 ASME sec.

V Article 7

Performance 9

10

Sensitivity on As shown in Table 1) As shown in Table known crack X1.1 And X 1.2 in X1.1 And X 1.2 in ASTM E-1444 specimen i.e on ASTM E-1444 Test Ring and 2) all cracks should Reference block be seen on type 1 reference block Photograph No. 5 type I

2) ISO 9934-2

Storage Stability

ISO 9934-2

2 years

Given by producer

Significance of a few important tests mentioned in certificate is as follows.

5.

If the tests are skipped or not done at all there may be serious implications.

1.

Viscosity: If viscosity is out of the specified range, of +/-5 , of the nominal value, Dwell time, Cleaning Method i.e. cleaning time will require adjustment. If the adjustment is not done it will result adversely on crack detection sensitivity.

2.

Flash Point: If Flash Point is less than the specified range, in addition to having a fire hazard, the Penetrant may evaporate fast and may not penetrate into crack or may not come out from a crack as is expected and will consequently affect crack detection sensitivity.

3.

4.

Corrosion: If corrosion property of Dye Penetrant is not controlled it may result in corrosion of the product at the time of testing, it will also affect crack detection sensitivity as the Penetrant may not come out of the cracks as effectively. The corrosive nature will affect life of the component leading to premature failure and / or will reduce life of the component.

Sulfur and Halides content: If sulfur and halide contents are beyond the specified range they will lead to corrosion and the effect will be as mentioned in point no. 3.

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1) ASTM E-1444

Sensitivity on known crack specimen: This test takes care of wettability of Penetrant, color contrast, dwell time, compatibility with developer and cleaner and sensitivity. Failure to meet sensitivity requirement proves lack of the fundamental properties of Penetrant material, some of which are mentioned above.

This also proves that the correct procedure has to be followed while conducting sensitivity test.

A lack of desired skill will lead to non-detection of desired cracks.

To verify quality and consistency of Penetrant Material, the user should perform following tests at his end to ensure consistency of the Product.

1.

Meniscus Test: This test can be performed on a ‘Meniscus Test Kit’.

2.

This test covers color stability, drying test, color concentration and penetration capacity of Penetrant and solubility of coloring material.

3.

‘Bead’ formation Test on ‘S.S.Plate’: This covers wettability, ability to remain in liquid form without drying and bead formation of Penetrant material.

4.

Sensitivity on known crack specimen: e.g. Nickel Chrome test panel or Aluminum Comparator Block

5.

This covers Wettability, Sensitivity, Dwell Time, Color Contrast, Compatibility with Developer www.isnt.org.in

ARTICLES

and Solvent Remover and points mentioned in significance of ‘Sensitivity on known crack specimen’ as mentioned above.

6.

Corrosion Test: Corrosion must be verified by the user on his job for minimum 48 hours, otherwise, Penetrant remaining in the cracks will cause corrosion and affect the life of the specimen.

Ideal test Certificate for Red Solvent Removable Penetrant or Wet application Magnetic powder for visual inspection (oil based) should carry following information:

PHYSICAL DESCRIPTION OF PRODUCT BEING CERTIFIED •

Date of certificate

•

Lot number

•

Manufacturing and Expiry date

•

Conformity to Manufacturers internal standard

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•

Conformity to Standard

•

Conformity to users requirements, if any

•

Sensitivity on known crack specimen

•

Flash Point (PT) / Settling volume (MT)

•

Disposal Instruction

•

Special Instructions to user

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Conclusion: We are sure that this information will be helpful to Manufacturers, End Users, Third party Inspectors and Consultants to assess the certification of Surface NDE Consumables.

Standards Referred: 1)

For Dye Penetrant : ASTM E-165,ASME Section V Article 6, ISO 3452-2, AMS 2644

2)

For Magnetic Powder : ASTM E-709, ASTM E-1444, ASME Section V Article 7, ISO 9934-2

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THE JOURNEY OF MAGNETIC PARTICLE TESTING IN BHARAT FORGE S.Bapat, S.Kamthe, P.Mantrawadi, A Chauthai

HISTORY Bharat Forge Ltd is one of the most innovative and exciting companies to emerge in the history of the forging industry. The Indian Automotive Industry in the 50’s was more like the story of imported kits.

Ancillaries were nominal and infrastructure was scarce and inadequate. It was then, that Bharat Forge came into existence in 1961 to meet the forging needs of the Indian Automotive Industry.

The 70’s witnessed a spurt in the Indian forging industry with more and more units coming up. For Bharat Forge, it was a period of consolidation and growth. With the largest integrated facilities in Asia and an unbeatable track record, Bharat Forge emerged as the undisputed leader - the first name in the forgings industry in India. With an emphasis on diversification, the 80’s saw Bharat Forge grow from a primarily automotive ancillary to an engineering enterprise focusing on technological supremacy, resilience and total customer-orientation. Today, the art of forging metal is a tradition at Bharat Forge, and all of our products are built with the expertise necessary to accommodate various industries. Each customer specification is carefully transformed into a cost-efficient reality. Every part we create is a representation of our overall dedication to craftsmanship. An outstanding reputation for customer service coupled with the Management commitment to quality has made Bharat Forge the preferred domestic and global supplier for major OEM’s. Under the intense and caring supervision of the Chairman & Managing Director, Mr. Babasaheb N. Kalyani, the company continues to expand and its markets continue to grow, while the goal remains the same : to deliver competitive, quality products and services - time after time.

1961- The Company was incorporated on 19th June at Mumbai.

The main object of the Company is to manufacture of forgings and finished crankshafts.

1989- The Company undertook modernization and rationalization of the steel forgings & furnishes machined crankshafts division at Pune.

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Journal of Non Destructive Testing & Evaluation

- Under the modernization program at the steel forgings division, Pune. Both the presses were installed by 1991-92.

1995- The Company proposed to set up a plant for the manufacture of Finish Machined Crankshafts with a capacity of 1,80,000 nos. per annum at Pune.

- The Company had entered into a technical knowhow and Assistance agreement with Metalart Corporation, Japan for the manufacture of small precision forgings.

1998- The Company has decided to go ahead with the implementation of the Mundhwa project for additional forgings capacity of 38,000 Tons.

- 2008 -Bharat Forge Commissioned India’s Largest Commercial Open Forging Press. & Ring Rolling Facility at Baramati Today Bharat Forge is become the largest producer of automotive crankshafts and axels for commercial vehicles and also diversifying in different non-auto areas like defense aerospace, oil and gas, power sectors.

‘MAGNETIC PARTICLE INSPECTION FACILITIES AT BFL’ Being a steel component manufacturer and supplier Nondestructive testing becomes part of manufacturing process of forgings in Bharat Forge Bharat Forge has a world class state of- the art advanced NDT testing facility approved by all global OEM's in Automotive and Non-automotive sectors, for validation of various components to ensure higher and consistent level of quality.

Bharat Forge is using different NDT methods like – Ultrasonic testing, Magnetic particle testing, Penetrant testing, Eddy current testing etc.

As all auto components has to qualify for fatigue strength, stringent surface quality are required to be maintained .To ensure the product surface is free of defects Magnetic particle testing is most widely used as the surface NDT method in Bharat forge.

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When Bharat Forge started its journey, we were having only 5 bench type machines ,From 1965 to 1991 (first 25 years of journey) the products were produced mainly on the hammers. The volumes of productions were relatively lower. The machines for checking magnetic particle tests were running mostly with lot of manual controls .During this period most of the products Bharat Forge produced, goes for domestic market only.

After the Modernization started in 1991and because of the open economy, Bharat Forge started supplying its products to various global OEM’s in the world.

Huge competition, High volumes, higher quality demand, strict control on quality and delivery PPM were the challenges for Bharat forge while entering into global world of auto component.

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ASNT NDT Level III trainers are conducting in house NDT Level 1, 2 training and certification courses on Magnetic particle testing and other NDT inspection methods.

Today Bharat Forge is having @ 150 MPI equipment’s for testing variety of components like crankshafts, steering Knuckle connecting rods pistons , Big parts like marine crank shafts , Fluid ends ,Rotors etc.

Based on part configuration equipment’s are designed to meet product size, shape, volume, weight, cycle time and types of defects to be tested.

This resulted in modernization of magnetic particle test facilities and addition of new magnetic particle testing lines at Bharat Forge which includes, •

Specialized Magnetic Particle inspection equipments with different techniques for different applications.

•

Modern high amperage magnetic particle testing equipments including electromagnetic yokes

•

Equipments ranging from 500 amperes to 10000 amperes stationery wet horizontal type for inspection with AC, HWDC and FWDC facilities.

•

High intensity LED black light kits for fluorescent inspection

Today all manufacturing lines are supported with dedicated magnetic particle specially designed and developed for highest quality output.

To run these ultramodern facilities Bharat forge started creating a qualified work force with different in-house and outbound training programs for Nondestructive testing. Today key manufacturing persons undergo awareness programs for nondestructive tests.

Magnetic particle testing professionals are qualified and certified to MT Level I, II as per ASNT recommended practice SNT-TC-1A, are approved by leading third party inspection authorities Experienced in house ASNT NDT Level III and experts for providing techniques establishment, procedure preparation, approval.

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Equipments BFL has got multiple equipment’s like Bench Type, Conveyor type, Robotic transfer line, Multi contact Type for small parts and Special purpose equipment’s for heavy components. These are highly sophisticated equipment’s with robotic handling and PLC control integrated NDT testing lines. A great number of variations of these typical magnetizing units are available. These variations are in size, current output, methods of current controls and numerous types of fittings to expedite magnetization of odd shaped parts. In addition there are many accessories available such as pad contacts, steady rests for heavy parts, special shaped coil etc.

The objectives of the set up design is 1)

To provide convenient means for accomplishing correct magnetization. Magnetization with respect to field strength and direction and convenient means providing sufficient power of the right sort, suitable contacts and coils, proper system for applying magnetic particles and well lightened space for careful examination of the processed parts for indications.

2)

To make possible rapid testing of parts at required speed with assurance that the results will be reliable and reproducible. With suitable equipment’s all parts can be tested under identical conditions of contacts, current types and values and techniques of particle application.

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3)

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As BFL has got multiple equipments at different locations and with different operators .The control of process becomes more and more important as the size of defect sought becomes smaller and finer; or as it becomes desirable to find defects over certain minimum size ignoring the non-relevant types.

MPI Process Design consideration in Bharat Forge.

To increase the speed of testing process in BFL following steps are taken.

Following are important points to be considered before designing MPI process

•

Handling of parts on conveyors, manipulators, and robots through one or more of the inspection steps involved in the entire testing.

To understand thoroughly the purpose of the proposed testing; define the part or parts involved in testing with respect to size, shape, weight, surface finish, magnetic characteristics, heat treatment, pre-processing of the part, service requirements and production speed.

•

Method consideration

•

Technique consideration

•

Material handling

•

Automatic rotation or manipulation of the parts for viewing by inspector

•

Testing speed

•

Multi directional, Multi contact or swinging field magnetization of parts to reduce the number of processing steps.

•

Type of defect sought to be detected

•

Operating conditions

•

Light Intensity

Use of special fixtures to simplify the task of positioning parts accurately for required magnetizing operation.

•

Ergonomics

•

Operator comfort.

Automatic segregation of the inspected parts upon signal by the inspector, into such categories as “good”, “repair’’ or “scrap’’.

MPI Process Control System

•

•

With the increased Automation BFL has achieved not only output per hour but consistent field strength on part, controlled duration of the leakage field, controlled bath application with sufficient particles and proper sequencing of magnetizing current.

This has helped BFL to reduce the variation in the appearance of the indications that was causing due to manual processing.

Every equipment in BFL is fitted with error proofing (POKA YOKE) with Visual/audio alarm systems, where system will automatically stop and will give alarm to operator.

•

Magnetization current failure,

•

Less or excess field strength ( On selected units)

•

De-magnetization failure

•

Less bath level

•

Ensure correct agitation of the bath (Magnetization will not start unless bath is agitated for minimum five minutes)

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Journal of Non Destructive Testing & Evaluation

Since magnetic particle test considered to be final product test before delivery of product, Process control becomes very important to achieve require objectives like •

Assurance of adequate controlled sensitivity

•

Uniformity of the testing

•

Test production output, to keep pace with production rate for the part

•

Avoidance of potential damage to parts during magnetization.

•

Minimizing reliance on human factor.

Bharat Forge has developed their own methodology of process control to fulfill the objectives by introducing •

On job training of operator and helper

•

Periodic Use of different standard test samples to verify the consistency in quality of Magnetic Field strength at various locations.

•

Daily/ shift wise process Control check

•

Part specific Visual Process Control Display sheets (VPS) on every machine

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Sample Visual Procedure Standard

Sample MPI Process Control Sheet

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•

Periodically (Six Monthly) machine calibration

•

•

MPI machines are fitted with POKA-YOKE (Error Proofing) for magnetization, De-magnetization and currents /magnetization failure.

Multi contact Magnetization with Poke-Yoke for safety Bracket & Steering Knuckles

•

•

All MPI are fitted with safety system and ergonomically designed to avoid operator fatigue.

Integrated Robotic transfer NDT testing facility for Passenger Car Crankshafts - EDDY current testing, Magnetic Particle testing, Visual inspection, Dimensional inspection

•

Central- Conductor Magnetization Unit for Gear parts

ADVANCE MAGNETIC PARTICLE TEST FACILITIES AVAILABLE AT BHARAT FORGE •

Automatic Magnetization and material transfer line for Transmission shafts

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Journal of Non Destructive Testing & Evaluation

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MAGNETIC PARTICLE TESTING AT FORGE SHOP BARAMATI

NEW DEVELOPMENT FOR MPI MACHINE FOR FLUID ENDS IN 2015

MP test facility at Bharat forge, Baramati was installed in 2010.Bharat Forge has 2 types of product segment (Crankshaft & Fluid End) and accordingly we have MPI machines.

Machine was designed with compact feature & manufactured in India. Machine features:

NEW DEVELOPMENT FOR MPI MACHINE FOR CRANKSHAFTS: BFL designed & manufactured in India which is accommodating all types of crankshafts.

•

Feature of the machine: Variety of products: All types of crankshafts (Medium duty, Heavy duty, locomotive cranks)

Maximum size can be accommodated: •

Envelope size 500 mm

•

Maximum Length 4500 mm

•

Benefits: Due to above features, there is less handling of the bigger jobs which has reduced cycle time for MPI inspection and increased productivity.

1.

Job rotation for inspection

2.

100 magnetization with the help of head shot & central conductor

3.

Demagnetization on machine

4.

Digital display

5.

Platforms are designed for inspection suitability (Ergonomics)

•

Benefits: Due to above features, there is less handling of the job which has reduced cycle time for MPI inspection and increases the productivity.

Photos showing ergonomically benefits to operator while detecting the cracks Today in Bharat forge thousand tons of steel components gets checked for magnetic particles every day from their different facilities.

As the global supplier of components Bharat Forge has achieved excellence in product quality and bagged many awards globally. This has achieved by Bharat Forge because of its highly technological, innovative design and execution capability.

EARLIER CRACK DETECTION PROCESS

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Bharat Forge runs an excellence program for all their processes and MP test considered to be one of the important one along with all manufacturing process. Excellent tools like TPM, SMED, 4M, VSM, HEP are effectively used to improve quality of work, less operator fatigue

Method

CRACK DETECTION WITH NEW MACHINE and high degree of consistent output.

Measurement  Layered process audit to target zero PPM

The use of 4 M methodology always resulted achieving Zero PPM.

In Bharat Forge, Magnetic particle test is not only used as an Inspection method, but the output or results of the daily inspections are used as one of the major inputs for Improvements in fatigue life of the components and design changes .these Inputs are also being used for improvement in techniques of testing and quality of work.

Man

 Only qualified level-2 operators are authorized for MPI inspection  Periodical training for up gradation of existing level of certification

Machine

 Adequate Poka- yoke for “current failure detection” are installed on each MPI machine  Motorized rotation of parts for easy crack inspection  Machines are getting reviewed for SMED, TPM for improvisation in the MPI inspection

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 Robust design of technique  Use of high Intensity LED type UV lamps  Verification for all process parameters in each shift

Bharat forge also engages themselves with the magnetic particle equipment suppliers while design and erection of the Magnetic particle test line. This takes relationship with the suppliers to new heights to produce highly innovative and technically qualified machines.

The excellence program has resulted Bharat forge for getting very high customer Delight.

References 1.

Bharat Forge history journal

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PHYSICAL PRINCIPLES, PROPERTIES AND DYNAMIC CHARACTERISTICS OF PENETRANT PROCESSING MATERIALS D.J.Varde-Director Pradeep Group of Industries

Penetrant inspection has proven to be a crucial quality control method and currently one of the most widely used NDT method among various NDT techniques used in various industries. As a result of many years of developments, much knowledge has been acquired on how to obtain the best possible results from penetrant systems under a wide range of conditions. Researchers have developed a wide variety of special-application penetrants to meet specific needs. It is expected that the Penetrants will continue to be one the most widely used NDT methods available to the engineering industry. Due to cost effectiveness, reliability, and simplicity of use, penetrant inspection in all its forms will always remain an indispensable inspection tool in the future.

The dynamic characteristics and principles of physics can give better clarity to the user to select and use the proper penetrant testing products for optimum benefits in variety of industrial applications If we carefully look at the penetrant testing procedure, it consists of Surface wetting by probing fluid, formation of entrapment within surface connected discontinuities, removal of excess penetrant, depletion of entrapment & enhancement of indication by developer interaction with entrapped penetrant fluid.

The understanding of fluid mechanics , the molecular characteristics of liquids, forces acting on liquid surface at the interfaces, the surface chemistry & mechanism involved during infiltration of penetrant into the surface discontinuities, the geometry of surface discontinuities, the surface tension & Contact angle of probing fluid, surface temperature at the interface etc affect the speed of infiltration of probing liquid into the defect, the entrapment , the depletion of entrapped penetrant and thus the estimation and detection of smallest defect. The efficiency of the penetrant system depends upon the properties of penetrant materials which can enhance entrapment into the flaws, the ability of the

www.isnt.org.in

penetrant liquid to retain the entrapped penetrant during the penetrant removal process from the surface after the penetrant or emulsifier dwell time and the development mechanism by using variety of modern high performance developers In order to understand the physical principle of penetrant testing it is necessary to deal with the most important terms of fluid mechanics in physics and physical chemistry such as, phases, the reactions at interface between different phases, Molecular actions at liquid surfaces & also between liquid molecules, intermolecular forces within liquid surface which retain the molecules in the liquid phase and the forces at the surface of liquid, free energy at the liquid surface and the mathematical equivalent quantity known as Surface Tension, thermal agitation of molecules, interfacial tensions at the interface of two liquids, the adhesive & Cohesive forces, evaporation process of liquids and vapour pressures and so on. However, in simple terms Liquid penetrant method of Non Destructive testing may be stated as the one based on the reactions between two or more phases, the special characteristic occurring depending upon the phenomenon & forces acting at the interface.

As the first step of the penetrant testing process, it is essential to understand formation of Penetrant Entrapment in the crack.

The wetting ability or spreading ability of any liquid to spread over the solid surface plays an important role in penetrant entrapment. The liquids with high contact angle and high surface tensions give low degree of wetting whereas the lower contact angle liquids will have high degree of wetting ability.

In penetrant liquid the contact angle is expected to be less than 10 deg to zero degree for effective wetting of the solid surface. In order to have better spreading of penetrant liquid over solid surface, the surface energy of solid gas interface need to be more than the surface energy of the solid liquid

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interface which will spread or move the liquid on to the solid surface. When such liquid spreading on the solid surface reaches the crack tip, triple interface between solid, liquid & gaseous phase occurs. Eventually the penetrant liquid enters the crack and starts filling the crack volume. Initially at the tip of the crack some amount of gas phase will escape but subsequently, the gas phase inside the crack will continue to get compressed until the gas pressure counterbalances the surface tension of the penetrant liquid till the equilibrium is attained which will stop further infiltration of penetrant fluid towards crack tip.This leads to Formation of Penetrant entrapment into the flaw and the equilibrium at triple interface can be mathematically indicated by following equation (Fig-1) (YsG - YsL) x ds (P-P0) x dy Where YsG Surface energy at solid gas interface YsL Surface energy at solid gas interface P Final pressure of the entrapped gas P0 Initial atmospheric pressure S & ds perimeter & surface element of this perimeter x & y width & length of moving triple interphase

the probing fluid may be defined as the minimum amount of any non emulsified liquid (Oil) required to be added to the emulsifier in order to destroy itâ&#x20AC;&#x2122;s washability with water.

The Penetrant entrapment efficiency depends upon the Emulsification Index of the probing fluid and may be mathematically expressed by the equation Entrapment Efficiency 100 / (100 + EI ) Where EI is emulsifying Index of the penetrant fluid When the penetrant is removed from the surface of the component after the dwell time of penetrant or after the emulsification time of emulsifier Neither 100 entrapment of liquid penetrant into the discontinuity is practical nor the complete removal of the penetrant from the discontinuity i.e. 0 entrapment is desirable. However, it is always the objective to retain maximum amount of penetrant in the flaw to enhance the efficiency of the penetrant fluid.

Once the penetrant enters the crack efficiently it needs be stable in order to enhance penetrant efficiency to detect the defect. The stability of penetrant entrapment into the discontinuity or crack is called Entrapment Stability and depends upon the viscosity & the emulsification index of the probing fluid.It may be understood that there are emulsifiable and Non emulsifiable liquids. Oils with high emulsifying index are easy to emulsify however the liquids which are difficult to emulsify are best suitable as penetrant fluids. Non emulsifiable liquids have no use in the penetrant materials Viscosity of the Penetrant Fluid Entrapment Stability ------------------------Emulsification Index Entrapment stability maybe further understood by understanding the behaviour of entrapped penetrant in the discontinuity.

FIG 1

The efficiency with which the penetrant fluid gets entrapped into the crack is termed as Penetrant Flaw Entrapment efficiency and It is nothing but the proportional penetrant remains trapped in the flaw after emulsification or after washing of penetrant fluid after the dwell time of emulsifier in case of post emulsifiable penetrants or penetrant well time in case of solvent clean or water washable penetrants.

The emulsifiability or emulsifying index (EI) of September 2016

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FIG 2

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ARTICLES

In case of solvent removable type of penetrant, the penetrant entrapment may be shown by two simple zones , soluble zone & diffusion zone, as shown in the attached figure (Fig-2). The soluble zone is complete entrapment of penetrant whereas the diffusion zone is required to be controlled carefully by the operator so that excessive cleaning will not remove the entrapped penetrant completely so as to affect the sensitivity of the penetrant system.Solubility Characteristic of penetrant fluid in the removing solvents plays a great role resulting into higher or lower flaw detection efficiency.

In case of water washable i.e. pre emulsified penetrants, the zones can be shown as in fig-3 where 1.

2.

The top most zone may be called as washable zone at the opening of the crack. The efficient washability is extremely important however this depends on the solubility of probing fluid in the removing solvents which is water in this case.

The complete entrapment of water washable penetrant in to the crack may be termed as Soluble zone which is shown deeper inside the crack. The probing fluid definitely has greater solubility into the removing solvent which is water in this case.

3.

In case of these type of penetrant the water diffusion zone is larger but during washing of excessive penetrant after the dwell period the water does not enter fully into the diffusion zone due to formation of gel at the at the interface.

4.

This zone is shown as Gel zone which is part of the diffusion zone. The gel formation at the boundary restricts the excessive removal of the penetrants from the defect and in turn improves the flaw detection efficiency.

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Water tolerance characteristics in water washable penetrant system is an important parameter for flaw detection efficiency. Water tolerance index is the percentage of water required to produce a gel break in water washable penetrant system. The function of the addition of emulsifier in water washable penetrants is to produce water washable mixture which can easily remove excessive penetrant fluid after the dwell period. The excessive use of water can result into gel break and may affect the sensitivity of water washable penetrant system .

In case of Post emulsifiable penetrant systems, the entrapment stability may shown by adding emulsifier diffusion zone & insoluble zone Similar to water washable, pre emulsified penetrant system, in this case the zones can be shown as follows The top most zone may be called as washable zone at the opening of the crack. The efficient washability after emulsification time is extremely important however this depends on the careful control of emulsification time so as to optimise solubility of probing fluid in the removing solvents which is water. This will help to retain the maximum entrapped penetrant into the defect.

In post emulsified penetrants the soluble zone almost does not exist or is extremely small depending upon how carefully the emulsification time is controlled.

FIG 4

The Water and emulsifier can diffuse into the entrapped penetrant and the said zone may be termed as diffusion zones.

FIG 3

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During washing of the excess penetrant, the water forms hard gel at the interface of probing fluid and water which forms Gel zone which remains as part of the emulsifier diffusion zone. This formation of hard gel prevent entry of washing liquid further into the

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entrapped penetrant and improves stability of the entrapment and hence the detectability of the flaw.

The deepest region of the crack is termed as insoluble zone which remains deep inside the crack and impossible to remove by washing fluid which is water. This deeply entrapped penetrant will be required to be removed by suitable means prior to putting the component to final use.

In case of Post emulsifiable penetrant systems,the penetrant entrapment stability chart can drawn by plotting viscosity on y-axis and emulsifying index at X-axis which can be used for determination of contact time of emulsifier with penetrant for highest possible entrapment into the flaws. This chart can also help to indicate the contact time for different penetrants with same emulsifier to have same degree of penetrant entrapment into the flaw.

It may be noted that there are non emulsifiable , easy emulsifiable and difficult to emulsifiable liquids.

If we plot a chart with viscosity of various liquids against their emulsifying index, the said chart is called as Emulsifiability chart and the said chart is most useful for selection of correct type of liquid for making of penetrants. The liquids which are difficult to emulsify and having emulsifying index in the range of 1 to 10 are considered as most suitable for the penetrant fluids.

Water tolerance characteristics of the emulsifier in post emulsifiable penetrant system is an important parameter for flaw detection efficiency.

Water tolerance index is the percentage of water required to produce a gel break in emulsifier in post emulsifiable penetrant system. The function of the emulsifier is to produce water washable mixture.

When water is added to the emulsifier, the viscosity increases initially and further addition shows sudden drop at particular addition. Both these points are of importance from the point of flaw detection efficiency of the penetrant system.

Many other characteristics of post emulsifiable penetrant and emulsifier shall be of interest to the manufacturer of penetrant testing material and also to some of the inquisitive users.These terms can be emulsifier tolerance for contamination in penetrant liquid, the coupling index for emulsifier and the emulsification rate of post emulsifiable penetrant, penetrant miscibility rating with emulsifier, the gel range etc. although these terms are more or less interrelated to each other.

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Various methods are also tried to have near 100 flaw entrapment efficiency. Use of particulate scrubbers and liquid type spray scrubber where the penetrant is difficult to remove except by mechanical scrubbing by spray action.It will be possible to adjust the flaw entrapment efficiency to desired level. The water washable scrubbing, broadening of gel range of the emulsifiers, spray quench technique etc are used to improve the entrapment stability of the penetrant into the flaw and in turn to result into high degree of efficient detectability.

DEVELOPER MECHANISM DURING FLAW INDICATION DEVELOPMENT The efficient development of defect indications is the most important mechanism which improves the defect detectability. The penetrant entrapment is required to be made visible by bringing it to the surface by the process of development. The basic function of developer is to draw out the penetrant entrapped into the defect and provide bright white & non fluorescent contrast back ground and increase the brightness of the indications. It also spread out by way of enlargement of the indications of the fine and narrow cracks on the surface and make it visible to the human eyes without strain. Some of the efficient penetrants have the capability to develop the indication without the application of developers and such development of cracks is by means of self development, However the film of such penetrant coming out of the entrapment is some times so thin that it falls below the threshold limit of visibility and application of suitable developer can enhance this above the visibility threshold to indicate extremely minute & fine defects.

It has been seen that after removal of the penetrant material after the penetrant dwell time or emulsification dwell time the entrapped penetrant in the crack at triple interface is at equilibrium condition and in order to bring the entrapped penetrant out of the entrapment, the developer must overcome the forces which have kept the entrapped penetrant at equilibrium. We have seen that the liquid having lower contact angle flows easily on the surface. Incase of application of developer there are two surfaces, one which is surface inside the crack and the second is the surface of developer. In order to spread the entrapped penetrant from itâ&#x20AC;&#x2122;s inside surface onto the developer particle surface, the contact angle of penetrant material with developer www.isnt.org.in

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particle should be smaller than the contact angle at the metal surface inside the crack. In other words the spreading coefficient of penetrant on developer surface should be more than that at the metal surface inside the crack.

of entrapped penetrant to spread over the developer particles which in turn can bring the penetrant to the threshold limits of visibility . The use of dilution expansion developers can expand the film thickness so as to be above the threshold of visibility.

The mechanism of development can be explained as entrapped penetrant after cleaning of the surface exude out and form a thin film on the surface near crack opening and become visible by self development process without the application of developer and become visible if this thin film is within the threshold limits of visibility whereas in other cases the developer is required for the thin film

The researchers have extensively studied & used the various underlying dynamic characteristics of various liquids particularly in relation to the reactions at the interfaces to continuously enhance the efficiency of the penetrant testing materials.

Development in the more efficient surface active substances have also resulted into higher efficiency in the performance in penetrant inspection.

www.isnt.org.in

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PRODUCT GALLERY SMALL CONTROLLED AREA RADIOGRAPHY (SCAR) SYSTEM Objective of Small Controlled Area Radiography (SCAR) system is to carry out radiography in open field using special projectors with Selenium 75 sources and controlling beam with tungsten collimators towards area of interest. Additionally all scattered and secondary radiations are blocked by Radshield mats as a additional shielding mat to bring down the radiation levels below 0.2 mR/hr at 5 meter.

This system is approved by competent authorities and has proven its usefulness in the construction field beyond doubt. SCAR systems are at present are used in all running plants, shutdown work and confined areas to reduce radiation impact. Unique aspect of this system is that it helps contractor’s protect their work force affectively while radiography work is on 24x7 and utilize their construction time for uninterrupted productivity and obtain results for QA to control weld quality while construction work is on. The contractors using SCAR system vouch for the nominal increase in cost of projection type radiography system compared to SCAR system is paid off by great saving in time.

When SCAR system is used with Computed Radiography (CR) this entire setup becomes film less/ darkroom less completely a dry radiography system with top notch quality of image. This is tried, tested and proven system. Ask for a demonstration.

GEECY VINCOTTE INDIA www.geecyvincotte.com

EECIFLUX ULTRA VIOLET-LED INSPECTION LAMP “BL-LED5K” • “BL-LED5K” Series NDT Lamps SALIENT FEATURES two Ultra-HiFlux UVA-LEDs plus a convenient white light LED to quickly switch between fluorescent inspection and flaw location.

• The “BL-LED5K” utilises a new generation of LED Technology generating broad beam configuration for producing an extremely wide coverage area, making it ideal for both handheld and in-line application.

• A unique dual intensity SALIENT FEATURES provides both high and standard UV and White Light output for added versatility. Also LED operation with long operating life in low power consumption with built-in fan makes “BL-LED5K” a complete solution for MPI inspection.

• Outer casing is made of rubber handle and tough aluminum housing for rugged use.

• “BL-LED5K” Lamps are safe to be used in closed spaces like pipelines, vessels and closed containers.

SALIENT FEATURES : • Delivers over 5000 W/cm2 @ distance of 15”, with a beam spread of approximately 6” • Low Visible light Emission- less than 2 foot candle (20 LUX)

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• Built-in fan keeps LEDs cool to maintain optimum light output during extended use • Easy to switch between ultraviolet and white light • Rubber made handle for easy grip • Tough Aluminum Housing , Rugged, Modular Construction allows for easy field serviceability • LED life 25000+ hours ELECTRONIC & ENGINEERING CO. (I) PVT. LTD www.eecindia.com www.isnt.org.in

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Applications SENTINELTM Model 1075 SCARPro source projector is used for industrial non-destructive testing applications of gamma radiography with Selenium-75. SCARPro can be used as a category I or II exposure device. When used in SCAR mode (category I), the SCARPro allows radiography to be performed in congested work areas with a minimal distance to the controlled areas. When used as a traditional projector (category II), standard SENTINELTM source guide tubes and collimators allow the Selenium-75 source to be used for axial, radial • and panoramic exposures.

SALIENT FEATURES •

The dual mode radiographic exposure device for Small Controlled Area Radiography and traditional projection Radiography.

•

Interchangeable projector front end plate and SCAR collimator.

•

Precision machined stainless steel body and tungsen shield.

Utilises standard 880 controls and guide tubes with ISO 3999 compliant interlock.

QSA GLOBAL www.qsa-global.com

WHITE LIGHT ASSEMBLY FOR USE IN PENETRANT TESTING (PT) It is mandatory in PT, to have sufficient illumination on surface being tested to achieve maximum sensitivity results.

The American Society for Mechanical Engineers (ASME) Section V Non-Destructive Testing Article6, and Interpretation (T-676), sub clause T-676.3- Color Contrast Penetrants states: T-676.3 COLOR CONTRAST PENETRANTS -

•

• Illumination (natural or supplemental white light) of the examination surface is required for the evaluation of indications. The minimum • light intensity shall be 100 fc (1000 lx). The light intensity, natural or supplemental white light source, shall be measured with a white light meter prior to the evaluation of indications or a verified light source shall be used. Verification of light sources is required to be demonstrated only one time, documented, and maintained on file.

•

SALIENT FEATURES •

Handy, Light weight White Light for inspection.

•

Diameter :105mm, length :160mm with handle

•

Weight : 750gm (without cable)

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Cable - attached 3 meters Input Source : 230volt 5 Amp. Single phase Intensity: 200fc (2000 lx) at 15 inches from light source when the bulb is new and when it is switched ON for 15 minutes Works continuously for 8 hours without overheating.

FERROCHEM NDT SYSTEMS PVT. LTD. www.ferrochemndtsystems.com

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WHAT'S NEW

1075 SCARPRO SOURCE PROJECTOR

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UV LED TORCH & LAMPS Arora Technologies (P) Limited (ATPL) has designed & manufacturing array of portable, versatile and robust UV LED Lamps for day to day Fluorescent Magnetic Particle or Liquid Penetrant inspection.

SALIENT FEATURES •

Provides an extremely large coverage area during inspection with a minimum UV-A light intensity of 2,000 w/cm

•

Assembled with a constant current regulator keeping UV-A light • intensity stable when battery voltage fades during inspection

Available with or without black light filter

•

Equipped with a standard mechanical cooling system to prevent • excess heat from LEDs

•

Durable, Waterproof and Easy to operate in the most difficult inspection areas

Certificate of Compliance for both wavelength & light intensity measurements supplied with every product

•

Powered by AC Mains & Rechargeable Li-Ion Battery and provides ARORA TECHNOLOGIES (P) LIMITED www.arorandt.com continuous operation while charging

WATER WASHABLE FLUORESCENT PENETRANT SYSTEM Water Washable Fluorescent Penetrants system is extremely popular technique for detection of surface cracks & fine porosities in variety of industrial components all over the world . Exceptional sensitivity, Operator friendliness, high reliability , Water washability , Bio degradability , high productivity are the major SALIENT FEATURES of this product and when used with highly sensitive Developer Powder makes this NDT technique highly economic without compromising on • sensitivity.

•

SALIENT FEATURES •

Guaranted Sensitivity on 0.05 x 10 micron Ni-Cr.Panel

•

Guaranted Detection of 5 stars in TAM Panel

•

Bright Yellow Green Fluorescence

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Excellent Water Washability

•

Viscosity between 5 to 10 cst

•

Operator Friendly- No objectionable odour

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Journal of Non Destructive Testing & Evaluation

Extremely Powder

fine

Developer

Halogen & Sulphur within acceptable limits

•

Operating Temperature 10 to 50 Deg C

•

Minimum Two Year Performance Guarantee

PRADEEP METALS PVT. LTD. www.pradeepndt.com

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Carestream HPX -1 Plus family of products has earned many of the NDT Industry’s most prestigious awards & changed the CR landscape& raise the bar in Industry.

The new HPX -1 Plus offers many improvements, improved Optics for better imaging up to 30 faster through put on long saturated plates (very high exposure), an improved imaging plate transports system to protect Imaging plates, higher mechanical reliability & user friendly DICOND compliant software running Extra long Imaging plate, wide dynamic range with high sensitivity for any type of imaging applications Xray, Gamma sources.

•

Adjustable PMT & Laser Power

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Smart Erase system – check plates after scanning & during the erase cycle automatically adjust & optimize the erase level

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Approved by leading Engineering companies & Third party Inspection companies.

Unique designed IP transport drive systems – minimized contact – increased life

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DICOM & DICONDE Compliant

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Only CR system in the market – Positive airflow keeps unit cool & contamination outside

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EHS compliant

•

Wide applications & Economical

•

Any make (non magnetic) IPS can be used

SALIENT FEATURES •

Ultrahigh Image Quality & Resolution Imaging

•

Handles bare Imaging plates, multiple plates at one time, custom cut size plates (with plate carrier), Imaging plates in Rigid Cassettes & long plate up to 85” without special feed guide

•

TOPAX NDT SOLUTIONS LLP www.topaxndtsolutions.com

VANTA New handheld XRF analyzers, Vanta, are rugged and built for analytically demanding applications in the harshest environments. Vanta analyzers are IP 65 rated for protection against dust and water, are drop tested, and built to withstand a temperature range of -10 C to 50 C (14 F to 122 F)i.

Vanta SALIENT FEATURES new Axon technology, a revolution in XRF signal processing that provides accurate, repeatable results for greater productivity and a fast return on investment. Vanta analyzers feature an intuitive interface and application-specific software so new users can work with the device with minimal training. Data is easily exported via Wi-Fi, Bluetooth , or USB OLYMPUS MEDICAL SYSTEMS INDIA PVT LTD. www.olympus-ap.com

www.isnt.org.in

Journal of Non Destructive Testing & Evaluation

September 2016

WHAT'S NEW

CARESTREAM HPX -1 PLUS

EVENTS

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| EVENTS

LIST OF INDIAN / INTERNATIONAL CONFERENCE/ WORKSHOPS IN NDT (2016) SEPTEMBER 2016 25-28: ENDE 2016 Workshop Venue: Lisbon, Portugal.

Contact: Helena Geirinhas Ramos and Artur Lopes Ribeiro, Portugal. Email: ende2016@lx.it.pt

25-27: 16th International Exhibition of Equipment for Non-Destructive Testing and Technical Diagnostics.

Venue: Crocus Expo, Moscow, Russia Contact: 190000, Russia, St. Petersburg, Yakubovich st., 24A, Russia. Web: www.ndt-russia.ru/

OCTOBER 2016

NOVEMBER 2016

4-6: 12th International Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components Venue: Dubrovnik, Croatia; Email: 12thnde@12thnde.com; Web: www.12thnde.com

24-27: 75th ASNT Annual Conference.

Venue: Long Beach Convention Center, Long Beach, California, USA. Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus, OH 43228-0518, USA. Tel: +1 614 274 6003; Fax: +1 614 274 6899; Email: conferences@asnt.org; Web: www.asnt.org

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26-28: ACNDT 2016, IC-WNDT-MI'16 Venue: Oran, Algeria Email:wndt16@csc.dz / wndt16@gmail.com

DECEMBER 2016 15 -17th â&#x20AC;&#x201C; NDE 2016 Venue - Alsaj Convention Centre, Trivandrum, India.

Web: www.nde2016.com

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As decided in the Executive Committee Meeting, this year Late Dr. N Kondal Rao Memorial Award was bestowed on Prof S. A. Bhardwaj, Homi Bhabha Chair Professor, DAE & Chairman, and Atomic Energy Regulatory Board. To commemorate this occasion, a lecture program was arranged on the eve of Dr. Kondal Rao’s birthday, 14th July 2016 at NFC auditorium, 4th floor, Saradhi Building.

Prof. Bhardwaj, Sri. G. KalyanaKrishnan, Chairman & Chief Executive, NFC, Sri. P. Mohan, Chairman, ISNT-HC and Sri. Venkata Reddy, Secretary, ISNTHC adorned the dais. The program began with the dignitaries on the dais offering floral tributes to Dr. Kondal Rao’s photo.

Sri. Mohan welcoming the audience briefly put

forth the genesis of ISNT starting from IINDIE & NDT Society of India and the support extended by Dr. Kondal Rao in the formative days, thus justifying the institution of the Memorial Award.

Sri. KalyanaKrishnan brought out the crucial role being played by NDT in assuring quality of fuel, that too when the targets are very high.

Sri. C Phanibabu, Vice Chairman, ISNT-HC & GM, QA, NFC presented the salient contributions of Dr. Kondal Rao and various facets of his outstanding personality.

Sri. J R Joshi, Vice Chairman, ISNT-HC & Project Director, Dr. DL introduced the awardee & guest speaker Prof. Bhardwaj to the audience.

www.isnt.org.in

During the one hour Memorial Award Lecture on “Role of QA processes on Radiation Safety” Prof.

Bhardwaj enthralled the audience taking them from radiation basics to its latest applications leaving nothing untouched. And the voyage was scintillating.

100+ audience including yesteryear stalwarts, Ex Chairmen of ISNT & Former Chief Execuives of NFC S/ Sri. K Balaramamoorty, KK Sinha, BP Verma, Dr. R.Kalidas, Dr. N Saibaba, GVSRK Somayajulu, GVS Hemantha Rao, ISNT members, Scientists from NFC , Dr.DL, NPCIL, MIDHANI, C-MET, BDL, ECIL Private Entrepreneurs listened to the lecture with rapt attention and highly appreciated the same.

ISNT-HC presented the Dr. Kondal Rao Memorial Award to Prof. Bhardwaj. While Sri. KalyanaKrishnan presented a silk shawl, Sri. Balaramamoorty presented a Silver Plaque amidst thunderous applause as all the other veterans came to the dais and greeted him.

Sri. Venkata Reddy proposed vote of thanks. The program came to an end with National Anthem.

Sri. B S Rama Rao anchored the Program in an impressive manner.

ISNT-HC hosted dinner in the honor of Prof.

Bhardwaj.

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EVENTS

DR. N. KONDAL RAO MEMORIAL AWARD

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BRIEF REPORT ON STUDENTâ&#x20AC;&#x2122;S SEMINAR

"BEHIND THE TEACHER'S DESK" (BTTD - 2016) JUNE 9-10, 2016 AT CSIR-NATIONAL METALLURGICAL LABORATORY, JAMSHEDPUR, ORGANISED BY The Indian Institute Of Metals (IIM), Jamshedpur Chapter Indian Society For Non-Destructive Testing, Jamshedpur Chapter CSIR - National Metallurgical Laboratory & Tata Steel Limited

The studentâ&#x20AC;&#x2122;s seminar on "Behind The Teacher's Desk" (BTTD - 2016) was jointly organized by The Indian Institute of Metals (IIM), Jamshedpur Chapter Indian Society for Non-destructive Testing (ISNT), Jamshedpur Chapter, CSIR-National Metallurgical Laboratory & Tata Steel Limited during June 09 -10, 2016 at CSIR- National Metallurgical Laboratory, Jamshedpur.

"Behind The Teacher's Desk" (BTTD) is an annual Students' Seminar, for the promising and aspiring metallurgists, providing a befitting platform for interaction of student and the experts from industry / R&D/academia.

In this event, the young generation of professional metallurgists/NDE practitioners get an opportunity to share their academic achievement, innovation, creativity, sense of adventure and new ideas in the field of metallurgy and NDE. Eminent personalities (from India & abroad) in the field of NDE from academic institutions, R&D Laboratories and Industries have delivered lectures in the seminar.

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Journal of Non Destructive Testing & Evaluation

About 100 delegates from various industries, academic institutions and R&D organisations participated in the seminar. There were good interaction between the participants and the speakers.

The seminar ended with a vote of thanks.

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EVENTS

REFRESHER COURSE ON RADIATION SAFETY FOR RADIATION PROFESSIONALS, RADIOLOGY PROFESSIONALS, QA, QC & NON RADIATION PERSONNEL 30 SEPTEMBER - 1 OCT 2016 ORGANIZED BY INDIAN SOCIETY FOR NON-DESTRUCTIVE TESTING INTRODUCTION

WHO SHOULD ATTEND

Radioactivity is a natural phenomenon and natural source of radiation are features of the environment.

Radiation and radioactive substance have many beneficial uses, ranging from power generation to application in medicine, industry and agriculture.

One of the oldest established industrial applications of radiation is the use of radiography for the nondestructive testing and diagnostic applications in medicines.

This is a unique and first of its kind refresher course designed exclusively for the Radiation Safety Officers in industrial radiography, radiation therapy, diagnostic radiology, QA personnel, industrial radiographers, site In-charges, QA & QC executives and managers, & industrial safety executives.

The radiation risks to the workers and the public that may arise have to be assessed and controlled.

Safety measures and security measures must be designed and implemented in an integrated manner so that security measures do not compromise safety and safety measures do not compromise security.

This is a refresher course for the radiation professionals and for the non-radiation workers, it provides radiation detection, measurement, protection and other safety related aspects.

OBJECTIVE The course intends to provide a holistic overview of radiation detection, measurement, protection principles with emphasis on regulatory aspects of industrial radiography, radio therapy, diagnostic radiology, radiation hazard evaluation and control, operational limits, transport of radioactive materials, radiation accidents in industrial radiography, emergency response plans and preparedness (mockup demo), & radiation detectors and monitors.

Faculty for the course are experienced personnel being drawn from IGCAR, BARC and AERB.

TOPICS COVERED IN THE COURSE Radiation Basics, Detection Hazards Evaluation and Control, Regulatory aspects for Industrial Radiography, Safety and Security of Radioactive Sources, Transport of Radioactive Source & Device Accidents and Lessons learnt – Industrial, Radiography, Emergency Response in Case of Accidents and Preparedness plan eLora – An overview COURSE FEE Industrial Person: Rs. 7500/ISNT Members: Rs. 7000/Bulk Booking 3 and more – 10% discount Service Tax applicable at 15% Extra VENUE 30 SEPTEMBER - 1 OCTOBER 2016 Indian Society for Non-Destructive Testing Modules 60 & 61, 3rd Floor, Readymade Garment Complex, SIDCO Industrial Estate, Guindy, Chennai – 600 032, Tamilnadu, INDIA Ph: 044-2250 0412/4203 8175 Email: isntheadoffice@gmail.com For further details: www.isnt.org.in COURSE IS LIMITED TO 25 FOR EFFECTIVE PARTICIPATION ON FIRST COME BASIS

www.isnt.org.in

Journal of Non Destructive Testing & Evaluation

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| EVENTS

A BRIEF REPORT

19TH WCNDT 2016 in MUNICH, GERMANY 13 – 17 JUNE 2016 Compiled by Dr. Shyamsunder Mandayam Chairman, National Certification Board, ISNT

The 19th edition of the “Olympics” of NDT which goes by the name of World Conference on NDT was truly a mega event. 2500+ delegates, 250+ exhibitors, 650+ papers and to top it all an event so meticulously planned and executed by the brilliant team from the German Society for NDT with content and style.

Starting off with a crisp and impressive Inaugural function comprising of short welcome addresses, some melodious Bavarian music, a breath taking show of a solo aerial dance and an NDT professional turned Astronaut recounting his experiences in space. It ended with a flavor of the season "European Football" as Dr. Matthias Purschke, the President of the 19th WCNDT formally "kicked off" the event with a football!

According to the official book of Participants there were 2120 registered delegates. However the final actual numbers were much higher considering Spot Registrations and Day visitors which probably ran into more than a 1200.

Virtually every country in the world actively pursuing NDT was represented at WCNDT at least by 2 to 3 participants. Maximum representation was from Germany and other European countries including France, Sweden, Switzerland, Denmark, Belgium, Austria, UK, Netherlands, Italy and many others. There was good representation from USA, China, Japan, Australia, Korea, New Zealand, Canada, Singapore, Russia, Middle East, India and several African countries. India too was well represented by several ISNT officials as well as delegates from the Academia and Industry & a big contingent of more than 40 members from NANSO who traveled as a group. EECI, Mumbai & Technofour, Pune were the two Indian exhibitors who were show casing their products at the exhibition. A quick glance at the distribution also indicated highest participation from Industries (50%), followed by Academics (30%) and Research institutes (20%).

September 2016

Journal of Non Destructive Testing & Evaluation

The technical sessions were well planned and distributed over several parallel sessions and covered an extensive range of topics ranging from conventional to Advanced techniques, applications spreading to virtually every industry one can think of and provided adequate coverage to interest every delegate be it a student, a academician, a practicing professional or a researcher. About 650+ papers were presented across 140+ sessions. You can access the presented papers at http://www.wcndt2016.com/ programme or at http://www.ndt.net Strong representation was also seen from all the major National NDT Societies of the world including USA, Germany, Argentina, Britain, Australia, India, South Africa, Sri Lanka, Singapore, China, Taiwan, Japan, Czech republic, France, Korea, Canada, Iran, Israel, Turkey, Nigeria, Kenya, Egypt, and a few others. Overall a great assembly of world NDT community providing an excellent opportunity to learn what others are doing and network to build connections and collaborations.

The exhibition was a NDT professional’s delight with over 250 stalls from around the world displaying the latest in hardware, software, consumables, services and training. Almost every stall had something unique to showcase as an advancement from whatever one had seen in other exhibitions and Trade shows. It was impossible to miss the increased use of scanners and robotics for inspection, the miniaturization of equipment, the unlimited range of transducers and probes, the advanced training tools, the enhance suite of software and the list goes on.

On the sidelines of the main conference event there were several important and strategic meetings in progress which included ICNDT -PGP Committee and General Assembly and the APFNDT Board Meeting. ISNT was represented at the ICNDT General Assembly by Mr. V.Pari as the Voting

www.isnt.org.in

EVENTS

One of the important decisions made by attending members of ICNDT was voting for selection of the host country for 21st WCNDT to be held in 2024. USA and Argentina were the competing candidates and in the final voting process, the Argentinian Society for NDT and city of â&#x20AC;&#x153;Buenos Airesâ&#x20AC;? were chosen to be the host for the 21st WCNDT. ISNT representatives also had several meetings with other NDT societies including ASNT and COFREND to discuss mutual cooperation and activities for the future.

The Closing ceremony was an equally impressive event with the representatives from the NDT Societies around the world coming on stage and complimenting the German NDT Society and the ICNDT on putting up a superb and memorable show.

Mr. Rajul Parikh, Hon. General Secretary of ISNT, Mr.Dilip Takbhate and Mr.V.Pari, Past Presidents of ISNT along with Dr.Shyamsunder presented a memento on behalf of ISNT to Dr. Mike Farley President of ICNDT and Dr. Erhard (president of DGZFp) appreciating their efforts.

For those of you who are curious to get some glimpses of what happened at Munich, here are a few links which can be interesting https://youtu.be/999o2iJGttw and https://youtu. be/qOknnkAJrKA Overall a great assembly of world NDT community providing an excellent opportunity to learn what others are doing and network to build connections and collaborations. Looking forward to the 20th WCNDT in 2020 at Seoul, South Korea !

GLIMPSES FROM THE 19th WCNDT @ MUNICH, GERMANY

www.isnt.org.in

Journal of Non Destructive Testing & Evaluation

September 2016

EVENTS

Member and Dr.Shyamsunder MT as the Non-Voting member. We also had Mr. DJ Varde, Mr. Rajul Parikh and Mr. Dilip Takbhate attending as Observers.

The APFNDT Board Meeting was attended by Mr.V.Pari and Dr.Shyamsunder MT from ISNT. A report from the meeting can be accessed at http://www.apfndt.org/Documents/Regional %20Newsletter/APFNDT%20Regional%20 Newsletter%20Vol.3%20(web20160901).pdf

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EVENTS

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| EVENTS UPCOMING EVENT

NDE 2016 15th - 17th DECEMBER ORGANIZED BY ISNT THIRUVANANTHAPURAM CHAPTER Compiled by A.Shunmugavel, Secretary - ISNT Trivandrum Chapter ISNT Thiruvananthapuram chapter is organizing NDE 2016 after 13 years from 15 to 17th December, 2016 at Kerala's largest international convention centre, Pre conference tutorials will be held on 13 & 14th December, 2016.

VENUE - ALSAJ CONVENTION CENTRE, Kerala's largest international convention centre, Thiruvananthapuram, is also known as Trivandrum, the capital of God's Own country – Kerala, is a globally popular tourist destination. Mahatma Gandhi has referred Trivandrum as “Evergreen city of India“.

& Practices, 2. Corrosion – Detection, Measurement & Evaluation, 3. Advanced NDE for Propellants & Composites will be arranged at ATF, VSSC. A poster emphasizing the tutorials was prepared and circulated to academic institutions.

SOUVENIR - Design & layout are finalized. Messages are being received from dignitaries. Advertisement slots filling up.

TECHNICAL PAPERS - We are expecting more than 250 papers and the last date for abstract submission is extended to 30.09.16. Technical sessions and invited speakers are finalized.

We solicit support from all sectors, industries, academic institutions and individuals in the form of technical papers, advertisements, exhibition stalls and sponsorship. Come and be a part of NDE 2016, the mega event of ISNT. Hearty welcome to Thiruvananthapuram.

BROCHURE - The first announcement of the seminar was circulated in April 2016 & circulated to all committee members, chapter members, exhibitors, sponsors, academic institutions and R&D labs. Second announcement is getting ready and is planned to release by 15th of October – 2016 with updates.

WEBSITE - A dedicated website www.nde2016.com is established for the seminar. All registrations and abstracts are uploaded through the website. Latest updates & announcements are also made through the website.

SPONSORSHIP - Principal & Platinum sponsors are finalized. Silver & Bronze sponsors are also finalized.

We are exploring with various organizations for other possible sponsors.

EXHIBITION - More than 50% of available 50 stalls are already booked. Inquires are being received from parties across the world. ITPO approval has been obtained and is uploaded in our website for the benefit of exhibitors.

PRECONFERENCE TUTORIALS - Preconference tutorials covering three topics, viz. 1. Digital NDE – Principles September 2016

Journal of Non Destructive Testing & Evaluation

CONTACT US INDIAN SOCIETY FOR NON DESTRUCTIVE TESTING, Thiruvananthapuram Chapter Web: www.isnttvm.org Email: isnttvm@gmail.com 0471- 2563854 C/o. PRG, TERLS Area, VSSC, ISRO, Thiruvananthapuram – 695 022 For latest updates and inquiries please visit our website www.nde2016.com Chairman: Shri.G. Levin, GD, PRG, VSSC Phone : 0471-2563854 (O), 9496050075 Email: g_levin@vssc.gov.in Secretary: Shri.A.Shunmugavel, QCM, VSSC Phone : 04712562690(O), 9249562486 Email: a_shanmugavel@ vssc.gov.in, secretariat@nde2016.com, exhibition@ nde2016.com, technical@nde2016.com www.isnt.org.in

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The National Certification Board is an extended arm of Indian Society for Non-Destructive Testing with an objective to train and certify personnel engaged in NDT as per BIS standard IS-13805. NCB continued to organize the certification examinations directly and through the Chapters of ISNT and Accredited Centres. ISNT being the NSO of ASNT conducts the ASNT Level-III exams at different venues in India. ISNT Level-III examinations are also conducted in various methods. In addition, Level-I & Level-II Courses and Examinations under IS - 13805 & SNT - TC-1A.

Meeting Schedule / Updates

NCB Meeting - 24th September 2016 NGC Meeting - 25th September 2016

NGC/NCB Meeting - 14th December 2016 Venue - NDE Hotel arranged by Trivandrum Chapter

Venue - ISNT HO, Chennai

AGM - 16th December

NATIONAL

GOVERNING COUNCIL MEMBER'S LIST (NGC) 1. Shri D.J. Varde President - ISNT Cell: 9821131522 djvarde@gmail.com 5.

2. Shri Rajul R. Parikh Hon. Gen. Secretary-ISNT Cell: 9820192953 rajulparikh@eecindia.com / ndtsales@eecindia.com 3. Shri R.J. Pardikar President - Elect – ISNT Cell: 9442613146 r.j.pardikar@gmail.com 4. Dr. B. Venkatraman Vice President – ISNT Cell: 9443638974 bvenkat@igcar.gov.in; qadbvr@gmail.com 5. Shri Diwakar D. Joshi Vice President – ISNT Cell: 9822263475 diwakarj@gmail.com 6. Shri Samir K. Choksi Hon. Jt. Secretary - ISNT Cell: 9821011113 Choksiindia@yahoo.co.in 7. Shri P. Mohan Hon. Jt. Secretary - ISNT Cell: 0’94901 67000 metsonic@sify.com / mohanp45@rediffmail.com 8. Shri S. Subramanian Hon. Treasurer A-2, Athreya Srini Cell: 9444008685 nricsubramanian@gmail.com 9. Shri P.V. Sai Suryanarayana Hon. Co. Treasurer Cell: 9490142539 pvss@shar.gov.in / sai895956@gmail.com 10. Shri V. Pari Immediate Past President ISNT Cell: 9840104928 scaanray@vsnl.com / pari@ scaanray.com

www.isnt.org.in

CHAPATER CHAIRMEN / SECRETARIES

MEMBERS 11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

38.

39.

Shri S. Adalarasun Shri Anil V. Jain Ambresh Bahl Shri D.K. Goutham Shri Mandar A. Vinze Shri S.N. Moorthy Shri Mukesh Arora Shri Nerurkar K.A Shri B. Prahlad Shri Bhausaheb Krishnaji Pangare Shri Sadasivan. N Shri B.K. Shah Shri A.K. Singh Shri A.K. Singhi Shri R. Sundar Shri Sunil Gophan Dr. Sarmishtha Palit Sagar Shri Vivek Rajamani Shri N.V. Wagle Shri Shashidar Pallaki Shri R. Sampath Shri R.B. Bhardwaj Shri M.N.V. Viswanath Shri Bikash Ghose Shri Anil Kumar Das Shri Jaiteerth Joshi Shri T. Kamaraj Shri R.G. Ganesan Shri Sreemoy Saha

PERMANENT INVITEES

40. Prof. S. Rajagopal 41. Shri G. Ramachandran

PAST PRESIDENTS 42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

Shri V.R. Deenadayalu Shri K. Balaramamoorthy Shri Ramesh B. Parikh Shri A. Srinivasulu Dr. Baldev Raj Shri D.M.Mehta Shri K. Viswanathan Shri S. I. Sanklecha Shri Dilip P. Takbhate Shri K. Thambithurai Dr. P. Kalyanasundaram

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

67.

68.

69.

70.

71.

72.

73.

74.

Shri D.S Kushwah Shri Rajeev Vaghmare Shri Vijayaraghavan Shri Shashidhar P. Pallaki Dr. Krishnan Balasubramaniam Shri R. Vivek Shri Dayaram Gupta Shri T. Kamaraj Shri P. Mohan Shri M. Venkata Reddy Dr. Amitava Mitra Shri Tarun Kumar Das Shri B. Anandapadmanaban Shri G. Kempulraj Shri C.K. Soman Shri V. Sathyan Shri Dipankar Gautam Shri Sreebash Chandra Saha Shri Ambresh Bahl Shri A. Varshney Shri Hemant Madhukar Shri Samir K. Choksi

75.

76.

77.

78.

79.

80.

81.

82.

83.

84.

85.

86.

87.

88.

Shri Jeevan Ghime Shri Parag W. Pathak Shri M. S. Shendkar Shri Uday B. Kale Shri V Ranganathan Shri B Karthikeyan Shri Elangovan Mudliyar Shri D B Sathe Shri. Mathivanan Shri V. Deepesh Shri G. Levin Shri Shanmughavel Ms. Hemal Mehta Shri Jaidev Patel

Ex-Officio members 89.

90.

91.

92.

93.

94.

95.

Dr. M.T. Shyamsunder Shri P.P. Nanekar Shri S. Viswanathan Shri T. Loganathan Dr. Baldev Raj Shri V. Pari Dr. P. Kalyanasundaram

NATIONAL CERTIFICATION BOARD MEMBER'S LIST (NCB) 1.

2.

3.

4.

5.

Dr. M.T. Shyamsunder Shri P.P. Nanekar Shri T. Loganathan Shri S. Viswanathan Shri B. K. Shah

Regional Controller of Exams 6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Shri S.K. Bandyopadhyay Shri S.R. Ravindran Shri Jayaprakash Hiremath Shri K. Balaramamoorthy Shri R.B. Bhardwaj Shri V. Manoharan Shri Avinash U. Sonuwane Shri R. Sundar Shri Phani Babu Shri Dilip Gatti Shri ME. K.A Nerurkar

17. Shri Bikash Ghose 18. Shri Chintamani Khade 19. Shri G.V.S. Hemantha Rao Ex-Officio Members 20. Shri D.J. Varde 21. Shri. Rajul R. Parikh 22. Shri S. Subramanian 23. Dr. B. Venkatraman 24. Shri Diwakar D. Joshi 25. Dr. Baldev Raj 26. Shri V. Pari Chapter Representation 27. Shri Hemant Madhukar 28. Dr. Krishnan Balasubramaniam 29. Shri M. S. Shendkar 30. Shri P. Mohan

Journal of Non Destructive Testing & Evaluation

September 2016

NGC-NCB

NATIONAL CERTIFICATION BOARD (NCB)

TRAINING

102

| TRAINING

QUALIFICATION OF NDT PERSONNEL ISNT/NCB Certified NDT Personnel Level I, Level II, Level III The certificate of competence is issued in accordance with IS: 13805 or other international standards as the case are.

Notes: 1) The details here are incomplete and are likely to be in gross error. The information will be updated after receiving feedback from Certificate holder.

to report the results. He shall receive the necessary instruction and/or supervision from level II or level HI personnel. He shall not be responsible for the choice of the test method or technique to be used nor for the assessment of test results,

3.3

NDT Level II

Abstract from IS 13805:2004

An individual certified to NDT level II is qualified to perform and direct non-destructive testing according to established or recognized techniques. He shall be competent to choose the test techniques to be used, to set up and calibrate equipment, to interpret and evaluate results according to applicable codes, standards and specification, to carry out all duties for which a level I individual is qualified and to check that they are properly executed, to develop NDT procedures adopted to problems which are the subject of an NDT specification, and to prepare written instructions, organize and report the results of non-destructive tests. He shall also be familiar with the scope and limitations of the method for which he is qualified, and able to exercise assigned responsibility for on the job training and guidance of trainees and NDT level I personnel.

3 LEVELS OF COMPETENCE

3.4 NDT Level III

3.1 Classification

An individual certified to NDT level III shall be capable of assuming full responsibility for a test facility and staff, establishing techniques and procedures, interpreting codes, standards, specifications and procedures to be used. He shall have the competence to interpret and evaluate results in terms of existing codes, standards and specifications, a sufficient practical background in applicable materials, fabrication and product technology to select methods and establish techniques and to assist in establishing acceptance criteria where no standard practices are otherwise available, general familiarity with other NDT methods, and the ability to guide and train level I and level II personnel.

2) The certificate holders whose name is not appearing here are requested to please inform to us at offc@isnt.org 3) The names of the certificate holders which are not valid currently will be removed in three months time if no information is received from the certificate holder.

4) The organization is at the time of certificate issue and it quite likely the person may not be with the same organization General information about levels

An individual certified in accordance with this standard shall be classified in one of the three levels depending upon his respective level of competence.

One who has not yet attained certification may be registered as a trainee.

3.2 NDT Level I An individual certified to NDT level I is qualified to carry out NDT operations according to written instructions. He shall be able to set up the equipment, to carry out the tests, to record the results obtained, to classify the results in terms of written criteria; and

September 2016

Journal of Non Destructive Testing & Evaluation

www.isnt.org.in

TRAINING

| 103

ISNT MUMBAI CHAPTER NDT LEVEL II COURSE NDT plays an important role in pre-service inspection (PSI) as well as In-service inspection (ISI) of various process equipments and components in Chemical, Fertilizer, Aerospace and Thermal & Nuclear Power Plants. Liquid Penetrant Testing (PT), Magnetic Particle Testing (MT), Radiographic Testing (RT) and Ultrasonic Testing (UT) are the most common NDT methods widely used as an inspection tool for detecting flaws anywhere inside the material.

It is imperative that personnel who perform such tests are adequately trained and qualified as well as certified. Customers are becoming more aware of the importance and insisting on Central Certification.

To implement the centralized certification scheme throughout the country, the â&#x20AC;&#x2DC;National Certification Body (NCB)â&#x20AC;&#x2122; of ISNT has adapted National Standard IS 13805:2004 guidelines for training, qualification and certification of NDT personnel in various NDT methods.

The examination will be conducted by NCB and certificate will be awarded to successful candidates.

Certificate of participation will be issued by the chapter.

However, a student holding Level I certificate and thereafter involved in relevant NDT field activity with 3 months for MT and PT and 18 Months for RT and UT, can appear for the examination for Level II. A person who desires to appear directly for Level II should have working experience of 4 months for MT and PT and 21 months for RT and UT with minimum educational qualification as two years of Science at college or university / BSc / Diploma/Degree in Engineering.

Those who desire to undergo qualification and certification shall submit the enrollment form/s (Annex I) with required fee (as per fee schedule) latest by date given below in the (Programme) schedule.

PROGRAMME SCHEDULE Sr. No.

Course

From

To

Rest Day

Examination

Apply Before

1

MT-II

27-09-16

29-09-16

---

30-09-16

01-09-16

2

PT-II

09-11-16

11-11-16

---

12-11-16

09-10-16

3

RT-II

02-01-17

09-01-17

08-01-17

10-01-17

01-12-16

4

UT-II

30-01-17

06-02-17

05-02-17

07-02-17

01-01-17

FEE SCHEDULE Sr. No.

Course

For general Candidates Fee

ST @ 15

Total

For ISNT Members Fee

ST @ 15

Total

1

MT-II

12000

1800

13800

11250

1688

12938

2

PT-II

12000

1800

13800

11250

1688

12938

3

RT-II

22000

3300

25300

21250

3188

24438

4

UT-II

22000

3300

25300

21250

3188

24438

www.isnt.org.in

Journal of Non Destructive Testing & Evaluation

September 2016

TRAINING

TRAINING SCHEDULE FROM SEPTEMBER '16- JANUARY '17

TRAINING

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| TRAINING

The fee includes course material, working lunch and tea and the examination fee to be paid to NCB by us. A person who does not want to appear for examination but wants to learn and indicates in advance will get a discount for examination fee.

You may please download the forms for examination, course enrollment and vision check from our website www.isnt.org Vision check shall be certified by the doctor/physician.

Application form, experience certificate, vision certificate and one additional copy of the photograph shall be submitted at the time of attending the course.

For Enrollment Form & any further information contact : Samir Choksi - Hon. Secretary-ISNT, Mumbai Chapter Telefax : 022-28327521 Mob:9869642505 E-mail : isntmumbai@gmail.com, offc@isnt.org

ISNT CHENNAI CHAPTER COURSES FROM SEPTEMBER 2016 TO DECEMBER 2016 S. No.

Month

Certification Scheme

Course Code

1.

September

IS: 13805/SNTTC-1A

ASRI-166

2.

October

IS: 13805/SMTTC-1A

3.

November

4.

December

Courses

Training Period

Examination Date

Course Fees Rs.

Last date of receipt of application form

From

To

Radiographic Testing Level II

14.09.16

21.09.16

23.09.16 & 24.09.16

9,600/-

10.09.2016

ASST-167

Surface NDT Level II (MT & PT)

13.09.16

19.10.16

21.10.16 & 22.10.16

8,400/-

09.09.2016

IS: 13805/SNT-

ASUT-168

Ultrasonic Testing Level II

09.11.16

16.11.16

18.11.16 & 19.11.16

9,600/-

05.11.2016

IS: 13805/SNTTC-1A

ASRT-169

Radiographic Testing Level II

20.11.16

07.12.16

09.12.16 & 10.12.16

SERVICE TAX AS APPLICABLE (AT PRESENT 15%) FOR COURSE AND EXAMINATION FEES. Note 1: The course fee is inclusive of Course Material appear both by paying additional examination fees. and Coffee/Tea during the Course and Examination Note 4: ISNT members are eligible for a concession Days. Lunch can be arranged on request at actual. of Rs 400/- on each course they undertake.

Note 2: Examination fees of Rs.1,500/- (Rupees One Thousand Five Hundred only) + Service Tax as applicable is to be paid separately per candidate who is opting for the Examination. For Surface NDT (MT & PT) the examination fees will be Rs.2500/- + Service Tax.

Note 3: Candidates may choose to appear for examination either as per IS: 13805 (NCB) or as per SNT-TC-1A 2006. Candidates may also choose to

Note 5: UP to 25 concession may be given on course fees to candidates sponsored by NDT service providers and self sponsored candidates for limited seats. For further details contact ISNT Chennai Chapter.

Note 6: Venue â&#x20AC;&#x201C; Theory & Examination will be held at ISNT Chennai Chapter premises. Practical demonstrations & Practical Examinations will be conducted at respective Labs.

REPORTING TIME ON FIRST DAY OF THE COURSE IS 8.30 AM FOR REGISTRATION. COURSE COMMENCES AT 9.00 AM EVERY DAY The candidates shall bring their own non programmable Scientific Calculator.

Kindly ensure that the above information are conveyed to the candidates.

Please mail all correspondence to:

September 2016

Journal of Non Destructive Testing & Evaluation

Honorary Secretary, ISNT Chennai Chapter Module No. 59, Garment Complex, III Floor, SIDCO Industrial Estate, Opp. to Balaji Hospital, Guindy, Chennai-600 032. Phone: 044-6538 6075, 45532115 E-mail:isntchennaichapter@gmail.com

www.isnt.org.in

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| TRAINING

TRAINING

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S. No.

Course Title

Training Period

Level

Course Fees (Rs.)

From

To

Examination Date

Examination Fees (Rs.)

Total Fees including Service Tax (Rs.)

Venue

1.

Visual Tesing

I

5000

23.08.16

25.08.16

26.08.16

1000

6900

Gurukul, NFC

2.

Ultrasonic Testing

I

7000

06.09.16

10.09.16

13.09.16

1000

9200

Gurukul, NFC

3.

Visual Testing

II

6000

14.09.16

16.09.16

17.09.16 & 18.09.16

1000

8050

Gurukul, NFC

4.

Ultrasonic Testing

II

12000

19.09.16

27.09.16

28.09.16 & 29.09.16

1000

14950

DRDO

5.

Penetrant Testing

I

5000

28.09.16

30.09.16

01.10.16

1000

6900

Gurukul, NFC

6.

Penetrant Testing

II

8000

03.10.16

06.10.16

07.10.16 & 08.10.16

1000

10350

DRDO

7.

Helium Leak Testing

I

8000

17.10.16

27.10.16

28.10.16 & 29.10.16

1000

10350

Gurukul, NFC

8.

Helium Leak Testing

II

12000

17.10.16

27.10.16

28.10.16 & 29.10.16

1000

14950

Gurukul, NFC

9.

Radiographic Testing

II

12000

02.11.16

08.11.16

10.11.16 & 11.11.16

1000

14950

DRDO

10.

Eddy Current Testing

I

7000

14.11.16

18.11.16

19.11.16

1000

9200

Gurukul, NFC

11.

Eddy Current Testing

II

8000

21.11.16

25.11.16

26.11.16

1000

10350

Gurukul, NFC

NOTE: 1. Total fees includes course fees, examination fees and service tax ( 15 ).

2. Cheque or Demand draft are drawn in favour of “ISNT HYDERABAD CHAPTER” 3. Application can be downloaded from website www.isnt.org.in 4. Examination Requirements COURSE

MINIMUM QUALIFICATION

EXPERIENCE

Level – I

10TH Standard Diploma in Engg / RT, ET & Degree in Science or Engg.

UT PT & VT HLT

3 Months 1 Month 4 months

Level – II

10TH Standard Diploma in Engg / Degree in Science or Engg.

18 Months 9 Months 3 Months

5. Following documents are to be submitted by the Candidate before starting of the course, along with examination application form.

• 2 Pass port size photographs (cut size to passport from bigger sizes are not allowed) • Eye fitness certificate from the Ophthalmologist certifying for minimum vision of J2 on standard • Jaeger Chart and Ishihara Charts for colour blindness.

• Photostat Copies of the certificates for • Education Qualification, • Experience certificate from the present employer or self-declaration (for private NDT Practitioners) vetted by the client to whom they do the service.

www.isnt.org.in

METHODS

RT & UT ET & HLT PT & VT

Address for Correspondence: M. RAVI, Treasurer, ISNT Hyd. Chapter NPCIL Office, Near NFC Gurukul, ECIL (POST), Hyderabad-560062.Mobile: 9290179887 Email: ravim@npcil.co.in / mincheri@yahoo.co.in Courses-Director:M. VENKATA REDDY DRDL, Mobile: 9440472195 / Mallu.venkatareddy@ gmail.com Courses-Coordinator: B.S. RAMA RAO Ex. NFC, Mobile: 9652236300 Email: harpsitara@gmai.com C. Phanibabu Programme Director & Vice Chairman ISNT, Hyderabad Chapter.

GM, QA, Nuclear Fuel Complex, Hyderabad–500062.

E-mail: cpb@nfc.gov.in Mobile: 9493977823

Journal of Non Destructive Testing & Evaluation

September 2016

TRAINING

ISNT HYDERABAD CHAPTER COURSES FROM SEPTEMBER 2016 TO DECEMBER 2016

SPECIAL FEATURES

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NDE PATENTS Continuing our endeavor to provide you updates on NDE and Inspection relate patents, listed below are a few patents from areas related to Penetrant and Magnetic Particle inspection which were issued by USPTO in the last few years. If any of the patents are of interest to you, a complete copy of the patent including claims and drawings may be accessed at http://ep.espacenet.com/ United States Patent 9,349,516 Multidirectional Magnetic Particle Inspection System Inventors: Lombardo, Erik A. and Segletes, David S. Assignee: SIEMENS ENERGY, INC. (Orlando, FL) A magnetic particle inspection system for inspecting a plurality of articles. The system includes a first magnetizing coil for generating a first magnetic field oriented in a first direction. The system also includes a second magnetizing coil for generating a second magnetic field oriented in a second direction perpendicular to the first direction, wherein the first and second magnetizing coils are located in a common plane. In addition, the system may include a mat having a plurality of drainage holes, wherein the first and second magnetizing coils are located in the mat and the first and second magnetizing coils are sized to inspect a plurality of articles. Further, the system includes a power supply for supplying power for energizing the first and second magnetizing coils and a switching unit for switching current flow between the first and second magnetizing coils.

United States Patent 8,901,515 Method for Nondestructive Testing of Workpiece Surfaces Inventors: Bamberg, Joachim and Satzger, Wilhelm Assignee: MTU Aero Engines GmbH (Munich, DE) A method for nondestructive testing of workpiece surfaces by a fluorescent penetration test is disclosed. An embodiment of the method includes a) cleaning the area of the workpiece surface that is to be inspected; b) applying a fluorescent liquid penetrant to the area of the workpiece surface that is to be inspected, where the penetrant penetrates into possible recesses in the workpiece surface; c) removing the excess penetrant from the workpiece surface; d) applying a developer to the area of the workpiece surface that is to be inspected; e) bleaching the fluorescent penetrant by a beam of light in the layer formed by applying the developer to the workpiece surface; and f) visual evaluation of the fluorescent penetrant remaining in the recesses present in the workpiece surface.

United States Patent 8,003,009 Fluorescent and Visible Penetrant Inspection Inventors: Zaelke, Arnold E. Assignee: Sherwin, Inc. (South Gate, CA) September 2016

Journal of Non Destructive Testing & Evaluation

An environmentally friendly penetrant used in non-destructive testing of material includes a vegetable oil fatty acid ester. A first embodiment of the penetrant is a post-emulsifiable fluorescent penetrant, a second embodiment of the penetrant is a heatable fluorescent penetrant, a third embodiment of the penetrant is a water washable fluorescent penetrant, a fourth embodiment of the penetrant is a visible water washable penetrant, and a fifth embodiment is a visible solvent removable penetrant. The heatable fluorescent penetrant includes a phenolic antioxidant to provide stability to at least approximately 120 degrees Fahrenheit. A method for using the heatable fluorescent penetrant includes heating the penetrant to lower penetrant viscosity and thus provide better penetration into flaws in the material.

United States Patent 4,351,185 High Temperature Penetrant System Inventors: Garcia; Vilma A. Assignee: Magnaflux Corporation (Chicago, IL) A method and composition for non-destructive testing using the dye penetrant technique, and adapting the use of this technique at high temperatures. The invention is involved with using a marking crayon which includes a carrier composed of a solid which melts at a temperature below the temperature at which the workpiece is to be inspected and a visible or fluorescent dye. Upon application of the crayon to a hot workpiece, the solid penetrant composition becomes molten and the visible or fluorescent dye penetrates into any flaws in the surface in the usual manner. A remover, also consisting of a crayon composition, is used to remove excess penetrant, leaving only penetrant entrapped in the flaws. Upon removal of the excess penetrant and remover, the entrapped penetrant deposits are drawn to surface by the application of a finely divided developer either in dry form or as an aerosol. Inspection of the piece is then carried out under visible or ultraviolet light, depending upon the nature of the penetrant.

United States Patent 7,215,807 Nondestructive Inspection Method and Apparatus Inventors: Nomoto, Mineo ; Katsuta, Daiske ; Asano, Toshio ; Sakai, Kaoru ; Taguchi, Tetsuo ; Tanaka, Isao Assignee: Hitachi, Ltd. (Tokyo, JP) The present invention relates to a method for inspecting a crack in a metal surface or the like, and, particularly, to an inspection method and apparatus for nondestructive inspection such as liquid penetrant inspection and magnetic particle testing.

The present invention provides a flaw inspection method that essentially comprises the steps of www.isnt.org.in

SPECIAL FEATURES

United States Patent 20140306699 Magnetizing Apparatus for Magnetic Particle Testing of Wheel Inventors: Takashi Mochii, Michitaka Hori, Muneo Ishida Assignee: Nippon Steel & Sumitomo Metal Corporation, JP The present inventions provides a magnetizing apparatus 100 for magnetic particle testing of a wheel 7 that includes a hub 71, a plate 72, and a rim 73 in sequence from inward to outward in a radial direction of the wheel. The apparatus includes: a conductor 1 inserted through a bore 711 of the hub 71; and a pair of auxiliary conductors 2 connected to respective opposite end portions of the conductor 1,

and so disposed as to face respective opposite side surfaces of the wheel 7, and to extend from the hub 71 to the rim 73 outwardly in a radial direction of the wheel 7, wherein the pair of auxiliary conductors 2 and the conductor 1 are energized with alternating current.

United States Patent 20160136307 Nanoparticles for Magnetic Particle Imaging Applications Inventors: He Wei, Oliver T Bruns, Ou Chen, Moungi G Bawendi Assignee: Massachusetts Institute of Technology, MA, USA One method of preparing a nanoparticle can include decomposing a compound at a high temperature, adding an acid to the solvent to form a reaction mixture, increasing the temperature of the reaction mixture to boiling point of the reaction mixture and heating for 60 to 120 minutes to produce the nanoparticle. The coated nanoparticle can be used for magnetic particle imaging.

We hope that this section on NDE Patents, which is being revived from this issue of the journal will be found interesting and continue to trigger your curiosity on this very important topic of Intellectual property.

Please send your feedback, comments and suggestions on this section to mandayam.shyamsunder@gmail. com

NDT WORDSEARCH Time to stimulate your brain cells! The “Word Search Puzzle”, contains forty (40) words related to “Magnetic Particle Testing”. These include terminologies commonly associated with the technique. These words are hidden in the puzzle and may be present horizontally, vertically, diagonally in a forward or reverse manner but always in a straight line.

e hope ou ill find this interestin and educative Please send our feedbac su estions on this section to manda am sh amsunder mail com

www.isnt.org.in

comments and

Journal of Non Destructive Testing & Evaluation

September 2016

SPECIAL FEATURES

illuminating a surface of a sample to be inspected, obtaining an image of the surface, characterizing a potential flaw on the inspected surface by processing the obtained image, displaying an image of the potential flaw, verifying that the potential flaw is a true flaw, and storing an image of the verified flaw in memory.

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ADVERTISER'S INDEX

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Journal of Non Destructive Testing & Evaluation

September 2016