Non-Destructive Testing
• Non-destructive testing is a method used to examine an object, material, or system for
flaws (defects) without impairing its future usefulness.
• Other related names for Non-destructive testing are Non-destructive Examination (NDE) &
Non-destructive inspection (NDI).
• Non-destructive tests (NDTs) can be performed on raw materials, materials during the
manufacturing stages, and finished products.
• NDT is possible during the service of a particular object as well.
Basic NDT methods
• Visual testing (VT)
• Dye penetrant testing (PT)
• Eddy current testing (ET)
• Magnetic particle testing (MT)
• Radiographic testing (RT)
• Ultrasonic testing (UT)
This report discusses the Magnetic particle testing method & Ultrasonic testing or the Pulse-Echo
Technique (PET).
Non-Destructive tests carried out in Lanka Sugar Company-
Pelwatte on 1/7/2025.
• Teck-Explore International (PVT) Limited has been called to conduct non-destructive
testing.
Magnetic Particle Testing (MPT/MT)
Basic Principles
• Consider a bar magnet. It has a magnetic field in and around the magnet.
Magnetic fields of the bar magnet
• If this bar magnet is broken in the center of its length, two complete bar magnets with
magnetic poles on each end of each piece will be formed.
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A broken bar magnet
• The same thing will happen when the bar magnet is just cracked.
A cracked bar magnet
• The magnetic field exits the north pole and re-enters the south pole. It is called a flux
leakage field.
Flux Leakage
• If iron particles are sprinkled on a cracked magnet, the particles will be attracted to and
cluster at the edges of the crack
.
Magnetic particles (iron particles) cluster formation
• This testing method can only be used for the inspection of cracks on the surfaces and near
surfaces (up to a depth of 3-4 mm from the surface) of the objects.
• This testing can be done in two ways.
1. Fluorescent method
2. Visible method
The fluorescent method was used as its sensitivity is high compared to that of the
visible method.
• The shafts of the top mill rolls, delivery mill rolls, feed mill rolls, the shaft of the ACC drive
end sprocket, the shaft of the shredder elevator drive end sprocket, and the shafts of the
two cutters (1st cutter & 2nd cutter) were inspected using this testing method. The inspection
procedure employed for all these objects is the same.
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Inspection Procedure
• A chemical spray consisting of a mixture of industrial kerosine and iron powder was
prepared in the beginning. Iron powder (magnetic particles) are coated with a fluorescent
material for easy visualization using black light (UV light).
Industrial kerosine container Iron powder
• The component or the object to be inspected should be magnetized. For this, the “Yoke” is
used. DC and AC are both suitable for magnetizing.
Yoke
• Before directly going for the inspection of the shafts, the testing was done for a ring with
artificial cracks known as the “Test piece”. The purpose of that was to check the strength of
the yoke’s performance & the strength of the chemical spray.
The “Test Piece”
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• The surface of the object to be examined was cleaned and the prepared mixture of
chemicals was sprayed onto the surface in between the Yoke legs while being exposed to a
UV light emitted by a UV lamp. The test was done under a cover of black-colored polythene
to prevent light from falling onto the objects being tested.
During testing UV lamp
The crack identified on the top roll shaft of the first mill is shown below. Under UV light, the crack
was seen in yellowish green.
Cracks on the surfaces
Finally, this crack was measured, and the length of the crack was about 180 mm.
Measuring the crack length
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Ultrasonic Testing (UT)
• This is also known as the Pulse-Echo Technique (PET).
• This testing method can be used to inspect cracks inside objects.
• This technique employs the reflected ultrasonic sound waves to detect defects.
Basic Principles
• Ultrasonic testing uses high-frequency sound waves known as ultrasound waves –
frequencies above 20kHz.
• When falling onto a surface, Ultrasonic waves will partly reflect and partly pass through the
interfaces as shown below.
Ultrasonic wave falling onto a surface.
• The equipment that is employed for this purpose is known as the ultrasonic flaw detector.
Ultrasonic flow detector
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• Before starting the testing process, the detector should be calibrated. For that, a
“calibration piece” with a thickness of 12.5 mm is used.
Calibration Piece
• After the calibration, the machine is ready for testing. The surface of the object to be tested
should be cleaned. A coupling agent (grease) was applied onto the surface to improve the
sound energy transmission efficiency between the probe and the object, to reduce the
reflectivity, and lubrication to protect the sensor and the object.
Grease Applying Grease
• For the transmission as well as the receiving of the sound waves, a probe is used. There are
two types of probes,
▪ Angle Probe (Usually for welded joints)
▪ Normal probe (for normal surfaces)
The normal probe was used during the testing.
Normal probe During the testing
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Summary of the Ultrasonic testing
• Object without cracks.
Object without cracks
• Object with cracks.
Object with cracks
Failures of Non-destructive Testing
• Carrying out an NDT is crucial. If cracks inside the object are not identified properly (due to
poor testing procedures, selection of inefficient testing methods, or not performing an
NDT), the crack will propagate with time due to the loading on the object and fail
catastrophically.
Ex: The shaft of a mill roll has been broken in the past
