How can you use non-destructive testing (NDT) techniques to detect defects in manufacturing?

There is always a saying in the industry. Look first, you might be lucky to spot the crack right on spot I.e in composite you might be able to see laminate with an abnormal shape different from the other area or dents. In metal, that irregular linear marks which brings about the benefit of your magnifying lens to aid you in the visual check. Visual inspection is a very critical aspect of finding abnormalies.

Nondestructive testing (NDT) techniques are crucial for detecting defects in manufacturing without causing damage to the product. Common methods include ultrasonic testing, X-ray radiography, magnetic particle testing, and dye penetrant inspection. These techniques help identify flaws like cracks, porosity, or discontinuities in materials, ensuring the integrity of manufactured components.

Non-destructive testing (NDT) techniques are vital in detecting defects in manufacturing, particularly in additive manufacturing processes. To ensure quality, understanding the capabilities of your machine and materials is crucial. NDT methods like ultrasonic testing can be employed for porosity checks, revealing internal voids or air pockets. Additionally, techniques such as computed tomography (CT) scanning enable a thorough examination of the bonding within the manufactured component without causing damage. This ensures a comprehensive assessment of structural integrity, aiding in the identification and prevention of defects in additive manufacturing processes.

this is the most important NDT once should be doing, its like the first information reporting / early alert. Should be done at set interval.

NDT refers to an array of inspection techniques that allow inspectors to collect data about a material without damaging it. Visual Non-Destructive Testing is the act of collecting visual data on the status of a material. Visual Testing is the most basic way to examine a material or object without altering it in any way. (surface flaws etc,) Visual Testing can be done with the naked eye, by inspectors visually reviewing a material or asset. For indoor Visual Testing, inspectors use flashlights to add depth to the object being examined. Visual Testing can also be done with an RVI (Remote Visual Inspection) tool, like an inspection camera. To get the camera in place, NDT inspectors may use a robot or drone, or may simply hang it from a rope.

Liquid penetrant testing (LPT), also known as dye penetrant inspection (DPI) or penetrant testing (PT), is a widely used nondestructive testing (NDT) method for detecting surface-breaking defects in non-porous materials. Here are the basic steps involved in liquid penetrant testing: 1. Surface Preparation. 2. Application of Penetrant. 3. Excess Penetrant Removal. 4. Application of Developer. 5. Inspection. 6. Post-Cleaning. Liquid penetrant testing is effective for detecting cracks, porosity, and other surface-breaking defects in metals, plastics, ceramics, and other non-porous materials. It is commonly used in various industries, including aerospace, automotive, and manufacturing, for quality control and maintenance inspections.

Liquid or dye penetrant testing (PT) is a non-destructive material testing method which uses capillary forces to find surface cracks or pores and make them visible. It can detect surface-breaking flaws such as cracks, laps, porosity. Liquid dye penetrant testing is commonly used to inspect the surfaces of non-porous assets made out of ceramics, plastics, and metals, where inspectors will be looking at welds, castings, forgings, plates, bars, pipes. Liquid penetrant test looks for defects like: leaks, Joint flaws, Fractures, Porosity on the surface of the materials ,Cracks (cracks from fatigue, hairline cracks, or grinding and quenching cracks) Incomplete fusion. Liquid dye penetrant inspection eventually add dye to make cracks more visible

On continues mass producing foundries may not be viable. Process calls for applying dye, & developer. Widely can be used on tailor made parts only.

LPI is a very good method of cross-checking suspected surface cracks from HFEC. Sometimes materials variations tends to give false indications, the best way to sometimes evaluate the surface indication is by using LPI. The sensitivity of defects been looked for will determine the type of Inspection setting (1.B.3, 1.D.4). The good part is it’s practical ranging from simple hand testing to advanced technology implementation.

Like for MPI testing level 2 certificate is requirement from OEMS, what is the requirements for eddy current or ultrasonic testing

One of the best methods so far and its versatility. One need a good handling technique when it comes to contact testing. The ability to understand what echoes is needed is very important. One thing I wished could be further researched about UT thickness inspection is the ability to measure irregular shapes or components. However, I love shear waves and its ability to send a wave at an angle into a component to be able to detect cracks at other angles which are not perpendicular. I learn everyday when it comes to UT and I believe it is a method that will still give birth to several techniques apart from its existing ones.

Ultrasonic testing is done in materials to determine whether there are flaws or defects present in a material, and also to determine the thickness of a material. Ultrasonic testing methods use sound waves to find defects and measure thickness. Ultrasonic Testing (UT) is also often called Ultrasonic Thickness Measurement (UTM), Ultrasonic Thickness Testing (UTT), or Sonic Testing (ST). It is most commonly used on metal, because metal conducts sound waves in a manner that supports this kind of measurement. Ultrasonic testing is widely used on metals, plastics, composites, and ceramics. The only common engineering materials that are not suitable for ultrasonic testing with conventional equipment are wood and paper products

Ultrasonic Testing (UT) is a cornerstone Non-Destructive Testing (NDT) method in our manufacturing process. Its capability to detect both surface and subsurface defects in a variety of materials, including metals, composites, and plastics, is vital. By utilizing high-frequency sound waves, UT can identify cracks, voids, and delaminations, offering a comprehensive view of product integrity. However, its effectiveness hinges on skilled operators, proper probe contact, and the product's shape and size. Despite these requirements, UT's precision in ensuring product quality makes it an indispensable tool in our quality assurance arsenal.

Ultrasonic Testing (UT) is a non-destructive testing method that uses high-frequency sound waves to detect defects or measure material properties. The process involves applying a couplant to the surface, placing a probe, transmitting sound waves, receiving reflections, and analyzing data. UT can detect internal defects, measure material thickness, and inspect complex geometries, making it versatile and widely used in industries like aerospace, oil and gas, and power generation. However, it requires skilled operators and can be affected by material properties. UT is governed by standards like ASTM E2375 and ASME Section V, and is a valuable tool for ensuring material integrity and quality.

Radiographic Testing (RT) is a non-destructive testing (NDT) method which uses either x-rays or gamma rays to examine the internal structure of manufactured components identifying any flaws or defects. In Radiography Testing the test-part is placed between the radiation source and film (or detector). The material density and thickness differences of the test-part will attenuate the penetrating radiation through interaction processes involving scattering and/or absorption. The differences in absorption are then recorded on film(s) or through an electronic means. Various techniques to display the final image, i.e. Film Radiography, Real Time Radiography (RTR), Computed Tomography (CT), Digital Radiography (DR), and Computed Radiography (CR)

Eddy current testing is a non-destructive testing (NDT) method used for including for flaw detection, material and coating thickness measurements, material identification and establishing the heat treatment condition of certain materials. Eddy current testing is Non-destructive testing methods that uses the electromagnetism principle for flaw detection in conductive materials. A specially designed coil energised with an alternating-current is placed in proximity to the test surface, generating a changing magnetic field that interacts with the test-part and produces eddy currents in the vicinity. Eddy current testing is one of non-destructive testing methods that uses the electromagnetism principle for flaw detection in conductive materials.

In some circumstances, visual inspection is the best and only way to inspect due to there not being any quantitative/deterministic measurement system. In optics for example, defects such as scratches/digs, sleeks, stains and surface contamination have no reliable deterministic measurement systems. Qualitative visual inspection depends on many factors that include lighting conditions, viewing angles, surface cleaning and the inspector's own optical condition (eye care). The key to consistent quality is harmonizing internal inspection with customer/end-user expectations. This can take many months of collaboration and continual cross-checking of inspection results. In-person collaboration can be very helpful as well.

An Engineering company that understands the inclusion of NDT in their processes already saves themselves half of the future loss. When products are checked according to the required standards and codes before going into the final stage and roll out. Any quality defects would have been detected and rectified before getting to the end users. Thus saving company integrity, costs of product callback and probably loss of lives in some cases.

From a quality standpoint, the more NDT you can incorporate into your process, active or passive, the more opportunities for rework you have, which increases your final product total, improves quality, and decreases your scrap. Everyone wins.

Tanto en el proceso de fabricación, es una buena alternativa, pero ya en servicio las piezas se pueden examiar, de acuerdo a un historial de mantenimiento y detectar fallas que pueden generar una salida de servicio innecesaria de la máquina por su degradación o rotura, haciendo mas rentable y utilizable los END (NDT).

Non-Destructive Testing (NDT) offers numerous benefits, including cost savings by detecting defects early, improved safety by identifying potential failures, and increased reliability by ensuring equipment and components function as intended. NDT also extends asset life, ensures quality control, and protects the environment by detecting leaks and hazards. Additionally, NDT optimizes maintenance schedules, reducing unnecessary maintenance and enhancing a company's reputation by demonstrating a commitment to quality, safety, and reliability. By implementing NDT, industries can improve productivity, reduce downtime, and ensure public safety, making it a valuable tool for ensuring material integrity and quality.

Great article. In my professional journey of manufacturing NDT plays a significant role. With my certification and extended knowledge on welding and NDT together, I have addressed many issues and improved and ensured the quality of the steel components. And it becomes the important role to give awareness and explain the possibilities of addressing the welding defects and eliminating them with the support of NDT methods.

When implementing Non-Destructive Testing (NDT), additional factors to consider include ensuring technician qualifications and equipment calibration, understanding test limitations and material properties, proper surface preparation, accurate data interpretation, regulatory compliance, and continuous training. It's also crucial to implement quality control measures to guarantee reliable results. Considering these factors helps ensure effective NDT application, accurate defect detection, and maintenance of asset integrity, ultimately leading to improved safety, reduced costs, and increased productivity. By taking a comprehensive approach to NDT, industries can maximize its benefits and minimize potential pitfalls.

Es importante definir que se busca en una pieza a ensayar por END, ya que eso depende el metodo a utilizar, sobre superficie, podemos utilizar Liquidos Penetrartes, Particulas Magnetizables o Corrientes iducidas o de Foucault, pero al necesitar indagar en su interior ya tenemos que utilizar un método volumétrico Ultrasonido o Radiografia. Siempre realizando una inspección visual previa