Nondestructive Testing And Inspection Methods

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INTRODUCTION: Nondestructive Inspection (NDI) is the inspection of a structure or component in any manner that will not impair its future usefulness. The purpose of the inspection may be to detect f laws, measure geometric characteristics, determine material structure or composition, or characterize physical, electrical or thermal properties, without causing any change in the part. The NDI methods include the following: . Liquid Penetrant . Magnetic Particle . Electromagnetic . Ultrasonic . Penetrating Radiation. 2. This publication covers the theory and general applications of the various NDI methods. For specific information on the operation or maintenance of a particular item of NDI equipment, consult the appropriate Technical Manual. 3. NDI methods in the hands of a trained and experienced technician are capable of detecting f laws or defects with a high degree of accuracy and reliability. It is important that maintenance engineering personnel are fully knowledgeable of the capabilities of each method but it is equally important that they recognize the limitations of the methods. No NDI method should ever be considered conclusive. Often a defect indication developed by one method must be confirmed by another method to be considered reliable. Furthermore, the equipment is highly sensitive and is capable of detecting discontinuities and anomalies that may be of no consequence in the service for which a component is used. Limits for acceptance and rejection are thus as much a part of an inspection as the method itself. As an example, ultrasonic inspection equipment is fully capable of detecting normal grain boundaries in some cast alloys. The inspection criteria must be designed to overlook these ''normal'' indications and to discriminate in favor of the discontinuities that will affect the service of the component.
1 GENERAL INFORMATION . 1-1 1.1 INSPECTION FACILITY 1-1 1.1.1 Introduction 1-1 1.1.2 Notes for Floor Plan. 1-3 1.2 PERSONNEL TRAINING / QUALIFICATION / CERTIFICATION. 1-5 1.2.1 Guidelines. 1-5 1.2.2 Requirements . 1-5 1.2.3 Special Task Certification and Recurring Training 1-5 1.3 REPORTING NEW / IMPROVED NONDESTRUCTIVE INSPECTION TECHN 1-7 1.3.1 Summary 1-7 1.3.2 Authority 1-7 1.3.3 Scope . 1-7 1.3.4 Responsibilities 1-8 1.3.5 Entries on AFTO Form 242 1-9 1.4 PROCESS CONTROL . 1-14 1.4.1 Reason for Process Control . 1-14 1.4.2 Scope of Process Control 1-14 1.4.3 Scope of Documentation Requirements 1-14 1.4.4 Responsibilities 1-15 1.4.5 Suggested Documentation Method . 1-15 1.5 PENETRANT PROCESS CONTROL. 1-20 1.5.1 Need for Process Quality. 1-20 1.5.2 Process Control Requirements 1-22 1.5.3 Control of New Materials 1-29 1.5.4 Monitoring Process Performance (Stationary Inspection Units) 1-31 1.5.5 Testing of Material in Use 1-34 1.6 MAGNETIC PARTICLE INSPECTION PROCESS CONTROL 1-43 1.6.1 Purpose and Scope . 1-43 1.6.2 General . 1-43 1.6.3 Causes of Materials Degradation . 1-43 1.6.4 Frequency of Process Control 1-44 1.6.5 Material Requirements 1-44 1.6.6 Safety 1-45 1.6.7 Magnetic Particle Equipment / System Requirements . 1-45 1.6.8 Process Requirements 1-46 1.6.9 Quantitative Quality Indicators . 1-47 1.6.10 System Effectiveness Check 1-48 1.6.11 Ammeter C 1-49 1.6.12 Quick Break Tester 1-50 1.6.13 Establishing a Field Indicator Reference Standard 1-50 1.6.14 Checking the In Use Field Indicators . 1-50.1 1.7 Deleted 1.7.1 Deleted 1.8 ULTRASONIC PROCESS CONTROL REQUIREMENTS. 1-52 1.8.1 The Ultrasonic Process Control Requirements 1-52 1.8.2 Calibration of Equipment 1-57 1.9 PROCESS CONTROL FOR RADIOGRAPHY . 1-71 1.9.1 Scope and Purpose . 1-71 1.9.2 Radiographic Process Control Requirements. 1-71 2 LIQUID PENETRANT INSPECTION . 2-1 2.1 INTRODU 2-1 2.1.1 General . 2-1 2.1.2 Summary 2-1 2.1.3 Background. 2-1 2.1.4 Capabilities of Penetrant Inspection 2-2 2.1.5 Basic Penetrant Process 2-2 2.1.6 Leak Detection . 2-3 2.1.7 ...