Chapter 1 Introduction to Nondestructive Testing 1.1 I
Total Page：16
File Type：pdf, Size：1020Kb
www.NDTKALA.net www.NDTKALA.net www.NDTKALA.net www.NDTKALA.net HANDBOOK OF NONDESTRUCTIVE EVALUATION www.NDTKALA.net This page intentionally left blank. www.NDTKALA.net HANDBOOK OF NONDESTRUCTIVE EVALUATION Charles J. Hellier McGRAW-HILL New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto www.NDTKALA.net ebook_copyright 8 x 10.qxd 7/7/03 5:07 PM Page 1 Copyright © 2003 by The McGraw-Hill Companies, Inc. All rights reserved. Manufactured in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distrib- uted in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. 0-07-139947-X The material in this eBook also appears in the print version of this title: 0-07-028121-1 All trademarks are trademarks of their respective owners. Rather than put a trademark symbol after every occurrence of a trademarked name, we use names in an editorial fashion only, and to the benefit of the trademark owner, with no intention of infringement of the trademark. Where such designations appear in this book, they have been printed with initial caps. McGraw-Hill eBooks are available at special quantity discounts to use as premiums and sales promotions, or for use in cor- porate training programs. For more information, please contact George Hoare, Special Sales, at george_hoare@mcgraw- hill.com or (212) 904-4069. TERMS OF USE This is a copyrighted work and The McGraw-Hill Companies, Inc. (“McGraw-Hill”) and its licensors reserve all rights in and to the work. Use of this work is subject to these terms. Except as permitted under the Copyright Act of 1976 and the right to store and retrieve one copy of the work, you may not decompile, disassemble, reverse engineer, reproduce, modify, create derivative works based upon, transmit, distribute, disseminate, sell, publish or sublicense the work or any part of it without McGraw-Hill’s prior consent. You may use the work for your own noncommercial and personal use; any other use of the work is strictly prohibited. Your right to use the work may be terminated if you fail to comply with these terms. THE WORK IS PROVIDED “AS IS”. McGRAW-HILL AND ITS LICENSORS MAKE NO GUARANTEES OR WAR- RANTIES AS TO THE ACCURACY, ADEQUACY OR COMPLETENESS OF OR RESULTS TO BE OBTAINED FROM USING THE WORK, INCLUDING ANY INFORMATION THAT CAN BE ACCESSED THROUGH THE WORK VIA HYPERLINK OR OTHERWISE, AND EXPRESSLY DISCLAIM ANY WARRANTY, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PAR- TICULAR PURPOSE. McGraw-Hill and its licensors do not warrant or guarantee that the functions contained in the work will meet your requirements or that its operation will be uninterrupted or error free. Neither McGraw-Hill nor its licensors shall be liable to you or anyone else for any inaccuracy, error or omission, regardless of cause, in the work or for any dam- ages resulting therefrom. McGraw-Hill has no responsibility for the content of any information accessed through the work. Under no circumstances shall McGraw-Hill and/or its licensors be liable for any indirect, incidental, special, punitive, con- sequential or similar damages that result from the use of or inability to use the work, even if any of them has been advised of the possibility of such damages. This limitation of liability shall apply to any claim or cause whatsoever whether such claim or cause arises in contract, tort or otherwise. DOI: 10.1036/007139947X www.NDTKALA.net Want to learn more? , We hope you enjoy this McGraw-Hill eBook! If you d like more information about this book, its author, or related books and websites, please click here. www.NDTKALA.net This handbook is dedicated to the memory of two pioneers in the field of nondestuctive testing: Robert C. McMaster, 1913–1986 Samuel A. Wenk, 1914–1990 Their work served as the foundation for the technology that has become so important to industry. Without the contributions of these “giants,” the world would not be the same. www.NDTKALA.net This page intentionally left blank. www.NDTKALA.net For more information about this title, click here. CONTENTS Contributors xi Preface xv Chapter 1 Introduction to Nondestructive Testing 1.1 I. What is NDT? 1.1 II. Concerns Regarding NDT 1.2 III. History of Nondestructive Testing 1.3 IV. Nondestructive versus Destructive Tests 1.17 V. Conditions for Effective Nondestructive Testing 1.21 VI. Personnel Considerations 1.22 VII. Certification Summary 1.26 VIII. References 1.27 Chapter 2 Discontinuities—Origins 2.1 Chapter 2 and Classification I. Primary Production of Metals 2.2 II. Castings 2.4 III. Cracks 2.10 IV. Welding Discontinuities 2.11 V. Discontinuities from Plastic Deformation 2.15 VI. Corrosion-Induced Discontinuities 2.15 VII. Operationally Induced Discontinuities—Fatigue Cracking 2.18 VIII. Operationally Induced Discontinuities—Creep 2.19 IX. Operationally Induced Discontinuities—Brittle Fracture 2.20 X. Geometric Discontinuities 2.21 XI. Summary 2.23 XII. Glossary of Metallurgy and Discontinuity Terms 2.23 XIII. Discontinuity Guide 2.27 Chapter 3 Visual Testing 3.1 I. History and Development 3.1 II. Theory and Principles 3.3 III. Equipment and Accessories 3.9 IV. Applications and Techniques 3.22 V. Evaluation of Test Results 3.45 VI. Advantages and Limitations 3.49 VII. Glossary of Key Terms 3.53 Copyright 2003 by The McGraw-Hill Companies, Inc. Click here for Terms of Use. vii www.NDTKALA.net viii CONTENTS Chapter 4 Penetrant Testing 4.1 I. Introduction 4.1 II. History and Development 4.1 III. Theory and Principles 4.4 IV. Penetrant Equipment and Materials 4.6 V. Penetrant Procedures 4.14 VI. Techniques and Variables 4.18 VII. Evaluation and Disposition 4.27 VIII. Penetrant Testing Applications 4.29 IX. Quality Control Considerations 4.29 X. Advantages and Limitations 4.32 XI. Glossary of Penetrant Testing Terms 4.32 Chapter 5 Magnetic Particle Testing 5.1 I. History and Development 5.1 II. Theory and Principles 5.2 III. Equipment and Accessories 5.24 IV. Techniques 5.30 V. Variables 5.39 VI. Evaluation of Test Results and Reporting 5.44 VII. Applications 5.48 VIII. Advantages and Limitations 5.50 IX. Glossary of Key Terms 5.51 X. References 5.53 Chapter 6 Radiographic Testing 6.1 I. History and Development 6.1 II. Theory and Principles 6.10 III. Radiographic Equipment and Accessories 6.21 IV. Variables 6.25 V. Techniques and Procedures 6.39 VI. Radiographic Evaluation 6.50 VII. Applications 6.54 VIII. Advantages and Limitations of Radiography 6.58 IX. Compendium of Radiographs 6.60 X. Glossary 6.68 XI. Bibliography 6.70 Chapter 7 Ultrasonic Testing 7.1 I. History 7.1 II. Theory and Principles 7.4 III. Equipment for Ultrasonic Applications 7.29 IV. Techniques 7.52 V. Variables 7.103 VI. Evaluation of Test Results 7.105 VII. Applications 7.107 VIII. Advantages and Limitations 7.110 IX. Glossary of Terms 7.111 X. References 7.115 www.NDTKALA.net CONTENTS ix Chapter 8 Eddy Current Testing 8.1 8.1 History and Development 8.1 8.2 Theory and Principles 8.3 8.3 Alternating Current Principles 8.10 8.4 Eddy Currents 8.17 8.5 Test Equipment 8.24 8.6 Eddy Current Applications and Signal Display 8.40 8.7 Advantages and Limitations 8.64 8.8 Other Electromagnetic Test Techniques 8.65 8.9 Glossary of Key Terms 8.67 8.10 Suggestions for Further Reading 8.70 Chapter 9 Thermal Infrared Testing 9.1 1. History and Development 9.1 2. Theory and Principles 9.4 3. Equipment and Accessories 9.11 4. Techniques 9.16 5. Variables 9.23 6. Data Storage 9.26 7. Applications 9.27 8. Advantages and Limitations 9.43 9. Glossary 9.44 10. Bibliography and References 9.47 Chapter 10 Acoustic Emission Testing 10.1 1. History and Development 10.1 2. Principles of Acoustic Emission Testing 10.2 3. Advantages and Limitations of Acoustic Emission Testing 10.36 4. Glossary of Acoustic Emission Terms 10.37 5. References 10.39 Basic Metric–English Conversions B.1 Index I.1 www.NDTKALA.net This page intentionally left blank. www.NDTKALA.net CONTRIBUTORS Charles J. Hellier (primary author and reviewer, author of chapters 1, 4, and 6) was founder and is currently President of HELLIER (a division of Rockwood Service Corpo- ration), a multidisciplinary organization offering a wide range of technical services throughout North America. He has over 40 years of experience in nondestructive testing, quality assurance, and inspection. He completed his formal education at Penn State and Temple Universities. He is a Registered Professional Engineer, a Board Certified Foren- sic Examiner, and holds Level III Certifications in five nondestructive testing methods. He also holds a Level III Certificate in five methods issued by the American Society for Nondestructive Testing (ASNT). Mr. Hellier is past National President of ASNT and has been active in that organiza- tion for over 40 years, serving on many committees, boards, and various councils. He has presented many lectures and papers worldwide, and is widely published. Currently, he is the National President of the Nondestructive Testing Management Association (NDT- MA) and holds memberships in ASNT (Fellow), ASME, ASTM, AWS, ASM, ABFE (Fellow), and NDTMA. Michael W. Allgaier (author, Chapter 2) is presently the Manager NDE Instruction with Electric Power Research Institute (EPRI), supporting the NDE Center in Charlotte, NC.