Mechanical Engineering

ULTRASONIC TEST INTRODUCTION This method is used to test a variety of both metallic & non metallic products such as welds, forgings, castings, sheets, etc. It has an advantage of detecting sub-surface discontinues with accesses to only one side of the specimen. In this method beams of high frequency sound waves are introduced into the material being tested. The sound waves travel through the material with some loss of energy & are reflected back . This is detected & analysed to detect the presence of flaws. This test employs ultrasonic waves. These waves are mechanical waves that consist of oscillations or vibrations. METHOD TRANSMISSION SYSTEM This method employs two Transducers, one for sending & other for receiving the pulses. These may be short or continuous & are transmitted through the material. The result gets displayed on the CRO connected. The settings of the CRO can be adjusted with respect to time & distance. Prior to testing couplant is used to prov...

RADIOGRAPHY TEST INTRODUCTION : Industrial radiography is a nondestructive test method that uses X-rays or Gamma rays to show the presence and certain characteristics of internal discontinuities in solid materials. The method is based on the ability of X-ray or Gamma-ray radiation to penetrate solids, to a degree that varies with such factors as wave length of the radiation, and type and thickness of the material part of the radiation penetrates the material and part is absorbed. The amount absorbed and the amount transmitted are a function of the thickness of the material. Where a void or discontinuity exists, there is essentially less material to absorb the radiation. This creates a different in absorption, a difference that registers on photographic emulsions. The result is a shadow picture called a radiography Radio-graphic Sources : The common gamma ray radio-graphic sources : Cobalt - 60 Cesium - 137 Iridium - 192 Thulium - 170 Gamma Ray Radiography : Gamma rays ar...

MAGNETIC PARTICLE EXAMINATION (M.P.I.) INTRODUCTION This method is used for detecting cracks and other discontinuities open to surface or sub surface in ferromagnetic materials. Fine magnetic particles are applied to the surface of a part which has been suitably magnetized. The particles are attracted to regions of magnetic non-uniformity associated with defects and discontinuities, thus producing indication which are observed visually. PRINCIPLE When a piece of metal is placed in a magnetic field and the lines of magnetic flux get intersected by a discontinuity such as a crack or slag inclusion in a casting, magnetic poles are induced on either side of the discontinuity. The discontinuity causes an abrupt change in the path of magnetic flux flowing through the casting normal to the discontinuity, resulting a local flux leakage field and interfering with the magnetic lines of force. This local flux disturbance can be detected by its affect upon magnetic particles that collect o...

LIQUID (DYE) PENETRATION TEST INTRODUCTION A liquid penetrant test is non-destructive type of testing to detect flaws that are open to the surface. e.g. cracks, seams, laps, lack of bond, porosity, cold shuts etc. can be effectively used not only in the inspection of ferrous metals but is especially useful for non-ferrous metal products and on non-porous, non-metallic materials such as ceramics, plastics and glass. PRINCIPLE OF OPERATION The principle of liquid penetrant test is that the liquids used enter small openings such as cracks or porosities by capillary action. They are influenced by factors such as the condition of the surface of material and the interior of the discontinuity. For liquid to penetrate effectively, the surface of the material must be thoroughly cleaned of all material that would obstruct the entrance of the liquid into the defect. After cleaning, the liquid penetrant is applied evenly over the surface and allowed to remain long enough to permit penetration i...

VISUAL  INSPECTION OF WELDING INTRODUCTION Inspection starts with examination of the material prior to fabrication, scabs, seams, scale or other harmful surface conditions may be detected in visual inspection. The inspector should check the following : Weld preparation, dimensions and finish.  Clearance dimensions of backing strips.  Alignment and fit up to the pieces being welded.  Verification of cleanliness.  Visual Inspection During Welding Visual inspection checks details of the work while welding is in progress. Among the details to be checked are : Welding process.  Cleaning.  Preheat and inter pass temperature.  Joint preparation.  Filler metal.  Flux or shielding gas.  Chipping, grinding, or gouging.  Post heating temperature and time.  Visual Inspection After Welding Visual inspection is useful for finished-product verification of such items as : Profile irregularities of the weldment....

NDT (NON DESTRUCTIVE   TESTING) :-  Non Destructive Testing in great variety are in world   wide used to detect variations in structure, minute changes in surface finish, the presence of cracks or other physical discontinuities, measure   the thickness   of materials   and   coatings   and   to   determine  other characteristics of industrial products. REASON'S FOR THE USE OF NDT: "NDT" is used by the manufacturers for the following reasons:  1. To ensure product reliability. 2. To make profit for the user. a)    To ensure customer satisfaction b)   To aid in better product reliability. c)    To control the manufacturing processes. d)   To lower the manufacturing costs. e)    To maintain uniform quality level. SOME OF THE MOST COMMON NDT METHODS ARE : 1.VISUAL ...