When you are responsible for running an industry as big as Automotive Industry or Aerospace Industry, Power Generation Industry or Nuclear Industry, you will not mind the cost of materials testing. Each industrys well being depends on the testing of materials that are involved. Thus, a Power Generation Industry depends on massive turbines that churn out the power. The turbine in turn depends on its blades that are mounted on the rotor.

These blades will be subjected to wide variations in stresses that could be a combination of thermal and shear. Such high thermal stresses may cause the blades to fail under a phenomenon known as creep. When the material is selected for the blades, it is tested to ensure that it does not fail in such conditions of creep as it could experience in its working environment. Similarly, there are other properties of materials that are examined during materials testing.

These properties could be fatigue. Thus in the Aerospace Industry the undercarriage of the aircraft will generally be tested for the stresses during repeated cycles of lowering, landing and raising of the undercarriage. Other properties could be impact, hardness, elasticity or weldability, bendability, torsion, shear and tensile stresses among many others. Materials testing is carried out in laboratories with sophisticated equipment that are regularly calibrated and invariably operated by highly skilled and certified technical personnel.

Industries also depend on non-destructive testing of their systems to ensure that the systems do not fail during the course of operation as the failures or breakdowns can turn out to be extremely costly for the industry. Such testing could involve services such as Eddy Current, Radiography, Dye Penetrant, Visual or Magnetic Testing besides Ultrasonic Testing methods.

Ultrasonic testing methods could be used to detect a build up of corrosion, the thickness of various samples or when corrosion needs to be monitored. Some of the ultrasonic testing methods deploy equipment such as the Electromagnetic Acoustic Transmission also known as EMAT, the Time Of Flight Diffraction or TOFD, the Automated Ultrasonic Testing or AUT and the Phased Array or PA.

Testing is vital to ensure the smooth running of every industry.

Pipeline testing and Ultrasonic testing are two key methods of industrial materials testing. These two methods adopt different techniques to serve a common purpose.

Pipeline inspection:

Pipeline inspection is an indispensible operation that must be carried out periodically by the industries such as gas exploration and supply industry, which operate through and depend upon pipelines for their operations. Pipeline inspection is vital for the functioning of an industry as any blockage or scale formation can lead to losses running into millions of dollars. Pipeline inspection has to be carried out using non-destructive testing as it prevents losses. In-line inspection is carried out using MFL technique or Magnetic Flux Leakage where a powerful magnet is used to magnetize the steel to find out areas where steel is corroded or pitted analyzing the magnetic field “leaks” from the steel. In an MFL tool, a magnetic detector is placed between the poles of the magnet to detect the leakage field. Analysts interpret the chart recording of the leakage field to identify damaged areas and hopefully to estimate the depth of metal loss. Recently, advancements in digital imaging led to the development of high-resolution MFL tools that are becoming prevalent replacing the traditional uses for which it was developed at the first place. Originally, the modern High Resolution MFL tool was developed and designed for detecting areas of metal loss. However, now it is increasingly being used to accurately assess the extent of corrosion, pitting, inconsistencies, dents, wrinkles, buckles, and, in some cases, cracks. Thus, this technique can easily perform simultaneous tasks efficiently and proves cost-saving.

Ultrasonic testing:

Ultrasonic testing methods are used to measure the thickness of the samples and to monitor the extent of corrosion and any oxide deposit that might have built up. Some of the techniques of ultrasonic testing are the Electromagnetic Acoustic Transmission or EMAT, the Phased Array or PA and the Time of Flight Diffraction or TOFD. The TOFD is used to evaluate cracks in welds accurately. These devices are mounted on a travelling buggy that travels inside the area or along the weld that has to be tested.

Todays industries work 365 days round the clock. All systems are checked periodically to avoid the failures, as they could prove to be extremely costly. Non-destructive testing or NDT methods invariably carry out such checks so that there are no stoppages for accommodating these tests. This is true whether the industry in question is Nuclear or Aerospace and Power Generation or Pharmaceutical. Such NDT could utilize services such as Visual Testing, Radiography, Magnetic Testing, Eddy Current or Ultrasonic Testing.

Magnetic Testing utilizes different tools depending on the type of industry. Thus while the Pipeline Industry uses the Magnetic Flux Leakage (MFL) and the Portable Yoke, the Pulp & Paper Industry uses the Alternating Current Field Measurement Method or the ACFM. In the MFL method, which is used for the detection of pitting or corrosion in storage tanks, pipelines and other steel structures, a very powerful magnetic field is created for magnetizing the sample under test. The detector detects the gaps in the flux lines and analyzes them to assess the amount of missing metal as well as its dimensions. In an advanced version of this method, called the Magnetic Flux Leakage Inline Inspection Tool (MFL-ILI), the tool travels inside the pipeline and cleans the inner walls while detecting the corroded portions in the pipe wall. The ACFM method of magnetic testing can detect surface cracks as well as size them. The method applies to all metals and needs no direct contact, thereby making it possible to use it through coatings besides on surface temperatures up to 500 c.

Ultrasonic testing methods can not only detect flaws, cracks and corrosion in welded specimen such as piping, vessel and plate but it can also be used to measure the thickness of specimen. The professional equipment used could be Tank Crawlers, Near Drum Scanners, Internal Rotating Inspection Systems, Guided Ultrasonic Wave and Automated Pipe Scanners. Time Of Flight Diffraction (TOFD) method is used for both the Aerospace and Pulp & Paper Industries while the Aerospace and the Pipeline Industries use the Electromagnetic Acoustic Transmission (EMAT) method. The Petrochemical Industry uses Phased Array form of ultrasonic testing.

Industrial testing and maintenance are inescapable. This is essentially to keep the cost of repairs at an affordable level. Imagine the repair costs in large industries such as Pulp & Paper, Refining & Petrochemical, Automotive or Aerospace and Nuclear or Power Generation Industries. Such testing is non destructive in nature so that the wheels of the industry can keep rolling without any hindrance. The services for such non-destructive testing (NDT) are Eddy Current, Dye Penetrant Testing, Radiography and Visual Testing besides Magnetic Testing and Ultrasonic Testing.

Magnetic Testing methods are generally used for the examination of faults in welds of pipelines and cracks in blades for turbines among others. This form of testing utilizes the magnetic Flux Leakage (MFL), the Portable Yoke or the Alternating Current Field Measurement (ACFM) techniques. The ACFM is effective equally in ferrous and non-ferrous samples as well as their alloys. The ACFM can analyze samples through their coatings, as no direct contact is necessary. On the other hand, the MFL is a tool suited to steel structures only and involves the creation of a powerful magnetic field in the steel structure. The flux lines are next studied so as to detect likely pitted areas and those that may have cracks. There is an advanced version of this equipment called the Inline Inspection Tool or the MFL-ILI in which the tool travels inside the pipeline and cleans and collects the information. Other magnetic testing methods use multiple sensors to increase the resolution and hence the accuracy of the results.

Ultrasonic testing methods used in the industry relate to measuring of the thickness of the samples besides more importantly corrosion monitoring and the assessment of the oxide that may have built up. Some of the services in use are the Electromagnetic Acoustic Transmission or EMAT, the Phased Array or PA and the Time of Flight Diffraction or TOFD. The TOFD is used to evaluate cracks in welds accurately. It uses a set of probes that are mounted on a buggy that travels along the weld inspecting and records the data while it’s on the move. This technique is totally automated.

The article is contributed by a professional article writer, having experiences of working in different industries. For further information on rope access and failure analysis please visit http://www.acuren.com/

Heavy industries such as Aerospace, Nuclear, Petrochemical, Power and Paper besides Pharmaceutical, Automotive and Pipeline all need to be inspected from time to time. Such inspections are necessary in order to prevent failures from occurring since failures may not only be costly to rectify but could also bring the manufacturing process to a grinding halt. These inspections have to be carried out in a way as not to disrupt the industry’s functions. This, therefore, necessitates the use of nondestructive testing (NDT) processes. The various types of NDT commonly used are Eddy Current Testing, Penetrant Testing, Radiographic Testing, Specialized Testing, Magnetic testing, Visual Testing, and Ultrasonic Testing.

Magnetic testing methods are generally used for the examination of pipelines, welds, turbine blades and various structures. The various services that are used could be the Magnetic Flux Leakage (MFL), the Alternating Current Field Measurement (ACFM) and the Portable Yoke. The MFL is generally used for detecting pitting and corrosion in steel structures. In this technique, the structure is initially magnetized and thereafter an analysis is carried out of the areas that do not show flux lines. There is an advanced MFL technique that uses a tool called the In-line Inspection Tool (ILI) that travels inside the pipeline being inspected. The collected data is analyzed to yield defects pertaining to corrosion and pitting. Further improvement to the resolution is achieved by using multiple sensors. The ACFM technique, on the other hand, can be used on either ferrous or nonferrous materials with equal ease. No direct contact being necessary, this technique is effective through coatings as well.

The various ultrasonic testing methods being used relate to the detection and monitoring of the oxide that’s built up and corrosion. Thickness of samples is also measured. Different services in use include Phased Array or PA, the Electromagnetic Acoustic Transmission or EMAT and Automated Ultrasonic Testing or AUT besides Time of Flight Diffraction or TOFD. The PA reveals structural defects that are hidden by the use of a number of probes. These probes create a high-resolution beam that can be swept in order to produce the object’s internal structure.
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The article is contributed by a professional article writer, having experiences of working in different industries. For further information on rope access and materials analysis please visit http://www.acuren.com/

Whenever there is a failure either in a vehicle, an aircraft or equipment pertaining to the industry you have to analyze the facts of the case and come to a logical finding. The failure could have been due to a poor material, faulty design, a malfunction caused by multiple reasons; fatigue, creep or it could have been due to operator error or lack of maintenance. Proper failure analysis demands the utilization of advanced analytical techniques in the manner of forensic science. The reconstruction of the accident or failure is sometimes best done using computer modeling and simulation. However, in most cases the solution lies in investigating from the materials angle in order to rule out the likelihood of the accident having occurred due to poor material quality.

The investigation of a failure therefore implies that you need to ease the answer out of the failed component itself by carrying out a thorough materials analysis. This is carried out in a well-equipped laboratory using Destructive Testing, Metallography, Chemical Analysis or Non Destructive Testing methods. The various options of Destructive Testing include high temperature tensile testing at up to 1000 c or impact testing using a notched bar at as low as –196 c. The normal standards of Rockwell, Vickers and Brinell are used to determine the corresponding hardness values of both materials and joints that have been welded.

Materials analysis using metallographic examination involves the preparation of a sample for microscopic examination. The structure of the grain, the heat treatment that had been provided, the size of the grain and imperfections in welding can all be evaluated using this technique. Today’s advanced laboratories can provide optical vacuum emission spectrometry results using advanced computers to yield very accurate analysis of both ferrous and non-ferrous metals and their alloys. Non-destructive Testing techniques used involve methods such as Pulse Echo, Dye Penetrant, and Magnetic Induction among others.

The systematic failure analysis assumes significance since this could prevent future failures thereby obviating costly breakdowns and in extreme cases, fatalities. The implication is to utilize advanced metallurgical and engineering knowledge to analyze failures in suitably equipped laboratories.

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The article is contributed by a professional article writer, having experiences of working in different industries. For further information on rope access and materials testing please visit http://www.acuren.com/

Every production agency involved in the manufacturing business will have a requirement for material inspection either at the production stage or at the time of routine or breakdown maintenance. Frequently this inspection has to be carried out by Non Destructive Testing or NDT in order that the component under inspection is not rendered unserviceable in the process. The all-important field of NDT covers many options. Visual testing, magnetic testing, radiography, eddy current and ultrasonic testing are some of the well-known methods of NDT.

The role of ultrasonic testing is impressive. While it can be used to read thickness of samples it can also be used for the detection of flaws and corrosion. Welded specimen can be examined in applications like vessels, piping and plate. Companies involved in the field of Materials Engineering use specialist equipment for this task. Such professional equipment would be Tank Crawlers, Internal Rotating Inspection Systems, Near Drum Scanners, Automated Pipe Scanners and Guided Ultrasonic Wave.

While the Aerospace and the Pipeline industries utilize Electromagnetic Acoustic Transmission (EMAT) service for ultrasonic testing, the Refining & Petrochemical sector utilizes the Phased Array equipment also. The EMAT radiates an ultrasonic wave in the sample being assessed. The software to interpret the internal condition of the sample analyzes the electric current generated by the reflected wave. With this technique the thickness can be calculated and flaws and cracks assessed. The Phased Array uses multiple ultrasonic waves to create the internal image of the component.

Time of Flight Diffraction (TOFD) method is equally applicable for the Aerospace and the Pulp & Paper industries. TOFD is a fully automated and computerized system suitable for weld examination. In this technique probes are mounted on a buggy that travels along the welded track being inspected. The software used for the acquisition of data automatically and accurately reads off the dimensions of the cracks.

Today sophisticated equipment is available for the ultrasonic testing of materials used in various industries. These are specialized equipment with a direct relevance to the type of industry, the task and the environment. The focus is on accuracy and speed in the analysis of the evaluation process.

Some more services :-

Turbine inspection, Materials Testing etc.

Ultrasonic testing is acknowledged as one of the preferred methods of non-destructive testing or NDT. The services in ultrasonic testing entail not only the flaw detection thickness and its subsequent mapping using sophisticated data acquisition software but also corrosion affected products. Thus, the machines could be used for physical examination of welds in products like plate, vessels and piping. Latest technology and software make the task of examination, reporting as well as analysis of the defect pattern easy to achieve. The latest machines that are used for different products include Internal Rotating Inspection Systems, Automated Pipe Scanners, Near Drum Scanners, Tank Crawlers and Guided Ultrasonic Wave. All these machines meet the industry’s most rigorous standards in materials testing.

The present day machines used in ultrasonic testing can be applied to almost all the fields. These fields include Aerospace and Power Generation, Nuclear and Petrochemical, Automotive and Pharmaceutical besides Pipeline, Pulp and Paper Industries. Thus, in the field of Aerospace Electro Magnetic Acoustic Transmission or EMAT is used. EMAT essentially produces an ultrasonic wave in the part being tested as opposed to the transducer. By studying the pattern of echoes from the original pulses it is possible to analyze the sample to the extent of assessing the depths of individual cracks that might exist as flaws. You can therefore completely assess the structural integrity of the sample without having to damage it in any way.

Similarly, Time of Flight Diffraction or TOFD, which is an automated and computerized system, can be used for the inspection of welds. The inspection is carried out by the use of probes that are mounted on a buggy traveling along the welded track. The Data Acquisition Software records the dimensions of the cracks accurately unlike older and more conventional methods of ultrasonic testing. Modern tools have made it possible for you to keep your rejects low by identifying the extent of flaws in individual products without causing any damage to them. This is true irrespective of the industry your products lie in. As a result, the economic spin-offs of utilizing such a system can be appreciated.

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The article is contributed by a professional article writer, having experiences of working in different industries. For further information on rope access and materials analysis please visit http://www.acuren.com/