JNDE MARCH 2016
LETTERS
JNDE EDITORIAL Team Managing Editor : Mr. Rajul Parikh Chief Editor : Dr. Krishnan Balasubramaniam Editorial Team :
ARTICLES
- President Talk
........3
- Chief Editor Talk
........3
- Managing Editor Talk ........5 - JNDE Executive Talk ........5 ISNT CORNER
Mr. Paritosh Nanekar
- About ISNT
........6
- Awards & Awardees / .....9 Sponsors CHAPTER SPACE - Chapter Chairmen & Secretary
....13
- Chapter News
........15
Mr. Prabhu Rajagopal
- Spotlight - PUNE
........15
Mr. Diwakar Joshi Mr. Ravibabu Mulaveesala Dr. Debasish Mishra
TECHNICAL PAPERS - Non-Destructive ..29 Testing and Reverse Engineering from Computed Tomography
JNDE Executive : Ms.Rachna Jhaveri
.......49
- Radiography Evaluation 32 of Investment Castings for Aerospace applications - Neutron Diffraction: The State of Art in Non-invasive Stressfield Mapping
- Basic Principles and ........52 Industrial applications - Codes & Standards for ........55 Radiography Testing WHAT'S NEW Product Gallery
Mr. Arumugam Mr. Bikash Ghose
- Role of ASME SEC. V in NDE and Summary of Changes In Edition 2015 BACK TO BASICS
Ms. M.Menaka Dr. Sarmishtha Sagar
- History of Radiography ........46 in India
..36
........58
EVENTS - Indian / International Events Calendar 2016
.....62
- NDE 2015 – A Brief Report
.....64
NGC/NCB - Meeting Updates
.....67
RESOURCES - Qualification of NDT
........68
- Announcement Level II, III
........69
ADVERTISER'S Index
........72
- Flash X-ray Radiography 42 with Phosphor Imaging Plate
ON THE COVER Page A reconstructed image combining CT & image processing software for inspection & reverse engineering.
Image Courtesy : SIMPLEWARE LTD.
OBJECTIVE – This Journal of Non Destructive Testing & Evaluation (JNDE) is published quarterly by the Indian Society for Non Destructive Testing (ISNT) for promoting NDT Science & Technology. The objective of this journal is to provide a forum for dissemination of knowledge in NDE & related fields. Papers will be accepted on the basis of their contribution to the growth of NDE Science & Technology. The Journal is for private circulation to members only. All rights reserved throughout the world. Reproduction in any manner is prohibited. Views expressed in the Journal are those of the authors' alone. PUBLISHED BY:Mr. Rajul P. Parikh Managing Editor on behalf of Indian Society for Non Destructive Testing (ISNT) 8, 2nd Floor, Jyoti Wire House, Near Kolsite, Off.Veera Desai Road, Andheri (W), Mumbai – 400 053. INDIA. Phone: 022-61503800 Email : isnt.jnde@gmail.com and Printed at VRK Printing House, Chennai.
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HIGHLIGHTS
CONTENTS
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Non Destructive Testing & Evaluation field consists of Manufacturers of NDT equipments, industries & institutes who are direct users of such equipments, Service providers in the field of NDT and institutes or individuals involved in Training & Certification activities. The objective of JNDE published by ISNT is that, it should become useful to every NDT professional and all sectors of industries using NDT. The technical papers in the journal normally indicate the status of technical level & competence of the research scientists in the country. In fact, it is essential that the scientists involved in research & Development and also in advance NDT technique should shoulder the responsibility and send best of the articles in NDE journal to indicate the present status of NDT W.R.T. Global Developments in the field. Articles in the scientific magazines are always read very seriously and Scientific articles allow researchers to keep up to date with the developments in their field and also help them direct their own research and hence it becomes essential that the stalwarts in NDT field should publish their high quality research work to enhance the image not only of magazine & NDT profession but also country’s image in the eyes of global NDT professionals. We are trying to tie up with other international associations to share the technical papers which will benefit of NDT professionals from our country Efforts are also being made that the NDE journal should reach not only to the members of ISNT, but also the major industries in core industrial sectors so that the latest developments of equipments and services are brought to the notice of user industries through advertisements published in the journal. The case studies should be useful to the practicing NDT professionals and information on various workshops, Training & Certification program will help the members to upgrade their skill and help them to advance further in their respective field. With the above & many more objectives, the team of JNDE is taking all round efforts so that every one in the NDT profession will find this journal of interest to them in their respective NDT profession. I am sure that all the NDT professionals, manufacturers and suppliers from India will extend their support to see that JNDE becomes popular and reach to greater heights. Mr. D.J.Varde President-ISNT
MANAGING EDITOR Talk A new format, a new look, a new design and we hope the best of the NDT heritage. The quarterly journal JNDE - an ISNT publication, welcomes the challenge & strives to continue its excellence. At the same time, we open doors to a wider reach in the NDT Industry & broader topic coverage spectrum. In this issue we offer - recent trends in the NDT field while focusing on Radiography technique. We offer our reviewers and readers the space to reflect on specific topics, ask questions. Articles are invited, contributions from sharp sighted manufacturers, major technicians & professionals. These are visible changes going hand-in-hand with the new look JNDE and quarterly publication. At the same time, a final transformation has been underway behind the scenes, one that equally reflects our ambition for the journal. We do not intend to circumscribe JNDE to only specific readers. Rather, we have aimed to illustrate the diversity of topics and approaches in a way that interests people all around, thereby stating JNDE will be “Connecting NDT Professionals”. I am deeply indebted to our editors for their contributions. Advertisers are acknowledged for imbibing their trust in our venture. I am profoundly grateful to our associates for supporting the relaunch in every way. Old standards, new mechanisms: a mix of continuity and change. So, Come join the JNDE Family, stay Connected. Rajul Parikh Managing Editor-JNDE JOURNAL OF NON DESTRUCTIVE TESTING & EVALUATION ————————————————————————| 3
LETTERS
PRESIDENT Talk
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This issue is a new look JNDE with a new Managing Editor Mr Rajul Parikh and a new editorial board. I would like to first welcome the Managing Editor and thank all new members of the editorial board. I would also like to thank the previous board that served ISNT for many years. In this issue, there are many new threads including a section on new NDT products called Products Gallery that showcases many new developments in the NDT field. This issue focuses on Radiography with 2 articles that cover some of the basics, and several technical articles over a wide range of topics. A list of events and a brief report on the NDE2015 will keep all ISNT members aware of the recent and upcoming conferences and workshops. Other unique feature includes a section on Chapter Focus and Resources for training and certification. I wish this new team a great new beginning and a long collaboration towards making JNDE a renowned source of NDT information and knowledge. Krishnan Balasubramaniam Editor in Chief
JNDE EXECUTIVE Talk Greetings and a warm welcome to sharing our JNDE - A new look, lot of information & variety of topics covered, timely publication & much more! I have had the great fortune of being the 'JNDE Executive' & I thank Managing Editor & ISNT for giving me the honors. We have lined up different topics for our forthcoming Issues namely March-Radiographic Testing, JuneUltrasonic Testing, September-Magnetic Particle & Liquid Penetrant & December Issue highlighting NDE conference & a Buyer's guide. Please take some time to get to know the layout of our current 'Radiographic Testing Special' Issue categorised as follows:- Topics, Letters, ISNT Corner, Chapter News, Awards, Events, Articles, Just In-Product Gallery, Training & Certification, NGC/NCB Space, Advertisers. We have selective technical papers previewed by our esteemed editors, who have invested time in contributing information & inspiring articles. We are honored to share the work of so many committed and thoughtful people. Feel free to leave comments on the articles, to share your thoughts & suggestions or ask the author a question. We appreciate your support and are so happy to have you as a reader of JNDE. Ms.Rachna Jhaveri JNDE Executive Email: isnt.jnde@gmail.com
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LETTERS
CHIEF EDITOR Talk
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Indian Society For Non Destructive Testing (ISNT) was formed on 21st April 1989 by merger of two societies namely Non Destructive Testing Society of India registered in Calcutta in July 1972 and Non Destructive Inspection Engineering registered at Madras in March 1981. It is a non-profit organization and is registered under the Tamil Nadu Societies, Registration Act, 1975 (Tamil Nadu Act 27 of 1975) Regd. No.49 of 1981. The Indian Society for Non-destructive Testing (ISNT) is the society for NDT professionals and practitioners which offers invaluable resources, information and linkages for industrial quality development and professional development to its members. The objective of the Society is to promote the awareness of NDT Science and Technology through education, research and exchange of technical information within the country and internationally to its members and other professionals using NDT. The family of ISNT has more than 6000 strong members. It is a diverse and dynamic family of professionals representing NDT technicians, scientists, engineers, researchers, manufacturers and academicians – all dedicated to improve product safety and reliability. These specialists represent virtually every industry and discipline that may benefit from NDT technology. ISNT holds periodic seminars and workshops on topics relating to NDT methods and applications, as well as exhibitions displaying cutting edge NDT products and services. ISNT has 19 chapters spread all over the country with headquarters at Chennai. In addition to the above, we have two wings – •
National Certification Board The National Certification Board has been formed for the training and certification of NDT professionals in India and has been periodically conducting Level-I and Level-II courses through ISNT chapters. NCB-ISNT has been recognized by ASNT as the NSO in India and has been periodically conducting Level III ASNT exams right from 1986. NCB-ISNT plays key role in international harmonization of training and certification.
•
QUNEST – Quality through Non-Destructive Evaluation Science and Technology The QUNEST has been formed to : a)Identify NDE issues and thrust areas; b) Foster NDE Science and Technology nationally with international inputs; c) Continuing Education and d) Enhance international standing and make ISNT a global player.
ISNT keeps the members informed about technological advances, new products, certification and training and international linkages.
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ISNT CORNER
About ISNT
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NATIONAL Sl. No.
Name of Awardees
NDT
AWARDS – 2015 Category
Sponsored by
01.
Dr. Anish Kumar, IGCAR, Kalpakkam
ISNT-EEC Award for Excellence in Contribution in R & D – National NDT Award
M/s Electronic & Engineering Co. (I) Pvt. Ltd., Mumbai
02.
Shri Arumugam Muthusamy, VSSC, ISRO, Trivandrum
ISNT-P-MET Award for Excellence in contribution to Industrial Applications National NDT Award
M/s P-Met High Tech Co. Pvt. Ltd, Vadodara
03.
Shri Thirunavukkarasu, IGCAR, Kalpakkam
ISNT-NDTS award for Excellence in contribution to NDT Systems innovation & development – National NDT Award
M/s NDTS India (P) Limited, Navi Mumbai
04.
Shri R. Vidyasagar, Shri R.K. Singh & Shri S. Raviprakash
ISNT-IXAR Award for Best Paper in JNDE,R&D category (“Failure Analysis of Reinforce Concrete Structures using Acoustic Emission and 3D digital image correlation techniques – Vol. 13 Issue 2 September 2014)
M/s Industrial X-Ray and Allied Radiographers, Mumbai
05.
Shri R.J. Pardikar & Shri Deepesh. V
ISNT-Eastwest Best paper Award in Industrial application category. (“Evaluation of critical Weldments in super critical boilers using advanced Ultrasonic Imaging techniques” – Vol. 13 Issue 1 June 2014)
M/s Eastwest Engineering & Electronics Co, Mumbai
06.
ISNT Hyderabad Chapter
ISNT-PULSECHO Best Chapter Award for the Best Chapter of ISNT for the year 2015
M/s Pulsecho Systems (BOMBAY) Pvt. Ltd, Mumbai
07.
1) Dr. O. Prabhakar 2) Shri L.M. Tolani
ISNT Lifetime Achievement Award for the year 2015
ISNT
08.
1) Dr. B. Venkatraman 2) Dr. S. Annamala Pillai
Hon. Fellow Member
ISNT
09
Shri Tarun Kumar Das, CSIR- NML, Jamshedpur
ISNT- Hi Tech Imaging Award for Young Scientist.
M/s Hi Tech Imaging Private Limited, Mumbai
10.
Dr. B.P.C. Rao IGCAR, Kalpakkam
ISNT–FERROFLUX National NDT Award for International Recognition
M/s Ferroflux Products, Pune
Skill development is the need of the hour. This is the success story of the man who believed and proved the above maxim. He is none other than Surya Prakash Gajjalla, CEO of Associated Engineering Services, Hyderabad and the Vice chairman of ISNT, Hyderabad Surya prakash gajjalla did his vocational education in automobile technology in the year 1987 and went on to pursue his diploma in Mechanical Engineering in 1991. He completed his graduation in 2015 through distance education. He is today the proud recipient of Gold Award for outstanding entrepreneur in skill development after pursuing Vocational Education for the second year in a row. Receiving the award from Shri Rajeev Pratap Rudy, Union Minister of State for skill development
Surya Prakash Gajjalla is also the recipient of national award for the year 2012-2013 in the category of outstanding entrepreneur in MSME category. Today we all are proud to say that NDT as a skill has brought him the national recognition and has made the ISNT community proud.
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ISNT CORNER
AWARDS & AWARDEES
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Shri D.S Kushwah Chairman, ISNT-Ahmedabad Chapter, NDT Services, 1st Floor, Motilal Estate, Bhairavnath Road Maninagar, Ahmedabad: 380028 dskushwah@vsnl.net /deepak@ndtservices.co.in
Dr B. Venkatraman Chairman-ISNT-Kalpakkam Chapter Associate Director, (RSEG) Indira Gandhi Centre for Atomic Research, Kalpakkam-603 102 bvenkat@igcar.gov.in /qadbvr@gmail.com
Shri Rajeev Vaghmare Hon. Secretary, ISNT-Ahmedabad Chapter, C/o. Modsonic Instruments Mfg.co. Pvt. Ltd., Plot No.33, Phase III, GIDC Industrial Estate, Naroda, Ahmedabad - 382 330 modsonic@modsonic.com
Shri M. Dhanajeya Kumar Hon. Secretary, ISNT-Kalpakkam Chapter IGAR, Kalpakkam – 603 102 mdjkumar@igcar.gov.in
Shri V. Manoharan Chairman, ISNT-Bangalore Chapter GE (Global Research) John F Welch Technology Center122, EPIP, Whitefield Road, Bangalore- 560 061 Manoharan.V@ge.com Shri S. Kalyanasundaram Hon. Secretary, ISNT-Bangalore Chapter Principal Scientist Structural Technologies Division, CSIR - National Aerospace Laboratories Bangalore - 560 017 kalyanasunder@gmail.com isntblr@gmail.com Dr. Krishnan Balasubramaniam Chairman, ISNT-Chennai Chapter Dean & Professor of Mechanical Engineering, Head of Centre for Non Destructive Evaluation, "MEMH/MDS 301, Department of Mechanical Engineering" Indian Institute of Technology (IITM), Chennai – 600 036 balas@iitm.ac.in Shri S.R. Ravindran Hon. Secretary, ISNT-Chennai Chapter Executive Engineer, QA, Nuclear Power Corporation Limited, No.51, Montieth Road, Egmore, Chennai – 600 008. npcsrr@gmail.com Shri A.K. Pawar Chairman, ISNT-Delhi Chapter D-155 Sector -49, NOIDA -201301 (UP) itenoida@gmail.com Shri T. Kamaraj Hon. Secretary, ISNT-Delhi Chapter 799-Pocket - V, Mayur Vihar Phase - I, Delhi – 110091 isntdelhi@gmail.com /inicondt@yahoo.com Shri P. Mohan Chairman, ISNT-Hyderabad Chapter Metsonic Engineers ( P ) Ltd No, 63, Ishaq colony, Wellington Road, Secunderabad, Telangana - 500015 metsonic.engineers@gmail.com Shri M. Venkata Reddy Hon. Secretary, ISNT-Hyderabad Chapter Scientist, NDE Division, Defence R&D Laboratory Kanchanbagh, Hyderabad, Telangana-500058 mallu.venkatareddy@gmail.com Dr. A. Mitra Chairman, ISNT-Jamshedpur Chapter amitra@nmlindia.org Shri T.K. Das Hon. Secretary, ISNT-Jamshedpur Chapter Scientist, CSIR-National Metallurgical Laboratory Jamshedpur 831007. tkdas@nmlindia.org
Shri C.K. Soman Chairman, ISNTKochi Chapter, Dy. General Manager (P & U), Bharat Petroleum Corp. Ltd., (Kochi Refinery) P.O, Ambalamugal: 682302, Kochi somanck@bharatpetroleum.in Shri V. Sathyan Hon. Secretary, ISNT-Kochi Chapter, Chief Manager (SHA) Bharat Petroleum Corporation Ltd.Kochi Refinery P.O, Ambalamugal, Kochi-682302 sathyanv@bharatpetroleum.in Shri Dipankar Gautam Hon. Secretary, ISNT-Kolkata Chapter, Engineering Inspection Bureau, AB-121, Salt Lake, Kolkata-700 064 eib1956@gmail.com / dgautam1956@gmail.com Shri Hemant Madhukar Chairman, ISNT-Mumbai Chapter B-401/ 402, Raylon Arcade, Ramkrishna Mandir Road, Kondivita, J.B. Nagar, Andheri (East), Mumbai-400 059 metalanalysis1997@gmail.com Shri Samir K. Choksi Hon. Secretary, ISNT-Mumbai Chapter Choksi Imaging Ltd. Plot No.26, C Wing, 4th floor, Mahal Industrial Estate, Andheri (East), Mumbai - 400 093 choksiindia@yahoo.co.in Shri Jeevan Ghime Chairman, ISNT-Nagpur Chapter M/s. Becquerel Industries Pvt. Ltd. 33, Rushikesh Modern Co-op. Hsg. Society Ingole Nagar, Wardha Road, Nagpur - 440005 jeevan@biplndt.com
Shri P.G. Behere Chairman, ISNT-Tarapur Chapter E/25/1 BARC Colony, Boisar Dist. Thane, AFFF, BARC Tarapur-401504, Maharashtra pgbehere1@rediffmail.com / pgbehere@barctara.gov.in Shri Jamal Akhtar Hon. Secretary, ISNT-Tarapur Chapter Type D, U – 6, TAPS 1& 2, Colony Boisar, NPCIL, Dist. Thane, Tarapur-401504 jakhtar@npcil.co.in Shri. J. Kannan Chairman, ISNT-Trichy Chapter, No-20, Bharath Gardenia 12th cross street (West), Balaji Nagar, Kattur Tiruchirapalli - 620019 jkannanjayanthi@gmail.com Shri V. Deepesh Hon. Secretary, ISNT-Trichy Chapter, D-4 - 180, Kailasapuram, BHEL Township Trichirapalli - 620014 secyisnttry@gmail.com Shri G. Levin Chairman-ISNT-Trivandrum Chapter Group Director, PRG/PRSO, TERLS AREA VSSC, ISRO P.O, Trivandrum-695022 g_levin@vssc.gov.in / gopal_levin@yahoo.com Shri Shanmughavel Hon. Secretary, ISNT-Trivandrum Chapter SCI/ENGR SE, QCM/QCG/MME, RFF AREA VSSC, ISRO P.O. Trivandrum - 695022 a_shanmugavel@vssc.gov.in / isnttvm@gmail.com Ms. Hemal Mehta Chairman - ISNT-Vadodara Chapter C/o. P-MET HIGH-TECH COMPANY PVT. LTD. 1-5/6, Industrial Estate, Gorwa, Vadodara-390 016, Gujarat mehtapmet@gmail.com Shri Jaidev Patel Hon. Secretary, ISNT-Vadodara Chapter C/o TCR Advanced Engineering Pvt. Ltd. 250-252/9, GIDC Estate, Makarpura, Naren Hardware lane, Vadodara-390010, Gujarat jaidev@tcradvanced.com / jaipatel74@rediffmail.com Shri Ambresh Bahl Chairman, ISNT-Kota Chapter CE (QA), RR Site, NPCIL, PO – Anushakti, via – Kota, abahl@npcil.co.in
Shri Parag W. Pathak Hon. Secretary, ISNT-Nagpur Chapter M/s. NDT Solutions Saket - Pruthvi Appt. Plot No-. A+ B, Second Floor, Surendra Nagar, Nagpur - 440015 paragwpathak@yahoo.com
Shri Surendra Kumar Verma Hon. Secretary, ISNT-Kota Chapter, QAS, RR Site, Unit – 5 & 6, NPCIL, PO – Anushakti, Via: Kota (Rajasthan) - 323 307 surendrakverma@npcil.co.in
Shri M. S. Shendkar Chairman, ISNT-Pune Chapter Sonal Industrial Services, Sr. no. 415/1B, Manimangal Society, B-103, Near Siddharth motors, Kasarwadi, Pune-411034. sisndt@yahoo.com
Shri V. Ranganathan Chairman, ISNT-Sriharikota Chapter Chief General Manager, Solid Propellant Plant, SDSC – SHAR, Sriharikota – 524124 vranga@shar.gov.in
Mr. Uday B. Kale Hon. Secretary, ISNT-Pune Chapter KUB Quality Services Plot No 55, Scheme No 4, Sector 21, Yamunanagar, Nigdi, Pune-411044. anay2000@gmail.com secretary@isntpune.org.in
Shri B. Karthikeyan Hon. Secretary, ISNT-Sriharikota Chapter Sci/Eng. NDT/SPROB, SDSC – SHAR, Sriharikota – 524124 Ph:- 08623-223076,223382 karthikeyan.b@shar.gov.in
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CHAPTER SPACE
Chapter Chairmen & Secretary
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CHAPTER SPACE
CHAPTER NEWS MUMBAI – 01.07.2015 – 30.03.2016 MT Level- II Course and Examination Conducted by Mumbai Chapter. Shri L. M. Tolani was the course Director and Shri N. Sadasivan was the Examiner for the course. UT Level- II Course and Examination conducted for ONGC Engineers on 27th July to 1st August 2015. Shri Ashok Trivedi was the Course Director and Shri N. Sadasivan and Shri D. K. Sharma were the Examiners. NDT for Managers course to be conducted from 15-19, February 2016 for AERB Engineers. Shri L. M. Tolani will be the course Director. Training program on Testing of Electrical Equipment to be held at ISNT, Mumbai from 2229, February 2016 for ONGC Engineers. Shri R. S. Vaghasiya will be the course Director. Training Programme for RT Level- II (ASNT) to be conducted from 14-19, March 2016. For ONGC Engineers at ISNT, Mumbai. Shri Amar Pathare will be the course Director. Welding Inspector course to be conducted from 14-30, March (only 11 days) 2016 for AERB Engineers. Shri L. M. Tolani will be the Course Director. General NDT course to be conducted from 28th March to 1st April 2016 for ONGC Engineers. Shri L. M. Tolani will be the course Director. We have conducted one day conference, Exhibition and AGM on 10th October 2015 at Hotel VITS, Andheri. In this conference three lectures were
delivered on TOFD, Phase Array & Computer / Digital Radiography by following speakers- Shri Paritosh Nanekar, Shri Arvind Bhide and Shri V. Manoharan. Ten Organisations took part in Exhibition. After this Conference and Exhibition we have also conducted AGM 2015. Approx. 130 participants attended this conference. Office bearers / Core committee meeting held on 14th August 2015.
PUNE CHAPTER- 01/11/2015 TO 29/02/2016 Course for various methods were conducted from 30th December 2015 to 21st January 2016. Total 29 participants in 45 methods attended the course. The ASNT Level III examinations were conducted from 27th January to 29th January 2016. The results of this refresher course were encouraging with almost 85% passing rate. The following were course coordinators for the course a. Mr. Kalesh Nerurkar ( Course Director ) b. Mr. Sunil Gophan ( Basic ) c. Mr. Chintamani Khade ( UT )
d. Mr. B K Pangare ( RT ) e. Mrs. Sangita Kapote ( MT ) f. Mr. Vivek Kavishwar ( ET ) g. Mr. Kalesh Nerurkar ( PT ) h. Mr. Uday B Kale ( VT )
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1. Mr. Sagar Bapat ( Basic ) 2. Mr. Milind Shinde ( Basic ) 3. Mr. L Venkatraman ( UT ) 4. Mr. B B Mate ( Basic, VT ) 5. Mr. Sudhir Phansalkar ( Basic ) 6. Mr. B K Shah ( Basic ) 7. Mr. Arvind Bhide ( Basic , ET ) 8. Mr. Vishwakarma (RT) 9. Mr. Chintamani Khade ( Basic, RT, UT, PT, ET) 10. Mr. Bikash Ghose ( RT, UT ) 11. Mr. Uday B Kale (Basic, PT, MT, UT ) 1.
Technical Lecture :
A Technical Lecture on “Importance of ASME Section V in NDE and changes in Edition 2015 “ was delivered by Mr. D D Joshi on 13th January 2016. About 55 members attended the lecture. The lecture was well received by the members.
The faculties from ISNT Pune Chapter were : Mr. Kalesh Nerurkar (Course Director, PT and MT) Mr. Uday B Kale (VT and Careers IN NDT) Mr. Rahul Kulkarni (UT) Mr. Parag Pangare (RT) 3.
Other Activities : Introductory Workshop on NDT for Bharati Vidyapeeth, Jawaharlal Institute of Technology, Pune was conducted on 9th and 10th February 2016. About 125 students attended this program. The faculties from ISNT Pune Chapter were : Mr. Mandar Vinze ( Course Director) Mr. B B Mate (UT) Mr. Sarang Matade (VT) Mr. Sunil Gophan(PT) Mr. Biradar ( ET ) Mrs. Savita Itkarkar ( MT ) Mr. Bikash Ghose (RT ) 2.
Workshop on NDT for Annasaheb Dange College of Engineering and Technology, Ashta was conducted on 26th and 27th February 2016.
This workshop was attended by about 100 students of Engineering.
Presentation of IS 13805 Revision Project :
A presentation to NCB members on proposed changes to IS 13805 – 2004 was presented by Team Members of ISNT Pune Chapter on 29th January 2016. Mr. B Venkatraman and Mr. Paritosh Nanekar attended the same. IS 13805 is to be revised taking into consideration ISO 9712 and SNT TC 1A in the international scenario. The proposed draft is circulated to other NCB members by Mr. Paritosh Nanekar to have their views and comments. After receiving comments it will be presented in NCB for approval of draft and then will be submitted to BIS committee for consideration. The following were the persons from ISNT Pune Chapter who contributed in this project 1. 2. 3. 4. 5.
Mr. Mr. Mr. Mr. Mr.
Chintamani Khade ( Team Leader ) D D Joshi Jayprakash Hiremath Kalesh Nerurkar Uday B Kale
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CHAPTER SPACE
The following were supporting faculty members
CHAPTER SPACE
JNDE MARCH 2016
TRIVANDRUM - 01/11/201 5 TO 29/02/2016 Two days Foundation course on NDT – 30 & 31/10/15. Dr. K.Sivan, Director, VSSC inaugurated. Around 70 people participated. Both theoretical & practical classes were arranged by faculty from ISRO. Engineering & Technology, Trivandrum. Faculty from ISNT Trivandrum delivered lectures at the program. 1. 14.10.15; Talk on “State of the art Thermal / Infrared NDT&E for detection of subsurface defects and their properties” by Dr. Ravibabu Mulaveesala, Assistant Professor, Department of Electrical Engineering, Indian Institute of Technology – Ropar. 2. 04.02.16 Presentations on “Advanced NDT Technologies” by GE Inspection Technologies Lectures on Advanced radiography, Advanced Ultrasonics & Remote visual inspection were delivered by experts from GE Inspection Technologies. The event was coordinated by M/s. CMos processors, Chennai. DELHI - 01/12/2015 TO 29/02/2016 Executive committee meeting held on 9/1/2016, discussed future activities of the chapter, decided to hold AGM and election to elect new EC and office bearers on 6/3/2016 at our new
office. EC also decided to inaugurate the new office on 24/1/2016. The new office of ISNT Delhi Chapter inaugurated on 24/1/2016 which was attended by EC and chapter members.
OBITUARY “With deep sorrow, we regret to inform that President Elect of ISNT and our Beloved friend Mr. Swapan Chakraborty has le for heavenly abode on 7th Feb 2016. He was a very affec onate person and his contribu on to ISNT & NDT Profession was excep onal. He will always remain in the hearts of all the members of ISNT. On behalf of ISNT, we pray to almighty that his soul may rest in peace & all his near ones and well wishers get the strength and courage to withstand this great loss. 16 | ————————————————————————JOURNAL OF NON DESTRUCTIVE TESTING & EVALUATION
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JNDE MARCH 2016
ACCERDITED BY NATIONAL CERTIFICATION BOARD OF ISNT
Insight Quality Service Training
Consultancy
Inspection
NDE
___________________________________________________________________________________ API PREPARATORY TRAINING SCHEDULE MARCH TO JULY 2016
API 571 (Corrosion and Materials Professional) Preparatory Program API 577 (Welding Inspection and Metallurgy Professional) Preparatory Program API 580 (Risk Based Inspection Professional ) Preparatory Program API SIFE – Source Inspector Fixed Equipment Preparatory Program API 510 (Pressure Vessel Inspector) Preparatory Program API 570 (Piping Inspector) Preparatory Program API 653 (Aboveground Storage Tanks Inspector) Preparatory Program TRAINING COURSE Certification Courses in NDE Level II (RT,PT,UT,MT,VT,LT,ET) NDT Level III Preparatory (RT,PT,UT,MT,VT,LT,ET) EN ISO 9712 Level 2 & 3 Preparatory (RT,PT,UT,MT,VT) Welding inspectors / Welders, QC managers’ certification CWI / AWS preparatory, Fabrication Inspector CSWIP 3.0, 3.1, & 3.2 Training Internal Auditor, ISO 9000 Awareness ASME codes awareness, NDT Awareness Preparatory for API (510, 570, 653, 580, 577,571,SIFE) Computerized mock exams for API modules INSPECTION SERVICES Pressure vessels, Heat exchangers, Storage tanks, Casting, Forging, Static & rotary equipment, Pumps & Valves, Equipment of nuclear projects SHUTDOWN INSPECTIONS Team of managers and inspection Engineers for Shutdown Inspections
7th March to 10th March 4th April to 7th April 11th March to 13th March 31st March to 2nd April 14th March to 16th March 28th March to 30th March 17th March to 21st March 22th March to 26th March 18th April to 24th April 25th April to 02nd May 16th May to 21st May 23rd May to 28th May 20th June to 25th June 27th June to 2nd July
At Chennai At Pune At Chennai At Pune At Chennai At Pune At Chennai At Pune At Pune At Chennai At Pune At Chennai At Pune At Chennai
CONSULTANCY SERVICES ASME Certification ( U, R, U2, S, N, PP Stamps) Preparatory work ISO 9001,ISO 14001,OHSAS 18001 Certification preparatory work Developing ISO 9000 - quality manuals Setting up NDT labs, Procedures & Work Instructions Welding procedures & Welders’ review / approval Vendors assessment & development Developing QA / QC systems Setting up internal quality systems Quality & Safety audits (HSE) Liaison with third party / statutory inspection agencies NDT SERVICES NDE services for VT, PT,MT,UT and RT film interpretation as per NDE Level II OR EN ISO 9712 Level 2. WELDING TRAINING AND TESTING CENTER Basic and Advanced Level Programs in SMAW, GTAW
Mr. Diwakar D. Joshi (Director) - ASNT Level III (RT, UT, MT, PT, LT, ET, VT) – Cert. No. 60893, ACCP Level III (RT, UT, MT, PT,VT), RWTUV Certified Level III (RT+UT+MT+PT), Senior Certified Welding Inspector (SCWI), API 510 Pressure Vessel Inspector, API 653 Aboveground Storage Tank Inspector, API 570 Authorized Piping Inspector, API 571, API 577, API 580, Tank Entry Supervisor (TES), API 936 Inspector, API SIFE Source Inspector Fixed Equipment.
Insight Global FZE P.O. Box no. 4422 Fujairah, U.A.E. Mobile – (+971) 0563016586, 0563478926 Phone – 09-2283556 E mail :– insightglobal@iqs-ndt.org
Insight Welding Training & Testing Center Gala No.211, 212, 213, 2nd Floor, Yashada Industrial Complex, Survey No.50/40 to 43, Narhe-Ambegaon Road, Pune – 411041 Mobile: 9881244118, Tel: 020-24390501 Email : training@iqs-ndt.org Insight Quality Services Office 507, 508, 5th Floor, Building No.1, Siddharth Towers, S.No.12 / 3B, Near Sangam Press, Kothrud, Pune 411 029. Maharashtra (INDIA) Ph.: + 91 - 20 - 2546 4388 / 2546 0894 Mb.: 09689928561 / 09881244118 Email : support@iqs-ndt.org Website : www.iqs-ndt.org “It is good to have Education, It is Better to have Experience, butOFit NON is essential to haveTESTING Training!” DESTRUCTIVE & EVALUATION 18 | ————————————————————————JOURNAL
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Level-II courses (SNT-TC-1A)
Level-III Refresher Course
“SIX SIGMA – AN OVERVIEW” By Shri.R.SAIKUMAR Quality / Best Business Practice Leader M/s. Johnson Controls Inc, Michigan, USA
ISNT Chennai Chapter is organizing ISNT-TC1A Training & Certification on Leak Testing Level-II between 18th April 2016 to 22nd and examination on 23rd April 2016.
Venue: At ISNT, Conference Hall on 19th July'2015.
AGM was held on 25.07.2015 in a grand manner. 70 members attended the meeting. Returning Officer Dr.G.S.Kandasamy announced the New Executive Committee Members for the year 2015-2016. Dr.Krishnan Balasubramaniam gave a speech after taking charge of new Chairman. Mementos were given to all the members present. Outgoing Chairman Mr.N.Balakrishnan and Outgoing Treasurer Mr.T.V.Navanithakrishan were honoured during AGM.
Level-II courses "RESISTANCE WELDING ON AUTOMOBILE COMPONENTS" By Mr. Stefan Schreiber GSI SLV Duisburg, Germany Venue : Jointly with ASM and MMS at Hotel Radha Regent, Chennai on 10th October'2015 (IS 13805) THIRUVANANTHAPURAM - 01/10/2015 TO 18/02/16 30, 31/10/15 “Foundation course on NDT” at Hotel Classic Avenue, Trivandrum. Basics of all techniques of NDT covered by experienced faculty of ISRO. Around 50 delegates participated. 14/10/15 - Technical talk by the Young Engineers forum of ISNT Trivandrum Chapter at Hotel Nandanam Park, Trivandrum. Dr. Ravibabu, Asst. Prof., IIT Rupar delivered a talk on “State of the art Thermal / Infrared NDT&E for detection of Sub-surface defects”. The talk was well attended by 50 members of ISNT. EC meeting was conducted to review the proposal for NDE 2016. 03/12/15 & 21/12/15 EC meetings. Preliminary discussions on NDE 2016 & committee formation, theme finalization. 22/01/16 Technical Talk on “Proof Pressure Testing” by Shri. Yezhil Arasu, VSSC. At the same function, NDE 2015 awardees of Trivandrum chapter were felicitated. Around 60 members participated.
28/01/16 EC meeting with identified sub committees chairmen. Discussion on brochure, website etc. 05/02/16 One day Workshop on NDE was conducted at Rajadhani College of Engineering & Technology, Trivandrum. Faculty from ISNT Trivandrum delivered lectures at the program. 04/02/16 Technical presentations on Advanced radiography, Advanced Ultrasonics & Remote visual inspection were delivered by experts from GE Inspection Technologies. The event was coordinated by M/s. CMos processors, Chennai. 18/02/16 First meeting of Local Organising Committee of NDE 2016 held Discussions held on the formation of advisory committee, national organising committee, website & Brochure.
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CHAPTER SPACE
CHENNAI - 04/12/2015 TO 01/02/2016
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History of Pune Chapter: ISNT Pune Chapter is existing for more than 36 years and is catering services to Pune Industries. ISNT Pune Chapter Supports Pune Industries by Technical Lectures, Workshops, National Seminars, Field trips, Training and Certification, Special Group Projects Like:- 1) Developing Standards, 2) Training Trainers & Examiners & last but not the least, Training in Engineering Colleges for Students. Geographical Location and Industrial Scenario: Pune is famous for having world class education facilities and has grown as an Automobile and IT hub during last few years. Bharat Forge, TATA Motors, Alfa Laval , Thyssen Krupp etc are the names of industries who cater to variety of products. Major Defense Establishment like DRDO, HEMRL, ARDE are located in and near Pune. ISNT Pune chapter has more numbers of ASNT Level III personnel with hands on experience in various industrial sectors and also in training in India & Abroad. ISNT Pune Chapter functions in synchronization with other local chapters like Indian Institute of Foundry men, American Society for Materials International, Pune Chapter, International Institute of Welding etc. Not only NDE service providers, NDE equipment & consumables manufacturers and end users and Government Officials Third Party agencies are active members of Pune chapter.
Activities in the past: To name a few, the following activities/programs were taken up by ISNT Pune Chapter in the past. S.N.
Activity/Program
Year
1.
Training & Certification Seminar
1992
2.
NDT Examiners Workshop
1999
3.
Publishing of NDT Directory
2002
4.
ASNT Level III Refresher Course 2003 and Examination
5.
NDE Seminar and Exhibition
6.
ISNT Level III Refresher Course 2013 and Examination
7.
ASNT Level III Refresher Course 2014 and Examination
8.
ASNT LT Level III Refresher 2014 course for the first time (Result> 85%)2014
9.
NDT Examiners Workshop
2004
2014
10.
Back to Basics Lecture Series 2014 (4 years Program)
11.
NDE Seminar and Exhibition
12.
First ISNT LT Level III Course and 2015 Examination
13.
Question Bank Generation 2015 Project for NCB (General and Specific)
14.
IS 13805 Revision Project
15.
ASNT Level III Refresher Course 2016 and Examination
2015
2016
Activities in hand: As of now there are many activities which are being done as part of social commitment and to excel chapter progress. They are as follows: •
Membership Drive: The major focus is to encourage industry to have their active participation by taking Corporate or Life Corporate Memberships. We will be also focusing on getting Student Membership from Engineering Colleges by giving them Workshop on NDT and similar other knowledge sharing seminars.
•
ISO 9001 Certification
•
NCB Accreditation of Chapter: ISNT Pune Chapter wants to go for NCB Accreditation in Training for NDT Level I and NDT Level II personnel. We want to achieve it until end of February 2016.
•
Office Space for the Chapter: There was a dream to have an office space for last 10 years or so. ISNT Pune Chapter with the help of ISNT HO has purchased an office space in Pune admeasuring 358 sq. feet.
•
NDT Qualification for College Students: ISNT Pune Chapter has taken responsibility to prepare a Written Practice for this purpose and will also take into consideration of IS 13805 for Experience, Training, Examination and Certification. So far we have trained more than 1000 college students in General NDT in last 3 years.
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CHAPTER FOCUS
CHAPTER FOCUS: PUNE
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•
National Workshop on Calibration of NDT Equipment
•
ISNT and ASNT Level III Examinations: By conducting refresher courses and assist in examinations at any point of time.
•
Train the Trainers Program
•
Standardization of Course Notes and Presentation : ISNT Pune Chapter wish to develop standardized notes for NDT Level II course taking into consideration IS 13805 prescribed syllabus. EC members feel that this project is to be given to young ASNT Level III of ISNT Pune Chapters with senior members overseeing the project. This will help in maintaining standardization with respect to course notes and presentations for these course notes.
•
Online Examination Module for Level III/Level II
Question Bank Generation Project '2015 Milestones Achieved •
ISNT Best Chapter Award
•
Question Bank Specific),
•
IS 13805 Revision Project,
•
Examiners Workshop and one of our member has been appointed as Regional Controller of Examination (Western Region)
Generation
Project
(General
and
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CHAPTER FOCUS
Future Plans:
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QUANTITATIVE NDE FOR MATERIALS CHARACTERIZATION AND CONDITION MONITORING OF ENGINEERING COMPONENTS (QNDEMC -16, FEBRUARY 03, 2016) Jointly organised by CSIR - National Metallurgical Laboratory, Jamshedpur & ISNT, Jamshedpur Chapter he workshop on “Quantitative NDE for Materials Characterization and Condition Monitoring of Engineering Components (QNDEMC -16)” was jointly organized by CSIRNational Metallurgical Laboratory, Jamshedpur and ISNT Jamshedpur Chapter on February 03, 2016 at CSIR- National Metallurgical Laboratory, Jamshedpur. The prime objective of the workshop was to provide participants an opportunity to know the latest developments in NDE techniques for quantifying damages in materials for integrity assessment and condition monitoring of engineering components. Emphasis has been given to attract students so that they can be inspired to take Research on NDE as their future carrier. Eminent NDE personalities (from India & abroad) from academic institutions, Corporate and Government R&D Laboratories and NDE service provider were among the faculty members of the workshop. Among 40 delegates, 24 were students from institutions like Indian Institute of Technology, Kharagpur; Indian Institute Engineering Science & Technology, Shibpur, West Bengal; National Institute of Technology, Jamshedpur and Tiruchirappalli ; Jharkhand Central University; ISM-Dhanbad; O P Jindal Institute of Technology, Raigarh. In his inaugural address Dr. S. Srikanth, Director, CSIR – National Metallurgical Laboratory told about the role of NDE technology for engineering critical assessment of materials. The following lectures were delivered:
T
1. “Non-destructive non-contact microstructural characterization using electromagnetic sensors” by Prof. Claire Davis, University of Warwick, UK 2. “NDE for Materials Characterization and Condition Monitoring of Engineering Components : Advanced Tools, Techniques and
Enablers” By Dr.Shyamsunder Mandayam, GE Global Research Center, Bangalore. 3. “Non-destructive quantification of defects and microstructure in complex steels using ultrasonic-based techniques” Prof. M Strangwood, University of Birmingham, UK 4. “Diagnostic and therapeutic ultrasound in materials” by Dr. Sarmishtha Palit Sagar, CSIR-National Metallurgical Laboratory, Jamshedpur 5. “Condition assessment of critical components in steel industry using Quantitative NDE” by Mr. S. Balamurugan, TATA STEEL 6. “Infrared thermography and its applications in Blast Furnace with its periphery of steel plant” by Mr. A.K.Paul, TATA STEEL 7. “Long Range Ultrasonic Testing (LRUT) of pipelines & piping” by Mr.Sheetal Sasidharan, Sievert India Pvt. Ltd 8. “NDE Techniques for Evaluation of Residual Stress” by Dr. A.K.Panda, CSIR-National Metallurgical Laboratory, Jamshedpur
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BRIEF REPORT
A brief report of the Workshop on
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JNDE ON THE GO E-Version
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We would like you to share your knowledge by sharing some tips related to NDT industry, share exam tips. Send your entries to isnt.jnde@gmail. ——JOURNAL OFF NON — NON DES DESTRUCTIVE ESSTR TRUC UCTI UC TIVE TI VE TTE TESTING ESTING NG & EVALUATION 26 | ————————————————————————JOURNAL com.
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There were good interaction between the participants and the speakers. After the lecture laboratory visit took place which includes Mechanical Metallurgy, Microstructure and NDE facility. In the valedictory session the
participants felt that this type of workshop should be carried out at regular interval. Some delegates expressed the inclusion of new generation NDE technology in the deliberation of the workshop. It was felt that the technique like acoustic emission was not covered in the discussion which is one of the major tools for condition monitoring. The workshop was ended with vote of thanks by the chapter chairman.
Let's Hear from You What's New covers Technical Talk, Technical Papers / Articles, Press Releases & New Product Information related to NDT Community. JNDE invites you to write in and send your contributions / submissions to isnt.jnde@gmail.com at least 2 months before Publishing date of JNDE.
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BRIEF REPORT
9. Electromagnetic sensor for characterization of stainless steel subjected to carburization” by Dr. Amitava Mitra, CSIR-National Metallurgical Laboratory, Jamshedpur
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Gareth James PhD Simpleware Ltd., Bradninch Hall, Castle Street, Exeter, EX4 3PL, UK
ABSTRACT This paper will explore the software techniques and typical workflows associated with non-destructive testing (NDT) and reverse engineering from Computed Tomography (CT). The aim is to demonstrate how 3D image data of this type provides a valuable source for visualising and analysing the material properties of scanned industrial samples, and how this approach can be extended to physics-based simulation techniques such as Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD). Examples will be given of the successful applications of these and other techniques in the non-destructive testing of an automotive engine using Simpleware software.
I. INTRODUCTION Image-based computational modelling for analysing parts and components offers benefits in terms of being able to carry out detailed analysis of material properties and microstructure at different manufacturing, inspection and testing stages [1, 2]. Researchers and analysts can use software to create robust virtual models from 3D image data like CT and MicroComputed Tomography (micro-CT) for analysis and simulation. With image-based workflows, it is possible to visualise, segment, quantify and export models based on scans for simulation and other processes such as Additive Manufacturing. The addition of FEA and CFD steps to this work flow is particularly important for better understanding the performance of parts under expected conditions [3], with applications to industries such as automotive, aerospace and defence. II. TYPICAL WORKFLOWS BASED MODELLING
FOR
IMAGE-
Typical workflows involve obtaining volume data from a CT scanner, and reconstructing a geometry using image processing software like ScanIP (Simpleware Ltd., UK). At this stage, 3D image data can be processed to segment out regions of interest, including pore networks and any cracks or defects within the part, as shown in Figure 1. This approach is valuable for rapidly inspecting components, whereby the reverse engineering of components from image data can reveal previously unknown or under-analysed errors from the manufacturing process.
Fig. 1 : Example of manifold with internal defects
Moreover, image-based statistics and measurements tools can obtain information on defect sizes and distribution statistics to better understand the structure of scanned parts; this is useful for understanding how and why they might display quality problems during later design and manufacturing stages. The generation of multi-part FEA and CFD meshes, or numerical models, is crucial to this process, as it provides an additional step for analysis that extends image data visualisation and analysis into simulation of physical properties. III. GENERATING MODELS FOR SIMULATION Meshing techniques developed at Simpleware are particularly robust for generating numerical models of complex multi-part geometries suitable for analysis of defects, part durability and fluid-structure relationships. The image-based
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technical papers
NON-DESTRUCTIVE TESTING AND REVERSE ENGINEERING FROM COMPUTED TOMOGRAPHY
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Fig. 2 : Meshes generated of engine manifold
To segment the valves from the cylinder head, thresholding tools were used to separate the engine and the valve seat as image masks. However, at this point there was still noise and small connections between the individual parts that required further editing. 3D editing tools were employed to work on these specific features and more precisely isolate the preferred regions of interest. Surface highlighting was used to confirm the affected regions, while a morphological open filter was applied to the 3D ROI to clearly and more accurately segment the valves from the cylinder head of the engine.
meshing approach used in Simpleware software applies an ‘Enhanced Volumetric Marching Cubes’ (EVoMaCs) algorithm; this adapts the marching cubes algorithm [4] to support the meshing of multiple segmentation domains, and can be combined with a multi-part surface remeshing method that allows voxel-based meshes to be effectively decimated according to the size and complexity of local features [5]. Examples of different meshes are given in Figure 2.
Having prepared the image data, the crucial next step in the project was to convert the segmented geometry into a multi-part mesh suitable for FEA. The ability to go from multi-part image data to a simulation-ready mesh is crucial to enabling a straightforward non-destructive testing workflow from scan to FEA. In this case, the meshed engine was imported to the solver LS-DYNA (Livermore Software Technology Corporation, USA) for a preliminary analysis of
IV. APPLICATION: REVERSE ENGINEERING OF AN AUTOMOTIVE ENGINEERING Researchers at the JSOL Corporation in Japan have used image-based techniques for nondestructive testing and reverse engineering of an automotive engine from a CT scan [6]. The goal of the project was to evaluate the influence of voids in the engine on its performance. CT data measuring 0.4 mm x 0.4 mm x 0.5 mm in resolution was acquired and loaded in Simpleware ScanIP software. At this stage, the researchers were able to visualise the engine in 2D and 3D, while also using volume rendering, opacity and colour mapping tools to reconstruct the geometry of the image data. Fig. 4 : Analysis of the impact caused by the presence or absence of voids
Fig. 3 : 3D editing of valve seats from engine CT data
the impact caused by the presence or absence of voids in the cylinder head after casting in aluminium. As shown in Figure 4, comparisons were made of the principal stresses around the void for cases where a void was present or absent, while the influence of intake and exhaust temperature was taken into account. Using this approach, the researchers were able to collect qualitative and quantitative information from the scanned engine without having to rely on destructive testing.
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CONCLUSIONS Reverse engineering CT data for non-destructive testing provides a method for obtaining valuable information from scans. Being able to virtually evaluate material samples and experiment with different designs allows for the diversification of manufacturing research and development; by using FEA as a significant step in testing workflows, researchers and analysts can complement and reduce the cost of extensive physical testing. The image-based techniques discussed here and implemented into Simpleware software demonstrate the ease by which nondestructive workflows can be set up using image data like CT. REFERENCES 1. Felice, M.V., Velichko, A., Wilcox, P.D., Barden, T., Dunhill, T., 2014. Obtaining geometries of real cracks and using an efficient finite element method to simulate their ultrasonic array response. Insight - The Journal of the British Institute of Non-Destructive Testing, 2014.56(9): p. 492498.
2. Weglewski, W., Bochenek, K., Basista, M., Schubert, Th., Jehring, U., Litniewski, J., Mackiewicz, S., Comparative assessment of Young’s modulus measurements of metal-ceramic composites using mechanical and non-destructive tests and micro-CT based computational modeling. Computational Materials Science, 2013. 77: p. 19-30. 3. Abdul-Aziz, A., Integrating NDT with Computational Methods Such as Finite Element. Materials Evaluation, 2008. 66(1): p. 21-25. 4. Lorensen, W.E, Cline, H.E., Marching cubes: a high resolution 3D surface construction algorithm. Computer Graphics, 1987. (21): p. 163-169. 5. Young, P.G., Beresford-West, T.B.H., Coward, S.R.L., Notarberardino, B., Walker, B., AbdulAziz, A., An efficient approach to converting 3D image data into highly accurate computational models. Philosophical Transactions of the Royal Society A, 2008. 366: p. 3155-3173. 6. JSOL Corporation, Reverse Engineering Automotive Parts. November 2015. Available online at: http://simpleware.com/industries/ case-studies/show/?study=case-study-reverseengineering-automotive-parts.
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technical papers
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RADIOGRAPHY EVALUATION OF INVESTMENT CASTINGS FOR AEROSPACE APPLICATIONS M. Arumugam Group Head, Quality Control & Inspection Group, Systems Reliability and Quality Assurance, Liquid Propulsion Systems Centre, ISRO, Thiruvananthapuram -695 547.
1. INTRODUCTION Usage of Castings are unavoidable in many Engineering applications and Aerospace is not an exception. Considering the criticalities involved in size and shape, Investment castings are being used in Cryogenic propulsion systems. Investment casting process is one of the oldest casting process, though earlier it was used for very small castings, now it is used for larger size castings also. It is also called as Lost wax process. It is mainly used to produce complicated shapes that would be difficult or impossible with die/sand casting process and it require very little surface finishing/machining. Following figure explains the Investment casting process. sequence; Investment casting route is opted because of the following advantageous though it has some limitation in-terms of cost. Advantageous: 1. Excellent surface finish. 2. Close dimensional tolerances can achieved. 3. Complex and intricate shapes can produced. 4. Capability to cast thin walls.
be be
5. Useful for casting alloys that are difficult to machine. 6. No flash to be removed or parting line tolerances. 7. Low material waste. Disadvantageous: - Individual pattern is required for each casting. - Limited casting dimensions. - Relatively high cost (tooling cost, labor cost) 2. Classification of Casting defects and its causes Common casting defects classification and its causes are explained below; Four broad categories of Casting defects classification: - Defects due to Gas: Porosities and Gas holes. - Inclusions : High dense or low dense - Shrinkage based defects: Shrinkage Sponge, feathery/filamentary, dendritic, cavity. - Discrete discontinuities: Cracks, Hot tear, Insert, Misruns, Mottling, Cold shuts
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Casting defects
Causes
Defects due to Gas: Porosities and Gas holes
Entrapment of gas: Insufficient/Improper degassing of liquid metal, Interrupted / slow pouring, Inadequate metallostatic pressure, Use of rusty scrap, Moist conditions, Presence of liquid slag, Improper gating system &Turbulence while filling.
Foreign Material Inclusions: High dense or low dense
Entrapment of Foreign material: Low dense: Entrapment Slag from molten metal, shell or core material. High dense: Agglomeration of high dense metal without proper melting and distribution.
Shrinkage Shrinkage Shrinkage Shrinkage Shrinkage
Insufficient Molten metal feeding as Molten metal shrinks during solidification. Depending on the degree and nature, the classification differs.
based defects: Sponge, filamentary dendritic cavity.
Discrete discontinuities: Cracks, Hot tear, Misruns, Mottling, Cold shuts
Hot tear: Fracture that develops prior to completion of solidification due to restricted contraction-Open to surface. Cold crack: fracture that develops after solidification due to stress & hydrogen and it is also called as delayed cracking. Mis run: Molten metal solidifies before entire portion of the shell cavities. Cold shut: Improper directional solidification. Mottling: Diffraction created during Radiography inspection due to very coarse grains. for defects to supplement RT and to verify the adequacy of Gating system.
3. Radiography evaluation of Castings As we know the principle of Radiography inspection is differential absorption and due to this fact it is very much suitable for Castings inspection. Mostly X-ray radiography is preferred however for higher thickness castings, Gamma radiography is used. The Sensitivity achieved is 2-5%. Criticalities in Radiography inspection to ensure aerospace quality: -
It is very essential to evolve Shooting sketch to have maximum coverage, to maintain consistency and considering the design criticality.
-
To standardise the castings process, pilot batch samples used to be cut and evaluated Radiography evaluation of Welds
-
Un acceptable defect region are subjected to Weld repair as per the established WPS.
3.1 Difference between Radiography evaluation of Welds and Castings Unlike Weld radiography evaluation, in castings, the defects are not described with discrete sizes instead depending upon the size and distribution, defects are graded as per the standard ASTM reference radiographs. The following table gives the difference between Radiography evaluation of weld joints and Castings;
Radiography evaluation of Castings
Exact size and shape can be measured and Based on the size and distribution, defects reported. are graded. Size is reported for only discrete defects. 100% Radiography coverage is possible
Most of the cases 100% Radiography coverage is not possible.
No radiography shooting sketch is required
For every casting, procedure is required.
Radiography
exposure
For Internal defects, Complementary NDT It is very difficult use complementary NDT techniques like UT can be used. techniques like UT. Weld repair is an easy task
Casting weld repair is a tough task especially for Super alloy castings.
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3.2. Classification of Castings Considering the end use we follow guidelines given in Aerospace Material Specification AMS2175. Classification of Castings as per AMS2175 are given below; The "Casting Class" governs the frequency of inspection and controls the acceptance criteria. •
Class 1 - A casting, the single failure of which would endanger the lives of operating personnel, or cause the loss of a missile, aircraft, or other vehicle.
•
Class 2 - A casting, the single failure of which would result in a significant operational penalty. In the case of missiles, aircraft, and other vehicles, this includes loss of major components, unintentional release or inability to release armament stores, or failure of weapon installation components.
•
Class 3 - Castings not included in Class 1 or Class 2 and having a margin of safety of 200 percent or less.
•
Class 4 - Castings not included in Class 1 or Class 2 and having a margin of safety greater than 200 percent.
•
Grade A - The highest quality grade of casting, or area of a casting, with minimum allowable discontinuities and very difficult to produce except in local areas.
•
Grade B - The second highest quality grade of casting, or area of a casting, which allows slightly more discontinuities than Grade A, and difficult to produce, except in local areas.
•
Grade C - A high quality grade of casting, or area of a casting, that can be consistently produced.
•
Grade D - The lowest quality grade of a casting, or area of a casting, that is easily produced and is used primarily for low stress or noncritical areas adjacent to the higher graded areas.
•
Class 1 Casting Requirements: All areas of Class 1 castings shall be of a quality equivalent to or better than, Grade C, except that all highly stressed areas of a Class 1 casting shall be of a quality equivalent to, or better than, Grade B.
We do follow as per Class-1 requirement, but with an aim to achieve minimum Grade B in all region, however on selected non critical areas, Grade-C is permitted subject to the casting meeting design and Proof pressure test requirements. The following table gives the maximum permissible level of discontinuities as per AMS-2175. 3.3 ASTM reference radiographs List of some of the ASTM Reference Radiography standards are; E155 – castings
Aluminium
E186 – 114mm)
Heavy
and
walled
Magnesium steel
alloy
castings(50-
E192 – Investment castings for Aerospace appl. E242 – Appearance of Radiography images as certain parameters are changed. E272 – High strength Cu-Base & Ni-Cu alloys
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E280 – Heavy walled steel castings E310 – Tin bronze castings E390 – Steel fusion welds E431 – Semi conductors and related devices E446 – Steel castings up to 50mm thickness 4. Proof pressure testing Castings are always subjected to proof pressure testing (1.05-1.5times of the operating pressure) before further value addition. In some cases the design of castings are modified to accommodate fixtures for proof pressure testing.
For Individual defects:
•
Defect Identification
•
Cause identification
•
Remedy identification
The following photographs show some of the Investment castings successfully Indigenised and being used in ISRO’s space programme:
For defects over a Batch / period:
5. Process control and Product Inspection
-
Quality control Charts
As it is impossible to ensure 100% quality and Integrity of castings through radiography evaluation, process control plays a vital role in Castings, more so for Investment castings.
-
Defect frequency (Histogram)
-
Defect period)
spectrum
(pattern
over
a
5.1 Process Control
Expert systems are also used for defect analysis.
•
Monitoring all processing steps.
•
•
Chemical analysis & weighing of charge material, control of pattern and mould material, preparation of moulds & measurement of temp during melting & pouring.
•
Surveillance of process steps after establishing the desired quality level for consistency.
5.2 Product Quality control •
Accomplished Techniques
by
various
inspection
•
Pilot casting is made to assess quality and dimensional accuracy.
•
Acceptance and Qualification testing of pilot batch
•
Production clearance
•
Inspection of Production batch of Castings
6. Defect Analysis Defect analysis is being done to ascertain the process is controlled or not. Defect analysis is done based on the following;
Statistical process control (SPC) tools and Why? Why? Root cause analysis techniques were successfully used for evaluating the reasons for Radiographic defects observed in Investment castings used in Cryogenic propulsion engines.
7. Summary •
Radiography is the most effective NDT tool to detect internal discontinuities in Castings.
•
Unlike in Weld Radiography, In Casting Radiography, the size and distribution of the defects are considered and grades are defined accordingly as per the applicable ASTM reference radiography standards.
•
100% Radiography coverage of castings is impossible in most of the cases, hence - Structural test / Pressure test forms essential part of qualification & final acceptance.
•
Due to the aforesaid reasons, not only inspection but also the Process control forms the essential part of Castings qualification.
•
Foundry correction cycle can be effectively used for corrective and preventive measures.
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technical papers
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Neutron Diffraction: The State of Art in Non-invasive Stress-field Mapping Santosh Kumar1,2,a, Amrita Kundu3,b, K. A. Venkata4,c, A. Evans5,d, K. Bhanumurthy1,e, P. J. Bouchard3,f and G. K. Dey1,g Bhabha Atomic Research Centre, Mumbai, India Homi Bhabha National Institute, Mumbai, India 3 Materials Engineering, The Open University, Milton Keynes, MK7 6AA, UK 4 Department of Mechanical Engineering, University of Bristol, Bristol, BS8 1TR, UK 5 Institut Laue Langevin, Grenoble, France a santosh@barc.gov.in, b amrita.barc@gmail.com, c k.abburivenkata@bristol.ac.uk, d evans@ill.fr, e aditya@barc.gov.in, f John.Bouchard@open.ac.uk, g gkdey@barc.gov.in 1 2
ABSTRACT Internal self-equilibrated stress-fields (known as residual stresses) can develop in a component during different manufacturing steps and also under service conditions. Reliable knowledge of such stress-fields is essential for optimizing the manufacturing process, designing a component for the envisaged service conditions and determining the optimum operating conditions for a component given its design and the material properties. These stress-fields can be computed by modeling and simulation using finite element methods. However, reliable measurement of the stress-field is essential for adding confidence in the computed values and also for the further refinement and improvement of the computational procedure. Neutron diffraction is now a well-established method for measuring the residual stress-field in a component. In this method, the change in lattice spacing of a set of atomic planes is used to measure the strain and, when sufficient directions have been measured, the stress which has caused this change. Individual components of stress along desired directions can be measured, and thereby the complete residual stress tensor determined when required. Localised measurements can map rapidly fluctuating stress fields using a gauge volume as small as 1x1x1 mm. Moreover measurements can be done from regions deep inside the component owing to the low attenuation of neutrons in most engineering materials. Therefore, neutron diffraction can be used to map 3-dimensional stress fields in complex engineering components. Most importantly, this is a non-invasive method where in-situ neutron measurements can be done on actual components under simulated service loads and environmental conditions of interest. This paper presents the basic principles of residual stress measurement using neutrondiffraction and reports the results of high resolution measurements made in the vicinity of laser welded joints in 9Cr-1Mo(V, Nb) ferritic/martensitic steel. Keywords: Residual Stress, Neutron Diffraction, 9Cr-1Mo(V, Nb) Ferritic/Martensitic Steel, Laser Welding
Introduction Stress and Residual Stress When an object is constrained against rigid body motion, it develops stress in response to the external forces acting onto it. Such stresses arise due to in-service loads on a component. Reliable estimation of the stresses arising from in-service loads is essential for design of a component to assess its suitability for the intended service conditions. When the rate of application of the external forces is slow the
resulting stresses are reversible in nature and get relieved when the external forces are withdrawn. However, when the external forces are applied rapidly, the resulting stress is not relieved fully, even when the external forces are withdrawn. Instead, it remains locked in the body as self-equilibrating stress-field, also known as residual stress-field. Residual stress also arises due to thermo-metallurgical changes localized in a part of a component. Such rapid loading or localized thermo-metallurgical changes are associated with various fabrication
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processes like casting, rolling, forging, bending, welding etc.; leading to introduction of residual stresses in a component. Residual stresses play an important role in determining integrity of a component in service. Therefore, reliable estimation of the residual stresses is necessary to assess suitability of the component for the intended service. Besides, this knowledge can also help in optimizing the process parameters and fabrication flow-sheet to minimize the residual stresses in the fabricated components. Residual stresses are classified into following three groups on the basis of the length scales involved [1]. Type I: Macro residual stresses that develop over length scales encompassing many grains. Type II: Micro residual stresses that vary from grain to grain. Type III: Micro residual stresses that vary within a grain, due to defects like dislocation etc. and also because of precipitation and solid state phase transformations creating intra-granular hierarchical microstructures. Residual Stress Measurements Different experimental techniques have been developed over time for measurement of the residual stresses. These residual stress measurement techniques can be classified into following three broad categories [1]. Destructive: method.
Sectioning
methods,
Semi-Destructive: Hole-drilling, method, Deep-hole drilling method.
Contour Ring-core
Non-Destructive: Barkhausen noise method, Ultrasonic method, X-ray diffraction method, Neutron diffraction method. Detailed review of the different experimental methods for residual stress measurements has been presented by Rossini et at. [1]. Destructive and semi-destructive methods for residual stress measurements rely on measurements of the strain, as the stresses are relieved by sectioning of the stressed component or by drilling holes in the desired location in the component [2, 3]. The stresses are then back calculated from the measured strain. The problem with these invasive methods is that the stress relieving methods – sectioning or hole-drilling, may interfere with the residual stress field present in the component or worst still, may introduce
some stress by heating or plastic deformation. Besides, only partial information regarding the residual stress-field can be obtained, in terms of individual components of the stress and spatial variation of the same. Non-invasive methods do not interfere with the residual stress-field present in the component of interest; rather rely on differences in the interaction of the probe with stressed and un-stressed region in the component. Therefore, these methods can be used on actual components. Magnetic Barkhausen noise (MBN) method is based on magneto-elastic interaction, and can be used to measure surface stresses in ferromagnetic materials [4, 5]. Tensile stresses increase MBN signal, while compressive stresses reduce it. However, microstructural features like grain boundary, intra-grain interfaces and defects also affect MBN signal and therefore, the effect of microstructural features have to be accounted for. Ultrasonic method is based on acoustic-elasticity effects, wherein velocity of elastic wave propagation in solids is affected by the stress-field [6, 7]. This method is not limited to only ferromagnetic materials and can be used for measurements in reasonably thick components (~ 10 mm). However, this method has poor spatial resolution. X-ray diffraction method is based on the measurements of deviation in the inter-planer spacing in the crystalline material under the influence of stress [7, 8]. From this deviation, strain is computed and then stress is back calculated using elastic constants like modulus (E) and Poisson’s coefficient (ν) of the material. However, due to limited penetration of X-rays into the material, information from only thin surface layer (~ 10 – 100 µm, depending on atomic number of the material) can be obtained and therefore, only biaxial state of stress can be measured. These limitations are overcome if synchrotron radiation is used. In that case, one can measure up to 10 mm thickness and with greatly improved resolution of ~0.1 mm. Residual Stress Measurements by Neutron Diffraction Neutron diffraction is the most versatile, noninvasive method for stress measurement. This method is limited to the measurements of not just the residual stresses, but even the stresses arising from in-service loading can be measured by simulating the service conditions on the actual components. Stress measurements can be done even in thick (up to 30 mm) walled components, because of deep penetration capability of
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neutrons and the complete stress tensor can be determined by strain measurements in multiple directions in the gauge volume of interest. Like X-ray and synchrotron diffraction method, this method also, relies on deviation in the interplaner spacing under the influence of stress.
on the incident beam side and on the detector side. The direction of strain measurement is defined by the diffraction vector Q. Direction of measurement of the diffraction vector can be changed by reorienting the sample, without changing the gauge volume. Diffraction peaks are recorded in 2q domain in case of monochromatic beam and in time of flight (τ) domain in case of white neutron beam. There are many neutron diffraction facilities world over for residual stress measurements. Some important facilities are listed below. Reactor based
Fig.1a : Schematic dragram showing neutron diffraction set up using monochromatic neutron source [10]
Fig.1b : Schematic dragram showing neutron diffraction set up using white neutron source [10]
Neutron diffraction requires a high flux neutron source, which can be obtained either from a nuclear reactor or a spallation source. Nuclear reactors provide continuous neutron beam which is then made monochromatic, spallation sources on the other hand provide white neutron beam in pulsed mode. Dedicated beam lines, constructed in the vicinity of the neutron sources are used for these diffraction measurements. Schematic of neutron diffraction set up for residual stress measurements using continuous and monochromatic neutron beam from nuclear reactor, and pulsed and white neutron beam from a spallation source are shown in Fig. 1a and 1b respectively [10]. Gauge volume or measurement volume is defined by apertures
ILL, Grenoble, and Saclay, France; Berlin and Munich, Germany; Rˇ ež, Czech Republic; Chalk River, Canada; Petten, Netherlands; Budapest; NIST, MURR and HFIR, Oak Ridge, USA; ANSTO, Australia. Spallation source based ENGIN-X at ISIS, UK, POLDI on SINQ, Switzerland, SMARTS at Los Alamos and VULCAN at SNS, ORNL, USA. Neutron diffraction provides peak location (2q) for a particular plane (hkl) along the chosen scattering vector in the gauge volume. From this data lattice spacing (d) of the plane can be calculated using Bragg’s law, λ = 2dSinq. By conducting diffraction experiment, in the same setting, stress-free lattice spacing (do) for the same plane (hkl) along the same scattering vector can be obtained. Combining these two information one can calculate strain (e) along the scattering vector as, n = (d-do)/do. By measuring neutron diffraction peaks and therefore, strain along three principal directions x, y and z, one can obtain three orthogonal components σx, σy and σz of the residual stress in the gauge volume, using Eq. 1.
(1)
Where σi and ei are stress and strain components in principal directions i = x, y and z, and E and n are the crystallographic elastic modulus and Poisson’s ratio respectively for the (211) planes. Location of measurements can be changed by manipulating (translating, rotating) the sample and thus residual stress distribution can be mapped. Because, fine gauge volumes of size as small as 1x1x1 mm can be employed and therefore, it is possible to map very steep residual stress profiles resulting from high
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energy welding processes like laser and electron beam welding. Laser and electron beam welding are advanced joining processes capable of producing thick weld joints with with minimal heat input and negligible distortion. Due to low heat input and high welding speed, the fusion zone and the heat affected zone (HAZ) are narrow. This leads to steep, residual stress gradient in the vicinity of the fusion zone and HAZ. This poses challenges for the residual stress measurements. Very limited literature is available in the literature on residual stress measurements in laser and electron beam welded plates [11, 12]. This paper presents results of the residual stress measurements, in laser welded 9 mm thick 9Cr1Mo(V, Nb) ferritic martensitic steel plate, using neutron diffraction. Material and Method 9Cr-1Mo(V, Nb) ferritic martensitic steel plates (10 mm thick) in normalized (1800 s, 1050 oC) and temperd (1800 s, 770 oC) condition, were used in these studies. Its chemical composition is presented in Table 1. The plates were prepared for laser welding in square butt configuration (500x70x9 mm) by EDM wire cutting. Surface of the plate was machined to rempove the oxide layer and undulations resulting from rolling. Laser welding was carried out using continuous wave CO2 laser at 8 kW power and two welding speeds – 25 mm/s (Plate A) and 12.5 mm/s (Plate B). Laser welded plates are shown in Fig. 2a. Neutron diffraction was carried out at ILL, Grenoble in France. This is a research reactor based neutron source. It has a dedicated instrument SALSA, for residual stress measurments using a monochromatic neutron beam (λ = 1.648Ao).
The source-detector angle is 90o, giving a cuboidal gauge volume. This setting measures d-spacing for (211) planes oriented along the scattering vector. By suitably orienting the plate, diffractions peak for (211) were obtained along along three principal directions – longitudinal, transverse and normal. A fine gauge volume of 0.8x0.8x2 mm was chosen for measurements of d-spacing in the longitudinal direction. An extended length (along longitudinal direction) gauge volunme of 0.8x0.8x20 mm was used for d-spacing measurements in the transverse and the normal directions. Measurement points were changed by translating the plate. Measurements were made across the weld joint at 1.5 mm and 4.5 mm depth below the top surface of the welded plates and also, through the thickness of the plate along the weld centreline and at 2, 4 and 10 mm distance from it. The cross-weld measurements were made at a spacing of 0.5 mm to capture the anticipated sharp gradient in the stress profile, resulting from narrow fusion zone and HAZ. Measurement setting is shown in Fig. 2b. In this setting, the scattering vector is along the normal direction and therefore, these measurements provide d-spacing for (211) plane along the normal direction. The diffraction data was anslysed and converted into residual strain and then into residual stress, using measured strain and elastic constants (E and ν) of the material, emplying continuum mechanics equation (Eq. 1). Results and Discussion Diffraction Peak Width Analysis Full-width at half-maxima (FWHM) of the diffraction peaks shows a systematic variation across the weld joint (Fig. 3). Cross-section
Table 1 Chemical composition of the steel in wt. % (Balance Fe) C
Mn
Zr
Si
P
S
Cr
Mo
Ni
Cu
Al
N
Nb
Ti
V
0.11
0.44
0.005
0.22
0.02
0.001
8.96
0.90
0.21
0.045
0.010
0.046
0.07
0.004
0.19
Fig. 2a : Laser welded plates (500x140x9 mm) made at 8 kW laser power
Fig. 2b : Neutron diffraction measurements at ILL, France
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Fig. 3 : Cross-weld variation of FWHM of the neutron diffraction peaks, showing significant broadening of the diffraction peak in the fusion zone, due to martensitic transformation. Representative diffraction peaks of tempered martensite (parent metal) and as-transformed martensite (fusion zone) are also inserted.
Fig. 4 : Cross-weld residual stress profile, showing variation of the three principal components – longitudinal, transverse and normal of the residual stress at mid-length cross-section and 1.5 mm below top surface in the laser welded plate at 8 kW laser power and 25 mm/s welding speed.
of the weld joint and representative neutron diffraction peaks for the parent metal (tempered martensite) and fusion zone (as-transformed martensite) are also inserted in Fig. 3. Significant peak broadening in the fusion zone is on account of the microstresses resulting from the martensitic transformation.
Similar cross-weld residual stress profile, as that in Fig. 4, was obtained at varying depth from the top surface of the welded plate. Map of the longitudinal component of the residual stress on the one side of the weld centreline at the mid-length cross-section in the laser welded plate at 8 kW power and 25 mm/s welding speed is presented in Fig. 5. From this figure, it can be seen that there is very little variation in the residual stress-field through the thickness of the plate, however, the region below mid-thickness is under relatively compressive state of stress than that above in the fusion zone. Effect of Welding Speed on Residual Stress Profile Cross-weld profiles of the longitudinal component of residual stress for the plates welded at 8 kW laser power and two different welding speeds are shown in Fig. 6. Cross-weld microhardness profiles are also superimposed in this figure. From the microhardness profiles, it can be seen that lowering the welding speed, while keeping the laser power unchanged (8 kW), has resulted in broadening of the fusion zone and the HAZ. However, the basic nature of the residual stress profile (a trough in the fusion zone and a peak in the parent metal) remains unalteres as a result of the reduced welding speed. The only change is that the trough is wider in the crossweld residual stress profile at lower welding speed. This is on account of widening of the astransformed martensitic region i.e. fusion zone plus HAZ. The martensitic transformation has a compressive effect on the residual stress in the region of transformation and therefore, a wider as-transformed martensitic region results in a wider trough in the cross-weld residual stress profile.
Cross-weld Residual Stress Profile Cross-weld residual stress profile at 1.5 mm depth from the top surface for the plate welded at 8kW laser power and 25 mm/s welding speed is presented in Fig. 4. Weld joint crosssection is also inserted as a marker of location. The longitudinal and the normal components of the residual stress are the two significant components, while the transverse component is the least significant. This is because; the fusion zone and HAZ have significant dimensions along the longitudinal and the normal directions, because of high depth to width aspect ratio of the joint. Cross-weld profiles of the longitudinal and the normal components show a trough in the fusion zone and a peak in the parent metal, adjacent to the HAZ, on either side of the weld joint. Cross-weld microhardness profile is also superimposed to show that peaks are indeed located in the parent metal. The trough in the cross-weld profile, in the fusion zone, is on account of the martensitic transformation. There is very steep gradient in the profile as the longitudinal component of the residual stress rises from ~ 50 MPa in the fusion zone to ~ 500 MPa in the parent metal, within a distance of 1.5 mm. Besides neutron diffraction, only synchrotron diffraction is capable of capturing such a steep gradient in the stress field.
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account of high thickness to width aspect ratio of the joint. There is very little variation in the through thickness direction and the residual stress profile is very steep in the cross-weld direction. Lowering of welding speed, while keeping the laser power same, does not change shape of cross-weld profile of the residual stress, however, the trough gets widened. This is on account of wider fusion zone and HAZ region. References Fig. 5 : Map of longitudinal component of the residual stress on the one side of the mid-length cross-section of the plate welded at 8 kW laser power and 25 mm/s welding speed
Summary and Conclusions Cross-weld and through thickness residual stress profiles were measured in 9Cr-1Mo(V, Nb) FMS plates, laser welded at 8 kW laser power and two different welding speeds, using neutron diffraction. The results show that the residual stress-field is limited to very narrow region on the either side of the weld joint because of low heat input associated with laser welding process. Further, there is a clear ranking in the magnitude of the three components of the residual stress in the order – longitudunal, normal and transverse. Cross-weld profile of the longitudinal and the normal components of the residual stress show a trough in the fusion zone and a peak in the parent metal adjacent to the HAZ on either side of the weld joint. The trough in the fusion zone is on account of martensitic transformation of austenite as the joint cools after solidification, because martensitic transformation has a compressive effect on the stress-field in the region of transformation because of specific volume increase. The longitudinal and the normal components show similar cross-weld profile on
1. N.S. Rossini, M. Dassisti, K.Y. Benyounis, A.G. Olabi, Methods of measuring residual stresses in components, Mater. Des. 35 (2012) 572–588. 2. J. R. Shadley, E. F. Rybicki, W. S. Shealy, Application guidelines for the parting out in a through thickness residual stress measurement procedure, Strain 23 (1987) 157–166. 3. N. Tebedge, G. Alpsten G, L. Tall L, Residualstress measurement by the sectioning method, Exp. Mech. 13(2) (1973) 88–96. 4. D. M. Stewart, K. J. Stevens, K. B. Kaiser, Magnetic Barkhausen noise analysis of stress in steel, Curr. Appl. Phys. 4(2-4) (2004) 308–311. 5. H. Y. Ilker, C. Ibrahim, C. G. Hakan, Non-destructive determination of residual stress state in steel weldments by Magnetic Barkhausen Noise technique, NDT&E Int. 43 (2010) 29–33. 6. F. Balahcene, J. Lu, Study of residual stress induced in welded steel by surface longitudinal ultrasonic method, Proc. SEM Annual Conference on Theoretical, Experimental and Computational Mechanics (1999) 331–334. 7. T. Leon-Salamanca, D. E. Bray, Residual stress measurement in steel plates and welds using critically refracted waves, Res. Nondestruct. Eval. 7(4) (1996) 169–184. 8. J. H. Norton, D. Rosenthal, Stress measurement by x-ray diffraction, Proc. Soc. Exp. Stress Anal. 1(2) (1944) 73–76. 9. J. H. Norton, D. Rosenthal, Stress measurement by x-ray diffraction, Proc. Soc. Exp. Stress Anal. 1(2) (1944) 81–90. 10. P.J. Withers, Mapping residual and internal stress in materials by neutron diffraction, C.R. Physique 8 (2007) 806–820. 11. S. Kumar, A. Kundu, K.A. Venkata, A. Evans, C.E. Truman, J. A. Francis, K. Bhanumurthy, P.J. Bouchard and G. K. Dey, “Residual stresses in laser welded ASTM A387 Grade 91 steel”, Mater. Sci. Eng. A575(2013) 160-168.
Fig. 6 : Cross-weld profile of longitudinal component of the residual stress in plate A (8 kW, 25 mm/s) and plate B (8 kW, 12.5 mm/s), 1.5 mm below top surface
12. A. Kundu, P. J. Bouchard, S. Kumar, K. A. Venkata, J.A. Francis, A. Paradowska, G. K. Dey and C.E. Truman, “Residual stress in P91 steel electron beam welds”, Sci. Technol. Weld. Join. 18(1) (2013) 70-75.
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technical papers
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FLASH X-RAY RADIOGRAPHY WITH PHOSPHOR IMAGING PLATE A.M. Shaikh1, Romesh C.2, T.S. Kolge2 and Archana Sharma2
Raja Ramanna Fellow, Physics Group Accelerator and Pulse Power Division, Bhabha Atomic research Centre, Mumbai 400 085, India E-mail: shaikham@barc.gov.in 1 2
ABSTRACT
Flash X-rays generated by intense relativistic electron beams (REB) find their application in radiography of dynamic events and probing the objects like thick blocks of Stainless Steel or other metal in contrast to conventional low voltage sources. In flash X-ray radiography (FXR) the duration of the X-ray pulse, and therefore the exposure time, is extremely short and less than time constant of any dynamic phenomena to be studied. If X-ray energies appropriate for the desired application are selected, using very fast detection system, high contrast and sharp radiographs can be recorded. A system of this kind has been developed at APPD, BARC using a ~30GW, 80 ns relativistic electron beam generator KALI-30GW. Imaging plate (IP) made of BaFBr: Eu2+ phosphor is used for X-ray beam profile measurement and radiography. The paper describes the FXR system and use of IP for determination of spatial resolution of the imaging system using edge spread functions fitted to data obtained from radiographs of sharp edge objects. As high energy (400keV to 1030keV) and intense source there is possibility of using flash X-rays for radiography of thicker objects and selectively see the parts with high and low absorption coefficients with good contrast in much less time compared to normal X-ray radiography. Therefore, it may be useful in nuclear, aerospace, ordnance industries. In view of non availability of neutron sources flash X-ray radiography should serve the purpose of NDT. Keywords: Flash X-rays, X-ray Radiography, Edge spread function, Imaging plate, NDT
1. Introduction Relativistic electron beams are employed in high power microwave generation, flash X-ray generation and ion implantation for modification of certain materials [1-3]. The flash X-ray sources have advantage to conventional X-ray tubes in term of their very high dose rates and small X-ray duration. Due to a very high dose rate Flash X-rays can be used in the radiography of very dynamic objects, which gives blurred images when radiographed via a conventional X-ray source. The short duration gives freedom to freeze the motion of moving object. Due to very high dose and short duration of flash X-ray sources they are also utilized for precise radiography of radioactive samples, which due to their inherent radiation gives rise to huge noise when imaged via normal radiography methods and it discriminates the radiation coming from radioactive samples in this time domain. An excellent application of an intense Flash X-ray source is that it can penetrate very thick objects too (8-15 cm Stainless Steel), so it is also used for finding any structural flaw in the bulk of big samples. The pulse power system developed at Bhabha Atomic research Centre, KALI-30 GW [4,5] is capable of producing highly energetic voltage pulses of the magnitude 1 MV and current 30 kA. The electron beam is generated at this high power and then impinged upon a high atomic number (A>73) material anode producing flash X-rays. Note: the term KALI stands for ‘Kilo Ampere Linear Injector’.
2. Experimental set-up A schematic of the flash X-ray system developed is shown in Fig.1. It consists of an REB diode having an annular cathode ring made of stainless steel disc with a central hole of 20 mm diameter. The anode is a tungsten rod of 2 mm diameter with 15 mm length at one end is tapered to a tip of 0.5 mm diameter. The diode gap; between the anode tip and cathode ring centre is adjusted by varying the position of annular cathode over anode length. A 3mm thick aluminium window placed 15 cm away from the anode tip provides outlet for the X-rays emitted. Vacuum of 10-5 torr is maintained in the diode chamber. The diode is connected to the KALI-30GW pulse power source capable of delivering a pulse up to 1MeV, 30kA and ~80ns duration. The details of KALI-30GW are described elsewhere [6]. The pulse power is charged to positive polarity
Fig.1 : Schematic of FXR Radiography set up
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Fig.2 : The photograph of KALI-30GW FXR set up at BARC3. Determination FXR source size using imaging plate
and then discharged through a spark gap to pass on the voltage to the diode. The voltage is applied to the anode pin and cathode is at ground potential. The sudden discharge extracts burst of electrons from the cathode ring due to explosive field emission. These electrons strike the anode and X-rays are produced by bremsstrahlung process. Due to the geometry of the anode conical tip most of the X-rays go in the direction of the output window. The complete setup of KALI-30GW and the FXR diode chamber is shown in fig.2. The imaging plate (IP) is used to record X-ray beam spot size and radiograph of the object. IP made of BaFBr: Eu2+ phosphor is a twodimensional radiation detector. It is widely used for such as medical and industrial radiography, autoradiography, X-ray diffraction experiments, and transmission electron microscopy [7-8]. The advantages of IP include high spatial resolution, high sensitivity and a linear response to radiation dose over five orders of magnitude and storage effect of latent image formed by incident radiation in the form of F+ centers and Eu3+ ions in the phosphor. The latent image stored on the IP can be read out by irradiating the IP with He-Ne laser (=633 nm). The laser excites trapped electrons to recombine with Eu3+. The decay of Eu3+ to Eu2+ causes the emission of photons (=400 nm). The process is called photostimulated luminescence (PSL). A photomultiplier tube collects the PSL intensities. The resulting signal is converted and stored as a digital image and displayed on a monitor. After reading, the IP is exposed to strong visible light to erase the residual image and it can be reused. In our experiments Fujifilm IP BAS-SR2025 is used.After recording the FXR shots the IP is read on PC-controlled FUJIFILM BAS-5000 scanner (fig.3) with 50μm resolution, and 4000 sensitivity and data is stored in 8 bits gradation. Image is corrected for the background noise. The PSL intensities of selected area of the radiograph are obtained and analysed using the software provided with the scanner.It is seen that the dose distribution gets altered with different diode configurations. The shape of the radiation beam can be made from wide to narrow by changing diode configuration. In order to view the FXR source, diode configuration as shown in
Fig. 3 : PC-controlled FUJIFILM BAS-5000 scanner and reader and IP eraser
IP
Fig. 4 : (a) Diode configuration used in FXR spot size measurement (b) Direct beam recorded on IP with 780kV, 9 kA, and 80ns e- beam pulse.
fig. 4 is used. The X-ray shot is recorded with IP in close contact with the Al window (position IP-1 in fig. 1). The beam shows a sharp profile with maximum X-ray Intensity at the centre. A grey image of this direct beam in RGB mode with intensity contours is shown in figs. 4(b). The image as shown covers the whole area of the IP i.e. 200 x 250 mm2. The central spot has diameter of ~ 13mm and covers an area with intensity of ~27000 PSL/mm2. This is the size of X-ray source as received on the IP kept at a distance ~ 200 mm from the source which originates on the anode. If deeper penetration in the material is needed this type of intense beam is recommended. If the requirement is of uniform dose over a wide area at the same distance, as required for X-ray radiography, then diode configuration shown in fig.5 may be preferred with imaging plate kept at position IP-2 shown in fig. 1. 4. Spatial resolution of imaging plate with Flash X-Rays In radiography spatial resolution is defined as the ability of an imaging system to display two adjacent structures as being separate and sharply and clearly defined. The resolution depends on the thickness of the sample, sample to detector distance, the track size and the range of X-rays in the image plate. It is expressed in terms of total unsharpness, Ut. and evaluated by obtaining "edge-spread" function, ESF. The image plate is partially covered with a 50µm Pb foil and is exposed to flash X-rays (fig. 6(a). The IP is then read with 50µm scanning pitch. The edge profile measured is shown in fig. 6(b). The measured profile is fitted to Edge Spread Function of type, ESF=P1+P2.arctan(P3(x-P4)), where P1, P2, P3, and P4 are fit parameters [9]. The total unsharpness is given by Ut= 2/P3. The fit parameters for Pb edge are obtained as P1
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Fig. 5 : (a) Diode configuration used in flash X-ray radiography (b) Direct beam recorded on IP with 780kV, 9 kA, and 80ns e- beam pulse.
= 0.777 (1), P2 = 0.137 (1), P3 = 21.82 (1.37) and P4 = 1.892 (2) with r2 of the fit = 0.9985. A value of Ut= 92 ± 6 µm is obtained. The spatial resolution of a digital X-ray detector is always expressed in terms of modulation transfer function, MTF which measures performance of the imaging system in terms of signal transfer as a function of spatial frequency. MTF can be obtained using the ESF data. First a spatial differentiation of the ESF is done to produce a line spread function (LSF) and then the MTF is calculated by taking a Fourier transform of the LSF. Figs. 6(c) and (d) show the LSF and MTF derived from ESF data. For the present imaging system with BAS SR2025 imaging plate and 50µm step scan the modulation becomes zero near Nyquist frequency limit of 10 lp / mm. The value at MTF10 is 7 lp/mm, which is lower than the reported value of ~10 lp/mm [10-12]. The difference may be due to use of different scanners, measurement techniques and X-ray energies 8 keV, 5.9 keV and 10-50 keV respectively in these references. Our measurement is done with 650 keV, 10.5 kA, 80 ns single shot flash X-rays. 5. Radiography with flash X-rays and imaging plate Radiography with flash X-rays is very valuable in practice to investigate nuclear implosion, high speed processes. Another important application of flash X-rays is radiography for nondestructive testing of materials. As high energy and intense source, flash X-rays can be used for radiography of thicker objects and selectively see the parts with high and low absorption coefficients with good contrast in much less time compared to normal X-ray radiography. Therefore, it may be useful in nuclear, aerospace, ordnance industries. With this aim radiographs of various objects which are normally subjected to neutron radiography are recorded using present FXR system. Fig. 7(a) shows flash X-ray radiograph of an aero engine turbine blade (casted in Titanium alloy with internal air circulation channels). It is good quality radiograph giving a good insight of internal structure of the blade and is comparable to that obtained with neutrons shown in fig.7(b) [8]. In view of non availability of neutron sources flash X-ray radiography should serve the purpose of NDT. Figures 7(c) and 7(d) show flash X-ray radiograph and neutron radiograph of INSAT cable
Fig.6 : (a) Radiograph of FUJIFILM BAS-SR imaging plate partially covered with Pb foil (50 µm) recorded with flash X-rays (650 kV, 10.5 kA, 80 ns) shot and direction of the scan is shown with arrow across. (b) The measured Pb edge spread data (discrete points) fitted to ESF function (solid line) described in the text. (c) Line Spread Function (LSF) obtained from ESF by differentiation. (d) Modular Transfer Function (MTF) obtained from LSF by Fourier transform.
cutter respectively. The cable cutter has an outer body made of stainless steel and inner electrode assembly made of materials like Plastic, Teflon etc. The flash X-ray radiography though reveals the internal structure past outer SS thickness the image contrast and resolution is poor compared to that seen in the neutron radiograph [13]. This may be due to low absorption of X-rays in the materials of internal structure. Figs. 8(a-c) show radiographs of various technological important objects displaying their internal structures viz. radiograph (a) shows a GM counter: central anode wire of 1mm diameter is clearly seen, (b) a gas filled proportional counter: cathode end plugs and connectors are clearly seen but 50µm central anode wire is not visible, (c) 3/2 explosive manifold and Explosive Transfer Assembly used in space launch vehicles, the internal channels in the thick aluminum body and lead electrodes inside SS tubing are clearly seen 6. Conclusions KALI-30GW FXR system has been developed at APPD, BARC. The imaging plate is used for determination of spatial resolution of the imaging system using edge spread functions fitted to data obtained from radiographs of sharp edge objects. As high energy (400keV to 1030keV) and intense source there is possibility of using flash X-rays for radiography of thicker objects and selectively see the parts with high and low absorption coefficients with good contrast in much less time compared to normal X-ray radiography. It may be useful in nuclear, aerospace, ordnance industries. In view of non availability of neutron sources flash X-ray radiography should serve the purpose of NDT.
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Fig.7 : (a) Radiograph of Aero engine turbine blade with Flash X-rays from KALI-30 GW (650 kV, 10.5 kA, 80 ns) recorded on Imaging plate BAS-SR2025 (b) Neutron radiograph of aero engine turbine blade using CIRUS reactor facility with neutron flux 3.6 x 108 n/cm2. sec and Neutron Image plate BAS ND-2025. (c) Radiograph of INSAT cable cutter with KALI-30 GW and (d) Neutron radiograph of INSAT cable cutter with CIRUS facility.
Acknowledgements Authors express their thanks to Dr. L.M. Gantayet for his consistent encouragement and support. Thanks are also due to Dr. K.C. Mittal for his valuable guidance and significant contributions in this project and Dr. S.L. Chaplot, Director Physics Group for the support. Acknowledgement is due to Department of Atomic Energy, Government of India for award of Raja Ramanna Fellowship to one of the authors, AMS. References [1. Maenchen, G. Cooperstein, J. O’Malley, and I. Smith, “Advances in pulsed power-driven radiography systems,” Proc. IEEE, vol. 92, no. 7, pp. 1021–1042, Jul. 2004. 2. Archana Sharma, Senthil Kumar, S. Mitra, Vishnu Sharma, Ankur Patel, Amitava Roy, Rakhee Menon, K. V. Nagesh, and D. P. Chakravarthy, “Development and Characterization of Repetitive 1 kJ Marx Generator Driven Reflex Triode System for High Power Microwave Generation”, IEEE Transactions on Plasma Science. Vol. 39, No. 5, pp. 1262-1267 May 2011. 3. C.Ekdahl, “Modern Electron Accelerators for radiography”, IEEE-PS, Vol.30, No.1, pp.254261, Feb.2002; 4. D. D. P. Kumar, S. Mitra, K. Senthil, A. Sharma, K. V. Nagesh, S. K. Singh, J. Mondal, A. Roy, and D. P. Chakravarthy, “Characterization and analysis of a pulse power system based on Marx generator and Blumlein,” Rev. Sci. Instrum., vol. 78, no. 11, pp. 115 107-1–115 107-4, Nov. 2007.
Fig. 8 : Flash X-ray radiographs of (a) a GM counter (b) a gas filled proportional counter, (c) 2/3 explosive manifold, TBI manifold and TBI connectors. 5. Amitava Roy R. Menon, S. Mitra, D. D. P. Kumar, Senthil K., Archana Sharma, K. C. Mittal, K. V. Nagesh and D. P. Chakravarthy, “Intense Relativistic Beam Generation and Prepulse Effect in High Power Cylindrical Diodes” Journal of Applied Physics 103, 014905, 2008. 6. A. Sharma, A.M. Shaikh, K. Senthil, S. Mitra, R. Chandra, S. Vishnu,S. Sandeep, A. Roy, M. Rakhee, V. Sharma, M.B. Danish, T.S. Kolge,K. Ranjeet, R. Agrawal, P.C. Saroj, S.V. Tewari and K.C. Mittal, “First results of KALI-30 GW with 1 MV flash X-rays generation and characterization by Imaging plate” J. INST, 9, P 07011, 2014. 7. M. Sonada, J. Takano, J. Miyahara, H. Kato, Computed radiography utilizing scanning laser stimulated luminescence, Radiology, 148, 833, 1983. 8. A.M.Shaikh, Applications of image plates in various NDT techniques at BARC, http://www. ndt.net/article/nde-india2011/pdf/1-02A-5.pdf. pdf. 9. A.A. Harms, A.A. Zellinger, “ New formulation of total unsharpness in radiography”, Phys. Med. Biol., vol. 22(1), 70-80, 1977. 10. G. Fiskel, F.J. Marshall, C. Mileham and C. Stoeckl, “ Spatial resolution of Fuji BAS-TR and BAR-SR imaging plates”, Rev. Sci. Instrum. Vol. 83, 086103, 2012. 11. S. G. Gales and C. D. Bentley, “Image plates as X-ray detectors in plasma physics experiments” Rev. Sci. Instrum. Vol. 75, 4001, 2004. 12. John F. Seely, Glenn E. Holland, Lawrence T. Hudson, and Albert Henins, “X-ray modulation transfer functions of photostimulable phosphor image plates and scanners” Applied Optics, Vol. 47, Issue 31, pp. 5753-5761 (2008). 13. Akhtar M. Shaikh, Applications of various imaging techniques in neutron radiography at BARC, Trombay, 18th World Conference on Nondestructive Testing, www.ndt.net /article/ wcndt 2012 papers/646_wcndtfinal. 00647.pdf.
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HISTORY OF RADIOGRAPHY IN INDIA Shri Dilip Gatty Director Geecy Vincotte (I) Pvt Ltd, Mumbai
A
lthough topic of discussion is history of radiography in India it will be interesting to briefly note the history of radiography in the world too. In 1896, French scientist Henri Becquerel discovered natural radioactivity. Becquerel noticed that photographic plates fogged not due to stray light and only the plates that were with the Uranium compound were fogged. Unfortunately, Becquerel's discovery was virtually unnoticed by laymen and scientists alike. It was not until the discovery of Radium by the Curies two years later that interest in radioactivity became widespread. Marie and her husband, French scientist Pierre Curie, in 1898, discovered radioactive element in pitchblende and named it 'Polonium' and ‘Radium’ or shining element. Since these discoveries, many other radioactive elements have been discovered or produced. It is interesting that no attempt was made to use gamma sources for radiography. X-rays, though discovered 10 years later, found users in medical and industrial application. X-rays were discovered in 1895 by Wilhelm Conrad Roentgen, who was a Professor at Wurzburg University in Germany. Within 6 months of his discovery X-rays were being used by battlefield physicians to locate bullets in wounded soldiers. Roentgen's discovery was a scientific one but it brought revolution in industrial inspection and testing methods. Public fancy apart, scientific fancy was captured by the demonstration of a wavelength shorter than light. This generated new possibilities for investigating the structure of matter. Prior to 1912, X-rays were hardly used other than for medicine and dentistry. The reason that X-rays were not used in industrial application was because the X-ray tubes frequently broke down, limitation of handling vacuum tubes and the required penetration power for industrial purpose could not be produced. However, that changed in 1913 when the high vacuum X-ray tubes designed by Coolidge became available. Around 1922, first 200 KV X-ray machine started taking radiographs of thick
steel parts in a reasonable amount of time. In 1931, General Electric Company developed 1000 KV X-ray generators. That same year, the American Society of Mechanical Engineers (ASME) permitted X-ray testing of fusion welded pressure vessels that opened door to industrial acceptance and use. Records of radiography NDT methods practiced in India earlier to independence of our country is not available. Hence it will be interesting to review development of radiography industry in India post independence. Consideration for radiographic sensitivity in a radiograph was not a criterion prior to 1970 for final radiography result. IQI was mostly a step wedge with same diameter holes. Much changed after the advent of ASME codes, this defined various aspects of NDT. Radiography without a film was not possible until recent times. Prior to 1975 there were many brands of films available, in recent times, due to shrinking requirement we don’t see more than two or three manufacturers. Cut size films were always there but ready pack films with pre-packed lead screens for large production shops and roll films for pipelines radiography are available today. Darkroom was always a critical factor in film radiography. Automatic processors are now in vogue in large production shops and projects. Film radiography from beginning worked well in India. If major concern of radiation safety is covered, radiography is still the most preferred tool. With radiography examinations all planar indications such as LF, LP and crack are called for reject irrespective of type, size and location but only volumetric indications calls for inspector’s decision. It is the ease with which an inspector takes a decision, by seeing the indications on a radiographic film, makes it a favored tool in all quality plans of construction works. Nothing has changed much then and now except method of recording the images. Analog images on film are replaced by digital image on computer screen. Around 1950 in India, radiography technicians were recruited with any education level as trainee technicians in refineries in Burmah Shell and Esso refineries by foreign construction companies.
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Later during construction of BARC few corporate houses such as M/s X-ray Engineering Co. started a NDT service company in collaboration with a US based company. Indian operators were trained by these company’s on field but there were no formal qualification guidelines. They used Iridium sources in basic equipment. For light metal fabrication applications, Thulium and X-ray machines were commonly used. Selenium source is a latest addition in India from the year 2006 and it is fast replacing X ray for field radiography of low thickness pipe weld joints. I have not found any reference anywhere to tell why industrial gamma radiography devices were called ‘camera’. May be people found radiography activity similar to photography. Even now in common parlance radiography device is referred to as radiographic camera but in written communication it is IGRED (Industrial Gamma Radiographic Exposure Device). Story of radiography in India was different before 1970; I call this era as Stone Age. Radiography examination was limited to selective butt joints of boilers, pressure vessels & welded joints of pipe. High thickness steel fabrication was mostly done overseas hence hardly any high thickness radiography was done in India. Castings radiography was limited to large profiles. I am one of the few surviving radiographer from so called Stone Age of Indian radiography. Since the year 1978, I have handled very basic gamma radiography equipment supplied by BARC, the IRC-1 & IRC-2 devices which held Iridium 192 of 8 and 20 curies respectively. Source pellet was placed inside a hollow SS pencil holder and remained locked by a screw. The housing of the device was mainly of lead. Equipment was designed for taking exposure without taking out the source pencil. A difficult task, however with a two meter long manipulator rod (which had a male thread at one end and this fitted on female connector on the source pencil) it was possible to take out the source pencil place it on pipe joints for taking exposure, a risky but a routine procedure of that time. Imagine we have tested all power stations including TAPS, MAPS and fertilizer plants & refineries before 1990 using these devices, so all those radiographers from Stone Age deserve a special mention here. Radiography equipment in India then in today’s context was very unsafe and could be easily unsecured. During field operations loss of sources was very frequent and massive hunt to retrieve it needed. These devices were high risk.
Only few radiography agencies in India were using remotely operated radiography devices before 1975. All remotely operated devices were imported until 1995. There were mainly two different source housing designs available. Those coming from USA had ‘lazy S’ bend and European designs mostly had straight port as source housing. In all the cases it was depleted uranium shielding and Type B (U) package. IGRED with tungsten shielding material came in circulation around year 2005 in India. Around same time Division of Radiological Protection (DRP) withdrew IRC-1 & IRC-2 devices. Board of Radio Isotope Technology (BRIT) a division of BARC started supplying Roli 1, an indigenously manufactured remote operated device with a maximum activity of 35 curies of Ir 192 source. This equipment is withdrawn since 2015. New and better models are being launched by BRIT. At the same time imported devices introduced in India by various manufacturers from US and Europe are much lighter and of higher capacity and suitable for multiple sources. In last five years imported devices have tremendously changed the way radiography is being done in Indian industry. Services for personnel monitoring of radiation doses was controlled, like now, by PMS a personal dose monitoring division of BARC. Film badge contained mainly a Kodak film similar to one used in dentistry and every month it was replaced. Film badge holder had multiple metallic windows for reading of radiation energy. These films were developed and dose against each window was compared against calibrated density and dose received was estimated. These films were prone to damage during use and transportation due to light leakage. Present day TLD’s came in use in the year 2000. There were no training program to qualify Radiographers but for the radiation safety officers (RSO) one year post graduation course. Later around 1976 a one month diploma course on safety aspects of radiation application in industrial radiography was started which entitled qualifier to work as a safety site in charge. Now it is called BARC RT-2 course. In 1978, industrial radiographer Level 1 a one week course was started to train and qualify field radiographers and now this is known as BARC RT-1. Much has changed in radiography technology post 1970; I will prefer calling that era as Iron Age. As codes and specifications came in to the main stream of construction and application
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of NDT methods. System of qualifying NDT personnel became mandatory. BARC’s DRP started asserting radiation safety requirements not only on end user but on contractors in whose premises radiography examination was undertaken. This was also a longest era, during this era lot of radiography work was undertaken with very basic type of radiography devices. Trainee radiographers in India later than 1978 saw dramatic changes in industrial radiography. I am one of them who have been through the transformation. X-ray machines were made in India but were not sturdy; they were oil cooled, bulky and heavy. X-ray tubes were imported but HT coils were made locally. These machines were mostly used on shop floors. In early days, X-ray machines in India were primarily made of glass tube, nowadays they are available in ceramic tube, as well. Today X-ray machines used are of many types, broadly being portable or mobile type, from high to medium frequency or constant voltage type. High energy sources like Cobalt 60 were first used in India by a Canadian construction company at Tarapur Atomic Power Station during construction of TAPS 1. Uses of Cobalt now although limited to radiography enclosures, are used for testing casting, large forgings & pressure vessel. Betatron is the latest entry in India since 2011-12. Instruments used in radiography for detecting and measuring radiation like survey meters, dosimeters & dosimeter charger and densitometer and were used from early days though most of them were imported & their field use was not regular. Cross country pipeline welding joints needed high production of radiography and pipeline crawler was introduced in India around 1988 during HBJ pipeline. Pipeline crawlers now are all X-ray crawlers but earlier to 1995 gamma crawlers were prevalent. Tracking the crawler position inside the pipe was done using a hand held device containing 10 mili curie of Cesium and a GM sensor mounted on the crawler. However to reduce radiation mishap an alternative method of using high powered magnet to track the crawler came in use. If we closely analyze the trend of transformations in NDT business in India and especially in radiography business, the upward trend in investment and frequency of up gradation of equipment started around 1990. Industrial
radiography business in India rose to several levels up in terms of equipment used in India. Open field radiography in a running plant or a construction site routinely without stopping other activity needed special thinking. It is now possible by using integrated tungsten collimator directly mounted on the device and wrapping a flexible radiation protection mats all around the joint setup. These devices are known as Small Controlled Area Radiography (SCAR) or Close Proximity Radiography (CPR) or LO-Rad. The radiation level is below 0.2mR/hr at 3 meters. Most of the refineries are using this technique for 24x7, radiography during shutdown in a running plant. New construction sites are now saving radiography examination time by working safely, round the clock. Another new development in industrial radiography in India is onset of digital radiography. Computed Radiography (CR) technique which is totally eliminates darkroom, safelights, X-ray films, lead screens, photo chemicals, water, densitometer and film viewer. The quality of digital radiographic images in terms of sensitivity & contrast is much superior. USP of digital technology is dynamic range of image processing, this needs to be emphasized but often overlooked. Main advantage of digital technology is basic radiation sources; techniques and operators qualifications remain unchanged. Imaging plates can be used & erased and again reused several hundred times. Image quality is very high and sensitivity is exceptionally good. A bridge between film radiography and digital technology is digitization of radiographs. Processed radiographs are scanned and digitized for permanent archiving purpose. This technique is also slowly gaining it’s foot hold in India since last two years. One more technique which is not yet caught attention in India is radiography using CMOS imaging system. This will be very useful for continuous X-ray scanning of weld joints in real time display. In summary, radiography examination system in India has traveled a long distance in last sixty five years and time tested. The modern technology of image capturing is still using same techniques for testing but intricacies of testing requirements and application of radiography across product range has grown tremendously. The modern digital technology is bringing change at a such a pace that I sometimes wonder if I am able to understand it right.
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Diwakar Joshi Director, Insight Quality Services.
ABSTRACT ASME Boiler and Pressure Vessel (BPV) Code Edition 2015 is released! And the applicability date is 1sJanuary 2016. In globalization, International product certifications are playing a very important role in developing confidence at customer’s end. For example, ASME certification (U, U2, R, S, N Stamps etc.) is considered a hallmark in quality of fabricated equipments. Many of us use ASME Codes extensively. We design, manufacture, inspect, test, and evaluate as per the Code. We interpret the Code or get it interpreted so as to be totally compliant to the code and our customer requirements. Interpreting the code or getting to know the changes in the code requires a lot of effort. This could be a specialized job and may require a long time. But we definitely do not have that time with us! We are supposed to get to know the changes, understand the implications and do our best in implementing the changes, all in a short while. After all, the job, and in turn the customer is at stake! Considering all such requirements, an effort is made to project the role of ASME Section V in NDE with specific focus to Edition 2015 changes. Keywords: code, referencing code, referenced code, certification, discontinuity, defect, interpretation, evaluation, indication, flaw, Sensitivity, density, contrast, acceptance standard, resolution
ASME Boiler and Pressure Vessel Code is having 12 sections and ASME BPVC section V is basically dealing with Non-destructive testing. In ASME there are referencing codes and referenced codes e.g. ASME Section I Power Boilers, ASME BPVC Section VIII Div. 1, Div 2 Pressure Vessels, ASME Section III Nuclear Components, ASME Section IV Heating Boilers. They are called as referencing codes because they decide the rules for construction, whereas ASME Section V, ASME Section IX, ASME Section II Part A, B, C, D are called as referenced codes. They are supporting these referencing codes e. g. If a person is having stomach ache, he will
go to the physician and then physician will refer him to go to a specialist for having a scan of his stomach. Now this specialist who is giving a scan report is Section V and the main physician is Section VIII Div 1. Thus referencing code is always important for us. So before referring to ASME Section V the requirements of NDE and acceptance criteria shall be taken from referencing code i.e. ASME Section VIII Div 1 and the details for NDE procedures and equipments shall be followed from ASME Section V. The Figure is giving the relationship between referencing code and referenced code.
ASME - Boiler & Pressure Vessel Code Construction-Code (Referencing Codes)
Referenced Codes
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ROLE OF ASME SEC. V in NDE AND SUMMARY OF CHANGES IN EDITION 2015
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In Service Codes
Standards, Recommendations
Let us take one example, ASME BPVC Section VIII Div 1, UW 11 is specifying the weld joint radiographic testing requirements and it directs us to UW 51 acceptance standard. UW 51 says, “All welded joints to be radio graphed shall be examined in accordance with Article 2 of ASME Section V”. With this message we are entering into Section V. Section V Article 2 says that we need to refer Article 1 also. Now, whenever we are going for Section V Article 1 that is General Requirements - A calibrated equipment, demonstrated procedure and qualified manpower are the three basic things mentioned there and general NDE documentation requirements are also specified. Article 2 is talking about Radiographic Testing, Article 3 is not there. Article 4 is Ultrasonic Testing of Welds, Article 5 is Ultrasonic Testing of Materials, Article 6, 7, 8, 9, 10 are dealing with Penetrant Testing, Magnetic Particle Testing, Eddy Current Testing, Visual Testing and Leak Testing respectively. The qualification of the personnel is generally done as per SNT-TC-1A that is ASNT’s Recommended Practice and the document presently applicable is Edition 2006 (Section VIII Div 1 U-3 Table for applicable edition). Now, as per SNT-TC-1A, we need to qualify the operating person in Nondestructive testing in Level I, Level II and Level III. Thus, Level I is operating level, Level II is a supervisory level and Level III is the managerial level. Level I has to operate the machine, test the product. Level II has to interpret and evaluate the result and make the report. Level III has to train Level I, Level II people, prepare the procedures for Non-destructive testing and ensure that the calibration procedures are in place. It’s worth noting here that in Non-destructive testing, discontinuity is any continuity broken, flaw is any discontinuity that may be detectable by NDT and is not necessarily rejectable. Defect is unacceptable discontinuity. So any response
when we are getting in NDT, it becomes an indication and that indication or that discontinuity is evaluated in terms of acceptance standard and acceptance standard is always coming from referencing code. ASME Section V mainly has subsection A and Subsection B. Subsection A provides Non Destructive Methods of Examinations and Subsections B Provides documents adapted by Section V. Subsection B is the standards adopted by ASME. Before reviewing the changes of new code, one has to refer summary of changes. Overall if we see, the code changes we should segregate into three types: A, B and C. A: Major changes where we need to change the procedures B: We need to note but our working is not going to change due to such change and it is only for information. C: These changes are such as typographical errors, errata etc. which are not major things. Effort is made to have an overall idea of these changes. However, one cannot avoid reading the code. So always it is better to refer the code and take the message from the code itself. This paper is just to give an overall idea about the changes of A type. We are going to take a quick review of ‘A’ type of changes as mentioned above, in ASME Section V in 2015 Edition. General Change: Globally replaced references to a Manufacturer, Contractor, Fabricator, Installer, Assembler and Code User within the text of Section V with the generic term “organization” where appropriate for greater clarity of intent. Revised endnote 4 in Article 1 to define the term “organization” as used in Section V. Organization: The term “organization” is used generically throughout to refer to a Manufacturer, Fabricator, Installer, Assembler,
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or other entity responsible for complying with the requirements of this Section in the performance of nondestructive examinations Subsection A Article 1: General Requirements a) This Article is to be referred whenever referencing codes calls for it or whenever any of the Articles in Subsection A calls for it. In Edition 2015 Article 1 Mandatory Appendix 1 method-wise definitions have been added. So, all definitions are appearing in Article 1 only. b) Mandatory Appendix II in Article 1 has been added which states Supplemental Personnel Qualification Requirements for NDE Certification for Computed radiography (CR), Digital Radiography (DR), Phased Array Ultrasonic Technology (PAUT), and Ultrasonic Time of Flight Diffraction (TOFD). The new technological developments demand additional requirements on personnel qualification. Article 2: Radiographic Examination a) System of identification clause T -224: In Edition 2013 the Identification on each radiograph was not clear. In 2015 this clause has been revised to clarify the requirement of identification on each radiograph. b) The term Manufacturers symbol has been replaced by organization’s Symbol in clause T 224. So the organization (subcontractor performing radiography or manufacturer) responsible for performing and evaluating radiography also shall appear as a part of system of identification. Article 4: Ultrasonic Examination Methods for Welds a) Calibration Block for Piping Fig T-434.3-1: In earlier editions pipe having O.D. 4 in. (100 mm) or less, the minimum arc length was 2700 of the circumference which has been revised to 75% of the circumference. b) Addition of clause T-462.7 – Split DAC: No point on the DAC curve shall be less than 20% of full screen height (FSH). When any portion of the DAC curve will fall below 20% FSH, a split DAC shall be used. The first calibration reflector on the second DAC shall start at 80% ± 5% FSH. When reflector signal-to-noise ratio precludes effective indication evaluation and characterization, a split DAC should not be used. (Article 4, Non-mandatory Appendix Q provides an example). This Requirement has been made mandatory from Edition 2015.
c)
Mandatory Appendix II: The Values of Indication Limits % of Full Screen has been revised in miscellaneous requirements of Mandatory Appendix II Article 4. General Change in Article 6, Article 7 and Article 9: a) Illumination requirements have been revised to clarify that whenever a Natural or supplemental white light is used the light intensity on the examination surface shall be measured prior to Evaluation of indication or a verified light source may be used which shall be demonstrated and documented once. b) Documentation requirements: In Article 6, 7 and 9 the report shall also include the details mentioned in T - 190 (a) of Article 1 i.e. to include date of examination, NDE performers identification, Joint details, Examination technique and method and result of examination Article 6: Liquid Penetrant Examination a) T-621.3 Addition of table for Minimum and Maximum Step Times. The written procedure shall have minimum and maximum times for the applicable examination steps listed in Table T-621.3 which is added in Edition 2015. b) Maximum dwell Time: The maximum dwell time shall not exceed 2 hr or as qualified by demonstration for specific applications. Regardless of the length of the dwell time, the penetrant shall not be allowed to dry. If for any reason the penetrant does dry, the examination procedure shall be repeated, beginning with cleaning of the examination surface. This requirement has been added in edition 2015. Article 7: Liquid Penetrant Examination Verification of Magnetizing power of yoke: The magnetizing power of yokes shall be verified prior to use each day the yoke is used. The magnetizing power of yokes shall be verified whenever the yoke has been damaged or repaired. In earlier edition the Magnetizing Power of yoke was to be verified with the past year for electromagnetic yoke. The above mentioned changes are main changes published in ASME BPVC Section V Edition 2015 for common NDT techniques which needs to be incorporated in the NDE procedures and also in Quality control manual. However, it is needless to say that reading the original code is always important to know the stated and implied requirement of the code.
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BACK TO BASICS
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RADIOGRAPHY TESTING – BASIC PRINCIPLES AND INDUSTRIAL APPLICATIONS M. Arumugam Group Head, Quality Control & Inspection Group, Systems Reliability and Quality Assurance, Liquid Propulsion Systems Centre, ISRO, Thiruvananthapuram -695 547
adiography is a NDT method that utilizes x-rays or gamma radiation to detect discontinuities in materials and to present their images on recording medium. Radiography is used in wide range of applications which includes Engineering, Medicine, Security, Forensics etc. As far as NDT is concerned Radiography Testing (RT) is one of the most important methods. Radiography testing offers many advantages over other NDT techniques.
R
Basic Principles
in a weld is illustrated in Fig.01. The X-ray or Gamma ray incident on the material interacts with it and either par¬tially or fully get absorbed depending upon the thickness and nature of the material. The transmitted radiation is recorded on a photographic film. On processing the film an optical density distribution will be obtained which is related to the transmitted intensity distribution. The flaw appears as a higher optical density (dark) region in the radiograph. The choice of a particular radiography technique is based on the sensitivity requirements.
X-rays were discovered by WC Roentgen in Nov’ 1895. X-Rays & Gamma rays are electromagnetic radiation of the same physical nature as light, but with a very small wave length. Shorter wavelengths permit penetration through materials and hence they are used as NDT tool to examine materials of even very large thickness. Properties of Radiation are given below; •
Undetectable by human senses -
•
Cannot be seen, felt, heard, or smelled
Possesses no charge or mass -
Referred to as photons (packets of energy)
•
Generally travels in straight lines (can bend at material interfaces)
•
Characterized by frequency, wavelength, and velocity
•
Part of electromagnetic spectrum but not influenced by electrical or magnetic fields
The principle of radiography testing is differential absorption, hence it is more suitable for Volumnar defects than planar defects and the defect should be parallel to the Beam. The phenomenon of differential absorption enables us to record the flaw, variation in thickness or composition differences in the object. The basic radiographic method of flaw detection
Figure – 01
Radiography Testing (RT) Selection of radiation source is primarily based on the radiation energy which controls the absorption coefficient “μ” as well as the amount of scatter within the material. For higher contrast “μ” should be as large as possible and scatter should be the minimum. Depending upon the thickness of the object, the optimum energy can be selected and thus the suitable source of radiation, such as, low energy X-ray, Gamma ray or high energy X-ray, so that the exposure can be made in a reasonable time with requisite sensitivity.
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Exposure Techniques The Exposure required for RT depends upon; – – – – –
Material properties Radiation source Film Focus distance (FFD) Type of film and screen Processing condition and the optical density in the radiograph
In the case of X-ray machines, exposure charts are available which gives a correlation between the radiation exposure, the radiation energy required for and the thickness of material generally steel. In the case of gamma radiography also, exposure charts are available, in this case the exposure time varies with the source strength at the time radiography. The radiographer can make necessary changes in exposure factors using the basic relations for changes in material, FFD, film speed or optical density given in the exposure chart. 1.1.1.
Exposure calculation
While using X-Ray machines, the exposure can be calculated using the intensity values which is proportional to the product of the milli ampere and exposure time at one meter from the machine (I1). Intensity is inversely proportional to the square of the distance. I1 D12 = I2 D22 In the case of Gamma rays, even though it is similar in all physical properties to X-rays, the energy released by isotopes is in discrete levels but of X-ray machine (Bremsstrahlung) spectrum is continuous. The population of the radioisotope in a given source depletes with time. Half Value Layer (HVL) is defined as the thickness of a material needed to reduce the radiation intensity to ½ of its original value. The time required for the given source to disintegrate half of its original value is known as half life (T1/2 ). The activity of an isotope is measured in terms of disintegrations per second. Activity corresponding to 3.7 x 1010 dis/sec is designated as one curie (Ci). Source
HVL(Al)
Energy
C-60
5.3 Years
1.33, 1.17
1.3
20
66
Ir-192
74.4 days 0.47,0.32
0.5
15.5
48
Cs-137
33 Years
0.37
17.2
53
0.31, 0.296
RHMCi
HVL (Fe)
Half life
The radiation delivered per hour at one meter by one curie is constant for a particular isotope and
is abbreviated as RHM/Ci. The most important values of commonly used for some of the most commonly used isotopes are given, Radiography Image Quality Radiography Image quality is indicated as Sensitivity which is a measure of the smallest detail that may be detected. Radiography Sensitivity is given by: Smallest size of the artificial defect X 100 Thickness of the object Image Quality Indicators (IQI) or Penetrameters (considered as an artificial defect) are used to assess the sensitivity, lower values indicates better sensitivity.Various types of penetrameters are: Wire, Plaque or Step. Sensitivity depends upon: Contrast & Definition. Contrast Contrast is the variation in density from one area to another area in a radiograph. Two types of contrast are : Subject & Film contrast. Subject contrast can be: Due to thickness variation or In-homogeneities in the object. Film Contrast can be: Due to type of film, variation in film density or film processing. Definition One of the very important factors that affect sensitivity of a radiograph is definition, which is defined as the sharpness or clarity of the radiographic image. ie clear demarcation between two different densities. Definition is controlled by Geometric factors and Film. Geometric factors Source size, Source to Object distance, Oject to film distance: The radiation is not emitted from a spot whether it is X-ray or Gamma ray source. It has got a definite size. This source size affects the unsharpmess in the image. Conventional X-ray machine have focal spot of size 2 x 2 mm to 4 x 4 mm and high energy X-ray machine has focal spot of about 2mm. Similar to the penumbra formation in exposure with light, there will be an un-sharp region formed around the defect in the radiograph which is defined as the geometric un-sharpness (Ug). The following Figure-02, explains the same. The permitted level of geometrical unsharpness is 1% of object thickness or 1.5mm whichever is less. Usually
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Gas porosity.
FFD is chosen in such a way to restrict the Ug within this limit.
Gas hole.
Ug = f* b/a
Slag/Sand inclusion.
f = source focalspot size.
Micro shrinkage - Feathery and sponge Crack.
a = distance from x-ray source to front surface of material/object b = distance from the front surface of the object to the detector Figure -02
Cold shut. Segregation- low and high density material. Mis run. Advantageous and Disadvantageous of RT Advantageous of RT Both surface and Internal defects can be detected.
This is the reason for evolution of Microfocus and Minfocus X-Ray machines which are more common in the recent days.
Thickness - up to 500mm of steel equivalent can be radiographed.
Film
A permanent record is produced.
Each crystal of silver bromide in radiography film acts as a unit in photographic process and if the crystal size of the film emulsion is large the film will have poor definition and high speed. Hence a fine grain film is capable of producing image with higher level of definition. The use fluorescent intensifying screens results in poor definition as the fluorescent light travels for a larger distance on the film.The energy of the photoelectron produced in a lead intensifying screen increases with X-ray energy. Hence their length of path in the film emulsion also varies with X-ray energy, which is the reason for high film unsharpness when higher energy is used.
RT images are easy to interpret. Well documented procedures and techniques are available. It has very few material limitations. Good portability sources.
X-ray equipment for thick (>100mm) is very expensive.
Slag inclusion-ARC. Crack. Undercut. Burn through. Tungsten inclusion-For TIG welds. Castings
specimens
Crack detectability depends upon its opening/ tightness. Not suitable for fine planar defects. Hazardous –Strict safety measures are required during usage.
Weld joints
Lack of fusion (LF).
ray
Film RT is slow and expensive.
Some of the common defects that are revealed in Radiography testing are given below;
Lack of Penetration (LP).
Gamma
Disadvantageous of RT
Common defects revealed in RT
Porosity.
especially
Various Advanced Techniques
Imaging
Radiography
Several different imaging methods are available to display the final image in industrial radiography: -
Film Radiography
-
Real Time Radiography
-
Digital Radiography (DR)
-
Computed Radiography (CR)
-
Computed Tomography (CT)
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1. International Organization Standardization (ISO)
for
•
ISO 4993, Steel and iron castings Radiographic inspection
•
ISO 5579, Non-destructive testing Radiographic examination of metallic materials by X- and gamma-rays - Basic rules
•
ISO 9712, Non-destructive testing Qualification and certification of personnel.
•
ISO 10675-1, Non-destructive testing of welds - Acceptance levels for radiographic testing - Part 1: Steel, nickel, titanium and their alloys
•
ISO 11699-1, Non-destructive testing - Industrial radiographic films - Part 1: Classification of film systems for industrial radiography
•
•
ISO 11699-2, Non-destructive testing Industrial radiographic films - Part 2: Control of film processing by means of reference values ISO 14096-1, Non-destructive testing Qualification of radiographic film digitisation systems - Part 1: Definitions, quantitative measurements of image quality parameters, standard reference film and qualitative control
•
ISO 14096-2, Non-destructive testing Qualification of radiographic film digitisation systems - Part 2: Minimum requirements
•
ISO/IEC 17011, Conformity assessment - General requirements for accreditation bodies accrediting conformity assessment bodies.
2. European Committee for Standardization (CEN) •
EN 444, Non-destructive testing; general principles for the radiographic examination of metallic materials using X-rays and gammarays
•
EN 462-1: Non-destructive testing - image quality of radiographs - Part 1: Image quality indicators (wire type) - determination of image quality value
•
EN 462-2, Non-destructive testing - image quality of radiographs - Part 2: image quality indicators (step/hole type) determination of image quality value
•
EN 462-3, Non-destructive testing - Image quality of radiogrammes - Part 3: Image quality classes for ferrous metals
•
EN 462-4, Non-destructive testing - Image quality of radiographs - Part 4: Experimental evaluation of image quality values and image quality tables
•
EN 462-5, Non-destructive testing - Image quality of radiographs - Part 5: Image quality of indicators (duplex wire type), determination of image unsharpness value
•
EN 584-1, Non-destructive testing Industrial radiographic film - Part 1: Classification of film systems for industrial radiography
•
EN 584-2, Non-destructive testing Industrial radiographic film - Part 2: Control of film processing by means of reference values
•
EN 1330-3, Non-destructive testing Terminology - Part 3: Terms used in industrial radiographic testing
•
ISO/IEC 17024, Conformity assessment General requirements for bodies operating certification of persons.
•
EN 2002-21, Aerospace series - Metallic materials; test methods - Part 21: Radiographic testing of castings
•
ISO 17636-1: Non-destructive testing of welds. Radiographic testing. X- and gammaray techniques with film
•
•
ISO 17636-2: Non-destructive testing of welds. Radiographic testing. X- and gammaray techniques with digital detectors
EN 10246-10, Non-destructive testing of steel tubes - Part 10: Radiographic testing of the weld seam of automatic fusion arc welded steel tubes for the detection of imperfections
•
EN 12517-1, Non-destructive testing of welds - Part 1: Evaluation of welded joints in steel, nickel, titanium and their alloys by radiography - Acceptance levels
•
ISO 19232, Non-destructive testing - Image quality of radiographs
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BACK TO BASICS
CODES & STANDARDS FOR RADIOGRAPHY TESTING
JNDE MARCH 2016
•
EN 12517-2, Non-destructive testing of welds - Part 2: Evaluation of welded joints in aluminium and its alloys by radiography Acceptance levels
•
EN 12679, Non-destructive testing Determination of the size of industrial radiographic sources Radiographic method
•
EN 12681, examination
Founding
-
•
EN 13068, Non-destructive Radioscopic testing
•
EN 14096, Non-destructive testing Qualification of radiographic film digitisation systems
•
EN 14784-1, Non-destructive testing - Industrial computed radiography with storage phosphor imaging plates - Part 1: Classification of systems
•
EN 14584-2, Non-destructive testing - Industrial computed radiography with storage phosphor imaging plates - Part 2: General principles for testing of metallic materials using X-rays and gamma rays
•
ASTM E 280-98
Standard reference radiographs for heavy walled steel castings (4.5-12inch; 114305mm)
•
ASTM E 310-99
Standard reference radiographs for TinBronze castings.
•
ASTM E 390-95
Standard reference radiographs for steel fusion welds
•
ASTM E 431-96
Standard guide to Interpretation of radiographs of semiconductors and related devices.
•
ASTM E 446-98
Standard reference radiographs for steel castings up to 2inch (51mm) thickness.
•
ASTM E 505(1996)
Standard reference radiographs for Inspection of Aluminium and Magnesium die castings.
•
ASTM E 592-99,
Standard Guide to Obtainable ASTM Equivalent Penetrameter Sensitivity for Radiography of Steel Plates 1/4 to 2 in. [6 to 51 mm] Thick with X Rays and 1 to 6 in. [25 to 152 mm] Thick with Cobalt-60.
•
ASTM E 666-97
Standard practice for calculating absorbed dose from Gamma or X-Radiation.
•
ASTM E 689-95 (1999)
Standard reference radiographs for ductile iron castings.
•
ASTM E 746-02
Standard test method for determining relative image quality response of Industrial radiographic film.
•
ASTM E 747-97
Standard Practice for Design, Manufacture and Material Grouping Classification of Wire Image Quality Indicators (IQI) Used for Radiology
Radiographic testing
-
3. ASTM International (ASTM) •
ASTM C 63892(1997)
Standard descriptive nomenclature of constituents of aggregates for Radiation shielding concrete
•
ASTM E 94,
Standard Guide for Radiographic Examination
•
ASTM E 748-95
•
ASTM E142:
Method for Controlling Quality of Radiographic Testing
Standard practices for thermal neutron Radiography of materials.
•
•
ASTM E 155,
Standard Reference Radiographs for Inspection of Aluminum and Magnesium Castings
ASTM E 801(2001),
Standard Practice for Controlling Quality of Radiological Examination of Electronic Devices.
•
ASTM E 80295(1999)
Standard reference radiographs for grey Iron castings upto 4.5inch (114mm) thickness.
•
ASTM E 803
Standard test method for determining the L\D ratio of neutron beams.
•
ASTM E 975-00
Standard practice for X-Ray determination of retained austenite in steel with near random crystallographic orientation.
•
ASTM E 999-99:
Guide for Controlling the Quality of Industrial Radiographic Film Processing
•
ASTM E1000-98:
Guide for Radioscopy
•
ASTM E 1025-98
Standard practice for design, manufacture and material grouping classification of hole type Image quality Indicators (IQI) used for radiology.
•
ASTM E 170-99e1, Standard terminology relating to radiation measurements and dosimetry
•
ASTM E 186-98
Standard reference radiographs for heavy walled (2-4.5inch; 51-114mm) steel castings.
•
ASTM E 19295(1999)
Standard reference radiographs for Investment steel castings of aerospace applications.
•
•
ASTM E 242-95 (2000)
Standard reference radiographs for appearances of radiographic images as certain parameters are changed.
ASTM E 272-99
Standard reference radiographs for high strength copper base and Nickel-Copper alloy castings.
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•
ASTM E 1030-00,
Standard Test Method for Radiographic Examination of Metallic Castings
4. American Society of Mechanical Engineers (ASME)
•
ASTM E 1032-95,
Standard Test Method for Radiographic Examination of Weldments.
•
•
ASTM E 111492(1997)
Standard test method for determining the focal spot of Iridium-192 Industrial radiographic sources.
•
ASTM E 1161-95
Standard Practice for Radiologic Examination of Semiconductors and Electronic Components.
•
ASTM E 116592(2002)
Standard test method for measurement of focal spots of Industrial X-ray tubes by pin hole imaging.
•
ASTM E 1254-98
• •
BPVC Section V, Non destructive Examination: Article 2 Radiographic Examination
5. American Petroleum Institute (API) 1. API 1104, Welding of Pipelines and Related Facilities: 11.1 Radiographic Test Methods 6. SAE Standards AS
Aerospace Standards
AIR
Aerospace Information Reports
Standard guide for storage of radiographs and un exposed radiography films.
AMS
Aerospace Material Specifications
ASTM E 1255-96:
Standard practice for Radioscopy.
ARP
ASTM E 1320-00
Standard reference radiographs for Titanium castings.
Aerospace Recommended Practice
AIR4964
Exposure Levels of Uv Radiation in Non destructive Inspection Processes.
AMS 2175
Castings, Classification and Inspection
AM S 2635
Radiography inspection
•
ASTM E 139090(2000)
Standard guide for Illuminators used for viewing Industrial radiographs.
•
ASTM E 1411-00
Standard practice for qualification of radioscopic systems.
•
ASTM E 1441-
•
ASTM E 1648,
Standard Reference Radiographs for Examination of Aluminum Fusion Welds
AMS 7295/8 Radiographic Paper, 2.5-80 (NON CURRENT Jan 1998)
•
ASTM E 1735,
Standard Test Method for Determining Relative Image Quality of Industrial Radiographic Film Exposed to X-Radiation from 4 to 25 MeV
AMS 7295/9 Radiographic Paper, 2.0-80 (NON CURRENT Jul 1998)
•
ASTM E1742:
Practice for Radiographic Examination
•
ASTM E 1815,
Standard Test Method for Classification of Film Systems for Industrial Radiography
•
ASTM E 1817,
Standard Practice for Controlling Quality of Radiological Examination by Using Representative Quality Indicators (RQIs)
•
ASTM E 2007:
Standard Guide for Computed Radiography
•
ASTM E 2104,
Standard Practice for Radiographic Examination of Advanced Aero and Turbine Materials and Components
•
ASTM E2738:
Standard Practice for Digital Imaging and Communication Non destructive Evaluation (DICONDE) for Computed Radiography (CR) Test methods.
ARP1333
Non destructive Testing of Electron Beam Welded Joints in Titanium Base Alloys
AS7114/4
Nadcap Requirements for Non destructive Testing Facility Radiography
Compiled by: M.Arumugam, Group Head, Quality Control and Inspection Group, SRQA, Liquid Propulsion Systems Centre, ISRO, Thiruvananthapuram-695547.
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LABINO AB MIDBEAM 2.0: THE PERFECT TOOL! AN EXTREMELY ROBUST, LIGHTWEIGHT AND COMPACT UV INSPECTION LIGHT
Standard Version: The MidBeam 2.0 Standard generates an intensity in excess of > 4 500 μW/cm2 (at 15 inches) and is equipped with a white light LED for after inspection. Battery life is 1.5 hours.
Stockholm, Sweden— (October 5th, 2015) - MidBeam 2.0 is an extremely robust hand held lamp especially designed for use by heavy industries with very difficult operating environments. The light is compact in size, with four LEDs in a housing diameter of just 3.15 inches (8 cm)
Aerospace Version: The MidBeam 2.0 Aerospace differs from the Standard version as follows:
Unique Features of MidBeam 2.0: 1. IP68 Waterproof classification: Solids and liquids that often find their way into a light causing UV LEDs to burn cannot penetrate a MidBeam 2.0 unit. 2. Battery indicator: Four colors, green, yellow, orange and red signal the user when the batteries are over 75%, 50-75%, 25-50% and below 25% charged respectively. With less than 10% left the red signal starts flashing. 3. Operates while charging batteries: The battery version can operate like mains while charging the batteries via a connector at the back of the head. Each light consists of 4 LEDs offering an extremely even beam. The switch located at the back of the head provides instant power. It is easy for the battery version to switch batteries. The location of the batteries (inside pistol handle) makes the ergonomics of the unit stable. Four batteries are provided and two are needed to operate. The design of the mains version makes it easy to support the light with a common stand on a bench. MidBeam 2.0 Standard and Aerospace is classified as a Risk Group 3 (High Risk) in accordance with IEC / SS-EN 62471. The MidBeam 2.0 is available in three different versions, as Standard, Aerospace and Aerospace RRES 90061.
A. The Aerospace version does not have a white light LED for after inspection. B. The intensity of the Aerospace version is adjusted to never exceed 4 500 μW/cm2 at 15 inches. C. The battery life of the Aerospace version is in excess of three hours. Aerospace RRES 90061 Version: The MidBeam 2.0 Aerospace RRES 90061 generates an intensity of approximately 2 600 μW/cm2 (at 15 inches). While the remaining characteristics are the same as with MidBeam 2.0 Aerospace above, the optics of this unit is specifically designed to meet the Rolls Royce engineering specification RRES 90061. The beam profile is very crucial for the Aerospace industry. This UV light is specially developed to offer a beam that is extremely homogenous – without any footprints showing from the LEDs, shades, dark spots or other disturbing defects in the beam. Headquartered in Stockholm, Sweden, Labino AB (www.labino.com) is the world's leading manufacturer of ultraviolet equipment. Labino AB is a Swedish-American, family owned company dedicated to the development and manufacture of UV lamps since 1994. Labino AB high quality lights are designed to comply with all relevant international and ASTM standards, and are distributed to over 55 countries worldwide. Labino AB UV lights are used in multiple applications, industrial as well as non-industrial such as Nondestructive Testing, Medical Laboratories, Crime Laboratories, Forensics, UV Curing, leak Detection and others. We are very confident you will enjoy using our new generation of lights that are much lighter and more compact than many comparable products on the market today, but with even more power and higher safety standards. All Labino products comply with the RoHS Directive (2011/65/EU).
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WHAT'S NEW
PRODUCT GALLERY
JNDE MARCH 2016
RADIATION SURVEY METER SMARTRAD
The incident radiation can be displayed in terms of rate as well as dose with settable audible alarm for both Rate & Dose. Thus, SmartRad can be used as a survey meter as well as a dose meter. SmartRad comes in four different variations depending on your application: Mini, Low, Beta & Micro. SmartRad Mini & Low models can be used for general surveymetry and the Beta & Micro are contamination detectors used in detecting radiation contamination in the lab, metal products or in scrap material. Pulsecho’s SmartRads are Next Generation radiation detectors which we ‘MAKE IN INDIA’.
Pulsecho’s SmartRads are radiation detectors with a graphic LCD & menu driven operation. The graphic LCD along with its backlight enables SmartRad to show a digital reading along with an analogue bar to show sudden variations. SmartRad also shows the next calibration date.
WHITE CONTRACT(WC-23) & MAGNETIC INKS FOR MPI PRADEEP NDT PRODUCTS WC-23 is ready to use, quick drying white contrast coat supplied in aerosol cans which provide bright and uniform coat instantly with 95% contrast ratio. It is Operator & Environmental friendly. The Matt & non fluorescent coating makes it most suitable to use with black & Fluorescent Magnetic Powders & inks manufactured by us for dry or wet MPI testing. Black / Fluorescent Magnetic ready to use liquids manufactured by us are extremely sensitive and highly reliable.. For more information, please visit our web site or contact us on 00 91 22 67988781 / 2 / 3 (India) www.pradeepndt.com
SIMS MPI - Digital Series SIMS (Suvidha Inspection Methods & Systems) a Hyderabad based NDT Equipment manufacturing company founded in 2000 has launched the Digital Series of MPI (Magnetic Particle Inspection) equipment in December at the NDE 2015. The PLC & HMI Controlled MPI machine is the first of its kind in the country which is indigenously designed & manufactured meeting international standards. The Wet Horizontal Bench Type MPI machine ranging from 4000 to 14000 Amps output with a PLC & HMI automates the operation of the Head Shot & Coil Shot Methods and the Demagnetization as well. Ten different Job Sizes and their Testing Parameters including AC/ HWDC, Head Shot / Coil Shot / Both, Demag -
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Required / Not required and the Magnetic Bath ON / OFF. The Mag Current, Mag Time, Demag Current and Demag Time are calculated by the PLC, taking the Dia of the Job to be tested from the User. Provision is given to edit / delete any of the above mentioned saved parameters. All these operations are done through the Touch Screen on the HMI. After duly clamping the Test Piece between the Head & Tail Stocks, once the saved Job is loaded, all that the operator has to do is press the foot switch. As per the saved test parameters, the tests and/or demag cycle will be carried out by the PLC automatically. The operator then has to just de-clamp the test piece/job and clamp the next one. Thus in each Job Test Cycle, at least 18-20 anolog switching operations are avoided thus resulting in Higher Productivity. Further, since the PLC can be hooked on to a computer, all the test data can be transferred and stored in the computer. This will enable generation of several types of reports and ensures data integrity too. ADVANSCAN AS-414 – CSCR Electronic & Engineering Co. (I). Pvt. Ltd.'s, New Generation Ultrasonic Flaw Detector Advanscan AS-414 is provided with a Unique & Innovative feature Continuous Strip Chart Recorder (CSCR) that Captures, Stores, Retrieves, Analyzes & Prints reports in convenient A4 size paper of the complete job scanning information & also allows multiprobe scan collated on one report. The product features a 2 Axis information of proportional echo amplitude & scanning time. Has up to 25 sets of recording each of 60 minute with built-in memory. It is a Powerful tool for offline analysis of scan. It has a full screen display of both, A-Scan & Continuous Chart Recording simultaneously. Provides continuous recording for full proof scan record. Email : ndtsales@eecindia.com
FLIR A6700sc FLIR A6700sc thermal imaging camera
Compact, thermal imaging camera with cooled InSb detector at an extremely affordable price. Designed for electronics inspections, medical thermography, manufacturing monitoring, and non-destructive testing, FLIR A6700sc is ideal for high-speed thermal events and moving targets. Key features:•
Excellent image quality: 640 x 512 pixels
•
High sensitivity: <20 mK
•
High speed image acquisition: up to 480 Hz
•
Synchronization: with other instruments
•
Extender rings available
•
Wide choice of optics
•
Very low noise: cryogenically cooled InSb Detector
For further website.
information,
please
visit
our
Product Gallery The newly introduced 'Product Gallery' section will throw light on New Products in NDT. JNDE welcomes you to introduce your new product to gain eyeballs. Send in your contributions with 8-10 lines describing the product supported with an image to isnt.jnde@gmail.com at least 2 months before Publishing date of JNDE. JOURNAL OF NON DESTRUCTIVE TESTING & EVALUATION ————————————————————————| 61
EVENTS
JNDE MARCH 2016
LIST OF INDIAN / INTERNATIONAL CONFERENCE/ WORKSHOPS IN NDT (2016) APRIL 2016 A
2562285; Fax: +1 937 256 2603; Email: chris@ mfpt.org; Web: www.mfpt.org/mfpt2016/
1 12-14: Aerospace Event 2016. V Venue: BAWA Conference Centre, Filton, Bristol, U UK. C Contact: Karen Cambridge or Suzanne Purdy, C Conference Services, BINDT, Newton Building, St G George’s Avenue, Northampton NN2 6JB, UK. Te Tel: +44 (0)1604 89 3811; Fax: +44 (0)1604 8 89 3861; Email: conferences@bindt.org; Web: w www.bindt.org 1 12-14: Plant & Asset Management 2016.
13-17: 19th World Conference on NDT (WCNDT). Organised by the German Society for NDT (DGZfP). Venue: Munich, Germany. Contact: Stef Dehlau, German Society for Nondestructive Testing (DGZfP), Max-PlanckStraße 6, 12489 Berlin, Germany. Tel: +49 30 67807 120; Fax: +49 30 67807 129; Email: tagungen@ dgzfp.de; Web: www.wcndt2016.com
V Venue: NEC, Birmingham, UK. C Contact: DFA Media Limited, 192 High Street, To Tonbridge, Kent TN9 1BE. Tel: 01732 370340; F Fax: 01732 360034; Email: info@dfamedia. c co.uk; Web: http://www.maintenanceuk-expo. c com
JULY 2016 4-8: 5th International symposium on Laser Ultrasonics and Advanced Sensing Venue: Linz, Austria Web: lu2016.at
M MAY 2016 1 19-20: International Conference on Diagnostics of Structures aand Components using the Metal Magnetic Memory Method. O Organised by the Hungarian Association for NDT a and co-sponsored by EFNDT. Venue: Budapest, Hungary. Contact: Laszlo Gillemot, Hungarian Association for Non-Destructive Testing (MAROVISZ), 8-10 Varrogepgyar Str, Budapest H-1211, Hungary. Tel: +36 61 277 5696; Email: gillemot@ marovisz.hu; Web: www.marovisz.hu 24-26: MFPT 2016 and Instrumentation Symposium.
JUNE 2016
ISA’s
62nd
International
Venue: Dayton Convention Center, Dayton, Ohio, USA. Contact: MFPT Headquarters (Chris Pomfret or Rick Wade), 5100 Spring eld Street, Suite 420, Dayton, OH 45431-1264, USA. Tel: +1 937
4-8: 13th Quantitative Infrared Thermography Conference (QIRT 2016) Venue: Gdansk University of Technology, Poland Web: www.qirt2016.gda.pl 5-8: 8th European Workshop on Structural Health Monitoring (EWSHM 2016) Venue: Spain, Bilbao Web: www.ewshm2016.com 14-20: Advanced Training Nondestructive Testing & Evaluation in Civil Engineering This training aims to provide basic and cuttingedge knowledge on the latest development of instrumentation, principles, automation, signal processing, problem-solving techniques and case studies across multiple NDT&E-CE’s disciplines.
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Venue: BAM - Federal Institute for Materials Research and Testing in Berlin/Germany. Web: www.ndte-training.bam.de/en/home/index.htm
7-9: 32nd European Conference on Acoustic Emission Testing (EWGAE 2016).
16-22: Review of Progress in Quantitative Non-destructive Evaluation (QNDE 2016)
Contact: CNDT – EWGAE 2016, Brno University, Czech Republic. Tel: +420 541 143 229; Email: cndt@cndt.cz; Web:www.cndt.cz/ewgae2016
Venue: Georgia Tech Hotel and Conferenec Center, Atlanta,USA. Email: pkbackst@iastate. edu; Web: www.qndeprograms.org 25-26: Digital Imaging 2016. For suppliers and users of digital and radiographic imaging. Venue: Foxwoods Connecticut, USA.
Resort,
Mashantucket,
Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus, OH 43228-0518, USA. Tel: +1 614 274 6003; Fax: +1 614 274 6899; Email: conferences@asnt.org; Web: www.asnt. org 27-29: Ultrasonics for NDT. Venue: Foxwoods Connecticut, USA.
Resort,
Mashantucket,
Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus, OH 43228-0518, USA. Tel: +1 614 274 6003; Fax: +1 614 274 6899; Email: conferences@asnt.org; Web: www.asnt. org SEPTEMBER 2016 5-7: 11th International Conference on Advances in Experimental Mechanics.
Venue: Prague, Czech Republic.
12-16: 9th EUROSIM Congress on Modelling and Simulation.Venue: City of Oulu, Finland. Contact: Esko Juuso, President, EUROSIM. Email: of ce@automaatioseura. ; Web: www. eurosim.info OCTOBER 2016 4-6: 12th International Conference on NDE in Relation to Structural Integrity for Nuclear and Pressurized Components Venue: Dubrovnik, Croatia; Email: 12thnde@12thnde.com; Web: www.12thnde.com 24-27: 75th ASNT Annual Conference. Venue: Long Beach Convention Center, Long Beach, California, USA. Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus, OH 43228-0518, USA. Tel: +1 614 274 6003; Fax: +1 614 274 6899; Email: conferences@asnt.org; Web: www.asnt. org 25-27: 16th International exhibition of equipment for nondestructive testing and technical diagnostics.
Co-sponsored by BINDT.
Venue: Crocus Expo, Moscow, Russia
Venue: University of Exeter, UK.
Contact: 190000, Russia, St. Petersburg, Yakubovich st., 24A, Russia. Web: www.ndtrussia.ru
Contact: The British Society for Strain Measurement (BSSM). Tel: +44 (0)7756 915295; Email: info@bssm.org; Web: www. bssm.org
DECEMBER 2016 15 -17th – NDE 2016 Venue - Alsaj Convention Centre, Trivandrum, India.
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EVENTS
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NDE 2015 EXPO - MAKE IN INDIA N IISNT HYDERABAD CHAPTER A BRIEF REPORT ON NDE-2015 2 25th National Seminar & International Exhibition o on Non Destructive Evaluation : NDE – 2015 w with the theme “NDE for Make in India” was s successfully conducted during 26-28 Nov, 2 2015 at Hyderabad International Convention C Centre – HICC, Hyderabad. While Dr G Satish R Reddy, Scienti c Adviser to Diffence Minister, G Government of India inaugurated the Seminar on 2 26 Nov, 2015. Dr Dinesh Kumar Likhi, Chairman & Managing Director, Midhani inaugurated the In International Exhibition on the same day. Sri R N Jayaraj, Former Chairman & Chie Executive, N Nuclear Fuel Complex graced the valedictory ffunction on 28 Nov, 2015. In all, 635 NDE p professionals / experts including delegates, in invited speakers, chief executives, captains o of industry, leading equipment manufacturers a across the globe attended the seminar which le left an indelible mark on one and all. T The Executive Committee of Hyderabad Chapter p plunged into action the moment Chapter was b bestowed with the honor of hosting NDE-2015. U Utilizing the experience of the Pune Chapter and rrevised SOPs, formed various committees, xed tthe responsibilities and commenced the work in tthe right earnest under the guidance of Head Q Quarters. Sri P Mohan, Sri C Phanibabu, Sri M V Venkat Reddy, Sri GVS Hemantha Rao [Technical], S Sri G Suryaprakash [Exhibition & Marketing], S Sri M Ravi [Finance], Sri J R Joshi [Strategy / Planning], Sri Atul Khanna [Hospitality], Sri Sarath Reddy [Logistics], Sri MNV Viswanath & Sri V Vijaya Kumar [Event Management] Sri B Ravinder [Registration] formed the core group which led from the front. Executive / Core committee met regularly and monitored the progress of the work against the target dates. The rst and the right step was zeroing on HICC as the venue. Immediately appropriate Logo was designed for the of NDE – 2015 and First Brochure inviting technical papers; and giving the details such as delegate fee for various categories, tariff for exhibition stalls, accommodation, tourist information was brought out and sent to the potential participants / industries. Simultaneously, website was launched facilitating on-line registration. Sri B Ravinder, maintained the database of delegates of different
categories. Website was continuously updated. Parallelly, Chief Patron of the seminar Sri N Saibaba, Distinguished Scientist & Chairman & Chief Executive, Nuclear Fuel Complex wrote letters to captains of ndustry seeking support and participation. A press Conference was held at Hotel Marriott, Hyderabad and a Poster depicting salient features of NDE-2015 was released to disseminate the information among Engineering Colleges, Institutions, Sponsors & Donors, National Laboratories and all the concerned. National President of ISNT Sri V Pari, Sri P Mohan, Sri N Saibaba and Sri J R Joshi briefed the Print & Electronic media. Final Brochure giving the full details, exhibitions stalls’ lay-out & booking status, nearby hotels & their tariff was brought out, circulated and posted on the website. Pre-conference tutorials: As a pre-curser to the main seminar, Pre-conference Tutorials were organized on 24th and 25th November 2015 at Hotel Katria, Hyderabad. M/s Olympus handled the tutorials on PAUT&TOFD and M/s GE took care of Digital Radiography along with experts from industry. NDE for MSMEs was taken up with the help of Sri Sivaprasada Reddy & experts from ISNT-Hyderabad chapter. Sri Hemantha Rao ably supported by Sri GSS Sastry & Sri B S Rama Rao shouldered this responsibility. Kit containing course material was given to the participants. A book “Practical NDT by Dr Baldev Raj was given to participants of NDE for MSMEs. 29 delegates for PAUT&TOFD, 21 delegates for digital Radiography and 42 delegates for NDE for MSMEs attended the course. All the participants were given certi cate of participation. [photos] Inaugural Session: The Seminar began on 26 Nov, 2015 on an auspicious note with lighting of lamp followed by an invocation song. Sri Mohan, Chairman of the Seminar welcomed the chief Guest and the gathering. Sri Pari, National President, ISNT gave a glimpse of the activities of ISNT during the past 25 years. Sri J R Joshi, Vice Chairman of the Seminar made a brief but excellent presentation on the role NDE is going to play in realizing the avowed objective of “Make in India”. Sri C Phanibabu, Convener of the Seminar gave an overview of the seminar. Dr Dinesh Kumar Likhi, CMD, Midhani
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brought out the role of NDE in churning out quality strategic materials. Dr G Satish Reddy, Scienti c Adviser, Ministry of Defence gave an inspiring inaugural address putting forth the unfolding industrial scenario and the challenges before the NDT fraternity. He, ably supported by Sri Dilip Takbote & Sri Rajul Parikh presented national NDT awards in various categories to the best performers. ISNT-Hyderabad Chapter received the Best Chapter Award for the year 2015 amidst thunderous applause. Sri G Suryaprakash, Chairman, Exhibition Committee & Sri Atul Khanna, Chairman, Hospitality Committee together proposed vote of thanks. All the delegates gave a standing ovation to Bheeshma Pitamaha of NDT in India, Sri K Balaramamoorty who graced the inaugural session and the exhibition.
of which 23 were invited talks. 150 contributory papers were selected for oral presentation and the rest were listed for Poster-session. On the rst day 4 plenary talks were arranged after lunch. All the technical papers were grouped into 29 sessions and presentations were held parallelly in 5 halls on the 2nd and 3rd day. 30 minutes for invited speakers and 15 minutes for the contributory papers were the times allotted respectively. For identifying the best papers, the sessions’ chairmen were given evaluation sheets with maximum marks for each attribute. Similarly, for selecting the best posters, a three-member committee was constituted that went around and interacted with the poster presenters. Each delegate including invitees was given a kit containing Souvenir, pad, pen, CD, program booklet.
Memorial Talks: Dr Dinesh Kumar Likhi, CMD, MIDHANI delivered Prof A K Rao memorial lecture and Dr P Chellapandi, CMD, BHAVINI gave V S Jain memorial lecture (Shri Rajan Babu Delivered the lecture)
International Exhibition of NDT equipment, accessories & services: Dr Dinesh Kumar Likhi, CMD, Midhani inaugurated the international exhibition on 26 Nov, 2015 after the inaugural session. Exhibition was organized in Hall number 4 of the sprawling Hyderabad International Convention Centre. 60 leading NDT equipment manufacturers showcased their state-ofthe-art hardware and software. About 8000 professionals including many other visitors had a glimpse of the equipment over three days
Technical Sessions: Technical committee under the chairmanship of Sri GVS Hemantha Rao put in steadfast work and ensured participation of good number of delegates with quality technical papers. In all, 248 abstracts were received, out
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and exhibitors got good no of enquiries. Dr. K. Jayraman, Director, DRDL spent full 2 hours in the stalls with keen interest and gave away mementos to the exhibitors. Cultural programs: Delegates had memorable evenings on 26th and 27th November, 2015. A “Violin Symphony” by Sri Ashok Gurjale & Group of 25 artists of Aarabhi School organized on 26th November, 2015 evening at HICC, Hyderabad enthralled the music loving delegates. “Ghazal & Musical Night” by Sri B. Vinod Babu & Troupe, Sangeet Sitare on 27th evening at Rock Heights, Shilparamam, Hyderabad lifted the spirits of the delegates to new heights. While technical papers touched the minds of the delegates, cultural programs stirred their souls. Souvenir: Sri Venkata Reddy put in herculean efforts and brought out the souvenir in a record time, the quality of which received accolades from everyone. Valedictory: Sri R N Jayaraj, gave a brief, but inspiring valedictory talk on the journey of NDE in India and gave away Prizes to the winners of poster session, oral presentations, exhibition stalls. On this occasion Sri D J Varde, took charge as National President of ISNT from Sri
Pari and sought the cooperation of everyone in taking ISNT ahead. Last word: All the good things have to come to an end. So did the NDE-2015. Quality technical presentations, the Souvenir, display of the latest NDT equipment, excellent venue, beautiful ambience, delicious food; melli uous, exciting and engaging cultural programs, logistic support, cozy Hyderabad weather and unforgettable hospitality – all these culminated in creating a great sense of satisfaction among the delegates - both on the professional and personal fronts. Everyone left HICC, Hyderabad with sweet memories looking forward to an exciting NDE2016 at Trivandrum. ISNT acknowledges the support of: ISNT head Quarters led by S/Sri Pari, Rajul Parikh & S Subrahmanian, Principal Sponsors M/s Olympus, Platinum Sponsor-M/s GE, Gold Sponsor- M/s V J Technologies and Sponsors -M/s Blue Star, M/s FLIR, M/s EECI, and MIDHANI, SPEC, ADVANCED OEM SOLUTIONS; Defence Research & Development Organization [DRDO], Department of Atomic Energy [DAE], and Indian Space Research Organization [ISRO] etc., for their unstinted support.
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NCB Meeting - 5th March 2016 NGC Meeting - 6th March 2016 Venue ; ISNT HO Chennai NCB Meeting - 4th June 2016 NGC Meeting - 5h June 2016 Venue: In Mumbai hotel arranged by Mumbai Chapter
NATIONAL GOVERNING COUNCIL MEMBER'S LIST (NGC) 1. Shri D.J. Varde Cell: 9821131522 djvarde@gmail.com admpmtc@gmail.com 2. Dr. Prabhat Kumar Cell: 9894088448 prabhatbhavini@gmail.com 3. Shri R.J. Pardikar Cell: 9442613146 r.j.pardikar@gmail.com 4. Dr. B. Venkatraman Cell: 9443638974 bvenkat@igcar.gov.in qadbvr@gmail.com 5. Shri Rajul R. Parikh Cell: 9820192953 rajulparikh@eecindia.com / ndtsales@eecindia.com 6. Shri Samir K. Choksi Cell: 9821011113 Choksiindia@yahoo.co.in 7. Shri P. Mohan Cell: 94901 67000 metsonic@sify.com / mohanp45@rediffmail.com 8. Shri S. Subramanian Cell: 9444008685 nricsubramanian@gmail.com 9. Shri P.V. Sai Suryanarayana Cell: 9490142539 pvss@shar.gov.in / sai895956@gmail.com
NCB Meeting - 24th September 2016 NGC Meeting - 25th September 2016 Venue ; ISNT HO Chennai NGC/NCB Meeting - 14th December 2016 Venue ; NDE Hotel arranged by Trivandrum Chapter AGM : 16th December
NATIONAL CERTIFICATION BOARD MEMBER'S LIST (NCB) 1. Dr.B.Venkatraman Mobile : 9443638974 Email : bvenkat@igcar.gov.in / qadbvr@gmail.com 2. Dr. M.T. Shyamsunder Mobile : 0'9880508266 Email : mt.shyamsunder@ge.com / controller.exams.ncbisnt@gmail.com 3. Shri P.P. Nanekar Mobile : 0'9892161750 Email : pnanekar@barc.gov.in / paritoshn@yahoo.com 4. Shri B. K. Shah Mobile : 0'9969190618 Email : bks0490@yahoo.co.in 5. Shri T. Loganathan Mobile : 9442121839 Email : loganath@igcar.gov.in 6. Shri S.K. Bandyopadhyay Mobile : 0'9433070529 Email : Subrata1950@gmail.com 7. Shri R.J. Pardikar Mobile : 0'9442613146 Email : r.j.pardikar@gmail.com 8. Shri N.V. Wagle Mobile : 0'9821888658 Email : ulhaswagle@yahoo.co.in / nvw2011@gmail.com
10. Shri V. Pari Cell: 9840104928 scaanray@vsnl.com / pari@scaanray.com
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NGC-NCB
MEETING Updates
RESOURCES
JNDE MARCH 2016
QUALIFICATION OF NDT PERSONNEL Q IS ISNT/NCB Certi ed NDT Personnel Level I, Level II, Level III L T The certi cate of competence is issued in a accordance with IS: 13805 or other international s standards as the case are. N Notes:
He shall receive the necessary instruction and/ or supervision from level II or level HI personnel. He shall not be responsible for the choice of the test method or technique to be used nor for the assessment of test results, 3.3 NDT Level II
G General information about levels
An individual certi ed to NDT level II is quali ed to perform and direct non-destructive testing according to established or recognized techniques. He shall be competent to choose the test techniques to be used, to set up and calibrate equipment, to interpret and evaluate results according to applicable codes, standards and speci cation, to carry out all duties for which a level I individual is quali ed and to check that they are properly executed, to develop NDT procedures adopted to problems which are the subject of an NDT speci cation, and to prepare written instructions, organize and report the results of non-destructive tests. He shall also be familiar with the scope and limitations of the method for which he is quali ed, and able to exercise assigned responsibility for on the job training and guidance of trainees and NDT level I personnel.
A Abstract from IS 13805:2004
3.4 NDT Level III
3 LEVELS OF COMPETENCE
An individual certi ed to NDT level III shall be capable of assuming full responsibility for a test facility and staff, establishing techniques and procedures, interpreting codes, standards, speci cations and procedures to be used. He shall have the competence to interpret and evaluate results in terms of existing codes, standards and speci cations, a suf cient practical background in applicable materials, fabrication and product technology to select methods and establish techniques and to assist in establishing acceptance criteria where no standard practices are otherwise available, general familiarity with other NDT methods, and the ability to guide and train level I and level II personnel.
1) The details here are incomplete and are likely to be in gross error. The information will be updated after receiving feedback from Certi cate holder. 2) The certi cate holders whose name is not appearing here are requested to please inform to us at offc@isnt.org 3) The names of the certi cate holders which are not valid currently will be removed in three months time if no information is received from the certi cate holder. 4) The organization is at the time of certi cate issue and it quite likely the person may not be with the same organization
3.1 Classi cation An individual certi ed in accordance with this standard shall be classi ed in one of the three levels depending upon his respective level of competence. One who has not yet attained certi cation may be registered as a trainee. 3.2 NDT Level I An individual certi ed to NDT level I is quali ed to carry out NDT operations according to written instructions. He shall be able to set up the equipment, to carry out the tests, to record the results obtained, to classify the results in terms of written criteria; and to report the results.
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Training & Certi cation Course on Leak Testing Level-II As per SNT-TC-1A (2006) Course: April 18 – 22, 2016 Examination on 23rd April 2016 Organised by Indian Society for Non-destructive Testing Chennai Chapter The Venue, Date and Time Indian Society for Non-destructive Testing Chennai Chapter Module No. 60, Readymade Garments Complex, Third Floor, SIDCO Industrial Estate, Guindy, Chennai – 600032. Date: 18th April 2016 Timings: 9.00 TO 18.00 Hrs.
Communication and Correspondence: Shri.R.Subbaratnam, Course Director, ISNT, Chennai chapter Module No. 59, Readymade Garments Complex, Third Floor, SIDCO Industrial Estate, Guindy, Chennai – 600032. Phone: 044-6538 6075, 45532115 Email: isntchennaichapter@gmail.com
NDT Level-III Refresher Course at Mumbai, India Fees details for Refresher Courses are given below: Method
Course Duration
Dates
Course Fee in INR
Tax (@14.5%) in INR
Total in INR
Visual testing (VT)
3days
23rd April 2016 to 25th
12,000
1,740
13,740
Eddy current (ET)
4 days
26rd to 29th April 2016
16,000
2,320
18,320
Liquid Penetrant Testing (PT)
3 days
30th April 2nd May 2016
9,000
1,305
10,305
Magnetic Particle Testing (MT)
3 days
3th to 5th May 2016
9,000
1,305
10,305
Radiographic Testing (RT)
5 days
6th to 10th May 2016
15,000
2,175
17,175 17,175
Basic
5 days
11th to 15th May 2016
15,000
2,175
Ultrasonic Testing (UT)
5 days
16th to 20th May 2016
15,000
2,175
17,175
Leak Testing (LT)*
3 days
13th to 15th May 2016
12,000
1740
13,740
Indian Society for Non-Destructive Testing Mumbai Chapter B-401-402, Raylon Arcade, 4th Floor, Ram Krishna Mandir Road, Kondivita, J.B. Nagar, Andheri (East) MUMBAI -400 059 Attn: Shri Niranjan Sthalekar Ph:+91 22 28327521 Mob: +919869642505 (Monday to Saturday- From IST 09:00 hrs to 17:00 hrs) E Mail: isntmumbai@gmail.com; offc@isnt.org
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ADVERTISER'S INDEX
JNDE MARCH 2016
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Hi Tech Imaging Pvt Ltd
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P-Met High Tech Co.Pvt Ltd
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12
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Pulsecho Systems (Bombay) Pvt Ltd
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Insight Quality Service
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Ferrochem
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Electronic & Engineering Co. (I) Pvt. Ltd
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Electro Mag eld & Eastwest Engineering
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Olympus Medical Systems India P. Ltd
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