ID: 766338 Internship(3181901)

APPLICATION OF NDT TESTING IN

FABRICATION INDUSTRY

AN INTERNSHIP REPORT

Submitted by

ARYANS VIRENDRABHAI DOBARIYA

210760119023

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

In
Mechanical Engineering

Shree Swami Atmanand Saraswati Institute of Technology,

Surat

Gujarat Technological University, Ahmedabad

April, 2025

Gujarat Technological University SSASIT

ID: 766338 Internship(3181901)

Shree Swami Atmanand Saraswati Institute of Technology

Opp. Kapodra Police Station, Varachha Road, Surat-395006

CERTIFICATE

This is to certify that the project report submitted along with the project entitled application

of NDT testing in fabrication industry has been carried out by Aryans V. Dobariya under

my guidance in partial fulfillment for the degree of Bachelor of Engineering in Mechanical

engineering, 8th Semester of Gujarat Technological University, Ahmadabad during the

academic year 2024-25.

Date:

Place:

Prof. Mayur S. Modi Dr. Jignesh G. Vaghasiya

(Assi. Prof. – MED) (I/C Principal)
Internal Guide Head of Department

Gujarat Technological University SSASIT

ID: 766338 Internship(3181901)

INDUSTRY LETTER HEAD

Gujarat Technological University SSASIT

ID: 766338 Internship(3181901)

Shree Swami Atmanand Saraswati Institute of Technology

Opp. Kapodra Police Station, Varachha Road, Surat-395006

DECLARATION

We hereby declare that the Internship report submitted along with the Internship entitled

application of NDT testing in fabrication industry submitted in partial fulfillment for the

degree of Bachelor of Engineering in Mechanical engineering to Gujarat Technological

University, Ahmedabad, is a Bonafide record of original project work carried out by me at

Metafirm Metallurgical Services under the supervision of Mr. Bharat M. Gajera and that

no part of this report has been directly copied from any students’ reports or taken from any

other source, without providing due reference.

Name of student Signature

Aryans V. Dobariya

Gujarat Technological University I SSASIT

ID: 766338 Internship(3181901)

ACKNOWLEDGMENT

The success of any task relies on the efforts made by person but it cannot be achieved

without cooperation of other persons which are being helpful. So, I would like to thank

SHREE SWAMI ATMANAND SARASWATI INSTITUTE OF TECHNOLOGY

and METAFIRM METALLURGYCAL SERVICES for giving us the opportunity of

doing this Summer Internship.

The entire session of our internship completion was a great experience providing us with

the insight & invocation into learning various mechanical engineering concepts &

benefits of team work. We would like to take this opportunity to express our sincere

thanks to all those people without whose support and co-operation, it would have been

difficult to complete this internship.

Primarily, I am very much thankful to our Internship Mentor Mr. Bharat Gajera and

PMMS Internship guide Prof. Mayur S. Modi for their leading guidance and sincere

efforts throughout internship. They took deep interest in simplifying the difficulties. Also,

they have been consistent source of inspiration for us.

I am grateful to our H.O.D. Prof. Anil M. Mangukiya and our beloved Principal Dr.

Jignesh Vaghasiya for providing us deep knowledge and all necessary resources.

I am also thankful to our Friends and Non-teaching Staff for their valuable time & help

for completion of internship.

Once again, I am grateful to all those without whom this work would not has been

successful.

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ID: 766338 Internship(3181901)

ABSTRACT

As per GTU Academic Syllabus, they have introduced a minimum of twelve weeks of
Internship / Industrial Training in an Industry to get exposure to the practical aspects in
the field of Mechanical Engineering. So, I have applied for interviews in some of the
industries related to mechanical engineering and got selected in Metafirm metallurgical
services as an Intern. At the beginning of the Internship, I get to know about the different
type of material testing methods. I learn different method to analyze material properties
during my period of Internship. The goal of this internship is to learn metallurgical
properties which can be helpful in the future.

This internship experience has been an essential step in my professional journey,

bridging the gap between academic knowledge and industrial application, preparing me
for future career opportunities in the mechanical engineering domain.

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ID: 766338 Internship(3181901)

LIST OF FIGURES

Fig. 4.1 Working Principle Of Spectrometer ...................................................................... 10

Fig. 4.2 Spectrometer ......................................................................................................... 11
Fig. 4.3 Spectrometer And Trolly........................................................................................ 12
Fig. 4.4 Assembly And Disassembly Of Machine ............................................................... 12
Fig. 4.5 Working Principle Of XRF....................................................................................... 14
Fig. 4.6 PMI Machine ......................................................................................................... 14
Fig. 5.1 Heat Exchanger Tubes ........................................................................................... 17
Fig. 5.2 Chemical Composition Of SS304 And SS316 ......................................................... 18
Fig. 5.3 Inspection Of Skeleton........................................................................................... 18
Fig. 5.4 Design Of Heat Exchanger ..................................................................................... 19
Fig. 5.5 PMI Of Complete Assembly ................................................................................... 19
Fig. 5.6 Process Equipment ................................................................................................ 20
Fig. 5.7 Inside Of Equipment .............................................................................................. 20
Fig. 5.8 Design Of Spool And Sample Report ..................................................................... 21
Fig. 5.9 PMI Testing At LTPC ............................................................................................ 22
Fig. 5.10 Mixed Up Material ............................................................................................... 22
Fig. 5.11 Workshop Of Anandia ......................................................................................... 23
Fig. 5.12 Material Inspection By XRF.................................................................................. 23
Fig. 5.13 Hajira Port ............................................................................................................ 24
Fig. 5.14 Antique Items ...................................................................................................... 24
Fig. 5.15 Scrape Yard .......................................................................................................... 25
Fig. 6.1 Step By Step Process.............................................................................................. 27
Fig. 6.2 Emery Papers ......................................................................................................... 27
Fig. 6.3 Replica Of Polished Surface ................................................................................... 30
Fig. 6.4 Optical Microscope ................................................................................................ 31
Fig. 6.5 Scanning Electron Microscope .............................................................................. 32
Fig 7.1 Principle Of Feritscope ........................................................................................... 33
Fig 7.2 Feritscope ............................................................................................................... 34
Fig 7.3 Calibration Blocks ................................................................................................... 34
Fig 7.4 Weld Joint Testing ................................................................................................... 35
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Fig 7.5 Measuring Instrument With Calibration ................................................................ 37

Fig 7.6 MPT Testing ............................................................................................................ 39
Fig 7.7 DPT Test ................................................................................................................. 42

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ID: 766338 Internship(3181901)

ABREVIATION

NDT Non-Destructive Testing

ISO International organization for standardization
PMI Positive Material Identification
XRF X-Ray Fluorecence
OES Optical Emission Spectroscopy
CRM Certified Reference Material
TPI Third Party Inspector
SEM Scanning Electron Microscope
EDS Energy Dispersive X-Ray Spectroscopy
OM Optical Microscopy
ASS Austenitic Stainless Steel
DSS Duplex Stainless Steel
FN Ferrite Number
HAZ Heat-Affected Zone
MPI Magnetic Particle Inspection
DPI Dye Penetrant Test
ASTM American Society for Testing and Material

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TABLE OF CONTENT

DECLARATION ................................................................................................................ I

ACKNOWLEDGMENT .................................................................................................. II

ABSTRACT ..................................................................................................................... III

LIST OF FIGURES .........................................................................................................IV

ABREVIATION ...............................................................................................................VI

TABLE OF CONTENT ................................................................................................. VII

CHAPTER 1: INTRODUCTION TO INDUSTRY ........................................................ 1

1.1 DETAIL: ................................................................................................................. 1

1.2 ABOUT: ................................................................................................................. 1

1.3 QUALITY POLICY: .................................................................................................. 2

1.4 SCOPE OF WORK: ................................................................................................. 2

CHAPTER 2: WHAT IS MATERIAL SCIENCE AND METALLURGY? ................. 4

2.1 MATERIAL SCIENCE: ............................................................................................. 4

2.2 METALLURGY: ....................................................................................................... 4

2.2.1 Definition: .................................................................................................... 4

2.2.2 Importance of Metallurgy: ........................................................................... 5

2.2.3 History of Metallurgy: .................................................................................. 5

2.2.4 Classification of Metallurgy: ......................................................................... 6

CHAPTER 3: TESTING OF MATERIAL ...................................................................... 7

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3.1 INTRODUCTION: ................................................................................................... 7

3.2 DESTRUCTIVE TESTINNG: ..................................................................................... 7

3.3 NON-DESTRUCTIVE TESTING:............................................................................... 8

CHAPTER 4: CHEMICAL ANALYSIS BY PMI ......................................................... 10

4.1 PORTABLE SPECTRO TESTING:............................................................................ 10

4.1.1 Working Principle: ...................................................................................... 10

4.1.2 Spectroport by Ametek: ............................................................................. 11

4.1.3 Product Specifications:............................................................................... 11

4.1.4 Advantages: ................................................................................................ 12

4.1.5 Disadvantages: ........................................................................................... 13

4.2 XRF TESTING: ...................................................................................................... 13

4.2.1 Working principle: ...................................................................................... 13

4.2.2 Positive material identification by Hitachi X-MET8000:............................. 14

4.2.3 Product Specification: ................................................................................ 15

4.2.4 Advantages: ................................................................................................ 15

4.2.5 Disadvantages: ........................................................................................... 16

CHATER 5: WORKDONE ON CHEMICAL ANALYSIS .......................................... 17

5.1 PMI BY OES METHOD AT DIFFERENT INDUSTRIES: ............................................ 17

5.1.1 TEMA India Pvt. Ltd.: .................................................................................. 17

5.1.2 Godrej and Boyce manufacturing company limited: ................................. 20

5.2 PMI BY XRF METHOD AT DIFFERENT INDUSTRIES: ............................................ 21

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ID: 766338 Internship(3181901)

5.2.1 Larson & turbo piping center, Hajira: ......................................................... 21

5.2.2 Anandia engineering, Ankleshwar GIDC: .................................................. 23

5.2.3 Seabird logistics, Hajira: ............................................................................. 24

5.2.4 Other places: .............................................................................................. 24

CHAPTER 6: IN-SITU METALLOGRAPHY (REPLICA METHOD)..................... 26

6.1 INTRODUCTION: ................................................................................................. 26

6.2 PROCEDURE: ...................................................................................................... 27

6.2.1 Surface prepration: .................................................................................... 27

6.2.2 Etching:....................................................................................................... 28

6.2.3 Replica Application:.................................................................................... 29

6.2.4 Microscopic Examination: .......................................................................... 30

CHAPTER 7: OTHER NDT METHODS ..................................................................... 33

7.1 FERRITE TESTING OF ASS AND DSS: ................................................................... 33

7.1.1 Introduction: .............................................................................................. 33

7.1.2 Principle of feritscope: ............................................................................... 33

7.1.3 Procedure: .................................................................................................. 34

7.1.4 Observation: ............................................................................................... 35

7.1.5 Advantages: ................................................................................................ 35

7.1.6 Limitations:................................................................................................. 35

7.2 SURFACE ROUGHNESS: ...................................................................................... 36

7.2.1 Introduction: .............................................................................................. 36

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7.2.2 Principle: .................................................................................................... 36

7.2.3 Process: ...................................................................................................... 37

7.2.4 Measurement parameter:.......................................................................... 38

7.2.5 Advantages: ................................................................................................ 38

7.2.6 Disadvantages: ........................................................................................... 38

7.3 MAGNETIC PARTICAL INSPECTION: .................................................................... 39

7.3.1 Principle: .................................................................................................... 39

7.3.2 Procedure: .................................................................................................. 39

7.3.3 Advantages: ................................................................................................ 40

7.3.4 Disadvantages: ........................................................................................... 40

7.4 DYE PENETRANT TEST (DPT): ............................................................................. 41

7.4.1 Principle: .................................................................................................... 41

7.4.2 Procedure: .................................................................................................. 41

7.4.3 Advantages: ................................................................................................ 43

7.4.4 Disadvantages: ........................................................................................... 43

CONCLUSION ................................................................................................................ 44

REFERENCES................................................................................................................. 45

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ID: 766338 Introduction To Industry

CHAPTER 1: INTRODUCTION TO INDUSTRY

1.1 DETAIL:

Name: Metafirm Metallurgical Services

Founder: Mr. Bharat Kumar M. Gajera
Location: RJD textile park, Ichchhapore
Email: [email protected]

1.2 ABOUT:

Metafirm Metallurgical Services was founded in 2016 by technically competent

technocrats having in depth knowledge & experience in the field of metal testing, quality
control to provide service of metal testing to industries. Metafirm Metallurgical Services
has a competent team of metallurgical engineers, technicians and other field staff working
for catering the need of Metallography and testing work. Today ‘Metafirm Metallurgical
Services’ is one of the independent metal testing laboratories of Gujarat, which is
acknowledged for its modern facilities, quality test results, reliability, organizational
integrity, non-compromising approach, very fast services with competitive rates.

Metafirm Metallurgical Services technically competent technocrats having in depth

knowledge & experience with the stat of art sophisticated testing equipment in the field of
metallurgical testing, NDT testing, asset Integrity and failure analysis to various industries
like power generation & renewable, construction & fabrication, pulp & paper, oil & gas,
petrochemicals and pharma.

Metafirm Metallurgical Services believes in providing prompt service while strictly

adhering to the stringent standards of material testing. We believe in providing in depth
analysis and consulting to our customers to help them gain an upper hand in a highly
competitive market. Our goal is to provide the customer with true and accurate results.
Along with providing test results we believe in educating our customers in the field of
material testing so that they can understand and interpret test results better. And to achieve

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this goal of ours we regularly conduct technical workshops in- house or at the customer’s
place.

Metafirm Metallurgical Services going to establish an entire range of metal testing

activities under one roof. Metafirm metallurgical services has provided quality services to
its clients with a basic policy as "ACCURATE QUALITY SERVICES IN COMPETITIVE
PRICE TO MEET THE CUSTOMERS REQUIREMENT".

1.3 QUALITY POLICY:

Management and internationally recognized standards and the regulations of the local
authorities of the Metafirm Metallurgical Services is committed to perform Material
Testing and Services in the most efficient and accurate manner in accordance with
Nationally.

Laboratory shall document, establish and maintain a quality management system based on
the guidelines, set by the ISO/IEC 17025. The quality management system shall cover all
laboratory activities performed in the laboratory or on site. Management would continually
strive towards achieving a high level of reliability in all of our testing practices and results
through the use of highly reliable equipment and well-trained personnel.

Management is committed to hear to the customers, identify their needs, deliver solutions
and continuously improve on its process and services. At the same time ensure complete
customer satisfaction and achieving trust by delivering innovative and sophisticated
services.

1.4 SCOPE OF WORK:

A company specializing in metallurgical testing has a broad scope, encompassing various

industries and applications, including material characterization, quality control, failure
analysis, and research and development, ultimately ensuring the reliability and performance
of metal products.

Growing Demand from Manufacturing and Heavy Industries: Industries such as

automotive, aerospace, construction, and energy rely heavily on metallurgical testing to

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ensure the quality, performance, and safety of metals and alloys used in manufacturing
components, which boosts the demand for testing services.

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ID: 766338 What Is Material Science And Metallurgy?

CHAPTER 2: WHAT IS MATERIAL SCIENCE AND

METALLURGY?

2.1 MATERIAL SCIENCE:

Material is something that consists of matter. Material is the stuff of which some-thing is
made. Materials comprise a wide range of metals and non-metals which must be operated
upon to form the end product.

Whether this end product is a bridge, a computer, a space vehicle or an automobile, an

engineer must have an intimate knowledge of the properties and behavioral characteristics
of the materials he intends to use.

The understanding of the properties of materials is highly essential because without this
information and knowledge, the manufacturing process may be an expensive and complex
task which negates the profit and utility of the end product.

In the modern complex society of today, which is producing more technically qualified
people, complex products and more information than ever before, a constant challenge is
being posed by the ever-increasing demands for materials of greater strength, lightness,
safety, reliability, electrical conductivity, electro-magnetism, hardness, hardenability,
cutting power, softness, cheapness, resistance to corrosion and radiation, and resistance to
heat.

The tremendous increase in available materials, coupled with demands from new
applications and more severe service requirements, has brought about many changes in
attitude and viewpoints. In effect, many and diverse factors have forced a renaissance in
materials. Coupled with advances in fundamental science, they have led to the development
of a new technical area which is known as Science of Materials or Material Science.

2.2 METALLURGY:

2.2.1 Definition:

- Metallurgy is the science and technology of metals.

- Metallurgy embraces the practice and science of

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1. Extracting metals from their ores,

2. Refining of crude metal,
3. Production of alloys and the study of their constitution, structure and properties,
and
4. The relationship of physical and mechanical properties to thermal and mechanical
treatment of metals and alloys.

2.2.2 Importance of Metallurgy:

It is almost impossible to imagine any object used in everyday life that does not require
metal for its fabrication. Tools and machines, from typewriters to gasoline engines, from
small watches to big space crafts, all objects are made chiefly of metals.

Seeing all these, one may say that as an industry and wealth producer, metallurgy is second
only to farming.

In earlier days, metallurgy consisted largely of a collection of empirical facts. Trial and
error determined the tools and methods used to perfect and carry out various processes. But
in modern times, scientific methods are used to evaluate, plan, produce and perfect
metallurgical processes.

As a recognized branch of Science and Engineering, metallurgy has a great deal to offer as
a vocation.

The metallurgical field encompasses so wide a scope and involves so many industries and
materials, that the work need never be routine. Then, too, the growth of the industry and
the constant demand for improved materials lead to employment stability equal to or better
than any other engineering branch.

2.2.3 History of Metallurgy:

Since prehistoric times, wars have been fought over the wealth represented by mines and
metallic deposits. Great conquests were spurred by desire to possess precious metals. Gold
because it is commonly found in a pure state in nature, was probably the first metal to be
used by mankind. Copper was probably next. In the Old Testament there are over eighty
references to iron alone.

Chinese legend and traditions suggest that about 2800 B.C. the emperor Shen Nung
discovered the process of smelting. The oldest evidence of iron consists of the remains of

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some iron beads found in a predynastic (4000 B.C.) cemetery at Giza near Cairo. An ancient
clay tablet refers to the subject of iron making in a letter from the King of the Hittites to
Rameses II (r. 1290-1223 B.C.) of Egypt.

Earlier users of metals knew little or nothing about the actual chemical and physical
changes they were producing in shaping metal components. Very little was written on
metallurgical processes until Brancaccio published his Pyrotechnical in 1540, followed by
Agricola's De Re Metallurgical in 1556.

In succeeding years, much knowledge was added to the field by people trying to duplicate
the composition and etched structure of Damascus steel.

Starting in the middle of the 19th century, more and more attention was directed to develop
the art of metal producing and metal working. In September 1864 Sorby (UK) exhibited a
number of micro-scopical photographs of various kinds of steels. Work by Martens in
Germany (1878) revived Sorb's interest in metallurgical problems and in 1887 he, in a
paper, summarized all his work in the field.

About 1922, more knowledge of the structure and properties of metals was added by the
application of X-ray diffraction and wave mechanics. And, thus, gradually metallurgical
science got evolved.

2.2.4 Classification of Metallurgy:

-Metallurgical field may be broadly divided into following groups:

(A) Extractive Metallurgy

(B) Mechanical Metallurgy

(C) Physical Metallurgy

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CHAPTER 3: TESTING OF MATERIAL

3.1 INTRODUCTION:

- Materials are tested for one or more of the following purposes:

a. To assess numerically the fundamental mechanical properties of ductility.

malleability, toughness, etc.
b. To determine data, i.e., force-deformation (or stress) values to draw up sets of
specifications upon which the engineer can base his design.
c. To determine the surface or sub-surface defects in raw materials or processed parts.
d. To check chemical composition.
e. To determine suitability of a material for a particular application.

Considering the utmost utility of the material testing, various tests for determining the
properties and flaws in materials have become well standardized.

- Tests on materials may be broadly classified as:

a) Destructive tests. After being destructively tested, the component or specimen either
breaks or remains no longer useful for future use. Examples of destructive tests are:
tensile test, impact test, bend test, torsion test, fatigue test, etc.
b) Non-destructive tests. A component does not break in nondestructive testing and even
after being tested so, it can be used for the purpose for which it was made. Examples of
non-destructive tests: radiography, ultrasonic inspection, etc.
c) Process Inspection/Tests. The name of process inspection or process tests may come
from the type of manufacture where it is performed, such as foundry, welding assembly,
etc. There is first-piece inspection or final inspection, of sampling and check
inspections. The location often affects the name of the inspection, as in receiving or
incoming inspection, conveyor or hopper inspection, stores or stock inspection. All of
these are varieties or classes of process inspections.

3.2 DESTRUCTIVE TESTINNG:

• Specimen for mechanical testing are normally machined out of wrought or cast test
bars.
• Mechanical tests are primarily indicative of metal characteristics.
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• The tensile test is most commonly specified. It is performed on a universal tensile

testing machine. It should be carried out preferably on full-sized standard test pieces,
considering the relatively large grain size of the material and structural heterogeneity.
• The tensile test is frequently supplemented by hardness testing where practicable.
Hardness tests give information about wear resistance of the material, its machinability
and the effectiveness of heat-treatment given to the castings.
• In notched bar impact tests both Izod and Charpy tests are used. Most of the testing is
carried out at room temperature, but subzero testing is also specified for castings for
cryogenic and other low temperature applications.
• Other mechanical tests are bend test and compression test which may be carried out
along with tensile test on the same universal tensile testing machine.
• Depending upon the service conditions, fatigue and creep tests are also specified in
some cases.

METHODS:

1. Tensile test
2. Compression test
3. Hardness test
a. Brinell test
b. Rockwell test
4. Impact test
5. Bend test
a. Free bend test
b. Guided bend test
6. Torsion test
7. Fatigue test

3.3 NON-DESTRUCTIVE TESTING:

• Various techniques are available for finding the internal soundness of components
without sectioning or other destructive tests.
• The ability to detect the invisible subsurface defects not only aids in maintaining high
quality standards, but provides a valuable help to the development of manufacturing
methods.

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• Some of the non-destructive methods of testing which have become well established
will be discussed in this Chapter.
• A non-destructive test is an examination of a component in any manner which will not
impair its future use.
• Although non-destructive tests do not provide direct measurement of mechanical
properties, yet they are extremely useful in revealing defects in components that could
impair their performance when put in service.
• Non-destructive tests make components more reliable, safe and economical.

METHODS:

1. Visual inspection
2. Radiography
a. X-ray radiography
b. Gamma-ray radiography
3. Magnetic particle inspection
4. Liquid penetrant test
5. Fluorescent penetrant test
6. Ultra sonic inspection
7. Testing for metal composition
a. Wet analysis
b. Spectroscopy

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CHAPTER 4: CHEMICAL ANALYSIS BY PMI

4.1 PORTABLE SPECTRO TESTING:

4.1.1 Working Principle:

Fig. 4.1 Working Principle of Spectrometer

Optical Emission Spectrometry (OES) analyzes a sample by exciting its atoms, causing
them to emit light at characteristic wavelengths, which are then measured to determine the
sample's elemental composition.

The principle of the analysis method of SPECTRO´s portable and mobile metal analyzers
is optical emission spectroscopy (arc spark OES or spark OES). Sample material is
vaporized with the testing probe by an arc spark discharge.

The atoms and ions contained in the atomic vapor are excited into emission of radiation.
The radiation emitted is passed to the spectrometer (arc spark OES) optics via an optical
fiber, where it is dispersed into its spectral components. From the range of wavelengths
emitted by each element, the most suitable line for the application is measured by means
of a CCD.

The radiation intensity, which is proportional to the concentration of the element in the
sample, is recalculated internally from a stored set of calibration curves and can be shown

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directly as percent concentration.

4.1.2 Spectroport by Ametek:

Fig. 4.2 Spectrometer

Inspecting the metals makeup of incoming and outgoing components is a critical task for
countless companies. It’s a quality control necessity in metal producing, processing,
recycling, service contracting, and more. Metal alloys must be accurately tested, identified,
and verified based on defined chemical composition. Mistakes matter. An alloy mix up at
the shipping dock or on the factory floor can cause an inconvenient batch rework — or a
lost contract. Many firms use a handheld X-ray fluorescence (XRF) analyzer for these jobs.

However, this can cause problems. For instance, a handheld XRF can’t determine precise
levels of carbon content: the only way to distinguish among many low-alloy steels. It also
has trouble handling elements like phosphorus or sulfur at critical levels.

4.1.3 Product Specifications:

• Protective cover / screen shade

• Simplified software with new plug-in extendibility
• Same field-proven low-power-consumption eco-plasma generator as high-end
SPECTROTEST metals analyzer
• Unique iCAL 2.0 one-sample standardization of the entire system Fast performance
2-3 seconds in arc, 10 seconds in spark
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• Battery operation: up to 800 measurements on a single charge

Fig. 4.3 Spectrometer and Trolly

• Battery operation: up to 800 measurements on a single charge

• Innovative optics: Resilient to temperature changes
• Definitive data management
• Stable, lightweight, highly ergonomic transport trolley or minimum-weight mini-
trolley
• Maximum mobility
• Excellent ease of use

Fig. 4.4 Assembly and Disassembly of Machine

4.1.4 Advantages:

• Speed and Efficiency: OES is a fast and relatively easy-to-use technique for elemental
analysis.
• Wide Elemental Coverage: It can measure a wide range of elements and
concentrations in various materials.
• Low Cost: Compared to other analytical techniques, OES is relatively inexpensive.
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• Non-Destructive: OES can be used for non-destructive testing, meaning the sample is
not damaged during analysis.
• Versatility: OES can be used for a variety of applications, including determining the
composition of solid metals, testing the purity of specimens, and analyzing materials in
various industries.
• In-Situ Analysis: OES can be used for in-situ analysis, meaning the analysis can be
performed on the sample in its original location.
• Minimal Sample Preparation: OES typically requires minimal sample preparation.
• High Matrix Tolerance: OES can tolerate a wide range of sample matrices.
• simplicity: OES is relatively easy to use compared to other analytical methods.
• Real-Time Capabilities: OES can provide real-time analysis, allowing for quick
feedback and process control.

4.1.5 Disadvantages:

• Spectral Interferences: OES can be affected by spectral interferences, where the

emission lines of different elements overlap, making it difficult to accurately identify
and quantify elements.
• Sample Preparation: While minimal, some sample preparation, such as coating non-
conductive samples, may be required.
• Inaccurate Identification: Inaccurate identification can occur when the OES signal
identifies a signal as corresponding to one element when it in fact belongs to a different
element, though this can be minimized by selecting wavelengths with limited overlap.
• Instrument Size and Portability: OES instruments can be large and may not be as
easily portable as other analytical techniques.
• Safety Concerns: OES instruments involve sparks, which can pose safety risks.
• Cost: While OES is relatively inexpensive compared to some other techniques, the
initial investment in equipment can be significant.
• Operating Costs: The cost of operation and maintenance can also be a factor.

4.2 XRF TESTING:

4.2.1 Working principle:

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X-ray fluorescence (XRF) analysis works by bombarding a sample with X-rays, causing the
sample to emit fluorescent X-rays that are characteristic of its elemental composition,
enabling both qualitative and quantitative elemental analysis.

Fig. 4.5 Working Principle Of XRF

4.2.2 Positive material identification by Hitachi X-MET8000:

PMI (Positive Material Identification) testing using an XRF (X-Ray Fluorescence) machine
is a non-destructive method to rapidly verify the chemical composition of metals and
alloys, ensuring materials conform to standards and specifications.

Fig. 4.6 PMI Machine

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PMI is a crucial non-destructive testing (NDT) method used to verify the chemical
composition of metals and alloys.

PMI helps ensure that materials used in critical applications, like manufacturing,
construction, and infrastructure, meet the required standards and specifications, preventing
potential failures and ensuring safety.

4.2.3 Product Specification:

• Technology: X-ray Fluorescence (XRF)

• X-ray Tube: Rh target X-ray tube (40 kV max., 200 µA max.)

• Detector: Large area SDD

• Element Range: Mg to U

• Calibrations: Standardless (includes light elements analysis)

• Grade Libraries: Comprehensive pre-installed libraries (AISI, DIN, JIS, GB) with
over 1600 alloy grades

• Measurement Time: From 2 seconds (depends on application)

• Sample Types: Solids, powders, liquids

• IP54 rating (splash water and dust proof)

• Tested to MIL-STD-810G military grade standard for robustness
• Data storage (up to 100,000 results)
• Report generation (X-MET report generator)
• Data transfer (USB, Wi-Fi, Bluetooth)

4.2.4 Advantages:

• Non-destructive: XRF analysis does not damage the sample, allowing for repeated
analysis or the preservation of the sample for other purposes.
• Rapid analysis: XRF provides quick results, enabling efficient analysis and decision-
making in various applications.
• Minimal sample preparation: XRF typically requires little to no sample preparation,
saving time and resources compared to other analytical techniques.

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• Versatile: XRF can be used to analyze a wide range of materials, including solids,
liquids, and powders, and can detect a broad range of elements.
• Accuracy and precision: Modern XRF instruments offer high levels of accuracy and
precision, ensuring reliable results even at trace element levels.
• Low operating costs: XRF generally has low ongoing costs for calibration and
maintenance, making it a cost-effective solution.
• At-line analysis: XRF can be used for on-site or at-line analysis, allowing for real-time
monitoring of processes and quality control.
• No need for daily re-calibration: XRF instruments often do not require daily re-
calibration, saving time and effort.

4.2.5 Disadvantages:

• Cannot measure light elements: XRF analyzers struggle to detect elements lighter
than magnesium, including crucial elements like carbon, nitrogen, phosphorus, sulfur,
and silicon.

• Inability to verify specific grades: XRF cannot distinguish between standard and
low-carbon grades of stainless steel, or verify nitrogen content in nitrogen-alloyed
stainless steels.

• Radiation exposure: XRF uses radiation, which can be harmful if not handled
properly.

• Fragile and expensive to repair: Handheld XRF units can be fragile and expensive
to repair, with costs ranging from $7,000 to $10,000 or more.

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ID: 766338 Workdone On Chemical Analysis

CHATER 5: WORKDONE ON CHEMICAL ANALYSIS

5.1 PMI BY OES METHOD AT DIFFERENT INDUSTRIES:

5.1.1 TEMA India Pvt. Ltd.:

Tema India is working on the project of heat exchanger given by an Australian company
Saipem. It is necessary to consider the material requirement proposed by them. For the heat
exchanger they have suggested to use stainless steel material grade SS304L and SS316L.
for this it is required to know chemistry of the material, how much carbon content is there.
And, to detect the carbon it is mandatory use OES method of detection because XRF
method is failed to detect lite elements like C, Al, Mg, S, P.

Fig. 5.1 Heat Exchanger Tubes

Above given picture shows the inspection of tube with are fitted inside the exchanger. We
have tested around 800 noc. of tubes with is 10% of total tubes. Material for tube is SS316L.

Chemical composition by weightage of SS316L an SS304L for low carbon and high carbon
is given in table.

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Fig. 5.2 Chemical Composition of SS304 And SS316

Now, skeleton of heat exchanger is also inspection at different parts like tube sheets, baffles,
sliding strips, spacer tube, etc. For this some allowance is also given like 3% parts out of
whole has to be analyzed randomly.

Fig. 5.3 Inspection of Skeleton

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ID: 766338 Workdone On Chemical Analysis

Fig. 5.4 Design of Heat Exchanger

Picture shows detailed design with weld lines of complete job. We have to inspect all the
weld joint to come to the result that material used to joint to parts are according to
requirement.

Fig. 5.5 PMI Of Complete Assembly

As shown in design all the joints and parent metal are tested by OES method. Moreover,
channels of left and right side are also required to inspect. All this inspection are carried
out under the surveillance of TPI (Third Party Inspector) who is hired by the Customer. He
will give final approval to job whether all the requirements are fulfilled or not.

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5.1.2 Godrej and Boyce manufacturing company limited:

Fig. 5.6 Process Equipment

The project of process equipment is given by Mundra Petrochem limited. For which we
have to Spectro of pipes and the joints of pipes withing vessel as shown in figure. The
material inspected is SS316.

Fig. 5.7 Inside of Equipment

Moreover, I have also visited SRF limited for the inspection of kiln plate which are used
in boiler. They have to joint these plates so firstly it is necessary to know about the chemical
composition of it. Hence, they have approached us to do so.

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5.2 PMI BY XRF METHOD AT DIFFERENT INDUSTRIES:

5.2.1 Larson & turbo piping center, Hajira:

They are working on the project of reliance named CVD REACTOR OFFGAS
PRIMARY COOLER. Number of spools are manufactured and after that they all are
going to joined together. For which it is required by the client that to do PMI by XRF
method of every joint which have the grade Inconel 600 and SS304. Some nozzles and
parent metal of pipe is also inspected by XRF machine. It is the project of around 3 to 4
months and contract of XRF testing is given to us.

Fig. 5.8 Design Of Spool And Sample Report

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ID: 766338 Workdone On Chemical Analysis

Picture shows design of spool with all the weld joints which is required to analyze internally
as well as to the third party inspector. Sample report after inspection was also generated as
shown in figure.

Working at a site is shown in figure 14 where I am measuring chemical composition on

joint between flange and a pipe which have the material grade INCONEL600. Basically
major components in this grad are Ni having more than 59%, Cr is 16 to 23%.

Fig. 5.9 PMI Testing At LTPC

Some time incoming material as well as mixed up material are also required to do XRF
for differentiate them according to their grades.

Fig. 5.10 Mixed Up Material

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5.2.2 Anandia engineering, Ankleshwar GIDC:

Fig. 5.11 Workshop Of Anandia

At this industry we have to do XRF of reactor shell as well as end caps of it. Material which
they are using for this is SS304. The company has required to do 100% inspection of
chemical analysis. So, we have to check each and every part as well as weld joints. It
became more difficult when we have to enter the reactors standing vertically. Total 5
reactors have been tested with third party inspector.

Fig. 5.12 Material Inspection by XRF

XRF analysis of material ordered for fabrication at anandia engineering.

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5.2.3 Seabird logistics, Hajira:

Fig. 5.13 Hajira Port

It is one the best experience of my life as I get the chance to visit port near Hajira. There
we have to check material imported from Hong Kong. company named Bhushan steel
located at Mumbai has approached us to identify the material to decide the custom duty. As
it is different for different material like it is more for stainless steel compare to carbon steel.

5.2.4 Other places:

Fig. 5.14 Antique Items

It is the place where I come across with many historic items. Person named Mahendra Bhai
is working as a dealer of antique items. He has to do PMI of many items to identify the
material type and then decide value on the bases of report made by us.

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For doing XRF I have also visited Reliance Industries, Hajira as well. Disabled or out of
working heat exchanger are going to rebuild hence they are organizing auction to get best
price. So, person working as a scrape dealer approach us to identify the material type of
scrape and bid according to it.

Fig. 5.15 Scrape Yard

Near Sachin GIDC there are many scrape dealer who are calling us to identify and decide
the price of material as well as to differentiate the material which are mixed up.

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ID: 766338 In-Situ Metallography

CHAPTER 6: IN-SITU METALLOGRAPHY (REPLICA

METHOD)

In-situ metallography is the examination of the microstructure of metals directly at the

site of the component, without cutting a sample and taking it to the lab. This is useful for
large, expensive, or in-service components (e.g., in power plants, pipelines, or aircraft)
where removing a sample is impractical or destructive.

The replica method is a non-destructive technique within in-situ metallography. Instead of

directly observing the surface under a microscope, you create a replica (copy) of the
metal's surface microstructure and study it under a lab microscope.

6.1 INTRODUCTION:

The regions susceptible to metallurgical degradations will be subjected to metallography

examination and evaluation will be made on both optical as well Scanning Electron
Microscopy. The recommendations derived are pragmatic and would ensure the utilization
of full life cycle of the component.

Small area is polished by the portable grinder and polisher and made to mirror finish by
employing various steps. The microstructures are prepared by applying suitable etching and
subsequently transferred on a plastic tape by replication method. Replication is carried out
to arrive at microstructure degradation of the components.

As corrosion damage is concentrated in narrowly limited zones or on uniform zones,

replication is most suitable method of detecting these zones. Replica spots may be selected
based on metallic thickness and oxide scale measurement and susceptible areas. In general,
corrosive failures initiate mostly at surface of the components of complex component
geometry associated with major branch connections selected for replica spots as these are
vulnerable for corrosion damage.

Microstructures are being viewed under high powered microscopes in the laboratory and
judgments are made for different damages mechanisms like to check the heat treatments/
amount of cold worked /carbide precipitation and presence of any ferrite content in the
stainless-steel surfaces.

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6.2 PROCEDURE:

Fig. 6.1 Step By Step Process

6.2.1 Surface Prepration:

Surface preparation is a critical and foundational step in in-situ metallography, particularly

when employing the replica technique. The quality and clarity of the microstructural details
observable in the replica are directly dependent upon the effectiveness of the surface
preparation process. A well-prepared surface ensures that the true microstructural features
of the material are revealed without distortion or contamination.

Fig. 6.2 Emery Papers

a. Grinding: Grinding is the initial stage of surface preparation and involves the use of
abrasive papers to remove surface irregularities, scale, corrosion, and mechanically
deformed layers. It is performed in progressive steps using silicon carbide (SiC) emery
papers of increasing fineness.

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• The process typically begins with coarser grits (e.g., 240 or 320) and proceeds
through finer grits such as 400, 600, 800, 1000, and 1200.

• Grinding should be carried out in such a manner that each successive stage removes
the scratches introduced by the previous grit.

• The direction of grinding is usually alternated between stages (i.e., perpendicular

orientation) to ensure complete removal of prior markings.

• Care must be taken to avoid overheating the surface, which can cause thermal
damage and alter the microstructure.

b. Polishing: Following grinding, the specimen is subjected to polishing to remove fine

scratches and achieve a mirror-like finish. Polishing is generally performed using soft
cloths or felt pads, in combination with suitable polishing media.

• Commonly used polishing agents include alumina suspensions (typically 0.3 µm or

0.05 µm particle size) or diamond pastes (ranging from 6 µm down to 0.25 µm).

• The surface is polished until all visible scratches are eliminated and a smooth,
reflective finish is obtained.

• Uniform pressure and controlled rotation are essential to achieve a consistent

surface.

c. Cleaning: After polishing, it is imperative to thoroughly clean the surface to remove any
residual abrasives, oils, or foreign matter that may interfere with the subsequent etching
and replica application.

• Cleaning is typically performed using ethanol, acetone, or other volatile organic

solvents.

• The surface is then dried using clean, lint-free cloths or compressed air.

6.2.2 Etching:

Etching is a fundamental step in the process of in-situ metallography using the replica
method. It is performed after surface preparation and before replica application to
reveal the microstructural features of a metallic surface. The success of the replica
method in capturing accurate metallographic information is heavily dependent on proper
etching.

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a. Objective of Etching

An etchant is a chemical solution used in metallography to selectively attack and reveal the
microstructural features of a metal or alloy. It enhances the visibility of grains, phases,
inclusions, and defects by creating contrast under a microscope.

The primary purpose of etching is to:

• Reveal microstructural features such as grain boundaries, phases, inclusions,

carbides, precipitates, and cracks.

• Create sufficient surface topography that can be captured by the replica film.

• Enhance contrast between different microstructural constituents for optical or SEM

examination.

In unetched polished metals, microstructures are often not visible under the microscope due
to the uniform reflectivity of the surface.

6.2.3 Replica Application:

Replica application is the critical stage in in-situ metallography where a faithful

impression of the etched microstructure of a metal surface is transferred onto a thin film.
This replica is then removed and studied under an optical or scanning electron microscope
(SEM) in a laboratory environment. The method is widely used for non-destructive
evaluation (NDE), especially in field inspections of large or critical components.

The main objective of applying a replica is to:

• Obtain a permanent and transportable record of the surface microstructure.

• Avoid destructive sectioning of components.

• Facilitate laboratory-based microscopic analysis away from the inspection site.

Step Structure: Characterized by no ditches or etching at the grain boundaries,

indicating minimal or no sensitization.

Dual Structure: Shows some ditches or etching at the grain boundaries, suggesting some
degree of sensitization.

Ditch Structure: Features one or more grains completely surrounded by ditches,

indicating significant sensitization and requiring further testing.
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Fig. 6.3 Replica Of Polished Surface

Sensitization: In stainless steel, sensitization refers to the chromium depletion at grain

boundaries due to the formation of chromium carbides, which can lead to intergranular
corrosion.

6.2.4 Microscopic Examination:

Microscopic examination is the final and most critical phase in the in-situ replica
metallography process. After preparing the surface, etching, and obtaining a high-quality
replica, the film is transferred to the laboratory for optical or scanning electron
microscope (SEM) analysis. The aim is to interpret the microstructural features
faithfully recorded on the replica, providing vital information about the material's condition
without destructively cutting the component. The main objectives of microscopic
examination in replica metallography are to:

• Reveal and analyze microstructural features such as grains, phases, carbides, inclusions,
and damage.

• Detect early signs of degradation, such as creep cavitation, fatigue cracks, intergranular
corrosion, and sensitization.

• Evaluate the health of critical components like boiler tubes, turbine blades, pressure
vessels, and welds.

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• Provide documentation for maintenance decisions, safety compliance, or failure

analysis.

Types of Microscopies Used:

a. Optical Microscopy (OM)

Fig. 6.4 Optical Microscope

• Suitable for general microstructure observation.

• Magnification typically ranges from 50x to 1000x.

• Requires reflected light due to the opaque nature of metal replicas.

• Used for analyzing:

o Grain size and structure

o Phase distribution

o Micro-cracks and surface defects

o Carbide networks and precipitates

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b. Scanning Electron Microscopy (SEM)

Fig. 6.5 Scanning Electron Microscope

• Provides higher magnification (up to 100,000x) and resolution.

• Ideal for observing fine features, such as:

o Creep voids and micro-cavities

o Submicron inclusions

o Intergranular cracking

• Replicas must be electrically conductive; often coated with a thin film of carbon or
gold (sputter coating) before SEM examination.

• SEM may also include energy dispersive X-ray spectroscopy (EDS) for elemental
analysis.

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CHAPTER 7: OTHER NDT METHODS

7.1 FERRITE TESTING OF ASS AND DSS:

7.1.1 Introduction:

Ferrite content is a critical factor influencing the mechanical properties, corrosion

resistance, and weldability of stainless steels. In Austenitic Stainless Steel (ASS), a small
amount of ferrite is desirable to prevent hot cracking during welding. In Duplex Stainless
Steel (DSS), a controlled balance between ferrite and austenite (typically 40–60% ferrite)
ensures strength and corrosion resistance.

To evaluate ferrite content, the Feritscope is a widely used, non-destructive instrument

based on magnetic induction. This test helps verify compliance with standards and
specifications in welded structures, pressure vessels, pipelines, and other critical
applications.

7.1.2 Principle Of Feritscope:

Fig 7.1 Principle Of Feritscope

The Feritscope operates on the principle of magnetic induction. Ferrite is ferromagnetic,

while austenite is non-magnetic. When the probe is placed on a stainless steel surface, the
magnetic permeability of the material is measured. This value is then converted into a
Ferrite Number (FN), which correlates approximately with the volume percent of ferrite.

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7.1.3 Procedure:

Fig 7.2 Feritscope

1. Surface Preparation:

• Clean the test area to remove dust, grease, and oxide scales.

• Ensure the surface is flat and smooth to avoid probe errors.

2. Calibration:

Fig 7.3 Calibration Blocks

• Calibrate the Feritscope using certified calibration standards (e.g., 0 FN, 10 FN, 30
FN blocks).

• Calibration is verified before and after testing.

3. Measurement:

• Place the probe perpendicularly on the test surface.

• Take multiple readings (minimum 3–5) at each location.

• Record the average FN value.

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4. Locations Tested:

• Base metal

• Weld metal

• Heat-Affected Zone (HAZ)

Fig 7.4 Weld Joint Testing

7.1.4 Observation:

• ASS welds consistently showed ferrite content between 4–8 FN, which is within
acceptable limits.
• DSS samples showed balanced ferrite content in the range of 35–45%, confirming
proper welding and post-weld treatment.
• Some DSS welds near high heat input zones had slightly lower ferrite, which was
flagged for possible rework or post-weld solution treatment.

7.1.5 Advantages:

• Non-destructive and fast

• Portable – ideal for in-situ measurements
• High repeatability and easy calibration
• No need for sample sectioning or preparation

7.1.6 Limitations:

• Surface roughness or curvature can affect accuracy

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• Not suitable for detecting microstructural defects

• FN does not exactly equal % ferrite – approximate correlation only

7.2 SURFACE ROUGHNESS:

7.2.1 Introduction:

Surface roughness refers to the texture of a surface, characterized by the small deviations
in its profile from an ideal, smooth form. It is a key aspect of surface finish and is typically
measured in terms of the height, frequency, and distribution of these deviations.

In engineering, surface roughness plays a crucial role in determining how a component

interacts with its environment. For instance:

• Friction and Wear: Rough surfaces tend to have higher friction and wear rates
compared to smoother ones.

• Performance: Irregularities on a surface can act as nucleation sites for cracks or

corrosion, affecting the durability and performance of mechanical parts.

• Adhesion: In some cases, controlled roughness is desirable to enhance adhesion for

coatings or finishes.

Surface roughness is quantified using parameters like Ra (average roughness) and Rq (root
mean square roughness). It can be measured using tools like profilometers or optical
instruments.

Surface roughness refers to the small, finely spaced irregularities on the surface of a
material. It is a key indicator of the texture or quality of a surface and is usually measured
in micrometers (µm).

7.2.2 Principle:

The principle of surface roughness measurement is based on detecting and evaluating the
deviations of the actual surface from a perfectly smooth (ideal) reference surface. These
deviations are typically measured using contact (stylus) or non-contact (optical or laser)
techniques, and are analyzed using parameters like Ra, Rz, or Rt.

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7.2.3 Process:

Fig 7.5 Measuring Instrument With Calibration

1. Preparation:

• Clean the specimen to remove dust, oil, or burrs.

• Place the workpiece on a stable, vibration-free surface.

• Power on the Mitutoyo surface roughness tester.

2. Setup the Instrument:

• Select appropriate stylus and drive unit (depends on part size and geometry).

• Mount the drive unit properly, ensuring it is aligned with the surface to be measured.

• Set the cut-off length, evaluation length, and measuring speed on the device or software.

3. Calibration (if needed):

• Place the standard roughness specimen (master sample) on the base.

• Run a quick measurement and adjust if values don’t match the standard.

• Mitutoyo machines often come pre-calibrated, but periodic checks ensure accuracy.

4. Measurement:

• Position the stylus gently on the surface.

• Press the start/measure button.

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• The stylus moves over the surface, tracing the profile.

• Vertical movements are recorded as surface deviations.

5. Data Analysis:

• The built-in processor calculates values such as:

o Ra (average roughness)

o Rz, Rq, etc.

• The results appear on the digital screen or are sent to a connected PC/software (e.g.,
Formtracepak).

6. Result Interpretation & Output:

• Print the results via built-in printer (some models).

• Export data for report generation or quality documentation.

7.2.4 Measurement parameter:

• Ra (Arithmetic Average Roughness): The average height of surface irregularities.

• Rq (Root Mean Square Roughness): A statistical measure of surface texture.
• Rz (Maximum Height of the Profile): The average of the five highest peaks and valleys.

7.2.5 Advantages:

• Helps ensure tight tolerance and precise fits in mechanical assemblies.

• Improves lubrication performance by retaining oil in surface valleys.
• Enhances coating and adhesive bonding on rougher surfaces.
• Critical for quality control and product performance.
• Helps reduce wear and tear when optimized correctly.

7.2.6 Disadvantages:

• Surface Preparation: Cleanliness of the surface is critical for accurate results, and rough
surfaces with large features might require more advanced methods.
• Surface Size: Limited by the size of the measuring area, which may not cover very large
or irregularly shaped parts.

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• Measurement Speed: While precise, the process can be time-consuming for large
batches of parts.

7.3 MAGNETIC PARTICAL INSPECTION:

Magnetic Particle Inspection (MPI) is a non-destructive testing technique used to detect

cracks, laps, seams, inclusions, and other discontinuities on or near the surface of
ferromagnetic materials like iron, nickel, cobalt, and some of their alloys.

It works by magnetizing the material and then applying magnetic particles to the surface.
If there's a defect, the magnetic field is distorted, and the particles gather at the defect,
making it visible.

7.3.1 Principle:

Fig 7.6 MPT Testing

When a ferromagnetic material is magnetized, magnetic lines of force (flux) are established
within it. If there's a surface or near-surface discontinuity (like a crack), it causes a leakage
field — meaning magnetic flux "leaks" out at the defect.

Fine magnetic particles (either dry powder or suspended in liquid) are applied to the
surface. These particles are attracted to the leakage field and accumulate, forming a visible
indication of the defect.

7.3.2 Procedure:

1. Pre-cleaning:

• Clean the surface to remove dirt, oil, rust, paint, or grease for accurate results.

2. Magnetization:

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• The part is magnetized using one of these methods:

o Direct Magnetization: Current is passed through the part.

o Indirect Magnetization: Current is passed through a coil around the part.

3. Application of Magnetic Particles:

• Apply magnetic particles:

o Dry Powder for field use or rough surfaces.

o Wet Suspension (particles in oil or water) for fine, detailed detection.

• Apply during or immediately after magnetization.

4. Inspection:

• Observe the surface under visible or UV light (if using fluorescent particles).

• Particles gather at discontinuities, forming clear indications.

5. Demagnetization:

• After testing, remove residual magnetism to avoid affecting future use of the
component.

6. Cleaning:

• Clean off the particles after inspection is complete.

7.3.3 Advantages:

• Rapid inspection of large surfaces

• Relatively low equipment cost
• Detection of surface and subsurface defects
• Immediate interpretation of indications
• Can be used in workshop and on site
• Surface preparation is less critical than with Penetrant Testing (PT)

7.3.4 Disadvantages:

• Restricted to ferromagnetic materials

• Requires supply of electricity

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• It is sometimes unclear whether the magnetic field is sufficiently strong to give good
indications
• Cannot be used if thick paint coating is present
• Some of the paints and particle suspension fluids can cause fire risk, particularly in a
confined space

7.4 DYE PENETRANT TEST (DPT):

Dye Penetrant Testing (DPT) is a surface inspection method that detects cracks, porosity,
laps, seams, and other surface-breaking discontinuities in non-porous materials (metals,
plastics, ceramics).

It uses a visible or fluorescent colored dye that penetrates into surface flaws. After removing
excess dye and applying a developer, any trapped dye is drawn out, revealing the flaw as a
visible indication.

7.4.1 Principle:

The test is based on the capillary action principle:

• When a low-viscosity liquid (penetrant) is applied to a surface, it seeps into cracks or

openings.

• After some time, the excess is removed, and a developer is applied.

• The developer draws the penetrant out of the flaws by reverse capillary action, creating
a visible indication.

7.4.2 Procedure:

1. Pre-cleaning

• Remove oil, dirt, rust, paint, or scale from the test surface.

• Use solvents, alkaline cleaners, or abrasive pads.

• A clean, dry, non-porous surface is essential.

2. Application of Penetrant

• Apply visible red dye or fluorescent dye (under UV light).

• Methods: spraying, brushing, or dipping.

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• Allow dwell time (typically 5–30 minutes) for the dye to seep into flaws.

Fig 7.7 DPT Test

3. Excess Penetrant Removal

• Gently remove surface dye without disturbing the penetrant inside flaws.

• Methods:

o Water washable

o Solvent removable

o Post-emulsifiable (requires emulsifier before water rinse)

4. Application of Developer

• Spray or dust the surface with developer (white powder or suspension).

• The developer pulls trapped penetrant out of defects.

• A visible red (or fluorescent) indication appears at the flaw.

5. Inspection

• Inspect under white light (for red dye) or UV light (for fluorescent).

• Look for lines, dots, or blotches that may indicate cracks, pores, etc.

6. Post-cleaning

• Remove all testing chemicals.

• Essential for components going back into service.

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7.4.3 Advantages:

• High sensitivity to small surface discontinuities

• Suitable for large range of materials: metallic and non-metallic, magnetic and non-
magnetic, and conductive and non-conductive
• Large surface areas and large volumes parts can be inspected rapidly and at low cost
• Parts with complex geometry can be tested without changing the inspection
procedure
• Indications are produced directly on the surface of the part
• Aerosol spray cans make penetrant materials very portable
• Required materials and equipment are relatively inexpensive

7.4.4 Disadvantages:

• Only surface breaking defects can be detected

• Only materials with relatively nonporous surface can be inspected
• Precleaning is critical
• Metal smearing from machining, grinding, and grit or vapor blasting must be
removed prior to inspection.
• Surface finish and roughness can affect inspection sensitivity
• Multiple process operations must be performed with waiting intervals
• Post cleaning of acceptable parts or materials is required
• Handling and proper disposal of chemicals is required

Gujarat Technological University 43 SSASIT

ID: 766338 Conclusion

CONCLUSION

The application of Non-Destructive Testing (NDT) in the fabrication industry plays a

crucial role in ensuring the reliability, quality, and safety of materials and structures without
causing any damage to the components under evaluation. Throughout this internship, I had
the opportunity to gain firsthand experience with several NDT methods such as Optical
Emission Spectroscopy (OES), X-ray Fluorescence (XRF), in-situ metallography, and
techniques like dye penetrant, magnetic particle, and ferrite testing.

These methods were applied across various industrial setups including heat exchanger
inspections, process equipment analysis, and material verification at fabrication sites and
ports. The ability to identify and differentiate materials, detect flaws, and verify weld
quality in real-time not only ensures product integrity but also helps in minimizing
operational risks and costly failures.

The insights gathered from this experience have deepened my understanding of the
metallurgical aspects of mechanical engineering and highlighted the importance of quality
assurance in industrial processes. This practical exposure has significantly enhanced my
analytical and technical skills, bridging the gap between academic learning and real-world
application.

Moving forward, the knowledge and experience gained through this internship will serve
as a strong foundation for my professional journey in the mechanical and metallurgical
engineering domains.

Gujarat Technological University 44 SSASIT

ID: 766338 References

REFERENCES

• Website of Metafirm Metallurgical Services: www.metafirm.in

• Ametek, Inc. (SPECTRO). SPECTROPORT Mobile Arc/Spark OES
Spectrometer – Product Brochure.
• Hitachi High-Tech Analytical Science. X-MET8000 Series Handheld XRF
Analyzers – User Manual and Specifications.
• www.astm.org
• Book: Material Science & Metallurgy by O.P. Khanna

Gujarat Technological University 45 SSASIT