NDT Certification Courses

Total hours of instruction for this course: 20 hours

PDH/ CEU:       20PDH/ 2.0 CEUs

Date(s):           Saturdays: April 6, 13 and 20, 2019

Time:               April 6 and 13, 2019; 7:30 AM – 4:00 PM

                         April 20, 2019; 7:30 AM - 11:30 AM

Venue:             801 Montrose Avenue, South Plainfield, NJ 07080

Course Fee:     $800.00

 

PRESENTER(S)

 

Nagesh Goel: Mechanical Engineer with specialization in Nondestructive Testing and Metallurgical Failure Analysis. He has 20+ years’ experience in inspection and supervision of static and dynamic loaded Steel Structures, Pressure Piping, Pressure Vessels, Tanks and Mechanical Systems. Inspection experience has been accumulated in various industry segments such as Structural Steel Construction (Buildings and Bridges), Petrochemical and Power. Administered extensive training programs in Welding, Non-Destructive Testing, Metallurgy, and Fire Code. Knowledgeable about a variety of materials, product forms, processes, inspection techniques, and test methods.

Prof. O. Prabhakar: Dr.O.Prabhakar (OP) obtained his B.Tech and Ph.D in Metallurgy from the Indian Institute of Technology, Chennai and M.E. in Mechanical Engineering from Indian Institute of Science, Bangalore. He underwent training in Non‑Destructive Testing at Bundesanstalt fuer Material Pruefung, Berlin, Germany from 1970 to 1972. After an illustrious career of teaching and conducting research in the areas of nondestructive evaluation, metallurgy and metal casting for nearly 30 years, OP retired as a Professor from the Indian Institute of Technology, Chennai (Department of Metallurgical Engineering) in 1998. He worked at VPI & SU, USA from 1980 to 1982, stationed at NASA Langley AFB, Hampton. He also taught at NTU, Singapore from 1998 to 2004.  Dr. O Prabhakar is a recipient of numerous awards in metallurgy and NDT.

 

COURSE DESCRIPTION/ ACVTIVITY CONTENT

 

Total hours of instruction for this course: 20 hours

 

1. Principles of Magnets and Magnetic Fields

1. Theory of magnetic fields

• Earth’s magnetic field

• Magnetic fields around magnetized materials

2. Theory of magnetism

• Magnetic poles

• Law of magnetism

• Materials influenced by magnetic fields

• Ferromagnetic

• Paramagnetic

• Magnetic characteristics of nonferrous materials

3. Terminology associated with magnetic particle testing
4. Theory

• Flux patterns

• Frequency and voltage factors

• Current calculations

• Surface flux strength

• Subsurface effects

5. Magnets and magnetism

• Distance factors vs. strength of flux

• Internal and external flux patterns

• Phenomenon action at the discontinuity

• Heat effects on magnetism

• Material hardness vs. magnetic retention

 

2. Characteristics of Magnetic Fields

1. Bar magnet
2. Ring magnet

 

3. Flux Fields

1. Direct current

• Depth of penetration factors

• Source of current

2. Direct pulsating current

• Similarity to direct current

• Advantages

• Typical fields

c.         Alternating current

• Cyclic effects

• Surface strength characteristics

• Safety precautions

• Voltage and current factors
• Source of current

 

3.         Effect of Discontinuities of Materials

1. Surface cracks
2. Scratches
3. Subsurface defects
4. Design factors

• Mechanical properties

• Part use

5. Relationship to load-carrying ability

 

4.         Magnetization by Means of Electric Current

1. Circular field

• Field around a straight conductor

• Right-hand rule

• Field in parts through which current flows

• Long, solid, cylindrical, regular parts

• Irregularly-shaped parts

• Tubular parts

• Parts containing machined holes, slots, etc.

• Methods of inducing current flow in parts

• Contact plates

• Prods

• Current calculations

• Depth-factor considerations

• Precautions – safety and overheating

• Contact prods and yokes

• Requirements for prods and yokes

• Current-carrying capabilities

• Discontinuities commonly detected

2. Longitudinal field

• Field produced by current flow in a coil

• Field direction in a current-carrying coil

• Field strength in a current-carrying coil

• Principles of induced flux fields

• Geometry of part to be inspected

• Shapes and size of coils

• Use of coils and cables

• Strength of field

• Current directional flow vs. flux field

• Shapes, sizes, and current capacities

• Current calculations

• Formulas

• Types of current required

• Current demand

• Advantages of longitudinal magnetization

• Disadvantages of longitudinal magnetization

• Discontinuities commonly detected

 

5.         Selecting the Proper Method of Magnetization

1. Alloy, shape, and condition of part
2. Type of magnetizing current
3. Direction of magnetic field
4. Sequence of operations
5. Value of flux density

 

6.         Principles of Demagnetization

1. Residual magnetism
2. Reasons for requiring demagnetization
3. Longitudinal and circular residual fields
4. Basic principles of demagnetization
5. Retentivity and coercive force
6. Methods of demagnetization

1. Current, frequency, and field orientation
2. Heat factors and precautions
3. Need for collapsing flux fields

 

7.         Inspection Materials

1. Wet particles
2. Dry particles

 

8.         Magnetic Particle Testing Equipment

1. Equipment-selection considerations

• Type of magnetizing current

• Location and nature of test

• Test materials used

• Purpose of test

• Area inspected

2. Manual inspection equipment
3. Medium- and heavy- duty equipment
4. Stationary equipment
5. Mechanized inspection equipment

• Semiautomatic inspection equipment

• Single-purpose semiautomatic equipment

• Multipurpose semiautomatic equipment

• Fully automatic equipment

6. Portable type

• Reason for portable equipment

• Capabilities of portable equipment

• Similarity to stationary equipment

7. Stationary type

• Capability of handling large and heavy parts

• Flexibility in use

• Need for stationary equipment

• Use of accessories and attachments

8. Automatic type

• Requirements for automation

• Sequential operations

• Control and operation factors

• Alarm and rejection mechanisms

1. Liquids and powders

• Liquid requirements as a particle vehicle

• Safety precautions

• Temperature needs

• Powder and paste contents

• Mixing procedures

• Need for accurate proportions

10. Black-light type

• Black light and fluorescence

• Visible- and black-light comparisons

• Requirements in the testing cycle

• Techniques in use

11. Light- sensitive instruments

• Need for instrumentation

• Light characteristics

 

9.         Types of Discontinuities detected by Magnetic Particle Testing

1. Inclusions
2. Blowholes
3. Porosity
4. Flakes
5. Cracks
6. Pipes
7. Laminations
8. Laps
1. Forging bursts
10. Voids

 

10.       Magnetic Particle Test Indications and Interpretations

1. Indications of nonmetallic inclusions
2. Indications of surface seams
3. Indications of cracks
4. Indications of laminations
5. Indications of laps
6. Indications of bursts and flakes
7. Indications of porosity
8. Non-relevant indications

 

11.       Evaluation Techniques

1. Use of standards

• Need for standards and references

• Comparison of known with unknown

• Specifications and certifications

• Comparison techniques

2. Defect appraisal

• History of part

• Manufacturing process

• Possible causes of defect

• Use of part

• Acceptance and rejection criteria

• Use of tolerances

 

12.       Quality Control of Equipment and Processes

1. Malfunctioning of equipment
2. Proper magnetic particles and bath liquid
3. Bath concentration

• Settling test

• Other bath- strength tests

4. Tests for black-light intensity

 

 

TEACHING METHOD

PowerPoint presentation, Hands-on Lab, discussion of the topics, Interactive  CD, evaluation of real discontinuities in materials and welds.

 

LEARNING OBJECTIVE

Experienced instructors provide extens