Experiment 1:
Non-destructive evaluation of surface discontinuities in metallic materials using technique of Visual Testing (VT) and Liquid or Dye Penetrant Testing (LPT or DPT).

Experiment 2:
Non-destructive evaluation of internal defects in metallic materials using technique of Ultrasonic testing. Familiarization with UT equipment/techniques. Contact Type Normal Beam Pulse-Echo Method – details of the technique, presentation and interpretation of pulse-echo data.

Experiment 3:
Introduction to IIW V1 standard blocks – its dimensions, importance and uses; Calibration of the ultrasonic test (UT) systems using normal beam probe and IIW V1 standard block for Horizontal Linearity (Range Calibration), Vertical Linearity (Amplitude Calibration), and Sensitivity (Reference Level Setting). Estimation of Near-field length (N) and Beam Divergence angle for the given probe.

Experiment 4:
Measurement of thickness and velocity of ultrasonic wave in different medium. Estimation of acoustic impedance. Calculation of the acoustic peak pressure and intensity of the wave reaching the defect. Calculation of the acoustic RMS pressure and intensity of the echo returning from the defect to the front surface of the steel plate

Experiment 5:
Contact Type Angle Beam Pulse-Echo Method – details of the technique, presentation and interpretation of pulse-echo data; Hands-on experience with the Contact Type Angle Beam Pulse-Echo Method using an actual UT machine and calibration of the UT unit using angle beam probe and IIW V1 standard block. Detection of known cracks and their sizing using ultrasonic testing on metallic materials.

Experiment 6:
Ultrasonic inspection standards, Difference between Reference blocks and Standard reference blocks (IIW blocks and Distance-Amplitude blocks), Determination of Distance-Amplitude Curves (DAC) for Al alloy.

Experiment 7:
Practical skills through hands-on experience in performing ultrasonic inspections on a variety of products, such as (i) Inspection of primary mill-products (forging/extrusion/rolling), (ii) Inspection of welded/bonded joints. Dimension measurement using UT.

1. To develop practical proficiency in Non-Destructive Evaluation (NDE) of metallic materials using Visual Testing (VT), Liquid/Dye Penetrant Testing (LPT/DPT), and Ultrasonic Testing (UT) for the detection and evaluation of surface and internal discontinuities.

2. To develop hands-on skills in Ultrasonic Testing equipment operation, probe selection, calibration, and inspection, including normal-beam and angle-beam pulse-echo techniques, using IIW V1 standard blocks for range calibration, amplitude calibration, sensitivity setting, and practical inspection.

3. To understand and experimentally evaluate the fundamental acoustic parameters governing ultrasonic inspection, including ultrasonic velocity, thickness, acoustic impedance, near-field length, beam divergence, acoustic pressure, and intensity, and to relate these parameters to defect detection and signal response.

4. To develop practical competency in the application of ultrasonic inspection standards and evaluation procedures, including the use of reference/standard reference blocks, determination of Distance-Amplitude Curves (DAC), defect detection and sizing, and dimensional measurement of forgings, extrusions, rolled products, and welded/bonded joints.

After successful completion of the MM6263 – Advanced Skill Development Lab, students will be able to:

CO1: Perform Visual Testing (VT), Liquid/Dye Penetrant Testing (LPT/DPT), and basic Ultrasonic Testing (UT) for the detection and evaluation of surface and internal discontinuities in metallic materials.

CO2: Operate and calibrate ultrasonic testing equipment using normal-beam and angle-beam probes and IIW V1 standard blocks, including range calibration, amplitude/vertical linearity calibration, sensitivity setting, and practical interpretation of pulse-echo signals.

CO3: Determine and evaluate important ultrasonic and acoustic parameters, including ultrasonic velocity, material thickness, acoustic impedance, near-field length, beam divergence, acoustic pressure, and intensity, and relate these parameters to ultrasonic inspection responses.

CO4: Apply UT standards, reference blocks, and Distance-Amplitude Correction (DAC) curves for defect detection and sizing, and conduct ultrasonic inspections and dimensional measurements on engineering components such as forgings, extrusions, rolled products, and welded/bonded joints.

Baldev Raj, T Jayakumar, and M. Thabasimuthu, Practical Non-Destructive Testing, Practical Non-Destructive Testing, ASM International , 2001

C. V. Subramanian, Practical Ultrasonic, Narosa Publishing House , 2006

Louis Cartz, Non-Destructive Testing, ASM International , 1995