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When discussing pipes and their maintenance, we usually think of oil and gas industries and the vast extent of pipelines that are on the rise. But there is more to the application of pipes than just petroleum transport. For example, they are commonly used in nuclear, biopharmaceutical manufacturing, and food and beverage industries, all heavily dependent on pipes and tubes for proper operation. This also gives rise to the need for pipe weld inspection in these industries. 

Pipes and welds in such industries can be required to adhere to strict sanitary and structural standards. To serve this need materials such as steel, or other austenitic materials are mostly used. To examine if the weld performed in such pipe materials are strong, flawless, and pure, various non-destructive testing (NDT) technology can be used. 

Ferritic and Austenitic Metal Pipe Welds

Carbon steel has been a go-to material for industries when it comes to piping for excellent structural integrity. However, carbon steel pipes don’t quite fit the role for industries such as biopharma and food processing, where sanitation and purity are the topmost requirements. In addition, the corrosive behavior of the metal can be an issue that can be further exacerbated by acids and bases in the food or chemical content. Ferritic and austenitic stainless steels are thus preferred due to their corrosion-resistant properties. 

Austenitic and ferritic metals can provide a similar structural strength as carbon steel while adding corrosion-resistant features to the equation. The weld priority of these pipe materials can, however, be unique due to their varying microstructures.

Ferritic generally have poorer weldability than austenitic metals. So, welding such material can result in loss of toughness and ductility while increasing the possibility of hot cracking and embrittlement in the heat-affected area. Similarly, for austenitic metal with low thermal conductivity properties, heat input during welding requires careful consideration. They are also equally susceptible to corrosion and microcracking. 

Any flaw developed due to inaccurate weld can cause contamination which is a major concern for industries adhering to strict sanitary regulations. To avoid such a situation, pipe weld inspection with NDT is befitting. 

NDT for Pipe Weld Inspection Ensures Industry Standards

Pipe weld inspection of stainless steel can have technicians looking out for flaws such as microcracking, corrosion, inclusion, and lack of fusion. These are all the results of an improper weld process. While visual, magnetic particle and radiographic testing have been used, industries are increasingly choosing ultrasonic (UT) and eddy current (EC) testing methods. 

EC inspection method is favorable in identifying surface or near-surface flaws such as microcracking. As the eddy current is induced in the metal, the variation in the magnetic field can be detected, indicating the possibility of cracks in the surface that may not be obvious during visual inspection. Similarly, using the PAUT (Phased Array Ultrasonic Testing) method, in-depth flaws such as inclusions, lack of weld fusion, cracks, and pores can be easily identified with the help of ultrasonic waves traveling within the pipelines.   

The utilization of these inspection techniques is important if operational efficiency is to be maintained and contamination avoided. Contamination can pose severe health risks to the consumer. EC and UT can help industries avoid this situation by detecting flaws pre-installation and periodically while in-service. 

Maintaining Safety and Sanitary Standards with NDT

Once welded, NDT solutions can help in analyzing the quality of the pipes and tubes. Through periodic inspection, flaws developed with time can be detected, initiating the need for repair and maintenance. NDT methods like EC and UT can ensure pipe weld inspection in-service with minimal disruption of the operation. Through effective inspection, any source of contamination can be easily eliminated, helping industries meet their sanitary standards and maintain their cost-effectiveness and productivity.

Zetec can support your pipe weld inspection needs with advanced EC and UT equipment on the market. For more information, contact Zetec today to get a custom NDT plan that can serve your industrial sanitary requirements. 

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Almost 5,512 pipeline incidents were reported from 2010 to 2018 in the United States alone. This data says a lot about the need for inspection of such crucial infrastructure around the world. Pipeline failure can be extremely damaging; thereby, the risk for human lives, the environment, and damage and repair costs can be massive. Pain points like welds are contributing factors to such failure. To identify such risk areas and foster operational safety, exploration for advanced inspection methods is a must. 

Exploring Pipeline Weld Inspection Techniques

Welding of pipelines in either upstream, midstream, or downstream oil and gas operations needs to be of high quality if long-lasting performance is to be expected. Extreme temperature, pressure, and chemical interactions are other reasons why robust welding is desired. But given the challenge associated with the welding of pipelines, i.e., potential weld flaws, difficult weld setup for different pipe sizes, and improper welding around complex geometrical areas, the inspection need becomes imperative.

Over the years, various inspection methods have been implemented by industries to cover a wide range of inspection needs of pipeline welds. Based on their effectiveness, some of these types of inspection techniques are discussed below: 

1. Destructive testing: Destructive testing focuses on inspecting the integrity of the pipe material itself and that of the welded joint through various tests to examine the metals’ robustness up to its failure point. The detection of point of failure allows technicians to analyze the weld quality and study the impact of load and stress on the joint. The weld certified through destructive testing can be set as the standard for pipeline welding and closely recreated for future operations.

The major drawback of this inspection system is its inability to represent all load conditions during a sample test. The weld sample used is completely destroyed, which increases waste, manufacturing and inspection costs. The test is basically used for certification purposes; thus, the weld quality cannot be accurately assured each time under a different operating environment.  

2. Visual inspection: Visual inspection is the primary inspection method all technicians go for to make assumptions of the weld quality in pipelines. It is the most uncomplicated and inexpensive method of inspection and an effective one in recognizing any major weld issues as it occurs. Visual inspection can be performed pre-, during, or post-weld, which prevents the flaw from carrying on onto the next phase of the process. The more observable flaws such as cracks, weld splatter, distortion, incomplete fusion, and larger pores can be located easily. To inspect for leaks in pipeline welds, a basic approach is to pressurize the pipeline and use media like soap water that can visualize air escaping in the form of bubbles. 

The disadvantage with this inspection method is its inability to capture all minor and underlying flaws in the weld surface. However, it can be used as a way to prevent significant flaws from occurring, reducing the need for extensive nondestructive testing (NDT) analysis. 

3. Dye penetrant testing: Dye penetrant testing is often considered to be an advanced visual inspection technique. As the visible dye penetrant is applied to the weld surface, any cracks or pinholes not easily identified during visual inspection can be displayed as a contrast in color. Although quick, portable, and suitable for all kinds of geometries, only surface flaws on smooth surfaces can be identified, which can be a problem, especially for critical structures like pipelines.   

4. Nondestructive testing: Nondestructive testing has been an industry choice due to its effectiveness and ability to inspect pipelines without causing them any damage. Advanced NDT instruments and probes have proved their efficiency in pipeline weld inspection. NDT can facilitate precise identification of all major and minor flaws in the weld surface and sub-surface to give a complete overview of the weld quality. This is supported by the flexibility and portability of advanced NDT instruments, which further provide the benefit of inspection in complex areas, on-site inspection, and real-time inspection, desirable features for pipeline weld inspection. 

The major issues concerning destructive and visual inspection are their inability to detect all flaws and discontinuities within the weld, causing a major efficiency problem. The advantage of precision, accuracy, and flexibility that NDT provides is why its favorability over other inspection techniques has been increasing.

Improving Inspection Efficiency with Advancement in NDT

As we discuss the effectiveness of NDT for pipeline weld inspection over other inspection techniques, the question that arises is how does NDT make it possible. Here are some reasons why:

1. Complete inspection: With advanced eddy current (EC) and ultrasonic testing (UT) instruments, a wide range of flaws in the weld can be identified. Flexible probes and scanners mean an inspection can be done even in complex geometries such as pipe bends. A complete scanning allows for effective data analysis.
2. Portable scanning: With portable NDT solutions, easy and speedy inspection is possible. On-site inspection ability of instruments reduces travel times and time between scans, plus wider coverage from probes increases inspection efficiency. Portability also improves inspection efficiency in low-clearance or difficult to access areas of the pipeline by eliminating the need to create access or be exposed to potential hazards.  
3. Scalability: With instruments configurable to scale and the ability to combine multiple instruments for highly challenging volumetric inspections, the time taken for complete pipeline weld inspection can be reduced.   
4. Improved data analysis: Advanced NDT scanners and probes can scan and capture large amounts of data quickly. Faster analysis using advanced instrumentation and software improves communication and reduces inspection downtime. With real-time analysis, it is possible to speed up the process further. The improved A and C-scan display capabilities foster accuracy during flaw detection and characterization.

Pipeline weld inspection is made easier for oil and gas industries with advanced features of NDT instruments, software, scanners and probes. By giving technicians access and coverage for inspection, improved flaw detection, and weld quality analysis can be achieved. 

Pipeline Weld Inspection is Made Easy With NDT Solutions

The risk factor involved in oil and gas pipelines and welds is huge, thus requiring accurate inspection technology. With ultrasonic scanning technologies such as the Weld Crawler and ElbowFlex scanner from Zetec, portable and flexible inspection ability can be achieved. In addition, Weld quality ensured through advanced NDT instruments, probes and software can allow oil and gas industries to minimize hazards and needs for repairs and look forward to a more profitable operation.  

Zetec specializes in advanced eddy current and ultrasonic testing solutions that can match your pipeline weld inspection needs. Our portable scanners and NDT weld crawlers can help in reducing your inspection downtime and improve productivity. To learn more, contact us today!

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It is normal for the metal or components to go through various metallurgical changes during the manufacturing process. This holds true during machining and fabrication phases, including melting, rolling, stamping, forming, grinding, welding, plating, or heat treating. During these processes, it is common to develop some processing discontinuities. Investigating the extent of these discontinuities can be challenging for technicians, especially if they rely on visual inspection.

Nondestructive testing (NDT) technologies effectively identify material imperfections at all stages of production without damaging the properties or performance ability of the material.  In particular, Eddy current (EC) testing and ultrasonic testing (UT), can look into these processing discontinuities for in-depth analysis and keep them off the production line. 

Understanding Processing Discontinuities In Manufacturing Setting

Discontinuities originate when the materials are subjected to extreme stress or temperature to alter the physical or chemical properties to satisfy the manufacturing needs.  These may appear in the form of inclusions, cracks, laps, seams, laminations, shrinkages, cold shuts, voids, and so on. Depending on when and how they are formed, processing discontinuities can be classified as:

1. Primary processing discontinuities: These discontinuities occur in the primary manufacturing phases when the metal ingots are worked down using casting, hot and cold forming, and rolling processes to give it a desirable shape and size. Poor practices, rapid temperature changes, extreme stress application, and improper surface preparation contribute to the following types of primary processing discontinuities:

Casting discontinuities	Porosity, cold shuts, shrinkage, dross
Rolling discontinuities	Laminations, stringers
Forging discontinuities	Laps, bursts

2. Secondary processing discontinuities: These discontinuities originate during the finishing operations, such as grinding, heat treating, plating, grinding, welding, and machining. The most prominent types of secondary processing discontinuities include:

Machining discontinuities	Tears
Grinding discontinuities	Cracks
Heat treating discontinuities	Stress cracking
Welding discontinuities	Undercut, lack of fusion, porosity, cracks, inclusions, lamellar tearing

As industries use these processed materials further down the production line, ensuring their defect-free status becomes vital for analyzing the safety and quality of the product. This confirmation can be achieved with EC and UT methods of NDT testing. 

Volumetric Inspection of Processing Discontinuities With NDT 

From raw metal ingot to the processed final product, at each stage of production, NDT can recognize indications of flaws. With eddy current testing, the probability, and accuracy of detecting surface or near-surface flaws increases. With ultrasonic testing, in-depth, volumetric subsurface flaws can be identified by focusing on the ultrasonic beam and analyzing the deflection. 

Although the accuracy and precision in an inspection are an advantage, the sheer scale desired for maintaining a healthy production level in the manufacturing industry can be challenging for complex inspections using regular NDT instruments. NDT instruments with scalability options can be used as a solution. These instruments can be configured to scale, and multiple units can be stacked together and operated in parallel to cover a wide inspection area. This approach is advantageous for the following reasons:

• Large volumes of data collected in a single scan can help in detailed inspection and analysis.
• Volumetric scanning increases inspection speed fostering higher productivity.
• Real-time inspection can help in the speedy analysis and immediate filtering of defective products.   

With the flexibility to inspect complex geometries and scalability to test volumes of products, discontinuities during manufacturing can be easily discerned while avoiding bottlenecks in the production environment.  

NDT Enhances Productivity and Quality

Metal processing is a common manufacturing phase, as is the inspection of processed products. Products with discontinuities can pose a significant risk to human lives, the environment, and the operation. NDT instruments can prevent these products with discontinuities from moving forward in the production stream. Through flexible, advanced, compact, and scalable instruments such as Zetec’s Emerald (www.zetec.com/emerald) and Quartz, manufacturers can look forward to increased productivity of quality products. 

Zetec’s advanced NDT instruments with powerful inspection and data analysis capabilities can provide reliable inspection results to meet your manufacturing standards. Contact us today to learn more about how Zetec can help improve quality by identifying processing discontinuities.

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With increasing quality and production demand globally, industries should constantly focus on quality improvement opportunities to gain a competitive edge. This means not only utilization of advanced manufacturing technology but also a constant lookout for flaws in machinery and products. Hence, the role of nondestructive testing (NDT) technologies becomes to identify these weaknesses or flaws in industrial settings that can damage product quality, productivity, and cost for the industry at large. 

With advanced NDT instruments and probes, accurate inspection and analysis of the material, industrial components, and products can be achieved. In addition, industrial plant NDT methods can foster improvement in performance and efficiency goals through quality control and regulatory compliance in industrial plants.

Inspection in Industrial Plants: NDT Methods Ensure Quality Control

Effective manufacturing requires regular inspection of industrial assets as well as manufactured components. NDT not only serves as a quality control measure but also fosters flaw detection at an early stage. In heavy manufacturing industries where large components may be manufactured, NDT supports the production environment by reducing waste, ensuring operational safety, and improving cost-efficiency.

Learn more about NDT for heavy manufacturing solutions. 

Similarly, in automotive industrial plants, NDT methods like ultrasonic testing (UT) and eddy current testing (ECT) can accurately and reliably inspect welds and composites in the components, helping to improve productivity and reduce downtime at all stages of production. 

Learn more about NDT in the automotive industry. 

Plants manufacturing pipes, tubes, and other steel components seek assessment for material integrity throughout the production process. NDT ensures this by examining material and welds for cracks, pores, laminations, inclusion, or other flaws in the production line.

Learn more about NDT for pipes, tubes, and steel products manufacturing.

Verifying Material Integrity Through NDT in Manufacturing

Carefully engineered machined parts and components can be key to precise manufacturing. To ensure these parts can be flaw-free, industrial plants generally look for inspection opportunities in forged, heat-treated, and machined components. This is applicable for many industries including automotive, pipes and tubes, or other heavy-duty manufacturing. 

Forged components go through extreme stress and temperature changes. During the process, the probability of occurrence of flaws like cracks or grains is high. Phased array ultrasonic testing (PAUT) and corrosion scanning methods can evaluate grain structure and identify parallel cracks and other inherent discontinuities even at greater subsurface depth with accuracy and precision. With volumetric scanning ability even along unconventional surfaces, a large amount of data can be analyzed to ensure product integrity.

Learn more about how ultrasonic testing of forging ensures heavy manufacturing product quality.

Many metallic components going forward in the production line face heat treatment to optimize their mechanical properties. However, the constant heating and cooling during the process can result in flaws and irregularities that can be difficult to detect visually. In industrial plants, the NDT method of ECT can monitor heat-treated components for potential cracks, void, inclusion, or other flaws. 

In the automotive industry, this can be done for components like gears, shafts, axles, and wheel bearings. With multi-frequency testing capabilities of ECT instruments, parts with improper heat treatment can be identified. This can help manufacturers to rule out flawed components and products to ensure safety and quality compliance. 

Read more about the use of eddy current testing for improper heat treatment testing in automotive manufacturing.

Quality assessment of fasteners or welds and metals or composites is an integral part of the NDT process in industrial plants. The combination of different material layers can make it difficult to identify voids, inclusions, and fractures developed between the layers. Similarly, weld flaws in irregular surfaces and complex geometries can also be difficult for technicians to spot. 

Especially in high-stake industries like automotive or aerospace, the flaws in final products can have serious consequences. With ECT and UT, manufacturers can ensure quality control through regular inspection of industrial components and products during each manufacturing process step. Timely detection can help industries reduce downtime while ensuring safety and quality. 

Learn more on how NDT provides inspection and quality control in manufacturing.

NDT Ensure Compliance To Industrial Standards

A wide range of industrial plants have been utilizing various NDT methods to ensure manufacturing quality control. However, ECT and UT have been the most prominent choice for their ability to detect surface and subsurface flaws accurately, perform volumetric inspections, and precisely analyze the data for different types of flaws. Zetec’s TOPAZ Phased Array Ultrasonic Instruments, NDT Paintbrush Scanner, Weld Crawler Scanner, as well as the MIZ-200 and InSite Eddy Current Instruments provide advanced solutions for the inspection of complex and critical components during the product manufacturing process. 

With the right NDT solution and effortless assessment, industrial plants can address flaws early and efficiently, ensure quality control and meet industry standards.

Zetec, with decades of experience, can help you find the right solution for industrial plant NDT. Contact Zetec to learn more about the best NDT method for you and discuss the custom inspection plans that match your needs.

The space industry has come a long way from Sputnik 1, the first-ever artificial satellite, to the New Shepard rocket with the first passenger flight. The recent extraordinary successes have shifted the immense focus of the world towards these space ventures. However, delivering a successful mission requires intricate attention to structural and other details of launch vehicles, satellites, and other payloads. One of the essential details for spacecraft and their payload is quality control of its components utilizing nondestructive testing (NDT) technology.   

Utilizing NDT to test spacecraft components and payloads is essential to ensure they perform with full efficiency for the long term without unexpectedany maintenance requirements. 

Areas to Pay Attention To for Spacecraft NDT

Space industries have focused on different ways to improve component quality and cost-efficiency in every space launch. However, with commercial space tourism on the rise, the stakes to increase spacecraft safety is higher than ever before. 

Whenever we think of a spacecraft, we can imagine the low gravity, extreme temperature variations, and immense pressure the launch vehicle can withstand. Like aircraft, there is also a necessity to keep the craft light yet strong enough to carry the payload. All these pre- and post-launch activities need to be completed without a single flaws in the system. Although each component is designed at its highest quality standards, flaws canare always be a possibility. A singular flaw can mean a catastrophic failure, massive investment loss, or loss of human lives in worst-case scenarios.

Composed of tanks for the propulsion system, launch vehicle frame, turbine and engine, pressure vessel, wings, fuselage, number of fasteners and other accessories, as well as composites and welds, the need for inspection is crucial. In addition, payloads such as satellites also need to be of excellent quality to ensure stable performance where no maintenance provision is available. Utilizing NDT, space industries assess the integrity of these materials and components without causing any damage. Identifying flaws early in the process can saves costs, ensures efficiency, and prevents hazards in this complex process. 

Importance of NDT for Successful Space Launch

Material quality, probable flaws, and their impact on the spacecraft’s performance and payloads can be examined utilizing NDT methods such as ultrasonic testing (UT) and eddy current (EC) testing methods. Additionally, the advanced probes, instruments, and software help industries fulfill the high NDT standards that the components are adhered to and provide the corrective maintenance opportunity.

• EC testing facilitates inspection of flaws such as cracks and other surface flaws for components like spacecraft frame, turbine or engine, fasteners, and the heat-affected areas of the weld. Eddy current array (ECA) instruments and probes can test in complex and difficult-to-reach sections to detect minor surface and subsurface flaws, thus increasing the probability of flaw detection. 
• Ultrasonic testing (UT) is most commonly used for NDT space. From thickness testing to corrosion detection, UT can effectively assess composite spacecraft structures, engines, and gears for the presence of cracks, corrosion, or inclusions. Advanced Pphased array ultrasonic testing (PAUT) instruments with TFM (Total Focusing Method) facilitate scanning along the complex geometries and wide surfaces for volumetric inspection in a short amount of time. 

NDT Ensures Mission Success

Construction and maintenance of the space shuttle and their various payloads are subjected to stringent inspection requirements. This is due to the immense risk it carries. The inspection should be carried out at greater speed with maximum accuracy and precision for the time- and quality-bound space missions. With PAUT and ECA methods of NDT, the space industry can easily detect minor flaws at an early stage, saving the project from major catastrophes. With quality components, space industries can venture into successful space missions.

Zetec is a leading provider of nondestructive testing solutions for inspecting spacecraft and payloads in the space industry. To learn more about our advanced NDT solutions, contact us today.

As one of the earliest known manufacturing processes, metal casting has been a go-to metalworking process in industries for centuries. Oil and gas and nuclear industries have been casting steel and other materials for components like pipes, elbows, or risers. 

The casting process involves pouring hot molten metal into the die or mold and letting it solidify to get a desired geometrical shape. This technique has made it easier to design custom or complex geometrical components in an economical way. As a result, we can often see cast metals being used in our daily lives in, for instance, engine blocks on cars, train wheels, or traffic light posts. 

However, before these components are put to use, they must go through an elaborate inspection process. This is required because the molten metal may leave pores or voids within the cast during solidification. The probability of these flaws developing into more severe cracks during stress exposure is high. Nondestructive testing (NDT) can easily identify these metal casting defects without damaging the component. The quality and safety assessment through NDT is vital to ensure that the component is fit enough to be used.

Types of Metal Casting Defects

As with any other manufacturing process, there is a probability that defects may occur during metal casting. Usually, heat treatment of the metal or metallurgical factors can play a role in developing metal casting defects. These defects can exist in metal in many forms, such as:

• Porosity: When the metal is liquified, it dissolves a large amount of gas within it. When the molten metal is poured, these gaseous bubbles are trapped. During solidification, these trapped gases induce the formation of pores in the metal.  
• Inclusion: Inclusion is another common occurrence in cast metal. The impurities or contamination present in the molten metal or the mold can affect the ductility or strength of the component. The concentration of these foreign matters in one spot during solidification can be even more severe, leading to cracking.  
• Cracks: Cracks can be observed once the cast metal has been solidified. There can be many reasons for the cracks to form, including mold design faults, shrinkage, uneven cooling, excess porosity, and thermal stress. 
• Shrinkage: Shrinkage is a major concern for industries during metal casting. Expansion and contraction are leading reasons for shrinkage. Closed shrinkage defects occur when the poured metal starts to solidify, and hot spots form inside the solidified metal. These can be difficult to detect visually. Open shrinkage defects are exposed to the atmosphere and easily detectable due to their presence on the metal surface. The “pipe” type defect starts at the surface and burrows within the cast, while “caved surface” defects are scattered across the surface as hollow cavities. 

The severity of these defects requires a proper inspection method that can identify macro and micro defects present in the cast metal without error. NDT is an effective solution to identify these metal casting defects to ensure the safety and efficiency of the cast metal component.

Identifying Different Types of Defects in Cast Metals With NDT

Surface or internal metal casting defects can be identified with NDT technologies such as Eddy Current Testing (ECT) or Ultrasonic Testing (UT). 

ECT can essentially replace Liquid Penetration Testing (LPT) and Magnetic Particle Testing (MPT) to be the most effective choice for identifying the surface or near-surface defects and casting irregularities. Eddy Current Array (ECA) probes and instruments can sense the change in the magnetic field induced within the cast metal, which indicates a flaw. This mechanism also enables technicians to use ECA for examining complex geometrical components. 

UT, however, is most commonly adopted by industries for its volumetric and accurate defect detection ability. As the ultrasonic wave-induced through the transducer within the cast metal is reflected back, the deflection of the wave can be analyzed to identify the presence of cracks, pores and voids, inclusions, and shrinkage defects. 

In addition, advanced UT instruments, probes and scanners can enable high-resolution A-scan displays, making it easier to distinguish and locate pores, grains, and other metal casting defects. The advanced NDT probes, instruments, and software make it possible to locate difficult-to-detect defects to ensure quality and meet standards for casting.

NDT Assessment of Metal Casting Defects for Quality Assurance

Meeting quality standards is the foremost priority of manufacturers. With a wide range of cast metals being used across industries, ensuring the quality of these cast components is crucial for safety and efficiency. With NDT, metal casting defects can be identified early in the process. Evaluation of flaws through NDT can help industries evaluate material integrity, safety, and thus, production excellence. 

Zetec provides advanced NDT solutions to facilitate your need to identify metal casting defects for a wide range of applications. To learn more, contact us today! 

Manufacturing is a complex process requiring materials to go through metallurgical, physical, and chemical changes. Discontinuities can therefore be a common occurrence during the fabrication or processing phase of manufacturing. This is true for all kinds of materials, be it metal or composites. The discontinuities in the material can disrupt the operation during the manufacturing process or shorten the lifespan of the material. 

At any stage of manufacturing, nondestructive testing (NDT) can facilitate the detection of manufacturing discontinuities. Especially with ultrasonic testing (UT) or eddy current testing (ECT), manufacturing discontinuities can be identified early on in the process, saving industries from carrying over the flaws only for the material to fail or spend multiple folds to correct the flaw. 

Discontinuities in Metals and Composites

Automotive or aerospace manufacturers, and many other industries use composite materials and metals to ensure the integrity of their structural components. However, discontinuities in the material can affect the material’s properties, compromising its strength and ability. Discontinuities in the material can be inherent or can appear during the processing or service phase. This includes processes such as metal casting, machining, fabrication, or welding, which can develop discontinuities in the form of surface irregularities, cracks, pores, cavities, or inclusions. These discontinuities can develop as a result of mechanical or thermal stresses, fatigue, or corrosive environment. 

The visual detection of discontinuities can be very difficult in metals and even more so in composite materials due to their multi-layered nature. Thus, ECT and UT are suitable NDT options for effective flaw detection and analysis in metal and composites. Conductive metals can leverage the benefits of ECT, which is ideal in identifying surface discontinuities with high sensitivity. However, for non-conductive options like composites, UT inspection can help identify surface and subsurface discontinuities with a high degree of accuracy. 

NDT Solutions for Discontinuities Inspection in Manufacturing

Metal like steel that makes up industrial components, including plates, tubes, pipes, or equipment parts, needs a thorough NDT assessment to examine structural integrity. Most discontinuities in these metals result from metallurgical issues during manufacturing or are induced around the heat-affected zones. 

• Eddy current array (ECA) technology can detect discontinuities induced due to metal fatigue. It can provide surface and near-surface inspection for metallic structures of a wide geometric range. The conductive nature of the metallic components increases the sensitivity of ECA probes to detect discontinuities with a high degree of accuracy. 
• Phased array ultrasonic testing (PAUT) facilitates inspection for possible pores and cracks in the metal and weld area. With the help of a focused ultrasonic beam, it is easier to navigate through different geometries and approach varying metal thickness to identify, size, and locate discontinuities.

Composite materials have a complex, yet important, inspection process, given the increasing use of the material in high-risk industries like aerospace. In addition, composites generally blend fiber and polymer additives that give the material its non-conductive nature. Because of this, ECT is not ideal for composite testing NDT. 

However, manufacturing discontinuities for composites can be identified with PAUT probes that facilitate volumetric and speedy testing through real-time visualization. PAUT utilizes the time-reversal technique and time-of-flight diffraction (TOFD) of reflected waves to study surface or geometrical changes. 

A variety of discontinuities can lead to material quality degradation during the manufacturing process. With the use of UT and ECT as the primary method of NDT, manufacturing discontinuities can be identified with a high degree of precision at early stages. Rework and rejects can be identified before the stress causes the component to fail.

Meeting Quality Needs with Discontinuities Detection in Manufacturing with NDT

Zetec provides a wide range of inspection solutions such as the paintbrush scanner or TOPAZ that make high-resolution scanning and real-time analysis possible for discontinuities detection. The pre- and in-service inspection during manufacturing facilitates high-quality production of components, minimizing the need for costly reworks. In addition, PAUT supports volumetric testing in large-scale operations.  

The flexibility and portability of probes also mean that complex geometries can be quickly inspected. These features support high-quality component manufacturing with enhanced safety and productivity.

If you are looking for equipment that provides powerful inspection and data analysis capabilities with reliable results, Zetec can help you with its best ultrasonic and eddy current NDT tools to meet your manufacturing needs. To learn more about how Zetec can help with the manufacturing discontinuities detection process, contact us today.

Gear failure is one of the prominent causes of machinery and operational damage. Usually, a flaw in a gear occurs from excess stress and fatigue resulting from high strain mechanical usage. However, the damage is also possible due to errors like misalignment or lack of regular maintenance. The result can be bigger issues like the development of cracks, fractures, pitting, or other metallurgical failures. 

To ensure that these gears operate reliably, technicians may use technologies that help them identify any potential flaws that can hurt the operation and its productivity. For example, nondestructive testing (NDT) techniques can help with gear inspection during various operation phases to yield reliable results. The analysis of the available data through NDT can help operators identify the level of gear damage and potential maintenance options. 

Wear and Tear in Gears

Gears are a vital part of mechanical devices and motorized equipment in industries such as automotive. They help in the transfer of power and motion from one part of the equipment to another. In doing so, a gear engages its design components like “teeth” in the gear wheel. 

When exposed to extreme load stress conditions, the gear wheel and teeth can develop fatigue cracks. Other reasons for flaw development in gears can include:

• Excess load and stress
• Misalignment
• High friction and vibration
• Excess heat generation

There is a possibility that the surface cracks or pitting, if not detected in time, can develop into a more severe issue such as machine failure, which can cost industries their valuable time, cost, and productivity.

To stand up to the highly demanding conditions, the gears should be free of flaws. NDT such as ultrasonic testing (UT) and eddy current testing (ECT) are suitable for flaw detection and diagnosis during gear inspection. These NDT methods can inspect gears of varying dimensions and geometries without costing industries any downtime or extraordinary cost.

Gear Inspection with NDT to Minimize Damage

Traditionally, NDT methods like magnetic particle testing (MPT) and liquid penetrant testing (PT) were used to detect surface cracks during gear inspection. However, the accuracy of results from these inspections depended on the operators’ ability and the extent of surface cleaning for inspection. This may have led to flaws being missed. Because of which, a more accurate inspection approach with ECT and UT could improve probability of detection. 

Eddy current array (ECA) testing uses electromagnetic waves to detect surface and subsurface flaws in the gear. ECA probes with multiple coils can be sequentially excited to induce a magnetic field into the gear teeth. The presence of surface cracks can hinder the flow of current and magnetic field, which the probe can sense.

The high sensitivity of ECA to surface flaws can help technicians identify the flaws in any orientation along with information on shape, size, and depth. Zetec’s Surf-X eddy current array probe can provide all these features along with recording and analyzing each signal and 2D/3D display to facilitate a detailed result. 

Similarly, during phased array ultrasonic testing (PAUT), multiple transducers propagate ultrasonic waves into the gear teeth. Since each transducer can be individually pulsed and focused, it is much easier to inspect the varying geometries in the gear. Any time delays or amplitude changes can be viewed in the A-scan, indicating flaws in gear teeth. PAUT can be especially useful for inspecting pitted gear teeth to identify the subsurface flaws resulting from pitting, which ECA can be insensitive to during gear inspection.

Ultrasonic and Eddy Current Testing as Gear Inspection Solutions

The ideal inspection technique helps operators easily identify flaws while minimizing time and effort. Given the complex geometry of gears, the inspection process is bound to be challenging. The use of ECA and PAUT technologies are, thus, much to the advantage of the industries to address the unique challenges of gear inspection due to their high sensitivity to surface and subsurface flaws, high-resolution scanning, and volumetric inspection ability. 

Zetec is a leader in the world of advanced nondestructive testing instruments and services and has industries that increase their productivity and returns by addressing their NDT needs. Our advanced ECA and UT probes suitable for gear inspection enables manufacturers to improve the quality of their machinery and products. For more information—contact Zetec today.

Welding is the most commonly observed method for fusion and fabrication in many industries. The quality of the weld dictates the component quality, which ultimately reflects on the efficiency of the operation. Thus, many welding methods can achieve this quality depending on the types of materials involved. First, however, an inspection of the weld is necessary to make sure this weld is seamless and flaw-free.

The examination of weld penetration is the most vital in the process as it plays a direct role in ensuring the strength of the weld. However, it is difficult to assess the penetration depth in tubes or pipes, making it difficult to inspect the weld visually. Nondestructive testing (NDT) technologies can check for any flaw in the weld and test the depth of weld penetration without causing damage to the material and without hindering the operation. Portable equipment further simplifies the testing process by allowing in-field inspection and real-time analysis. 

Weld Penetration Testing

In oil and gas, automotive, or aerospace industries, welding is commonly used to join metallic components together. Ensuring the weld formed is strong enough is to confirm there is a deep enough penetration of the molten filler materials into the seams. Either the requirement is a partial or full penetration, the strength of the joint relies on the depth of the weld penetration achieved. The lack of proper penetration can create weak and poor-quality joints, leading to flaws like lamellar tears or cracks, thus, affecting the strength and integrity of the metal component. On the other hand, excessive penetration can lead to issues like corrosion or erosion. 

Although visual inspection can help determine the weld quality, it may not apply in all applications. For instance, in oil and gas pipelines, where the groove is welded from just one side, it may be challenging to inspect the bond at the root of the joint due to the visual obscurity to the back of the weld. Thus, to thoroughly examine the weld, a non-visual and nondestructive method of inspection is often necessary. While NDT methods like eddy current testing have been used, the ultrasonic testing (UT) method can be the most effective weld penetration testing.    

Ultrasonic Testing to Examine Weld Penetration

Weld flaw and penetration depth assessment are simplified with the UT inspection method. Especially in components like pipes or tubes, ultrasonic weld penetration test equipment is suitable as only the access from one side of the material is enough for inspection. The transducer propagates the ultrasonic waves through the weld and the metal layer to perform the testing. Any interruptions or deflection in the reflected signal can be analyzed to locate and characterize the weld’s discontinuities, such as underbead cracks, inclusion, or pores. 

In the analysis of weld penetration, the reflected signal can be analyzed to identify the time taken for the beam to reflect back and see if it has been reflected from a lesser depth. This can indicate incomplete root penetration or lack of fusion in the weld zone. Similarly, in the case of excessive weld penetration, the reflected ultrasonic beam may have lesser energy. 

The sensitivity provided by ultrasonic waves to these flaws means the flaws are hard to miss, and results obtained from the test can be highly accurate and precise. This accuracy and precision can now be made accessible in the field with the help of portable weld penetration test equipment.

Portable NDT Solution Simplifies the Testing Anywhere

The advantages provided by ultrasonic weld penetration test equipment are most required in the field for applications like petroleum pipelines and refineries. With the help of portable equipment, such as Zetec’s TOPAZ family of instruments and the WELD Crawler, industries and operators can leverage the benefit of weld penetration testing flexibly without compromising on the accuracy of flaw detection. The study of root fusion, lack of penetration, or crack formation can be utilized to perform corrective measures and ensure proper weld design for the future.  

Zetec provides a wide range of ultrasonic testing technologies with weld quality inspection options. Our portable weld penetration test equipment fosters inspection efficiency and accuracy. Contact Zetec today to get NDT inspection equipment that conforms to your company’s needs.

TTurbine shafts face high-level stresses during operation in large-scale fossil, nuclear, wind, or steam power generation plants. During fabrication, sometimes, a methodology like welding is used to join smaller metals together. These factors in fabrication and operation can give rise to flaws in the turbine shafts. The flaws can significantly increase the risk in operation and affect the performance or damage the adjacent equipment. So, an inspection of the turbine shafts holds greater importance.

Ultrasonic nondestructive testing facilitates the assessment of material and weld quality in the turbine shaft. Any flaw identified during the turbine shaft inspection can be an opportunity to implement corrective measures to ensure a safe and smooth run of the turbine. 

Welds and Stresses in Large Turbine Shafts

In power generation plants, turbine shafts are more exposed to fatigue and stress than any other components. This is especially true for large-scale power plants where the dynamic, thermodynamic, and corrosive load can affect the turbine shaft. In addition, these variable loads can give rise to flaws like cracks in different parts of the turbine shaft. This is why the fabrication process of the shaft needs proper attention. 

One way turbine shaft fabrication is done is through welding. Large rotatable turbine shafts form by fusing two or more different portions of metals in large-scale power generation plants. The fusion is made possible with welding, which also helps attain an excellent ultimate strength of the component. Welding can also be utilized to connect the turbine shaft with the generator or gearbox. The expense at which the power plant equipment is attached to the turbine shaft means that the weld or metal quality itself should be top-notch without even a minor flaw. 

Although industries try to achieve nearly perfect and seamless welds, the possibility of flaws cannot be eliminated. Therefore, along with stress-induced cracks, as discussed earlier, various weld flaws such as porosity, inclusion, or lack of bonding should also be assessed. The assessment is made possible with nondestructive testing (NDT) technology like ultrasonic testing (UT) which can efficiently identify and characterize flaws without significantly affecting the operation. 

Ultrasonic Examination of Turbine Shafts 

Ultrasonic inspection is an effective way of identifying, locating, and characterizing flaws in turbine shafts. The inspection remains equally effective for different materials, weld processes, as well as varying shaft diameters. A high-frequency ultrasonic beam can be induced in the shaft with the help of an ultrasonic transducer, and the reflecting beam can be analyzed to identify potential stress-induced or heat-induced flaws. For welded turbine shaft, ultrasonic testing fosters inspection through identification of:

• Cracks or pores in the heat-affected zone
• Weld penetration depth and lack of fusion in the joint
• Inclusions in the weld
• Weld thickness measurement
• Corrosion and erosion

This flaw detection is facilitated with the help of advanced ultrasonic testing equipment, which ensures weld quality in turbine shaft with features such as:

• High-speed scanning and analysis
• High-resolution C-scan imaging and visualization
• Flexibility to inspect along curves or bends where the shaft may be connected to other equipment
• High volumetric coverage

In large-scale power plants, these features can be beneficial for turbine shaft inspection to ensure seamless and optimal welds as well as efficient power generation.

NDT Ensures Quality and Integrity During Turbine Shaft Inspection 

The quality of the turbine shaft directly correlates to the power generation output. Ensuring the integrity of the turbine shaft with ultrasonic testing means the adjacent equipment can also operate at its full potential, thus, improving the efficiency of the operation. The welded shaft can be examined for any potential flaws and remedied before moving further in the process.

With turbine shaft quality assurance via NDT inspection, power generation industries can improve productivity and efficiency while mitigating risks and saving operational costs. 

Zetec can partner with you to help you find the right NDT solution that can match your turbine shaft inspection and weld inspection requirements. For more information, contact us today.