Detecting Defects for NDT Failure Analysis

NDT failure analysis asks two primary questions, depending on when it is performed: “Will this fail?” and “Why did this fail?” To answer either question, powerful nondestructive testing (NDT) tools are needed to identify flaws and defects hidden beneath the surface.

Companies and government bodies perform NDT in order to protect their customers, their workers, their assets, and even the environment. Identifying an impending failure before it occurs can give companies time to repair or replace the component in question before it causes harm.

How Failure Analysis Protects the Bottom Line

Failure analysis can be performed before a product ships, while an asset is being used in the field, or after a failure has occurred. Testing products for defects before they ship out protects a company’s reputation while providing value by minimizing defective products. It may also be required for compliance. For sensitive products, it may further prevent public harm that could occur if a product were to fail in the field. Automakers and aerospace manufacturers are good examples of companies that must perform failure analysis, or pre-service safety inspections, before shipping product.

Companies with large assets in the field, like oil pipelines or chemical refineries, must also subject their equipment to NDT failure analysis. Power plants, aerospace companies, shipping companies, and rail companies all perform some level of NDT in the field. By identifying emerging issues early, they can provide time to take assets out of service before they cause serious harm. Additionally, having the ability to look at historical inspection data to determine what has changed over time can be extremely valuable. The benefits are clear—preventing a single major oil spill from a faulty weld, for instance, can cover the cost of purchasing NDT equipment, software, and employing trained staff.

When NDT failure analysis is performed after a product or asset failure, it seeks to identify the root cause. Like with pre-failure NDT, it requires powerful equipment and software to map the full extent of damage present. Once established, this can be analyzed to determine a failure’s proximate cause, and provide indications of how a small flaw may have worsened over time. By doing so, and comparing this information to other failure analyses, companies can develop a more accurate picture of how and when issues will worsen or fail. This helps them set forth detailed maintenance standards that can prevent similar failures in the future. 

Choosing NDT Methods for Failure Analysis

Many different types of NDT can be used to identify flaws for failure analysis, including:

• Ultrasonic
• Eddy Current
• Radiography
• Liquid Penetrant
• Magnetic Particle

Visual inspections are often performed to identify surface-level defects and can serve as a “front line” for other methods of NDT. If some corrosion is noticed during a visual inspection, for instance, the area can be flagged for a follow-up inspection with an ultrasonic scanner. The ultrasonic image will provide a full map of the area’s corrosion and wall thickness, arming maintenance with the information they need to take any appropriate action. 

The right type of NDT depends on the application, namely the materials and shape of the area that must be inspected. For example, eddy current NDT is mostly limited to conductive materials and optimized for surface or sub-surface inspections, while ultrasonic scanning is ideal for volumetric inspections. The right type of NDT additionally depends on social as well as physical factors, such as speed (slow tests cost more), safety, and regulations.

NDT Equipment Quality for Failure Analysis

Better equipment means better data, and consequently, better analysis. High-quality NDT equipment can reduce inspection times, perform more accurate tests, and test more complex or difficult applications. Modern, intuitive software simplifies testing and analysis. Some of the most important attributes of NDT equipment for failure analysis are related to its software, such as data analysis, reporting capabilities, and set-up tools. Equipment that can quickly generate, store, process, and transmit data facilitates efficient nondestructive testing by making as much information available for failure analysis as possible.

Additionally, physical attributes contribute to NDT success. Durable equipment can stand up to the rigors of field testing, even in inclement conditions. Equipment without air intakes is protected against dusty outdoor or indoor environments. Lightweight equipment reduces technician fatigue while increasing the number of scans that can be accomplished in a day.

Failure analysis protects everyone involved with a product or asset. Preventing breakdowns and failures can save lives, and safeguard revenue. Top-shelf NDT equipment can improve defect detection, providing companies all the time they need to fix issues long before they get out of hand.

Zetec provides state-of-the-art NDT equipment to detect defects for failure analysis. To learn more, contact Zetec today!