Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

. MI L- HDBK-72811
16 December 1985
SUPERSEDING
SEE NOTES

I ,

I MILITARY HANDBOOK

NONDESTRUCTIVE TESTING

i (

NO DELIVERABLE DATA REQUIRED BY THIS DOCUMENT

I

I AMSC NIA
$ FA ND T II
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBE-72R/l

Department of Defense
Washington, DC 20301

MIL-HDBK-728
Military Handbook af Nondestructive Testing
16 December 1985

1. This Military Handbook is approved for use by all Departments and

Agencies of the Department af Defense.

2. This publication was approved on 21 October 1985 for printing and

inclusion in the military standardization handbook series.

3. T~i: d~~~efit pr~vi,je~ b~~i~ and fund~~e~t~] i~f~~ati~” ~~

nondestructive testing, inspection and evaluation useful durin~ all phases of
the DoD hardware’s life cycle.

4. Every effort has been made to reflect the latest information on

nondestructive examination. It is the intent to review this handbook
periodically to insure its completeness and currency. Fleneficial cmments
(recommendations, additions, deletions) and nny pertinent data which may be of
use in inp?ovin~ this document should he nddressed t~: Director, U.S. AririY
Materials Technology Laboratory, ATTN : SLCPIT-MSR-ES, Waterto!m, MA 02172-0001
by using the self-addressed Standardization Document Impr~vement Proposal
(DD Form 1426) at the end of this document or by letter.

l-ii
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l

FOREWORD

This handbook provideg to all Department of Defense (DoD) personnel

information, facts, and principles on the science of nondestructive testing,
inspection, and evaluation. By proper use of this science, the safety, the
reliabili ty, and the efficiency of the procurement and use of all DoD material
and hardware will be increased. This handbook information should be ugeful
during all phases of the L?uDhardware’ s life cycle including production,
maintenance, and repair of the hardware.

Thie handbook, by combining the existing nondestructive testing handhoks

and releted materials from all DoD agencies into one document, should help to
establish unity in the nondestructive testing area within and between all the
‘itienki~iof the “DoD. Th6 6i@fiiXition and- lo”ose-leaf format will”make it easy
to correct, update, and tailor to fit individual, needs within the DoD.

Since the hand book’.g effectiveness depends upon continuous, feedback from
its users, individuals are encouraged to contribute comments and suggestions
by filling in and mailing Form DD 1426 provided at the end of this document.

1 (;

l-iii
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MIL-HDBE-728/l

TABLE OF CONTENTS
(
F’aJ&
!2EEEz
1. General Information l-i

2. Eddy Current Testing 2-i

3. Liquid Penetranc Testin& >-i

Magnetic Particle Testing ~-i

4.

5. Radiographic Testing 5-i

b. Ultrasonic Testing 6-i

l-iv
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
‘ MIL-HDBK-728/l

TABLE OF CONTENTS - CHAPTER 1

Section &“
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1.0 SCOPE . . . . . . . . ...’.. . . . . . . . . . . . . . . . . 1.1-1
1.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1-1
1.2 USERS GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . .1.2-1
1.2.1 Handbook Organization . . . . . . . . . . . . . . . . . . 1.2-1
1.2.2 References. . . . . . . . . . . . . . . . . . . . . . . .1.2-1
1.2.3 Index . . . . . . . . . . . . . . . . . . . . . . . . . .1.2-1
1.2.4 Format forDefinitione . . . . . . . . . . . . . . . ...1.2-1
1.2.5 Handbook Revisions . . . . . . . . . . . . . . . . . . . . 1.2-1
1.3 Definitions for NDT, NDI, and NDE . . . . . . . . . . . . . . . 1.3-1
1.4 General Principles and Guidelines . . . . . . . . . . . . . . . 1.4-1
1.4.1 C6rierel Principle and Guidelines for Using NDT . . . . . 1.4-1
1.4.2 Principles and Guidelines for Adninistratore . . . . . . . 1.4-4
1.4.3 Principles and Cuideline8 for Designers . . . . . . . . . 1.4-6
1.4.4 Principles and Guidelines for Production Engineers . . . . 1.4-?
1.4.5 Principles and Guidelines for Quality Aaeurance Personnel 1.4-9
1.4.6 Principles and Guidelines for NDT Engineers . . . .. . . .1.4-11
1.4.7 Principles and Guidelines for NDT Technicians . . . . . . 1.4-13
1.5 Choosing Tegt Methods . . . . .’. . . .. . . . . . . . . . .. 1.5-1
1.6 GIOSSa~ . . . . . . . . . . . . . . . . . . . . . . . . ...1.6-]
1.7 Bibliography . . . . . . . . . . . . . . . . . . . . .. . . .. 1.7-1
1.8 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8-I
1.9 Notes . . . . . . . . . . . . . . . . . . . . . . . . . . ...1.9-1
(.

I ‘.

l-v
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
M 11,-1{1)S!:
-“l?.%’1

List of Revisions: (
Tnis is the first issue, witk: n> revisi>ns, appraved for
publication 16 December 1935

List sf Current Pages:

Page 11>. Latest Issue Date Page 110. Latest Issue Date

i to iv 16 December 1985 4-i to 4-ii 16 December 1985

l-i to l-ii 16 December 1985 4-071 to 4.0-2 16 December 1985
1.1-1 to 1.1-2 16 December 1985 4.1-1 to 4.1-2 16 December 1985
1.2-1 t> 1.2-2 16 December 1985 4.2-1 to 4.2-12 16 December 1985
1.3-1 to 1.3-2 16 December 1985 4.3-1 to 4.3-6 16 December 1995
1.4-1 t~ 1.4-2 lb December 1985 4.4-1 to 4.4-14 16 December 1985
1.5-1 to 1.5-14 16 December 1985 4.5-1 to 4.5-2 16 December lq85
1.6-1 t.? 1.6-6 16 December 1985 4.6-1 to 4.6-2 16 December 1995
1.7-1 t~.1.7-2 16 December 1985 4.7-1 to 4.7-2 16 December lq85
1.$3-!to 1.8-8 16 December 1985 A.8-1 to 4.8-2 16 December 19R5
1.9-1 ta 1.9-2 16 December 1985 4.9-1 to 4.9-8 16 December 1985
2-i t~ 2 ii 16 December 19S5 4 .10-1 to 4.10-2 16 December 1085
2.0-1 to 2.0-2 16 December 1985 4.11-1 to 4.11-2 16 December 1985
2.1-1 to 2-1-2 16 December IW5 5.0-1 to 5.0-2 16 December 1985
2-2-1 to 2.2-12 16 December 1985 5.1-1 to 5.1-2 16 December lq95
2.3-1 t> 2.3-8 16 December 1985 5.2-1 to 5.2-18 16 December 1985
2.4-1 to 2.4-10 16 December 1985 5.3-1 to 5.3-16 16 December 1985
2.5-1 t~ 2.5-2 16 December I%W 5.4-1 to 5.4-6 16 December 1’385
2.6-1 to 2-6-2 16 December 1985 5.5-1 to 5.5-2 16 December 1985
7.7-1 to 2.7-2 16 December 1985 5 .%-1 ?? 5.6-2 16 December !?35
2.8-1 to 2.8-2 16 December 1985 5.7-1 t3 5.7-2 16 December 1’2S5
?.9-1 t) 2.9-A 16 December 1?85 5.t3-i to 5.t3-12 ]6 December l?~~
,?.10-1 t..3
?. 10-2 16 ‘Jecenher 19P! 5 .9-1 t9 ?.9-14 16 !leccnber 1?95
2- II-I to ?.il-2 16 December 19P:, 5 .10-1 t9 5. 10-2 16 December IW5
3-i to ?-ii 16 December 1%5 5. 11-1 to 5.11-4 16 December 1985
-5.0-1 to 3.0-2 16 December I!E35 6.0-1 t> 6.0-2 16 December 1’285
3.1-1 tO 3.1-2 16 December 1985 6.1-1 to 6.0-2 16 December 19P.5
3.2-1 t$ 3.2-6 16 December 1985 6.2-1 to 6.2-22 16 December 1985
3.3-1 to 3.3-8 16 December 1985 6.3-1 to 6.3-2 16 December 1985
3.4-1 to 3.4-1o 16 December 1985 6.4-1 to 6.4-24 16 December L985
3.5-1 to 3.5-2 16 December 1985 6.5-1 to 6.5-12 16 December 19S5
3.6-1 t~ 3.6-2 16 December 1985 6.&l to 6.6-2 16 December 1985
3.7-1 t03.7-4 16 December 1985 6.7-1 to 6.7-4 16 December 19S5
3.8-1 ts 3.8-2 16 December 1985 6.8-1 t.>6.8-4 16 December 1985
3.9-1 to 3.9-6 16 December 1985 6.9-1 to 6.9-8 16 December 1985
3.10-1 to 3.10-2 16 December 1985 6.10-1 to 6.10-2 16 December 1985
3.11-1 tO 3.11-2 16 December 1985 6.11-1 to 6.11-2 16 December 1985

l-t,
i
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MI L-HDBK-728/l

1.0 scoPi

1.1 *. Although this handbook is provided as a guide to all those

employed in nondestructive testing (NDT), it will be of specific interest to
administrators, designers, production engineers, quality assurance personnel,
and nondestructive test engineers and technicians. lt has been formulated to
cover both broad and specific applications of NDT, so as to satisfy
individuality, as well as conformity, of interests and knowledge smong the
divisions of responsibility in NDT. Not everyone will be interested in all of
the specially identified sections. However, to obtain optimum benefits, it is
recommended that users of this document review it in ita entirety, while
paying particular’at tention “to those sectiori:, often identified by a heading
or subnote, which may be of specific concern to them.

The handbook, which currently inco~poratez Seneral principles and procedures

(as well as safety items) of eddy current, liquid penetrant, magnetic
particle, radiographic and ultrasonic testing, will be updated, to include
chapters on other NDT methods as they become appropriate.

It must be emphasised that this handbook is not a training manual. Nor can it
replace other written directives, procedures or specifications. However, it
can serve aa a reaciy reference to the important principles and facts relating
to the employment of nondestructive testing, inspection and evaluation. It
can be used to refresh one’s me”ory of a particular NDT principle or
relationship, to double check or establish a particular fact, or to review the
( main ideas, concepts or completeness of a particular approach.
...

I I

1.1-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MI L-HDBK-728/l

THIS PACE LEFT INTENTIONALLY BLAlff

1.1-2

1.
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBti-728/l

1.2 USERS CUIDE

1.2.1 NANDBOOi O&NIZATIOti ‘“

This handbook, which is intended to make chaages, additions and tailoring

easy, use$ chapters as independent organizational elements. Each chapter is
reasonably complete and self-contained with respect to each specific topic
presented and is divided into numbered eections and subsections for ease of
~~ reference and use.

Pages ere numbered consecutively within each section: ”sections are numbered
consecutively within each chapter; and chaptera are numbered consecutively
within the handbook. The publication or revision date of each page is loceted
at the bottom inner edge of the page.

Tables, monographs. drawings, and other illustrative material are nO~allY

presented within the text. They are identified by the number of the section
in which they first are referenced, followed by a sequence riumber in
parentheses: e.g. , the first Table in section 5.2 is designated as Table 5.2
(1), the second Table in the same section is designated Table 5.2(2), etc.

The general Table of Contents listing all chapters in the handbook is found on
page iv. A.Table of Contents listing all sections in a chapter is located at
the beginning of each chapter.

1.2.2 REFERENCES
(
There are two t.yp.?~
of references used in this handbook; (1) cross-references
to paragraphs in the handbook, and (2) references to other publications which
are the sources of specific ❑ateriel. Cross-references are uged within this
handbook wherever poesible to avoid duplication of information.

1.2.3 INDEx

A detailed index of subject matter, keyed to section numbers, is provided at

the end of each chapter.

1.2.4 FORFIAT FOR DEFINITIONS

Terms which apply to a specialized area and are not.defined in standard

publication are usually explatned in this handbook. If a term is used only
once or infrequently, it is explained in the text whe~ it Occurs - If it is
used frequently throughout a chapter, it will appear. in the glossary at the
end of the chapter. Common terns, or those whose definitiona appear in
standard glossaries or dictionaries,
. ore not normally included in this
handbook.

1.2.5 RANDBOOK REVISIONS

“Every effort haa been made to reflect the latest imfonnation on eddy current,
liquid penetra6t, magnetic particle, radiographic, and ultrasonic testing. It
ia the intent to review this handbook periodically to engure ita completeness
i
and currency. Each revision will include a revised List of Current Pages
which will show the latest issue of each page of the handbook.

1.2-1
Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
l.l
II!-
I!
I”19K-72$;
;2

‘?;11SPAGE LEFT IIJTWTIOI)ALLY BLAIJ}: (

1.2-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l

1.3
... .. ....’. ,,’ ‘.

)
Although extensive definitions are included in each chapter, several basic
terms -- Nondestructive Testing (NDT), Nondestructive Inspection (NDI), .snd
Nondestructive Evaluation (NDE) -- are worthy of special discussion.

Any tes,ting, inspection, or evaluation that does not cause harm to or impair
the usefullnesa of an object satisfies the ❑eaning of the word
“nondestructive.” In common usage, testing often refers just to test ❑ethods
and test equipment with only a general reference to materials and/or parts.
Inspection relates to specific written requirements, procedures, personnel,
standards, and controls for the testing of a particular material or a specific
part. Evaluation is concerned with the decision~making process, the
‘d~fetiination of the meaning of the ras”lt’g, or the final acceptance or
rejection of the material or part und may be qualitative or quantitative.
When only qualitative or ralative values are required, the “se of reference
standards is minimized. For quantitative evaluations, however, ertensiive “se
of reference standards and controls is often involved.

Although these distinctions between NDT, ND1, and NDE can be (and often are)
made, the terms are also often interchanged. In order to evaluate, the
results of an inspection must be available. In order to have the results of
an inspection, a test must “be conducted. And no test or inspection is really
complece without an evaluation. As a result of these interdependancies, no
strict differentiations batween these terms are made in this handbook.
(

1.3-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MIL-HD9K-728/l

(
THIS PAGE LEFT INTENTIONALLY BLANK

I “
I

1.Z-2
I Downloaded from http://www.everyspec.com
t.iIL-HDBK-7X3/lon 2011-11-29T0:55:24.

>,
1.4 GENERAL PRINCIPLES AND GUIDELINES

1 The following section presents principles and guidelines for the general
employment of NDT, as well as for specific NOT disciplines. In some cases,
the material is repetitive, since several disciplines are involved in similar
activities. It is important, however, to understand differences, as well as
,
similarities, between the disciplines, and to recognize how cooperation
between these disparate disciplines is vital to the overall success of NDT.

Guides for applying specific NDT methods are contained in the chaptera for
those.specific methods. The principles and guides covered in this section are
all summarized in tables at the end of each subsection, and can ba used as
handy raference guideline.

1.4.1 C!ZHERAL FRINCIF’LEX AXD GIJIDELIiJI?S

FO17USING ND’T

Before specifing the use of NDT in any program, “several things .should be
considered. First, detenaine exactly why, or if, NIX’is z-squired. There are
many reasona why NDT may be desired or necessary: to increase the production
rate (by assuring a higher success rate), to increase reliability, “to improve
or maintain safety, to meet legal requirements, to differentiate or identify
improved processing methods, or to detect changes in the product before they
become a problem.
~
There is a danger that specifying NDT has become routine practice rather than
(“ the result of a real need: i.e., it was done this way last time: it is always
done this way; they did it, we have to do it; everyone else is doin& it; or
let’s do it just to be safe. Sometimes NIYT is specified just for
administrative reasons: the contract requires it.

Often, although the use of NDT is specified to satisfy a legitimate

requirement, it may actually be inappropriate. For example, the ultimate
purpose of a test may be to ensure that a part has it? re,quireddesigned
stren~th. NDT tests are often ueed to accomplish this determination, even
though they do not directly measure the strength of a ?art: its strength can
only be inferred by the absence of certain detectable flaws. A simple proof
tast, which does not require any assumptions, standarda, correlations, or
other inferred relationships, would have been much more appropriate. The
principle here being that an affort 9hould alwaya be made to dete.mine the
critical properties directly. Inferring the rasults by secondary means should
only be considered when specific circumstances warrant. Since al,moat all ND’T
❑ethods are indirect or “secondary”” types of ’measurements, they are often best
replaced by more direct methods. Direct methods are not relevant to
nondestructive test methods deployed in end items where destructive tests are
not feasible, i.e. thermal damage to aircraft structure.

Whatever the reasons given for specifying ND1’, it ia important that everyone
involved in NDT recognizes and evaluates those reaaons realistically so that
those rssponsiblezfor implementation are able to provide logical and affective
responses.” Certainly, all progriuns should consider specifying the use of NDT;
however, its automatic use should be evoided. NDT should always have an
identifiable purpose that justifies its expense. The reasons for the
requirement of NDT will often affect all other decisiong.

1.4-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

1411,
-NDB<-723/l

Once the reasons fo:, the.requirement of NDT haye been established, iL is al- (
~ays wise to determine if the requirement csn be eliaina tea or reducsd through
the use of better materials, or better processing controls, or a better design.
NOnde~tr~~tive testing has no intrinsic value. Specimens do not last longer
simply because they have been ultrasonically inspected. Specimens are not
made stronger simply because they have been X-rayed. (If they were, we would
inspect and X-ray every part ten times over. ) The removing of the
justification for any NDT is therefore desirable. The requirement for NGT,
however, camot always be removed. Therefore, although alternatives should
ideally be considered first, NDT will often be specified.

It is the designer who has the largest responsibility in this area. (See
section 1.4.3 for information on the subject aS it relates tO the designer. )
Once it becomes clear that NDT is appropriate or otherwise required, the
designer must consider other impnrtant aspects of tbe situetinn, including
whether the design can be inspected and whether it can be improved to ❑ake the
inspection more reliable or efficient.

Since NDT can be (and is) used for a multitude of rsasons, it is important
that all needs be correlated. The production engineer may want to inspect the
raw material as soon as possible, even before it arrives on site. NDT engi-
neers, if given a choice, would prefer to inspect material after it has been
machined to a simple shape with smooch surfaces. Reliability and safety engi-
neers would prefer that the IJDT test be performed after all major operations
have been completed. Many times, all of these tests are not affordable.
Therefore, it is important to decide exactly when and where in the manufactur-
ing process NDT should and will be specified.

For every place NDT is specified in the manufacturing process, one of the most
important factors to be stipulated is the critical flaw limitations that must
be detectable. Almost all materials, and all items made of materials, have
imperfections of one size or annther. These imperfections can be defined as
fl.sws. However, the very small imperfections or flaws do not always impair
the usefulness of an item. When this is the situation, it would be
inefficient to inspect for these non-critical flaws. Therefore, the
specifying of this critical size where the usefulness becomes potentially
impaired is important. Those imperfections or flaws that are critical, or
larger than that acceptable, are called defects. It is impossible to
determine the flaw limitations required for an inspection without knowing the
purposes of the inspection, as well as the complete design requirements of the
finished parts.

The dete”&ination of this limitation in flaw size is not always ‘easy. One
vety common limitation specified in the use of ND’1’is “’noflaws are allowed.”’
Certainly such an achievement would be desirable. However, no test or inspec-
tion with that kind of limitation can be expected to succeed. Often, when
this impossibility is eventually understood, the naxt requirement specified is
“find the smallegt flaws poggible. ”’ Again, although tbe desirability of this
type of requirement is apparent, testing to this degree is generally not
affordable.
/

1.4-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

I MI L-HDBK-728/l

... ,. Ultimately, the decision on the proper limitation for allowable flaw size must
be made by the d“esigner working in cooperation with production, stress, and
msterial engineers. They must determine the types of flaws expected and the
maximum allowable flaw limits required to,achieve or maintain design goala.

1, Only after this groundwork has been completed, can the proper decisions ”for
the requirements for NDT be made. Depending upon the NDT capabilities that
exist, trade-off studies may be necessary to ensure that the critical flaws,
“. at their specified limits, can be effectively and reliably detected. Although
trade-off studies and decisions should be accomplished at the design level,
they often are not because of insufficient infnnmation. When “not made at the
design level, choices becnme more limited, often resulting in either a
reduction of the original design goals or the acceptance of unreliable
prnducts.
~
Once tileseflaws and flaw limitations have been determined, then NDT engineers
must respond by finding answers to ❑nre queetions -- What NDT method must be
used? What equipment, persotiel, and contrnls are necessary? .Many times, one
method alone may not be adequste.

No ,test or inspection is complete” withnut the proper and adequate evaluation

I of the data. If a permanent test record is required, the documentation must
be considered in the NDT test itself. Since snme methods of NDT.do not
provide results in terms of a permanent record, specifying permanent records
“’or documented proof of the passing nf a test dries limit the choices available.
This limitation nf test methnds should be considered befnre such requests are
( made.

Principles and guidelines for specific disciplines are given in the paragraphs
that fnllow. The assignment nf principles and guidelines to specific
disciplines clarifies who is responsible fnr implementing the concepts nf NDT
and hnw each discipline must suppnrt the other if success is to be achieved.

1.4-3
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MIL-HDB[-72ti/1

Table 1.4(1). General principles and guide lines ”for NDT. (

1. Determine exactly why NDT is required.

2. If unreasonable, to remove the HDT requirement or minimize it.

3. If the need for NDT cannot be denied, design for inspection.

4. Determine the proper plsce(s) in the life cycle for performing NDT.

5. Establish critical flaw limitations in quantitive items. These

limitations cannot be: “’Noflaws allowed” or “Find the smallest
possible flaws.” They should be in terms such as ‘“Nocracks shall
exceed a length of 4 mm in any direction or “’anypores or combination
of contiguous pores that equal or exceed the volume of a 3 mm sphere
shall be rejected”’.

6. Determine the appropriate method(s), equipment, personnel, standards,

and controls. Remember, most NDT methods do not reveal flaws
directly und interprc+.ation is ~ften possible only through the use of
proper standards. NDT methods usually only find indications or
differences. These indications .re significant only to the degree
that they can be interpreted correctly. Also remember that complete
answers (positive answers) cann>t always be obtained by a single
inspection method. Two or more meth~ds may be required for a
complete analysis.

7. Establish the means for complete, pr~per, or adequate evaluations

(to include reports end documentation).

1.4.2 PRINCIPLES ANP GUIDELINES FOR ADMINISTRATORS

The s,]ceess for any NPT pr~ernm will alwnys rest l]ponman~eers. It is the
m:ln.accrwhl muxt decidr? the overz?11 Rsals, the proper divisim of the
availahl? funds, and the coordination that must be maintained. It is the
mnna~er krhodetermi~es the decree to which the total life cycle of a component
is considered -- including the producti~n of raw stock to the final salvaee of
worn-out parts. The mans.gcr must sften accept the responsibility if proper
funds hnve not been set aside for adequate NDT, if degigners did not properly
coordinate with production and NDT engineers to design a system that could be
efficiently inspected anti built, and if completed parts cannot be properly
inspected in the field. Beceuse the nanacer plays such an important role,
special administrative directives have been published by”DoD. The guidelines

I and principles given in DAP 11-25, should receive seri.ms attention.

Mana<ers must recognize and mnintain consistent control over the integrity of
the total inspection system by separating quality inspecti~n command from the
production gr~up, while simultaneously encouraging communication and
caordinatian between the twa areas. The manager must determine the relative
degree of this sep~ration, effectively balancing the pressure of meeting
production rates with the necessity for successful inspection bY using
independent manaEers.

I 1.4-.!
I Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
NiL-HDBl~-728/ 1

Keeping communications active betweer, functional groups is important,

especially during the design phase. Communication, which can be either formal
or informal, often takes the form of written release statements required on
all design drawings by Quality Assurance (QA) and NDT engineers. Since the
effect iveness”of communications dependa on the time, money snd personnel
available to ❑ake analyses, it is up to the manager tn determine the degree of
effort to devote to specific communications actions.

Communication during the production phase is especially required if there are

incomplete design decisions, since QA and NDT engineers cannot do their jobs
I effectively until designers have established specific flaw limitation
requirements and allowable trade-offs. Although it is true that msny testing
decisions cannot be made during the design phase, until the flaw limitations
are established, the designer must remain on the project and in communicatnn
with QA personnel.

The manager must emplny sound management practices to encourage quality

resultg by fostering high morale and positive motivation among his
subordinates. Most importantly he ❑ust be provided with the means tn
establish accountability and given the”pnwer and the authority to take
definitive action when .necessary.

I Table 1.4(2). Guidelines for administration of NDT (managers).

1. Maintain integrity (clear separation of responsibilities) between:

( o Rate of production (Production Engineering).

o Quality of production (Inspection, QA, etc.).

2. Ensure adequate communications (before, during, and after) between:

o Designer.

o 9A.
.
0 Production Engineer.

o NDT Engineer.

o Materials Engineer.

“3. Provide adequate personnel, facilities and avenues for implementation.

4. Employ sound management practices.

1.4-5
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-7iK!/l

1.4.3 PRINCIPLES AND CUIDELINSS FOR DESICNFH?S (

To achieve a successful design, a designer has to deal with several
constraints, such as size, weight, weight distribution, dimensional tolerances
and fits, ❑aterial computabilities, production capabilities, cost limitations,
strength, fatigue life, appearance, surface finish, etc. Although e designer
should be careful about adopting unnecessary constraints, he should be aware
of the inspectability of his design and whether it will require NDT or whether
choices exist that could render NDT nonessential. A designer who has a
background in NDT can ❑ore readily reach this determination (taking into
account cost-effectiveness, safety, and legal obligations associated with
safety and reliability) and can ❑ake decisions, when required, that favor a
successful NDT program.

One of the most important obligations of the designer, when NDT is determined
to be 3~C~S33Y;, :s to cotablish the requirefients for the inspection, with the
help of stress, material, and test engineers. If these limits are not
reasonable relative to the liDTmethods available, then trade-offs must be
considered.

One area that is seldom considered by desiGners is the use of internal

standards. For exnmple, almost all ultrasonic inspections require a special
setup b’ithcomparisons to reference standards. Ideally, there must be a like
correspondence between significant factors within the comparison. Reference
standards should perfectly match the test article in the type of material, the
hardness, the thickness, the surface finish, etc. Test setups should produce
equal indications for equivalent flaws. With very little extra cost,
cor,ysnefitacan be devel~psd thht hhvti Lideiruwn internal sianaartisdesigned
into them as an alternative. When ar.andards are designed into the component,
all the correlations required for surface finish, for type of material,
hflrdness, etc. , are all automatically achieved and the inspection is greatly
improved in terms or time and reliability. The arrangement of itaving the
designer create the NDT standard saves time and provides the desiRner with
important NDT knowledge.

Almoac all NDT testa, including radiof;raphic,eddj current, and ultrasonics,

can be improved by similar considerations. Designers should exercise a direct
effort to improve the inspect ability of the parts they design, not just in the
development and construction phase, but also in terms of inspection required
during the service and repair phases of the component’s life. Only a designer
can accomplish this desirable total life cYcle apprOach.

1.4-6
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
NIL-HDBK-728/l

Table 1.4(3). Guidelines for designers.

1. Determine if NDT is really required.

)
2. Determine if the need for NDT can be rsmoved by:

Improving the design.

Using an over-design approach.

Usiug redundancy.

Using better materials.

Selecting better production methods.

Establishing better production controls.

.
Accepting more risks.

Substituting proof tests.

3. If NDT requirements cannot be removed:’

Does the design allow NI)T?

( Will trade-offs be necessary, or can trade-offs be found, to

make possible andior improve the NDT inspection?

Will internal standards be necessary and/or practical?

:IuTE: Sometimes NDT will be. required by contract. The refore, if NDT must
be done, use it to .vour advantflCe. The “se of cheaper material nay
be feasible, etc.

1.4.4 PRINCIPLES AND CUIDEL1NE5 FOE PRODUCTION ENCINEERS

Production engineers alko work under constraints. Thej must produce

acceptable products within an assigned time schedule and fixed budget. Their
success depends upon the employment of both basic and technical knowledge, of
which optimal use of NDT is an important part.

Production engineers must constantly assess the smount of NDT required and
determine exactly where it is to be accomplished. Forexanple; expensive
machine time cannot be spent cuttin& raw material into a finished product only
to find, at the-last cut, an internal flaw that requires rejection of the
psrt. Such flaws should be found before such operations are initiated.
/

1.4-7
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

(
Production engineers normally desire to perform NDT at the earliest possible
point in time, usually at receipt of raw stock. The NDT engineers, however,
usually want to do NDT when the parts have the simplest shape with the most
uniformly prepared surfaceg. Reliability engineers often want to do the ND?
after all uossible disturbing-. operations are completed. Usually, there is not
sufficient time or money to do ell these inspections. The final decisions
often rest with the project engineer who must meet overall budget and time
constraints.
~
Production engineers should also be aware that production methods and
controls, ❑aw times, establish the need for NDT. Although selectinn of
production methods and controls that prevent flaws from occuring would, of
course, be ideal, trade-offs between the costs of using a more expensive but
less flaw-inducing method, versug the cost of testing and possible rejection,
must be a consideration for every choice being umdk.

One of the most productive uses of NDT is the direct emplnpent of inspection
during the actual manufacturing prncegs. For example, a ❑ethod that
completely changes the approach to the ❑anufacturing process and weatly
increaseg the reliability of the finished product is the use of ultrasonically
controlled cutting machines which determine material thickness as each cut is
made. Automatic tiDTcontrols such as these provide great opportunities for
increased productivity and reliability.

Table 1.4(4). Principle and guidelines for production engineers,

1. Determine the earliest point in time when NDT ig desired.

2. Ensure that the rate of inspection is adequate or initiated early

enough to maintain adequate stock levels.

3. Know the &terial, the reputation of the sources of the material, and
the characteristics of the production operations as affected by the
material.

4. Select production operations and controls that minimize material

problems.

5. Coordinate the NDT tasks with requirements from QA and Design.

6. Use the science of NDT as a direct production control methnd where

developed and appropriate

1.4-8
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

NIL-HDBK-728/l

1.4.5 PRINCIPLES AND GUIDELINES FOR QUALITY ASSURANCE PERSONNEL

, The information given herein should be taken only as Eeneral guidelines for
Quality Assurance (QA) personnel. Specific detailed instructions a“reprovided
by each. of the separate branches of the DoD. All QA personnel should refer to
their respective manuals for specific instructions.

Quality Assurance (9A) responsibilities extend over the full ND’I spectrum.
The total magnitude of administrative and technical responsibilities depends
upon the size of the operation involved. However, whether only one individual
or many individuals are involved in the QA task, the following areas must be
considered as part of the QA responsibilities:

1. Train, test, and classify inspection personnel and maintain their

records.

2. Know the availability, effectiveness, and costs of NDT facilities and

operations.

3. Maintain teat records and reports.

4. Establish and maintain communications with design, production, and

program managers.

5. Maintain a’ “corrective action” system.

(
b. Maintain an advanced technolo~ical improvement program.

Administration of the QA task includes -control over personnel, NDT facilities

and data records. Personnel rosters, showing IJDT related education, traininc,
tests, test scores, qualifications, classifications, and appropriate medical
records should b maintained on all individuals responsible for NDT (including
those ostside of QA who are involved in NDT). Comments on their abilities ani
limitations should also be included. These records should be continually
checked and updated. In addition, QA administration should,provide a formal
training, testing, $cor@g, and class ificati”on,program ”utilizing assigned
instructors and persomel to administer these areas. Retesting and
reclassification of personnel should be done periodically on a continuous
basis with maximum time periods specified for retesting each time a
classification is assigned.

QA should maintain a current inventory of all ND1’ equipment with ready

references to the “accuracy, resolution, reliability, maintenance schedule,
average downtime, and inspection rate of each item. In addition, racords
should be kept on all other factors that might impact on time, money, and
pereonnel. Cost of labor, maintenance, electricity, and other power eources
must all ba monitored and kept current. All of this information ia vital for
making the decisions that must be made by QA.

One of tbe msjor.hdm.iniatrative dutieg performed by 9A includes maintaining

inspection recordi and reports. As a result, the following questions should
be considered by QA:

1.4-9
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

HIL-HI)
HE-’l28/1

(
1. records arc to be kept’?
‘m””n~L

2. I{OK 10nG should they be kept?

3. How shall they be maint~ined?

4. How should they be purged or corrected?

5. Who shall have access?

Many of these records must be maintained fo~ the life of the progran or the.
parts involved.

Communication is another large area of administration for QA. Communication

with upper management, pro,iect en,.?
ineers, desicners, production and material
enCineers, facilities, and laboratory standards personnel should be
established findmaintained by OA.

In the technical area, QA ~hould proi.

irleprcdesi~n support to help the
dcxiGners develop parts that are inspcctable to the degree necessary to assure
the,required reliability. QA sliould;IISO !W able to check the completeness of
i.tw.
desiCriers‘ approach to lil
IT.

‘Qu.qli
t.y:ms”rance mu:;t support the :W:tUP, or initiation, of proriuction runs.
This support requires an understanding of exactly what is required, why it is
rvquired. and all appropriate trade-offs thnt mW be Present. Decisions on
exact methods to be used must be made. whether those methods are NDT or
others, and the standards or verifications required must be established. It
Lhen becomes necessary for CIA to monitor the existing production runs to
,jll~urethat all ~riginal ~ssumptiarls are still valid, that all procedures are
being followed, and thnt proper records, reports, and interpretations are
boin~ developed.

!t is essential that (3Am,ain Lain o,.yscem~,

for detecting potential or actual
problems and expeditiously solvin~ those problems. These “corrective action””
s:;
stems may consist of several items, includin~ formal report procedures,
review boards, and rejection tags for defective parts.

In addition, for any QA department to be successful over a’10ng periOd Of

time, it must recognize that changes must be made as technology is impmved.
QA should have a formal interest and obligation to stay up-to-date with the
state-of-the-art of NDT, thus allowing personnel to become knowledgeable and
experienced, so they can periodically improve NDT capabilities as new
developments occur. Although funding for this area of effort is not always
available, it is essential to effective preplanning activities that personnel
have access to current technology.

It does not hsve to be assumed that QA accomplishes all the details of everY
assigned task in all these areas, either adminiatratively or technically. But
it is QA’s responsibility to see that, oversll, these details are accounted
for or that reports to the contrary are made. Much of QA”s success will
depend upon the quality of com..unications established with all the involved
areas and the formulation of decisions based upon their cOmbined .inPu=.

1.4-10
 Downloaded from http://www.everyspec.com
MIL-HDBK-728/1 on 2011-11-29T0:55:24.

Table 1.4(5). Guidelines for oualitv assurance personnel.

A. Administrative Areas:

1. Administer Personnel Training and Classification (including resters,

NDT education, training, tests, test scores, qualification. ratings,
work classifications, medical historieg, NDT work experiences, ‘and
evaluations by supervisors).

2. Maintain Current Inventories of NDT Facilities to include specified

accuracy, resolution, reliability, maintenance schedule, average down-
times, inspection rates, availability of operators, operator costs,
depreciation rates, maintenance costs, availability of power,
operating costs, etcl

3. Maintain Inspection Data’Records - What records, hnw maint~ined, h>w

long, how purged and/or corrected, who has accesa.

4. Establish Communication (Policies, Planning, Scheduling,

Coordination, Proposals, etc. ) with and between administrators,
p:ojact engineers, designers, production, material, and facilities.

B. Technical h~eno

1. Support Design Drawing Reviews - Assist in checking and approving

completeness of designers approach, ‘“tradeoffs, and decisions.
(
2. SUFpOr[ t!l=?rOgrSn - !lctc=inc exactly vh,
a: is required, why it is
required, and what methods are to be used. Establish procedures for
chosen method, standards, reports, and data controls.

3. IJetectand Solve Problems (Corrective Action) - Establish corrective

action review boards, and rejection tags.

4. EncourxKe Hesearcb apti Ikvclo?nent (R & D) - Sca.ving up with the

state-Of-the-.arL.

1.4.6 PRINCIPLES AND CUII)ELINES’FOR NDT ENGINEERS

Some ND? engineers nay be directly involved with receiving and inspection,
quality assurance, or production activities, while other NDT en&ineers are
ase.ociaLea with research and development efforts. Different qualifications
are often required in each of these areas. Basically, however, it is the NDT
engineer who must understand the principles of each type of nondestructive
test and the specific limitations of those tests. He must be able to recognize
which inspection procedures are proper or adequate for the desired results and
he must understand the results and their interpretation.

I /
(
I
1.4-11
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MI L-HDBX-728/l

ln order for the NM’ engineer to perform his duties to the fullest, he must (
have certain specific information. He must know the materials involved and
how the part was fabricated. He ❑ust know what defects and/or properties are
to be detected andlor measured. He must be able to identify the kinds of
false indicating that may be encountered so that they may”be properly
considered. It is the NDT engineer who must often communicate and explain the
1-
differences and difficulties when what is requested differs from what can
actually be obtained.

Because the NEW engineer knows the equipment and personnel available, he can
provide a significant amount of data necessary for scheduling nondestructive
tests. Sometimes an NDT engineer receives complete instructions from QA where
test plans, procedures, and standards have all been ptiedetexmined. It is a
requirement thet the NDT engineer double check these procedures and standards,
and essentially, reverify their effectiveness.

The NDT engineer will normally have NDT technicians under his direction, and
the treining and instruction of these technicians will be one of his prima~
concerns. He must understand each technician’s ability to handle complicated
tasks and the limits or the “’confusion” level with which an individual
technician can adequately cope. These factors will greatly influence the
assignment of tasks and the degree of independence that can be given to each
technician.

All of the preceding factors will affect the type Of inspection rOutine that
an NDT engineer will institute. The NLYTengineer should also be cognizant of
the sorting routines and scanning methods that have proven to be the most
reiia”Die for his personnel to roiiuu it,any particular sit.u~tior,. k%ea a
vsriety of flaws are to be detected, the approach, sorting routines, order of
the search, number of repeats in the search operation, direction of scanning,
scanning rate, and type of data comparisons (digital or analog) that must be
observed will affect the reliability of the results. Often, a search for one
kind of flsw at a time, on one type of part, will serve to remove some of the
complexities which exist for multiple parts and fIaws, as Well as to establish
rsliabillty.

One parameter beyond the control of the NDT engineer is the rate at which the
presence of flaws is indicated. When parts are relatively “clean” and free of
indications, or alternately, when there are a great many indications, the
percentage of flaw indications missed usually increases, for ❑ost inspectors.
NDT engineers should be aware of tha frequency of occurence of the flaws to be
detected and adjust the inspection routine as necessary to maintain the
required reliability.

1.4-12
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l
I
Table 1.d(6). Guidelines for l:DT engineers.

●1. ““
KflOU exactly what is wanted and why.

●2. Know the part and/or material to be inspected.

●3. Know the defect and/or property to be detected andfor measured.

,.

4. Know limitations of equipment and pergonnel.

5. Establish time requirements and schedule.

6. Double check exact procedures and standards raquired.

7. Provide the technician with adequate material, facilities, and

working conditions.

8. Ensure that an honest and complete report is made (that both

assumptions and lirnitationa are known to those.receiving the
l-sport). Provide information and training to technicians, and
guidance and suggestions to QA, designers, and msnagers. This is
done both formally and informally. These lines of communications
should be established and well used.

Information that should be provided to the NDT engineer by QA or

I project engineer.
( “*

1..4.7 PRINCIPLES AND’CUIDELII:ES FOR NDT TEcHNICIANS

Technicians are the final key r,IJ

successful !(DT. The personal efforts of
knowledgeable and experienced technicians can often save a pro&ram ntherwise
doomed to failure. Likewise, a seemingly successful program CRO fail if
proper rssponies to indications a“re not maintained by the technicians.

Even though a technician’s task -- to note all exceptions tO that which is

nnrm.al-- app6ars fairly simple, it “can often become complicated. In fiDT,
meaningful observations may consist of only slight changes or fleeting signals
that can easily go undetected -- particularly if they randomly occur between
extensive amounts of unimportant data. Sometimes, the.problem can develop
frotntoo much information. If a technician is being presented with a
multitude of nonrelevant or false indications that must be continuously
rejected, valid indications can sometimes be automatically rejected as well,
through force of habit. A good technician will be aware of these problems and
their impact on NDT and will consciously guard against them.

The danger of fatigue and hypnotic effects on the technician must also be
consciously fought sgainst, ~d the technician should not hesitate to ask for
a break or change in routine that might prevent these kinds of difficulties
from developing. Present efforts to automate all inspections exist msiply
because of these hiunsn weaknesses.
i
However, since automatic inspection systems are incapable of noticing all the
various types of exceptions that a technician can, technicians will still be
needed snd valued for their technical knowledge and attentiveness to detail.

1.4-13
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l

(
Ceneral guides for technicians include: 1) Not hesitating to ask questions or
double- checki~ procedures releting to”the “NDT work: 2) Recording all NDT
tasks and results; 3) Always checking all dial settings each time an
instrument is used for a new setup; 4) Knowing the capabilities and
limitations of the equipment is essential.

Table 1.4(7). Guidelines for NDT technicians.

1. Be aware of the dangers of fatigue and hypnotic effects (Know how to

fight these effects. Do not hesitate to ask for a break when any
sign of these effects are present).

2. Always note all exceptions to that which is normal - they may be

important.

3. If you are not sure if you should ask about something, YOU probabls
should.

4. Always record everything done in NUT.

5. Always check all dial settings each time an instrument is used for a
new setup.

6. Know your equipment and your own limitations.

1.4-14
 Downloaded from http://www.everyspec.com
MIL-NDBK-728/l on 2011-11-29T0:55:24.

. 1.5 CHOOSING TEST METHODS

Choosing a proper NDT method requires a knowledge of the types of flaws that
must be found, their maximum acceptable limits in size and distribution, and
their possible locations and orientations. Also the presence of all other
possible variables that may affect the inspection must be known. This might
include the orientation and accessibility of the part, the part’geometry and
size, internal variables in densities, ‘etc. ‘l’his knowledge must then be
coupled with knowledge of the basic principles and limitations of all NDT
❑ethods, their availability, and costs. One must also be fsmiliar with the
requirements and availability of atandarda to employ thase nethoda and the
typs of records required. (See Table 1.5[1) at end of this section. )

The appropriate method may conaiat of iaveral separate inspections. One

inspection by itself may indicate the presence of a possible flaw and other
inspections may be required to confirm or verify the original indication.

When the choosing of NDT methods is done routinely, then it is important that
a list of average basic costs of each available ❑ethod is formulated. An
example would be as follows:

LIST OF PRELIMINARY SET UP ACTUAL TEST COSTS

AVAILABLE REQUIREMENTS LABOR ADDITIONAL
KETHODS LABOR STANDARDS NH/Part COSTS AVAILABILITY
Liquid
!. ,,Penetrant Minor Minor 0.8 Minor Good
Rag ?articie Minor i.iino
r i.i Iiinor in heavy use
...-.
Eddy Current Possibly Ye9 - “-~.2 ““ “-None Good -
extensive
Ultrasonic Possibly Nollrlally 2.0 Paper Not working
(C-scan) exten3ive extensive until next
month
X rays Minor Routine 2.0 Film”“and Good
development

With such a chart, one can start with the cheapest method available and then
progress through tha list to the first available method that will meet
acceptable detaction limits. Thase lists must be individualized for each
oparation, taking into consideration how modern the available equipnent and
facilities are and the level of personnel staffing. Although these lists can
provide some broad guidance, they should not be used as a definitive
standard. Costs for each tast vary and the ma.xim~ or minirn~. of.On? test
mathod may, in some cases, overlap the costs for another test method.

Tha choice of a proper NDT nethod requires an understanding of the bssic

principles, and advantages and disadvantage of all available NDT test
methods. Detailed knowledge of their comparative effect iveneag, availability,
and costs are all critical in ❑aking the corract decisions. Tables 1.5(2)
through 1.5(6) (it the end of this section) list some of the general
advantages and disadvantages of a number of general NDT methods. All NDT
users should maintain similar lists, basad upon axperiance with their
particular equipment.

i.5-l
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l

There are times when the choice of ❑ethods is very clear. When small
delaruinations between layers deep within a flat composi te panel must be
detected, an ultrasonic test of some type will almost always be chosen. If
surface cracks on an iron part were to be detected, liquid penetrant, magnetic
particle, ultrasonic, eddy current and X-my tests could all be individually
considered. If porosity were to be found, a quick ultrasonic C-scan might be
used to locate potential areas, followed by X rays concentrated in those areas
identified by the C-scan, to confirm if porosity is really involved and, if
so, to what extent.

Since the difference between success or failure depends on knowing the details
of the specimen and/or material being inspected, many NM’ coumes properly
begin with a study of raw material manufacturing processes to indicate the
orijzinand causes of flaws in castings, ingots, and forgings. The reshaping
and redistribution of the flaws in subsequent manufacturing processe3 must be
understood.

Although a study of these flaws and processes will nat be given in this
handbook, the importance of this area should not be minimized. All NDT
personnel should be familiar with: porosity, nonmetallic inclusions. pipe.
macrosegregation, cold shots, cold shuts, hot tears, shrinkage cracks,
blowholes, migruns. forging laps, stress cracks, grinding cracks, fatigue
cracks, galling, and gcale. They should know whera they occur or can be
expected to exist, and what i,mpact they may have in each of the test methods.
The comprehension that flaws are to be expected does not always exist with
those who are inexperienced . Yet it is the first step in chooging a proper
NDT method. Knowing what the fiaws might be and where to look for them is the
(
next step. Therefore, a study of materials, as well as the relevant produc-
tion and manufacturing processes, is vital to the choice and administration of
an NDT program.

Lastly, the most cri tical (and of ten the most unavailable) dats for determin-
ing an appropriate method involves what the acceptable limits on the size of
the defect are. Those limits determine whether the method would he feasible
and how expensive an effort would be required. Figure 1.5(1) expresses the
importance of this size tolerance. References to sections 1.4.3 (Designers),
1.4.’4 (QA) and 1.4.1 (General Principles) all discuss the importance of
defining this limit.

1.5-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBX-728/l

Table 1.5(1). Choosing proper NDT ❑ethods.

1. Determine the material to be inspected and the type of flaws or

1
difficulties common to that material.

2. Detemine the material manufacturing processes and the type of flaws

or inconsistencies associated with those processes.

3. Know the part to be inspected and determine “its design requirements

ao that critical flaw limits can be established.

4. Know the baaic principles and limitations of all NDT methods.

5. Know costs and availability of NOT personnel and facilities.

6. Determine what starldards are required and their availability.

7. Determine what records and controls are rsquired.

Table 1.5(2). Advantages and disadvantages of liquid penetrant.

Advantages:

1. Usually very cheap (of ten is the cheapeat methOd).

(
2. ija~aily quick, even for iarge pnrt.s.

3. Can be portable (taken to test site).

4. Reasonably easy to interpret.

Disadvantages:

1. Can only detect defec~s opened to the surface.

2. No automatic or permanent records.

3. Often requires a pre-cleaning step.

4. Use of fluorescence required for maximum sensitivity.

5. Not good for rough or porous surfacea.

6. Penetrants chemically attack some rubbers and plaatics, and

should have a low’sulfur and/or chlorine content when used with
certain stainlesa steel, nickel, or titanium materiala.

I (

1.5-3
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MIL-HDBK-728/l

Table 1.5(3). Advantages and disadvantages of magnetic particle. (

Advantages:

1. Surface or near surface flaws can be detected.

2. Reasonably cheap and quick.

Disadvantages:

1. Magnetic type materials only.

2. No permanent records.
3. Uust often demagnetize parts following test.
4. Surfaces can be marred vhere contact probes are used.

Table 1.5(4). Advantages and disadvantages of eddy current.

Advantages:

1. Surface or near surface flaw can be detected.

2. Very sensitive to ❑any variables such as :
geometry (thickness, stand-off).
surface roughness.
frequency.
electrical conductivity.
magnetic properties.
cracks.
3. Direct 60/no-go type answers can be obtained quickly.
4. Portable.
5. No physical contact required (can be accomplished in a vacuum) .

6. Not too expensive.

7. Easily adaptable to production line situations (electrical
signals for electrical controls) .

Disadvantages:

1. Must involve one or more layers and/or surfaces that are

electrically conductive or ❑agnetic in nature.
2.. Requires skill when many variables are involved.

3. Adequate reparation of variables cannot always be Achieved,

1.5-4
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-726/l

Table 1.5(5). Advantages and disadvantages of ultrasonics.

Advantages:

1. Internal inspection method (the deepest penetrating method).

2. Can be adapted for thick or thin panels.

3. Extremely sensitive to many speciinan variables:

porosity.

delamination.

micro cracks.

geome try

density changes.

grain or fiber size.

orientations.

I 4. Many test control variables:

(“ transducer frequency.

transducer size.

transducer t,ype.

transducer focal lcn~th.

type of test (immersed, contact, or jet).

llisadvantaCes:

1. Non-linear responses (variable relationship between flaw size

and indication size).

2. Sometimes too sensi tive (impossible CO separate out desired

parameter).

3. Often limited by geometry and surface roughness.

4. Often must have special standards (especially when details are

as small or smaller than the width of the inspection beam) .

/
I
(.
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MI L-HDBK-728/l
~

Table 1.5(6). Advantages and disadvantages of X-rays (radiography).

Advantages:

1. Good internal inspection ❑ethod.

2. Excellent geometric representations.

3. Good sensitivity, .2%is reasonable.

4. SmaIl detsils are visible (the limit is often the size of the
grains on the film being used).

Disadvantages :

1. The image is a shadow only (The shadow varies only as the amount
or density of the material varies. Therefore, it can “see”
missiag material, but if a delamination exists perpendicular to
the X-ray beam with ❑aterial pulled apart but not ❑issing, an X
ray will not detect it).

2. Sometimes expensive in time, lflbor,and facilities.

3. Personnel safety requirements.

4. Sensitive to orientation of cracks. (

cOST CURVE VARIESWITH

EACH METHOD ANO EACH
MATERIAL AND PART
/ OESIGN,ETC

I 1, IMPOSSIBLE —---- .—
I
t-l----sO’s’BLE
I I 1 I I b
!0 +1/4IN. ? 1/2IN.
SIZETOLERANCE
/
Figure 1.5(1). Cost curve.

1.5-6
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBi-728/l

1.6 GLOSSARY

I Classifications (for NDT persomel) . Personnel classifications can be ❑ade by

nondestructive test methods, by specific equipment, or by specific product
lines in which qualifications have been obtained,

Corrective Action. Action taken ‘(or plans for actions to be taken) for
solving problems that occur during production.

Correlation. Establishing relationships between facts or events.

Critical” Flaw Size. The minimum extent of a flaw (e.g.. miiim~. depth.
length, etc. ) that prevents achievement of the designed goala for a particular
part.
I

1 Defect. Any condition of a part that prevents achievement of a designed goal

is a defect. A flaw that is of critical size or larger is a defect.

I Delamination. A delamination is a partial or complets separation between two

layers of a material which should be bonded together.

~
Discipline. A specialty of professinn or training.

Documentation. Writteri or recorded proof, usually includes a ‘picture” or

other data recording msde in a controlled test. Documentation should include
( names, date, equipment, and all other vital information necessa~ to confirm
LIW stcitus of & part .cr the results of a teat.

Fatigue Life. The expected number of load cycles that a part can withstand
and still perfoxm adequately.

Flaw. Any imperfection in a part can be considered to be a flaw. By this

~nition, all parts have flaws. Many flaws are too small to be of concern.
Some flaws may be large enough to cause a part to fail. When flaws are large
enough to cauae failure, they can be called “de
fects. ”

Flaw Size Limitation (eee critical flaw size).

Indications. Any signal or markings obtained in a test is an indication.

Indications mu-st be interpreted. There can be falae indications (not due to

I the material variable of concern) and valid indications.. There can be

acceptable indications and rejectable indications.
I
Integritv. Integrity ia a meaaure of the completeness of a part, or the
property of being solid or continuous, with no break in tha uniformity of the
part.

Life-Cycle. The complete history or activi ties associated with a part, from
its manufacturi~, to ita ultimate utility as a waste product.

I (“ Nondestructive Evaluation. (See Section 1.3).

..’
1.6-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MI L-H:)li[-7?F/’:

CLOSSAftY (COI!TINUED) (

ilondestructive .Insuection. (See Section 1.3). a

Nondestructive Testing. (See Section 1.3).

Permanent Record. Any automatically produced “’picture”’

or recording of data
(e.g., X-ray negatives, C-Scans) abtained from a test which i.spermanent and
can be used at any time to confimn the results of a test. It forms part of
the Documentation that might be specified for particular inspections.

Qualifications (for NDT personnel). The minimum education, knowledge and

experience required of an individual to use a particular NDT method. ASNT
qualifications include three levels: I, II and III. All inspection super-
VIS.:TS should be lCVC1 11 or higher.

Cluality Assurance (QA). Qualit.v Assurance can be the organization, the con-
trol, or the actions taken to ensure th~t parts will meet all design goals. A
particular group 1s often ~ssigned responsibility to ensure that Parts are
c~rrcctlx built, inspected and tested to confirm their quality and reliability.

llel]:ib]l]Ly. Confidence in the achievement of speci flc coals, often expressed

in statistical terms.

Reference Standards. Any part or image that is used to judge the status or
acceptability of another part or image can be called a reference standard.

Standards. The bsse upon which or by whirh other variables are judged or
measured.

Tailorinc. The act af changinc someth]nc from one state or condit>on to

another state or condition to better fit or apply to particular circumstances.

Trade-off. Mutually exclusive events or condi tion% often require a choice

between them. A trade-off is exchanging one state or condition for another,
wi th subsequent Rains rind losses.

1.6-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-72B/l

1.7 BIBLIOGRAPHY
I
The following ists of Specif cations, Standards, Handbooks and other
I publications are
provided as dditional sources of information to aid in an.v
I particular NDT problems that may arise.

1“ 1.7.1 GOVERNMENT DOCUMENTS

I TECHNICAL ORDERS

Air Force TO 00-25-224 Welding High Pressure & Cryogenic Systems

(Section 4 - Nondestructive Inspection by
Ultrasonic and Eddy Current Methods)

Air F“rce TO 3311-1-1 Hondestructi.x. Testir& !lethods

Navy NAVAIR 01-lA-16 (Chapter 1 - General, Chapter 2 - Magnetic
A 1711y TM 43-0103 Partical Method, Chapter 3 - Eddy Current
Method , Chapter 4, Ultrasonic Inspection
Method, Chapter 5, Radiographic Inspection
t4ethod, Chapter 6, Floureacent and Dye
I Penetrant Method).

1 KILITARY STANIJARDS AND SPECIFICATIONS

1 MIL-STD-?71 Nondestructive Testing Requirements for Metals (Radiography,

Magnetic Forticie, Liquid ?enetrant, Leak Testing. Ultrasonics) .
I
I MIL-STIJ-79EI Nondestructive Testing, Welding Quality Control, Material
Control & Identification & Hi-Shock Test Requirements for PipinC
System Components for Naval Shipboard Use (Radiography, Magnetic
Particle, Penetrant) .

}11L-I-6870 Inspection Requiremen~s, Nondestructive for Aircraft Materials &

Parts (Magnetic Particle, Penetrant, Radiographic, Ultrasonic,
Eddy Current).

MIL-STD-41O Qualification of Personnel.

MIL-STfI-721 Definition of Terms for Reliability, Maintainability, Human

Factors, and Safety .

1.7-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

MI L-HDBK-728/l

(
MILITARY QUALITY ASSURANCE PAMPHLETS

Af’lCP702-3 Reliability Handbook (Army Material Command)

DAP 11-25 Life Cycle Management Model for Anuy Systems (Department of the
Army)

NASA PUBLICATIONS

NASA SP-3079, Nondestructive Evaluation Technique Guide, A. Vary (U. S.

Covernmant Printing Office, Washington, DC) 1973

NASA 5P-5113, Nondestructive Testing - A survey, (U. S. Government Printing

Office, Washington, DC) 1973

NBS-PUBLICATIONS

NBS Nandbook 14, General safety standard far installations usinc non-material
x-ray and sealed gamma ray sources, enereiez up to 10 Me V (U. S. Government.
PrintinflOffice, Washington, D.C. )

NE!SHandhoo!? 50, X-ra:; protection de~ifln (Ij.3. Government Prlntlng Office,

Washington, D.C.)
(
NBS Handbook 57, Photographic dosimetry of X and <aroma rays (U. S. Government
?rinti’fig
Or fice, iasnington D.c. j

N= Handbook 66, Safety design snd use of intiustrial beta ray aaurces (U. S.
Government Printing Office, WtishinCton, D.
C.)

NBS Handbook 114, Ceneral safety nt,lnri?rds f9r installation u3icg llJ1l-medi
Cni
x-ray and sealed gamma ray sources, ener<ies up to 10 Me V (U. S. Government
Printing Office, Washington, O.C. ) 1975

1.7.2 OTHER PUBLICATIONS

ASNE Boiler and Pressure Vessel Code (Section 1, Section 111, Section IV,
Section V, Section VIII, Section IX, Division 2, and Section IV)

ASNT-TC.l A Recommended Practice Iandestructive Testing Personnel

Qualification and Certification (Supplement A, Radiographic
Testing; Supplement B, Ma&netic Particle: Supplement C,
Ultrasonic Testing; Supplement D, Liquid Penetrant; snd
Supplement Z, Eddy Current)

AWS-A2.4 Nondestructive Testing SymtIcIls

,’

1.7-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
}lIL-t{DBii-728/l

Annual Book of ASTfiStandards, Part 03.03, “Metallography; Nondestructive

Testing”’ (American Society for Testing and Materials, Philadelphia) 19@0.

Classroom Training! Handbook, CT-6-5. ‘“Nondestructive.Testin&. Eddv

Current, ” (Generai Dynamics” Convairl San Disgo) 1979 (Secon~’Edition) .

5. ClassrOOm Training Handbook, CT-6-2, “’Nondestructive Testing, Liquid

Penetrant, “ (General Dynamics Convair, San Diego) 1979 (Fourth Edition).

6. Classroom Training Handbook, CT-6-3, “Nondestmctive Testing, Magnetic

Particle, ” (General Dynamics Convair, San Diego) 1977 (Second Edition).

7. Classroom Training Handbook, CT-6-6, “Nondestmctive Testing,

Radio
graphic,” (General Dypamicg Copvair, San D>ego) 1967.

6. Class&mn Training Hand”book, CT-6-4, “Nondestructive Testing, Ultrasonic,”’

(General Dynamics Convair, San Diego) 1981 (Second Edition) .

9. Classroom Training Handbook, CT-6-6, “Nondestructive Testing,

Radiographic ,“ (General Dynamics Convair, San Diego) 1967.

10. Nondestructive Testing ‘Handbook, t?.C. 14cMaster, Ed. , (Ronald Press, N.Y.)
1959.

11. Nondestructive Testin&, Warren J. !lcGonnsgle, (McCraw-Hill, N.Y.) 1961.

12. Metals Handbook, Vol 11, (American Society for Metals, Metsls Park, OH. )
lY’(6(8th Edition).

13. Suggested “Course Outline for Training NDT Personnel, V. L. Stokes (ASNT,
Columbus. ) 1976.

14. NTIAC Handbook, R.E.Engelhardt, Ed. , (Southwest Research Institute, San

Antonio. ) 1979.

15. Ultrasonic Testing, J. Szilard, Ed. , (John Wiley & Sons, N-Y. ) 1982.

16. Radiation Detection and Measurement, G. F. Knoll, (John Wiley & Sons,
N.Y.) 1979.

17. Ultrasonic Testing of Materials, J. and H. Krautkramer, (Springer- Verlag,

Berlin) 1977.

18. Advanced Ultrasonic Testing Systems, H. S. Silvus Jr. , (Southwest Research

Institute, San Antonio) 1976.

19. Basic Physics in Diagnostic U1 trasound, J. L. Rose and B. B. Goldberg,

(John Wiiey a Sons, N.y. ) 1979.

23. Principles of,Magnetic Particle Tegting, C. E. Betz, (Magnaflux Corp. ,

Chicago. ) 1967.

21. Introduction of Electromagnetic Nondestructive Test Methods, H. L. Libby,

(Krieger, N.Y.) 1979.

1.7-3
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

N!L-lll)RK-”1’2&’I

~~ . Principles of Penetra”ts, C. E. Bet: (MaKn~flux Corp. ,

23. hcaustic Emiss] or! Techn>qaez and A?Dlicatians, J. C. Spa””er, (lntex

Corp. , IL.) 1974

2A. Introduction ta Nondestructive Testl”g, G. P. Hayward, (America” Society

for Quality Control, WI. )

25. Techniques of Nondestructive Testinc, C. A. Hogarth and J. Betz,

(Butterworths, London) 1960.

26. Quality Control Handbook, J. M. Juran, Ed. , (McCraw-Hill, N.Y. ) 1962,

27. Ultrasonic Technology, E. Goldman (Reinhold, N.Y.) 1962.

.?6. ultrasonics, B. Carlln, \}lcCraw-Hill, N.Y.), 1960.

29. STP 624, Nondestructive TestinC Standards - A Review, H. lkrger, Ed.,

(ASTM, Philadelphia) 1977.

30. Radlograph,v in Nodern Industry, (F;astmanKodak, Co. , Rochester) 1980

(Fourth Edition).

31. Practical Appll rations of Neutron F:atiloflraphyand GagL~, H. Berger, Ed.

(ASTM, Philadelphia) 1976.

32. Physical Ultrasonic, R. T. Beyer and S. V. Letcher, (Academic Press, 11.

Y. )
1969.

:3. Research Technlaues in Nonaestmctlve Te~ting, R. S. :har~e, Eli.. 4

Volumes (Academic Press, N.Y.) 1989.

’34. NASA SF-5113, Nondestructive Test]nc - A Survey, (U.S. Cctvernment Print~n,y

Office, Washin~ton D.C.) 1973.

1.7.2 h’HER5TO OBTAIN SPECIFICATI(Jr!:;

AND STANDARDS

All U.S. Department of Commerce, National Bureau of Standards Hand beaks are
avai lable from the Superintendent of Doc”me”ts, Government Printing Office,
Washington, D.C. 20402.

All other government. agency spec]f]catl~ns or standards are under the central
of the Department of Defense.

A1l requests for copies af specifications, standards, and qualified products

lists should state the title a“d identifying “~ber e“d should be ~“bnitted to
Commanding Officer, Naval Supply Depot, 5801 Tabor Ave. , Philadelphia, PA
19120, Attn. - Code CDS, except:

1.7-4
 Downloaded from http://www.everyspec.com
MIL-}{ DBK-728/lon 2011-11-29T0:55:24.

a. Copies of specifications, standards and qualified products lists raquired

by contrac Cors in connection #i th specific procurement functions should be
obtained from the procuring agency awardin~ the contract or as directed by
the contracting officer.

b. Federal Specifications and Standards and Military Book Form Standards ‘will
not generally be furnished by the Naval Supply Depot to commercial
concerns unless required in conjunction ii th a bid or contract, or for
sufficient other justification. Copies of federal documents may be
purchased from the Business Service Center, General Service
Administration, Washington, D.C. 20405. Most book-form Military
Standards may be purchased from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402.

c. Only current, “in effect” issues of standatiization documents will be

available from tk,eNaval Supply !!cpot. Copies of canceled or superseded
documents required for contractual purposes will have to be obtained from
the contracting office of the concerned service.

a. Information regarding obtaining DoE “standards relative to the Division of

Reactor Development and Technology may be obtained from Oak Ridge National
Laboratory, P.O. Box X, Oak Ridge, TN 37830.

All specifications or standards as issued by the organization.? listed below

are available di rectl.yfrom the organization at the address given.
(“
.AE!S American Bureau or Siiippillg
45 Broad Street .
New,York, NY 10004

AIA Aerospace Industries Association of America

1725 De Sales’ St. , NW
Washington, DC 20036

AIS1 American Iron,and Steel Institute

1000 16th St.,, NW
Washington, D.C. 20036

Al. AsSOC. The Aluminum Association

420 Lexington Avenue
New York, NY 10017

ANS American Nuclear Society

555 N. Kensin@on Avenue
La Gra~e Park, IL 60525

ANSI American National Standards Institute, Inc.

I 1430 Broadway
, New York, NY 10018

1.7-5
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-728/l

f
AH American Petroleum lrwtitute
50 iiest 50th Street
New Iork, NY 10019

ASME American Society of Mechanical Engineers

345 East 47th Street
Ueu York, NY 10017

ASNT American Society for Nondestructive Testing, Inc.

4153 Arlingate Plaza
Caller 28518
Columbus, OH 43228

ASTM American Society for Testing and Materials

1916 Race Street
Philadelphia, PA 19103

AVS American Vacuum Society

335 East 45th Street
New York, NY 10017

AWS American Welding Society

2501 N.W. 7th Street
Miami, FL 33125

ICRU International Commission on Radiation Units

7910 Woodmont Avenue, Suite 1016
C. 2COL4
Washing coft,1).

MSFC National Aeronautics and Space Administration

George C. Flarsh811 Space Flight Center
Huntsville; AL 35812

NCRP National Commission on Radiation Protection

NCRP Publications
P.O. BOX 4867
Washington, D.C. 20008

SAE Society of Automotive Engineers, Inc.

400 Commonwealth Drive
Warrendale, PA 15096

1.7-6
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.
MIL-HDBK-72f3/l

1.8 I!iDEX

Section

Administrators 1.4.2

Definitions
(Format for handbook) 1.2.4
(NDT, NDI a,ndNDE) 1.3
(Glossary]. 1.6

Designers 1.4.3

Liquid Penetrants, NDT Method 1.5

Sddy Current, NDT Method 1.5

“E~-in+6rs 1.4

Clossaxy 1.6

Guidelines 1.4

Index Guide 1.2.3

MagnetlC Particle, NDT Method 1.5

Military Handbooks 1.7.3

Organization (of Handbook) 1.2

Organizations (Addresses) 1.7

( 1.4
Principles
I
Production Engineers 1.4.4

Publications (Commercial) 1.7.6

Quality Assurance 1.4.5

References
(User’s Guide) 1.2.2
(Bibliography) 1.7

Revisions
(Guides) 1.2.5
(Procedures to Recommend Changes) 1.0
Scope (of Handbook) 1.1

Technicians 1.4.7

Ultrasonic, NDT Method 1.5

X-Rays, NDT Method 1.5

1.8-1
Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

1.s-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

1.9 NOTES
... . .

1.9.1 KIL-HDBK-72811, 12, 13, /4. 15 and /6 supersede the f0110win8

documents:

MIL-HDBK-54
15 October 1965

MIL-HDBK-55
1 April 1966

MIL-HDBK-726
10 June 1974

MI L-HDBK-333
10 April 1975

APICP702-10
Apri 1 1970

I
Custodians: Preparing activity:

I Army -- MR Army -- MR
Navy -- AS
Air Force -- ?0 Project No. NI)TI-0047
I Review activities:

Army -- AR
Navy -- OS

WP# ID-1336P/Dl~C OO1OV. POR AKMRC USE ONLY.

!

1.9-1
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

Fll
L-1{
DNK-72Ei/1

THIS PAGE INTENTIONALLY LE?T BLANK

1.9-2
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

I
INS TRUCII-5: In a Wnfmuma mom 10 CMks our CtMdu’dhuorl datttmnb fmttmx, flu DoD pexida @ [arm for UM in
wbmittiu IXImrJM md suuadotn kc imFxvu=nta All usmt ot callltcq rtandudknfkn dornlmnti 088 invited La provide
i O+V+OW. 7%b 1-M -Y ~ d=@b-t. fo* dOrU h km tndhtod, taped OIMI h h + (DO NOT STML&, , -d
tikd. In bhrk 6, & M WC@ - tibh IbOUl @CUIU pnbkm ~ rudt w - wb,M rgquind hterpmwtio”. .M
tc.a ritid, mwirthe. loom. amblmmu, ar m kmcompatibk, and gim ~ wodk# ~ ~kh uwkd dlcrisk the
@biecm. En@I in black 6 my rmauks act mhld to ● apcciYk paragr@ of Un domuMo1. [f blat 7 isrt!edWI. ..
mckno.ledgernmt wIN b mdhd 10 YOU wifhkn 30 day- to Id loo kao. tit yaw ccamanYI ,en naind md ●m bd”g

candde-d.

NOTE: ‘I%u (OMI IMY DOt be ~ to nquwl cmpiei of documeau, mar w uquat aim dtitiocu, or .Iuificntkm d
cxlflcstlom requirwnenu on current rmtmcti. Gmmenu submltled on lbh kwrn do nol corufltute or imply tulhorimtian
LO -iw my parlim of tbe mfemwed document(#) or to ●mend rontrsctud requkiemeow

I
.
(Fold d.”, ,JdI I(.u,

oEP4nTMENTor THE&RMv

111111
rl
NG.KL57AGE
NEcEs5aFl Y
,, A4A,. fo
(M T“$
UN’4TC0 s7A7ES

BUSINESS
F,I+S7 REPLY MAIL
cl-assERMIT ● No. ,2052 WA S” ONG, OI’4 o c
POSTAGE WILL EE PAID BY THE DEPAI?TMENT OF THE ARMY

Director
U.S. Army Materials Technology Laboratory
ATTN:’ SLCHT-FYSR-ES
Watertown, HA 02172-0001

I
 Downloaded from http://www.everyspec.com on 2011-11-29T0:55:24.

STANDARDIZATION ODCXMENT IWROVEMENT PRofosAL

(h htnulbu - RpuT& ~)
00 CUUt NT UUUm#m 2. WCUWWT Till.,
MI L-1llJHK-7?8/1 NONDESTRUCTIVE TESTING
m WAUE 0S 9U8Mtl_ll N0 OMOANl?.AT1m
4. TVM OP OmOANIZATlON (Ma -,

/
UA”E Os ,“a”,,, ~”
hat. mm,, MI, - *,,-*
b, Wonx Tc LEPHOME N wOEn (f.cb& A-
Cadl, - ti,lo,m.1
MAILING ADO FIESS ,Slr, a,.Clly, 9“., ZIP Code, - OII,W
● O&TE OF 9U8M1WIOM lYYMMOLM

~!):“fl. 1426 ●mEvIOua EO1TIOU ,0 ~CILETE.