EL

PT
N
Dr. Amandeep Singh
Imagineering Laboratory
IIT Kanpur
▪ CAD softwares

EL
▪ Demonstration on CAD

PT
N
▪ AutoCAD

EL
▪ Fusion 360
▪ Solidworks
▪ CATIA
▪ Inventor
▪ Creo Parametric
PT
N
▪ FreeCAD
▪ Ansys Spaceclaim
Feature Solidworks Fusion 360

EL
Parametric Assembly-Oriented Multi-Component Part System
Feature

Complex
PT
Advancement Professionals

Customizable
Interfaces
Entirely Cloud-based For
Remote Teams
N
Usage & More Traditionally Much More Versatile Program
Applications Used By
Professionals

Source:
https://roboticsandautomationnews.co
m/
Cont.

Feature Solidworks Fusion 360

EL
Support online materials A Number Of Free Official
and learning Training Materials From
resources Autodesk
Final
Thoughts PT
Robust Simulation
Packages And 3D
Modeling Tools
Very Intuitive Assembly
Interface, Being Versatile And
Friendly Enough For Different
N
Applications
▪ COMSOL MULTIPHYSICS

EL
▪ MATLAB
▪ ANSYS
▪ Fusion 360
▪ Inventor
▪ Solidworks
PT
N

Source:
https://www.mechanical360.net/
N
PT
EL
 EL
PT
N
Dr. Amandeep Singh
Imagineering Laboratory
IIT Kanpur
▪ Non Destructive Testing

EL
▪ Contact Methods
▪ Ultrasonic Testing
▪ Eddy Current Testing
▪ Magnetic Testing
▪ Penetrant Testing
▪ Acoustic Testing

▪ Non-Contact Methods
PT
N
▪ Radiography Testing
▪ Thermographic Testing
▪ Visual Inspection
▪ X-Ray Computed Tomography
▪ Nondestructive testing (NDT) is the practice of looking for flaws
or differences in a

EL
▪ material,
▪ component, or
▪ assembly

normally. PT
without damaging the part's or system's capacity to function

▪ It’s inspecting, testing, or evaluating materials, components or

N
assemblies for discontinuities, or differences in characteristics
without destroying the serviceability of the part or system.
▪ In other words, when the inspection or test is completed the
part can still be used.
▪ Modern nondestructive tests are being utilised in
manufacturing, fabrication, and in-service inspections to

EL
guarantee product integrity and dependability,
▪ to regulate manufacturing processes,
▪ to cut costs, and

PT
▪ to keep output levels uniform.

▪ In-service NDT inspections are used to make sure that the

products being used continue to have the integrity required to
N
ensure their usefulness and the safety of the general public.
Test method names often refer to the type of penetrating medium or
the equipment used to perform that test.

EL
NDT
Contact Methods
• Ultrasonic Testing
• Eddy Current Testing
• Magnetic Testing
• Penetrant Testing
PT
N
• Acoustic Testing

Non-Contact Methods
• Radiography Testing
• Thermographic Testing
• Visual Inspection Source:
• X-Ray Computed Tomography tuv.com
N
PT
EL
▪ This technique is used for the detection of internal and surface
defects in sound conducting materials.

EL
▪ A short pulse of ultrasound is generated by means of an
electric charge applied to a piezoelectric crystal

PT
▪ Pulse vibrates for a very short period at a frequency related to
the thickness of the crystal.
▪ Frequency range 1 MHz to 6 MHz
N
 EL
PT
N

Schematic diagram of ultrasonic detection of defects

Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4.
▪ Thickness and lengths up to 30 ft can be tested.

EL
▪ Position, size, and type of defect can be determined.
▪ Instant test results.
▪ Portable.
▪ Extremely sensitivePT
▪ Capable of being fully automated
N
▪ Access to only one side is necessary.
▪ No consumables.
▪ No permanent record available unless one of the more
sophisticated test results and data collection systems is used.

EL
▪ The operator can decide whether the test piece is defective or
not whilst the test is in progress.

PT
▪ Indications require interpretation.
▪ Considerable degree of skill necessary to obtain the fullest
information from the test.
N
▪ Very thin sections can prove difficult
▪ Thickness Measurement

EL
▪ Delamination & Inclusions Identification
▪ Flaw detection in welds, castings and connections

PT
N

Source:
tmmarin.com
▪ Eddy currents can be produced in any electrically conducting
material

EL
▪ The alternating magnetic field is normally generated by
passing an alternating current through a coil

PT
▪ Any change in the material or geometry can be detected by the
excitation coil as a change in the coil impedance.
▪ When a crack occurs in the product surface the eddy currents
must travel farther around the crack.
N
 EL
PT
N

Illustration of eddy current testing

Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4.
▪ Faster process & little or no surface preparation needed.

EL
▪ Easily automated
▪ No contact needed

PT
▪ No special operator skills are needed
▪ Extremely compact and portable units are available
▪ No consumables
N
▪ Flexibility in the selection of probes and test frequencies
▪ Probe size affects sensitivity

EL
▪ For simple geometries
▪ Shallow depth of penetration

PT
▪ Generally, tests are restricted to surface breaking conditions
N
▪ Cracks & Porosity

EL
▪ Defect discontinuities such as
▪ seams
▪ laps
▪ pits
▪ cracks
▪ voids
PT
N
▪ inclusions

▪ Material thickness measurement

Source:
Twiglobal.com
 ▪ The principle is to generate
magnetic flux in the article to be

EL
examined.
▪ With the flux lines running along
the surface at right angles to the
suspected defect.
▪ Where the flux lines approach a
discontinuity, they will stray out
PT
N
into the air at the mouth of the Principle of Magnetic Particle Inspection
crack.

Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4.
▪ Faster process

EL
▪ Easily automated
▪ Little and no surface preparation

PT
▪ Cheap and robust probes
▪ Simplicity of operation and application.
▪ Quantitative.
N
▪ Restricted to ferromagnetic materials.

EL
▪ Restricted to the surface or near-surface flaws.
▪ Every component needed to be tested twice

PT
▪ Diagonal defects are difficult to detect
N
▪ Subsurface defects
▪ Checking pipes for crack & Cast and welds

EL
▪ Fully automated inspection of drive shafts
▪ Inspection of gear

PT Drive shaft with material defect,

N
Greyscale image of the MT indication

Magnetic testing of gear

Source:
www.ndt.net
 ▪ Frequently used for the detection of surface breaking flaws in
nonferromagnetic materials.

EL
PT
N

Illustration of penetrant testing

Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4.
▪ Simplicity of operation

EL
▪ Best method for surface breaking cracks in non-ferrous metals.
▪ Suitable for automatic testing, with reservation concerning
viewing.

PT
▪ Low cost and no sophisticated equipment needed
▪ Quantitative
N
▪ Multiple stages in the complete process so difficult to automate

EL
▪ Requirescasting conditions like suitable of the light
arrangement
▪ Restricted to surface breaking defects only.

PT
▪ Surface cleanliness needed.
▪ Decreased sensitivity.
N
▪ Uses a considerable number of consumables.
▪ Surface crack, Porosity

EL
▪ Crack detection in weld
▪ The forging surface detects like Laps and Bursts can be easily
identified by performing a liquid penetrant test.

PT
N

Source:

Theconstructor.org
▪ The term acoustic emission refers to the generation of transient
waves during the rapid release of energy from localized

EL
sources within a material.
▪ In an acoustic emission test, an inspector records elastic

PT
ultrasonic waves traveling through the surface of solid material
using one or more sensors.
▪ As an acoustic wave travels on or through the surface of an
object any defect it encounters can change that wave
N
 EL
PT
N
Principle of acoustic emission testing

Source:
onestopndt.com
▪ It gives you a direct measure of failure mechanisms

EL
▪ It is highly sensitive
▪ It provides data immediately

PT
▪ It is non-destructive to the material being tested
▪ It allows for a structure to be globally monitored
▪ It can be used in hazardous environments
N
▪ It can be done remotely and can detect defects in materials that
might be hard to test using other NDT methods
▪ Its usefulness is generally limited to locating a defect, not
describing it in detail

EL
▪ It cannot detect defects that do not change over time
▪ It can be slow to implement

PT
▪ It can be hard to use
N
▪ Acoustic emission is commonly
used to test for

EL
▪ cracking
▪ corrosion
▪ delamination
▪ breakages.

PT
▪ Airplane longevity estimation
▪ Bridge inspections
N
▪ Concrete corrosion monitoring
▪ Mine wall stability inspections
▪ Pressure vessel inspections
▪ Structural integrity inspections Source:
Wikipedia.org

▪ Wind turbine inspections

N
PT
EL
▪ Non Destructive Testing

EL
▪ Non-Contact Methods
▪ Radiography Testing
▪ Thermographic Testing

PT
▪ Visual Inspection
▪ X-Ray Computed Tomography
N
 ▪ This technique is suitable for the
detection of internal defects within

EL
the volume of the examined part.
▪ The source of radiation can be
either an X-ray tube or a
radioactive isotope.
▪ Radiation from X-rays and Gamma
rays differentially absorbed by the
material through which it passes.
PT
N

Schematic illustration of a typical exposure

arrangement for radiography

Kumar, Sanjay & Mahto, Dalgobind. (2013). Recent Trends In Industrial And Other Engineering Applications Of Non Destructive Testing: A Review. 4.
▪ Information is presented pictorially.

EL
▪ A permanent record is provided which may be viewed at a time
and place distant from the test.
▪ Useful for thin sections.

PT
▪ Sensitivity declared on each film.
▪ Suitable for any material.
N
▪ Generally, an inability to cope with thick sections.

EL
▪ Possible health hazard.
▪ Need to direct the beam accurately for two-dimensional
defects.

exposure compound.PT
▪ Film processing and viewing facilities are necessary, as is an

▪ Not suitable for automation, unless the system incorporates

N
fluoroscopy with an image intensifier or other electronic aids
▪ Not suitable for surface defects.
▪ No indication of the depth of a defect below the surface
 ▪ Detect deep or embedded defects
▪ For detection of porosity, defects in casting, and lack of fusion in
welding.

EL
▪ For measurement of geometry variation and thickness of the
component.

PT
N

Yang, J.; Li, S.; Wang, Z.; Dong, H.; Wang, J.; Tang, S. Using Deep Learning to Detect
Defects in Manufacturing: A Comprehensive Survey and Current
Challenges. Materials 2020, 13, 5755.
 EL
PT
N
Radiographic weld inspections Pipe inspection using digital radiography

Source:
vidisco.com
atslab.com
▪ Detects radiation in the infrared range of the electromagnetic
spectrum and produce images of that radiation called

EL
thermograms.
▪ Performed using an infrared sensor

PT
N

Thermal inspection

Source:
photonics.com
▪ Large areas can be scanned fast

EL
▪ No downtime or production interruptions for testing
▪ Requires no contact with components or machines

▪ Real-time output PT
▪ Easy-to-read visual images

▪ Does not emit any radiation

N
▪ Affected by weather conditions

EL
▪ Expensive
▪ Infrared technology can’t detect temperature if a component is
separated by a non-transparent material such as a glass cover.

PT
▪ Penetration is possible only for a few mm’s
▪ Infrared data requires significant expertise and an extensive
knowledge base to evaluate imaging results
N
▪ Detection of near-surface defects

EL
▪ Rolling element bearing fault detection
▪ Electrical Wiring maintenance
▪ Infrared imaging is widely used in industries to detect gas
leaks
PT
N

Source:

Theconstructor.org
▪ To detect surface defects by naked eye.
▪ Particularly effective in detecting

EL
macroscopic flaws, such as poor welds,
improper surface finish, large cracks,
cavities etc.

PT
▪ Normally applied without the use of
any additional equipment
▪ VT can be improved by using aids such
N
as a boroscope to improve its
effectiveness and scope. Visual inspection

Source:
indsutriallndt.com
 EL
PT
N
Principle of the visual inspection system for monitoring of
the powder layer top surface.

Craeghs, Tom & Clijsters, Stijn & Yasa, Evren & Kruth, Jean-Pierre. (2011). Online quality control of selective laser melting. 22nd Annual
International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2011.
▪ Faster process

EL
▪ Applicable at all stages of construction or manufacturing
▪ Modest skills required
▪ Low cost

PT
N
▪ Lighting requirements

EL
▪ Superficial
▪ Only for surface defects

PT
▪ High interpretation skills needed
▪ The use of optical aids is often required to monitor AM
processes
N
 ▪ Inspection of newly manufactured components

EL
▪ Condition monitoring during service

PT
N

Source: single-peak.com
▪ Examining the critical aero-engine components like:
▪ turbine shafts

EL
▪ blades
▪ intermediate casing
▪ oil tank etc.

PT
N

Source: single-peak.com
▪ Computed tomography or CT, refers to a computerized x-ray
imaging procedure

EL
▪ Works on the principle of
▪ irradiating a sample with a beam of X-rays,

PT
▪ measuring the subsequent absorption X-ray image, and
▪ repeatedly acquiring such images as the sample rotates.

▪ The X-ray absorption images represent views of the sample

N
from many angles, providing internal detail due to the
penetration of X-rays.
 EL
PT
N

Withers, P.J., Bouman, C., Carmignato, S. et al. X-ray computed tomography.

Nat Rev Methods Primers 1, 18 (2021)
 EL
PT
N

Schematic of an X-ray microCT scan

Du Plessis, Anton, et al. "X-ray microcomputed tomography in additive manufacturing: a review of the current
technology and applications." 3D Printing and Additive Manufacturing 5.3 (2018): 227-247.
▪ The CT technique eliminates the superimposition of images of
undesired structures completely.

EL
▪ Multiplanar reformatted imaging is possible due to multiple
contiguous or single helical scans.

PT
▪ It provides more detail compared to ultrasonography.
▪ It is quicker, cheaper, and superior to MRI scanning.
▪ Motion artifacts are of less concern in CT scans than in MRI.
N
▪ It is time-consuming.

EL
▪ It is expensive for routine clinical use.
▪ The operator is exposed to higher radiation.

PT
▪ There is a risk of ionizing radiation and iodinated contrast
agents.
N
 1. Porosity and defect analysis 2. Surface roughness or topography

EL
PT
N

Transparent view of the porosity Surface roughness/topography analysis of

analysis in 3D AM part on a cylindrical geometry

Du Plessis, Anton, et al. "X-ray microcomputed tomography in additive manufacturing: a review of the current
technology and applications." 3D Printing and Additive Manufacturing 5.3 (2018): 227-247.
▪ How has X-ray computed tomography brought advances to
industrial design?

EL
▪ How can we improve limitations of visual testing?
▪ How can we increase the scope and utilities of Radiographic
testing?
PT
▪ How has ultrasonic testing been revolutionary in field of metal
additive manufacturing?
N
▪ How can we broaden domain of eddy current testing in terms of
testing complex geometries?
▪ How can we remove constraints of on surface testing in
penetrant testing?

EL
▪ How can we bring down costs of thermographic testing?
▪ Why is acoustic testing difficult to use and how can we

PT
eliminate requirements of extreme sensitivity?
▪ How can we reduce trials of testing in magnetic testing?
N
N
PT
EL