Non-Destructive and Destructive Testing

Course Description

This course introduces students to the fundamental principles, methods, and applications of both non-destructive testing (NDT) and destructive testing (DT) as applied in industrial systems technology. Students examine the history, advantages, and limitations of NDT and DT, explore how discontinuities form in materials during processing, and gain hands-on experience operating testing equipment including hardness testers, bend jigs, and NDT instruments. The course is aligned with the American Society for Nondestructive Testing (ASNT) Recommended Practice SNT-TC-1A and relevant AWS and ASME standards for weld and materials inspection.

This is a combined lecture and laboratory ("C") course within the Engineering Technologies — Industrial Systems Technology taxonomy of the Florida Statewide Course Numbering System (SCNS). Laboratory exercises reinforce theoretical content through direct application of testing procedures on sample materials and weld coupons.

Learning Outcomes

Required Learning Outcomes

Upon successful completion of this course, students will be able to:

• Explain the principles, history, and industrial applications of non-destructive testing (NDT) and destructive testing (DT).
• Identify and describe the five primary NDT methods: Visual Testing (VT), Liquid Penetrant Testing (PT), Magnetic Particle Testing (MT), Ultrasonic Testing (UT), and Radiographic Testing (RT).
• Perform basic NDT procedures using standard equipment and interpret test results in accordance with applicable codes and standards.
• Identify and classify material discontinuities and defects detected during NDT and DT inspections.
• Demonstrate an understanding of destructive testing methods including tensile testing, guided bend testing, hardness testing, and impact testing.
• Prepare test specimens, perform destructive tests in a safe and controlled manner, and accurately document and report results.
• Analyze and interpret test data to assess material and weld quality against applicable specifications.
• Apply relevant safety practices, including proper handling of hazardous materials (e.g., penetrant chemicals, radiographic sources), personal protective equipment (PPE), and OSHA-compliant laboratory procedures.
• Identify applicable industry codes and standards (ASNT SNT-TC-1A, AWS D1.1, ASME Section IX) governing NDT and DT procedures.

Optional Learning Outcomes

The following outcomes may be addressed depending on available equipment, program emphasis, and institutional resources:

• Perform Eddy Current Testing (ET) procedures and interpret results on conductive materials.
• Describe advanced NDT methods such as phased array ultrasonic testing (PAUT) and digital radiography (DR).
• Conduct macro etch and fillet weld break tests and evaluate results for weld discontinuities.
• Explain the requirements for NDT personnel qualification and certification under ASNT SNT-TC-1A and ANSI/ASNT CP-189.
• Correlate destructive test data (tensile strength, hardness, ductility) to material selection and engineering design requirements.
• Prepare written inspection reports suitable for quality control records and regulatory compliance.

Major Topics

Required Topics

1. Introduction to NDT and DT
   • History and evolution of non-destructive and destructive testing
   • Roles of NDT/DT in quality assurance and industrial safety
   • Overview of applicable codes and standards (ASNT SNT-TC-1A, AWS, ASME)
   • NDT personnel qualification levels (Level I, II, III)
2. Material Discontinuities and Defects
   • Types of discontinuities: inherent, processing, and service-induced
   • Weld discontinuities: porosity, slag inclusions, lack of fusion, undercut, cracks
   • Effects of discontinuities on structural integrity
3. Visual Testing (VT)
   • Direct and remote visual inspection techniques
   • Tools: mirrors, borescopes, magnifiers, weld gauges
   • Acceptance/rejection criteria per applicable codes
4. Liquid Penetrant Testing (PT)
   • Principles of capillary action and penetrant indication
   • Visible dye and fluorescent penetrant systems
   • Surface preparation, dwell time, developer application, and interpretation
5. Magnetic Particle Testing (MT)
   • Principles of magnetism and flux leakage
   • Wet and dry particle methods; fluorescent and visible particles
   • Limitations: ferromagnetic materials only
6. Ultrasonic Testing (UT)
   • Sound wave principles: frequency, velocity, attenuation
   • Contact and immersion techniques; straight beam and angle beam
   • Equipment calibration and flaw sizing
7. Radiographic Testing (RT)
   • X-ray and gamma-ray sources and radiation safety
   • Film selection, exposure techniques, and image quality indicators (IQI)
   • Interpretation of radiographic images for weld and material evaluation
8. Destructive Testing Methods
   • Tensile testing: yield strength, ultimate tensile strength, elongation, reduction in area
   • Guided bend testing: face bend, root bend, side bend; ductility evaluation
   • Hardness testing: Brinell, Rockwell, Vickers methods and applications
   • Impact testing: Charpy V-notch test; toughness and ductile-to-brittle transition
   • Macro etch testing and fillet weld break testing
   • Specimen preparation and universal testing machine operation
9. Safety in Testing Environments
   • PPE requirements for NDT and DT laboratories
   • Hazardous materials handling (penetrant chemicals, acids for etch testing)
   • Radiation safety protocols for RT operations
   • OSHA regulations applicable to testing environments
10. Documentation and Reporting
    • Recording test parameters, observations, and results
    • Acceptance/rejection criteria and code compliance
    • Basic inspection report preparation

Optional Topics

• Eddy Current Testing (ET) — principles, equipment, and applications on non-ferromagnetic conductive materials
• Advanced NDT methods — phased array ultrasonic testing (PAUT), time-of-flight diffraction (TOFD), digital/computed radiography
• Fatigue and fracture testing — fatigue test specimens, S-N curves, failure mode analysis
• Welder and procedure qualification — welding procedure specification (WPS), procedure qualification record (PQR), and performance qualification testing per AWS D1.1 or ASME Section IX
• Nondestructive evaluation (NDE) of composites — inspection challenges and methods for fiber-reinforced and non-metallic materials
• Industry-specific applications — aerospace, nuclear, oil and gas, and infrastructure inspection scenarios

Resources & Tools

• ASNT SNT-TC-1A — Recommended Practice for Personnel Qualification and Certification in Nondestructive Testing (American Society for Nondestructive Testing)
• ANSI/ASNT CP-189 — Standard for Qualification and Certification of Nondestructive Testing Personnel
• AWS D1.1 — Structural Welding Code — Steel (American Welding Society)
• ASME Section IX — Welding, Brazing, and Fusing Qualifications
• NDE Resource Center (nde-ed.org) — NDEE open-access reference for NDT physics, methods, and practice
• Laboratory Equipment: Universal testing machine (UTM), Rockwell/Brinell/Vickers hardness testers, Charpy impact tester, MT yoke and bench unit, PT kit (visible and fluorescent), UT flaw detector with angle beam and straight beam transducers, radiographic viewing equipment
• Textbook: Recommended: Introduction to Nondestructive Testing (ASNT); supplemental AWS and ASME code books

Career Pathways

Completion of this course prepares students for entry-level roles and supports advancement in quality control and inspection careers across a wide range of industries, including:

• NDT Technician / Inspector (Level I or Level II) in aerospace, manufacturing, construction, shipbuilding, and oil & gas
• Quality Control Inspector in fabrication, welding, and heavy manufacturing
• Weld Inspector — pathway toward AWS Certified Welding Inspector (CWI) credential
• Maintenance Technician in power generation, nuclear, and petrochemical facilities
• Industrial Systems Technologist — supporting reliability and predictive maintenance programs
• Pipeline and Pressure Vessel Inspector — relevant to API 570 and API 510 inspection roles

Students are encouraged to pursue ASNT NDT Level I/II certification in one or more methods following successful course completion, as industry employers widely recognize these credentials.

Special Information

Certification Preparation

This course is structured to support student preparation for industry-recognized NDT and welding inspection certifications:

• ASNT NDT Level I & II Certification — Classroom and laboratory contact hours in this course contribute toward the formal training hour requirements specified in ASNT SNT-TC-1A and ANSI/ASNT CP-189 for methods covered (VT, PT, MT, UT, RT). Students must accumulate additional hours and pass written and practical examinations administered or approved by a Level III NDT technician to achieve certification.
• AWS Certified Welding Inspector (CWI) Exam Preparation — Topics in destructive testing (tensile, bend, impact, hardness) and NDT directly align with content tested on the AWS CWI Part A (Fundamentals) examination. Students interested in the CWI credential should also complete welding-related coursework in the Industrial Systems Technology program.
• Radiation Safety — Students performing or observing radiographic testing exercises must follow all applicable state and federal radiation safety regulations. Institutions offering RT laboratory activities typically require compliance with Florida Department of Health radiation control rules and may require a separate radiation safety orientation.

Laboratory Safety Note

The laboratory component of this course involves hazardous chemicals (liquid penetrant materials, acid etch solutions), high-load mechanical testing equipment, and potentially ionizing radiation (RT demonstrations). Students are required to complete a laboratory safety orientation before participating in hands-on activities. Appropriate PPE — including gloves, safety glasses, and hearing protection — is mandatory during all lab sessions.