NDT Training and Welder Certifications – An Overview

Posted on November 9, 2011 by admin

The success of the mechanical sector largely depends on the skill force that gets implemented. The segment of skilled labor to a very high extent is dependent on factors like educational degrees, training, hands-on experience, relative experience and the all important: skill quotient. Talking about trainings, some important skill based trainings include:

  • Radiography courses
  • Welder certification trainings
  • Visual testing
  • Metallurgical studies
  • Ultrasonic procedures
  • Forging based training
  • Metal cutting courses
  • NDT training

There are hundreds of training courses and certifications available all over the world. A good number of training and certification courses are offered by universities and technical schools in terms of part time, full time and even online modules.

NDT Training and welder certification courses are some popular training courses both in terms of employability and also with respect to patronage. NDT stands for non destructive testing which is a set of procedures and techniques used during researches and in industry for the evaluation of properties of the material, system or components in question. Non destructive testing is performed and supervised by NDT inspectors. Popular grades in this line of inspectors are the NDT level II inspector series, ASNT NDT Level III certification, ACCP certification etc.

The line of inspectors in the field of NDT are dependent on a variety of certifications, popular amongst these include central certification and SNT-TC-1A certification. These certifications elevate nondestructive testing as a profession. Central certification is a certification process by an independent and nationally recognized body in the field of NDT while SNT-TC-1A is an employer based system. In terms of NDT based certifications, test methods or inspection techniques include MT, PT, UT, RT and VT. When all certifications in terms of NDT training are sorted out, common testing points are as follows:

  • General and specific written examinations covering codes, standards, principles and theory
  • Practical examinations on samples with defects
  • Method examination
  • Procedure preparation examination

Same ways, the concept of ‘qualified welders’ also depends on certifications and welder programs that include ‘weld inspection and related testing’ trainings. AWS or American Welding Society is a common Accreditation here.

Be it NDT training or welder certifications, it is very important to choose the right platform. Some important factors in this regard are as follows:

·         When it comes to certification, choosing an agency which provides testing solutions as well is recommended.

·         The best of certification agencies would have the best of inventory in terms of free samples, equipments etc.

  • Lastly, be it NYC based welder certification or for that matter any American NDT training institute always zero-in on an industry oriented agency.
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Why Do Welding Consultants Suggest Tensile Test?

Posted on November 7, 2011 by admin

Most of the times the welding consultant suggest tensile test and the client wonders about what it exactly is and how it helps. To answer the question and clear the doubts, one has to understand the essence of tensile testing first of all.

Tensile Test Features

Main features of the test are as follows.

  • Tensile test is also known as the tension test;
  • It is most fundamental mechanical test that is performed on any material;
  • They are simple and inexpensive tests; and
  • Such tests are fully standardized.

Application of Force

It is all a matter of applying force on some material and measuring its resistance to such force applied. Reaction of the material to the force applied is called tension and this helps the user to perfectly assess the strength and elongation of the material in question.

Benefits of the Test

Some of the major benefits of the test are as follows.

  • Such test offers a lot of information about the quality and durability of the material in question;
  • Since the test is carried out applying force till the material breaks, a full-fledged tensile profile of the material is created; A display curve will indicate how the force worked on the material and gauging accurately the tensile strength of the material against various pressure points; and
  • The point of failure is the ultimate testing point or UTS on the chart.

Why Consultant Recommendations?

Welding consultants are largely involved with the tensile strength of any material since cutting and welding depends on such strength of the materials. That is why most of the consultants suggest analysis of tensile strength of the material before taking up welding works so that perfect welding can be conducted. Such testing may also be taken up after the welding to judge the UTS of the welding performed so that the user and the engineer would both have fair knowledge about the strength generated in the materials after welding.

Basic Principles of Tensile Tests

Basic principles of the tensile or tension test are Hooke’s Law and the modus of elasticity. According to Hooke’s Law the ration of stress to strain is always a constant and the proportion of the slope to the strain is called the modus of elasticity and also as the “Young’s Modulus”.

Various other methods like determination of yield strength, alternate moduli, offset method, and strain measurement also help determine the strength of the materials and constitute integral parts of advanced tensile test.

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A Guide to Inspection and Testing with Emphasis on Tensile Test and NDT Testing Aspects

Posted on November 2, 2011 by admin

“What many folks overlook in terms of the assurance, the core sectors of mechanical and production engineering provide is that this assurance is not a matter of chance but a result of a very important process: inspection. And inspection is a broader perspective which accommodates aspects like testing, analysis, research or specific aspects like say, a tensile test, material stress analysis etc.”

In a way, the overall inspection process stands on sub aspects and these sub aspects stand on specific tests and trainings. One such important test is the good old tensile test wherein the sample is subjected to tension until failure. The tension or tensile tests are used for the following main purposes:

  • During the selection of a material for any type of application
  • Quality control purposes
  • Understanding the effect of physical stress and forces on a material

In the same way, a tension test provides an estimate on the following properties:

  • Ultimate tensile strength
  • Maximum elongation
  • Yield strength
  • Strain-hardening characteristics
  • Reduction in area
  • Measures like Young’s modulus, Poisson’s ratio etc.

Hence a major part of the importance of tests, analysis and researches is the end result they provide. These results like physical properties ( both in ideal and tension conditions), reaction to forces etc. influence a lot of aspects like the life cycle and working aspects of the product in question. Talking about another important physical test, the NDT (nondestructive testing) is a set of techniques used to evaluate properties of materials without causing any damage to it. Other important tests include failure analysis, material stress tests, and many quality assurance processes catering towards norms, standards and even customer requirements.

When it comes to the capacity of testing and research, it is heavily dependent on quality and experience of the personnel. This in turn depends on training, experience and in a way the related qualification examinations these personnel require. Whether it’s training or solutions, geographical aspects don’t hold much ground, so NDT training in NY can suit the worldwide audience and so on.

As the full scale segment of inspection is not only critical but huge as well, many critical aspects like quality assurance processes, radiation testing, NDT solutions etc. many companies prefer outsourcing their work to commercial testing laboratories.  While choosing a commercial testing laboratory, aspects which need to be given importance include quality of testing services the firm provides, accreditations, experience, company feedback and the availability of white papers related to the tests and trainings.

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Dos for an amateur welder

Posted on October 14, 2011 by admin

Mishapenings frequently take place in welding operations, and in many cases consequences is serious injury to the welder or other personnel working in the instant area. What many welders fail to appreciate is that accidents often  happen  NOT  because  of  a  lack  of protective equipment,   but because   of carelessness,   lack   of knowledge,  and  the maltreatment  of  available  equipment.

You, the welder, should have a methodical data of safety defense relating to the job. But that is not all. You should also consider it a liability to carefully monitor the applicable safety precautions. In welding, being slapdash can cause serious injury not only to you, but to others as well. Bear  in  mind  that  safety  precautions  for  the process  of  welding equipment  vary  significantly because  of  the  different  types  of  equipment  involved. Therefore, only general precautions on operating metal arc-welding equipment are given here. For specific instructions  on  the  operation,  maintenance,  and  care  of individual equipment,  use  the  equipment  manufacturer’s training manual as a guide.

In regard to general precautions as per AWS welder Certification, know your tools and how to operate it. Use only standard welding equipment, and see that it is kept in good, clean condition. One of the better ways to get familiar with your work is to go through NDT Training. Before you start to work, make sure that the welding  machine  frame  is  stuck, that  neither terminal of the welding generator is attached to the frame, and  that  all electrical  connections  are  securely  made. The ground connection must be attached firmly to the work, not merely laid insecurely upon it. Keep  welding  cables  dry  and  free  of  oil or  grease Keep  cables  in  good  condition,  and,  at  all  times,  take suitable steps to protect them from smash up.

If it is essential  to  carry  cables  some  distance  from  the machines,  run  the  cables overhead,  if  possible,  and  use sufficient  underneath  strategy. When you use a moveable machine, take care to see that the primary supply cable is laid disjointedly so that it does not become disheveled with the welding supply cable. Any portable equipment mounted on wheels should be securely blocked to prevent unplanned association during the welding operations. When you stop work for any considerable length of time, be certain to de-energize the gear.  When not in   use,   the   equipment should   be   completely disconnected from the source of power.

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Detect Surface – Breaking Flaws with Penetrant Inspection

Posted on September 15, 2011 by admin

Tensile test is used to perform the quality of material and to measure the suitability of the material for specific applications. Tensile test can measure the resistance of materials to stretching or pulling forces as well. Tests are conducted to determine the tensile strength of materials used in engineering applications and mechanical devices and structures. Tensile test involves application of a controlled force on a sample of the material with a fixed cross section area until the sample changes shapes or breaks. Tensile test is thus used as both quantitative and qualitative method.

To ensure the highest quality and accuracy, it is very essential to ensure quality checks like tensile tests, which also comes handy in developing new compounds and materials.

Penetrant testing is another mode of inspection, which is used on non-porous metal and non-metallic components to trace any leaks and material discontinuities that may not be evident in normal visual inspection. The material surface should be cleaned thoroughly before carrying out penetrant testing. A dye penetrant inspection will enable to find even minute gaps and pores.

Liquid Penetrant Inspection is very effective in detecting flaws that are open to the surface such as fatigue, grinding cracks; bursts and impact fractures. It is a simple, non-destructive method that will not damage the material. Liquid penetrant method is safe to use on a range of surfaces like glass, plastics, ceramics and metals among others. It works by the simple principle that the liquid dye seeps into the pores, forming a surface indication. In cases where dye is not used this surface indication can be observed under special lighting.

The penetrant testing method is effective for detecting surface defects in non-magnetic metals and non-metals. It can also be used to inspect items made from ferromagnetic steels as it is more accurate than that of magnetic particle inspection. Though it is highly superior to visual inspection, there are major draw backs for this method. For instance the penetrant testing can detect only those discontinuities that are open to the surface and is not useful in detecting sub service flaws. Surface roughness and porosity of materials also can interfere with the inspection results, which might lead to inaccurate conclusions.

There are various types of dye penetrant Equipment that varies from simple aerosol cans to fully automatic computer-controlled systems. There are different types of dye penetrants like water soluble and oil base penetrants, each of which may require different cleaning facilities and procedures.

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Welding Consultant Safety Gear and Certification Tests

Posted on September 7, 2011 by admin

The safety gears for welding purposes can be acquired in different sizes and designs. The aim is to provide maximum safety and protection to the welding workers. Choosing welding safety items or equipment should be done with care.

Such safety devices are mainly produced to protect human body from likely perils such as the eyes, head, legs or feet. Welding consultant often get hurt when they work; therefore welding safety gears are a must for them. Welding safety gadgets should necessarily include goggles, head gear, body apparel, gloves and harnesses for 100% safety of the welding consultants.

Most companies who employ welding workers purchase safety equipment in bulk from dealers for discounted prices. One can also browse online sources for similar information about safety gears for welding professionals. Companies often surf online welding equipment dealers to get competitive rates and quality products.

Welding apparels are available in the market in various forms, according to the nature of the welding work. For example; a headgear is used to protect from high flames and heat generated during welding activities. Another is the safety gloves that are made primarily from deerskin, cow-skin or fibre glass.

Most of these welding professionals have to procure a welder certification that certifies their skills and abilities. They have to pass some stringent tests to get the ASME welder certification. Such tests are conducted according to specific codes and as per the American Welding Society (AWS) or the American Society of Mechanical Engineers (ASME) rules regulations.

Welders can procure special certificates for associated professions such as welding instructors, welding inspection experts or welding engineers. Such certificates are also issued by the American Society of Mechanical Engineers for working in plant operation and related factories. Most of the welding certificates expire or have limited time period, and have to be renewed by the welding professionals.

The U.S welding society offers some classic programs like certified welding inspector, Senior welding inspector and certified radiographic interpreter. In United States; such welder qualification tests are conducted by ASME and AWS standards. You can log on to the internet for more exhaustive information on this subject.

Those students who aspire to become welding consultants or inspectors can surf the official website of AWS or ASME and go through the written data. Even those who are searching for cheap welding equipment dealers can find helpful links and web portals.

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Everything That You Need To Know About AWS Welder Certification

Posted on September 1, 2011 by admin

Welding was invented in 1881-1882 by a Russian inventor Bernardos who succeeded in creating an electric arc for the first time. However the process employed was complex and cumbersome that nobody was willing to learn welding. However, today welding courses are offered by schools and colleges to make the students competent enough in welding, which holds immense job potential.

Without welding procedure it would have been rather impossible to build bridges, ships automobiles, power plants and refineries among others. Welding procedure involves joining of metals, materials and thermo plastics. In the earlier days forge was the only process available, later on oxy fuel and resistance were developed. Now there are many latest welding procedures including Mig and tig welding submerged arc and flux core.

Welding has a pivotal role in the construction and manufacturing industry and to meet the heavy demand many new welding tools and technologies are in use these days. There are two main categories of welding, the consumable and non consumable electrode methods.

Shielded metal, gas metal arc welding, flux-cored arc welding and submerged arc are some of the welding techniques under the consumable electrode methods whereas gas tungsten, plasma arc, and electro slag welding fall under the non consumable electrode methods.

Some of the many welder machines available today include mig welder, tig welder, on board welder and reconditioned welder among others.

There are many institutions that offer certificate courses in welding. The AWS welder certification (American Welding Society) is one such coveted degree that will enhance the career prospects of the students. The construction trades welders like pipe fitters, boilermakers etc are required to pass welding certification tests every time they take up a new job. In some cases the welders take the test many times in a year. The AWS certified welder program is designed to eliminate the unnecessary testing system being followed in various industries.

The AWS welder certification is awarded after an auditing process and on site visit if the stipulated criteria are met. Welders who wish to get AWS welder certification can search for accredited test facilities on the AWS website. Once the facility is chosen, the welder can seek an appointment for the welding certification test event.

Welding certification tests are given using a qualified welding procedure. The AWS welder certification is valid for life time provided the welder provides acceptable evidence of welding activity at required intervals. However, the high cost of The AWS welder certification and lack of awareness has not made this program popular as yet.

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What Aspects Should Be Considered to Choose NDT Training?

Posted on August 29, 2011 by admin

Non-destructive Testing (NDT) refers to a set of processes that are employed to evaluate a material or products without causing any damage. This type of evaluation is important for various scientific and industrial applications to prevent serious accidents. From various automobile engine parts to gas turbines, welds, boilers, bridges and submarines can be inspected using this technique. Apart from the right qualification, the testing professionals need to undergo NDT Training to enhance their expertise and skills. Many countries have made it a standard for these professionals to get fully trained in this direction.

Non-destructive testing training is offered by a number of reputed institutes and organizations. Here are some important aspects you must consider while choosing a training course.

Various Options Available

NDT training courses are offered by consultancies who work in close association with the companies that require NDT experts. There are specialized training companies that offer NDT courses to the qualified people. Besides, there are companies that offer third party non-destructive testing services and equipments to various industries. These companies too offer training and certifications to the interested candidates.

Training Specialization

You must consider the fields in which the training provider excels. The content for non-destructive testing courses may differ for various industries like automotive, construction, manufacturing, mining and medical industry. Based on the area you wish to specialize in, you must choose the resource offering the specific training courses.

Course Content

Non-destructive testing makes use of a number of techniques. The most popular of these are electromagnetic testing, infrared and thermal testing, laser testing, radiography testing, ultrasonic testing, chemical analysis and liquid penetration testing. Have a look at the content of the training course and have an idea on the theoretical and practical knowledge that it offers.

Credibility of Training Courses

It is important that you join a training course offered by a credible resource. Learn about the industries and clients to which the training provider has been offering training and services. The training provider must follow the codes and regulations in this direction. For instance, standard welding procedure specification must be followed by the company while providing welding consultation.

You must hire a reputed training resource if you wish your company staff to get trained in non-destructive testing. It is also a good idea to choose a trainer who can visit your premises to train your staff. At the same time, online NDT training too is a popular option, if you wish to take advantage of convenient learning.

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Thank god, X-rays can help in electronic failure analysis

Posted on July 21, 2011 by admin
“With such small and complex integrated circuits, it is difficult to penetrate deeper. There has to be a solution to it to find an answer to all the problems. The solution I am offering is X-ray rays. Do not under-estimate them. They have loads of potential in it to make things move on the right path. Find out all the positives of X-rays and how can they help you in NDT testing.”

Failure analysis is becoming more and more difficult with the advent of Integrated Circuit(IC). These kinds of circuits are used in many smaller components. The smaller it is, the more difficult it is to penetrate deeper for the failure analysis. The graph of density and complexity goes up making it more difficult for the technicians.

No default should be underestimated. Sometimes major defaults come with a solution to it and at other times, even a minor default can take loads of time of the concerned repair men. It may lead to malfunctioning in some cases. In today’s times, it is not easy to find as to what went wrong.

Thankfully, X-rays with the help of penetrant testing can prove to be the rescue in case of electronic failures. While testing, proper imaging is an important component because of its function of underpinning. Take care of the fact that next time you provide samples for testing; they should be as elaborative as they can be.

Always remember that the more the information you provide, the better it is for the technicians with appropriate welder qualification. In addition to that, when you are sending samples comprising of expensive components, do make sure that your piece does not receive any harm.

Let me tell you that techniques like electron microscopes do not take care of this and usually hurt the sample in question. In this particular technique, you need to smooth the surface which damages it. When the analysis or welding happens without any harm, it is known as Non Destructive Testing which can only be performed by the ones having NDT training.

X-rays can do a lot which others cannot. Let us see why and how:

  • X-rays have tiny wavelengths, much smaller than the visible light allowing to seize high resolution pictures
  • Amount of energy carried by X-rays can be varied
  • Penetrating powers of X-rays allows technicians to look at the internal structure
  • Leaving the 2D micrographs, X-rays lead their way to 3D X-rays to get clearer pictures
  • It is possible to mount the concerned and rotate it with the help of the joystick as required
  • You get a better understanding of the structure of the electronic system

Such high resolution rays can help you find out many weaknesses in the electronic system. When you get to know the fault, the solution can be easily find out. Therefore, I grant much more value to finding the fault rather than finding a solution. The latter is the second stage and the former is the first stage. Do what comes first.

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Know-how of Laser Welding

Posted on July 15, 2011 by admin
“Laser welding is the progressive version of the ongoing progressive field of welding. The thin welds are possible only because of this kind of welding. I am giving a short yet comprehensive study of laser welding. It is much better than the classical welding and benefits are enumerated below. Read on to get some knowledge about welding.”

One of the quote-able examples to display the level of progress in science and technology is laser technology. It is nothing but the emission of a stimulated light which produces monochromatic beams with a purpose. Purposes vary from cutting on speed, capacity, enhancing quality and lessening production most. Although it is used in many industries, mostly we are able to spot this kind of technology in fabrication industry. It is seen as being used for slicing different types of metals as well like aluminium, stainless steel, carbon steel and copper alloys. Other cutting processes do exist but the beam light is the most effective of all.

Which particular thing does not have disadvantages? The better question is to ask which one has more advantages than disadvantages. The little ones yet the effective ones are precision, speed and high quality. The negative point is that it uses high amount of voltage and not anyone and everyone can afford it.

The light in question possesses high concentration and can pass through anything. It can produce very high energy in small area. Therefore, the user should be put under strict vigilance and he should be completed the welder qualification before putting hands onto it. Better to control it with the help of mirrors and lenses. Also take into consideration the fact that light travels in a straight line and at very high speed.

What is the operational basis of cutting edge laser technology? It lies in the emission generated between light and the metal in question and the latter produces force radiation. When we follow this welding procedure, you will realise that it is a deep weld penetration and it uses minimal level of heat inputs. One big difference between classical welding and laser welding is that of energy transfer. Two points enhance the efficiency of the latter. They are:

  • Heat ratio required by the work piece
  • Melting power in fusion area
  • No dependence on AC, DC outputs
  • Conductive property of material does not make a difference

The resultant welding joint has superior resistant properties. With laser technology, the melting is instant although the heating can affect the operational area. If we apply the correct lenses and mirror, the streak of light can concentrate on spots smaller than 0.005.

The narrow welds made possible by laser technology are used in host of industries like medical research, military and defence, electronics, aerospace and instrumentation.

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