Fundamentals of Non-Destructive Testing (NDT) - 5 Days Comprehensive Training Course

Course Overview

This intensive 5-day NDT fundamentals training program provides comprehensive knowledge of non-destructive testing methods, industry standards, and practical applications. Aligned with ASNT SNT-TC-1A and ISO 9712 certification requirements, this course prepares participants for NDT Level I and Level II certification pathways.

Target Audience: Quality control inspectors, maintenance engineers, welding inspectors, manufacturing technicians, safety professionals, and anyone seeking NDT certification.

DAY 1: Introduction to NDT & Visual Testing (VT)

Morning Session (8:00 AM - 12:00 PM)

Module 1.1: NDT Fundamentals & Industry Overview

• What is Non-Destructive Testing (NDT)?

• History and evolution of NDT methods

• Importance of NDT in modern industries

• NDT vs. Destructive Testing: Key differences

• Applications across industries (aerospace, automotive, oil & gas, construction, manufacturing)

• Economic benefits and safety implications

• Career pathways in NDT inspection

Module 1.2: NDT Certification Standards

• ASNT (American Society for Nondestructive Testing) standards

• SNT-TC-1A personnel qualification guidelines

• ISO 9712 international certification requirements

• ASNT CP-105 topical outlines

• NAS 410 aerospace certification

• Level I, II, and III technician responsibilities

• Training hour requirements and examination processes

Afternoon Session (1:00 PM - 5:00 PM)

Module 1.3: Visual Testing (VT) Methods

• Principles of visual inspection

• Direct vs. remote visual testing

• Optical physics and light principles

• Visual acuity and eye physiology

• Common discontinuities and defects

• Surface preparation requirements

Module 1.4: VT Equipment & Techniques

• Magnifying glasses and borescopes

• Video inspection systems

• Fiberscopes and endoscopes

• Illumination requirements (lux levels)

• Measurement tools (scales, gauges, templates)

• Documentation and reporting procedures

Module 1.5: Hands-On VT Practice

• Weld inspection exercises

• Corrosion detection practice

• Crack identification techniques

• Report writing workshop

DAY 2: Liquid Penetrant Testing (PT) & Magnetic Particle Testing (MT)

Morning Session (8:00 AM - 12:00 PM)

Module 2.1: Liquid Penetrant Testing Fundamentals

• PT principles and physical properties

• Types of penetrants (visible dye vs. fluorescent)

• Capillary action and surface tension

• Penetrant sensitivity levels

• Application methods (spray, brush, dip)

• Processing steps: clean, penetrate, remove, develop, inspect

Module 2.2: PT Materials & Procedures

• Penetrant systems (Type I, Type II)

• Developer types (dry, water-soluble, non-aqueous)

• Emulsifiers and removers

• Temperature considerations

• Dwell time requirements

• Safety and environmental considerations

• Standards: ASTM E1417, ISO 3452

Module 2.3: Hands-On PT Laboratory

• Surface preparation exercises

• Penetrant application techniques

• Development process practice

• Defect interpretation

• Documentation procedures

Afternoon Session (1:00 PM - 5:00 PM)

Module 2.4: Magnetic Particle Testing Principles

• Fundamentals of magnetism

• Ferromagnetic materials

• Magnetic field orientation

• Continuous vs. residual magnetization

• Circular and longitudinal magnetization

• Demagnetization procedures

Module 2.5: MT Equipment & Applications

• Electromagnetic yokes

• Prods and coils

• Permanent magnets

• Wet vs. dry particle methods

• Fluorescent vs. visible particles

• Field strength measurements

• Standards: ASTM E1444, ISO 9934

Module 2.6: MT Practical Training

• Equipment setup and calibration

• Magnetization techniques

• Particle application methods

• Indication interpretation

• False vs. relevant indications

DAY 3: Ultrasonic Testing (UT) Fundamentals

Morning Session (8:00 AM - 12:00 PM)

Module 3.1: Ultrasonic Theory & Wave Propagation

• Sound wave physics and acoustics

• Frequency, wavelength, and velocity

• Wave modes (longitudinal, shear, surface, lamb)

• Reflection, refraction, and mode conversion

• Snell’s law and critical angles

• Attenuation and scattering

• Near field vs. far field

Module 3.2: UT Equipment & Transducers

• Pulse-echo principles

• Flaw detectors and display modes (A-scan, B-scan, C-scan)

• Transducer types (normal beam, angle beam, dual element)

• Piezoelectric crystals

• Couplants and their selection

• Calibration blocks and reference standards

• Equipment calibration procedures

Module 3.3: UT Techniques & Applications

• Contact testing methods

• Immersion testing

• Time-corrected gain (TCG)

• Distance-amplitude correction (DAC)

• Thickness measurement

• Weld inspection techniques

• Corrosion mapping

Afternoon Session (1:00 PM - 5:00 PM)

Module 3.4: Phased Array Ultrasonic Testing (PAUT)

• Introduction to phased array technology

• Electronic beam steering and focusing

• S-scan (sectorial scan) imaging

• Encoder systems for automated scanning

• Advantages over conventional UT

• Aerospace and pipeline applications

Module 3.5: UT Standards & Procedures

• ASTM E114, E164, E317, E587

• AWS D1.1 welding code requirements

• ASME Section V requirements

• Acceptance criteria and reporting

Module 3.6: Hands-On UT Training

• Equipment setup and calibration exercises

• Thickness measurement practice

• Flaw detection in test blocks

• Angle beam weld inspection

• Data interpretation and reporting

DAY 4: Radiographic Testing (RT) & Electromagnetic Methods

Morning Session (8:00 AM - 12:00 PM)

Module 4.1: Radiographic Testing Principles

• X-ray and gamma-ray generation

• Radiation physics and interactions

• Penetrating power and energy levels

• Image formation fundamentals

• Radiographic sensitivity and contrast

• Geometric unsharpness

• Film vs. digital radiography

Module 4.2: RT Equipment & Techniques

• X-ray machines and gamma sources (Ir-192, Co-60)

• Film types and processing

• Computed radiography (CR)

• Digital radiography (DR)

• Image quality indicators (IQI/penetrameters)

• Exposure calculations

• Single-wall vs. double-wall techniques

Module 4.3: Radiation Safety

• Ionizing radiation hazards

• ALARA principles (As Low As Reasonably Achievable)

• Shielding requirements

• Controlled areas and barriers

• Personal protective equipment

• Dosimetry and monitoring

• Regulatory requirements (NRC, OSHA, DOT)

• Emergency procedures

Afternoon Session (1:00 PM - 5:00 PM)

Module 4.4: Film Interpretation & Standards

• Radiographic film reading techniques

• Discontinuity identification (porosity, cracks, inclusions, lack of fusion)

• Acceptance criteria per codes

• ASTM E94, E142, E1025, E1742

• ASME Section V Article 2

• AWS D1.1 radiographic requirements

Module 4.5: Electromagnetic Testing Methods

• Eddy current testing (ET) principles

• Impedance analysis

• Frequency effects and penetration depth

• Probe types (absolute, differential, encircling)

• Applications: conductivity measurement, crack detection, coating thickness

• Magnetic flux leakage (MFL) testing

• Remote field testing (RFT) for tubes

Module 4.6: ET/MFL Practical Demonstrations

• Eddy current equipment demonstration

• Tube inspection exercises

• Conductivity sorting practice

• Coating thickness measurements

DAY 5: Advanced NDT Methods, Quality Systems & Practical Assessment

Morning Session (8:00 AM - 12:00 PM)

Module 5.1: Acoustic Emission Testing (AE)

• AE principles and wave propagation

• Sensor technology and signal processing

• Source location techniques

• Applications: pressure vessel monitoring, leak detection

• Advantages and limitations

Module 5.2: Thermographic (Infrared) Testing

• Infrared radiation principles

• Active vs. passive thermography

• IR camera technology

• Temperature measurement and thermal imaging

• Applications: electrical inspection, building diagnostics, composite testing

Module 5.3: Other NDT Methods

• Leak testing methods (bubble, pressure change, tracer gas)

• Vibration analysis and resonance testing

• Microwave and terahertz testing

• Laser testing techniques

• Ground penetrating radar (GPR)

Module 5.4: NDT in Industry 4.0

• Digital transformation in NDT

• Automated inspection systems

• Artificial intelligence and machine learning applications

• Remote and robotic inspection

• Data analytics and predictive maintenance

• Cloud-based reporting systems

Afternoon Session (1:00 PM - 5:00 PM)

Module 5.5: Quality Management & Procedures

• Written practice development per SNT-TC-1A

• Procedure writing and approval

• Calibration programs

• Documentation and record keeping

• Quality control and quality assurance

• Auditing and compliance

• ISO 9001 integration with NDT programs

Module 5.6: Ethics, Responsibilities & Safety

• Code of ethics for NDT professionals

• Legal responsibilities and liability

• Reporting obligations

• Conflict resolution

• Workplace safety culture

• Environmental considerations

Module 5.7: Comprehensive Practical Assessment

• Multi-method practical examination

• Real-world scenario problem-solving

• Equipment selection exercises

• Procedure development workshop

• Inspection report writing

Module 5.8: Course Review & Certification Preparation

• Review of key concepts from all modules

• Q&A session

• Certification pathway guidance

• Next steps for Level I and Level II certification

• Study resources and continuing education

• Course evaluation and certificates of completion

Course Delivery Methods

Training Format:

• Instructor-led classroom lectures with multimedia presentations

• Hands-on laboratory exercises with industry-standard equipment

• Live demonstrations of all major NDT methods

• Case study analysis from real-world applications

• Interactive discussions and problem-solving sessions

• Written and practical assessments throughout the course

Equipment & Materials Provided:

• Complete NDT equipment sets for all methods

• Calibration standards and reference blocks

• Test specimens with known defects

• Safety equipment and PPE

• Course manuals and reference materials

• Digital learning resources and videos

Learning Outcomes

Upon successful completion of this 5-day course, participants will be able to:

✅ Understand fundamental principles of all major NDT methods
✅ Select appropriate NDT techniques for specific applications
✅ Operate basic NDT equipment safely and effectively
✅ Interpret test results and identify discontinuities
✅ Comply with industry standards (ASNT, ASTM, ISO, ASME)
✅ Write technical inspection reports
✅ Prepare for NDT Level I and Level II certification exams
✅ Apply quality management principles to NDT programs
✅ Understand radiation safety and regulatory requirements
✅ Implement best practices in industrial inspection programs

Prerequisites

• Basic understanding of manufacturing processes (recommended)

• High school diploma or equivalent

• No prior NDT experience required

• Physical ability to perform inspection tasks

• Normal color vision and visual acuity

Certification Pathways After This Course

This fundamentals course prepares participants for:

1. ASNT NDT Level I Certification (method-specific)

2. ASNT NDT Level II Certification (with additional training and OJT hours)

3. ASNT CP-189 (Central Certification Program)

4. ISO 9712 Level 1 and Level 2 certification

5. AWS CWI Certified Welding Inspector (supplemental knowledge)

Industries Benefiting from NDT Training

• ✈️ Aerospace & Aviation - Aircraft inspection and maintenance

• 🏭 Manufacturing - Quality control and production testing

• ⚡ Power Generation - Nuclear, thermal, and renewable energy facilities

• 🛢️ Oil & Gas - Pipeline, refinery, and offshore platform inspection

• 🚢 Maritime - Ship hull and component testing

• 🏗️ Construction - Structural integrity and weld inspection

• 🚗 Automotive - Component testing and failure analysis

• 🚆 Railway - Track, wheel, and structural inspection

• 🏥 Medical Devices - Quality assurance testing

• 🎯 Defense & Military - Critical component inspection

Course Information

Duration: 5 days (40 hours total)
Schedule: 8:00 AM - 5:00 PM daily (includes breaks and lunch)
Class Size: Limited to 12-16 participants for optimal hands-on training
Language: English (other languages available upon request)
Certificate: Course completion certificate issued to all participants