Visual Inspection and Basics - Module 1

Question 1

To conduct an inspection there are 5 different steps:

Answer 1

1. Prepare for inspection
2. Conduct inspection
3. Determine the significance of indications
4. Communicate or report the findings of the inspection
5. Close out the job

Question 2

1. Prepare for inspection

Answer 2

• Discover what needs to be inspected
• Understand why it needs to be inspected
• Learn what you are looking for during the inspection
• Ensure the areas to be inspected are clean and accessible
• Be sure the correct documentation and contract requirements are in place
• Identify the equipment that well be used to perform the inspection
• Organize the work flow for efficiency and reliability

Question 3

2. Conduct inspection

Answer 3

• Set up equipment as required
• Perform the inspection
• Identify indications

Question 4

3. Determine the significance of indications

Answer 4

• Determine the nature of the indication
• Measure indications as necessary
• Accept or reject the indications using a specification

Question 5

4. Communicate or report the findings of the inspection

Answer 5

• Create written reports

* Create images if necessary

Question 6

5. Close out the job

Answer 6

• Clean up as required

* Confirm inspection equipment is in good order at the end of the inspection

Question 7

Work Scope (def)…

Answer 7

generally refers to what we are going to inspect and, at times, it can also mean the how.

Question 8

This step is often critical to finding defects….

Answer 8

Cleaning and Surface Preparation

Question 9

Contamination that affects inspection includes:

Answer 9

• Dust and dirt
• Grease and oils
• Buildups left behind from liquids, gases etc., coming in contact with the inspection areas
• Corrosion by-products like rust and oxides
• Scaling from the manufacturing process
• Paint that covers the inspection area
• Plating and cladding

Question 10

Who’s job is it to clean the piece before inspection?

Answer 10

Might be the inspector, might not be…

Question 11

When performing or specifying a cleaning operation(s), consider the following two questions:

Answer 11

1. Will the cleaning methods remove the contaminates that would otherwise compromise the inspection?
2. Will the cleaning methods harm the part or affect its serviceability?

Question 12

What should you use to clean dust, dirt, clay, soils and other organic contaminents?

Answer 12

• Water
• Water and soap
• Pressure washers or sprayers

Question 13

What should you use to clean oils and grease?

Answer 13

• Solvents – usually used in liquid form (in rare cases, vapours may be used) such as Varsol or brake cleaner, lacquer thinners or similar chemicals
• Soap and water
• Steam
• Acids for pickling (sometimes called etching)

Question 14

The risk in using chemicals lies in that the chemicals may also have undesirable reactions with the underlying structural material…

Answer 14

• Halogenated and chlorinated cleaners can cause cracking in metals containing nickel. Stainless steel, Inconel, Monel, and Hastalloy are examples of alloys containing nickel. These types of cleaners can also affect titanium alloys.
• Phosphates and alkaline cleaners can cause corrosion in aluminium alloys, especially at elevated temperatures.
• Acids can cause unwanted corrosion if the directions for their use are not followed; they can also cause hydrogen cracking.

Question 15

Some things may not be removable with chemicals…

Answer 15

• Scale and oxides from the manufacturing process
• Residues from the products in contact with the materials being inspected
• Corrosion by-products

Question 16

What can be used for buildup that cannot be removed with chemicals?

Answer 16

Abrasives!
• Sanding
• Wire brushes, hand and power
• Scrapers
• Grinding and filing
• Blasting operations like sand, grit, glass bead, plastic media, crushed walnut shell,
baking soda etc.

Question 17

Other resources to use when choosing a cleaning method:

Answer 17

• Codes or specifications
• Contracts and related summaries like job sheets or purchase orders
• Conversations with clients, supervisors
• Industry best practices or standards

Question 18

Surface Condition

Considered important because?

Answer 18

generally describes the roughness (or smoothness) of a surface. Considered important in visual inspections because the wrong surface condition can reduce the visual difference between the part and the defect in the part.

Question 19

Three critical steps to correctly performing an inspection as they give us the best chance of finding defects:

Answer 19

Prepare by identifying and understanding the work scope

Identify resources that can be used during the inspection

Prepare the surface