Destructive vs Non-Destructive Testing | Complete Guide (2023)

Non-Destructive Testing December 2021

Destructive Vs Non-Destructive Testing: A Guide

Destructive vs Non-Destructive Testing | Complete Guide (1)

Component testing is a valuable part of the product production process. Whether you work in the automotive, fabrication or occupational health and safety field, extensive testing is necessary to verify that your machines and materials have the strength and durability needed to uphold asset longevity and reliability for years to come.

Destructive testing is a type of evaluation that determines how a component will behave under pressure until it fails. Non-destructive testing also assesses an object’s behavior but does so without permanently damaging it. While both methods deliver valuable information, non-destructive tests are emerging as a more efficient means of analyzing materials.

What Is Destructive Testing?

Destructive testing is a test method used tounderstand the performance or behaviorof a machine, component or material by determining its exact point of failure. Through this process, the specimen in question undergoes continuous stresses until it eventually fails, either by material deformation or destruction. The destructive testing process can either follow specific procedures or be geared to generate particular service conditions.

Destructive tests often detect failures using high-speed cameras that record continuously until they identify the malfunction. Sound detectors or stress gauges transmit a signal to set the camera into motion. After the failure, the camera will stop recording, and you can review the images in slow motion to determine what happened before, during and after the destructive event.

In most cases, destructive testing methods test components before mass production begins. Destructive tests give original equipment manufacturers (OEMs) an idea of their products’ limits to administer the necessary machine maintenance and operating recommendations.

Because destructive tests result in irreversible damage, the tested item and its parts cannot be reused in regular operation after enduring destructive testing. Though these items become damaged through destructive testing without the chance of recovery, this method still has legitimate use cases.

Machines have physical and chemical properties that aren’t appropriate for all working conditions. For example, metals that are prone to corrosion are not well-suited for use in humid environments. Destructive testing points out these incompatibilities and potential drawbacks to prevent them from failing for end users. In some industries, this test method is a regulatory requirement.

(Video) [English] Non Destructive Testing (NDT)

Types of Destructive Testing

There are various destructive testing methods that organizations use to evaluate material quality and performance. Each destructive testing procedure has specific case uses and follows particular standards and practices.

Though there are several types of destructive testing, the following tests are some of the most commonly used.

Corrosion Testing

Corrosion testing is used to evaluate the effectiveness of corrosion-resistance measures to prevent metal components from rusting, tarnishing and pitting in diverse environments, including freshwater and seawater settings. According to the American Society for Testing and Materials (ASTM), destructive corrosion testsexamine a material’s susceptibility, behavior and extent of resistance to various types of corrosion.

Fracture and Mechanical Testing

Fracture testing refers to measures of resistance to the extension of a crack. Fracture mechanical testing methods examine the effects of flaws on a material’s load-bearing capacity and toughness.

Fracture and mechanical testing methods include various destructive tests, including:

  • Tension tests
  • Charpy impact tests
  • Peel tests
  • Crush testing
  • Bend tests
  • Pellini drop weight testing
  • Pressure testing
  • Fracture testing

These types of destructive testing are used under different temperatures and strain rates to evaluate fracture toughness, static behavior, strength and cyclic behavior in pressure performance, creep and seawater environments. The results of these destructive tests can help assess and validate material integrity.

Aggressive Environmental Testing

This destructive test type uses fracture and fatigue testing to measure a machine’s effectiveness in corrosive environments, such as sour and sweet conditions, under various pressures and temperatures. Through aggressive environmental testing, users test materials based on the characteristics of their intended operating settings.

For example, when testing building materials for a beach house, you’d use aggressive environmental testing to ensure that it could withstand the humidity, high winds and salinity typical of coastal areas.

Fatigue Testing

Fatigue testing is a type of mechanical destructive test used to generate data on crack growth and fatigue life, identify areas susceptible to fatigue, or demonstrate structural safety. These evaluations determine a welded joint’s ability to endure cyclic fatigue loading conditions in either air or seawater environments.

Fatigue testing is often used on components for full-size test articles like aircraft and automobiles. It’s also used for fatigue crack growth testing on base metals, heat-affected zones and welds.

(Video) [English] Difference between Destructive Test (DT) and Non Destructive Test (NDT)

Residual Stress Measurement

Destructive vs Non-Destructive Testing | Complete Guide (2)

Residual stress isstress distribution present in a component, structure, sheet or plate without the application of an external load. These stresses can lead to plastic deformation, warping, fracturing, fatigue and distortion.

Residual stress measurement determines whether a material can withstand extreme load conditions throughout its intended service life. These destructive tests allow engineers and designers to assess crucial component flaws and generate critical assessments.

Tensile Testing

Tensile testing, also known as elongation testing, is the process of applying controlled forces to a test material until it fails. Through this destructive testing method, the specimen is elongated or compressed based on the applicable measurement characteristics to determine the material’s strength. With these results, you can discover which materials will perform well under excessive amounts of force.

Properties you can assess through tensile testing include breaking strength, reduction, ultimate tensile strength and maximum elongation.

Destructive Testing Applications

Destructive testing methods have long been a reliable source for testing specimen failure. Numerous industries utilize the destructive testing of materials in all of the following applications:

  • Earthquake testing:Destructive tests can evaluate how large structures like buildings will perform during earthquake events. These evaluations often take place on a shake table, which produces similar movement as an earthquake.
  • Software testing:You can use destructing testing to test a software’s robustness and stability. By causing the software to fail, you can establish range limits accordingly to ensure reliable operation.
  • Automotive testing:Crash tests are a type of destructive testing designed to ensure safe vehicle design standards, such as crash compatibility and crashworthiness, by subjecting an automobile to crash conditions.
  • Aircraft testing:It is standard to use destructive testing to evaluate passenger and military aircraft production models by loading components until they fail.
  • Fabrication validation:Manufacturing validation is the process of ensuring thata product will satisfy certain criteriabased on its service conditions and time between failures.
  • Materials characterization:Destructive testing methods help measure a material’s properties and structure in the materials science field. They give valuable insights into why certain substances exhibit different behaviors and characteristics.
  • Failure investigation:Failure investigation through destructive testing is used to improve asset performance by identifying the causes of failures and understanding the primary elements of these failures.
  • Safety equipment evaluation:Destructive testing is used in the occupational health and safety industry to confirm the protective capacities of safety equipment under physically demanding conditions. For example, certain personal protective equipment (PPE) requires certification under International Electrotechnical Commission (IEC) and ASTM standards, which use destructive test methods.
  • Hazard identification and safety assurance:Some projects require destructive testing to ensure that workplace structures and machinery will not fail and pose safety hazards when used within their limits.

Drawbacks of Destructive Testing

Destructive vs Non-Destructive Testing | Complete Guide (3)

Though destructive testing is known for its reliability and accuracy, it also has its downsides. If your company is considering performing destructive tests to evaluate your materials, machines or components, you should first understand the drawbacks of doing so.

Resource Waste

When using destructive testing to discover a material’s performance flaws, you must destroy every item you test— that means you may demolish a machine’s vital components or its entire infrastructure. Because destructive tests deem products unsalvagable after testing, you cannot use them again in the future. While some view these losses as necessary, others see them as unnecessary material waste.

High Expenses

Because destructive tests completely destroy test specimens, they result in significant expenses for the companies conducting them. These businesses lose money from material costs and must forfeit more funds to replace them. These expenses can be particularly severe when testing larger infrastructures that cost upwards of millions of dollars.

(Video) Destructive and Non Destructive Testing of Materials - NDT vs DT

Due to its weighty costs, destructive testing is only suitable for companies with plentiful materials that can afford to waste and replace resources.

Time Requirements

Destructive material testing is a time-consuming process compared to other testing methods. Because these types of tests involve manual processes, they’re not as efficient as automated methods. Destructive tests also require extensive prep and prolonged inspection times. Companies must also shut down job site operations to administer testing, leading to increased downtime.

Distance Limitations

When conducting destructive tests, inspectors must interact directly with the test specimens. Due to these hands-on procedures, you cannot use destructive methods to detect machine flaws across long distances as you could with other test types.

What Is Non-Destructive Testing?

Non-destructive testing (NDT) is a set of examination methods that enable inspectors to collect data and evaluate systems, materials or components without causing permanent damage. Like destructive testing, non-destructive tests are also used to pinpoint a test item’s defects.

Non-destructive testing is an umbrella term that encompasses many testing methods. Some of theprimary non-destructive testing techniquesinclude:

  • Acoustic emission testing:This tactic detects short bursts of ultrasound discharged from active cracks beneath a load and evaluates their arrival time, intensity and location to identify potential problems.
  • Visual testing:Through visual testing, inspectors gather visual data regarding a material’s status either by looking at the test specimen or using remote visual inspection devices for more in-depth results.
  • Magnetic particle testing:Non-destructive magnetic particle testing involves identifying material flaws by observing disruptions in magnetic field flow. Through this method, inspectors induce a magnetic field in the asset and position iron particles over its surface to reveal visual defects.
  • Ultrasonic testing:Inspectors transmit high-frequency waves to a material to evaluate property changes and spot surface imperfections.
  • Radiography testing:This technique uses X- or gamma-radiation to pinpoint flaws by sending radiation into an asset and observing results on a shadowgraph.
  • Leak testing:If a vessel leaks, you can use leak testing to determine where the defects lie.
  • Liquid penetrant testing:Liquid penetrant testing uses a dye to visually reveal any issues and a fluorescent light to further examine them.
  • Eddy current testing:This electromagnetic testing method is used to measure a material’s magnetic field for the strength of eddy, or electrical, currents to locate defects.

Non-destructive testing methods are increasing in popularity and are used in all of the following industries:

  • Medicine
  • Art
  • Oil and gas
  • Electrical engineering
  • Aerospace
  • Chemicals
  • Petroleum
  • Forensics
  • Power generation
  • Mining
  • Automotive
  • Maritime
  • Mechanical engineering
  • Construction

Advantages of Non-Destructive Testing

Destructive vs Non-Destructive Testing | Complete Guide (4)

Non-destructive tests are the ideal methods for testing assets across practically every industry. This technique comes with many advantages that you can’t find with destructive testing.

If you’re debating whether to conduct non-destructive or destructive tests for your company, consider the many benefits of NDT.

Reduced Material Waste

Perhaps the greatest benefit of non-destructive testing is that this process leaves the test sample completely functional while still providing useful insights. That means less wasted resources. Unlike destructive testing, you don’t have to dispose of your materials after testing them. This factor is particularly beneficial for companies testing expensive or limited materials, as they won’t suffer any considerable losses.

(Video) Destructive VS Non Destructive Testing. What is Material Testing?

Cost Efficiency

Because non-destructive testing preserves test specimens, it results in significant cost savings. With these test methods, you can save money on materials and replacement costs instead of enduring losses through destructive tests.

Using non-destructive testing to identify potential machine problems before malfunctions occur will also save you money by preventing costly equipment repairs and replacements in the future.

Minimal Downtime

Non-destructive processes are highly efficient and take considerably less time to perform than destructive testing. That’s because, with NDT, there’s no need to break down materials for testing purposes or perform repeated manual tests.

You can also test materials while they’re still in use, meaning you won’t have to cease operations during testing, minimizing downtime.

Increased Safety

Non-destructive testing helps companies identify potential issues and determine whether components require improvements or repairs. These tests ensure that machines operate safely, preventing accidents on the job site. When your systems function as they should, you maintain a safe and secure work environment.

Reliable Results

Non-destructive tests detect material defects with high accuracy, producing reliable results. Using these outcomes, you can gain valuable insights regarding product performance and behavior and make adjustments as needed. With more reliable testing and modification comes better product manufacturing.

Choose Fujifilm for Your NDT Needs

You can experience superior non-destructive testing imaging quality through state-of-the-art solutions fromFUJIFILM North America Corporation.Our NDT equipment, including film, digital detector arrays (DDTs) and computed radiology (CR) solutions, produce clear images that you can easily view on our innovative software. We’re proud to provide top-quality products and services that helpto advance the consumer,healthcareandbusiness industrieswhile delivering improved health and environmental protection.

When you choose Fujifilm as your go-to NDT imaging solutions provider, you’ll reduce inspection downtime and unnecessary material waste while improving the performance and quality of products. We also offer training programs so your team can learn how to meet the applicable industry requirements.

Contact us to inquireabout our non-destructive testing solutions today!

(Video) What is Destructive Testing (DT) | Methods of Destructive Testing


What is the difference between destructive and non-destructive testing? ›

The difference between destructive and non destructive testing. Destructive testing is conducted by damaging the specimen that is being tested. In contrast, during non-destructive testing (NDT), the tested item does not suffer any physical damage and can be used in active operation after the testing.

Which is a non destructive test answer? ›

Electromagnetic Testing (ET), Magnetic Particle Testing (MT), Liquid Penetrant Testing (PT), Visual Testing (VT), are the six most frequently used non-destructive tests.

Why NDT is considered better than destructive testing? ›

However, nondestructive testing (NDT) retains a significant advantage over destructive testing because it covers more ground and saves on material costs. With NDT, analysts can avoid damaging assets and find more flaws in the process.

What are 3 basic types of destructive testing? ›

Fracture and Mechanical Testing

This includes different types of destructive testing methods such as tension tests, bend tests, Charpy impact tests, Pellini drop weight testing, peel tests, crush testing, pressure and fracture testing.

Why is NDT test important? ›

The purpose of NDT is to inspect a component in a safe, reliable, and cost effective manner without causing damage to the equipment or shutting down plant operations. This is in contrast to destructive testing where the part being tested is damaged or destroyed during the inspection process.

How many types of NDT test are there? ›

Many different NDT methods are available in the industry, each of them having their own advantages and limitations, but six of them are most frequently used: ultrasonic testing (UT), radiographic testing (RT), electromagnetic testing (ET), magnetic particle testing (MT), liquid penetrant testing (PT) and visual testing ...

What is an example of a destructive test? ›

Destructive Testing Examples

Perhaps one of the most common examples of destructive physical analysis is crash simulations. Automakers and aerospace industries alike will use destructive testing to test the limits and ability of their safety equipment to function when other components fail.

What is NDT testing explain in brief? ›

Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials, components or 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.

Which is the most common method of non-destructive testing? ›

NDT refers to an array of inspection techniques that allow inspectors to collect data about a material without damaging it.
The most common welding NDT methods include:
  • Ultrasonic testing NDT.
  • Magnetic particle inspection NDT.
  • Acoustic emission NDT.
  • Dye penetrant NDT.
  • Radiography NDT.
  • Eddy Current NDT.

How NDT is useful for quality control? ›

Non-destructive testing is a crucial aspect of quality control, helping to ensure that components are manufactured to the correct standards and specifications. NDT is used across many industries, including aerospace, oil and gas, nuclear, power generation, medical, rail and general manufacturing.

How accurate is NDT? ›

Non-destructive testing is also a very accurate way of inspection since the tests are repeatable and a number of tests can be used together to correlate results.

What equipment is used for NDT? ›

NDT equipment includes a wide variety of instruments and systems. Examples include thickness gauges, flaw detectors, material condition testers, and eddy current instruments, as well as devices that measure conductivity, resistivity and corrosion.

Which test is called destructive test? ›

In destructive testing (or destructive physical analysis, DPA) tests are carried out to the specimen's failure, in order to understand a specimen's performance or material behavior under different loads.

Where is non destructive testing used? ›

Welding. NDT techniques can identify the various defects that occur during the welding process. We have enumerated many welding defects in the previous sections that we can reliably test through NDT. As a quick recap, we can use NDT inspections to identify both external and internal welding defects.

Which NDT is suitable for internal defects? ›

Radiography (X-ray) test: In this test internal photographs of the welds are taken. The test specimen is placed between the X-ray unit and film. Then the X-ray is passed. If there is any hidden defect, that will be seen in the film after developing it.

Which NDT makes defects easier? ›


Measures or detects surface and qualified subsurface defects, cracks, seams, porosity, inclusions, and very sensitive for locating small tight cracks.

Does NDT expire? ›

Renewal of your NDT certification is a process that extends the period of its validity. You can renew your NDT certification shortly prior to its expiry. Renewals are valid for a period of up to five years (60 months or less).

Which type of hammer is used in NDT? ›

UTC-3030 Concrete Test Hammer is used for the non-destructive testing of the surface of hardened concrete in order to evaluate the strength in various parts of a structure. The concrete hammer is supplied complete with plastic carrying case, grinding stone and instruction manual.

What are 3 parts of a weld? ›

Every welding process has the following three basic elements: Heat source. Filler metal. Shielding gas or flux.

How do you calculate weld size? ›

Calculate the weld size, s, at each node on the intersecting edge of the terminated part:
  1. SS or DS groove welds: s = t. w
  2. SS or DS 45 ° fillet welds: s = sqrt(2) × t. w

What is 2F and 3G means? ›

A number is used to define the position, and an F for Fillet or G for groove refers to the type of weld. An architect's blueprints would indicate the welding symbol. 1 refers to a flat position – either 1F or 1G. 2 refers to a horizontal position – either 2F or 2G. 3 is a vertical position – either 3F or 3G.

What is DT analysis? ›

Destructive testing (DT) is a form of object analysis that involves applying a test to break down a particular material to determine its physical properties, such as the mechanical properties of strength, toughness, flexibility, and hardness.

Is hardness a destructive test? ›

Hardness testing is a non-destructive test method that involves applying a constant load via a rounded or pointed object, under controlled conditions, to create an indentation in a metal surface. This is then measured to determine the hardness of the material.

What are the different destructive and non destructive tests of concrete? ›

In this context, the crushing of the samples is the usual destructive test to determine the concrete strength. The rebound hammer test and the ultrasonic device are used in the field of non-destructive tests to determine respectively the compression strength and the ultrasonic pulse velocity (UPV) in the concrete.

What is a destructive testing method? ›

Destructive testing (DT) is a form of object analysis that involves applying a test to break down a particular material to determine its physical properties, such as the mechanical properties of strength, toughness, flexibility, and hardness.

What is a destructive test in forensics? ›

The destructive tests of materials are tests included within the branch of forensic engineering that are applied to different compounds to determine what their physical, chemical and mechanical properties are. The objective is to verify if they meet the necessary quality standards to guarantee their reliability.

Why is NDT used for concrete? ›

Non-destructive testing methods are used to evaluate concrete properties by assessing the strength and other properties such as corrosion of reinforcement, permeability, cracking, and void structure. This type of testing is important for the evaluation of both new and old structures.

How many types of NDT tests are there? ›

In this blog, we'll discuss four main types of NDT/NDE – Liquid Penetrant Inspection, Magnetic Particle Testing, Radiographic Testing and Ultrasonic Testing.

What is the most common non-destructive test? ›

Ultrasonic testing remains the most popular nondestructive testing method after visual testing. In this method, a high-frequency sound wave generated by a transmitter travels through the object under test. The frequency of this wave is usually between 1 and 10 MHz.

Where is destructive testing used? ›

The destructive testing method is used to find mechanical properties of materials such as tensile strength, yield strength, hardness, impact toughness, elongation, etc. The method determines the point of failure of the material.

What is the most destructive test? ›

The most popular destructive test is the Sand Cone Test (ASTM D-1556-1556M).


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