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Penetrant Testing and the CWI

BY LYNDSEY DECKARD
The requirement for ASNT TC1-A certification of the NDT technician in order for that person to perform official penetrant testing (PT) for most clients is well known. The role of the CWI or SCWI is sometimes not quite so clearly understood. While the AWS CWI certification does not qualify a person to perform any NDE methods other than visual (VT), it does require the CWI to verify that the NDE was performed by qualified personnel in the specified manner. Performance of this duty requires familiarity with the popular NDE methods, their capabilities, advantages, and limitations. On pages 252 and 253, AWS CM, Certification Manual for Welding Inspectors, fourth edition, addresses the subject of penetrant testing. The following is an excerpt from the manual. Fig. 1 Developer interpretation. This method employs a penetrating liquid that is applied to the surface to be examined and which enters the discontinuity. The excess penetrant is then cleaned from the surface. Any penetrant that subsequently exudes from openings and causes discoloration of developer powder on the surface indicates the location of a discontinuity Fig. 1. There are two general classifications of penetrants: visible dye and fluorescent. They differ in that the visible dye can be observed under normal white light, while the fluorescent type requires an ultraviolet (or black) light to produce an indication. There are several methods for effective application of penetrants, such as dipping, brushing, flooding, or spraying. Use of fluorescent penetrants results in a more sensitive test, because the eyes can more readily detect a fluorescent indication. Consequently, for critical applications where minute discontinuities must be detected, the fluorescent penetrant method is desirable. The penetrant test generally consists

Penetrant Testing (PT)

Penetrant testing is a sensitive method used for locating discontinuities, such as cracks and porosity, in nonporous materials. The discontinuities must be clean and open to the surface.

of four steps, including precleaning the test surface, application of the penetrant that remains for some prescribed time (referred to as the dwell time), removal of excess penetrant from the test surface, and application of the developer. Following the application and drying of the developer, all indications are evaluated in accordance with applicable standards. For a detailed explanation of these steps, refer to ASTM E 165, Standard Practice for Liquid Penetrant Inspection.

penetrant will give many false indications, such as a general glow under a black light for fluorescent penetrant testing, or a pink coloration of the developer with visible dye penetrant testing. Precleaning the surface without the addition of more penetrant provides a clearer indication, showing only seepage from surface discontinuities. Indications that repeat at the same location through several cleanings undoubtedly reveal open discontinuities. Care must also be taken to avoid spraying cleaner directly on the test sur-

face between application of the penetrant and developer. Lyndsey Deckard (Deckard@pbworld.com) is Quality Manager of the Vehicle Division of Parsons Brinckerhoff Transit & Rail Systems Inc. He is an AWS Senior Certified Welding Inspector, a ASQ Certified Quality Auditor, and a member of the AWS Certification Committee, the Examination Question Bank Subcommittee, and the Ethics Subcommittee.

Uses
Penetrant testing is applicable to magnetic materials; however, it is particularly useful on nonmagnetic materials such as aluminum, magnesium, and austenitic stainless steels, which cannot be examined by magnetic particle testing.

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Advantages
Penetrant testing is relatively inexpensive and quick. The process is simple and operators find little difficulty in learning to apply it properly. There are few, if any, false or nonrelevant indications to be observed on smooth surfaces.

Limitations
The main limitation of PT is that discontinuities must be clean and open to the surface to be detected. Some substances used as penetrants can have a deleterious effect on welds and base metals and can affect the service life of the weldment or end use of the product. Penetrants are difficult to remove completely from discontinuities. If a penetrant is corrosive to the material or otherwise incompatible with the use of the product, it should be avoided. The contour of the surface under examination should not have sharp depressions between beads or weld ripples that may interfere with complete cleaning and excess penetrant removal, and result in false observations or irrelevant indications. If these conditions do exist, the weld surface should be ground smooth before inspection.

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Interpretations
It is important that the technician not reduce the recommended dwell times for penetrant or developer. Large cracks and voids can quickly be found without penetrant testing; however, tightly closed cracks take longer to discover because they absorb the penetrant slowly and respond to the developer equally as slow. Inadequate removal of the superficial

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