Liquid Penetrant Testing Lecture 2

Nondestructive Evaluation of Structures
Lecture 8
Liquid Penetrant Testing

Applications
MEC 4867
Dr. Meftah Hrairi
Outline
Processing cycles
Applications
Advantages and limitations
Project discussion
Dr. M. Hrairi
MEC 4867 - Nondestructive Evaluation of Structures
Processing Cycles
1.
Pre-Cleaning
2.
Penetrant Application
3.
Excess Penetrant Removal
4.
Developer Application
5.
Inspection/Evaluatation
6.
Post-cleaning
Dr. M. Hrairi
Step 1 Pre-cleaning
Parts must be free of dirt,

rust, scale, oil, grease, etc.
to perform a reliable
inspection.
The cleaning process must

remove contaminants from
the surfaces of the part
and defects, and must not
plug any of the defects.
Dr. M. Hrairi
Pre-cleaning is the
most important step
in the PT process!!!
Step 1 Pre-cleaning
Some metal-finishing processes can obscure surface

defects, and should be removed prior to penetrant testing:
Dr. M. Hrairi
Oxidising
phosphating
anodising
chromating
electrodeposition
metallising
Penetrant methods should not be used after these metalfinishing procedures.
Caution about Metal Smearing
Some machining, surface finishing and cleaning

operations can cause a thin layer of metal to
smear on the surface and prevent penetrant from
entering any flaws that may be present.
Etching of the surface prior to inspection is

sometimes required.
Dr. M. Hrairi
Step 1 Pre-cleaning
The first stage of precleaning is usually the removal of

scale with appropriate descaling or rust-removing liquids.
These generally contain inhibitors, but may be strongly

acid or alkaline and residual acid or alkali can adversely
affect the performance of penetrants.
After descaling, the liquid must be thoroughly removed.
Dr. M. Hrairi
Step 1 Pre-cleaning
Dr. M. Hrairi
The second stage of precleaning is degreasing followed by

a detergent wash and subsequent drying in hot air.
In general, chemical methods of contaminant removal are
preferred to physical methods.
As the latter essentially only remove material from the
surface, and may partially seal the surface discontinuities
which are being sought.
If any contaminants, or the liquids used for cleaning, or
any deposits produced by these liquids, fill the cracks, the
flaws will not be detected.
The ideal surface preparation therefore is one which leaves
the surface and the flaw in a clean, dry condition.
Moisture must be removed, as well as any chemical or
physical residues.
Step 1 Pre-cleaning
Dr. M. Hrairi
In the aerospace industry, a high proportion of aluminum alloy

components have a high-resistance paint coating, and adhesion is
improved by the application of a chromating or anodized layer.
If this paint has to be removed during overhaul, methods should be
used which leave the surface suitable for subsequent penetrant testing.
Usually, blasting methods are used, nowadays with lignocelluloses
powder, or with materials derived from fruit stones (plum, walnut,
almond, hazel-nut, etc.).
It has been found that both the precise nature of the material and the
blasting pressure are critical.
Loss of flaw sensitivity is probable if the blasting pressure is greater
than 1. 7 bar on aluminum alloy components of hardness 160 VPN or
less, and a light chemical etch is recommended to render the surface
receptive to penetrant inspection.
10
Step 2 Penetrant Application
Many methods
of application
are possible
such as:
Brushing
Spraying
Dipping/Immersing
Flow-on
And more
Dr. M. Hrairi
11
Dwell Time
The penetrant solution

must be allowed to
dwell on the surface of
the part to allow the
penetrant time to fill any
defects present.
The dwell time vary

according to:
Dr. M. Hrairi
Penetrant type
Temperature
material type
Surface finish.
12
Dwell Time
Dr. M. Hrairi
13
Step 3 Excess Penetrant Removal
Dr. M. Hrairi
The removal technique depends upon the type of

penetrant used, as stated earlier
Water Washable
Solvent Removable
Post Emulsifiable
14
Water Washable
A coarse water spray

is used to remove the
excess penetrant.
The procedure used as

a guideline for the
inspection will specify:
- water temperature (typically 10-38C)
- pressure (typically not more than 275 kPa),
- etc.
Dr. M. Hrairi
15
Solvent Removable
The part is wiped with

a clean dry cloth to
remove the bulk of the
excess penetrant.
Then, a cloth lightly
dampened with solvent
is used to remove any
remaining penetrant on
the surface.
Any time a solvent is used in the penetrant
inspection process, a suitable flash time is
required to allow excess solvent to
evaporate.
Dr. M. Hrairi
16
Dr. M. Hrairi
Post Emulsifiable
When there is concern about removing much of the penetrant from the
defect, a post emulsifiable system is used.
This involves an additional step

in which an emulsifier is applied
to the surface of the part after
the penetrant dwell time.
The emulsifier is given just

enough time to react with
the penetrant on the surface
to render it water washable
but not enough time to diffuse
into the penetrant trapped in
the defects.
17
Step 4 Developer Application
The method of developer application is dependent on the

type of developer used.
Dwell time for developer should be similar to the

penetrant one. It needs to be determined in each case
(minimum time is 10 min).
Dr. M. Hrairi
18
Dry Powder Developer
Dr. M. Hrairi
Prior to applying a dry

powder developer, the
component must be
thoroughly dried. Drying
is usually accomplished
in a hot air circulating
oven.
The developer is then
applied by immersing the
part in the powder or by
dusting of the part with
the powder.
The part can also be
placed in a developer dust
cloud chamber.
19
Dr. M. Hrairi
Wet Developer (water-suspended and water-soluble)
Wet developers are applied by

immersing or spraying the
part while it is still wet from
the penetrant removal process.
The part is completely coated

and the excess liquid allowed
to drain to prevent pooling.
The part is then dried in a hot

air circulating oven.
20
Nonaqueous Developer (aka Solvent-Suspended)
Dr. M. Hrairi
Nonaqueous developer is
applied by a aerosol spray
to a thoroughly dried and
cooled part.
A thin even coating should
be applied. The coating
should be white but still
slightly transparent when
performing a visible dye
penetrant inspection, and
even thinner when
performing a fluorescent
penetrant inspection.
21
Step 5 Inspection/Evaluation
Dr. M. Hrairi
In this step the

inspector evaluates the
penetrant indications
against specified
accept/reject criteria
and attempts to
determine the origin of
the indication.
The indications are
judged to be either
relevant, non-relevant or
false.
22
A very important
step of evaluation is
to document findings
on an inspection
report form or other
record keeping form.
This may be
supported with
drawings or photos
of indications, etc.
Dr. M. Hrairi
23
Indication interpretation is dependent on inspector

False, Nonrelevant and True indications
False indications can arise from poor cleaning, presence of
lint, dirt, handling, contamination, etc.
Nonrelevant indications could be due to a fluorescent
background on a rough surface repeat PT in such case.
True indications are of 3 general types:
Dr. M. Hrairi
Continuous lines: cracks, cold shuts, forging laps, scratches

Broken lines: continuous lines becomes partially closed by working such
as grinding, peening, forging, machining.
Small round holes: general porosity, gas holes, pinholes, very large grains
24
Step 6 Post-cleaning
The final step in the

penetrant inspection
process is to thoroughly
clean the part that has
been tested to remove all
penetrant processing
materials.
The residual materials

could possibly affect the
performance of the part or
affect its visual appeal.
Dr. M. Hrairi
25
Viewing and Recording
In most penetrant inspection, the indications are viewed by eye.
With color contrast materials, very good lighting should be used (500
lux minimum) on the specimen surface.
With UV light, it should be in the UV(A) band (315-400 nm), with a

minimum of 50 lux.
Recently, attempts have been made to automate the viewing process.
The specimen is manipulated by a robotic handler, is 'seen' by a closedcircuit television (CCTV) camera, and the output signal is digitized.
Computer programs for this type of procedure are quite feasible. It is

also possible to program a computer to recognize and ignore some
types of spurious indication.
Dr. M. Hrairi
26
Viewing and Recording
Penetrant indications can obviously be photographed, or

video-recorded with a CCTV camera.
As with magnetic indications, with specialized methods, a

fluorescent indication can be photographed to retain some
identifying background.
The dry indication can be lifted off the surface with

transparent adhesive tape, or a replica can be made of the
surface with replica-transfer-coating (RTC).
This is a resin in a volatile solvent, with a white pigment

and a silicone de-bonding agent.
RTC is applied instead of developer, by aerosol spray, and

allowed to dry. After drying, the edges are trimmed with a
knife and the replica peeled off.
Dr. M. Hrairi
27
Applications
Penetrant testing is used on a wide range of materials,

including all metals and alloys as well as certain ceramics
and plastics.
PT can also be carried out successfully on nonmetallic

surfaces: glass, plastics: teflon and nylon, rubber after
compatibility testing.
PT is somewhat limited when examining very porous

objects.
PT is not applicable to subsurface cracks.
Finest cracks that can be determined using PT have been

estimated to be about 5 m wide by 10 m deep (depends
on penetrant/developer system).
Dr. M. Hrairi
28
Applications
Penetrant inspection systems have been developed to

inspect some very large components.
Large machined aluminum forgings used to support the

number three engine in the tail of a DC-10 aircraft.
Dr. M. Hrairi
29
Applications
PT can be used for crack detection in components such as

this connecting rod, and for leak detection in assemblies
such as this welded tank heater.
Dr. M. Hrairi
30
Applications
For small components, for production inspection, it is often

automated, with a series of tanks and an inspection booth
with mechanized handling, timing, solution agitation, etc.
The critical factors are the cleaning process and the

avoidance of contamination of all solutions.
Penetrants are occasionally used as a form of leak detector,

by applying penetrant to one side of a specimen and a
developing agent to the other side, but the overwhelming
use is for crack detection on non-ferrous specimens.
Dr. M. Hrairi
31
Safety Precautions
Many of the materials used in penetrant flaw detection are

a potential fire hazard and some can be toxic.
Suitable safety precautions need to be taken on any

inspection installation.
If ultraviolet light is used for the inspection of fluorescent

indications, this also can be a hazard.
Dr. M. Hrairi
32
Advantages of Penetrant Flaw Detection
Relative ease of use.
Can be used on a wide range of material types.
Large areas or large volumes of parts/materials can be

inspected rapidly and at low cost.
Parts with complex geometries are routinely inspected.
Indications are produced directly on surface of the part

providing a visual image of the discontinuity.
Initial equipment investment is low.
Aerosol spray cans can make equipment very portable.
Dr. M. Hrairi
33
Limitations of Penetrant Flaw Detection
Only detects surface breaking defects.
Requires relatively smooth nonporous material.
Pre-cleaning is critical. Contaminants can mask defects.
Requires multiple operations under controlled conditions.
Chemical handling precautions necessary (toxicity, fire,

waste).
Metal smearing from machining, grinding and other

operations inhibits detection. Materials may need to be
etched prior to inspection.
Post cleaning is necessary to remove chemicals.
Dr. M. Hrairi
34
Project Discussion
Dr. M. Hrairi
35
Next Topics
Magnetic Particle Testing
Further Readings
Handouts:
Liquid penetrant

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they change what is in themselves
al quran 13:11

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Nondestructive Evaluation of Structures

Liquid Penetrant Testing

Advantages and limitations

MEC 4867 - Nondestructive Evaluation of Structures

Excess Penetrant Removal

MEC 4867 - Nondestructive Evaluation of Structures

Parts must be free of dirt,

The cleaning process must

MEC 4867 - Nondestructive Evaluation of Structures

Some metal-finishing processes can obscure surface

Penetrant methods should not be used after these metalfinishing procedures.

MEC 4867 - Nondestructive Evaluation of Structures

Caution about Metal Smearing

Some machining, surface finishing and cleaning

Etching of the surface prior to inspection is

MEC 4867 - Nondestructive Evaluation of Structures

The first stage of precleaning is usually the removal of

These generally contain inhibitors, but may be strongly

After descaling, the liquid must be thoroughly removed.

MEC 4867 - Nondestructive Evaluation of Structures

The second stage of precleaning is degreasing followed by

In the aerospace industry, a high proportion of aluminum alloy

MEC 4867 - Nondestructive Evaluation of Structures

Step 2 Penetrant Application

MEC 4867 - Nondestructive Evaluation of Structures

The penetrant solution

The dwell time vary

MEC 4867 - Nondestructive Evaluation of Structures

MEC 4867 - Nondestructive Evaluation of Structures

Step 3 Excess Penetrant Removal

The removal technique depends upon the type of

MEC 4867 - Nondestructive Evaluation of Structures

Step 3 Excess Penetrant Removal

A coarse water spray

The procedure used as

MEC 4867 - Nondestructive Evaluation of Structures

Step 3 Excess Penetrant Removal

The part is wiped with

MEC 4867 - Nondestructive Evaluation of Structures

Step 3 Excess Penetrant Removal

This involves an additional step

The emulsifier is given just

Step 4 Developer Application

The method of developer application is dependent on the

Dwell time for developer should be similar to the

MEC 4867 - Nondestructive Evaluation of Structures

Step 4 Developer Application

Dry Powder Developer

Prior to applying a dry

Step 4 Developer Application

Wet Developer (water-suspended and water-soluble)

Wet developers are applied by

The part is completely coated

The part is then dried in a hot

MEC 4867 - Nondestructive Evaluation of Structures

Step 4 Developer Application

Nonaqueous Developer (aka Solvent-Suspended)

In this step the

MEC 4867 - Nondestructive Evaluation of Structures

Indication interpretation is dependent on inspector

Continuous lines: cracks, cold shuts, forging laps, scratches

MEC 4867 - Nondestructive Evaluation of Structures

The final step in the