Introduction

Liquid penetrant testing is a nondestructive means of locating surface discontinuities based on capillarity or capillary action. The liquid penetrant method , the liquid is applied to the surface of the specimen, and sufficient time is allowed for penetration of surface discontinuities. If the discontinuity is small or narrow , as in a crack or pinhole , capillarity assists the penetration.

DEVELOPMENT

Historically , penetrant inspection was called the oil and whiting method as it used kerosene and a white powder for the inspection of railed road parts. However , in the past 40 years the process has been improved tremendously top the point where it is a reliable and accurate inspection technique.

After sufficient time has passed for the penetrant to enter the discontinuity, the surface of the part is cleaned , capillary action is again employed to act as a blotter to draw penetrant from the discontinuity.

To insure visibility , the liquid penetrant contains either a colored dye easily seen in white light, or a florescent dye visible under black light.

LIMITATIONS

Discontinuities that are subsurface in stage of production could be open to the surface at another stage, such as after grinding , machining. Nonmetallic inclusions and porosity in the ingot may cause stringers, seams forging laps. Cold shuts, and the like as the billet or slab is processed in the manner shown below.

BEWARE OF THINGS

Anything that could block the penetrant from entering the discontinuity must be removed. A last of contaminates that must be removed would include dirt, grease, rust, scale, acids, and even water. The cleaning solvent used must be volatile ( Readily vaporized) so that it easily evaporates out of the discontinuity and does not dilute the penetrant. Surface preparation by shot or sandblasting is not recommended. Discontinuities that were open to the surface may be closed by the shot or sand blasting

TYPES OF PENETRANTS

VISIBLE DYE PENETRANTS FLORESCENT PENETRANTS

DUAL SENSITYVITY PENETRANTS

CATEGORIZED BY THE PROCESSES USED TO REMOVE THE EXCESS PENETRANT

WATER WASHABLE POST EMILISIFIED

SOLVENT REMOVABLE

WHY CLEANING IS REQUIRED?

IF THE SPECIMEN IS NOT CLEAN AND DRY, PENETRANT TESTING IS INEFFECTIVE IF ALL TRACES OF PENETRANT MATERIALS ARE NOT REMOVED AFTER THE TEST, THEY MAY HAVE A HARMFUL EFFECT ON THE SPECIMEN.(CHLORINE AND SULFAR MAY AFFET SOME ALLOYS)

DIFFERENT CLEANING METHOD

DETERGENT CLEANING VAPOUR DEGREASING STEAM CLEANING SOLVENT CLEANING

ALKALINE CLEANING
ETCHING(ALKALINE SOLUTION)

WHY SURFACE CLEANING NOT RECOMENDED?

SURFACE CLEANING PROCESSES TEND TO CLOSE DISCONTINUITIES BY PEENING OR COLD WORKING THE SURFACE OF THE SPECIMEN THESE PROCESSES ARE SHOT BLASTING, SAND BLASTING, GRIT BLASTING, LIQUID HONING, EMERY CLOTH AND METAL SCRAPPERS.

SELECTION OF BEST PROCESS

Sensitivity required Number of articles to be tested Surface condition of part being inspected Configuration of test specimen Availability of water, electricity , compressed air, suitable testing area, etc.

ADVANTAGES OF PENETRANT TESTING

Penetrant testing is successfully used on metals such as aluminum, magnesium , brass, copper, cast iron, stainless steel , titanium, and most other common alloys. It ca also be used test other materials , including ceramics plastics , molded rubber, powdered metal products, or glass. Penetrant testing is limited by its inability to , test material with discontinuities that are not open to the surface or having an extremely porous surface.

PENETRANT TEST EQUIPMENT (STAINNARY)

Pre-cleaning station (usually in remote area) Penetrant station (Tank) Drain station Emulsification station (Tank) Rinse station (Tank) Developing station( Tank) Drying station (Usually oven) Inspection station (Enclosed booth or table with proper lighting) Post cleaning station (Usually in remote area

VISIBLE PENETRANT TEST EQUIPMENT (PORTABLE)

A visible dye penetrant kit usually contains: Pressurized spray cans of cleaning or removal fluid. Pressurized spray cans of visible dye penetrant Pressurized spray cans of non-aqua's developer Wiping cloths and brushes

FLOURESCENT DYE PENETRANT EQUIPMENT

A Fluorescent dye penetrant kit usually contains: A portable black light and transformer Pressurized spray cans of cleaning or removal fluid Pressurized spray cans of fluorescent dye penetrant Pressurized spray cans of non-aqueous developer Wiping cloths and brushes

PENETRANT TESTING MATERIALS

SOLVENT REMOVABLE PENETRANTS WATER WASHABLE PENETRANTS POST EMULSIFIABLE PENETRANTS EMULSIFIERS REMOVERS(SOLVENT) DRY DEVELOPERS WET DEVELOPERS NON AQUEOUS WET DEVELOPERS

CHARECTERISTIC PENETRANT

Readily penetrate very fine openings Be able to remain in relatively coarse openings. Not evaporate or dry too rapidly. Be removed easily from the surface on which it has been applied. Bleed from discontinuities when developer is applied. Have ability to spread out in very thin florescence, even when spread in very thin films. Have permamnce of colour in exposure to heat , light and / or black light. Have great brilliance of colur or fluorescence, even when spread in very thin films. Be inert with respect to the materials being tested and to the containers Odorless. Nonflammable. Stable under conditions of storage and use Nontoxic Low in cost.

CHARACTERISTICS OF DEVELOPER

HIGH ABSORPTION TO OCCURE MAXIMUM BLOTTING ACTION ESAILY DISPERSED TO EXPOSE THE DISCONTINUITYBY A SMALL AMOUNT OF PENETRANT COVERING A LARGE SURFACE AREA. THIS PROVIDES A STRONG INDICATION WITH SHARP DEFINITION. PROVIDE A CONTRAST BACKGROUND FOR INDICATIONS, PARTICULARLY WITH VISIBLE DYE PENETRANTS. EASILY EVENLY, AND READILY APPLIED. FORM A THIN UNIFORM COATING OVER THE SURFACE. EASILY WET T ALLOW PENETRANT TO SPREAD OVER THE PARITICLE SURFACES. NONFLUORESCENT IF USED WITH FLOURESCENT PENETRANT EASILY REMOED AFTER THE INSPECTION IS EQUIPMENT BEING USED. NONTOXIC INEXPENSIVE

TYPES OF DISCONTINUITIES

INHERENT INHERENT WROUGHT DISCONTINUITIES INHERENT CAST DISCONTINUITIES PROCESSING DISCONTINUITIES SERVICE DISCONTINUITIES

QUIZ