Penetrants TESTING

DYE PENETRANT TESTING CONSULTANTS
SAIMIRA
CONTENTS
1. 2. 3. 4. 5.
INTRODUCTION PRINCIPLES OF DYE PENETRANT TESTING CLASSIFICATION OF DYE PENETRANT TESTING METHODS FLOW CHART OF VARIOUS PROCESS COMBINATIONS FLOW CHART FOR PROCESS SEQUENCE OF VISIBLE DYE AND FLOURESCENT TYPE PENETRANTS,
01 04 10 13 14
. !. ". #. 10. 11. 12. 13. 14. 15. 1 .
DUAL SENSITIVITY PENETRANTS PROCESS SEQUENCE TYPES OF PENETRANTS THE PROCESS OF EMULSIFICATION DEVELOPERS ULTRAVIOLET LIGHT CLEANING OF TEST SURFACE STANDARD SPECIMEN SYSTEM PERFORMANCE CHEC$ % $DM PANELS EVALUATION INSPECTION TEST PROCESS
15 1! 23 32 3" 40 43 44 55 51 5
PREPARED BY S.MUTHUKUMAR, B.Tech lll
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SAIMIRA
INTRODUCTION LIQUID PENETRANT TESTING Liquid penetrant test method enhances the $"a's such as crac%s( $issures( cre ices and isi!i"it# o$ sur$ace !rea%in& can !e used er#
pores) It
success$u""# re&ard"ess o$ component si*e and can to"erate comp"icated part &eometr#) Liquid penetrants can seep into arious t#pes o$ minute sur$ace pores or openin&s !# capi""ar# action( !ecause o$ this( the process is 'e"" suited $or detection o$ a"" t#pes o$ sur$ace crac%s( "aps( porosit#( shrin%a&e areas( "aminations and simi"ar t#pe o$ discontinuities) It is e+tensi e"# used $or the inspection o$ cast and 'rou&ht and 'e"ded products o$ !oth $errous and non $errous meta"s( po'der meta""ur&# parts ( ceramics( p"astics( and &"ass o!,ects) Penetrant testin& is used on meta"s such as a"uminium( ma&nesium( !rass( copper( cast iron( stee"( stain"ess stee"( titanium and other common a""o#s) It can a"so test other materia"s( inc"udin& &"a*ed ceramics( p"astics( mo"ded ru!!er( po'dered meta" products and &"ass) Some "imitations are( The discontinuit# to !e detected must !e open to the sur$ace and the interior $ree $rom $orei&n materia"s) The test sur$ace shou"d not !e porous) The materia" under test must not !e suscepti!"e to dama&e $rom the "iquids used $or the e+amination The test process has temperature Specia" requirements( Penetrant materia"s must !e "imitations - ./ to 01 / C 2) - usin& specia" materia"s( the ran&e is 3.0 to 1// / C part temperatures 2) As desi&ned 'ith a "o' su"$ur and ha"o&en content to a oid harm$u" e$$ects on the test parts) Stain"ess stee"s are especia""# suscepti!"e to corrosion 'hen e+posed to ch"orine and Car!on stee"s to su"$ur) Titanium is e+treme"#
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suscepti!"e to em!ritt"ement 'hen in contact 'ith ha"o&ens) 4i&h Nic%e" a""o#s are a"so a$$ected !# su"pher and ha"o&ens) These harm$u" chemica"s can !e $ound in penetrant materia"s !ut are "imited to .5 !# 'ei&ht o$ content) Common penetrant materia"s attac% P6C( ma%in& it !ritt"e( 'hich "eads to crac%in&) Liquid o+#&en compati!"e penetrant materia"s must !e used 'hen testin& parts that 'i"" !e in contact 'ith either "iquid or &aseous o+#&en) 7ethod 8 A penetratin& "iquid is app"ied to the c"ean and dr# test sur$ace and a""o'ed to enter the discontinuit# openin& o er a period o$ time) The "iquid soa%s into materia" $"a's that are open at the test sur$ace) A$ter a suita!"e penetration time( the e+cess sur$ace penetrant is remo ed and the test sur$ace is dried) A de e"oper is then app"ied in a thin uni$orm coatin& 'hich acts as !"otter and dra's some o$ the entrapped penetrant out o$ the discontinuities) The penetrant stains the de e"oper and the indication !ecomes isi!"e) The sur$ace $"a' !ecomes increasin&"# isi!"e to the e#e( !ecause the d#e spreads in the de e"oper and e$$ecti e"# !roadens the trace) The d#e indicator appears either red or !"ue on a 'hite !ac%&round $or co"or contrast penetrants or appears 9e""o' : &reen or oran&e 3 red on a dar% io"et !ac%&round( 'hen the sur$ace is i""uminated !# an u"tra io"et "amp $or a $"uorescent test process) The sensiti it# o$ the test depends on the si*e o$ the discontinuit# openin& and not on the "en&th) Crac% 'idth is the more important determinant o$ a penetrant;s a!i"it# to detect crac%s) Ti&ht narro' crac%s( re&ard"ess o$ "en&th( are more di$$icu"t $or penetrants to $ind) <ati&ue crac%s and $or&in& crac%s are ti&hter and require more ,udicious processin& and hi&her sensiti it# penetrants to "ocate than castin& crac%s o$ the same "en&th) The crac% "imit $or this inspection method is appro+imate"# /)0 =m crac% 'idth) Detection o$ sur$ace $"a's depends on the &enera" condition and $inish o$ the test sur$ace) The depth o$ the anticipated de$ect shou"d !e three times deeper than the &enera" sur$ace rou&hness > a""e#> depth) De$ect detect3 a!i"it# can !e $urther diminished !# norma""# accepta!"e sur$ace conditions such as
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too" mar%s( scratches( sca"e( ed&es( &roo es( notches( rou&h 'e"d sur$aces etc( 'here penetrant is trapped) A"thou&h the d#e penetrant test is a er# eas# process( it is a"so er# eas# to ma%e mista%es and ma%e the test ine$$ecti e) Care must !e e+ercised !# the operator in order to per$orm a"" the steps o$ the e+amination correct"#)
Sensiti it# : equa" or !etter than 7T : !etter than RT $or sur$ace discontinuities . ?m + ./ ?m + 0/ ?m can !e detected) App"ications : on a"" materia"s : meta"s@$errous and non$errousA nonmeta"s @ru!!er (p"astic etcA a"" t#pe o$ de$ects @open to sur$aceA Norma""# not app"ica!"e to porous materia"s @un$ired ceramics and po'der meta""ur&ica" partsA Present"# <i"tered partic"e penetrant $or porous materia"s has !een de e"oped) Rou&h sur$aces 3 B .10 ?m3!ac%&round poses pro!"em in usin& penetrant testin&) 4i&h"# co"oured @ isi!"e or $"uorescentA or&anic d#e "iquid 'hich is a"so sur$ace acti e in nature @ca""ed penetrantsA is app"ied on to the c"ean sur$ace o$ the component and a""o'ed su$$icient time $or penetration into discontinuities) The e+cess sur$ace penetrant on the component is remo ed) This "ea es a c"ean sur$ace o$ the component 'ith pentrant residin& in the discontinuities) At this point O$ time( de e"opr( 'hich is hi&h"# a!sorpti e in nature( is app"ied) The de e"oper !rin&s !ac% or !"eeds out the penetrant there!# pro idin& an indication in a !ac%&round o$ 'hite co"our o$ de e"oper) .)Preparation o$ part 1) App"ication o$ penetrant PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL contrastin&
SAIMIRA
C) Remo a" o$ e+cess sur$ace penetrant D) De e"opment 0) Inspection and E a"uation E) Post C"eanin&
Ph#sica" princip"es
Cle& !+()&ce %) C%,"% e # Pe e#(& # &""l$c&#$%
Re,%*&l %) e-ce!! !+()&ce "e e#(& #
A)#e( (e,%*&l %) e-ce!! !+()&ce "e e#(& # & ' .e)%(e &""l$c&#$% 'e*el%"e(
A""l$c&#$% %) 'e*el%"e(
I !"ec#$% & ' I #e("(e#&#$%
Fig.1. Principle of Penetrant Testing
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SAIMIRA
"iquid penetrant inspection depends main"# on penetrant e$$ecti e"# 'ettin& the sur$ace o$ a so"id 'or% piece or specimen( $"o'in& o er that sur$ace to $orm a continuous and reasona!"# uni$orm coatin& and the mi&ratin& into ca ities that are open to the sur$ace) So this a!i"it# o$ &i en penetrant to $"o' o er a sur$ace and enter sur$ace ca ities depends principa""# on the $o""o'in&8 C"ean"iness o$ the sur$aces Con$i&uration o$ the ca it# C"ean"iness o$ the ca it# si*e o$ sur$ace openin& o$ the ca it# Sur$ace tension o$ the $"uid A!i"it# o$ the "iquid to 'et the sur$ace Contact an&"e o$ the "iquid The cohesi e $orces !et'een mo"ecu"es o$ "iquid causes the sur$ace tension( a !est e+amp"e $or this phenomenon is tendenc# o$ "iquid o er the sur$ace such as drop"et O$ 'ater( these contracts into sphere( in such drop"et( sur$ace tension is counter !a"anced !# interna" h#drostatic pressure o$ the $"uid) Fhen the "iquid comes into contact 'ith a so"id sur$ace( a cohesi e $orces responsi!"e $or sur$ace tension competes 'ith the adhesi e $orces !et'een the mo"ecu"es o$ the "iquid and so"id sur$aces(( these t'o $orces ,oint"# determines the contact an&"e !et'een the "iquid and 'et sur$ace(! There are are three t#pes o$ "iquid 'ets the so"id sur$ace in re"ation to contact an&"e( I$ contact an&"e is G H/ de&rees I$ contact an&"e is B H/ de&rees I$ contact an&"e is I H/ de&rees "iquid ha in& &ood 'ettin& a!i"it# "iquid ha in& poor 'ettin& a!i"it# "iquid ha in& poor 'ettin& a!i"it#
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The propert# o$ a "iquid ca""ed capi""arit# is e+p"ained as the process o$ increase in the meniscus or o$ the $"uid in a thin tu!e o er the 'ater "e e" 'hen this tu!e is immersed in 'ater in container( this capi""ar# rise is a"so c"ose"# re"ated to 'ettin& an&"e !et'een the "iquid that 'ets the tu!e and the inner sur$ace o$ the tu!e( Fettin& an&"e !et'een capi""ar# tu!e And "iquid Less than H/ de&rees then meniscus o$ the "iquid 'i"" !e conca e and "iquid "e e" in the tu!e raises in the tu!e o er the "iquid "e e" in a container : ha in& &ood 'ettin& a!i"it#
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Physical principles
C&'())&*+ '*,--.*,/ 0 1 2T 23- 45
W,66(75 &8()(6+
5339, :#0;
'33*, 43*-6 1 #0; < #0;
Fettin& an&"e !et'een capi""ar# tu!e And "iquid
&reater
than H/ de&rees
then
meniscus o$ the "iquid 'i"" !e con e+ and "iquid "e e" in the tu!e reduces in the tu!e o er the "iquid "e e" in a container : ha in& poor 'ettin& a!i"it# This is due to h#drostatic pressure immediate"# under the meniscus is reduced !# the distri!ution o$ sur$ace tension in the conca e sur$ace( and the "iquid is pushed up !# the h#drau"ica""# transmitted pressure o$ the atmosphere at the $ree sur$ace o$ the "iquid outside the capi""ar# tu!e) The hei&ht to 'hich the "iquid rises is direct"# proportiona" to the sur$ace tension o$ the "iquid and to the cosine an&"e o$ contact( and it is in erse"# proportiona" to the densit# o$ the "iquid and the radius o$ the capi""ar# tu!e( This a!o e e+p"ained simi"ar phenomena is app"ica!"e $or the penetrants enterin& the discontinuit# and seepin& out 'hen de e"oper is app"ied)The term iscosit# is a"so re"ated to rate at 'hich the "iquid 'i"" $"o' and it is ha in& ne&"i&i!"e e$$ect in penetratin& a!i"it#) hi&h"# mi&rate into $ine $"a's) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL iscous "iquids are not suita!"e $or not suita!"e $or penetrants( since rate o$ $"o' is s"o'er one consequent"# requires "on&er time to
SAIMIRA
The princip"e o$ "iquid penetrant testin& is !ased on the a!i"it# o$ some "iquids to enter a discontinuit# openin& and then re3emer&e $rom it 'hen the e+cess penetrant is remo ed $rom the sur$ace) Capi""ar# action is the means !#
A liquid drop on a ideally smooth, clean surface at equilibrium
SL
'33* 4,66(75 G339 4,66(75 : #0
SL
SG
L
<#0
L COS
SG
L 1 LIQUID= GAS, SG1 SOLID=GAS, SL1 LIQUID=SOLID FOR GOOD SPRE ADING SG < SL T0, &83>, 9,-2*('6(37 (- ?3* & )(@.(9 9*3' 37 & -3)(9 -.*?&2, &79 &83>, 60, )(@.(9 (- 5&-,3.- A ,9(.A
) 'hich a "iquid enters a discontinuit# openin&) This action is 'hat causes a piece o$ spon&e to a!sor! "iquid Capi""ar# action is a phenomenon in 'hich 'ater or other "iquids 'i"" rise a!o e the norma" "iquid "e e" in a sma"" !ore or capi""ar# tu!e due to the attraction o$ the mo"ecu"es in the "iquid $or each other and $or the 'a"" o$ the tu!e - cohesion and adhesion 2) Cohesion is interaction !et'een t'o sur$aces o$ the same materia" in contact( ma%es them c"in& to&ether - 'ith t'o di$$erent materia"s the simi"ar phenomenon is ca""ed adhesion 2) Accordin& to %inetic theor#( cohesion is caused !# attraction !et'een partic"es at the atomic or mo"ecu"ar "e e") Sur$ace PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS tension( cohesion) 'hich causes "iquids to
14 $orm spherica"
SAIMIRA drop"ets( is caused !#
The distance the "iquid 'i"" rise up the tu!e o$ a &i en diameter and materia" is a $unction o$ three $actorsJ Sur$ace tension( Fettin& a!i"it#( Tu!e open or c"ose at the top end) Liquid 'i"" rise "ess in a c"osed end tu!e) The practica" circumstances( a penetrant encounters durin& testin& is more comp"e+) Crac%s( $or e+amp"e are not capi""ar# tu!es( !ut simu"ate the !asic interaction !et'een a "iquid and a so"id sur$ace( 'hich is responsi!"e $or the mi&ration o$ penetrant into its open space) This same interaction acts a&ain and penetrant emer&es $rom the discontinuit# 'hen the e+cess penetrant is remo ed $rom the sur$ace
Factors influencing Penetrant infiltration into discontinuities

1. -.*?&2, 6,7-(37 3? 60, )(@.(9 ',7,6*&76 2. 9(-2376(7.(6+ 237?(5.*&6(37 237-6&76 3. -.*?&2, 23&6(75- &79 2376&A(7&764. &99(6(>,- &79 2376&A(7&76- (7 60, )(@.(9 ',7,6*&76 5. A,20&7(2&) 38-6*.26(37. 6,A',*&6.*, 3? 60, 6,-6 38B,26 !. *3.507,-- 3? 60, (76,*(3* 4&))- 3? 60, 9(-2376(7.(6+
Norma""#( the penetrants need to ha e a
er# "o' contact an&"e and the
commercia" penetrants ha e contact an&"es !et'een / :0)) Contact an&"e depends on the so"id sur$ace to !e 'etted) Fater3&"ass has a contact an&"e o$ / de&) compared to 'ater3si" er 'hich is H/ de&
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SAIMIRA
Once the "iquid 'ets the sur$ace( the a!i"it# o$ the "iquid t Sur$ace tension Is one o$ the most important properties 'hich determines the penetratin& a!i"it# o$ a "iquid) Lo' sur$ace tension "iquids pro ide !etter penetration and spreads 'e"" on part sur$ace) Fettin& a!i"it# is a"so determines the penetratin& a!i"it# o$ a "iquid) A!i"it# to 'et or spread on the sur$ace is re"ated direct"# to the contact an&"e !et'een the "iquid and the sur$ace at the point o$ contact) To ha e a &ood 'ettin& a!i"it#( the contact an&"e must !e sma"") Penetrants used $or testin& ha e contact an&"e o$ 0/ or "ess) Kri&htness The d#e in the penetrant shou"d !e hi&h"# sta!"e and !ri&ht enou&h to !e isi!"e in er# thin $i"m) 6o"ati"it# is the speed 'ith 'hich a o"ati"e to a""o' "on& penetration and inspection apor is &i en o$$) <or sa$et# purpose( a "iquid e aporates) Penetrant shou"d !e non time) The penetrant must not dr# durin& the e+amination period) <"ash point is the temperature at 'hich $"amma!"e penetrant shou"d ha e hi&her or no $"ash point) Chemica" Innertness is the a!i"it# o$ a materia" not to interact 'hen mi+ed 'ith or !rou&ht into contact 'ith other materia"s) Penetrant shou"d !e as inert and non corrosi e as possi!"e to'ards the materia"s to !e tested) So"u!i"it# is the a!i"it# o$ a materia" to !e disso" ed into another materia") Penetrant must !e so"u!"e in order to !e easi"# remo ed $rom the sur$ace o$ the part !ein& e+amined) Creep is the a!i"it# o$ sma"" amounts o$ "iquid in discontinuities to com !ac% out to $orm an indication) To"erance $or Contamination is the a!i"it# to to"erate sma"" amounts o$ $orei&n su!stances and not a$$ect un$a ora!"# the action o$ a penetrant) A penetrant is a compound o$ se era" in&redients and a "itt"e 'ater( acids( deter&ents and de&reaser so" ents ma# upset the !a"ance and cause the penetrant to "ose some or a"" o$ its important properties) To+icit#( S%in irritation and odor No penetrant shou"d contain poisonous( corrosi e or s%in irritatin& materia" or ha e an o$$ensi e odor) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
Penetrant properties points to remem!er .) Lo' sur$ace tension and contact an&"e( capa!"e o$ smooth"# and e en"# spread on the part sur$ace) 1) Lo' C) Non iscosit#( capa!"e o$ enterin& sma"" discontinuit# openin&s $aster) o"ati"e)
D) Eas# remo a" $rom part sur$ace !ut not $rom the discontinuities) The penetrant shou"d &et remo ed 'ith no d#e precipitation) 0) Capa!"e remo ed) E) 4i&h isi!i"it# and contrast in sma"" quantities and thin $i"ms on part sur$ace) L) Does not corrode the test sur$ace) M) 7ust !e Non To+ic The rise in the capi""ar# or enter into the openin&s is determined !# sur$ace tension @TA 4ence the main properties o$ penetrant are T and ) The a!i"it# o$ the "iquid to spread or 'et the so"id sur$ace is re"ated to the contact an&"e ( 'hich quanti$ies the resu"tant adhesi e and cohesi e $orces( The contact an&"e is de$ined as the an&"e !et'een the so"id sur$ace and the tan&ent dra'n to the "iquid at the point o$ contact) It can !e seen that spreadin& a!i"it# and contact an&"e are in erse"# re"ated) Co"our contrast ratio o$ isi!"e d#e is N.8./ @The "i&ht re$"ected !# the 'hite !ac%&round to !ri&ht red o$ the d#eA) Co"our contrast ratio o$ the $"uorescent d#e is N.8.// @"i&ht emitted !# the indication to the "i&ht emitted !# the dar% !ac%&roundA Kecause o$ this co"our contrast ratio( the indication is !etter seen in the case o$ $"uorescent indication ) The human e#e !rin&s an e$$ect ca""ed ha"ation e$$ect( the a!i"it# to ma&ni$# the indication propert# o$ penetrant is d#e so"ou!"e capa!i"it# to produce easi"# isi!"e indications($ina""# this penetrants must !e easi"# remo ed !# suita!"e so" ents or remo er or emu"si$ier 'ithout precipitatin& the d#e( PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL o$ emer&in& $rom discontinuities a$ter e+cess penetrant is
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SAIMIRA
The per$ormance o$ a penetrant is achie ed !# a com!ination o$ contro""ed ph#sica" and chemica" properties J 6iscosit# Is re"ated to the rate at 'hich a "iquid 'i"" $"o' under some app"ied $orce) It a$$ects the speed o$ penetration throu&h the discontinuit# openin&) A "o' iscosit# "iquid is used $or $aster penetration and a"so "ess dra& out in immersion) There are main"# three t#pes o$ penetrants name"# Liquid Penetrant T9PE E+cess Penetrant Remo a" 7ethod O Fater Fasha!"e 7ethod @AA Post3Emu"si$ia!"e( Liphophi"ic 7ethod @KA So" ent remo a!"e 7ethod @CA Post3Emu"si$ia!"e( 4#drophi"ic 7ethod @DA <"uorescent BBB T#pe @IA J 6isi!"e BBB T#pe @IIA
De e"oper <orm Dr# De e"oper BB <orm @aA Fater3so"u!"e BB <orm @!A Fater3suspended Non3aqueous BB <orm @cA
BB <orm @dA
So" ents $or pre3c"eanin& CLASS ha"o&nated Non3<"amma!"e C"ass @.A non3ha"o&nated <"amma!"e C"ass @1A
App"ication o$ penetrant Penetrant can !e app"ied !# immersion( dippin& (spra#in&( s'a!!in& and pourin& PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
D'e"" time 8 The tota" time the penetrant is contact 'ith the test sur$ace inc"udin& the time required $or app"ication and $or drain ) D'e"" time I app"ication time P drain time Norma""# 03C/ mts) Depends on the si*e and nature o$ discontinuit# and the materia" and sur$ace condition o$ the materia" etc) The on"# requirement is that a thin "a#er o$ penetrant shou"d !e present $or the speci$ied time @d'e"" timeA on the sur$ace to !e inspected Remo a" o$ e+cess penetrant The e+cess sur$ace penetrant on the sur$ace is care$u""# remo ed 'ithout a$$ectin& the penetrant that is residin& in the discontinuit#) In an# NDT method the Si&na" to Noise ratio is important and this shou"d !e as hi&h as possi!"e S3 6o"ume o$ penetrant that has entered into the discontinuit# N3 Unremo ed e+cess sur$ace penetrant in the discontinuit# This is an important step as the unremo ed e+cess sur$ace penetrant 'i"" a$$ect su!sequent"# !# a$$ectin& the contrast o$ the indication @e+cessi e !ac%&roundA and i$ an# penetrant in the discontinuit# is distur!ed the o"ume o$ the penetrant indication 'i"" &et reduced @The o"ume o$ penetrant is a"read# er# sma""A It is o! ious that in PT to achie e a hi&h SQN ratio( the e+cess penetrant on the sur$ace shou"d !e remo ed as comp"ete"# as possi!"e and the penetrant is the discontinuit# shou"d not !e "ost !# o er'ashin& Penetrant remo a" methods Disso" e and remo e .) Disperse @emu"si$#A and remo e !# 'ater 'asha!"eQpost emu"si$ication 1) Simp"# 'ater 'ash i$ penetrant contains !ui"t in Emu"si$ier @FFA In each case( care need !e e+ercised so as to comp"ete"# remo e the e+cess penetrant on the sur$ace comp"ete"# and at the same time the penetrant in the discontinuit# is not a$$ected) Fash : donRt o er 'ash ) In the case( 'e"ds( 'hen need !e inspected 'ithout $"ushin& the cro'n( the sur$ace ou&hness poses pro!"ems &i in& !ac%&round co"ouration there!# a$$ectin& the isi!i"it# o$ the ndication) 4ence So" ent remo a!"e and 'ater 'asha!"e ASNT NDT LEVEL
1/
SAIMIRA
ariations are norma""# emp"o#ed) 4ere o er'ashin& tendenc# o$ these methods( ista%en to ad anta&e( meanin&( the sur$ace is retained penetrant in the discontinuit# DE6ELOPING A$ter indication) De e"oper $unctions) The de e"oper $unctions are .)To assist the natura" seepa&e o$ the penetrant in the discontinuit# and e+tract or !"ot out the penetrant so as to $orm indicationA 1) To pro ide a contrastin& !ase 'hich enhances the detection an indication) K"ue3 !"ac% to #e""o'ish &reen8 'hite to red C) To spread the penetrant so as to increase the apparent si*e o$ the indication D) To mas% some con$usin& indications 7echanism o$ de e"opin& action 8 Natura" seepa&e is assisted and the a!sopti e de e"opers !"ot out more penetrant $rom the discontinuit#) The thic%ness o$ the penetrant "a#er is increased to the "e e"s a!o e the thresho"d isi!i"it# )@ Some $"uorescent penetrant indications can !e seen 'ithout de e"opin& 'ith hi&h intensit# !"ac% "i&ht 3C/// micro'attQsq)cmA De e"oper has t'o ariations8 Dr# and Fet) In the case o$ 'et( aqueous and non aqueous)As the sensiti it# o$ 'et de e"opers are !etter than( dr# de e"opers and since in 'e"d inspection( "ess sensiti e methods name"# 'ater 'asha!"e and so" ent remo a!"e are emp"o#ed ( it is !etter to use 'et de e"opers @most"# nonaqueousA in 'e"d inspection in spite sur$ace rou&hness) Norma""# $or hi&h sur$ace rou&hness( dr# po'der is !etter suited ) <LOF C4ART ILLUSTRATES 6ARIOUS PROCESS CO7KINATIONS PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL an isua" indication @mechanism o$ isua" the remo a" o$ the e+cess sur$ace penetrant ( in de e"opin& step( the penetrant $rom the discontinuit# is !rou&ht to the sur$ace so as to $orm an isi!"e much $ree $rom the !ac%&round co"ouration) O$ course( the sensiti it# su$$ers) Sensiti it# depends on the amount o$
10
SAIMIRA
6ISIKLE
<LOURESCENT
DUAL SENSITI6IT9
FATER
E7ULSI<IE R
SOL6ENT
FATER
SOL6ENT
FATER
FET
DR9
NONAQUEOUS FET
FATER SUSPENDED PARTICLE
FATER SOLOUKLE
<LOF C4ART <OR PROCESS SEQUENCE O< 6ISIKLE D9E AND <LOURESCENT T9PE PENETRANTS( PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
11
SAIMIRA
FATER FAS4AKLE APPL9 PENETRANT
POST E7ULSI<IED APPL9 PENETRANT APPL9 E7ULSI<IER
SOL6ENT RE7O6AL APPL9 PENETRANT
FATER FAS4
SOL6ENT FIPE
DR9
APPL9 FATER KASED FET DE6ELOPER
APPL9 DR9 POFDER DE6ELOPER
APPL9 NON AQUEOUS FE DE6ELOPE R
APPL9 DR9 POFDER DE6ELOPER
DR9 INSPECT POST CLEAN
ASNT NDT LEVEL
12
SAIMIRA
DUAL SENSITI6IT9 PENETRANTS PROCESS SEQUENCE
DUAL SENSITI6IT9 PENETRANTS PROCESS SEQUENCE
PRECLEAN APPL9 PENETRANT FATER FAS4 APPL9 DR9 POFDER DE6ELOPER SOL6ENT FIPE
DR9 APPL9 NON AQUEOUS FET DE6ELOPER
INSPECT POST CLEAN
De e"opin& action at the end o$ de e"oper time re ea"s an indication) In this step the indications are interpreted as to the ori&in o$ the indication name"# 'hether True or $a"se indications and i$ true indication 'hether re"e ant or nonre"e ant and i$ PREPARED BY S.MUTHUKUMAR, B.Tech ASNT NDT LEVEL lll
DYE PENETRANT TESTING CONSULTANTS re"e ant as to the nature
13 o$ discontinuities
SAIMIRA "inear or o"umetric)
Inspection en ironement depends on the t#pe o$ d#e 3 6isi!"e or $"uorescent d#e 'hite "i&ht $or isi!"e and !"ac% "i&ht $or $"uoresecent) T#pes o$ penetrants Penetrants are &enera""# a chemica" so"ution o$ hi&h"# sta!"e d#es( either isi!"e or $"uorescent( in a mi+ture o$ sur$ace acti e a&ents 'ith a !"end o$ hi&h"# re$ined h#drocar!on disti""ate) The carrier "iquid is practica""# co"or"ess and transparent) The d#e pro ides a hi&h contrast indication a&ainst the !ac%&round) Petro"eum disti""ates( 'hich are re"ati e"# non o"ati"e and used to di"ute !oth 'ater 'asha!"e and non 3 'ater 'asha!"e penetrants( contri!ute to penetrant per$ormance in se era" 'a#s) As a di"uent( a "i&ht petro"eum disti""ate disso" es "i&ht or&anic soi"s on sur$aces and in $"a's( and it assists crac% penetration 'ith its "o' sur$ace tension and a$$init# $or meta" sur$aces) A"so( petro"eum disti""ates natura""# $"uoresce a "i&ht !"ue co"or and( in a minor 'a#( contri!ute to penetrant !ri&htness) Petro"eum disti""ates are source o$ ha"o&ens and su"phur) Fater !ased $"uorescent penetrants - usin& 'ater as di"uent 'hich
represents at "east 0/5 o$ a penetrant 2 ha e !een de e"oped $or eas# disposa"( pre ious"# used as non3certi$ied app"ications( are no' appro ed) Fater !ased $"uorescent penetrants are restricted to a ai"a!"e in sensiti it# "e e" . and 1) The 'ater 'asha!"e method and penetrants are "iquid o+#&en
compati!"e( suita!"e $or use as a "ea% detector and $or inspection o$ p"astics) The penetrants are compati!"e 'ith 'ater !ased prec"eaners( e)&)( hot a"%a"ine( 'hich $or en ironmenta" reasons ha e rep"aced petro"eum so" ents and apor de&reasers) Kein& compati!"e 'ith the aqueous c"eaner( these penetrants ha e to"erance $or rinse 'ater carr# o er) A"so( $"a' entrapped 'ater is "ess "i%e"# to impair the inspection process( such as 'ou"d happen 'hen $"a' entrapped 'ater repe""ed a petro"eum !ased penetrant) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
24
SAIMIRA
Fater in 'ater !ased penetrants 'i"" e aporate( and re&u"ar( testin& 'ith a re$ractometer is necessar# to measure the "oss) Periodic 'ater additions are part o$ the maintenance criteria $or these penetrants) Lon&er penetration time - C/ mins 2 impro es sensiti it# and dr# de e"opers are "ess suita!"e $or these penetrants) Se"ection o$ penetrant t#pe depends on( Sensiti it# required) - ti&htness o$ the openin& 2 Num!er o$ artic"es to !e tested) Sur$ace condition o$ the part to !e tested) Con$i&uration o$ the test specimen) A ai"a!i"it# o$ 'ater( e"ectricit#( compressed air and other equipments) Suita!i"it# in en ironment 'here the test 'i"" !e per$ormed) Cost o$ inspection) In 'e"d inspection( "o'er sensiti it# methods(name"# 'ater Fasha!"e and so" ent remo a!"e are emp"o#ed due to sur$ace rou&hness o$ the 'e"d) 4ence( use o$ hi&h sensiti it# penetrant name"# $"uorescent d#e penetrant ma# !e pre$erred) 6isi!"e D#e 8 6isi!"e d#e or co"or contrast penetrant inspection ma%es use o$ a d#e that is isi!"e in ordinar# "i&ht) These penetrants contain a hi&h"# sta!"e !ri&ht isi!"e in er# thin red or purp"e d#e( so that the indications produce a de$inite contrast 'ith the 'hite !ac%&round o$ the de e"oper po'der) The d#es are $i"m) Co"or contrast penetrant can not achie e the "e e" o$ sensiti it# 'hich is iscosit# and er# ti&ht crac%s) isi!"e penetrant e+amination is rou&h"#
possi!"e 'ith the $"uorescent penetrants !ecause o$ hi&her ina!i"it# to enter As a &enera" ru"e o$ thum!(
equa" to $"uorescent penetrant e+amination o$ "e e" . sensiti it#) Discontinuities in the ran&e o$ 0/ in NiCr pane"s are routine"# detected and under the ri&ht conditions and processin& C/ discontinuities PREPARED BY S.MUTHUKUMAR, B.Tech lll can !e hi&h"i&hted) The ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS ad anta&e o$ usin& a
21
SAIMIRA
isi!"e penetrant is that it can !e used 'ith ordinar#
shop "i&htin& and $rom a sma"" porta!"e so" ent remo a!"e %it at an# "ocation) The# are specia""# suita!"e $or $ie"d app"ications and 'here dar%enin& the inspection area is impractica")
ASNT NDT LEVEL
22
SAIMIRA
Se !$#$*$#5 %) "e e#(& #! All )l+%(e!ce # ,e#h%'! &(e ,%(e !e !$#$*e #h& *$!$.le '5e "e e#(& #
Pe e#(& # T5"e P(%"e(#$e! I '$c&#$% B&c;7(%+ ' V$!$!.le '5e 6l+%(e!ce # '5e Yell%8$!h 7(ee 9% e-c$#&#$% : D&(; 9,&-. 2 )#.c& 'le!: =1>144 Ve(5 h$7h H$7h
B($7h# (e' c%l%+(
I 8el' $ !"ec#$% , l%8e( !e !$#$*$#5 ,e#h%'!, &,el5 8&#e( <&!h&.le & ' !%l*e # (e,%*&.le &(e e,"l%5e' '+e #% !+()&ce (%+7h e!! %) #he 8el'. He ce, +!e %) h$7h !e !$#$*$#5 "e e#(& # &,el5 )l+%(e!ce # '5e "e e#(& # ,&5 .e "(e)e((e'.
<h$#e c%l%+( %) #he 'e*el%"e( C%l%+( c% #(&!# (&#$% =1>14 V$!$.$l$#59!ee&.$l$#5: Me'$+, H&l&#$% N%(,&l e))ec#9&.$l$#5 %) #he e5e #% ,&7 $)5 #he $ '$c&#$% : Se !$#$*$#5 Me'$+,
H$7h
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS 6isi!"e penetrants are "ess
23
SAIMIRA
u"nera!"e to contamination $rom c"eanin& $"uid that
can si&ni$icant"# reduce the !ri&htness o$ a $"uorescent indication) 6isi!"e penetrants are used in maintenance( repair and in manu$acturin& processes 'here a isi!"e indication he"ps in "ocatin& the area $or su!sequent repair 'or%( such as "ar&e rou&h castin&s) These penetrants are a"so used $or throu&h "ea% testin& o$ heat e+chan&ers and tan%s( 'here penetrant is app"ied to one side and de e"oper to the other) E$$ect o$ Temperature8 Penetrants are norma""# de e"oped $or use $rom a!out ./ to 01/ C) 4o'e er the# can !e used as "o' as D / C !ut penetration time must !e increased !# 1 to C times) At "o' temperature( penetrant !ecomes hi&h"# C and iscous and s"u&&ish) CM/ C) Penetrant testin& at hi&her part temperature has positi e Idea" operatin& temperatures $or norma" use o$ penetrants "ie !et'een ./ / ad anta&e) The mo"ecu"ar mo ement o$ a "iquid is direct"# re"ated to the "iquid;s a!so"ute temperature) The hi&her the temperature( the &reater the mo ement and iscosit# decreases) Thus( a penetrant( in contact 'ith a heated part( 'i"" !e "ess iscous and $ast penetrate into $"a's !# disp"acin& an# &as or "iquid $rom 4eat $rom apori*es discontinuit# entrapped so" ents and moisture( 'hich mi&ht processin&( $aci"itatin& penetrant disp"acement) Thus( a heated the interior o$ the discontinuit#) other'ise inter$ere 'ith penetration) 4eat "ique$ies hea # oi"s and 'a+es present pre ious penetrant 'i"" more e$$ecti e"# $i"" a crac%) In addition( 'hen penetrants are heated( d'e"" time ma# !e reduced !ecause o$ $aster penetration) Durin& the d'e"" time( the part temperature 'i"" $a"" and the iscosit# o$ the penetrant 'i"" increase) This 'i"" resist o er remo a") Simi"ar"#( the de e"opin& step is a"so $aster( penetrant mo"ecu"es are more readi"# a!sor!ed !# the de e"oper "a#er( and the de e"oper dries $aster) Fhen inspectin& heated sur$aces 'ith 'ater 'asha!"e penetrants( it 'ou"d !e prudent to 'ipe the sur$ace 'ith a so" ent or c"eaner resistant to hi&h temperatures( since !oi"in& 'ater ma# not rinse e+cess penetrant satis$actori"#) 4i&h temp certi$ied penetrant materia"s sha"" !e used) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
24
SAIMIRA
<"uorescent D#e - T#pe I 2 8 <"uorescent penetrant uses minera"s or chemica" compounds <"uorescent 'hich emit isi!"e response "i&ht is 'hen e+posed 'hen to u"tra io"et to "i&ht) penetrantRs ma+imum e+posed CE0 nm
'a e"en&th u"tra io"et "i&ht)
The d#e a!sor!s this ener&# and emits !et'een 01/ nm to E1/ nm 'a e"en&ths U6 "i&ht to 'hich is isi!"e as !ri""iant #e""o'3&reen) Oran&e 3 red t#pe penetrants are a"so a ai"a!"e) The e$$icienc# o$ $"uorescent d#es in con ertin& isi!"e "i&ht ma# !e reduced !# pro"on&ed e+posure to U6 "i&ht) E"e ated temperature can reduce the $"uorescence o$ penetrant in open tan%s) <"uorescent penetrants are desi&ned $or di$$erent sensiti it# "e e"s J Le e" .Q1 Le e" . Le e" 1 Le e" C Le e" D U"tra "o'( $or castin&s and rou&h sur$aces)
Lo' sensiti it# 0/?m NiCr crac% pane"s) Norma" sensiti it# D/?m( &enera" purpose use) 4i&h sensiti it# 1/ 3 C/?m) U"tra hi&h sensiti it# ./?m e+treme"# critica" use)
The actua" certi$ications $or sensiti it# "e e" S to D( in o" es the use o$ a series o$ titanium and nic%e" a""o# pane"s containin& d#e !ecause the# ha e "o'er er# sma""( "a!orator# isi!"e &enerated $ati&ue crac%s) <"uorescent penetrants are more sensiti e than
iscosit#( can penetrate sma""er openin&s( and ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS ha e e+ce""ent indications are
2/
SAIMIRA
isi!i"it#) It is easier to detect somethin& &"o'in& in the dar% man# times !ri&hter than their dar% surroundin&s) The
than to o!ser e a sma"" co"ored area on a 'hite !ac%&round) <"uorescent !ri&htness o$ indications depends on the incident U6 3 "i&ht intensit# and minimum ./// micro 'atts Q cm1 is required at the test sur$ace) Kac%&round 'hite "i&ht i""umination is to !e "imited to 1/ Lu+) <"uorescent necessar#) De e"oper indications are penetrants is require on"# a $or de e"oper the 'ith "o'er partic"e concentration( !ecause the 'hite !ac%&round pro ided !# the de e"oper is not required !"ottin& action) <"uorescent isi!"e in er# thin $i"m) <or these penetrants( remo a" o$ e+cess
penetrant !# so" ent 'ipin& requires more care and is a pro!"em 'hen a "ar&e sur$ace area is to !e c"eaned) Fater 'asha!"e t#pe 'i"" reduce this pro!"em) <or $"uorescent penetrant testin&( it is perman&anate( acid comp"ete"#) chromate er# important to ensure that the $erric so"utions( pero+ides( part sur$ace is comp"ete"# $ree $rom nitric( su"phuric( chromic acids( a"%a"ine so"utions( acid persu"phates etc) These common c"eaners a"" de&rade or %i"" the $"uorescence
Dua" sensiti it# com!ination o$ red indications $o""o'ed
penetrants - T#pe III 2 8
These
penetrant
contains
isi!"e d#e and oran&e $"uorescent d#e( such as TK# Lu+R ie'ed under 'hite "i&ht $or red d#e in a dar%ened area $or oran&e isi!"e !# u"tra io"et "i&ht
$rom Sher'in) The test o!,ect is $irst
indications) These penetrants pro ide t'o "e e"s o$ inspection sensiti it#) One ad anta&e is that $"a's "ocated durin& U6 e+amination are mar%ed !#
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS indications $or repeat
20
SAIMIRA e+amination or repair 'or%)
Another ad anta&e is that $"a's $ound in one mode can !e second mode) 4o'e er( the !ri&htness o$ the isi!"e red $"uorescent co"or are "ess than the indi idua" penetrants)
eri$ied in the and the
co"or
isi!"e d#e and $"uorescent
Important 8 <"uorescent penetrant shou"d ne er !e used on sur$aces 'hich ha e !een processed pre ious"# 'ith co"or contrast penetrant) In man# cases residues o$ d#es persist in a de$ect( the $"uorescent process su$$ers not on"# $rom the residue reducin& the amount a!"e to &et into the de$ect( residues o$ co"or d#es 'i"" compete $or "i&ht and e$$ecti e"# %i"" the $"uorescence o$ an# entrapped $"uorescent penetrant in su!sequent tests) .5 isi!"e penetrant can stop the $"uorescence) I$ $"uorescent inspection is required( then the part sha"" !e c"eaned thorou&h"# to remo e an# co"or penetrant residue $rom the interior o$ the discontinuities) App"#in& a re ersi!"e penetrant de e"oper( 'hich contains a $"uorescent d#e( reacts 'ith(
ASNT NDT LEVEL
21
SAIMIRA
and thus is quenched !#( the red d#e) Fhen the sur$ace is
ie'ed under U6 stands out
i""umination( the residua" spots o$ red d#e can !e detected( 'hich penetrant d#e has !een comp"eted and eri$ied !# this
as dar% spots a&ainst a $"uorescent !ac%&round) Once the remo a" o$ red procedure( the de e"oper is remo ed !# rinsin& 'ith 'ater) <"uorescent Kri&htness 8 is the amount o$ O the thic%ness o$ the penetrant $i"m) O the intensit# o$ the U6 "i&ht) O amount o$ $"uorescent d#e and its capa!i"it# to a!sor! U6 "i&ht) O the e$$icienc# o$ the d#e in con ertin& the "i&ht) Penetrants 'ere e+amined !# p"acin& a drop o$ used and ne' penetrant ne+t to each other on a paper to'e" $or a isua" comparison) 7ost penetrant speci$ications require rep"acement 'hen the !ri&htness drops !# more than ./5) Under test situations( the human e#e ma# detect a chan&e o$ a!out .05 or more in !ri&htness) <"uorescent !ri&htness measurement can !e per$ormed usin& a appro ed Photo $"uorometer Note 8 The &enera" ru"e is penetrant that to use the "o'est sensiti it# $"uorescent re ea"s the discontinuities o$ interest) re"eased e"ectrons to isi!"e isi!"e "i&ht &i en o$$ 'hen a
$"uorescent d#e is e+posed to U6 "i&ht) It depends on J
ASNT NDT LEVEL
22
SAIMIRA
Post Emu"si$ication penetrants 8 These penetrants are not direct"# 'ater 'asha!"e and the dan&er o$ o er3 'ashin& the penetrant $rom the discontinuities is reduced) An emu"si$#in& a&ent is used that ma%es the sur$ace penetrant so"u!"e in 'ater so that the e+cess penetrant can !e remo ed !# 'ater rinse and then a de e"oper can !e app"ied) These penetrants ha e !etter penetratin& a!i"it# than 'ater 'asha!"e penetrants and can detect minute $"a's) These processes are 'ide"# used 'ith $"uorescent penetrants !ut much "ess 'ith co"or contrast penetrant) Emu"si$iers are "iquids used to render the e+cess penetrant 'ater 'asha!"e) The manu$acturers care$u""# $ormu"ate the emu"si$iers dependin& upon the penetrant to !e used) Penetrants and emu"si$iers are used as a s#stem( and emu"si$ier $rom one manu$acturer ma# not per$orm adequate"# on a di$$erent manu$acturerRs penetrant) There are t'o t#pes o$ emu"si$iers used in the remo a" processes J The# are Lipophi"ic emu"si$iers and 4#drophi"ic remo ers - deter&ents 2 )Lipophi"ic emu"si$iers - 7ethod K 2 are oi" !ased and contain !"ends o$ sur$actants( esters and hi&h !oi"in& point h#drocar!on disti""ates) The# are co"ored other than &reen to a""o' eas# identi$ication) These emu"si$iers are used as supp"ied( and $unction !# mechanica" and chemica" action) The commonest method $or app"ication o$ "ipophi"ic emu"si$iers is direct immersion $o""o'ed !# draina&e) A$ter the emu"si$ier has coated the sur$ace o$ the part( mechanica" action starts to remo es some o$ the e+cess penetrant as the mi+ture drains $rom the part) Durin& the emu"si$ication time( the emu"si$ier di$$uses into the remainin& penetrant $i"m on the sur$ace o$ the part and PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
23
SAIMIRA
render it 'ater 'asha!"e) The emu"si$ier is $ast actin&( thus ma%in& the emu"si$ication - or contact time 2 ta%e p"ace quic%"# er# critica") The emu"si$ier continues to act as component ma# !e "on& as it is in contact 'ith the penetrant( there$ore( the rinse operation shou"d to a oid o er 3 emu"si$ication) The immersed rapid"# in a "ar&e rinsin&) Spra# app"ication $o""o'ed !# draina&e has a"so !een used success$u""#) Krush app"ication o$ "ipophi"ic emu"si$iers is prohi!ited( !ecause this 'ou"d mechanica""# mi+ the emu"si$ier into the penetrant resu"tin& in non uni$orm emu"si$ication) recommended <"o'in& the emu"si$ier ma# not !e on the component to co er sur$ace the is not !ecause it possi!"e component o"ume o$ 'ater to stop the action o$ the
emu"si$#in& a&ent) On remo a" $rom the 'ater( the 'ash is comp"eted !# spra#
sur$aces rapid"# enou&h to ensure uni$orm emu"si$ication) It is essentia" that comp"e+ shaped components are rotated durin& the draina&e sta&e so that the arious sur$aces recei e simi"ar processin&) The three properties o$ "ipophi"ic emu"si$iers that contro" the 'ashin& characteristics are acti it#( contact time can iscosit#( and 'ater to"erance) Speci$ic contact times $or "ipophi"ic emu"si$iers shou"d !e esta!"ished $or each app"ication) The ar# !et'een E/ and .M/ seconds dependin& on the t#pe o$ the emu"si$#in& a&ent( the penetrant in use and the sur$ace condition o$ the components) Lipophi"ic emu"si$iers are used at temperatures !et'een .0 and 10/ C) Lipoph#"ic emu"si$ier are misci!"e 'ith penetrants in a"" concentrations) 4o'e er( i$ the concentration o$ penetrant contamination in the emu"si$ier !ecomes too &reat( the mi+ture 'i"" not $unction a$$ecti e"# as a remo er) A speci$ication requirement is that( "ipophi"ic emu"si$iers !e capa!"e o$ to"eratin& 1/5 penetrant contamination 'ithout a reduction in per$ormance) The emu"si$ier is to !e rep"aced 'hen its c"eanin& action is "ess than that o$ ne' materia") Since "ipophi"ic emu"si$iers are oi" 3 !ased( the# ha e a "imited to"erance $or 'ater) Fhen the to"erance "e e" is reached( the emu"si$ier starts to thic%en and 'i"" e entua""# $orm a &e" as more 'ater is added) Speci$ication requires that PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
34
SAIMIRA
"ipophi"ic emu"si$iers !e $ormu"ated to $unction adequate"# 'ith at "east 05 'ater contamination and that "ipophi"ic emu"si$iers !e rep"aced 'hen the 'ater concentration reaches the "imit)
Flow diagram for PE lipophilic

M,6039
P*, 2),&7
D *,A3>&) '*32,-- ASTM E 1 5

9*+ *,B,26 N37 A@.,3.9,>,)3',* 9*+ A'')+ ',7,6*&76 94,)) D(' (7 EA.)-(?(,*
T(A, (- 2*(6(2&)C C
*(7-,
(7-',26 P3-6 2),&7 O$
ASNT NDT LEVEL
31
SAIMIRA
4#drophi"ic remo ers are app"ied !# immersion in an aqueous so"ution) The concentration $or immersion and up to C/ 5 dependin& on aries !et'een the ran&e o$ 1)05 to ./5( 1/5 !rands and conditions o$ a&itation) The
manu$acturer o$ the emu"si$ier can pro ide the proper in$ormation concernin& this concentration) Concentrations hi&her than recommended !# the emu"si$ier manu$acturer or the qua"i$ied percenta&e is prohi!ited) The immersion time aries $rom 1/ seconds to 0 minutes dependin& on the penetrant( emu"si$ier concentration( sur$ace rou&hness and a&itation) The sur$ace acti e a&ent in the remo er com!ines 'ith a sma"" quantit# o$ penetrant $rom the sur$ace and pre ents the penetrant $rom recom!inin& 'ith the remainin& sur$ace penetrant) A s"i&ht a&itation is necessar# to remo e the co""oida" suspension o$ penetrant : emu"si$ier $rom the sur$ace and to e+pose $resh penetrant) The pre$erred method o$ a&itation is mechanica")
A&itation usin& compressed air can cause hea # $oamin& and ma# introduce PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS contaminants) Fhen app"ication is
32 !#
SAIMIRA immersion( h#drophi"ic emu"si$iers
ma"$unction as a resu"t o$ penetrant accumu"ation) Contamination increases 'hen part &eometr# inc"udes ca ities( or areas 'hich entrap penetrant to !e carried o er to the emu"si$ier tan%) Emu"si$ier 'ith "o'er concentration &ets contaminated $aster) The C/5 concentration( i$ used( to"erates some three times more penetrant contamination as the ./5 concentration does) E er#thin& !ein& equa"( a C/5 concentration "asts three times "on&er than a ./5 concentration( and is economica" !ecause o$ "ess $requent disposa"s) 4#drophi"ic emu"si$iers are in$ested !# $un&us and a"&ae and the tan%s must remain co ered 'hen not in acti e use) C/5 concentration has more resistance to this in$estation) 4#drophi"ic remo er so"utions are a"so app"ied !# spra# or as $oam) The concentration o$ the so"ution tend to !e much "o'er up to 05) 4o'e er( hi&her concentration ma# !e used dependin& on the manu$acturers recommendation) Immediate"# $o""o'in& the remo er spra#in&( a $resh'ater rinse o$ the entire part is required to stop the action o$ an# remo er remainin& on the sur$ace o$ the part) 4#drophi"ic remo ers minimi*e !ac%&round $"uorescence on part sur$aces as 'e"" as !"eed out o$ e+cess penetrant $rom ho""o' parts) The concentration o$ the deter&ent so"ution is critica" to the success o$ the process and must !e contro""ed) Fater "oss in h#drophi"ic emu"si$iers resu"ts in more concentrated and more acti e so"utions( a cause $or o er3 emu"si$ication 'ith resu"tant $ai"ure o$ the penetrant process) To monitor the concentration( the re$racti e inde+ o$ the 'or%in& so"ution is &enera""# measured and compared a&ainst &raphs &enerated !# measurin& the re$racti e inde+ o$ so"utions o$ %no'n concentrations( usin& a Re$ractometer - an optica" de ice 'ith a readin& sca"e 2) A drop o$ the 'or%in& so"ution is p"aced on the proper spot on the re$ractometer and a readin& is made on the sca"e and then con erted into percenta&e !# usin& a ta!"e or a &raph app"ica!"e $or the particu"ar remo er and supp"ied !# the emu"si$ier manu$acturer) The &raph ma# !e &enerated in the 'or%station usin& prepared so"utions o$ the standard
ASNT NDT LEVEL
33
SAIMIRA
remo er $rom 0/5 o$ the 'or%in& stren&th to 0/ 5 a!o e) A minimum o$ 0 so"utions o$ di$$erent stren&ths shou"d !e prepared $or this purpose)
Hydrophilic emulsifier Method D

P*, 2),&7 A'')+ ',7,6*&76 P*, *(7-,
9*+
94,))
P3-6 2),&7
I7-',26 W(60 BL
A'')+ 9,>,)3',*
I7-',26 W(60 BL
C3)),26 T0, 8.)D EE2,-',7,6*&76
So" ent remo a!"e penetrant process 8 Penetrants 'hich cannot !e remo ed direct"# 'ith 'ater can !e remo ed !# use o$ or&anic so" ents) The so" ents used are quite ersati"e and dries quic%"# 'ithout a residue and a de e"oper can !e app"ied on the dr# sur$ace) Norma""#( the same t#pe o$ so" ent is used $or pre c"eanin& and $or remo in& e+cess penetrant $rom the test sur$ace) T#pica" app"ications in o" e in situ inspection or testin& o$ a speci$ic "ocation on the component 'hen it is not practica" to remo e the penetrant usin& 'ater( 'hich 'ou"d in o" e su!sequent dr#in& o$ the component) Three t#pes o$ so" ent remo ers are used 8 6o"ati"e h#drocar!on disti""ates) 4a"o&eneted h#drocar!on so" ents - non $"amma!"e 2) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS 6o"ati"e a"iphatic a"coho"s)
34
SAIMIRA
The $"amma!"e c"eaners are potentia" $ire ha*ards !ut are $ree $rom ha"o&ens( 'hi"e the non $"amma!"e c"eaners contain ha"o&ens( 'hich render them unsuita!"e $or some app"ications) sma"" test area( !rushin& penetrant is easier) E+cess penetrant remo a" is per$ormed !# 'ipin& the part sur$ace in one direction on"#( 'ith a c"ean and "int $ree c"oth or a!sor!ent paper) The proper procedure is to ma%e a sin&"e pass( then $o"d the c"oth to e+pose a c"ean sur$ace $or each succeedin& 'ipe) This 'i"" remo e most o$ the penetrant) The remainin& traces are then remo ed !# 'ipin& 'ith a ne' c"oth or paper "i&ht"# 'etted 'ith the so" ent remo er) A$ter each pass( the sur$ace o$ the c"oth is e+amined) I$ there is more than a trace o$ penetrant on the c"oth( the c"oth is $o"ded to e+pose a c"ean sur$ace( remoistened 'ith the so" ent( and the sur$ace is 'iped a&ain) The process is repeated unti" there is "itt"e or no trace o$ penetrant on the c"oth) C"eanin& shou"d !e done quic%"#( usin& a minimum o$ c"eaner) I$ the operation is pro"on&ed or i$ e+cessi e amount o$ the c"eaner is used( some penetrant ma# !e remo ed $rom discontinuities) The sur$ace is then 'ipin&) ie'ed under suita!"e "i&ht to ensure that the e+cess penetrant is remo ed) <or app"ication o$ de e"oper( the sur$ace is dried !# e aporation or So" ent remo a!"e penetrant ma# !e app"ied to the test sur$ace !# spra#in&( dippin&( $"oodin& or !rushin&) <or a contro"s app"ied penetrant and remo a" o$ e+cess
ASNT NDT LEVEL
3/
SAIMIRA
Non $"amma!"e(
o"ati"e so" ents can !e used in the
apor phase in
automatic processin& stations - "i%e
apor de&reasin& 2) The so" ent shou"d !e
redisti""ed $requent"# to a oid hea # contamination 'ith penetrant( since the penetrant 'i"" start to co3disti" 'ith the so" ent and cause hea # !ac%&round) Note 8 The o"ati"e or&anic so" ents used $or penetrant remo a" are the most a&&ressi e and &reat care must !e ta%en in their use to pre ent o er3 remo a") <or manua" processin&( the so" ent remo er must !e used !# 'ipin& 'ith a c"oth) Use o$ a so" ent remo er !# spra#in& or $"oodin& 'i"" resu"ts in o er 'ash or di"ution o$ the penetrant and the indications 'i"" !ecome di$$used and 'ea%) The optimum sensiti it# is achie ed 'hen the !ri&htest indications appear a&ainst a thin de e"oper contrastin& !ac%&round) Fhen norma" c"eanin& cannot su$$icient"# remo e penetrant $rom as3 'e"ded sur$aces( machined parts 'ith sharp inside corners( or parts 'ith depressions or pits( such areas can !e $urther c"eaned 'ith a commercia""# a ai"a!"e cotton s'a! or 'ith a cotton s'a! on a toothpic% 'etted 'ith the so" ent)
ASNT NDT LEVEL
30
SAIMIRA
some hints .) Due to sur$ace rou&hness o$ un$"ushed 'e"ds( it is !etter to use( 'ater 'asha!"e and so" ent remo a!"e methods to a oid undesira!"e !ac%&round) 1) In the case o$ So" ent remo a!"e pentrants( usua" precaution o$ 'ipin& 'ith so" ent moistened "int $ree c"oth ma# not #ie"d the desired resu"ts !ecause o$ e+cessi e !ac%&round) Sometimes( the so" ent is direct"# app"ied to the 'e"d to o ercome this di$$icu"t#) O$ course $ine crac%s ma# !e missed C) In the case o$ TIG and 7IG 'here !etter sur$ace is o!tained( it is !etter to &o so" ent 'ipin& method D) Inspection 'ith mu"tip"e pass 'e"ds 'ith penetrants requires that each 'e"d !ead is inspected prior to the ne+t pass to pro ide the ne+t the !est re"ia!i"it#) C"eanin& a$ter each testin& 0) 0)Fater 'asha!"e $"uorescent penetrants esse"s or other can !e used on "ar&e pressure dr#in&) can pro ide &ood sensiti it# readi"# $rom most 'e"d 'e"ds !e$ore penetrant desira!"e) Grindin& "ar&e structures !# 'ashin& 'ith a hose and air
De e"opent 'ith so" ent suspended de e"oper Fater 'asha!"e penetrants can !e 'ashed more testin&)
E) E) It is important to remo e a"" the o$ the s"a& $rom Grindin& o$$ the ripp"es on rou&h 'e"ds is shou"d not smear the meta"
L) L) Kra*ed ,oints can discontinuities simi"ar to 'e"d !eads that can !e detected !# PT) De e"opers 8 Norma""# a de e"oper is used to comp"ete the penetrant process) De e"opers are $ine 'hite po'ders app"ied as dr# or 'ith a "iquid carrier to PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL A !ra*e that does not 'et the sur$ace is indication o$ a poor ,oint)
31
SAIMIRA
$orm a thin uni$orm coatin& on the test sur$ace) De e"oper acts "i%e a spon&e 'ith er# $ine random capi""ar# paths) Fhen the penetrant contacts the de e"oper( it spreads throu&h these paths !# capi""ar# action - %no'n as !"ottin& or re erse capi""ar# action 2) The penetrant &radua""# di$$uses into the de e"oper and indications !ecome "ar&er than the discontinuit# openin&) The 'hite co"or o$ the de e"oper pro ides contrast 'ith co"or contrast penetrants and a"so pro ides a dar%er !ac%&round $or $"uorescent indications) It shou"d !e noted that the de e"oper itse"$ does not produce indications !ut simp"# a!sor!s the penetrant a"read# present !e"o' it and ma%es it more isi!"e) De e"oper shou"d !e app"ied as soon as possi!"e or 'ithin C/ minutes a$ter the remo a" o$ the e+cess penetrant) Dr# de e"opers - <orm A 2 8 - !"ends o$ chemica""# inert 'hite po'ders 2 Dr# de e"opers are a non to+ic $"u$$# a!sor!ent 'hite po'der that is used most"# 'ith $"orescent penetrant process) These dr# po'ders do not norma""# pro ide su$$icient 'hite !ac%&round $or contrast 'ith co"or contrast penetrants) This ma# !e achie ed !# use o$ e"ectrostatic spra# app"ication !ut is not a"'a#s contro""ed easi"#) Dr# po'ders must !e used on dr# sur$ace on"#) Dr# de e"opers are the "east sensiti e) The dr# po'ders shou"d !e used in a c"osed container or( i$ spra#ed( inside a !ooth 'ith &ood e+traction) Fhere the throu&hput o$ components is "o'( components can !e p"aced on a &rid in a tan% and po'der app"ied usin& a scoop or $rom a pear shaped ru!!er pu$$er) E+cess po'der is then remo ed !# &ent"e air !"ast( sha%in& or tappin&) Dr# po'der ma# a"so !e app"ied !# !rushin& on rou&h test sur$aces) Dr# po'der is !est app"ied !# p"acin& the component in a dust storm ca!inet 'hich ma# !e o$ the tunne" t#pe or top "oadin&) The ca!inet is sea"ed to !e dust proo$) 7ost ca!inets 'or% on a preset c#c"e so that once started the ca!inet cannot !e opened unti" the c#c"e is comp"ete) The dr# po'der de e"oper is then a&itated 'ith dr# and oi" $ree compressed air( 'hich !"o's the po'der into a c"oud around the component to coat the sur$ace) It is PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS ad isa!"e to incorporate an
32
SAIMIRA
> e+tract and return > s#stem 'ith the ca!inets( er# "on& time to sett"e $rom the air) Dust
since the $ine partic"es ta%e a
cham!ers shou"d !e $itted 'ith heaters to maintain a dr# inside atmosphere) Insta""in& a $an at the !ottom o$ the container to !"o' the po'der e"iminates most o$ the pro!"ems associated 'ith the use o$ compressed air) Dr# po'ders can !e app"ied a$ter char&in& them in a e"ectrostatic spra# s#stem) Some dr# po'ders are o$ a chemica" composition 'hich does not !ecome su$$icient"# char&ed and this point shou"d !e chec%ed !e$ore attemptin& to use this method o$ app"ication) Dr# de e"opers shou"d c"in& to dr# meta""ic sur$aces in a $ine $i"m o$ dust) The adherence o$ the po'ders shou"d not !e e+cessi e( as the amount o$ !"ac% "i&ht a ai"a!"e to ener&i*e indications 'i"" !e reduced) In automatic processin& s#stems( dr# po'ders are app"ied !# passin& the part throu&h a con e#or in a $"uidi*ed !ed tunne" s#stem) This app"ication re"ies on producin& a contro""ed air Q po'der mi+ture 'hich passes o er the components and coat the sur$aces)E+treme"# $ine dr# de e"oper po'ders are a ai"a!"e $or app"ication !# dippin& the dried part into it) This process has the disad anta&e that the de e"oper &radua""# !ecomes contaminated !# $"uorescent $"ec%s and produces $a"se indications) <or purpose o$ stora&e and app"ications( the dr# po'ders shou"d not !e h#&roscopic and the# shou"d remain dr#) I$ the# pic%up moisture 'hen stored in areas o$ hi&h humidit#( the# a&&"omerate or "ump up and "ose their a!i"it# to $"o' and dust the sur$ace adequate"#) The de e"oper shou"d !e chec%ed dai"# $or ca%in& and contamination) Dr# po'der de e"opers can dr# the s%in and irritate the e#es and the respirator# s#stem) Use o$ ru!!er &"o es and respirators is desira!"e)
ASNT NDT LEVEL
33
SAIMIRA
De e"oper properties Good !"ottin& action) 7ust !e easi"# 'etted !# penetrant and dra' the ma+imum amount o$ penetrant $rom the de$ect) <ine &rained Sho' indications $rom sma"" amount o$ penetrant) 7as% out inter$erin& penetrant and part sur$ace !ac%&round) To $orm a thin and uni$orm coatin&) Non $"uorescent) Easi"# c"eaned $rom the sur$ace) Non $"amma!"e) Non to+ic and non corrosi e) De e"oper se"ection 8 Se"ect 'et de e"oper in pre$erence to dr# on Se"ect dr# de e"oper in pre$erence to 'et on 'as used $or a prior inspection) Fet de e"opers can not at !e used re"ia!"# 'here such part as con$i&uration accumu"ates de e"oper certain "ocations threads) E+cess er# smooth test sur$aces) er# rou&h test sur$aces)
C"eanin& and re inspectin& a rou&h sur$ace is di$$icu"t( i$ a 'et de e"oper
de e"oper can mas% out indications) Dr# de e"oper can !e used) So" ent suspended de e"opers are er# e$$ecti e $or $"a's 'ith narro' openin&( !ut are not satis$actor# $or $indin& 'ide sha""o' de$ects) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
44
SAIMIRA
Aqueous - Fet 2 de e"opers 8 These de e"opers are used in penetrant inspection stations) Aqueous de e"oper uses 'ater as the carrier o$ the de e"oper partic"es) The de e"oper is used as a so"ution - <orm K 2 or as suspension - <orm C 2) Fater !ased de e"oper inc"udes a 'ettin& a&ent( corrosion inhi!ition s#stem and dispersin& medium) These de e"opers are app"ied direct"# on a 'ater 'ashed sur$ace and a$ter dr#in& a so" ent 'ashed sur$ace) Parts are dried immediate"# a$ter e+cess de e"oper has drained $rom the component) These de e"opers are "ess sensiti e 'hen compared to non 3 aqueous de e"opers) Fater So"u!"e de e"opers - <orm K 2 8 - K"ends o$ 'hite cr#sta""ine po'ders to !e disso" ed in 'ater 2 Supp"ied as so"u!"e 'hite po'ders to !e disso" ed in 'ater at a concentration recommended !# the manu$acturer - D/ 3 E/ & Q "it 2 to prepare a transparent 'or%in& so"ution) The prepared !ath is comp"ete"# so"u!"e and does not require a&itation) I$ the so"utions are stored in open tan%s( precipitate ma# $orm due to "oss o$ 'ater !# e aporation) The concentration o$ the so"ution is monitored !# measurin& the speci$ic &ra it# 'ith a h#drometer) Fater so"u!"e de e"opers are not recommended $or use 'ith 'ater 'asha!"e penetrants !ecause o$ the potentia" to 'ash the penetrant $rom 'ithin the $"a' un"ess the de e"oper app"ication is er# care$u""# contro""ed) Fater so"ution de e"opers can !e app"ied !# immersion $o""o'ed !# draina&e in a stain"ess stee" tan%) The de e"oper ma# !e app"ied !# $"o'3on( !rush or a 'et spra#) Fhen spra# app"ication is used( it is important( that the spra# is 'et and the drop"ets coa"esce to $orm a continuous "a#er on the test sur$ace) The part sur$ace must !e dried acti e"# a$ter the de e"oper app"ication to $orm an uni$orm "a#er) The dried de e"oper $i"m is 'ater so"u!"e and can !e remo ed a$ter inspection !# simp"e 'ater rinsin&) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
41
SAIMIRA
So"u!"e de e"opers contain inor&anic compounds 'hich ioni*es in the so"ution) Dippin& di$$erent meta"s in contact 'ith each other and use o$ uncoated !as%et produce &a" anic corrosion) The contaminated de e"oper so"ution !ecomes &ra# to dar% &ra# in co"or) Fater Suspended de e"opers - <orm C 2 8 - K"ends o$ 'hite inert po'ders and sur$actants $or suspension in 'ater 2 supp"ied as inso"u!"e 'hite po'ders to !e suspended in 'ater at a concentration recommended !# the manu$acturer - around L/ & Q "it 2 to &i e a 'or%in& preparation) Fater suspension de e"opers ma# !e app"ied !# immersion in an a&itated !ath or !# spra#in&) The immersion tan% shou"d !e o$ stain"ess stee" 'ith mechanica" stirrer to pre ent sett"in&) Air a&itation shou"d !e a oided since the de e"opers contain 'ettin& a&ents and corrosion inhi!itors 'hich ma# !ecome de&raded !# chemica" reaction 'ith the o+#&en or car!on dio+ide in the air) I$ the de e"oper is to !e app"ied !# spra#in&( the desi&n and operation o$ the spra# apparatus must a""o' continuous a&itation o$ the reser oir o$ de e"oper and the app"ication must a""o' the suspension to arri e 'et at the test sur$ace) <oamin& must !e a oided !ecause 'hen $oam !u!!"es !rea% the# "ea e ho"es in the de e"oper coatin&) The amount o$ po'der in suspension must !e care$u""# maintained) Too much or too "itt"e de e"oper on the test sur$ace can serious"# a$$ect sensiti it#) It is essentia" that the de e"oper !ath is monitored !# chec%in& the speci$ic &ra it# and the 'ettin& characteristics) Fater suspension de e"oper is app"ied !e$ore dr#in&( the de e"opin& time decreases !ecause the heat $rom the dr#in& operation he"ps penetrant !ac% to the sur$ace openin& and the de e"oper $i"m !ein& a"read# in p"ace( the de e"opin& action !e&ins at once) Non Aqueous Suspension de e"opers - <orm D 2 8 - Chemica""# inert 'hite pi&ments suspended in o"ati"e "iquid carriers 2 ASNT NDT LEVEL
42
SAIMIRA o"ati"e or&anic
These consist o$ de e"oper partic"es suspended in a
so" ent) The use o$ a quic% dr#in& so" ent as carrier ma%es non aqueous 'et de e"oper the most sensiti e $or detection o$ minute crac%s) The so" ent com!ines 'ith the penetrant in the crac%s( and the resu"t is a "ess iscous "iquid 'hich !"eeds into the de e"oper $air"# quic%"# as the so" ent e aporates) Non aqueous suspension de e"opers must !e app"ied !# spra#in& on a dried part sur$ace) Spra#in& ma# !e !# aeroso" can or con entiona" spra# &un) Since o"ati"e so" ents are used in these de e"opers( e$$icient e+traction $aci"it# The suspended partic"es separate on standin& - sett"es to the !ottom o$ the container 2 and so must !e a&itated !e$ore use to an homo&eneous mi+ture) Fhen aeroso" cans are used( this is done !# sha%in& the can) <or a spra# &un app"ication( the reser oir must !e equipped 'ith an e$$icient a&itator) A"ternati e methods o$ app"ication( such as immersion( $"o'3on or !rushin& on 'i"" cause "oss o$ sensiti it#) must !e pro ided in the inspection area)
A de e"oper coat 'hich is ,ust thic% enou&h to mas% the meta" sur$ace is a!out ri&ht) I$ the coat is too thic%( the penetrant mi&ht not !"ot throu&h to the sur$ace) I$ it is too thin( it mi&ht not !"ot 'e"" enou&h) Spra#in& shou"d !e per$ormed $rom a distance o$ M to ./ inches $rom the test sur$ace) 4o"din& the can too c"ose to the sur$ace 'i"" resu"t in e+cessi e de e"oper !ein& app"ied e er# time)
ASNT NDT LEVEL
43
SAIMIRA
Startin& the spra# path $rom one side o$ the part( mo in& the spra# onto and across the part( and $inishin& the spra# pass !e#ond the part( is the pre$erred technique) Additiona" spra# passes are required to ensure $u""( !ut minimum co era&e) This method resu"ts in e en coat 'ithout pudd"es that can resu"t 'hen the spra# path is !e&un !# aimin& direct"# at the part) The so" ent sha"" not !e a""o'ed to accumu"ate on the test sur$ace or the penetrant 'i"" !e di"uted and the indications 'i"" !ecome di$$used and 'ea%) U"tra io"et "i&ht 8 Inspection en ironment 6isi!"e d#e penetrant indications are inspected under 'hite "i&ht and $"uorescent d#e penetrant indications are ie'ed under !"ach "i&ht @u"tra io"et "i&htUA E"ectroma&netic radiation spectrum 6isi!"e and u"tra io"et spectrum 6isi!"e "i&ht spectrum 3 CM/ nm to LL/ nm or @ 6 to R A or U"tra io"et spectrum 3 ./ nm to CM/ nm or .// 3CM// Ao K"ac% "i&ht spectrum 3 C1/ nm to CM/ nm or @'ith pea% at CE0 nmA 4& arc apour "amp produces u"tra io"et "i&ht in addition to isi!"e "i&ht) The $i"ters are used to remo e the harm$u" portion o$ U6 @!e"o' C1/ nmA and a"so isi!"e "i&ht 'hich a$$ects the $"uorescence o$ the $"uorescent d#e) The $i"ters that are common"# used &i e !"ac% "i&ht 'ith ma+imum pea% intensit# at CE0 nm)) Co"our : part o$ the 'hite "i&ht that is re$"ected !# the sur$ace that is $"ooded 'ith the 'hite "i&ht <"uorescent co"our : Emission o$ isi!"e "i&ht @an# co"ourA on the impin&ement o$ hi&h ener&# radiation on the sur$ace) In PT V 7T( the impin&ement o$ !"ac% "i&ht @U6A "eads to emission o$ #e""o'ish &reen "i&ht U"tra io"et radiation is a !and o$ 'a e"en&ths 'ithin the e"ectroma&netic spectrum and !e"o' !oundar# !et'een isi!"e - 'hite 2 "i&ht) U"tra io"et 'a e"en&ths are too short to !e seen !# the human e#e) The isi!"e "i&ht - 'hite 2 and U6 - !"ac% 2 "i&ht is a 'a e"en&th o$ D// nm - nano meters 2 or - D/// An&stroms 2) U6 3 spectrum is di ided into three ran&es 8 PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL CM// Ao to L/// Ao It is 'ise to test the aeroso" can $or its uni$orm spra#in& a!i"it# !e$ore usin& it on the test part)
44
SAIMIRA
U6 3 A - D// 3 C// nm 2 3 Lon& Fa e) U6 3 K - C// 3 1M/ nm 2 3 7edium Fa e) U6 3 C - 1M/ 3 .M/ nm 2 3 Short Fa e) U"tra io"et A is not considered harm$u" to the human e#e) U"tra io"et K can cause sun!urn as 'e"" as !e harm$u" to the e#es) U"tra io"et C is used $or &ermicida" purposes and is harm$u" to the e#es and the !od#) Da#"i&ht nm) The $"uorescent materia"s used in NDT $or !oth the ma&netic and penetrant inspections are se"ected to pro ide ma+imum $"uorescent properties 'ith U6 3 A e+citation in the CE0 nm 'a e"en&th) In $act these materia"s norma""# $"uoresce under e+citation o$ an# 'a e"en&th( $rom C1/ 3 D// nm) The $"uorescence( 'hich is re$"ected !ac% is in the ran&e o$ 0D/ 3 E1/ nm and is isi!"e as #e""o'3&reen to the human e#e) An# e+cessi e 'hite "i&ht in the inspection area - especia""# those in the &reen Q #e""o' 'a e"en&ths 2 'i"" decrease the contrast o$ indication to !ac%&round( $or this reason( speci$ications "imit the am!ient 'hite "i&ht "e e" to 1/ "u+ ma+imum) K"ac% "i&ht sources are norma""# hi&h pressure mercur# arc !u"!s and "o' pressure mercur# apor dischar&e tu!es) Lo' pressure mercur# and !"oc%s the apor "i&ht sources ha e a deep purp"e coatin& on the inside sur$ace o$ the !u"! to $i"ter out undesired U6 'a e"en&ths !u"!) 7ercur# 'a e"en&th) Ne' micro po'er &as dischar&e techno"o&# - 7PWL 2( is reco&ni*ed to create a much hi&her contrast o$ $"uorescent indication to !ac%&round( thus impro in& the operator;s isua" acuit#) 7PWL spot "amps produce in e+cess o$ H/(/// micro 'atts Q cm 1 $rom .1 inch distance( and a""o' inspection to !e per$ormed in areas 'here pre ious"# it 'ou"d ha e !een impossi!"e) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL isi!"e "i&ht &enerated !# the apor arc - 4ID 2 "amps used $or NDT ha e on"# t'o "ines o$ U6 3 ie'in& is considered to !e a ran&e o$ 0D/ throu&h 0L/ nm( 'ith the a era&e !ein& 000
A ener&# in si&ni$icant intensities) One o$ these !ands is at CE0 3 nanometer
4/
SAIMIRA
The "i&ht intensit# o$ u"tra io"et "amps is measured 'ith a suita!"e U6 "i&ht meter) 7ost o$ the U6 intensit# measurement meters $or NDT usa&e are desi&ned $or use on mercur# apor "i&ht sources at CE0 nanometers) <"uorescence 8 is the emission o$ e"ectroma&netic radiation !# a su!stance as the resu"t o$ the a!sorption o$ e"ectroma&netic or corpuscu"ar radiation o$ &reater ener&# than that o$ the $"uorescent radiation) <"uorescence is characteri*ed !# the $act radiation is maintained) U6 "i&ht $i"ter 8 U"tra io"et "amps produce !oth the harm$u" u"tra io"et radiations and isi!"e "i&ht) The deep purp"e $i"ter in the "amp a""o's on"# the 'a e"en&ths !et'een C1/ and D// nanometers to pass throu&h and e"iminates the harm$u" u"tra io"et radiations) The dar% co"or o$ the $i"ter a"so cuts o$$ su$$icient isi!"e - 'hite 2 "i&ht) U6 radiations !e"o' C1/ nm can !urn the retina o$ the e#es and a"so the s%in o$ the e+posed person) E+aminers must protect themse" es $rom the harm$u" U6 "i&ht !# ensurin& that the $i"ter used in the U6 "amp is in per$ect condition) An# crac%ed or dama&ed $i"ter sha"" !e immediate"# rep"aced or the Lamp sha"" !e re,ected) A "amp 'ith a dama&ed $i"ter must not !e used) Loo%in& direct"# at the "amp 'ith a proper $i"ter 'i"" not cause an# harm !ut ma# cause temporar# !"urrin& o$ C"eanin& o$ test sur$ace Paint Remo a" 8 The paint $i"m must !e comp"ete"# remo ed to e+pose the sur$ace o$ the e+amination area) Paint remo ers are chemica" !ond re"ease a&ents or so" ent strippers $or the remo a" o$ paint and corrosion inhi!itor coatin&s) The# are app"ied !# dippin& or !rushin& and 'or% 'e"" 'ith heat to acce"erate the remo a" process) The paint strippers is remo ed and the sur$ace is c"eaned !# deter&ents or so" ents) ision) that it occurs on"# so "on& as the stimu"atin&
ASNT NDT LEVEL
40
SAIMIRA
U"trasonic C"eanin& 8
is
per$ormed
on
"ar&e
num!er
o$
sma""
parts
!#
immersion or dippin& the part in a u"trasonic c"eanin& tan% 'ith a"most an# %ind o$ c"eanin& so"ution) So" ents and a"coho" 'or% 'e"" 'ith u"trasonic a&itation) It is the most e$$ecti e method $or openin& up de$ects !# remo in& contaminants im!edded in the discontinuit# ca it#) U"trasonic c"eanin& has !een $ound to !e e$$ecti e in remo in& penetrant entrapped in discontinuities) Ti&ht $"a's require 1 hours o$ c"eanin&) <or &eometrica""# comp"e+ components( hu&e !ene$its resu"t $rom com!inin& the chemica" action o$ a so" ent 'ith u"trasonic a&itation) U"trasonic c"eanin& is !ased on the princip"e o$ producin& ca itations in a "iquid so" ent in 'hich the component to !e c"eaned is immersed) Lar&e quantities o$ tin# !u!!"es are created in the so" ent - ca itations 2 !# hi&h intensit# compression 'a es) The co""apsin& pressure o$ the !u!!"es $orces them into cre ices 'here the $"uid penetrates !et'een contamination and the 'or% piece sur$ace) This action $orces the contaminant o$$ the 'or% piece "ea in& it tota""# c"ean) The $requenc# o$ u"trasonic static so" ents or i!ration is C/ to D/%4* t#pes) a"thou&h hi&her $requencies ma# sometimes !e used) C"eaners are a ai"a!"e as u"trasonic Etchin& 8 This process uses acids or a"%a"ine so"utions to disso" e smeared meta" $rom the sur$ace) Etchin& is per$ormed a$ter an# operation that cou"d mechanica""# the remo e materia" $rom the sur$ace( tend such to as sand and !"astin&( c"ose the machinin&( &rindin& or po'er !rushin&( to assure that the crac%s are opened to sur$ace) These mechanica" operations smear discontinuit# openin&s)
ASNT NDT LEVEL
41
SAIMIRA
Etchin& on stee" is accomp"ished usin& 0 to 1/5 o$ acid so"utions or 1/5 so"ution o$ ammonium per su"phate) The so"ution is app"ied $or a speci$ic period o$ time( neutra"i*ed and rinsed) The etchin& time is depends on the amount o$ materia" that is to !e remo ed) Etchin& usua""# requires a separate certi$ication !ecause o$ the inherent dan&er to the test operator and the component !ein& used) Acid entrapment $rom etchin& can ha e disastrous e$$ects on the penetrant inspection) Sodium h#dro+ide !oth acid caustic and o$ten caustic used to etch !e$ore a"uminum penetrant parts does not is a$$ect hi&h"# penetrants !ut can reduce the !ri&htness o$ indications) Care$u" c"eanin& o$ etches inspection recommended) Dr#in& the PartRs sur$ace 8 Components that require the use o$ c"eanin& a&ents $or the pre c"eanin& process must !e dried comp"ete"# !e$ore penetrant app"ication) Fhen 'ater !ased c"eaners are used durin& pre c"eanin&( the $ina" step is a 'ash 'ith c"ean 'ater and the parts are thorou&h"# dried) Fater or c"eanin& "iquid residue 'i"" hinder entrance o$ penetrant into discontinuities) The norma" 'a# o$ remo in& 'ater $rom c"eaned parts !e$ore penetrant app"ication is to heat them in a temperature contro""ed re 3 circu"atin& air o en $or one hour at around .10 / C) An a"ternati e is to immerse the components in a de'aterin& $"uid 'hich is then itse"$ remo ed !# apor de&reasin&) The Part sur$aces are to !e dried a&ain a$ter remo a" o$ e+cess penetrant and the sta&e at 'hich sur$aces are dried depends on the t#pe o$ de e"oper to !e used) Fhen dr# po'ders or non aqueous so" ent suspension de e"oper is used( the sur$aces must !e comp"ete"# dr# !e$ore app"ication) Fhen 'ater so"u!"e or 'ater suspended app"ication o$ the de e"oper) Dr#in& temperatures o$ E/ 3 M/XC - .D/ 3 .LEX< 2 is norma" $or o en dr#in&) O ens shou"d !e thermostatica""# contro""ed 'ith supp"# o$ c"ean dr# re 3 circu"atin& air and shou"d !e capa!"e o$ dr#in& the parts in ./ minutes) Care shou"d !e ta%en so as not to raise the sur$ace temperature o$ the part a!o e PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL de e"oper is used( the parts are dried a$ter the
42
SAIMIRA
E// C) In an o en( dr#in& o$ sma"" and "ar&e parts to&ether is not recommended !ecause o$ dissimi"ar dr#in& time) E+cessi e dr#in& can dama&e the part as 'e"" as e aporation o$ the penetrant( 'hich can impair the sensiti it# o$ the inspection) Dr#in& components !e$ore penetrant app"ication ma# require heatin& them to .1// C $or at "east . hour in an o en operatin& at am!ient pressure) The component must coo" do'n to D/ / C !e$ore the app"ication o$ the penetrant) A acuum dr#in& o en can dr# the component 'ithin ./ minutes) 6acuum dr#in& o ens can maintain a 'or%in& pressure as "o' as ./ mi""i !ars a!so"ute and this can !e achie ed 'ithin 1 minutes) At this pressure( 'ater !oi"s at a temperature !e"o' 0/ C) 4o'e er( atmospheric 'ater apor 'i"" condense on 'or% pieces remo ed $rom a dr#in& o en operatin& at this temperature) 6acuum dr#in& o ens equipped 'ith e+terna" heatin& e"ements in their !ase and 'a"" to maintain a 'or%in& temperature at nomina" D// C can reduce dr#in& times to "ess than ./ minutes) The residua" temperature o$ appro+imate"# D/ / C is achie ed a$ter dr#in&( 'hich is idea" $or penetrant app"ication) The o ens are sma""er in si*e and can accommodate a sin&"e( re"ati e"# "ar&e 'or% piece( or man# sma""er components) Fith recommended care( the o en pro ides a "on& and e$$icient ser ice enhancin& the dr#in& process a$ter prec"eanin&) Standard Q Test samp"es 8 Quench crac%ed a"uminium !"oc% 8 These !"oc%s are made o$ AST7 K 1/H( SK 1.. or 1/1D 3 TC a"uminum appro+imate"# 1> 'ide W C> "on& W CQMRR thic% pieces) The !"oc%s are heated and quenched to produce an o era"" circu"ar crac% pattern) A &roo e is machined in the midd"e o$ the !"oc% to separate the crac%s into t'o *ones) Since the crac%s are uncontro""ed( the !"oc%s are used $or comparin& the per$ormance o$ penetrants on"# and not $or a!so"ute e a"uations) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
43
SAIMIRA
At the center o$ the $ace( an area appro+imate"# . inch in diameter sha"" !e mar%ed 'ith H0/ / < temperature indicatin& cra#on or paint) The mar%ed area sha"" !e heated 'ith a !"o' torch to a temperature !et'een H0/ The area shou"d !e heated 'ithin D minutes to produce a
/
and HL0 / <) temperature
di$$erence 'ithin the !"oc%) The !"oc% is then immediate"# quenched in co"d 'ater 'hich produces a net'or% o$ re"ati e"# ti&ht and uni$orm crac% pattern on the $ace) The !"oc% sha"" then !e dried !# heatin& to appro+imate"# C// / <) It is !ecause o$ ti&ht crac% pattern( that co"or contrast penetrants are not norma""# chec%ed 'ith this !"oc%) These penetrants are not as sensiti e as $"uorescent penetrants) The crac%in& 'i"" !e s#mmetrica" on either side o$ the separation &roo e !ut the depth and the 'idth o$ the crac%s produced is uncontro""ed and un%no'n) <or the co"or contrast penetrants comparison on"#( the H0/
/
< crac%ed !"oc% is heated a second time to M//
< and quenched
a&ain to open the crac%s 'ider) Ne' and used penetrants or di$$erent !rands o$ penetrants can !e processed and then compared side !# side) A penetrant in use can !e chec%ed $or its crac% detection a!i"it# and indicatin& !ri&htness a&ainst $resh penetrant samp"es) One ha"$ o$ the !"oc% is processed 'ith the used penetrant and the other ha"$ 'ith the $resh penetrant) The 'ho"e p"ate is then processed to comp"etion in the re"e ant 'a#) The indications $rom each ha"$ can !e tested under identica" i""umination on the same a""o# 'ith the same sur$ace condition( resu"tin& in a true comparison o$ re"ati e sensiti it#) The s"i&ht potentia" $or error 'ith this de ice arises 'ith the requirement that the discontinuities in !oth ha" es !e as identica" as possi!"e) I$ crac%s detected on the used penetrant side is not as comp"ete as the $resh penetrant side( the used penetrant is considered contaminated and shou"d !e discarded) I$ the !ri&htness o$ the used penetrant indications appear to !e !e"o' H/ 5 o$ the !ri&htness o$ the $resh penetrant indications( the used penetrant is discarded)
ASNT NDT LEVEL
/4
SAIMIRA
/
Use o$ penetrant outside their norma" operatin& temperature ran&e - .E 01

/
to
C 2
can
!e
qua"i$ied is
usin&
these or
!"oc%s) T'o to the
separate proposed
!"oc%s
are
processed) One
!"oc%
heated
coo"ed
e+amination
temperature and maintained at that temperature throu&hout the processin& c#c"e) The other !"oc% is processed 'ithin the norma" operationa" temperature o$ the penetrant) I$ the indications o!tained under the proposed conditions are essentia""# the same as o!tained 'ith the norma" conditions( the proposed technique sha"" !e considered to !e qua"i$ied $or use) These !"oc%s can !e reused !# care$u" c"eanin&) A C/ minutes soa% in isoprop#" a"coho" c"ears the induced crac%s o$ residua" penetrant) S#stem per$ormance chec% Q YDS Pane"s 8 The t'o outer ed&es ha e 10 mm 'ide strips o$ !ritt"e chrome p"atin& o$ /). mm thic%ness) <i e contro""ed induced crac%s o$ ar#in& dimensions are produced in pairs) The sheet is sheared into t'o equa" sections and the# are irtua" t'ins) Koth the sections are processed $or side !# side comparison) S#stem per$ormance chec%s in o" e processin& a test specimen 'ith %no'n de$ects to determine i$ the process 'i"" re ea" discontinuities o$ the si*e required) The purpose o$ the %no'n de$ect Standard is not to penetrant e+amination s#stem) <urther( The specimen must !e processed $o""o'in& the same procedure used to process production parts) A s#stem per$ormance chec% is t#pica""# required dai"#( at the reacti ation o$ a s#stem a$ter maintenance or repairs( or an# time the s#stem is suspected o$ !ein& out o$ contro") As 'ith penetrant inspection( resu"ts are direct"# dependent on the s%i"" o$ the operator( there$ore each operator shou"d process a pane") Yno'n Discontinuit# Standards - YDS pane"s 2 8 The pane"s come in pairs ha in& %no'n discontinuities in %no'n "ocations) T'o YDS pane"s are produced simu"taneous"# $rom a sin&"e sheet o$ stain"ess stee"( so the# are precise"# matched as to p"atin& thic%ness( crac% si*e( and sur$ace rou&hness) The center PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL eri$# the sensiti it# "e e" o$ the penterant( !ut to monitor the per$ormance o$ the entire
/1
SAIMIRA
section is &rit !"asted to speci$ication rou&hness) This rou&h section is used to compare 'asha!i"it# o$ di$$erent t#pes o$ penetrant)
Standard Q Test samp"es 18 YDS pane"s permit the monitorin& o$ in use penetrants as 'e"" as side !# side comparison to ne'( unused penetrant) The# are ru&&ed and can 'ithstand dai"# s#stem processin&) A simp"e C/ min soa% in isoprop#" a"coho" c"ears the induced crac%s o$ residua" penetrant) Crac%ed nic%e" chromium p"ated pane"s 8 The nic%e" chromium test pane"s are idea" penetrant sensiti it# comparators) The pane"s are a ai"a!"e 'ith crac% o$ ./( 1/( C/( 0/ microns and come in matched pairs) The si*e re$ers to the depth o$ the nic%e" p"atin&) 7atched pairs ena!"es studies o$ the e$$ects o$ PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
/2
SAIMIRA
process chan&es as compared to a standard process or comparin& used materia" s $resh materia") er# thin "a#er o$ chromium A thic% !rass pane" measurin& .3.Q1> + D>( p"ated 'ith !ritt"e nic%e"( on one side) The nic%e" p"atin& is then p"ated 'ith a $or protection) The pane" is stress "oaded on one side( 'hich produces $ine "atera" crac%s throu&h the p"atin&) These crac%s are then used $or the penetrant s#stem per$ormance chec%) T'o pane"s containin& identica" or near"# identica" crac% patterns are used to per$orm the chec%s) The depth o$ the p"atin& can !e contro""ed( and pane"s are a ai"a!"e 'ith p"atin& thic%ness o$ ./=m - /)///D> 2) Nic%e" chromium pane"s ha e !een sectioned and micro3photo&raphed) The photo&raphs re ea" crac% 'idth to !e .Q1/th o$ the depth) So( the 'idth o$ the crac%s in the ./=m p"ated pane" 'ou"d !e /)0=m - /)////1> 2) Under "a!orator# conditions( hi&h sensiti it# penetrants !oth 'ater 'asha!"e and non 'ater3 'asha!"e $ind the $"a' "ines in these ./=m pane"s) So( theoretica""#( the penetrant that can sho' crac%s in a ./=m nic%e" chromium sensiti it# pane"( is e+pected to $ind a $"a' measurin& /)0=m + /)0=m + ./=m) Apart $rom "en&th( another measure o$ concern shou"d !e $"a' 'idth( since a penetrant;s a!i"it# to enter a crac% depends more on a crac%Rs 'idth than its "en&th) <or e+amp"e( crac%s in $or&in&s are inherent"# ti&hter and more di$$icu"t to re ea" than crac%s o$ equa" "en&th in castin&s or e+trusions) Crac%s under compression( squee*ed ti&ht and ha in& to sho' 'ith penetrant inspection) Limitations 8 A pro!"em 'ith test pieces is that once a penetrant process has sho'n a"" the discontinuities in a test piece no other process can appear more sensiti e) Simi"ar"# i$ the discontinuities are di$$icu"t to sho' and can !e $ound on"# !# use o$ the most sensiti e process a"" other processes appear equa""# ine$$ecti e) The si*e o$ the re$erence discontinuities itse"$ increase 'ith use) The si*e o$ the indications must !e recorded - photo&raph Q trans$er "acquer rep"ica 2 'hen the !"oc% is $irst used and compared 'ith the indications o!tained 'ith su!sequent uses) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL irtua""# no 'idth( are o$ten impossi!"e
/3
SAIMIRA
Important 8 Se era" precautions are necessar# 'hen usin& the penetrant test pane"s) The pane"s must !e thorou&h"# c"eaned as quic%"# as possi!"e a$ter each use) Penetrant residues 'hen "e$t in discontinuities !ecome er# iscous and e+treme"# di$$icu"t to remo e) In cases o$ se ere contamination !# pre ious residues( the PS70 and NiCr test pane"s can !e !oi"ed in 0 to 1/5 deter&ent so"ution $or C/ minutes) This is $o""o'ed( a$ter coo"in&( !# a 'ater rinse then a rinse 'ith acetone) In !et'een uses the# shou"d !e %ept in dr# acetone - $"amma!"e 2 or .(.(.( trich"oroethane) I$ 'ater is a""o'ed to contaminate either o$ the so" ents( the discontinuities can !ecome corroded) So" ents are !est %ept dr# !# use o$ mo"ecu"ar sie es or si"ica &e") Some speci$ications "imit the num!er o$ times that a test pane" can !e reused) The "e$t picture sho's crac% comparisions on Ni3Cr ri&ht sho's 'asha!i"it# test $or t'o di$$erent penetrants E a"uation is the process o$ decidin& the se erit# o$ the condition a$ter the discontinuit# indications ha e !een interpreted) E a"uation "eads to the decision as to 'hether the part must !e re,ected( to !e repaired or direct"# accepted $or use) In "iquid penetrant testin&( discontinuities are ,ud&ed on the si*e o$ the indication and not on the actua" si*e o$ the discontinuit# openin& isi!"e at the sur$ace) The indication en"ar&es 'ith time and it is !etter to e a"uate the indications at the minimum de e"opment time a""o'ed !# the procedure) Recommended de e"opment time as per AS7E Sec 6 is minimum L to ma+imum C/ minutes) E a"uation shou"d !e&in 'ith an o er a"" e+amination o$ the test sur$ace to determine that the 'or% piece has !een proper"# processed and is in satis$actor# condition $or inspection) Usua""#( the indications are c"assi$ied as "inear or rounded) Linear t#pe is an indication 'ith a "en&th &reater than three times the 'idth) It 'i"" appear as a continuous( strai&ht or ,a&&ed "ine) These indications represents more harm$u" discontinuities) Crac%s( seams( deep scratch( undercut( PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL pane"s and the
/4
SAIMIRA
"ac% o$ $usion at sur$ace( ro""in& and $or&in& "aps( co"d shut etc produce "inear indications) The same $"a's ma# sho' up as an intermittent "ine indicatin& that the $"a' ma# !e partia""# c"osed at the sur$ace)
A rounded indication is de$ined as a circu"ar or e""iptica" and 'ith a "en&th o$ three times or "ess than its 'idth) Porosit# or a ca it# at sur$ace produces such indications) Co"or contrast penetrant indications 8 Indications 'i"" appear in red a&ainst 'hite !ac%&round at the "ocations o$ the discontinuities) Depth or si*e o$ the interna" ca it# ma# !e co3re"ated 'ith the !ri&htness o$ co"or( speed o$ !"eedin& and d#e spread) Usua""#( a crac%( deep scratch or simi"ar openin& 'i"" sho' up as a so"id "ine) Ti&ht crac% or a "ap sho' as a !ro%en "ine) Gross porosit# 'i"" produce "ar&e rounded indications) <ine porosit# is indicated !# red dots) Porous materia" 'i"" produce random"# distri!uted tin# red dots) Crater crac% ma# produce round indication !ecause the# tend to trap "ar&e amount o$ penetrant) Indications 'ith a "i&ht pin% co"or ma# indicate e+cessi e c"eanin&) Di$$used or 'ea% indications are di$$icu"t to interpret and the part shou"d !e
ASNT NDT LEVEL
//
SAIMIRA
reprocessed) In man# cases the# turn out to !e $a"se indications caused !# improper processin&) <"uorescent indications 8 These indications are The indication &"o's !ac%&round o$ the de e"oper) Porosit# 'i"" sho' as &"o'in& spots) Crac%s 'i"" sho' as $"uorescent "ines) Fhere a "ar&e discontinuit# has trapped a quantit# o$ penetrant( the indication 'i"" spread 'ide on the sur$ace) E+perience in the use o$ this method a""o's conc"usion to !e dra'n $rom the e+tent o$ this spread 'ith respect to the re"ati e si*e o$ the discontinuities) Poor"# processed part 'i"" ha e !road $"uorescent patches) Acceptance standard $or 'e"ds 8 AS7E Sec 6III Appendi+ L a) re"e ant indications 8 indications 'ith ma,or dimensions &reater than . Q .E in) - .)E mm 2) !) "inear indications 8 times the 'idth) c) rounded indications 8 an indication o$ circu"ar or e""iptica" shape 'ith the "en&th equa" to or "ess than three times the 'idth) An indication in e+cess o$ the "imits speci$ied !e"o' is not accepta!"e 8 a) Re"e ant "inear indicationsJ !) Re"e ant rounded indications &reater than C Q .E in) - D)M mm 2 c) <our or more re"e ant rounded indications in a "ine separated !# . Q .E in) @.)E mmA or "ess - ed&e : to : ed&e 2 an indication ha in& a "en&th &reater than three ie'ed under u"tra io"et "i&ht in a dar%ened area) #e""o' &reen or oran&e red a&ainst io"et !ri""iant
ASNT NDT LEVEL
/0
SAIMIRA
Inspection 8 De e"opment time 8 A$ter app"ication o$ the de e"oper( it must !e a""o'ed to 'or%) I$ the si*e o$ the discontinuit# openin& is sma""( the penetrant !"eeds out s"o'"# into the de e"oper) Dr# po'der de e"oper re"# upon capi""ar# action( 'hich is s"o'er) The de e"oper shou"d !e "e$t on the sur$ace $or a minimum o$ ten minutes !e$ore inspection o$ indications)
ASNT NDT LEVEL
/1
SAIMIRA
A 'ater !ase - aqueous 2 de e"oper is to !e dried !# circu"atin& hot air or heatin& in a temperature contro""ed o en) The minimum de e"opment time is 0 minutes( a$ter the de e"oper "a#er !ecomes dr#) A minimum o$ 0 minutes de e"opin& is a"so needed $or non aqueous de e"oper) This time is ta%en $rom the point 'hen the de e"oper "a#er appears to !e dr#) Fatchin& the indication $orm immediate"# a$ter de e"oper app"ication and a'areness o$ the t#pe o$ de$ects that ma# !e encountered !e$orehand is e+treme"# he"p$u") The indication is not the same si*e as the discontinuit# openin&( the de e"oper 'i"" ma&ni$# the discontinuit# si*e to ma%e it more isi!"e to the e#e $or easier detection) Penetrants continue to !"eed out into the de e"oper and indications !ecome "ar&er o er a period o$ time) Fise usa&e o$ minimum and ma+imum de e"opment time is there$ore hi&h"# recommended) Gross and "ar&e discontinuities 'i"" !e&in to $orm indication immediate"#) Ti&ht and e+treme"# sma"" discontinuities 'i"" ta%e "on& time to $orm) <or e a"uation o$ indications $or accept Q re,ect condition( a de e"opment time o$ L to C/ minutes is &enera""# used a$ter the de e"oper "a#er !ecomes dr#) Li&htin& 8 A"" penetrant e+aminations must !e per$ormed under recommended "i&ht "e e"s( as 'ritten in the test procedure) To see $aint indications 'ith co"or contrast penetrants( adequate 'hite "i&ht is required) Inspection shou"d !e carried out in &ood 'hite "i&ht o$ at "east 0// "u+ at the e+amination sur$ace) Inspection o$ $ine detai" ma# require up to 1/// "u+) In natura" da#"i&ht( penetrant indications appear deep red a&ainst the 'hite de e"oper !ac%&round) Under strip "i&ht - tu!e "amps 2( indications appear some'hat dar%er than in the natura" da#"i&ht) <or $"uorescent penetrant inspection the test sur$ace must !e e+amined under u"tra io"et - !"ac% "i&ht 2 o$ pea% 'a e"en&th around CE0 nm and intensit# o$ at "east ./// micro 'atts Q cm 1 at the e+amination sur$ace 'ith a minimum o$ E inches distance !et'een the test sur$ace and the "i&ht source) Inspection PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
must !e carried out in a dar%ened area 'here the am!ient 'hite "i&ht "e e" shou"d not e+ceed 1/ "u+) The interior o$ the inspection !ooths shou"d !e painted mat !"ac% to a oid distractin& re$"ections) Kri&htness o$ indication depends on the intensit# o$ incident u"tra io"et "i&ht and the dar%ness o$ the surroundin&) I$ $"uorescent inspection is to !e per$ormed under norma" "i&htin& condition( then the minimum intensit# shou"d !e C/// micro 'atts Q cm 1 at the e+amination sur$ace) The output o$ U6 "amp $a""s 'ith time( the e$$ecti e output a"so $a""s as !u"!s( re$"ectors( or $i"ters !ecome dirt#) Once a 'ee% the optica" parts o$ the "amp shou"d !e c"eaned 'ith a dr# c"oth 'hen the "amp is co"d) The U6 "i&ht must !e chec%ed $or presence o$ crac%s in the $i"ter) A "amp 'ith crac%ed $i"ter must not !e used) U6 "i&ht intensit# is to !e chec%ed 'hen $irst used each da# $or required intensit# 'ith a ca"i!rated U6 "i&ht meter( in the dar%ened room condition and a$ter a""o'in& a 0 minutes 'arm up period) <"uorescent indications appear !ri""iant #e""o'3&reen or oran&e3red dependin& on the t#pe o$ the d#e in the penetrant) The dar%er the area o$ inspection( the more !ri""iant"# the indications 'i"" &"o') Dar% adaptation $or $"uorescent inspection 8 Fhen e a"uatin& $"uorescent indications( the e+aminers must a""o' their e#es to ad,ust 'hen $irst enterin& the dar%ened inspection area) Norma""#( 0 minutes are enou&h time $or the e#es to adapt to the dar%ened condition) Inspection shou"d not start unti" the e+aminer;s e#es ha e adapted to the dar%ened conditions) Dar% adaptation time can !e shortened !# 'earin& suita!"e red e#e &"asses in 'hite "i&ht areas) Note 8 Photosensiti e e#e&"asses shou"d not !e used durin& inspection !ecause these &"asses dar%en in the presence o$ U6 radiation) E+aminers per$ormin& inspection under u"tra io"et "i&ht shou"d consider 'earin& #e""o'ish or specia" u"tra io"et $i"ter &o&&"es to reduce e#estrain) E a"uation o$ indications 8 PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
Penetrant inspection pro ides indirect indication o$ $"a's !# sho'in& *ones o$ penetrant accumu"ation) Penetrant ma# !e accumu"ated on the part( due to presence o$ $"a's( part con$i&uration or improper processin&) It cannot a"'a#s !e determined at $irst &"ance 'hether an indication is rea"( $a"se or non re"e ant) A rea" indication is caused !# a $"a' such as a crac%( porosit# or sur$ace !rea%in& de$ects) Non re"e ant and $a"se indications( are the indications( that ma# !e
interpreted erroneous"# as a $"a') Non re"e ant are true indications( 'hich occurs as a resu"t o$ the
component &eometr# or con$i&uration such as %e#'a#s( sp"ines( nut and !o"t threads( press $it parts( ri eted( assem!"ed part or re"e ant indications) A <a"se indication is an accumu"ation o$ penetrant( not caused !# a discontinuit# in the 'or% piece) It ma# appear as a resu"t o$ improper hand"in& or poor processin& durin& the inspection process) This ma# appear in the $orm o$ e+cessi e penetrant !ac%&round or strea%in& $rom insu$$icient or improper penetrant remo a") Common causes are( penetrant contaminated de e"oper( penetrant residue on inspection ta!"e( dirt( "int( or $in&er prints $rom hand"in& durin& the test process) <or $"uorescent penetrants( inadequate c"eanin& o$ oi" and &rease( can a"so !e a source o$ $a"se indications) er# rou&h sur$aces such as a 'e"d !ead) Too" mar%s( "oose sca"es and scratches ma# a"so produce non
6eri$ication o$ <"a' Indication 8 S'a!!in& the indication 'ith a er# $ast dr#in& so" ent dampened( cotton
tipped app"icator( re3app"ication o$ de e"oper and 'itnessin& the re3appearance PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS o$ an indication can a"so
04 &reat"# assist
SAIMIRA the interpretation process) An
acceptance or re,ection decision shou"d
!e made !e$ore this test) The a!i"it# o"ume) S'a!!in& an indication
o$ an indication to re3appear is ca""ed persistence) This 'i"" a"ert the inspector to the $act that the discontinuit# has depth or is an use$u" technique to $or si*e) I$ a""o'ed !# the speci$ic procedure( indications ma# !e e a"uated !# 'ipin& the indication 'ith a $ast dr#in& so" ent3dampened s'a!( a""o'in& the area to dr#( and rede e"opin&) Rede e"opment time sha"" !e as "on& as the ori&ina" de e"opment time( e+cept non aqueous rede e"opment time sha"" !e C min minimum) I$ no indication reappears( the ori&ina" indication is considered $a"se) This procedure ma# !e per$ormed t'ice $or an# &i en ori&ina" indication) Spra#in& non aqueous de e"oper onto a cotton s'a! and 'ipin&( remo es the indication( c"eans the sur$ace and reapp"ies de e"oper in one step) Fhether or not the $"a' indication re appears a$ter the so" ent 'ipe depends on J .) ho' o"ati"e the so" ent is( eri$# $a"se or retest a non re"e ant indication)
4o'e er( s'a!!in& shou"d not !e done unti" the indication has !een e a"uated
1) ho' much so" ent is app"ied( C) 'hich app"icator is used( D) $in&er pressure e+erted( 0) de e"oper used ZZ po'der or non aqueous( E) de e"opin& time !e$ore L) de e"opin& time a$ter M) num!er o$ 'ipes) eri$ication( eri$ication(
ASNT NDT LEVEL
01
SAIMIRA
Test Process 8 Sur$ace c"eanin& 8 Care$u" c"eanin& o$ the test sur$ace and inside o$ the discontinuities is an e+treme"# important step $or success o$ the penetrant inspection !ecause the penetrant method 'or%s !# a""o'in& a "iquid to enter a PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
02
SAIMIRA
de$ect 'hich is open to the sur$ace) I$ there is dirt in the crac%( there is no room $or the penetrant to enter it( and the process 'i"" not 'or%) Sur$aces to !e e+amined are c"eaned so that the# are $ree $rom dirt( sca"es( oi"( &rease( paint( rust and corrosion and discontinuities are $ree inside o$ 'ater( oi" or other contaminants) This is %no'n as pre c"eanin&) <o""o'in& c"eanin&( the parts sha"" !e thorou&h"# dried) Penetrant app"ication 8 A$ter dr#in&( the entire sur$ace to !e tested must !e 'etted 'ith a "a#er o$ the penetrant and %ept 'et durin& the entire d'e"" time) This can !e achie ed !# immersion( $"o' 3 on( spra#in& or !rushin& the "iquid) The temperature o$ the test sur$ace shou"d !e !et'een ./X C and 01X C) Ru!!in& the sur$ace 'ith a penetrant soa%ed c"oth is not permitted) Penetrant D'e"" 8 The penetrant is "e$t on the test sur$ace $or su$$icient time to a""o' penetration into the discontinuit# openin&s) The time in o" ed depends on the iscosit# o$ the penetrant( temperature o$ the part sur$ace and the ti&htness o$ the discontinuit# openin&) Penetration time used is &enera""# !et'een ./ and C/ minutes) At "o' temperatures( "on&er penetration time sha"" !e used !ecause the d'e"" time) Emu"si$ication 8 <or post emu"si$ication t#pe penetrant( the emu"si$ier is app"ied a$ter the comp"etion o$ the d'e"" time) penetrant 'ater 'asha!"e) Emu"si$ication time Emu"si$ication ma%es the aries !et'een . to C minutes( iscosit# o$ penetrant increases) This time is %no'n as
dependin& on the t#pe o$ emu"si$ier( the penetrant ( the sur$ace condition and actua" time sha"" !e determined !# practica" tests) Remo a" o$ e+cess penetrant 8 The purpose o$ remo in& e+cess penetrant is to $ree the sur$ace o$ penetrant so that the penetrant( 'hich has entered a discontinuit#( 'i"" !e readi"# isi!"e 'hen it re3emer&es onto the sur$ace) A$ter the d'e"" time( e+cess sur$ace penetrant is to !e remo ed 'ith a so" ent 'ipe( 'ater spra# rinse( or the penetrant has to !e emu"si$ied so that it can !e 'ashed3o$$ 'ith 'ater rinse) E+cess penetrant remo a" depends on the remo a" characteristic o$ the penetrant !ein& used) The remo a" o$ e+cess PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
03
SAIMIRA
penetrant is a de"icate procedure !ecause it is essentia" not to remo e penetrant $rom the discontinuities) Penetrant is so easi"# remo ed $rom smooth po"ished sur$aces that specia" procedures ma# !e required to pre ent o er 3 remo a") Rou&h sur$aces reduce remo a!i"it# !# retainin& penetrant in the indentations or recesses !# pre entin& the emu"si$ier $rom e en"# com!inin& 'ith the sur$ace penetrant) A comp"ete"# c"eaned sur$ace ma# remo e some or a"" o$ the penetrant trapped in discontinuities) To ma%e sure that the sur$ace has not !een o er 3 'ashed( the c"eanin& ma# a""o' a er# "o' "e e" penetrant isi!"e in the i""umination) !ac%&round to remain) A s"i&ht shadin& o$ penetrant shou"d !e $or residua" penetrant usin& suita!"e
de e"oper "a#er) Durin& this c"eanin& operation( the sur$ace has to !e chec%ed De e"oper app"ication 8 To ma%e the penetrant indication c"ear"# detecta!"e a de e"opin& medium is used) De e"oper ma# !e app"ied !# dustin& or dippin& $or dr# po'der or spra#in& or immersion $or 'ater !ase de e"opers) Non aqueous 'et de e"opers shou"d !e !est app"ied !# spra#in& on"#) The de e"oper shou"d then !e a""o'ed to d'e"" on the part sur$ace $or su$$icient isi!"e indications o$ such $"a's) This is %no'n
time - usua""# L to C/ minutes 2 to permit it to dra' penetrant out o$ an# sur$ace $"a's to $orm ma&ni$ied as de e"opin& time) Lon&er times ma# !e necessar# $or ti&ht crac%s) Inspection o$ indications 8 Inspection is then per$ormed under ordinar# "i&ht $or co"or contrast penetrants or under u"tra io"et i""umination $or $"uorescent penetrants to detect an# $"a's 'hich ma# !e present)
ASNT NDT LEVEL
04
SAIMIRA
Post C"eanin& 8 A$ter the comp"etion o$ e+amination( the test sur$ace is c"eaned to remo e de e"oper and penetrant) In some industries( such as nuc"ear( the $ai"ure to post c"ean a part can ha e er# detrimenta" resu"ts) <or
parts that 'i"" !e in contact 'ith "iquid o+#&en s#stems( the $ai"ure to post c"ean a part cou"d resu"t in a $ire and possi!"e serious in,ur#) I$ penetrants and de e"opers that contain ha"o&en and su"phur products are used( can ha e detrimenta" e$$ects on some meta"s and must !e c"eaned accordin& to appro ed technica" data) Penetrant and de e"oper residue tend to a!sor! moisture and cause corrosion) The remo a" o$ dr# de e"oper and non aqueous de e"oper is eas#) Fet aqueous de e"oper are di$$icu"t to remo e !ecause the# are !a%ed onto the part durin& the dr#in& process) So"u!"e de e"opers can !e remo ed !# 'ater rinse) The "on&er the de e"oper remains on a part the harder it is to remo e) The use o$ steam 'ith deter&ents is pro!a!"# the most e$$ecti e o$ a"" methods) PREPARED BY S.MUTHUKUMAR, B.Tech lll Some parts( such as those used ASNT NDT LEVEL
0/
SAIMIRA
in "iquid o+#&en s#stems( require tota" penetrant remo a" a$ter the inspection) Entraped penetrant in discontinuities can !e remo ed most e$$ecti e"# !# hot tan% so" ent c"eanin& or u"trasonic c"eanin&) Penetrant inspection norma""# "ea es the partRs sur$ace c"ean and e+posed and thus ma%in& it suscepti!"e to corrosion) A"" e$$orts shou"d !e made to protect the parts sur$aces $rom corrosion e$$ecti e"# a$ter the penetrant inspection)
Penetrant Testin& usin& $"uorescent and isi!"e d#es
G"ossar# o$ Terms o$ Liquid Penetrant Inspection Kac%&round8 @$"uorescent or co"our contrastA residue o$ penetrant o er &enera" sur$ace o$ part durin& inspection) Kac%&round Co"ouration8 co"ouration remainin& a$ter incomp"ete remo a" o$ d#e penetrant $rom the test sur$ace) Kac%&round <"uorescence8 $"uorescence remainin& a$ter incomp"ete remo a" o$ d#e PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS penetrant $rom the test sur$ace)
00
SAIMIRA
Kath8 re$ers to penetrant materia"s into 'hich parts are dipped or tota""# immersed) K"ac% Li&ht8 "i&ht radiatin& 'ith a 'a e"en&th ran&in& !et'een CE/ to D// nm) i)e) ,ust !e"o' isi!"e "i&ht and used to e+cite $"uorescence) K"ac% Li&ht <i"ter8 a $i"ter passin& !"ac% "i&ht !ut opaque to isi!"e and $ar u"tra io"et 'a e"en&ths) K"eedout8 the action o$ penetrant e+udin& $rom discontinuities on to the sur$ace o$ a part) K"ottin&8 the soa%in& action de e"oper has on penetrant as it !"eeds $rom a discontinuit#( increasin& sensiti it# and contrast) Capi""ar# Action8 the action !# 'hich the "e e" o$ a "iquid in contact 'ith a so"id sur$ace is e"e ated or depressed to a "e e" di$$erent $rom the "iquid not in contact 'ith the so"id;s sur$ace) C"ean8$ree o$ so"id or "iquid contaminants) Co"our Contrast D#e8 d#e used in penetrant to &i e su$$icient co"our intensit# to a""o' &ood contrast to the !ac%&round !ein& ie'ed under 'hite "i&ht) Co"our Contrast Penetrant8 a penetrant uti"i*in& co"our contrast d#e) Dar% Adaptation8 ad,ustment o$ the e#es 'hen one &oes $rom a !ri&ht area to a dar%ened area a""o'in& !etter isi!i"it# in dim "i&ht) De&reasin& <"uid8 a&ents used to c"ean oi" and &rease $rom a part prior to app"#in& penetrant) De e"oper8 a 'hite po'der app"ied to a part to dra' e+cess penetrant $rom discontinuities a$ter initia" remo a" o$ penetrant $rom part) A"so( pro ides a contrastin& !ac%&round to ie' a&ainst) De e"oper( Dr#8 "i&ht( $"u$$#( dr# a!sor!ent po'der) De e"oper( Nonaqueous8 a!sor!ent po'dered materia"s suspended in a nonaqueous "iquid)
ASNT NDT LEVEL
01
SAIMIRA
De e"oper( Fet8 a!sor!ent po'dered materia"s suspended in 'ater) De e"opment Time8 time a de e"oper is a""o'ed to remain on the sur$ace o$ a part !ein& inspected) Dra&out8 The "oss o$ $"uid as a resu"t o$ carr#3o er) Drain Time8 time a""o'ed $or e+cess penetrant to $"o' o$$ part a$ter it has !een immersed in a !ath) Dr#in& Time8 time in 'hich a 'ashed or 'et3de e"oped part is in the hot air dr#in& o en) D'e"" Time @Penetration timeA8 time that a penetrant is in contact 'ith a part;s sur$ace) D#e Penetrant8 a penetratin& $"uid containin& a d#e 'hich is isi!"e under norma" @'hiteA "i&ht) Emu"si$ier8 an a&ent that 'hen added to an inso"u!"e penetrant renders it so"u!"e a""o'in& the mi+ture to !e 'ashed o$$ the part) Emu"sion8 a sta!"e mi+ture o$ 'ater( oi" and emu"si$ier) Emu"si$ication Time @soa% timeA8 period 'hich emu"si$ier is a""o'ed to mi+ 'ith the "iquid penetrant prior to 'ater rinsin&) E a"uation8 process o$ decidin& on the se erit# o$ a discontinuit# a$ter it has !een interpreted( and in o" es acceptance or re,ection o$ the part) <a"se Indications8 irre"e ant indications) <ami"#8 the comp"ete series o$ materia"s o$ a speci$ic manu$acturer to per$orm a speci$ic t#pe or process o$ LPI) <"ash Point8 "o'est temperature at 'hich a su!stance 'i"" decompose to $orm a $"amma!"e &aseous mi+ture) <"uorescence8 propert# o$ emittin& "i&ht as a resu"t o$ and on"# durin& a!sorption o$ radiation o$ a shorter 'a e"en&th) <"uorescent Penetrants8 penetrants used to re ea" sur$ace discontinuities 'hich !ecome isi!"e 'hen irradiated 'ith !"ac% "i&ht) PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
02
SAIMIRA
4#drophi"ic8 re$ers to t#pe o$ emu"si$ier that is 'ater !ased) Indication8mar%s a discontinuit#) In LPI it is the presence o$ !"eed out) Interpretation8same as e a"uation) Irre"e ant Indication8 indication resu"tin& $rom poor technique and not associated 'ith a materia" discontinuit#) Lea% Testin&8 LPI technique 'here penetrant is app"ied to one side o$ a part and o!ser ations are made $rom the other side to "ocate an# throu&h3'a"" discontinuities) Lipophi"ic8 re$ers to t#pe o$ emu"si$ier that is oi" !ased) LOW3Sa$e Penetrant8 penetrant s#stem desi&ned to !e compati!"e or nonreacti e in the presence o$ "iquid o+#&en) 7onochromatic Li&ht8 "i&ht o$ one 'a e"en&th) Nonre"e ant Indications8 LPI indications resu"tin& $rom conditions not associated 'ith a materia" discontinuit#) Penetra!i"it#8 the propert# o$ a penetrant that a""o's it to enter er# $ine openin&s) Penetrant8 a "iquid possessin& properties ena!"in& it to enter er# $ine openin&s such as crac%s) Po"ar Attraction8 e"ectrostatic attraction !et'een positi e and ne&ati e"# char&ed ions) Reproduci!i"it#8 the reproducin& o$ one or more LPI indications @primari"# $or statistica" dataA) Re$erence Pieces8 test pieces containin& contro""ed arti$icia" discontinuities or natura" discontinuities( used $or chec%in& the e$$icienc# o$ the penetrant testin& method and materia"s) Seea!i"it#8 the a!i"it# o$ an indication to !e seen !# an o!ser er under ad erse conditions e)&) poor !ac%&round contrast or outside "i&ht @$"uorescent methodA) Soa% Time8 same as emu"si$ication time) So" ent C"eanin&8 process o$ remo in& e+cess penetrant $rom a sur$ace !# 'ipin& or PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS 'ashin& 'ith a so" ent)
03
SAIMIRA
So" ent Remo a!"e Penetrant8 a penetrant that must !e remo ed !# a suita!"e so" ent) Standard Crac%ed Test Pane"8 an intentiona""# crac%ed test pane" ha in& separate areas $or the app"ication o$ di$$erent penetrant materia"s so a direct comparison can !e o!tained) Fater Fasha!"e Penetrant8 a penetrant 'ith suita!"e emu"si$#in& a&ents incorporated to render it direct"# 'ater 'asha!"e) Sur$ace e+amination @such as 'ith "iquid penetrant e+amination 3 PTA is not per$ormed $or dama&e mechanisms %no'n to initiate $rom the inside sur$ace as it 'ou"d not !e e$$ecti e in these situations) A disad anta&e o$ d#e penetrant testin& is that crac%s not open to the sur$ace can not !e detected)
ASNT NDT LEVEL
14
SAIMIRA
The ABC's of Nondestructive Weld Examination Introduction The phi"osoph# that o$ten &uides the $a!rication o$ 'e"ded assem!"ies and structures is >to assure 'e"d qua"it#)> 4o'e er( the term >'e"d qua"it#> is re"ati e) The app"ication determines 'hat is &ood or !ad) Genera""#( an# 'e"d is o$ &ood qua"it# i$ it meets appearance requirements and 'i"" continue inde$inite"# to do the ,o! $or 'hich it is intended) The $irst step in assurin& 'e"d qua"it# is to determine the de&ree required !# the app"ication) A standard shou"d !e esta!"ished !ased on the ser ice requirements) >Fhate er the standard o$ qua"it#( a"" 'e"ds shou"d !e inspected)> Standards desi&ned to impart 'e"d qua"it# ma# di$$er $rom ,o! to ,o!( !ut the use o$ appropriate e+amination techniques can pro ide assurance that the app"ica!"e standards are !ein& met) Fhate er the standard o$ qua"it#( a"" 'e"ds shou"d !e inspected( e en i$ the inspection in o" es nothin& more than the 'e"der "oo%in& o er his o'n 'or% a$ter each 'e"d pass) A &ood3"oo%in& 'e"d sur$ace appearance is man# times considered indicati e o$ hi&h 'e"d qua"it#) 4o'e er( sur$ace appearance a"one does not assure &ood 'or%manship or interna" qua"it#) Nondestructi e e+amination @NDEA methods o$ inspection ma%e it possi!"e to eri$# comp"iance to the standards on an on&oin& !asis !# e+aminin& the sur$ace and su!sur$ace o$ the 'e"d and surroundin& !ase materia") <i e !asic methods are common"# used to e+amine $inished 'e"ds8 isua"( "iquid penetrant( ma&netic partic"e( u"trasonic and radio&raphic @W3ra#A) The &ro'in& use o$ computeri*ation 'ith some methods pro ides added ima&e enhancement( and a""o's rea"3time or near rea"3 time ie'in&( compar ati e inspections and archi a" capa!i"ities) A re ie' o$ each method 'i"" he"p in decidin& 'hich process or com!ination o$ processes to use $or a speci$ic ,o! and in per$ormin& the e+amination most e$$ecti e"#)
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS 6isua" Inspection @6TA
11
SAIMIRA
6isua" inspection is o$ten the most cost3e$$ecti e method( !ut it must ta%e p"ace prior to( durin& and a$ter 'e"din&) 7an# standards require its use !e$ore other methods( !ecause there is no point in su!mittin& an o! ious"# !ad 'e"d to sophisticated inspection techniques) The ANSIQAFS D.).( Structura" Fe"din& Code3Stee"( states( >Fe"ds su!,ect to nondestructi e e+amination sha"" ha e !een $ound accepta!"e !# isua" inspection)> 6isua" inspection requires "itt"e equipment) Aside $rom &ood e#esi&ht and su$$icient "i&ht( a"" it ta%es is a poc%et ru"e( a 'e"d si*e &au&e( a ma&ni$#in& &"ass( and possi!"# a strai&ht ed&e and square $or chec%in& strai&htness( a"i&nment and perpendicu"arit#) >6isua" inspection is the !est !u# in NDE( !ut it must ta%e p"ace prior to( durin& and a$ter 'e"din&)> Ke$ore the $irst 'e"din& arc is struc%( materia"s shou"d !e e+amined to see i$ the# meet speci$ications $or qua"it#( t#pe( si*e( c"ean"iness and $reedom $rom de$ects) Grease( paint( oi"( o+ide $i"m or hea # sca"e shou"d !e remo ed) The pieces to !e ,oined shou"d !e chec%ed $or $"atness( strai&htness and dimensiona" accurac#) Li%e'ise( a"i&nment( $it3up and ,oint preparation shou"d !e e+amined) <ina""#( process and procedure aria!"es shou"d !e eri$ied( inc"udin& e"ectrode si*e and t#pe( equipment settin&s and pro isions $or preheat or postheat) A"" o$ these precautions app"# re&ard"ess o$ the inspection method !ein& used) Durin& $a!rication( isua" e+amination o$ a 'e"d !ead and the end crater ma# re ea" pro!"ems such as crac%s( inadequate penetration( and &as or s"a& inc"usions) Amon& the 'e"d detects that can !e reco&ni*ed isua""# are crac%in&( sur$ace s"a& in inc"usions( sur$ace porosit# and undercut) On simp"e 'e"ds( inspectin& at the !e&innin& o$ each operation and periodica""# as 'or% pro&resses ma# !e adequate) Fhere more than one "a#er o$ $i""er meta" is !ein& deposited( ho'e er( it ma# !e desira!"e to inspect each "a#er !e$ore depositin& the ne+t) The root pass o$ a mu"tipass 'e"d is the most critica" to 'e"d soundness) It is especia""# suscepti!"e to crac%in&( and !ecause it so"idi$ies quic%"#( it ma# trap &as PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
and s"a&) On su!sequent passes( conditions caused !# the shape o$ the 'e"d !ead or chan&es in the ,oint con$i&uration can cause $urther crac%in&( as 'e"" as undercut and s"a& trappin&) Repair costs can !e minimi*ed i$ isua" inspection detects these $"a's !e$ore 'e"din& pro&resses) 6isua" inspection at an ear"# sta&e o$ production can a"so pre ent under'e"din& and o er'e"din&) Fe"ds that are sma""er than ca""ed $or in the speci$ications cannot !e to"erated) Keads that are too "ar&e increase costs unnecessari"# and can cause distortion throu&h added shrin%a&e stress) A$ter 'e"din&( isua" inspection can detect a ariet# o$ sur$ace $"a's( inc"udin& crac%s( porosit# and un$i""ed craters( re&ard"ess o$ su!sequent inspection procedures) Dimensiona" ariances( 'arpa&e and appearance $"a's( as 'e"" as 'e"d si*e characteristics( can !e e a"uated) Ke$ore chec%in& $or sur$ace $"a's( 'e"ds must !e c"eaned o$ s"a&) Shot!"astin& shou"d not !e done !e$ore e+amination( !ecause the peenin& action ma# sea" $ine crac%s and ma%e them in isi!"e) The AFS D.). Structural Welding Code( $or e+amp"e( does not a""o' peenin& >on the root or sur$ace "a#er o$ the 'e"d or the !ase meta" at the ed&es o$ the 'e"d)> 6isua" inspection can on"# "ocate de$ects in the 'e"d sur$ace) Speci$ications or app"ica!"e codes ma# require that the interna" portion o$ the 'e"d and ad,oinin& meta" *ones a"so !e e+amined) Nondestructi e e+aminations ma# !e used to determine the presence o$ a $"a'( !ut the# cannot measure its in$"uence on the ser icea!i"it# o$ the product un"ess the# are !ased on a corre"ation !et'een the $"a' and some characteristic that a$$ects ser ice) Other'ise( destructi e tests are the on"# sure 'a# to determine 'e"d ser icea!i"it#) Radio&raphic Inspection @RTA Radio&raph# @W3ra#A is one o$ the most important( ersati"e and 'ide"# accepted o$ a"" the nondestructi e e+amination methods 3 <i&) .) <i&) . 3 Radio&raph# is one o$ the most<i&) 1 3 Thic%er areas o$ a specimen PREPARED BY S.MUTHUKUMAR, B.Tech ASNT NDT LEVEL lll
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SAIMIRA
!ein& +3ra#ed or hi&her densit# important( ersati"e and 'ide"# accepted e+amination methods) materia" a!sor!s more radiation and the correspondin& areas on the radio&raph 'i"" !e "i&hter
W3ra# is used to determine the interna" soundness o$ 'e"ds) The term ;W3ra# qua"it#(> 'ide"# used to indicate hi&h qua"it# in 'e"ds( arises $rom this inspection method) Radio&raph# is !ased on the a!i"it# o$ W3ra#s and &amma ra#s to pass throu&h meta" and other materia"s opaque to ordinar# "i&ht( and produce photo&raphic records o$ the transmitted radiant ener&#) A"" materia"s 'i"" a!sor! %no'n amounts o$ this radiant ener&# and( there$ore( W3ra#s and &amma ra#s can !e used to sho' discontinuities and inc"usions 'ithin the opaque materia") The permanent $i"m record o$ the interna" conditions 'i"" sho' the !asic in$ormation !# 'hich 'e"d soundness can !e determined) >Radio&raph# is one o$ the most 'ide"# accepted NDE methods)> W3ra#s are produced !# hi&h3 o"ta&e &enerators) As the hi&h o"ta&e app"ied to an W3 ra# tu!e is increased( the 'a e"en&th o$ the emitted W3ra# !ecomes shorter( pro idin& more penetratin& po'er) Gamma ra#s are produced !# the atomic disinte&ration o$ radioisotopes) The radioacti e isotopes most 'ide"# used in industria" radio&raph# are Co!a"t E/ and Iridium .H1) Gamma ra#s emitted $rom these isotopes are simi"ar to PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
W3ra#s( e+cept their 'a e"en&ths are usua""# shorter) This a""o's them to penetrate to &reater depths than W3ra#s o$ the same po'er( ho'e er( e+posure times are considera!"# "on&er due to the "o'er intensit#) Fhen W3ra#s or &amma ra#s are directed at a section o$ 'e"dment( not a"" o$ the radiation passes throu&h the meta") Di$$erent materia"s( dependin& on their densit#( thic%ness and atomic num!er( 'i"" a!sor! di$$erent 'a e"en&ths o$ radiant ener&#) The de&ree to 'hich the di$$erent materia"s a!sor! these ra#s determines the intensit# o$ the ra#s penetratin& throu&h the materia") Fhen ariations o$ these ra#s are recorded( a means o$ seein& inside the materia" is a ai"a!"e) The ima&e on a de e"oped photo3sensiti*ed $i"m is %no'n as a radio&raph) The opaque materia" a!sor!s a certain amount o$ radiation( !ut 'here there is a thin section or a oid @s"a& inc"usion or porosit#A( "ess a!sorption ta%es p"ace) These areas 'i"" appear dar%er on the radio&raph) Thic%et areas o$ the specimen or hi&her densit# materia" @tun&sten inc"usionA( 'i"" a!sor! more radiation and their correspondin& areas on the radio&raph 'i"" !e "i&hter 3 <i&) 1) Fhether in the shop or in the $ie"d( the re"ia!i"it# and interpreti e a"ue o$ radio&raphic ima&es are a $unction o$ their sharpness and contrast) The a!i"it# o$ an o!ser er to detect a $"a' depends on the sharpness o$ its ima&e and its contrast 'ith the !ac%&round) To !e sure that the radio&raphic e+posure produces accepta!"e resu"ts( a &au&e %no'n as an Ima&e Qua"it# Indicator @IQIA is p"aced on the part so that its ima&e 'i"" !e produced on the radio&raph) IQ"s used to determine radio&raphic qua"it# are a"so ca""ed penetrameters) A standard ho"e3t#pe penetrameter is a rectan&u"ar piece o$ meta" 'ith three dri""ed ho"es o$ set diameters) The thic%ness o$ the piece o$ meta" is a percenta&e o$ the thic%ness o$ the specimen !ein& radio&raphed) The diameter o$ each ho"e is di$$erent and is a &i en mu"tip"e o$ the penetrameter thic%ness) Fire3t#pe penetrameters are a"so 'ide"# used( especia""# outside the United States) The# consist o$ se era" pieces o$ 'ire( each o$ a di$$erent diameter) Sensiti it# is determined !# the sma""est diameter o$ PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
'ire that can !e c"ear"# seen on the radio&raph) A penetrameter is not an indicator or &au&e to measure the si*e o$ a discontinuit# or the minimum detecta!"e $"a' si*e) It is an indicator o$ the qua"it# o$ the radio&raphic technique) Radio&raphic ima&es are not a"'a#s eas# to interpret) <i"mhand"in& mar%s and strea%s( $o& and spots caused !# de e"opin& errors ma# ma%e it di$$icu"t to identi$# de$ects) Such $i"m arti$acts ma# mas% 'e"d discontinuities) Sur$ace de$ects 'i"" sho' up on the $i"m and must !e reco&ni*ed) Kecause the an&"e o$ e+posure 'i"" a"so in$"uence the radio&raph( it is di$$icu"t or impossi!"e to e a"uate $i""et 'e"ds !# this method) Kecause a radio&raph compresses a"" the de$ects that occur throu&hout the thic%ness o$ the 'e"d into one p"ane( it tends to &i e an e+a&&erated impression o$ scattered3t#pe de$ects such as porosit# or inc"usions) An W3ra# ima&e o$ the interior o$ a 'e"d ma# !e ie'ed on a $"uorescent screen( as 'e"" as on de e"oped $i"m) This ma%es it possi!"e to inspect parts $aster and at "o'er cost( !ut ima&e de$inition is !ut ima&e de$inition is possi!"e to o ercome man# o$ the shortcomin&s o$ radio&raphic ima&in& !# "in%in& the $"uorescent screen 'ith a ideo camera) Instead o$ 'aitin& $or $i"m to !e de e"oped( the ima&es can !e ie'ed in rea" time) This can impro e qua"it# and reduce costs on production app"ications such as pipe 'e"din&( 'here a pro!"em can !e identi$ied and corrected quic%"#) K# di&iti*in& the ima&e and "oadin& it into a computer( the ima&e can !e enhanced and ana"#*ed to a de&ree ne er !e$ore possi!"e) 7u"tip"e ima&es can !e superimposed) Pi+e" a"ues can !e ad,usted to chan&e shadin& and contrast( !rin&in& out sma"" $"a's and discontinuities that 'ou"d not sho' up on $i"m) Co"ors can !e assi&ned to the arious shades o$ &ra# to $urther enhance the ima&e and ma%e $"a's stand out !etter) The process o$ di&iti*in& an ima&e ta%en $rom the $"uorescent screen 3 ha in& that ima&e computer enhanced and trans$erred to a ie'in& monitor 3 ta%es on"# a $e' seconds) 4o'e er( !ecause there is a time de"a#( 'e can no "on&er consider this >rea" time)> It is ca""ed >radioscop# ima&er#)> PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
E+istin& $i"ms can !e di&iti*ed to achie e the same resu"ts and impro e the ana"#sis process) Another ad anta&e is the a!i"it# to archi e ima&es on "aser optica" dis%s( 'hich ta%e up $ar "ess space than au"ts o$ o"d $i"ms and are much easier to reca"" 'hen needed) Industria" radio&raph#( then( is an inspection method usin& W3ra#s and &amma ra#s as a penetratin& medium( and densiti*ed $i"m as a recordin& medium( to o!tain a photo&raphic record o$ interna" qua"it#) Genera""#( de$ects in 'e"ds consist either o$ a oid in the 'e"d meta" itse"$ or an inc"usion that di$$ers in densit# $rom the surroundin& 'e"d meta") Radio&raphic equipment produces radiation that can !e harm$u" to !od# tissue in e+cessi e amounts( so a"" sa$et# precautions shou"d !e $o""o'ed c"ose"#) A"" instructions shou"d !e $o""o'ed care$u""# to achie e satis$actor# resu"ts) On"# personne" 'ho are trained in radiation sa$et# and qua"i$ied as industria" <i&) C 3 App"ications $or ma&netic partic"e testin& inc"ude inspectin& p"ate ed&es prior to 'e"din&( in process inspection o$ each 'e"dpass or "a#er( post'e"d e a"uation and repairs)
radio&raphers shou"d !e permitted to do radio&raphic testin&) 7a&netic Partic"e Inspection @7TA 7a&netic partic"e inspection is a method o$ "ocatin& and de$inin& discontinuities in ma&netic materia"s It is e+ce""ent $or detectin& sur$ace de$ects in 'e"ds( inc"udin& PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
discontinuities that are too sma"" to !e seen 'ith the na%ed e#e( and those that are s"i&ht"# su!sur$ace) This method ma# !e used to inspect p"ate ed&es prior to 'e"din&( in process inspection o$ each 'e"d pass or "a#er( post'e"d e a"uation and to inspect repairs 3 <i&) C) It is a &ood method $or detectin& sur$ace crac%s o$ a"" si*es in !oth the 'e"d and ad,acent !ase meta"( su!sur$ace crac%s( incomp"ete $usion( undercut and inadequate penetration in the 'e"d( as 'e"" as de$ects on the repaired ed&es o$ the !ase meta") A"thou&h ma&netic partic"e testin& shou"d not !e a su!stitute $or radio&raph# or u"trasonics $or su!sur$ace e a"uations( it ma# present an ad anta&e o er their methods in detectin& ti&ht crac%s and sur$ace discontinuities) Fith this method( pro!es are usua""# p"aced on each side o$ the area to !e inspected( and a hi&h ampera&e is passed throu&h the 'or%p"ace !et'een them) A ma&netic $"u+ is produced at ni&ht an&"es to the $"o' o$ current 3 <i&) C) Fhen these "ines o$ $orce encounter a discontinuit#( such as a "on&itudina" crac%) the# are di erted and "ea% throu&h the sur$ace( creatin& ma&netic po"es or points o$ attraction) A ma&netic po'der dusted onto the sur$ace 'i"" c"in& to the "ea%a&e area more tenacious"# than e"se'here( $ormin& an indication o$ the discontinuit#) <or this indication to de e"op( the discontinuit# must !e an&"ed a&ainst the ma&netic "ines o$ $orce) Thus( 'hen current is passed "on&itudina""# throu&h a 'or%piece( on"# "on&itudina" $"a's 'i"" sho') Puttin& the 'or%piece inside a so"enoid coi" 'i"" create "on&itudina" "ines o$ $orce @<i&) CA that cause trans erse and an&u"ar crac%s to !ecome isi!"e 'hen the ma&netic po'der is app"ied) A"thou&h much simp"er to use than radio&raphic inspection( the ma&netic partic"e method is "imited to use 'ith $erroma&netic materia"s and cannot !e used 'ith austenitic stee"s) A ,oint !et'een a !ase meta" and a 'e"d meta" o$ di$$erent ma&netic characteristics 'i"" create ma&netic discontinuities that ma# !e $a"se"# interpreted as PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
unsound) On the other hand a true de$ect can !e o!scured !# the po'der c"in&in& o er the harm"ess ma&netic discontinuit#) Sensiti it# decreases 'ith the si*e o$ the de$ect and is a"so "ess 'ith round $orms such as &as poc%ets) It is !est 'ith e"on&ated $orms( such as crac%s( and is "imited to sur$ace $"a's and some su!sur$ace $"a's( most"# on thinner materia"s) Kecause the $ie"d must !e distorted su$$icient"# to create the e+terna" "ea%a&e required to identi$# $"a's( the $ine( e"on&ated discontinuities( such as hair"ine crac%s( seams or inc"usions that are para""e" to the ma&netic $ie"d( 'i"" not sho' up) The# can !e de e"oped !# chan&in& the direction o$ the $ie"d( and it is ad isa!"e to app"# the $ie"d $rom t'o directions( pre$era!"# at ri&ht an&"es to each other) 7a&netic po'ders ma# !e app"ied dr# or 'et) The dr# po'der method is popu"ar $or inspectin& hea # 'e"dments( 'hi"e the 'et method is o$ten used in inspectin& aircra$t components) Dr# po'der is dusted uni$orm"# o er the 'or% 'ith a spra# &un( dustin& !a& or atomi*er) The $ine"# di ided ma&netic partic"es are coated to increase their mo!i"it# and are a ai"a!"e in &ra#( !"ac% and red co"ors to impro e isi!i"it#) In the 'et method( er# $ine red or !"ac% partic"es are suspended in 'ater or "i&ht petro"eum disti""ate) This can !e $"o'ed or spra#ed on( or the part ma# !e dipped into the "iquid) The 'et method is more sensiti e than the dr# method( !ecause it a""o's the use o$ $iner partic"es that can detect e+ceedin&"# $ine de$ects) <"uorescent po'ders ma# !e used $or $urther sensiti it# and are especia""# use$u" $or "ocatin& discontinuities in corners( %e#'a#s( sp"ines and deep ho"es) >7T ma# ha e an ad anta&e o er RT and UT in detectin& ti&ht crac%s and sur$ace discon$inui$ies)>
ASNT NDT LEVEL
<i&) D 3 D#e penetrant inspection is DYE PENETRANT TESTING CONSULTANTS 13 simi"ar to "iquidSAIMIRA penetrant inspection e+cept i id"# co"oredd#es isi!"e under ordinar# "i&ht are used)
Liquid Penetrant Inspection @PTA Sur$ace crac%s and pinho"es that are not isi!"e to the na%ed e#e can !e "ocated !# "iquid penetrant inspection) It is 'ide"# used to "ocate "ea%s in 'e"ds and can !e app"ied 'ith austenitic stee"s and non$errous materia"s 'here ma&netic partic"e inspection 'ou"d !e use"ess) Liquid penetrant inspection is o$ten re$erred to as an e+tension o$ the isua" inspection method) 7an# standards( such as the AFS D.). Code( sa# that >'e"ds su!,ect to "iquid penetrant testin& ))) sha"" !e e a"uated on the !asis o$ the requirements $or isua" inspection)> T'o t#pes o$ penetratin& "iquids are used 3 $"uorescent and isi!"e d#e) Fith $"uorescent penetrant inspection( a hi&h"# $"uorescent "iquid 'ith &ood penetratin& qua"ities is app"ied to the sur$ace o$ the part to !e e+amined) Capi""ar# action dra's the "iquid into the sur$ace openin&s( and the e+cess is then remo ed) A >de e"oper> is used to dra' the penetrant to the sur$ace( and the resu"tin& indication is ie'ed !# u"tra io"et @!"ac%A "i&ht) The hi&h contrast !et'een the $"uorescent materia" and the o!,ect ma%es it possi!"e to detect minute traces o$ penetrant that indicate sur$ace de$ects)
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SAIMIRA
D#e penetrant inspection is simi"ar( e+cept that i id"# co"ored d#es isi!"e under ordinar# "i&ht are used 3 <i& D) Norma""#( a 'hite de e"oper is used 'ith the d#e penetrants that creates a sharp"# contrastin& !ac%&round to the i id d#e co"or) this a""o's &reater porta!i"it# !# e"iminatin& the need $or u"tra io"et "i&ht) The part to !e inspected must !e c"ean and dr#( !ecause an# $orei&n matter cou"d c"ose the crac%s or pinho"es and e+c"ude the penetrant) Penetrants can !e app"ied !# dippin&( spra#in& or !rushin&( !ut su$$icient time must !e a""o'ed $or the "iquid to !e $u""# a!sor!ed into the discontinuities) This ma# ta%e an hour or more in er# e+actin& 'or%) Liquid penetrant inspection is 'ide"# used $or "ea% detection) A common procedure is to app"# $"uorescent materia" to one side o$ a ,oint( 'ait an adequate time $or capi""ar# action to ta%e p"ace( and then ie' the other side 'ith u"tra io"et "i&ht) In thin3'a""ed esse"s( this technique 'i"" identi$# "ea%s that ordinari"# 'ou"d not !e "ocated !# the usua" air test 'ith pressures o$ 031/ I!Qin 1) Fhen 'a"" thic%ness e+ceeds .QD in)( ho'e er( sensiti it# o$ the "ea% test decreases)
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21
SAIMIRA <i&) 0 3 U"trasonic inspection detects discontin ities !oth on and !e"o' the 'e"d sur$ace) Compact( porta!"e equipment ma%es it eas# to use in the $ie"d)
U"trasonic Inspection is a method o$ detectin& discontinuities !# directin& a hi&h3 $requenc# sound !eam throu&h the !ase p"ate and 'e"d on a predicta!"e path) Fhen the sound !eam;s path stri%es an interruption in the materia" continuit#( some o$ the sound is re$"ected !ac%) The sound is co""ected !# the instrument( amp"i$ied and disp"a#ed as a ertica" trace on a ideo screen 3 <i&) 0) Koth sur$ace and su!sur$ace de$ects in meta"s can !e detected( "ocated and measured !# u"trasonic inspection( inc"udin& $"a's too sma"" to !e detected !# other methods) The u"trasonic unit contains a cr#sta" o$ quart* or other pie*oe"ectric materia" encapsu"ated in a transducer or pro!e) Fhen a o"ta&e is app"ied( the cr#sta" i!rates rapid"#) As an u"trasonic transducer is he"d a&ainst the meta" to !e inspected( it imparts mechanica" i!rations o$ the same $requenc# as the cr#sta" throu&h a coup"et materia" into the !ase meta" and 'e"d) These i!rationa" 'a es are propa&ated throu&h the materia" unti" the# reach a discontinuit# or chan&e in densit#) At these points( some o$ the i!rationa" ener&# is re$"ected !ac%) As the current that causes the i!ration is shut o$$ and on at E/3./// times per second( the quart* cr#sta" intermittent"# acts as a recei er to pic% up the re$"ected i!rations)These cause pressure on the cr#sta" and &enerate an e"ectrica" current) <ed to a ideo screen( this PREPARED BY S.MUTHUKUMAR, B.Tech lll ASNT NDT LEVEL
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SAIMIRA
current produces ertica" de$"ections on the hori*onta" !ase "ine) The resu"tin& pattern on the $ace o$ the tu!e represents the re$"ected si&na" and the discontinuit#) Compact porta!"e u"trasonic equipment is a ai"a!"e $or $ie"d inspection and is common"# used on !rid&e and structura" 'or%) U"trasonic testin& is "ess suita!"e than other NDE methods $or determinin& porosit# in 'e"ds( !ecause round &as pores respond to u"trasonic tests as a series o$ sin&"e3point re$"ectors) This resu"ts in "o'3 amp"itude responses that are easiI# con$used 'ith >!ase "ine noise> inherent 'ith testin& parameters) 4o'e er( it is the pre$erred test method $or detectin& p"ainer3t#pe discontinuities and "amination) Porta!"e u"trasonic equipment is a ai"a!"e 'ith di&ita" operation and microprocessor contro"s) These instruments ma# ha e !ui"t3in memor# and can pro ide hard3cop# printouts or ideo monitorin& and recordin&) The# can !e inter$aced 'ith computers( 'hich a""o's $urther ana"#sis( documentation and archi in&( much as 'ith radio&raphic data) U"trasonic e+amination requires e+pert interpretation $rom hi&h"# s%i""ed and e+tensi e"# trained personne") Ta!"e . 3 Re$erence Guide to 7a,or 7ethods $or the Nondestructi e E+amination o$ Fe"ds Inspection 7ethod 6isua" Equipment Required 7a&ni$#in& &"ass Fe"d si*in& &au&e Poc%et ru"e Ena!"es Detectiort o$ Sur$ace $"a's 3 Lo' cost) crac%s( porosit#(Can !e s"a& inc"usions 'or% is in Farpa&e( process( correction o$ $au"ts) Gi es App"ica!"e to Shou"d a"'a#s sur$ace Pro ides no permanent record) !e the primar# inspection( no matter 'hat other techniques are required) Is the on"# >producti e> t#pe o$ ASNT NDT LEVEL Ad anta&es Limitations Remar%s
un$i""ed craters( app"ied 'hi"e de$ects on"#) method o$
Strai&ht ed&e under'e"din&( permittin& For%manship o er'e"din&( standards poor"# $ormed !eads(
misa"i&nments( indication o$ improper $itup incorrect PREPARED BY S.MUTHUKUMAR, B.Tech lll
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SAIMIRA
procedures)
inspection) Is the necessar# $unction o$ e er#one 'ho in an# 'a# contri!utes to the ma%in& o$ the 'e"d)
Radio&raphicCommercia" W3Interior ra# or &amma macroscopic units made inspectin& 'e"ds( $or&in&s) <i"m and processin& $aci"ities) ie'in& equipment)
Fhen the indications
Requires s%i"" W3ra# in choosin& inspection is required !# man# codes and speci$ications) Use$u" in qua"i$ication o$ 'e"ders and 'e"din& processes) Kecause o$ shou"d !e "imited to those areas 'here other methods 'i"" not pro ide the assurance required)
$"a's 3 crac%s( are recorded an&"es o$ ho"es( nonmeta""ic a permanent operatin& record) equipment( interpretin& Fhen ie'ed and $"uoroscopic indications) screen( a "o'3 Requires cost method sa$et# o$ interna" inspection precautions) suita!"e $or $i""et 'e"d inspection)
especia""# $or porosit#( !"o' on $i"m( &i ese+posure(
castin&s and inc"usions( penetration( undercuttin&( icic"es( and
incomp"ete root on a
<"uoroscopic !urnthrou&h)
Not &enera""# cost( its use
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS 7a&netic Partic"e Specia" commercia" equipment) 7a&netic or 'et $ormJ ma# !e $"uorescent $or ie'in& under u"tra io"et "i&ht) E+ce""ent $or detectin& sur$ace
24
SAIMIRA
Simp"er to use than
App"ica!"e to E"on&ated $erroma&netic de$ects para""e" Requires s%i"" $ie"d ma# not in &i e patternJ $or interpretation this reason the o$ indications $ie"d shou"d !e and irre"e ant patterns) on rou&h sur$aces) app"ied $rom at or near ri&ht an&"es to each reco&nition o$ t'o directions
radio&raphic materia"s on"#)to the ma&netic Permits sensiti it#) Re"ati e"# "o'3cost method)
discontinuities 3 inspection) sur$ace crac%s) contro""ed
po'ders 3 dr# especia""#
Di$$icu"t to useother)
Liquid Penetrant
Commercia"
Sur$ace crac%s App"ica!"e to On"# sur$ace In thin3'a""ed ma&netic andde$ects are nonma&netic detecta!"e) materia"s) Cannot !e Eas# to use) used hot assem!"ies) esse"s 'i"" re ea" "ea%s not ordinari"# "ocated !# irre"e ant sur$ace conditions @smo%e( s"a&A ma# &i e mis"eadin& indications)
%its containin&not readi"# $"uorescent or isi!"e to the d#e penetrants and de e"opers) App"ication equipment $or the de e"oper) A source o$ u"tra io"et "i&ht 3 i$ $"uorescent method is unaided e#e) E+ce""ent $or 'e"dments)
"ocatin& "ea%s inLo' cost)
e$$ecti e"# on usua" air tests)
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS used) U"trasonic Specia" commercia" equipment( either o$ the Sur$ace and su!sur$ace
2/
SAIMIRA
6er# sensiti e)
Requires hi&h Pu"se3echo de&ree o$ s%i"" equipment is in interpretin& hi&h"# pu"se3echo patterns) de e"oped $or 'e"d inspection purposes) transmission3 t#pe equipment simp"i$ies pattern interpretation 'here it is app"ica!"e)
$"a's inc"udin& Permits those too sma"" pro!in& o$
pu"se3echo or to !e detected ,oints transmission !# other t#pe) Standard re$erence patterns $or methods) Especia""# $or detectin& su!sur$ace to
inaccessi!"e Permanent radio&raph#) readi"# o!tained)
record is not The
interpretation "amination3"i%e o$ R< or ideo de$ects) patterns)
Choices Contro" Qua"it# A &ood NDE inspection pro&ram must reco&ni*e the inherent "imitations o$ each process) <or e+amp"e( !oth radio&raph# and u"trasound ha e distinct orientation $actors that ma# &uide the choice o$ 'hich process to use $or a particu"ar ,o!) Their stren&ths and 'ea%nesses tend to comp"ement each other) Fhi"e radio&raph# is una!"e to re"ia!"# detect "amination3"i%e de$ects( u"trasound is much !etter at it) On the other hand( u"trasound is poor"# suited to detectin& scattered porosit#( 'hi"e radio&raph# is er# &ood)
ASNT NDT LEVEL
DYE PENETRANT TESTING CONSULTANTS The <i e P;s are .) 1) C) D) 0) E) L) M) H)
20
SAIMIRA
Process Se"ection) The process must !e ri&ht $or the ,o!) Preparation) The ,oint con$i&uration must !e ri&ht and compati!"e 'ith the 'e"din& process) Procedures) The procedures must !e spe""ed out in detai" an $o""o'ed durin& 'e"din&) Pretestin&) <u""3sca"e moc%ups or simu"ated specimens shou"d !e used to pro e that the process and procedures &i e the desired standard o$ qua"it#) Personne") Qua"i$ied peop"e must !e assi&ned to the ,o!) Fhate er inspection techniques are used( pa#in& attention to the ><i e P;s> o$ 'e"d qua"it# 'i"" he"p reduce su!sequent inspection to a routine chec%in& acti it#) Then( the proper use o$ NDE methods 'i"" ser e as a chec% to %eep aria!"es in "ine and 'e"d qua"it# 'ithin standards)
ASNT NDT LEVEL

Penetrants TESTING

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Penetrants TESTING

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DYE PENETRANT TESTING CONSULTANTS

. !. ". #. 10. 11. 12. 13. 14. 15. 1 .

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS

Cle& !+()&ce %) C%,"% e # Pe e#(& # &""l$c&#$%

Re,%*&l %) e-ce!! !+()&ce "e e#(& #

I !"ec#$% & ' I #e("(e#&#$%

Fig.1. Principle of Penetrant Testing

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

'33*, 43*-6 1 #0; < #0;

Fettin& an&"e !et'een capi""ar# tu!e And "iquid

DYE PENETRANT TESTING CONSULTANTS

A liquid drop on a ideally smooth, clean surface at equilibrium

DYE PENETRANT TESTING CONSULTANTS tension( cohesion) 'hich causes "iquids to

SAIMIRA drop"ets( is caused !#

Factors influencing Penetrant infiltration into discontinuities

Norma""#( the penetrants need to ha e a

er# "o' contact an&"e and the

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS

PREPARED BY S.MUTHUKUMAR, B.Tech lll

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS

FATER SUSPENDED PARTICLE

DYE PENETRANT TESTING CONSULTANTS

FATER FAS4AKLE APPL9 PENETRANT

POST E7ULSI<IED APPL9 PENETRANT APPL9 E7ULSI<IER

SOL6ENT RE7O6AL APPL9 PENETRANT

APPL9 FATER KASED FET DE6ELOPER

APPL9 DR9 POFDER DE6ELOPER

APPL9 NON AQUEOUS FE DE6ELOPE R

APPL9 DR9 POFDER DE6ELOPER

DR9 INSPECT POST CLEAN

PREPARED BY S.MUTHUKUMAR, B.Tech lll

ASNT NDT LEVEL

DYE PENETRANT TESTING CONSULTANTS

DUAL SENSITI6IT9 PENETRANTS PROCESS SEQUENCE

DUAL SENSITI6IT9 PENETRANTS PROCESS SEQUENCE

DR9 APPL9 NON AQUEOUS FET DE6ELOPER

INSPECT POST CLEAN

DYE PENETRANT TESTING CONSULTANTS re"e ant as to the nature

SAIMIRA "inear or o"umetric)

DYE PENETRANT TESTING CONSULTANTS

DYE PENETRANT TESTING CONSULTANTS ad anta&e o$ usin& a

'33, 43-6 1 #0; < #0;

D ,A3>&) '32,-- ASTM E 1 5