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FAILURE MODE AND ACTIONS IN A PENETRANT INSPECTION PROCESS

Rubén Olmeda Sanz


Level 3 PT EN 4179
MPB AEROSPACE S.L.

This article describes, as example, some of the most common failure modes that can occur in a Penetrant Inspection process (water washable penetrant) and corrective and preventive actions to be
performed. This can be useful to be included in the Penetrant Inspection procedure to be available to the inspectors in order to facilitate a quick response to a failure.

FAILURE CAUSES CORRECTIVE ACTION PREVENTIVE ACTION

Check beforehand that the attack factor calculation and time in tank
During pre cleaning etching of 5 microns (or
Time inside the tank or incorrect Repeat pre-cleaning and etching removing the is correct
indicated in each case) is not performed or
installation malfunction number of microns necessary Preventive maintenance of the installation
insufficient
Calibration and periodic checks of the process control software

In case of parts with complex geometry, increasing the drying time


The parts have humidity before penetrant Continue drying to ensure that the parts are
Drying insufficient Preventive maintenance. Calibration and periodic checks of the
application completely dry
process control software

After the application of the penetrant it is Apply the penetrant manually in the areas that
Faulty installation Preventive maintenance. Calibration and periodic checks of the
observed that it does not completely cover require it, respecting again the corresponding
Parts placed improperly process control software Place the parts properly avoiding masks
the parts. penetration time

The maximum penetration time has been Preventive maintenance. Calibration and periodic checks of the
exceeded or dry penetrant is observed on the Faulty installation or human error Clean the parts again and reprocess process control software
surface of the parts. Apply more penetrant preventing drying as often as necessary

Preventive maintenance. Respect the guidelines established and


Improper wash or wash conditions
Overwashing during the penetrant removal Wash with water and re-reprocess the parts controlling pressure washing and wash temperature before
(pressure / temp) unfulfilled
processing each batch.

Temperature or maximum time of drying is Preventive maintenance. Calibration and periodic checks of the
Faulty installation Clean the parts again and reprocess
exceeded after penetrant removing process control software
FAILURE CAUSES CORRECTIVE ACTION PREVENTIVE ACTION

The maximum application time of developer has been Preventive maintenance. Calibration and periodic checks
Faulty installation Clean the parts again and reprocess
exceeded of the process control software

During the inspection parts have excessive Improper wash or penetrant Clean the parts again and reprocess Respect washing guidelines established Performing
background fluorescence deteriorated In case of repeated failure perform washability test periodic test of washability

Apply developer manually in areas with lack of Preventive maintenance. Calibration and periodic checks
The dry developer does not cover all the areas to be Faulty installation
coverage or change the position of the parts and of the process control software. Place the parts properly
inspected with a thin and uniform layer Parts placed improperly
reapply the developer using the fluid tank bed avoiding masks

After post cleaning are detected rests of product Manual cleaning with solvent and repeat the
Improper wash Respect washing guidelines established
(penetrant or developer) on the parts. washing process and dry

Interrupt the process and immediately report to


Equipment out of calibration are detected Human Error Adequate monitoring of calibrations plan
Quality Assurance

The intensity of light (UV or white) is out of maximum Failure or exhaustion of the light Interrupting and repair or replace the light sources. Preventive maintenance. Proper review of cleanliness and
or minimum values required sources Immediately notify the Quality Assurance integrity of filters. Have a safety stock of bulbs / lamps

Carefully clean again Tam Panel and re-process. If


the result is still negative, the process is
Tam Panel dirty, processed interrupted and immediately communicated to
incorrectly or damaged. Quality Assurance to perform root cause analysis Maintenance and proper cleaning of Tam Panel. Correct
The control process efficiency results non conform
Penetrating deteriorated (which must include completion of the testing processing of Tam Panel Robustness in the process
No efficient process process sensitivity and washability).
If it detects that the Tam panel is damaged,
replace and repeat the test with a new Tam Panel.

Product expired or
Properly control expiration and storage of the product.
deteriorated.
The condition of developer does not comply with the Interrupt the process, discard the developer, clean Remove excess of penetrant correctly both as parts of
Contamination by penetrant
requirements tank and replenish new developer baskets and racks to avoid dragging. Drying the parts
trawls (baskets / frame or
correctly
parts) or wet (incorrect drying)
FAILURE CAUSES CORRECTIVE ACTION PREVENTIVE ACTION

Penetrant in use does not comply with the Product expired or


Interrupt the process, replace the penetrant. In the
requirements (features, separation of constituents, deteriorated. Properly control expiration and storage of the product.
event of affected parts, immediately report to
pollution, washability, water content, fluorescence Contamination by moisture or Prior cleaning and drying the parts correctly performed
Quality Assurance
intensity, ..) other contaminants.

Carefully clean again Tam Panel (as shown in


Tam Panel dirty, processed Annex 4) and repeat the measurement. If the result Maintenance and proper cleaning of Tam Panel. Correct
Tam Panel degradation exceeds the required ± 30%
incorrectly or damaged. is still negative, the Tam panel is replaced by a processing of Tam Panel
new Tam Panel.

Rubén Olmeda Sanz


Level 3 PT EN 4179
MPB AEROSPACE S.L.