Se Lesson 1 Introduction to Liquid Penetrant Testing History OF LiQuip PENETRANT TESTING 1. Liquid penetrant testing is one of the oldest methods of nondestructive testing. 2. The origin of liquid penetrant testing is generally attributed to the inspection of wheel axles in the railroad industry in the 1890s. 3. The oil-and-whiting test involves immersing test objects in oil and then wiping with rags dampened with kerosene. Powdered chalk was used to dust the surface to increase the visibility of any oil leaking back onto the test object surface. @ NONDESTRUCTIVE TESTING METHODS Nondestructive testing methods are used by manufacturers for the following reasons. 1. To ensure product integrity and reliability. 2. To avoid test object failure, prevent accidents and save lives. 3. To make user profits. 4, To ensure customer satisfaction. 5. To aid in better product design. 6. To lower manufacturer’s cost. 7. To maintain uniform quality levels. 8. To ensure operations readiness.Reasons for Selecting Liquid Penetrant Testing ‘Some advantages of liquid penetrant testing include the following. 1. Liquid penetrant testing quickly examines all accessible surfaces. 2. Liquid penetrant testing detects very small surface discontinuities. 3. It-can be used on a wide variety of materials including ferrous and nonferrous ‘metals and alloys and fired ceramics. 4, Ituses relatively inexpensive and nonsophisticated equipment. 5. Sensitivity magnifies size and location of discontinuities. 6. Sensitivity can be adjusted by selection of penetrant, removal technique and type of developer. 7. Technicians can visually detect indications. 8. Liquid penetrant testing can be used for in-service checks to resolve production problems early. AVAILABILITY OF LiQuiD PENETRANT ‘There are three basic classification types by dye. 1, Type I: Fluorescent penetrant. 2, Type I: Visible penetrant (color contrast), 3. Type III: Dual mode (visible/ fluorescent). Type I Fluorescent ‘Type | fluorescent is further classified by five sensitivity levels as follows. 1. Level 1/2: Ultra low. 2. Level 1: Low. 3. Level 2: Medium. Personnel Training Publications4. Level 3: High. 5. Level 4: Ultra high. Note: There is no sensitivity level classification for Type II penetrant systems. Method of Removal Type I and II are further classified by method of removal of excess penetrant. 1. Method A: Water washable. Method B: Lipophilic postemulsifiable. Method C: Solvent removable. ew Method D: Hydrophilic postemulsifiable. Developer Forms Developers are classified as forms. 1. Form A: Dry powder. Form B: Water soluble. Form C: Water suspendible. Form D: Nonaqueous Type I (fluorescent). Form E: Nonaqueous Type II (visible dye). Form F: Special applications. Solvent Classes Solvents are divided into classes. 1 ‘Class 1: Halogenated. 2. — Class 2: Nonhalogenated. 3. Class 3: Special applications. ‘Student Guide: Liquid Penetrani TestingQUALIFICATION AND CERTIFICATION REQUIREMENTS The following U.S. documents outline personnel qualification and certification requirements. ASNT Recommended Practice No. SNT-TC-1A. ANSI/ASNT CP-189: Standard for Qualification and Certification of Nondestructive Personnel. ACCP: ASNT Central Certification Program. NAS 410, National Aerospace Standard Certification and Qualification of Nondestructive Testing Personnel. Training and Qualification Process A person who is in the process of yeep ing and qualification is considered a trainee. Three Basic Levels of Certification Level I. Level II. Level III. Qualification Requirements Organized training (required class hours). Required testing (general, specific, practical). Education (depends on written practice). Experience (documented hours). Physical attributes to perform examinations (vision acuity and color contrast test performed annually), Personnel Training PublicationsCertification Certification is a written testimony that an individual has met all the qualifications of a company’s written practice. Fire ay p SAFETY PRECAUTIONS Materials are usually combustible. ‘Minimum flash point on open tanks is usually 93 °C (200 °F). ‘Smoking and open flames should be avoided. Storage should be away from heat and open flames. Always review the material safety data sheets (MSDS) for precautions. Skin Irritation yore P Drying action can occur on skin from oil bases. Avoid splashing of materials. ‘Wear protective gloves, aprons and glasses. ‘Wash hands immediately when in contact with penetrant materials. Use protective hand creams. Air Pollution Dust and vapors are nontoxic. Inhalation of excessive amounts can be a health hazard. Exhaust fans should be installed for the use of dry developers. Fans should be used in test areas to remove vapors. Always follow recommendations for respirator or mask use. ‘Siudent Guides Liguid Penetrant TestingUltraviolet Radiation 1. 365 nm ultraviolet radiation causes fluorescence of penetrant material. 2. Higher frequencies are harmful to humans. 3. Ultraviolet lamp filters are used to prevent these harmful rays from harming humans. 4. Filters should be inspected for cracks and replaced as necessary. 5. Protective lenses or goggles should be used. Personnel Training PublicationsNotesNotesLesson 1 Qui Please answer true or false to the following questions. 1. Visual testing of materials, test objects and complete products is the principal ‘means of determining adequate quality of parts. 2. The liquid penetrant method detects the presence of cracks or other physical discontinuities both open to the surface and volumetric. 3. Liquid penetrant testing evolved from the oil-and-whiting test. 4, Liquid penetrant is used to avoid failure, prevent accidents, save human life, and to lower manufacturing costs. IZ, 5. Liquid penetrant testing can be used on a wide variety of materials including ferrous and nonferrous metals and alloys and nonfired ceramics. Liquid penetrant testing can be used for in-service checks to resolve production problems early. ‘There are three basic classification types by dye. ‘Type I fluorescent penetrant testing is further classified by five sensitivity levels. ‘Type I and Il are further classified by the method of removal of excess penetrant.10. Developers are classified as dry, wet 16. and nonaqueous. 11, Solvents are divided into halogen and nonhalogen. 17. 12. Recommended Practice No. SNT-TC-1A is required to be followed for the written practice. 18. 13, ANSASNT CP-189 - Standard for Qualification and Certification of Nondestructive Personnel is used as a guideline when required by the specification. 14, ACCP ASNT Central Certification Program is recognized nationally as a certifying agent. 15. Required testing consist of general, specific, practical and method for all levels of certification in nondestructive testing. Avhigh school diploma or a general education diploma is required for certification as a nondestructive testing technician. Exhaust fans should be installed for the use of wet developers to remove fumes. Ultaviolet lamp filters are used to prevent technicians from getting sun burned while performing tests. 0 Personnel Training Publications