Lesson 2 Liquid Penetrant Processing PROCEDURES AND TECHNIQUES 1. Procedures can be broad and cover several specific techniques. 2, — Each procedure and technique shall be approved and signed by a certified Level IIT PRECLEANING OF TEST OBJECTS Cleaning processes include the following. 1. Solvent. 2. Detergents. 3. Vapor degreasing. 4, Steam cleaning. 5. Ultrasonics. 6. Chemical. 7. Paint strippers. Alll cleaning methods must meet the following requirements. 1. Local environmental requirements. Health and safety requirements. Cause no harm to the test object. ‘Substrate should be wiped clean with an approved solvent cleaner. a) rol Solvent cleaner should be allowed to dry completely before application of penetrant. itPreparation of Test Objects 1. The surface properties of the test object determine surface preparation. 2. High nickel alloys, titaniums and stainless steels require the use of low sulfur and chloride products. 3. Surfaces need to be free of foreign materials which block open discontinuities. 4, Cleaning operations such as power wire brushing, grit blasting, shot peening and other metal smearing operations should be avoided. Precleaning and Postcleaning 1. Liquid penetrant test will be ineffective if substrate is not physically and chemically cleaned and dried. 2. Liquid penetrant residue may have a harmful effect on test objects if not properly removed before placing it in service. 3. The compatibility of cleaning agents and penetrant materials should be verified to ensure an acceptable penetrant test. Solvent Cleaning 1. The application of solvent cleaning may be immersion, sprayed, brushed or wiped. Solvent cleaning is commonly used for spot inspections. Solvent cleaners must evaporate readily and completely from the substrate, nS Solvent cleaners should be used to remove organic contaminants only. Detergent Cleaning Cleaning ‘accomplished by the use of immersion tanks and or detergent solutions. Cleaning is accomplished as follows. 1. Detergents wet the substrate. 2. Penetrates various soils. Personnel Training PublicationsEmulsification, 4. Saponification (change to soap). 5. Substrate is rinsed and dried. Detergent Cleaning Equipment 1. Suitable rinsing stations. 2. Suitable drying stations. 3. Thorough rinsing and drying after detergent cleaning will leave the substrate physically and chemically clean for liquid penetrant testing. Vapor Degreasing ‘Vapor degreasing is effective for the following procedures. 1. Removal of oils. Removal of greases. Removal of other similar organic contaminations. ‘Vapor degreasing does not require a rinse or drying (oven) step. ‘Vapor degreasing can be hazardous to the environment. ‘Vapor degreasing safety is a large concern due to health hazards. ‘Vapor degreasing is limited to cleaning of substrates that have been approved for this type of cleaning method. Steam Cleaning Precleaning with steam and alkaline detergents provide ideal cleaning. 1 2. Alkaline detergent emulsifies, softens or dissolves organic contamination Steam provides mechanical action for removal of detergents/contaminations from the surface of the substrate. ‘Steam cleaning is suitable for cleaning large, unwieldy components which are not easily submerged ‘Siudent Guide: Liquid Peneirant Testing 3BUltrasonic Cleaning 1, Ultrasonic cleaning is often combined with detergent or alkaline cleaning, Combined ultrasonic cleaning improves efficiency and reduces cleaning time. Ultrasonic cleaning is useful for cleaning large quantities of small test objects. Ultrasonic agitation requires special approval on some substrates. Rust and Surface Scale Removal Approved commercial rust and surface scale removers include the following. 1. Acid rust removers. 2. Alkaline rust removers. These require special equipment, and specific procedures should be followed. Paint Removal Paint removal methods include the following. 1, Dissolving hot tank paint strippers. 2. Bond release paint strippers. 3. Solvent paint strippers. ‘These require special equipment, and specific procedures should be followed. Etching Acid or alkaline solutions are used to remove smeared metal from operations, including the following, 1. Power wire brushing. 2. Sand blasting. Solutions open up grinding burrs and remove smeared metals. Etching and neutralization processes use either tanks/immersion or manual equipment. m Personnel Training Publicationse Precleaning Processes to be Avoided ‘The following methods should not be used before liquid penetrant tests. PN Blasting (shot, sand, grit, pressure, etc.). Liguid honing. Emery cloth. Power wire brushes. ‘These processes tend to close discontinuities by smearing metal, pening or cold working the surface, Drying Test Objects Test objects and potential discontinuities should be completely dry of cleaner before the application of penetrant. 1. Any remaining cleaner may prevent capillary action of the penetrant into discontinuities, 2. Some procedures require application of isopropyl alcohol or acetone to promote drying. 3. Drying ovens are sometimes required. Dwell Time 1, Penetrant dwell time is a period of time to allow penetrant to enter and fill any discontinuities open to the surface through capillary action. 2. Liquid penetrant is drawn out of discontinuity entrapments to the test object, surface during the so-called development time or developer dwell time. 3. Liquid penetrant may spread into the developer coating to form enhanced indications. This is sometimes referred to as reverse capillary action. ‘Student Guide: Liquid Penetrant Testing BAPPLICATION OF PENETRANT Penetrant applications include the following. 1. Spraying. 2. Brushing. 3. Pouring. 4. Dipping Test surfaces should remain wetted the entire penetrant dwell time. Ultraviolet radiation sources may assist when using fluorescents. Adequate Illumination 1, Fluorescent rinse station requires about 100 lux (10 ftc) of ambient (white) light and more than 100 x W/em? of near ultraviolet radiation (UV-A). 2. Fluorescent evaluation station is typically 1000 x W/em? of near ultraviolet radiation (UV-A) as measured at the test surface, and the ambient (white) light should not be greater than 20 tux (2 fic). 3. Visible dye penetrant (color contrast) usually requires 1000 lux (100 fic) at the test surface. These levels should always be verified against the governing procedure, standard or specification 6 Personnel Training Publications@ PENETRANT Water Rinse (Methods A, B and D) After the required dwell/emulsification time, the examination area is typically water rinsed. Course droplets are preferred, as the mechanical action is dependent on the size of drops and velocity at impact. Water rinse is typically applied at an oblique angle (45° to 75° is most effective angle). Normal distances of 15 to 61 em (6 to 24 in.) are acceptable and provide a uniform rate of removal. ‘Temperature ranges for rinse water is 10 to 38 °C (50 to 100 °I Water pressure of about 69 to 241 kPa (10 to 35 psi) is generally used. The pressure should not exceed 275 kPa (40 psi). Solvent Removable After required dwell time, the following functions are typically performed. Wipe test area with a lint-free, absorbent towel that has a color contrast with the penetrant. Use a clean section with each swipe. After removal of the bulk of penetrant, lightly dampen a clean cloth. Do not soak oor saturate the cloth with cleaner. Continue to swipe area until no evidence of penetrant is observed. ‘Make a final swipe with a clean dry cloth and verify that there is no evidence of penetrant on the cloth. Allow the cleaner to evaporate before the application of developer. ‘Student Guide: Liguid Penetrant Testing aDeveloper Application and Drying ‘The basic types of developer are as follows. a etal Form A: Dry powder (fine powder form), Form B: Water soluble (liquid dip tanks). Form C: Water suspendible (liquid dip tanks). Form D: Nonaqueous Type I (aerosol spray cans). Form E: Nonaqueous Type II (aerosol spray cans). Form F: Specific application developers. Dry Powder Developer Form A Dry powder developers are applied to dry test object surfaces by the following methods. wren Air suspension. Electrostatic spraying (common in automated systems). Test object immersion. ‘The powder is light and fluffy and clings to the test object surfaces in a fine film. Dry powder is most useful on rough surfaces and automated processing using fluorescent penetrants. Water Soluble Developer Form B Developers consist of a powder dissolved in water and applied by the following means. Dipping a test object in the solution. Flowing the solution over a test object. Spraying the solution onto the test object. This type of aqueous developer forms a translucent film. Water soluble developer can be used for fluorescent dyes. Not recommended for use with visible dye. is Personnel Training PublicationsNot recommended for use with water washable. Water in the developer may remove water washable penetrant from discontinuities. Can save time during processing, since drying is included in the developer dwell time. ‘Supplied as a dry concentrate that must be mixed and maintained at the proper ratio of developer to water. Developer is typically checked at regular intervals for penetrant contamination and water evaporation per approved specifications. Water Suspendible Developer Form C Supplied as a dry concentrate that must be mixed and maintained at the proper ratio of developer to water. Suspended aqueous developer does not dissolve in water so it must be thoroughly agitated just before application to suspend the particles in water. Development of indications does not begin until the moisture is completely evaporated from the developer. ‘Thickness of the coating and its white color work well with visible dyes. Test objects are typically checked to ensure a uniform coating of developer has been applied. Developer is typically checked at regular intervals for penetrant contamination and ‘water evaporation per approved specifications with a hydrometer. Removal of dried suspendible developers may be more difficult because they are not soluble in water. All aqueous developers necessarily contain biocides, corrosion inhibitors and wetting agents. ‘Student Guide: Liguid Penetrant Testing 9Prior Rep Nonaqueous (Aerosol Can) Type I and II Nonaqueous (solvent suspendible) developers are supplied in the ready-to-use condition, frequently in aerosol cans. Nonaqueous developer is the most sensitive form of developer because the solvent action contributes to the absorption and adsorption mechanisms of the developer by entering the discontinuity and dissolving into the liquid penetrant. a. Adsorption is the surrounding of the developer particles by adhesion, which coats the surface of the particles. b. Absorption is the assimilation of penetrant into the bulk of the particles. to spraying of developer, the following procedures should be followed. Aerosol can requires agitation before spraying. ‘The test object must be thoroughly dry. Several thin, uniform coats are preferred over one heavy coat. A check spray should be performed before spraying the test surface to prevent spattering of the developer. DEVELOPMENT/DWELL TIME The development of indications does not begin until the moisture is completely evaporated from the developer. The test object must be monitored very closely during the developer dwell time to properly evaluate the indications as they form. ‘Typically, the developer dwell time is a minimum of 10 min, Always reference the specifications, ‘The point at which the developer dwell time begins depends on the type of developer being used. eT) Personnel Training Publications5. Wet developer dwell time begins as soon as the developer is dry. 6. Dry and nonaqueous developers’ dwell time begin at application. INTERPRETATION AND EVALUATION 1. Interpretation: The determination of whether indications are relevant or nonrelevant. 2. Evaluation: A review, following interpretation of the indications noted, to determine whether they meet specified acceptance criteria. ‘TyPES OF INDICATIONS Indications form on the surface of test objects during examinations because of discontinuities located on the surfaces. They may be classified as the following. 1. False indications. 2. — Nonrelevant indications. 3. Relevant indications. a. Linear indications are those which contain a major dimension at least three times the minor dimension. b. Round indications are those whose major dimension is less than three times the minor dimension. Note: This is a general rule of thumb. Refer to the specification or procedure. Discontinuities 1, A discontinuity is an interruption in the normal structure of the test object. It may not be a defect. Student Guide: Liquid Penetrant Testing cra If, during the evaluation phase, it is determined that the discontinuity interferes with the serviceability of the test object or it does not meet the acceptance criteria, the discontinuity is then classified as a defect. False Indications False 2 awe Ye A nondestructive testing indication that is interpreted to be caused by a discontinuity at a location where no discontinuity exists. False indications are nonrelevant. In some reference documents, false indications and nonrelevant indications are considered to be the same thing. indications are caused by the following reasons. Lack of cleanliness by poor processing conditions. Lack of cleanliness in the testing booth or other aspects of the penetrant process. Penetrant on the hands of technicians, Contamination of wet or dry developer. Penetrant from other test objects. Penetrant on examination table. Fluorescent specks or particles. Cleaning and reprocessing a test object is required when false indications are noted. A typical false indication is a piece of lint on a part that resembles a crack during ultraviolet radiation testing. The most serious problem with false indications is determining whether the indication is masking a relevant indication, 2B Personnel Training Publications@ Nonrelevant Indications Nonrelevant indications are caused by surface irregularities or test object configuration and are not detrimental to the serviceability of the test object. They may appear on test objects at the following locations, 1. Press fitted joints. 2. Riveted connections. 3. Spot welds. 4, Substrates with rough surfaces. Relevant Indications 1. _ Relevant indications are those that are caused by discontinuities on the surface of a test object. 6 2, Alll relevant indications are discontinuities, but not all discontinuities are defects. Relevant indications are classified as: 1. Continuous line indications, 2. Intermittent line indications. 3. Round or dot indications. Within these groups there are large, small, weak and diffused indications. Continuous Line Indications Continuous line indications are discontinuities. 1. Cracks, 2. Seams. 3. Cold shuts. 4. Forging laps. ‘Student Guide: Liquid Penetrant Texting5. Continuous line indications can be jagged, like most cracks, or very straight, like a seam indication, 6. The degree of bleed-out depends on factors such as the width and depth of the indication and the penetrant and developer dwell times. Intermittent Line Indications 1. Intermittent line indications are caused by the same discontinuities as continuous line indications. 2, The difference is that these indications have been affected by previous processing steps, in-service use or are partially subsurface. Therefore, they are not continuous lines. Round or Dot Indications Round or dot indications are caused by porosity, pin holes, a porous surface or a coarse grain structure. 2 Round indications also can be caused by crater cracks because they tend to trap large amounts of penetrant. 3, A round indication becomes a linear indication when the length of the indication is more than three times the width. POSTCLEANING Postcleaning can involve the following. 1. Vapor degreasing 2. Solvent soak. 3. Ultrasonic cleaning Other postcleaning operations may be required by specifications and procedures. Personnel Training PublicationsNotesNotesLesson 2 Quiz Please answer true or false to the following 5 questions. 1, Each procedure and technique shall be approved and signed by a certified Level III. 6 2. High nickel alloys, titanium and stainless steels require the use of high 7. sulfur and chloride products. 3. Cleaning operations such as power wire brushing, grit blasting, shot pening and 8. other metal smearing operations should be used for cleaning prior to penetrant testing. 4. Penetrant testing will be effective if 9. the test object is not physically and chemically clean and dry. Compatibility of cleaning agents and penetrant materials should be verified to ensure an acceptable penetrant test. Solvent cleaning is commonly used for bulk inspections. Cleaning is accomplished by use of immersion tanks and or detergent solutions. Thorough rinsing and drying after detergent cleaning will leave the substrate physically and chemically clean for penetrant testing ‘Vapor degreasing is effective in removal of oils, greases and other similar organic contaminations. a10. u. 12. 13, 4. Alkaline detergent emulsifies, softens or dissolves organic contamination. Acid rust removers and alkaline rust removers require special equipment, and specific procedures should be followed. Acid or alkaline solutions are used to remove smeared metal from operations. The following should be used before liquid penetrant tests to ensure surfaces are clean: lasting (shot, sand, grit, Pressure, etc.); liquid honing; emery cloth; and power wire brushes. Penetrant dwell time is a period of time to allow penetrant to enter and fill any discontinuities open to the surface through capillary action. 15. 16. 17. 18 19. Liquid penetrant is drawn out of discontinuity entrapments to the test object surface during the so-called development time or developer dwell time. ‘Water rinsed with course droplets is preferred. The mechanical action is dependent on the size of the drops and velocity at impact. Dry powder should be used with visible liquid penetrant because it produces a satisfactory contrast coating on the surface of the test object. Water soluble developer can not be used for fluorescent dyes. Developer should be checked at regular intervals for penetrant contamination and water evaporation per approved specifications. Personnel Training Publications20. A discontinuity is an interruption in the 2. normal structure of the test object, making the part rejectable. In some reference documents, false indications and nonrelevant indications are considered to be the same thing. ‘Student Guide: Liquid Penetrant Testing 29