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    PT-Level III-Study Guide

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    Ayesha Ge

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    —————— ASNT Level III Study Guide Liquid Penetrant Testing Method second edition by Charles W. Eick edited by William E. Mooz The American Society for Nondestructive Testing, Inc. A acknowledgements ASNT Level IM Sue Guide: Liquid Penetrant Testing Method. published in 1998, was vatton by Bernie Boisvert fand Charles W. Eick, Dassault Falcon Jet. This second cdition started with that original document and was updated tnd revised by William E, Mooz, Mct-L-Chek. ASNT thanks the suthors for their contributions. ‘Aspecial thank you goes to the following technical reviewers who helped with this publication: ‘Claude Davis, Unified Testing Services, Ine Jim Hout, ASNT Senior Manager Technical Services Brian MacCracken, Pratt and Whitney Willian Svekric, Welding Consultants, Inc ‘The Publications Review Committee includes: Chaie, Nat Y. Faransso, Halliburton Company Sam J, Volk, North Atlantic Energy Services Company’ Gary L. Workman, University of Alabama Huntsville Cynthia M. Leeman Editor Published by ‘The American Society for Nondestructive Testing, Tne 1711 Arlingate Lane PO Box 28518 Columbus, OH 43228-0818 ‘Copyright © 2003 by The American Socicty for Nondestructive Testing, Inc. ASNT is not responsibie for the authenticity or accuracy of information herein. Published opinions and statements do nol necessarily reflect the opinion of ASNT. Products or services that are advertised or mentioned do-not vary the endorsement oF recommendation of ASNT, IRRSP, Level 1H Stuce Guide, Materials Evaluation, NDT Handbouk, Nondestructive Yewing Handbook, The NDE. Technician andl www.asnt.org are trademarks of The American Society for Nondestructive Testing. lnc. ACCP, ASNT, Research in Nondestructive Evaluation and RNDE are registered teademarks of The American Society for Nondestructive Testing, Ine. ASNT exists 10 create a safer world by promoting the profession and technologies of nondestructive testing. : ISBN 1-57117-108-8 Printed in the United States of America first edition First printing 1998 second printing with revision 1400 second edition first printing 10/03 second printing with revision 12/06 i y i seth ee Contents Contents ...0--2eeeeeeee ee fs HERES Wee Hoe orev 00d. oven sb s8889 25003 eetge te rane nvneeeenant vas References .. sian sates eat eee ceo lt Chapter 1 - Introduction . ‘Overview of Liquid Penetrant Testing... Personnel Requirements : Classification of Penetrant Materials... Advantages and Capabilities of Liquid Penetrant Testing» Limitations of Liquid Penetrant Testing - Chapter 1 - Review Questions ........+-+ Yo bbe Chapter 2 - Materials and Properties Qualified Products Listing Penetrant Properties : Hazardous Characteristics | Corrosive Properties ....+.+ (COLO sre ne sei sete Visible Dyes Fluorescent Dyes .. Viscosity . 2.2... weet Flash Point ....- Storage Stability Temperature Stability Sensitivity ....cceceeeeee Fluorescent Intensity =... Ultraviolet Stability Thermal Stability ‘Tank Life * ‘Water Tolerance Removabil . * Emulsifier/Remover Properties. Developer Properties Special Purpose Materials - ‘Oxygen Compatible Penetrants ..... Low Sulfur and Low Chlorine Penetrant Systems © 7 High Temperature Penetrant Materials... Dye Precipitation Penetrant Systems s+. .+520005 Reversed Fluorescence Method. toto oto bn te UL Thixotropic Penetrant Dilution Expansion Developers . . Plastic Film Developers . Chapter 2 - Review Questions . Chapter 3 - Mechanism of Penetrati Penetration _ fa Wetting Ability - Contact Angle Capillary Action . Effect of Temperature... - Emulsification .. Lipophilic Emulsifier Action ..s.e.s.00ce Hydrophilic Remover Action «+++ Solvent Removal, Method C Developer Action... +. Chapter 3 - Review Questions eee 3 Chapter 4 - Basic Penetrant Processing «- weeeeee Procleaning of Parts ea 23 bffect of Surface Contaminants vee 2 - Effect of Contaminants Within Discontinuities. peewee rene 23 Types of Contaminants : beeceeeeeentnenes 23 Cleaning Methods... -...--+080o8 Penetrant Application ...-. Application by Immersion Application by Spraying Application by Brushing Penetrant Dwell 02.2. 0-eeersereeees Faciors that Influence Dwell Time Void Size... eee eeeeee Penetrant Material ‘Type of Discontinuity . Penetrant Viscosity . Creanfiness ofthe Discontinuty ‘Types of Dwell .....2e-ee eee Removal of Surface Penetrant Factors Influencing Removability Part Surface Condition ..... Part Shape or Geometry - Discontinuity Size and Shape Penetrant Removal Processes Spray Rinse... +. 2 Recommended Rinsing Procedure Postemulsificution Processes . Lipophilic Method. Hydrophilic Method y Solvent Remover Process oe... ses eeeeeeeseeeseceeeeeeeeeeee eee ee BB Drying of Pans 229 Developer Application . 29 Developer Dwell i ees saat St es i es OE Inspection occ cece cece eects eeeeeeeee 29 Postcleaning of Parts ............. 8 58 WEA 8 Developer Removal 2 tone Entrapped Penetrant Removal ..... : Postinspection Treatment of Parts. Chapter 4 - Review Questions Chapter 5 - Inspection, Interpretation and Evaluation .. ‘Observation/Inspection 2 Interpretation of Indications False Indications cette eens Nonrelevant Indications ....... Relevant Indications. Discontinuities .... . Evaluation of Relevant Indications. Acceptance and Rejection Criteria Recording of Indications Chapter 5 - Review Questions Chapter 6 - Test Equipment .. Overview of Penetrant Test Equipment . Portable Test Equipment Stationary Test Equipment ........ Automated Test Equipment ....... Equipment Selection - Lighting, : Chapter 6 - Review Questions vee Chapter 7 - Selection of the Liquid Penetrant Testing Method .........62++ Penetrant Testing Compared with Other Nondestructive Testing Methods Penetrant as a Complementary Method . Selection of Penctrant Method .....+.sssescssseseeeeeeeeeees Chapter 7 - Review Questions... Chapter 8 - Process Control ......0000000eeeceeceeeeeeeeeeeneaeetenens Overview of Process Control ........ Z Performance Testing Reference Penetrant Materials ..... Standards and Test Panels Process Variables. . 2 been ee nen eenenene Process Control Frequency ......00cccsssesseeeceeeeeteeseeeeee Testing and Maintenance of Penetant Equipment and Materials Portable Equipmem ....... bieeeeee Stationary Equipment... 0.06 e sce ceeeeeeeeee Automated Equipment . , EGBEHI NI ans ac cts 8 FRE on ow Chapter 8 - Review Questions... Chapter 9 - Safety, Health and Disposal... General Safety Precautions : Flammability fetter Dermatological Considerations... Respiratory Considerations ....... 00.00. Physiological Effects of Ultraviolet Radiation Disposal of Penetrant Materials. Chapter 9 - Review Questions Chapter 10 - Test Procedure ., Controlling Liquid Penetrant Tests. Standards Specifications vee eeeeeee es Reference Documents Section Materials Section. Equipment Section IBF Personnel Qualification Section Process Control Section... . Written Procedure. . wee Written Practices oo... 0.000 Chapter 10 - Review Questions Appendix 1 - Sample Specification ~ Penetrant Testing Process Appendix 1 - Review Questions ..0.... oe... Appendix 2 - Answers to Review Questions .......... ee <- Foreword ‘The American Society for Nondestructive Testing, Inc. has prepared a series of Level If Study Guides that are intended to presemt major areas in each nondestructive testing method. The Level III candidate should use this study guide only as a review, because it does not contain all of the information necessary to pass a typical Level ITI examination In this study guide, specific references are cited, where detailed information can be obtained. A listing of the references used in this study guide can be found on page ix. Typical Level III questions are available at the end of each section to serve as a benchmark for determining comprehension of the ‘material Ne Atypical use of this study guide might include the following sequence: 1. Review the questions at the end of each section in the study guide to determine if your ‘comprehension of the liquid penetrant resting method is adequate. The questions will serve as an indicator of your ability to pass a Level HT examination, 2. Ifyou find questions in a certain section of the study guide to be difficult, itis suggested that you carefully study the information presented in that section. This review of the information in the study guide will refresh your memory of theory and facts. 3. If you encounter information that is new or not clearly understood, then it is important to note the " specific references given throughout the study guide and carefully read this information. ee References ‘The references used to develop this study guide are: 1. Reference A . Jhacy, Noel A., technical editor; Patrick O. Moore, editor, Nondest-ucre Testing Handbook, tied ae olunie 2, Liguid Perenrant Testing, Columbus, OH: The American Society for Nondestructive Testing, Ine. $999. Reference B Rete ome, Principles and Applications of Liquid Penetrant Testing’ A CYorsroom Training poi ei eabus, OH, The American Society for Nondestructive Testing. Ine, 1993, 3. Reference C Hereret Dynamics, Classroom Training Handbook. Liquid Penetrant, CTS Sourth edition. cererihue: OF: The American Society for Nondestructive Testing, nc. 1977 4. Reference D erommmended Practice No. SNI-TC-1A,2001 edition, Columbus, OF: The American Society for Nondestructive Testing, Inc. 200) 5, Reference E °L__ Aerospace Material Specification AMS-2644. 6. Reference F — IASTAT E1417, Standard Practice for Liquid Peneirant Examination SAE Socie™ of Mito sR Engineers i rr ee Chapter 1 Introduction Overview of Liquid Penctrant Testing ‘The liquid penetrant testing method is defined we pro discontinuities in nonporous materials. The method also reveals void type subsurface discontinuities that are open to the surface. ‘The objective of liquid penetrant testing is to locate cracks. porosity, laps. seams and other surface discontinuities rapidly and economically Reference A Personnel Requirements The success of liquid penetrant testing is dependent primarily on the personnel who perform the various processing steps and those who interpret the cause and severity of indications produced. Qualification, skill and excellence in performance are important for reliable penetrant testing. ‘The apparent simplicity of the process is deceptive. Very slight processing variations during ‘penetrant application, removal of excess surface penetrant. application of developer or examination of the part can produce varying results, Further complicating the process is that il is not always possible to determine the effectiveness of processing merely hy examining the part in the inspection booth. The operator who is responsible for processing the parts must be trained, must have some experience in processing requirements and rnust be aware of the detrimental effects of processing variations. Individuals responsible for examining and evaluating indications must also be trained and experienced in the processing requirements, They should also be aware of the detrimental effects of processing variations. Individuals responsible for evaluating indications not only must have these characteristics, but they must be capable of making decisions based on the interpretation of indications, “The penetrant process is highly dependent on the operator's skill, nowledge. vigilance and integrity. Unlike the operator who produced the part, there is no tangible evidence (n0 permanent record) of the quality of the test. The reliability of and confidence in the testing is totally dependent oon the operator. For reliable liquid penetrant testing. the personnel performing the processing and examination are requited to be: 1. physically and mentally qualified to perform the required processing steps. 2. trained and experienced as required in performing the actual processing steps, 3. alert to consistent processing and resultant indications 4. motivated to perform with vigilance at the required detection and reliability level, and 5. capable of consistent, independent and unbiased decisions based on interpretation of resultant penetrant indications. Recommended requirements for personnel training and experience are detailed in Recommended Practice No. SNT-TC-1A available from the American Society for Nondestructive ‘Testing, Ine. Reference A Reference B : Reference D Classification of Penetrant Materials From 1955, classification or designation of penetrant materials bas followed the military specification, MEL-I-25135. At that time, penetrant materials were listed as six famtily groups. In 1964, a seventh group, Group VIL, consisting of aerosol packaged Group VI penetrants, was added. In 1982, another change in designation occurred when Group VI was subdivided into Group VIA, high sensitivity, and Group VIB, ultra high sensitivity penetrant. Table 1. isa listing of the original groups. This table is provided because ae ee GroupT 2 BEE Ae ee there are a number of outdated process specifications stil in use with these designations, By 1980, it became apparent that additional designations were necessary to include: 1 of penetrant dye, enetrant sensitivities forms of developers, and lasses of solvent removers. “The MIL-I-25135D revision, released in June 1985, incorporated these designations. A subsequent revision, MIL-I-25135E, was released in June 1989-A consensus document (SAE/AMS) superseded MIL--25135E in August 1996, wd however, the designations are identical. The“ revisions also eliminate the we Nans oe (Penetrant, emulsifier and developer) and substitute the for postemuliable penctants ‘The'system concept is based on the Tact that tanscures fore ee lsiirsemovers tobe ne se (Pema dev) yawn yet WE Gasfausy Oz of one manufacturer’s penetrant with another manufacturer's or ty dropite Temover may not produce optimal res fore, 2 manufacturer's penetrant and ‘emulsifier/remover are considered to be a system and the components are not interchangeable from ‘manufacturer to manufacturer. Developers and solvent removers are not part of the yetem and, therefore, any qualified material may be used. However, because each manufacturer has its own Proprietary formula, the specification prohibits the ‘mixing or combining of developers or solvent removers of different manufacturers. Table 1.2 is a listing of material designations and their descriptions, Advantages and Capabilities of Liquid Penetrant Testing Liquid penetrant testing offers a number of advantages and capabilities when compared to other nondestructive testing methods, Some advantages are that: YA geste Table 1.1: MIL-I-25135E family group classifications MIL-I-25135E Designation Materials/Family Description Penetrant Remover Developer solvent removable, visible | solvent dry, wet, or dye nonaqueous (Wet) Group I postemulsifiable, emulsifier dry, wet, or visible dye nonaqueous (wet) Group Ii water washable, none dry, wet, or visible dye nonaqueous (wet) Group IV ‘water washable, Tone | ary, wet, or fluorescent onaqucous (wet) Group V ‘medium sensitivity, emulsifier ary, wet, or postemulsifiable AOnaqueous (wet) Group VI high sensitivity, emulsifier dry, wet, or postemulsifiable Tonaqueous (wet) fluorescent Group VIA high sensitivity, hydrophilic dry, water soluble or postemulsifiable, nonaqueous (wet) fluorescent Group VIB ultra high sensitivity, | hydrophilic dry, water soluble or postemulsifiable nonaqueous (wet) Group VII 5 solvent remover ‘nonaqueous (wet) UL CRC Cea emt a 1. liquid penetrant testing is capable of ‘examining the entire exterior surface in one operation even though the object may have a complex shape: discomtinui easier to see liquid penetrant testing can detect very small and the penetrant bleedout ‘magnifies the size of indications. making them nonferrous metals, ceramics, cements, glass and many types of plastics, snd the process sensitivity can be varied by selection of materials and processing procedures —a range of sensitivities are possible allowing suppression of sina, inconsequential discontinuities while indicating large discontinuities of concem. 3. panetrant indications are formed directly over discontinuities on the surface of the part Providing information on location, Reference A Reference B and approximate Iength of the discontinuity, 4. the process is relatively simple and rupid, and can easily be automated where a large volume of parts are to be tested; 5, Tiquid penetrant testing can be used on a wide Limitations of Liquid Penetrant Testing ‘There are a number of limitations associated with liquid penetrant testing, Some include: variety of materials including ferrous and Table 1.2: Categories and designations contained in AMS-2644 AMS-2644 Description Designation SPS (Type fluorescent dye pencirant Ra.) een visible dye penetrant Type lil | visible and fluorescent dye penetrant (dual mode) eh -{ Method A ‘water washable ia y Method B ostemalsifiable, lipophilic pry ‘Rene Method C solvent removable we Dar Method D- 4 Postemutsifiable, hydrophilic Jw /wef 2a Penk. _Sensitivity Level 172 | ultra low sensitivity | seengh .__Sensitivity Level | low sensitivity | For _ Sensitivity Level? | normal sensitivity Sensitivity Level 3 high sensitivity . “%S Sensitivity Level ultra high sensitivity Fon _ Forma dry powder developer ee ef _Formb ‘nena | water soluble developer/w. Bagd VF rb aE (m79?. ey. _Forme 7 Pvater suspended developepw SUE pote | OR Form d ‘nonaqueous developer weld ae | wr Forme T specific application developer class (_ Class ()* halogenated (nonflammable) solvent remover of nonhalogenated (flammable) solvent remover jae Specific application solvent remover “Class (1) was deleted from MIL-1-25135E in 1992 due to the ban on chlorinated compounds. 4 DTA one Ace a eecdicedee edee Led 1. liquid penetrant testing will not reveal discontinuities that are not open to the surface — subsurface discontinuities cannot be detected by penetrant testing; 2. the part surface and the interior of any discontinuities must be clean and free of contaminants, soils and moisture ~ materials on the surface of the part, at the discontinuity edges or inside the discontinuity can interfere with the penetrant entering and filling the discontinuity void: 3. porous materials, materials with intercomnecting subsurface networks or materials with seeped in penetrant that is not removed during posteleaning, cannot be inspected by the liquid penetrant testing process — the penetrant will enter the pores and ‘migrate through the network. producing an overall fluorescence or color background that ‘would mask any discontinuities: 4. penetrants usually contain petroteum based Tiquids that cun soften, craze or attack some nonmetallic rmaterials such as some plastic and rubber compounds; and penetrants, emulsifiers and developers all contain chemicals that have good wetting and detergent properties, however, they can dissolve and remove the natural oils from fhuman tissue if they come into contact with and remain on skin surfaces for any length of time, This causes drying and cracking, which are sources for secondary infections. Reference A. Reference B i i y MW b i i i i 12 a3 r tA 15 ee: Chapter 1 Review Questions ‘Liquid penetrant testing is defined as: ‘an electromagnetic process. a physical mechanical process. a physical chemical process, a mechanical chemical process. “The superseded classification of groups include which of the following? a, Type of penetrant, sensitivity. cemulsifier/remover and developer. b. Removal method, type of penetrang, sensitivity, emolsifier and developer, Removal method. t)Be of penetranitand developer, 4. Type of penetrant, solvent remover and developer. ‘The classification ferm ype refers tthe type of: = developer, removal. emulsifier. dye in the penetrant. eos ‘The classification term method refers to the method of, — a, applying penetrant. b, removing penetrant. cc. applying developer. UL testing the pat In the system concept. a system consists of: a, penctrant, emulsifier and developer. b, penetrant, solvent remover and developer, cc. penctcant and developer. d. penetrant and emulsifier. 16 18 19 Developers in the military specification are listed by form, What is form a? Dry powder. Water soluble, ‘Water suspendible, ‘Nonaqucous. eoge toN ‘When penetrant materials are qualified, \<*—’ they are tested with set provisions, What__— are the provision requirements for «qualifying « Type 1 penetrant? 4. Method A penetrants are tested using a _ wet developer b.” Method B penetrants arc tested usinga = Y dry developer. ©. Method C penetrants are tested using a water soluble developer. d. Method D penetrants are tested using a 7s, nonaqueous developer. . ‘According to SNT-TC-1A, the number of training hours required for direct certification to Level I is: a. 6h. b. 12h © 16h : d. 20h Penetrant bleedout of an indication ‘magnifies the upparent size of the discontinuity, making it easier to detect. a. Tre. b. False. 1.40 Laz PPD Rote ee cet icekclac eae ‘The ultimate reliability and confidence in liquid penetrant testing is based on the: ‘a. penctrant material b. developer material quality of the part operator of the process. Military specifications for penetrants list penetrants by systems. Whieb of the following systems is the most sensitive? ‘Type I, Method A, level 1/2. ‘Type L. Method A and B, level 2, ‘Type 1, Method C, level 2. ‘Type I, Method C. level 4. eogF ‘The growps listed in the military specifications have five levels of sensitivity. The lowest sensitivity level is: a, level 1/2. b, level! c. level 3 devel 4. aT ee =” Chapter 2 Materials and Properties Qualified Products Listing AMS-2644 (formerly MIL-I-25135) requires {qualification of all penetcant products to be used ‘on military contracts. Commercial products with ‘well documented properties are designated as reference standards, Many of the test requirements. ‘ensitiviy, Muorescent intensity and removability) are comparative, The material to be qualified and the reference standard material are processed °* simultaneously under the same conditions and the Tesults are compared, The material to be qualified: must equal or exceed the reference standard material's performance. Materials found to be acceptable are listed on a qualified products list, QPL-SAE-AMS-2644. The listing of a material on the qualified products list docs not guarantee that subsequent batches of product of the same formulation will be acceptable. The listing only indicates that the original raw materials, formulation and compounding practice can result in an acceptable product. There are many factors and eonditions in compounding and manufacturing penetrant pow pe materials that can reduce their performance. Many _i5 »_ Patt surface;p. users routinely verify the performance of each incoming batch of penetram materials, Reference B Penetrant Properties (i temperatures, then pitting, intergranular cotrosion Bo, g UF stress corrosion may occur, All porcine wg Matgrats must be subjected to thice conocy Be ces tse ature comenion, high, 7% ‘conpeatore Suess corrosion and high pera oe jor Grtsion rae alloys, Cote” Conaslon eating aa enetrant materials is ES etailed in SAE-AMS.2644 Color..:. vue ‘The carrier or vehicle in liquid penetrant ig Practically coforless and transparent. This makes it very difficult (0 see when it is entra x ” g 75 futlce openings and voids. Adve or Mend oh ayes ie Fis dished inthe eh provide a high cP SP Codie! readily visible indict, Two te of TOOT dyes ure usually used, visible or florence Visible Dyes Visible dye penetrants, also called color conttast Dee ped in smalls» €Quilibrium, the clee Je SE hate) 38 Fluorescent Dyes. “7 “27 <2 ‘minerals and chemical compounds have to emit visible light when exposed to it in the must be a Vac: When a photor impacts a fluorescent materi Outer shelis must be low and there ant Space in the outermost ring n of short wavelength radiation ial, some of the as electromagnetic radistion. Fluorescent penetrant dyes are designed to fotesce when exposed to 365 nm wavelength jtraviole light. The released energy always hes a Jonge wavelength than the exciting radiation, the released energ oe i ‘sible light range. The wavelength of released cee nme eed ander visible Hh and are, it ae fMilable in red, orange or purple."The most <=" energy Cepends on the type of dye used frequent Provide, Huoresvent peneirant dyes are usually in the ran high cont 1 metallic ss, QLA7S nm to 573 nm, which fin the eee oul Tein the Visible surfaces, ly dissolve SPSCttUm OF green TB yellowe in the per Usifiers or (Reb mote bast solvents, netrant. Viscosity — enetrant trappein the °¢ surface discontinuity is diluted when it spreads * +o fhrourh the developer. To compensate for this the “+ eepest shade of red and the highost ‘concentration of dye that can be dissolved in the ail without Precipitation is used, The red dyes are visible in Yay thin films, however, fluorescent dyes are visible in even thinner films. One of the basic Z2ai0ns that a visible dye is considered To be less jo Sestive than a fluorescent dye is that Tape © BRIIEINS GuiMocate an indication sae smaller, Suumner volume of oi The primary advantageer -an be used with itcan be applied from a pew visible penetrant is that it. coW ordinary shop lighting and small portable kt SHO ret eB atisco MSS AT Mal Boo yi a Viscosity s a measure of a lignid’s resistance to Saaninte it Physical shape Viscosity varies widely with temperature, decreasing when temperance ite tuised and increasing when temperatures are” lowered. Viscosity is an important factor in the pplication process of both penetramt and Hipophitic emulsifiers, Viscosity has no effect on peneirerin eo ability: some Very viscous fluids, such ‘as molasses, 4-7. 2:¥e Very good penetrating ability, while sooo ESS ena Hats Soc as ure water, have very pont Penetrating ability “From a appiation viewpoint, viscosity affects the ‘and higher viscosity fluids see & Tonge? pelctration time. Viscosity also determines how much penetrant or emulsiber Femains on the part surface at the end of the dwell Line, High viscosity penetrants cling 19 the part gitface and require increased Gfiort in removal WRU) che, e- iy which increases drag out losses. Very thin (low viscosity) penetrants may drain from the part so q part surface to fill any discontinuities. High viscosity emulsifiers are slow to diffuse into penetrant and require an increased emulsifier dwell time. Viscosity is measured in accordance with ASTM D 445, at 37.82 °C (100 + 5 °F), There is no set value required for viscosity. The ‘manufacturer must state the nominal viscosity of each penetrant and lipophilic emulsifier. This wpe. eda pigresire! ‘on each batch or lot Reference A Reference B Ge Flash Point Flash point isthe temperature at which a liquid gives off enough flammable vapor that it could ignite when in the presence of a flame, The flash point does not affect the performance of a penetrant, but it Flash point requirements have changed through the years. In 1975 it was as low as (150 °F). In 1977 the Occupational Safety and Health Administration established a minimum flash point =a for flammable liquids used in pen Tanks without special precautions and equipment, Flash point is measured in accordance with standard practice ASTM D 93, Penetrant materials packaged in aerosol containers are not affected, but must be labeled in accordance with CER 173.115, Reference A Reference B ih Storage Stability 7“ wp 2X, Penetrant materials are required to meet all iP et ification requirements od 88 oF storage in Tully closed containers stored at Sy . ‘emperatures between 16 ani and o Xe, 10°F). This is confirmed by submitted for qualification to the specification requirement = onsite > Mateos ‘Temperature Stability “Temperature stability is a requirement of the ewerpectsication and should not be confused with thermal stability. Temperature stability refers to the resistance to separation of penetrants and ‘emulsifiers when exposed to temperatures outside of the recommended processing range. Details of FoR HP. 2) ee sie per fas! itr ly that insufficient penetrant remains on the 6) important as a safety precaution.» » Sinan ve SOE oe cis at i Dy 14 Matas 9 pter 2, the stability test appear in SAE-AMS-2644. aml aii to the effect temperature as on a penetrant’s fluorescent intensity. Sensitivity ‘When used to describe a ees macs Bereta Satimity with €754,03 enough dye to produce a noticeable indication a Fluorescent penetrant systems ( are ord classified into five semi inge Y pu sensitivity level 72— ultra Tow, : sensitivity level 1 ~ low. sensitivity level 2— normal, sensitivity level 3 ~ high, and sensitivity level 4 ~ ultra high. ex \rea ca involves the use of ihe selected reference standard material. Test A yRepe processed using the applicable reference standard penetrant system. The luminatice of the resulting. ~~ Indications is measred using 9 photos 0 wv standardize the testing equipment. The panels are then cleaned and reprocessed using the penetrant system to be evaluated. The resulting luminance numbers must equal or exceed those of the a reference standard material. weyriess. ne set of qualification test ————> ie US Air Force is the qualifying agency Z End maintains the test panels. It is not possible t0 swe” duplicate fatigue cracks with identical penetrant system performance characteristics. Therefore, rnonqualification comparison tests are performed @ using aevariety of test panels, such as cracked . GAliernate fatigue cracked ~ ents (on the visual comparison of indications on thermal cracked aluminum blocks. Half of the block is. processed with the reference standard penetrant system and the other half is processed with the ‘material that is being evaluated. After processing, the two halves are visually compared. The penetrant under evaluation must produce indications equal to or greater than the standard. Figure 2.1 is a photograph of the indications from two visible dye penetrants. DPA MPP SeaTTA Egg assed 10 CEng Selection of the sensitivity level to be used depends on potential discontinuity size, width and of the discontinuity, part size, shape, : pan Vity is either too low or too high. Low vity levels may not reveal potentially harmful discontinuities, while a sensitivity level that is too high can result in a residual background that could obscure any discontinuity indications. CR EAT Reference B Fluorescent Intensity 77, Fluorescent intensity is the amount of visible’ «@- light wiven off when fluorescent dye is exposed to ultraviolet light. There are a number of variables that influence fluorescent intensity. Some of these are’ 1. the thickness of the penetrant film, 2. the intensity of the ultraviolet light impinging on the surface, 3. the amount or concentration of fluorescent dye in the penetrant, 4. the capability of the dye to absorb ultraviolet light (absorptivity), and out the efficiency of the dye in converting the 7 released electrons to visible light (quantum yield), priAe Ge Variables that can be controlled by the operator are the intensity of the ultraviolet light impinging ‘on the surface and the thickness of the penetrant film (emulsifying, washing and developing). The other variables are controlled by the penetrant manufacturer. Increasing the amount of dye in 57% solution proportionally increases the fluorescent “intensity. The absorptivity and quantum yield are EF characteristics of the dye system. These are. e controlled by the dye blends, because most’ © netrant systems contain a aS s cer oe 32! , = im wavelength region, may have a high ig BK y quantum yield but notin the 475 to 575 nm range (yellow-green). A second dye can be selected that ve" Measurement of fluorescent intensity is ” performed in accordance with ASTM E 1135, Guide: Liquid Penetrant Testing een Yak 445 diluting both the standard and material to be tested. Figure 2.1: Comparison of two visible dye (Type Il) penetrants on a cracked 2024-T3 alloy aluminum block Standard Test Method for Comparing the Brightness of Fluorescent Penetranis, Rel 4 cee A thin film is achieved by accurately ~ Four small squares of filter paper are dipped into the diluted reference standard and four squares are ipped into the diluted test material. The samples ‘ are then dried. This produces a thin, uniform film of penetrant on the filter paper squares. The Aluorescent intensity on both the reference standard and test material are measured using a fluorometet. For sensit penetrant, it z least 95% of the intensity of the reference standard. Sensitivity levels 1/2, 1,2 and 3 penetrant are also compared against sensitivity level 4 reference standard penetrant. Sensitivity level 1/2 must be at least 30%, sensitivity level | must be 65%. sensitivity level 2 must be 80% and sensitivity + level 3 must be at least 90% of the intensity of the reference standard penetrant Reference A Reference B Ultraviolet Stability ‘The efficiency of fluorescent dyes in converting ultraviolet light to visible light is reduced by ov prolonged exposure to ultraviolet light, The test for ultraviolet stability is performed in a manner similar to the test fe nt intensity TASTE TRG wih he ooo following changes. No reference standard specimens are necessary, Ten 7 4-8... whe de Oe kl mc filter paper specimens are dipped into the diluted ‘material to be tested. Five of the dried specimens pate then placed ina darkened area such as a desk drawer. The remaining five specimens are exposed ”” the specimens is measured in the fluorometer in accordance with ASTM E 1135, alternating between exposed and unexposed specimens. The ‘minimum aecepted averaged values are 1, sensitivity levels 4 and 3 — 70% of unexposed brightness, 2. sensitivity levels 2, 1 and 1/2 — 50% of the tunexposed specimens, rigs Thermal Stability “\"\té—» Ly Elevated temperatures can reduce the fluorescence of penetrant. The test for thermal sibility i intensity tests Teas previously ibe. Ten filer paper specimens are dipped into diluted penetrant to be tested. Five of the test specimens are placed in a location away from Strong light, heat and ai current "The remaining five estore are place on clean metal plate | and held in a dead air oven at 114.2 °C (237 4 °F) for | h. After exposure, the fluorescent @ intensity is measured according to ASTM E 1135. Alternating between exposed and unexposed _ samples is recommended, Average intensity of the exposed samples shall not be less than 60% for vity levels 1/2, 1 and 2, and 80% for + Sensitivity levels 3 and 4: compared to the average for the unexposed samples. Tank Life cupO P12 8 Save iding penetrants and lipophilic 8, iese problems usually result i ZF 1 Seu Forming on the surface of the rent after it has been in the tank. When problems occur, they result in degraded performance. The test for tank life involves placing a $0)miL. sample in an uncovered (39 in) nominal diameter petri dish that is in turn placed in a convection oven and maintained at a temperature ‘At the end of the period, the material is removed from the oven, allowed to cool and then examined visually. Any evidence of separation, precipitation or scum formation is cause for rejection Swe [er 2/S02) SS Wont Sane 25S = Loam > eat Ly Bs Semen: +50 mWien ultraviolet light for Aer the exposure period, the fluorescence of sql Possible thar problems can ocour When ~ — Beommlee Sco ark area) (0) eC AE Cea Manel seater) iW Water Tolerance Water washable penetrants (Method A) are controlled mixtures of penetrant and emulsifier. Water contamination from adjacent wash stations 5 ; or - Therefore, limiting water contamination Ts = necessary. Method A penetrants shall show no gelling, separating or coagulating at water Removability Removability. commonly referred to as ‘eal: com propery applicable to Water washable (Method A) and postemulsi penetrants (Methods B and D). The manufacturers carefully formulate the emulsifiers depending on the penetrant to be used, Therefore, penetrants and emulsifiers are tested as a system and emulsifier from one manufacturer may not perform adequately on a different manufacturer's penetrant, ‘The ute coughnes of the est it has an effect ‘on the test. Smooth machined parts are easily emulsified, while rough surface parts require a more active emulsifier. Overremoval is tested during the sensitivity test because removal of entrapped penetrant will decrease sensitivity on the relatively smooth panels. Underremoval, which ‘causes excessive background, can obscure potential discontinuities and is tested as a separate item, Special stainless steel test panels are produced by grit blasting under carefully controlled conditions. Procedures for producing and testing the panels and the type of washing apparatus to be used are detailed in SAB-AMS-2644. Four of the panels are processed in the applicable reference standard system and four are processed in the system to be tested. Procedures for immersing and draining water washable (Method A), postemulsified lipophilic (Method B) and : postemulsified hydrophilic (Method D) penetrants are the same. They consist of dipping the test samples and allowing them to drain for r eee drying, emulsifying and applying developer vary slightly, depending on the system being tested. Afler processing, the fluorescent background on the samples is measured using an electrooptical meter that is coracted for photopic response to visible light with negligible esponse to ultraviolet light. Three measurements BS mRgE On CHET paRET- The measurements are totaled and compared to the sum of the ‘measurements of the appropriate reference Lh Ad omits ot rant systems should leave no more residual penetrant than the same sensitivity level reFereney 2," 1” Emulsifier/Remoyer Properties Petroleum based penetrants are not soluble in 74 water, however, there ate chemicals that will re%?» combine with the peneteants to form a mixture that ww) can be removed with a water spray, The “20, } chemicals are called emulsifiers, 24 ) Emulsifier/temovers are a complex mixture of Yep2)”, chemicals. Ideally, during removal of surince co eu?" penetrant, all excess surface penctrant should be “y removed from all surf -as (including fillets, comers and recesses) without removing penettant entrapped in discontinuities, Formulating the ideal emulsifier mixture isa délitate balancing act. A Imixture that is too aggressive will leave a clean surface but will also remove entrapped penetrant, while a low aggressive mixture will leave an excessive background. Each manufacturer has its own formulation for penetrants and the emulsific ‘must be formulated for that specific penetrant (except for solvent removers). Emulsifiers from nanufacturer r eo penetrants Ss contain emulsifier as an integral part SP of their formulation. Adding a lipophilic emulsifier \ g3° 10 a postemulsitiable penetrant will not produce « o> {28 Satisfactory water washable penetrant. Because “eO% water washable penetrante already contain an f-—~ emulsifier, they are siisclBtible to water Y contamination. A spe: a ler addition without gelling. 12 coagulating, They mus Tor Tank Tife without separation of emulettes rave the penetrant & ee thod By sp ot oof © Tiguid soup that will diffuse into the peneiogan, producing a mixture that can be removed with Water spray. These emulsifiers are required to be a Gistinetly different color from the penetrant. sc {The three properties of lipophilic emulsificrs “=, that control the washing characteristics are activity” Piscouty and water tolerance, These propestcrare factored against the characteristics of the oil based penetrant. a penetrant ‘an emulsifier with a high activity is needed. The fate of diffusion of the emulsifier into the penetrant depends on the viscosity of the emulsifier: High ‘22 cougulates, A specification requiseient omits iad epee eae by ela fing. separating or coagulating and still Se ae 8 parts are processed through the emulsifier, @ emu highly resistant to water, )6* S/S yee Pepophilic (deted 8) 12 Se me Oa standard, Viscosity emulsifiers diffuse more slowly than low viscosity emulsifiers. A highly active emulsifier —- ‘ith @ low viscosity can be adjusted by blending‘it with a mote viscous emulsifier to provide the desired washing characteristics. Emulsifier stations are generally located next to the washitinse sfations and water contamination from overspray oF splashing can occur. As water is added to the» mulsifier the emulsifier gels, separates or that the thout some of the surface penctr er. Be are 4 gradual buildup of enetrant sTows the emulsification rate. With Continued buildup, the emulsilier begins to function as a penetrant. Method B emulsifiers must tolerate at least one part penetrant to s emulsifier and stil pass the removability test to differentiate them Trom lipophilic ulsifiers. They consist of a mixture of chemicals called surfactants, Surfactants are supplied as “ liquids and are mixed with water be ju s. The See cmttae is required to concain a maximumiot Developer Properties... Developers assist in the withdrawal of entrapped penetrant from discontinuities and Provide contrast between an indication and the part background. They must provide a smooth even couting covering the entire surface to be tested. ‘Their sensitivity and removability are tested using reference standard materials and are compared. only to the developer action of the material being tested. Dry powder (Form a) and nonaqueous (ay wb) developers are ‘supplied in the ready-to-use form> Water soluble (Form by and water suspended (Form e) developers tre supplied 2s concemrates to DemixGd with water according to the Manufactarer’s instructions. No form of developers shall contain compounds of Developers for Type I penetrant ) inust Rot exhiDIC any green, yellow or orange fluorescence and fluorescence of other colors shall Not be greater than that of the reference standart HESatury dvdope 3 cost (We ee Di Fem(A,O) ibis Fr<— 7 (68) eau ea eet developer, rants (visible dye) shall provide good contrast with the penetrant to be used. ‘shall not ie?” > B*D substances ded developer Mist sleo ee Kye capable of ‘after settling for a aN sci time, eo oe Reference E Special Purpose Materials There are a number of penetrant materials that are different from those previously described. ‘These materials are formulated for special applications and purposes. Because of their limited usage, they are not covered by SAE-AMS-2644. ‘Some of these special purpose materials are described in the following paragraphs. Oxygen Compatible Penetrants Liguid oxygen and gaseous oxygen are extremely chemically reactive. They can react explosively when they come into contact with a combustible material or when subjected to shock, impact or vibration. There is not too much of a testing problem for simple disassembled part from which all traces of penetrant testing residue is removed. Difficulties are encountered with assemblies and complex shaped parts that contain crevices, recessed areas or faying surfaces where testing residues become entrapped and are not removed by cleaning The test for liquid oxygen compatible materials *~ involves dropping a weight on the material while in contact with an oxygen environment. If the material is not liquid oxygen compatible, it will ‘Cause ar-audible explosion or a visible flash in a darkened room, discolor the anvil or leave evidence of charring wens ttorct ws lee 2 Reference A. Bia Reference B Low Sulfur and Low Chlorine Penetrant Systems ‘When small quantities of sulfur and chlorine are ionized and come into contact with austenitic stainless steels, high nickel alloys. ‘pol ‘andititaniumalloys, corrosion may result. This rosiveness is accelerated when the alloys are used at elevated temperatures and/or under residual stress resulting in intergranular corrosion® @ hystogenenibleionee’ ant spe oeteetoy 13 Satur nein ‘are not ? threshold film. b. a visible dye does not emit light to attract the eye c. a thick developer coat to provide a good white background can mask an indication 4d. all of the above. 26 fe. aandc above Fluorescent dyes used in penetrants absorb photon energy at a wavelength of 365 nm. ‘The approximate wavelength of the color that most fluorescent penetrants emit is: a. 425 nm. we be 525mm. €. 625m. 27 725 om. ‘The property that controls the rate of Penetration is the: = viscosity of the penetrant, surface tension of the penetrant, volatility of the penetrant. wetting action of the penetrant cee A penetrant must be lighter than water so that water contamination will always sink: (7 < to the bottom of the tank. This property is ~~ related to the: a. viscosity, b. surface tension. c. volatility. Yop, Under this condition, as liquid spreads over the solid surface and displaces the prior solid-gas interface, the enerey difference (y5¢~ Ysp) per unit area is released to do the work needed 0 move the liquid over the solid surface. Reference A Reference Bo phi (Bh Sa ie By Pewee wpe PDs Contact Angle | —> Waite ability 4 "The wetting bility and contact angle beiween the iquid-gas and solid: tguid ine inversely proportional. The higher the wetting ability. the Smaller the contact angle. The contact angle determines the wetting ability The contact angle will also vary with the substance to be wetted, The angle hetween water and glass nearly 0 degrees; the angle between Water and silver is 90 degrees; and the ingle hetween mercury and glass is 132 degrees when pure iguid and clean surlaces are involved. Figure 5.1 shows the relationship between contact angle and wel ability. Capillary Action Capillary action is responsible for both pest a ‘and exit from discontinuities Capillary detion is demonstrated by the rise of a Tiguid in a small diameter tube. The liquid rise will not occur unless the liquid wets the tube. When the Tiguid wets the tube, the ene quid level inside the tube $O°= uct angle and surface é fow comtact angle causes yi) edge of the Tiquid to curve up the tube wall. > —— nl the liquid causes the liquid 2, end Tadirertiene arate aim SMEs liquid to the wetted area and causing the liquid to, rise in the tube, When the contact angle approaches 90 degrees. the liquid does not spread and the level 5 ‘of liquid in the tube remains level with the outside 7,1) VE liquid. The reverse of this occurs when the contact angle is greater than 90 degrees. The high cont angle curves the liquid edge downward and the level is depressed. Figure 32 illustrates the ayy? S relationship between contact ungle and liquid lever* > <)>» inside the tube. oeiee Reference B yyy RYE LY Effect of Temperature ‘The effect of temperature on penetrants varies with the type of penetrant and the method used. 18 BC aoe Generally speaking, satisfactory performance from Penetranis can be achieved between a low temperature of 4 °C (40 °F) and a high temperature of 38 °C (100 °F). ae Temperatures below 4 °C (40 °F) have noticeable effects. The viscosity of the penetrant will increase und slow the capillary action of the penetrant. Or, using Method Can inspector might find that the aerosol containers may not produce spray. AL part temperatures above 49 °C (120 °F), the evaporation of lighter constituents ean affect the color intensity or the fluorescence of the penetrant and reduce the effectiveness of the test sg B torte Wid eabere aed Cte aed The heating of parts to increuse sensitivity is not recommended. The advantages that might be gained by heating a part are offset by the disadvantages of heat on the carefully compounded enetrants in use today Reference A Reference B Emulsification”’/~ Oil and water are mutually insoluble; however, if very small. amount of oil is added to water and the mixture is’ violenily stiaken, the oil will form small globules. Depending on the droplet size, i “ Reference A U, Hydrophilic Remover Action " —_— Reference B — ‘drophilic remover is a mixture of chemicals Pre. cal wey are supplied asa Concentrate andrare mixed with water either before or during the removal process. The surlace active va ‘agent in the remover combines with a small Sa Glanity of penetrant fom the surface an prevents 22° vo miscible iui that do not reat chemically the penetrant from recombining with the remaining are placed in the sume vessel, their molecular surface penetrant. Unlike ipophilic emulsifier.” 9 y* motion allows them to penetrate each other and lic rer in penetrantand eventually become uniform throughout, The rate of = eur. All removal action takes | YS diffusion inereases with inereased concentration lave atthe exposed surfuce and the penetrant just and higher temperatures. For example, when a salt below the surface is not involved until it becomes Solution is placed in a container and piain water is €SPOsed. Some agitation is required to remove the layered on top, the liquids remain separated at first, displaced penetrant and to allow fresh remover to The molecular motion at the interface causes the ome into contact with the newly exposed Figure 3.3: Mechanism of action of lipophilic emulsifiers (a) ) co) Apply Penetrant, Apply Emulsifier Diffusion Begins af @) fe) wp Diffusion Complete Rinse Clean Surface (a) © (i) L penetrant. Figure 3.4 illustrates the mechanism of action of hydrophilic emulsit Solyent Removal, Method C wey Ph - Ail oil based penetrants are soluble ina large’ Deygloper action Lis. a combination of sorveney ESF mumber of organ quis The most commeats Gehan ai ‘Adsorption Is the £77 0) x wed are color contrast, Type Il and postemulsified surrounding ofthe developer pa 3 77° Type I. Becaus et longer available, ‘p? mixtures of aliphatic petroleum or alcohols, mect reer AY GR (a) Cur holy Nl ovesad 2a ee NG <— Solvency ef Ps eveleRr AMON te - 1 ty wt vated ed Psu) anal yo av Pah von RA a9 ASU e eee a Figure 3.4. Mechanism of action of hydrophilic emulsi Ye; 94g 864 44, © O$FS Apply Penetrant Prerinse Detergent Action Begins x esas Ver ws we Detergent Action Ends Rinse Clean Surface and the transfer of at least some of this penetrant to the surf =/ increasing the effective sizc of the Surface film of penetrant exuded! from the penetrant entrapment, and increasing the contrast between the indication and the background edt! Reference A Reference B Ce pear ae les by adhesion. hlorinated hydrocarbons are no ,.;.»+ which coats the surface of the particles, Absorption the solvents are usually volatile is the of penetrant into the bull of the Is. The 2 particles. As the thin layer of éXtuded penetrant is of removal is through solvent and adsorbed/absorbed, surface tension draws hanis dilution action, Some petroleum distillates contain additional penetrant from the entrapment, which slowly evaporating oils; however, when used as a enlarges both the thickness of the surface penctrant Penctrant remover, this docs not affect its exit from layer and its size. discontinuities Developers also increase contrast for observing Penetrant indications. Under ultraviolet light, the Reference B Developer Action latefed The basic function of all developers is to paekground for viewing red indications. improve the visibility of penetrant indications. The Developers also reduce light reflection from shiny improvement in visibility is achieved through a, _Suftees of es parts, which cap lessen eye fiigue umber of mechanisms, including ee © aiding in the extraction of the penetrant | Reference B from an entrapment below the part surface APS (blue bl Flee fink, ai TUM est eT em MUUecaae! TIE eA XN) SULA Chapter 3 ‘Two basic properties of a liquid that control 3.5 its penetrating capability are a. contact angle and viscosity, b. contact angle and capillary action. surface tension and contact angle. d. capillary action and surface tension. What is the highest contact angle that a penetrant ean have and still penetrate spontanecusly? a. 15 degrees b. 5 degrees c. 40 degrees, G90 degrees, 3.6 ‘Capillary action is fastest in az yee a a, long crack. 'b. long, dirt filled crack. cc. fine, clean crack. d. wide, shallow crack. 37 a discontinuity and form a visible indication, Properties that influence the discontinuity entrapment efficiency include: the penetrability of the penetrant. the size and type of the discontinuity the processing procedures, the type of penetrant. 38 all of the above. gee Uns Daya +34 » 39 B- Aa SAN sade pearderen yo wn, on aa Review Questions ‘The contact angle is measured at the air- liguid surface interface on a solid material. Which of the following is true? The contact angle is the same on all ‘materials having the same surface roughness, b. Different materials with the same smooth finish can have different contact angles. ¢. The surface roughness does not influence the contact angle. 4. The contact angle is the same for all metals. e. None of the above are true, Oil in a crack can influence the penetration rate by partially filling the crack and possibly affecting: the surface tension. the contact angle. the viscosity all of the above eh see! Std ae Flaw entrapment efficiency is best “7! measured by the: wee aoge a, water wash test b. fluorescent intensity test ©) test. d. fluorescent stability test. ‘The rate of penetration can be compensated for by varying the: ‘emulsification time. penetrating time. c. drying time. water washing time, ‘The ability of the penetrant to enter a discontinuity is controlled by: a, its surface tension. b. its contact angle. ¢._ its viscosity. d. both a and b. 310 Lipophilic emulsifiers have limited water 3.15. The primary developing action associated tolerance. Excessive water can reduce thei with dry developer is: >) Aetivity, change their viscosity and change / their appearance. What is the tolerance <0 capillary action, ; (percentage by volume of water to expansion of the developer in a crack. « \ emulsifier? ©. provision of a uniform film surface for » a contrasting background, - a. 1%, 3 D\dissolutic of the penetrant in the é b. 2%, ots3 "\gesetutin of GSK. i a. 10%, 3.16 Nonaqueous developer forms an indication oe 3.11 Many penetrants are oil based and Meet flammable. What is the OSHA requirement 4, forming capillaries for the penetrant. for the minimum flash point of a penetrant b. expanding the penetrant in the crack. used in an open tank? ©. providing a uniform white coating,

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