Liquid Penetrant Inspection Ruane - TATITable of Contents Liquid Penetrant Inspection ee pee yt Introduction repecs sanoce : PTL The six basic steps to liquid penetrant testing , rit Safely aspects involved when using dye peuctrants pri2 Principles and stages of liquid penetrant inspection .-....-- Pris Properties of penetrants .....+ an Pra Properties of emulsifiers pond 5 5 Prie7 Typical penetration times for various materials... rir Contiol checks on equipment perforur Prien ‘Techniques (including advantagesdisadvantages of each system) ..... 2 PTLAS COSI Regulations 1988 .- see sees oe PTD Scope ....+ : ceeen cece PID Responsibilities peecoccne prot Occupational Exposure Limits (ENO). seseeeeecseseses PTZ Conversion Factors & Terminology -..-+++++sreeeeeeee . PT3 Old terminology vs new terminology «+--+ : veseeeeee PEM Commonly referred to standards in liquid penetrant inspection clas Glosarye ee ve cceeeeceeeeeeeneeeeeueers pra Examination Schemes - PTS PCN Examinations, coe PES ASNT Examinations... pys.2Macon « propery of speuctrant and whit the canary ection. Vawerer toes nfect thine fen of fnensity Te af afl 1 flow Meniscus Be wsing shodovereph, the Fanta gle may he Aetcrmined fora penctrent om a scifi ‘material A gon Aefined with contact lao inte er of Introduction . Penzteant testing provides a means of detecting sif fas clicks oF porosity itt relatively non-sbsorbent materials. It utilizes n ponetvating liquid which is applied to the surface to be tested and is dawn into any discontinuity, present as ere Uhe excess penetrant is removed after a suitable period of time and a white finely divided developer powder is applied to the surface wer test, ‘The developer assist drawing .the residual penetrant fiom the di location, An early form of penctrant testing was the oil and chalk process. ‘this mx consisted of coating the work piece with n heavy lubricating oil, usually thinned ‘with paraffin or other light oils. After allowing penetrating time, the oil was removed with dry rags and a mixture of chatk’auid alcohol was then applied to the surface. Possible defects would be indicated where the chalk was stained with ei tinuities, therehy reverting th CAPILLARY ACTION Capillary’ pressure is determined hy cp = 28c80 Oe here ter evn pass Se Suface tension Casd = Cosine ofthe cantact ange ‘ > Tithe diemeterd Hi flow wide The six basic steps (0 liquid penetrant testing 1 2. Penetra Wash. 4. Develop. 5. sInspeet. 6. Final elean, y 1 supplicrs of penetvant equipment: ‘The m: 1 Maguattes 2. Johnson & Alien, 1 Author. 4 Burmal Casuol note priestPeo Nel sone of 30g ne materials mst avoided, Sane lente of sete font which are aera ulvatoter Tene neni osing he honce of, ing iicotons UNIT SR EACCLU Iya Principles aud stages of liquid penetrant inspection Preparation : {As penettant inspection is toally dependent on the ability of a penettant to enter » sisface discoitinnity, contaminants sich as oil, grease, pain, rust, sale, welding Mas le, may restrict its cntry. Morcover, suet contaminants ean a masking fine defects or making, then difficult oF iampossible to iden sorb the penetiant, Fy or intexpret. Methods of cleaning can he divided into two main groups: physical and chemical Physteat ‘The physical methods, such as wire brushing or abrasive blasting, essentially remove contaminants (rom the surface and are generally incapable of removing any contamination which may exist within the discontinuity, thereby stopping or redu entty of the penetrant. [abrasive cleaning is used, it should be followed by a acid etching prior to pevetrant application in order to remove the peened surface. Care should be used whet itis intended to, use fluorescent penetrants because the acid kill the Muorescence and cteate poor of weak indic Chemteat i Chemical cleaning can be cartied ut by using detergents, steam cleaning or vapour degreasing. Detergent cleaning Detergents can be either acid or alkaline, therefore # detergent which is non-corrosive 1 the material should be chosen, Detergents can be applied fo small areas,‘or'used in a washing tank, therefore the size and shape of the component may have to be considered. 7 Steam cleaning ‘This protess is an excellent method of cleaning if the component cannot be successfully clenned by detergent or vapour degreasing. Steam cleaning is usually tased on Targe components. Vapour degreasing By applying o- immersing into the degreasing agent, the surface and also the discontinuity, ae effectively cleaned. “Tvichlovethylene is usually used as the degreasing agent, althouph this should not be weed on Glaninn alloys a6 the susceptibility of such alloys to stiess cortosion may be enhanced hy its wee. "Sutticient time should be allowed after cleaning for dying out otherwise the elficienes of the penetrant niay he affected. ‘The time interval allowed for the evaporatian of solvents can only be determined by the prevailing conditions of temperature, humility and the type of solvent used, Moisture from detergent cleasting can be removed bs ‘oven drying the component fe ear PrL-dheen Soe frforenced i Us P72 renetvens Oe ofthe tne tt gveneh D PENETRANT INSPECTION UNIT PTL ® LIQUi! See GF Safety aspects involved Whew using dye penetrants When the liquid peneuation’ method for"deteeting Maws in materials is sed, th aeetior ants atwnys fellow the recommended procedres and slandards ver th Frere Gately a Work Act 1974. ‘his act tales that recommended procedures ay erty fequivemeais are tnd dawn in BS G4A3 : 1984 and BS EN 571 nave ate specie requirennonts wi yg to safely. n these st Vire hazards” 7 7% * ! “The age of elesiieal eqjent, when involved in the inspection of materials, sha Ans Soft dice ie no risk of ite as 8 result of equipment sparking or overheating “The use of inflammable vafions or solvents*(actesol cans, cleaning soktions ete thould always be kept aay from any possible source of ignition. Special care shoxt Penner to use such equipment in confined spaces ws this could provide a build w ot gas, unless adequate ventilation is provided Electrical-safety ‘All equipment used with the liquiel penetrant metho! of inspection shall comply wit a iecteleal safely repulainig This means that any mains equipment of 110 V et abow Shall be fited with an carth Teakage current circuit breaker of rating 20 mA. Whe Frvtnble eqninment ix ised, the:requitement for a cient breaker is, 24 V and abox eqipiient and a rating’ot 12 1A ie oxic materials; When in use, sone aerosol sprays and solvent cleaners miay emit a toxic vapour wh use a havard (o the health of the operator, therefore, precautions shewld be take ic hazatels in accordance with the suppliers’ instructions. ‘Such precautions inchide the use of face masks to absorb any harunfil yists oF vapou in the atmosphere, especially when in edfined spaces, For the acceptable level in conlined space see regulation in FI40, Furthermore, there may remain risk fneitation to the skin duc {0 the use of aerosol sprays or solvents. Under the il the extensive ccicumstanees the recomunended safety garments should be wor fof protective clothing whete necessary. Permanent te Where it is necessary 10 ¢% switabte ron or building shold be available, Cemilation, lighting for the inspection of materials, access to move equipment # tnateriaks, both in and ont, atx sulTieient space for cleaning np locations ry out liquid pencteant testing on a continues basi. hig show contin, adeqye howl he well away fens any nian processes which may cause aithorne contamination® Ihe Hocation of evel a voor oF building Safe use of ultraviolet light ways engute the safe ure of wiiaviott Tight when ingpceting, @ matin wi fereacent peveliaat, “thie source of wlitaviolet Fight shoulel always be ee Hincaals te teork piece ane away from the naked eye as exposure ray ease hu The filters used on wltaviotet Tight equipmcnt show be regularly checked vee ie ot rediarion senses hele, 120 nny eam be very dangers es should he avoided as these sll Ihe use of pholochiomie specta the smaller nica alyavialet ight ane increase the possibility af mi HvoveseinsPeo Nell UNIT PT! ® LIQUID PENETRANT INSPECTION fou Spectal purpose penetrants Tet fF ‘These special inert penetrant materials are available for ceriain apptications, in particular, when testing nickel alloys, certain stainless stecls aud titanium where the Fesetraits inst be low in sulphur and chlorine because of their detrimental effects. vo] Effects of sulphur and chlorine Centait alloy's cls are susceptible to damage by sulphur or chlorine, especially when they ate hented in processing or in getvice.,The predominate mechanism of damage is intergranular corcasion and efacking. Decause of this detrimental effect, it is of the tinost imporimice to remave all traces of penetinnl, emulsifier or elevelaper fon these alloy steels, or use the specially ‘formulated so called sulphurfchtorine five 21 penetrants, emulsifiers and developers. Removal of penctrants The method of removal depends upon the type of penctiant used. Solvent removable penetrants The solvent can be applied by spray or by a cloth. During the initial inspection stage, excess penctrant should be rehvoved by applying the solvent 19 cloth and then wiping the surface clean, ‘This method ie used to limit the contact time of the solvent sith the penetrant to prevent it entering the discontinuity. If the solvent was allowed to flood fonto the surface from a high pressure spray, the penetrant could be washed ont From dof any wide, shallow discontinuities. Vapour solvent removeis can also be used. “The component, preferably of simple geometry, can be immersed info @ trichlorethylene vapour. The immersion time is Gritical because of mixing with the peneteant in the discontinuity. ‘The suecess of the process is dependent upon the absolute degree of skill in judging the ting of the Colvent application. Therefore, itis usually sed in an automatic penetrant process so} technique. Because of the severity of the solvent remover, this method shewld only tused sere svater tinsing is not feasible or technically unacceptable. Water wai able peneteants seman rons Self-emvisified or water washable penetsants are removed from the surface of ser senshi with the components by direct waler washing, ‘The application of water is by using a spray or ican fon gly immersing ino agitated water wath, ‘The surfce ofthe component should be Mrched to the point where the exeess penetinnt has only just beew removed. IF Tenrescent penetrnts are being wsed, washing should take place under wlravioter lyr conditions The penetrantennulsiict mixture in the discontinnity is just as susceptible to emulsification as the material on the swiface, se over-washing can he m very teal tisk "| ihe spray use! to remove the penctrant should be of a coarse water droplet type. with 86401 f mine a mcgure af 0-40 pet Higher pressure would result in washing the penetra ont sowef har t8 Seine discontinuity In all water washable methods, the water lemperatre should be salamiaenmmame | epeen *#158C aid 1" a vost ermine penetrants raapernmed “| Uke post emulsifying pacess bas been the one Uaditionally used Ww give the highest degree ee sensative Eimuliis mix th the surface penerant ae rene 8 sate Wehbe, the snccess being dependent om the telative ability ofthe eanulsifier to The eviginal conception of this process eae for use wi 3 gmp teil Toxingh af canteen thie being # material saith which the oily penetint ¥¢ msi solute ‘When the emulsifier applied, i disses the pewetnet hy’ a acess of di fusion ant |. fehdoney tor ihe esti to dao the penetant in sal, rlaiety wile sae Since the short comings of lipophilic emulsiler systems ave caused by the wine vod eae tatty othe penton al camer ewer seatvels rt pes of he, nerve PTLASa oe SS change froma sofuton 1 anemone the thse pment foe rant “‘Penetrants eT 5 e Types a dt oe Pehetrants are usually classified according (othe type of dye; vistal of fluorescent, vo] Colour contrast penetrants ‘the, brightly coloured, wsnsity red, highly penetrating Fiquids are viswally inspected under good daylight conditions, or with the use of adqquate artifical light Fluorescent pevietrants ’ th an ultraviolet ht (black “with these penetrants, the components are.irradiated c readily visible el ight) in darkened aren x0 that the yellow-green indications ‘The above classes of penetrant ean be fuitier sub-divided by the mar are removed from the material surface: in which they +. Solvent remavable b. Water washable af €.Post emulsifiable ‘itenatvg penetra aystems ince dual zesty used in poor Hing condition Aare erent used for porows materials. These specialist systems are not covers in depth due to their limited apptications. , - ‘Application 7 ‘Aficr the surface hias heen prepared Aird completely dried, application of the penctran Gan be by spraying, using a swab or,brush, of by immersing into g'tank. ‘The penetrar Goes not seep into a discontinuity, itis pulied into it by capillary action, ‘The penetrar Should be applied within’ the temperature range 4°C to 40°C, unless otherwise specifi: by the manufaciorce. Higher fempeiaiures will retard the penetrating ‘ability b evaporating. the’ volatile constituents. Lover temperatures will cause sain precipitation of the dye. Surface contact time of the penetrant varies between 5 minutes and GO minute Gepending upon the temperature, material and size of the defect being sought. Th Contact tinne oF dwell tine is astally between 20 to 30 ninutes for welds in low carbo. nonterials, proses the followin ble features of a good penetrant ares ol The desi characte a. The ability to penctsate fine su Must not Be easily removed From relatively coarse openi c._Beeasily cleaned fiom the Surface of the test piece ML Capable of being casily drawn from discontinuities by the developer ro Have the ability to spread as a fine In posression of inense colour or Miorescence, even 25 8 B Have permanence in colour or fTuorescence when expose hin fle, 1d to heat, white lig or ultsaviolet light nett to the materials, including containers with which it eowes im f Be odourtess, non-flammable, non-toxic and stable when stored and in Wse two other properties of a penetinit which pre iompertant an, whit not affecting penetrating ability. they affect its use, ‘These ave: Mash point Wa penchant is in bull is shold have # Hash point of S17 tek ca] this, special instal yy be mccessany, Yoxiciey 1h is ectential thatthe toxie effects of a ponte, om ination of the vapour amt ccomtnet with the skin, ae kuowen ane guarded aginnme She meta of Properties of penetrants 1 Surface tension. at: . Wetting ability Viscosity Density, “Toxicity, Volatility: Flash poi a1 z ¥ 4 5. 6. ‘Reonomy. 2 8 9. ~ Chemical inertness. 10. Solubility Therefore: A Sensitive pencivani equals: Measure of penetrability 1 2. Ability to ren 3. Ability ta be developed 4 Ability to be seen in-small quantities. "Properties of emulsifiers 1 Mustn 2. Blending with the ps ke the penetrant water washable, ilrant must be slow enovgh te vary contact time 3. Blending mnast be fast enough not to delay processing unduly 4, Suitable for use in open tanks. 5. ° Free from odour and non-toxic, There are two main crulsifiers Le Lipopbhilic (oil based) - typical contact time » 0-45 seconds 2. Uydraphilic (water hasedl) - typical contact time ~ 2 minutes penetration limes for various materials Detect type (iypleally) [|__Penetrant time iu i. iy fw bran Pri?Penal aveinapete Sip else American docunentaion fen referred io rope remivers ak ome servers : 1 © LIQUID PENETRANT INSPECTION Uifferent type of remover was intreduced in which the mutwal solubility seas not 4 prime factor . ¥ Bit To achieve this resul, i is desirable to remove most of the excess Helin by ushng preliminary water wash, leaving only « uniform and very thin film of penetcant, "f Colic of the excess pencirant is removed purely by the mechanical ation of the wat jeu To remove the thin film, » hydric (water loving) remover is used. This i simi inv aetion to a damestic detergent aud is used in x low concentrated for, AN completion of the conincl time, which is not ts exlical, subsequent washing by Sealer apnea elenne the SH¥face elfesiiely “without A excessive tendency tm wa pencteent out of shallow discontinuities end zo ® betier basie Maw sensitivity) achieved ' Pete ot vl