Dye penetrant inspection

Dye penetrant inspection (DP), also called liquid penetrate inspection (LPI) or penetrant testing
(PT), is a widely applied and low-cost inspection method used to check surface-breaking defects
in all non porous materials (metals, plastics, or ceramics).

It is one of the oldest and simplists NDT methods where its earliest versions (using kerosene
and oil mixture) dates back to the 19th century.

The penetrant may be applied to all non-ferrous materials and ferrous materials, although for
ferrous components magnetic-particle inspection is often used instead for its subsurface
detection capability.

It is used to detect casting, forging and welding surface defects such as hairline cracks, surface
porosity, leaks in new products, flaws in joints and fatigue cracks on in-service components.

SHORE HARDNESS
Shore hardness is a measure of the resistance of a material to penetration of a spring
loaded needle-like indenter.

Hardness of Polymers (rubbers, plastics) is usually measured by Shore scales. Shore

hardness value may vary in the range from 0 to 100. 

Value corresponds to minimum Shore hardness: 0.

Maximum hardness value 100 corresponds to zero penetration.

Hardness Application
30 Shore A Art gum erasers
35 Shore A Rubber bands
40 Shore A Can tester pads
50 Shore A Rubber stamps
55 Shore A Pencil erasers
60 Shore A Screen wiper blades
65 Shore A Automotive tires
70 Shore A Shoe heels
75 Shore A Abrasive handling pads
80 Shore A Shoe soles
85 Shore A Tap washers
90 Shore A Typewriter rollers
95 Shore A Fork lift solid tires
60 Shore Golf ball
 D
70 Shore
Metal forming wiper dies
D
SURFACE POROSITY
Porous surfaces refer to surfaces that contain pores. A porous surface allows the passing
through of water, liquid or vapor. Objects containing porous surfaces have empty spaces or
pores that allow external matter—like water, air and particles—to penetrate into the object.

Paper, untreated wood, cardboard, sponge and fabric are some examples of porous surfaces

Galvanising (Zinc Coated)

What are galvanized parts?

Galvanized parts are steel parts that have been dipped in a protective zinc coating
to prevent corrosion and rust.
Coat (iron or steel) with a protective layer of zinc. To prevent from rusting and corrosion.

All brought out items that are bolted and threaded should be galvanised. (Except Stainless steel
parts, it does not need galvainsed)

Bolted items – While tightening using spanners, paint will go off. So it should be galvanised
instead of painting.

Welded items – They are painted because while welding galvanising will go off.

THREAD
BSP – UK, Europe, Asia, Australia, New Zealand and South Africa (most countries worldwide)

BSP – British standard pipe threads

Types

BSPT- British standard pipe threads Tapered

BSPP- British standard pipe threads Parallel

BSP threads have a 55-degree included angle

NPT – United States, Canada

NPT – (American) National Pipe Thread (Tapered)

NPT is one of the U.S. national technical standards for both tapered and straight thread series
that are used for various purposes such as rigidity and pressure-tight sealing.  

NPT thread is always tapered.

NPS – National Pipe Straight

Both NPT & NPS threads have a 60degree included angle

Tapered Pipe Thread is commonly found on ends of pipe, nipples and fittings (i.e.
couplings, elbows, tees, etc.).

 Note: Sharply angled threads are very critical to joint being tight with no leaks. Thread
sealant or tape is typically required to complete the seal.

Straight Pipe Threads need a gasket or O-ring to create a seal.

While NPT and NPS threads will engage, they do not seal properly with each other.

Conclusion

Both NPT & BSP threads have the same pitch and the familiar shaped peaks and valleys.
However, the designs of the threads differ in two fundamental ways. With NPT, the peaks and
valleys of the threads are flat. In BSP, they are rounded. Secondly, the NPT angle of the thread
is 60 degrees and the BSP angle is 55 degrees.

LOCK NUT
A lock nut is a nut that will resist loosening under vibration and torque. There are many
types of lock nut but they can be broadly divided into those which use friction to
prevent loosening and those that have some form of positive locking device. 

Friction lock nuts

Lock nuts that use friction to resist loosening usually require a greater torque to both
tighten and loosen, especially during the initial free rotation before they start to clamp
down on the part.

Examples include:
  A nylon lock nut, or nyloc nut, has a polymer collar, inserted into a recess at
the top of the nut, which is slightly smaller than the outer thread diameter.
This collar deforms elastically when the nut is tightened, causing friction.
Because they rely on a polymer collar to provide friction, they are not
reliable at elevated temperatures.
Positive locking nuts
Lock nuts that use a positive locking device can be freely rotated to both tighten and
loosen, they only lock when a positive action is performed to lock them in their current
position, such as inserting a pin. This can enable both more rapid assembly and more
secure fastening. Examples include:

 A castellated nut, or castle nut, is a positive locking nut with a cylindrical

extension at one end containing notches. These bear against a pin inserted
through the threaded shaft, preventing the nut from rotating. A castellated nut
may be secured with a cotter pin, an R-clip or safety wire.
 A slotted nut is similar to a castellated nut but the notches are cut into the flat
face of the nut.

Vacuum (EMPTY PLACE)

It is created when there is no atmospheric air.

Vacuum Vent:

It acts as a breather. When air or fluid is removed completely from the tank.
It becomes empty and vacuum will be created making the tank shrink.

To avoid this vacuum, vent or breather will be provided so when anything is

emptying from the tank it will be filled with the air parallelly to avoid vacuum
creation.

Ex : In ACV range tanks we keep Fill vent open while discharging fuel from
feed to avoid vacuum.

If vacuum creates in a body or any medium storing it, then that body
will shrink.
Ex: Balloon – When air is sucked out it shrinks creating vacuum.

Piping in the syntax – one open pipe facing upwards will be provided
along with feed and fill lines. That open pipe acts as vacuum vent. So,
whenever the syntax is drained, vacuum creation will be avoided by
open pipe.