Liquid Penetrant Testing :Discontinuities are detected by a penetrating colored

liquid.Indications form directly over the defect.

This method detects surface breaking discontinuities only.

This examination process is useful for

detection of open to surface
discontinuities only.
Applicable to varieties of non porous
materials.
Produces enlarged indication for easy
detection.
Relative volume of a flaw is indicated by
the amount of bleed out.
Testing Limitations :
This process requires elaborate surface cleaning.
Surface cleaning shall be properly done otherwise there will not show
any indication.
Processing is time consuming.
The process has temperature limitations.
100 to 520 C. [ 2000 C, if high temp special penetrant materials are
used ].
requires careful processing.
Does not indicate the size of the discontinuities.
Difficult to test porous materials & rough surface.
Requires post cleaning.
Penetrant Process : Step 1Surface is cleaned to remove all contaminants to the
extent that the interior of the discontinuities are clean and dry.

Surface to be cleaned using

appropriate cleaning
methods such that dirt, oil,
grease, scale, rust, paint etc
are completely removed.
The flaw openings must be
clean to allow entry of
penetrant.
Following cleaning, the part
shall be completely dried.
Penetrant Process : Step 2penetrant may be applied by, spraying, dipping,
flooding, brushing.

For penetrant application the part

temperature must be within 100 to
500 C.
Penetrant must be applied to clean
dry surface.
The entire area to be tested must be
covered with a thin layer of
penetrant.
Penetrant must not dry during the
entire test cycle.
A penetration time between 10 to 30
minutes are used.
Penetrant Process : Step 3To detect entrapped penetrant, excess penetrant on the
surface is removed. Care must be taken not to remove entrapped penetrant from
the discontinuities.

Depending on the type of

penetrant, excess surface penetrant
is removed by one of the following
methods,
Rinsing with coarse water spray.
Emulsifying the penetrant and
rinsing with water spray.
Rinsing with emulsifier solution.
Manually wiping the surface with
solvent dampened cloth.
Penetrant Process : Step 4A Developer is applied to bring entrapped
penetrant back to the surface by reverse capillary action [ blotting ].

A developer, uniform coating of

fine white powder, is used for
blotting the penetrant out of the
discontinuities.
Developer also provides a
contrasting background
for the indication.
Penetrant bleeds and spreads into
developer and the indication
become easily detectable. The
indication may enlarge with time.
Penetrant test method :The pre cleaning operation removes surface
contaminants and opens up the discontinuities.
Penetrant test method :
Penetrant test method :
Penetrant test method :
Penetrant test method :
Penetrant test method :
Portable kit for Penetrant testing :For field use penetrant materials are packed in
aerosol spray cans.A set of cleaner / remover, penetrant and developer are all that
required to carry out the field examination.Aerosol cans provide uncontaminated
liquids for the examination and can have a shelf life of 5 years. However, if the
pressure inside the can drops significantly, the can becomes useless.
Penetrant materials are available in aerosol spray cans as well as in bulks.
Surface Cleaning :Very important step in penetrant testing.Cleaning must clear the
discontinuity opening to allow the penetrating liquid to enter.
Surface contaminations closes Discontinuity openings :Surface cleaning
plays critical role for effective penetrant testing

Any contamination such as oil, rust,

scale, corrosion & different types of
coatings and surface treatments cover
the discontinuity opening and prevent
entry of penetrant in to it.
To detect the discontinuities, test
surface shall be free from
abovementioned contaminations,
otherwise indications will not appear.
Contaminants does not allow penetrant to enter discontinuities

Dirt and contamination blocks or

closes the discontinuity openings
and prevent entry of penetrant.
If a discontinuity is filled, there is
no room for the penetranrt to
enter.
This is a limitation of liquid
penetrant testing where as
magnetic particle testing can be
carried out even with foreign
material embedded onto the
discontinuities.
Parts shall be cleaned such that the interior of the discontinuities
are free from contaminants and dry :

Cleaning Methods :
Detergents.
Steam cleaning for assemblies
Solvents for oil, grease etc
Hot Alkaline cleaning
Ultrasonic agitation with cleaning
materials.
Paint strippers
Acid or alkaline etching for rust
scales and corrosion.
Parts shall be cleaned such that the interior of the discontinuities are free from
contaminants and dry :
Cross section of a part shows entrapped penetrant :

The liquid must fill the cavity as much as

possible. This depends on the viscosity of
the penetrant and the temperature of the
part.
At higher temperature, the liquid has low
viscosity and enters and fill a cavity easily.
At low temperature the viscosity increases
and longer penetration time is needed.
Capillary action forces liquid into narrow openings :Color contrast
penetrant entered a crack.
Dirty part surface requires cleaning :
Rust and rough surfaces requires cleaning.
Rust and corrosion on test surface requires cleaning :
Rust and corrosion on test surface requires cleaning :
Paint closes and fills discontinuity
openings and blocks the passage of
penetrant entry. All traces of paint must be
removed.
A pair of Gears before cleaning :
The Gears after cleaning :
Light deposits of oil and grease on the part can be removed by
solvent cleaner supplied with the spraying kit.
Light deposits of oil and grease on the part can be removed by
solvent cleaner supplied with the spraying kit.
A large number of small parts can be
cleaned together for penetrant examination :
A large number of small parts can be cleaned together for penetrant
examination :
before cleaning after cleaning
Parts shall be cleaned such that all contaminants are removed :
Parts shall be cleaned such that all contaminants are
removed : before cleaning after cleaning
Parts being cleaned by detergent
washing :
Parts being cleaned by detergent
washing :
Parts being cleaned by detergent
washing :
Parts being cleaned by detergent
washing :
Parts being cleaned by detergent
washing :
Parts being cleaned by detergent
washing :
Parts to be cleaned by solvent removers :
Remover cleans oily deposits :
Appearance of part surface
after cleaning :
Solvent spray cleaning :
Solvent dip cleaning :
Removing paint with solvent wipe.
Removing paint with solvent.
Removing paint stripper
Removing rust
Removing paint stripper
Removing rust with solution.
Etching
Compact machine cleaning unit
with part basket.
Grid and basket inside the compact cleaning unit :
Large and heavy part
cleaning tank :
Agitation of cleaning liquid in the cleaning tank :
Agitated [Turbulent] water speed up cleaning :
Degreasing unit :for removing
oily deposits from used parts.
Remover agitation accelerates Degreasing :
Remover agitation used for Degreasing :
Cleaning line :
Ultrasonic cleaning : is
highly effective in cleaning the interior of discontinuities and residual penetrant after
examination.This method takes advantage of ultrasonic agitation with suitable cleaning
agents.The ultrasonic agitation makes microscopic bubbles.
Ultrasonic agitation produces microscopic bubbles which explodes and displaces
surrounding material. It may take 30 to 60 minutes for complete cleaning.
An Ultrasonic cleaning unit with power supply.
Ultrasonic units are available in different sizes. Different types of cleaning agents to
be used with, are also supplied :
Parts cleaned by ultrasonic method :
If water is used as the cleaning medium, the
parts must be thoroughly dried before
penetrant application.
Grid and hot airflow ducts in the drying cabinet :
Drying is achieved by circulating hot air through ducts inside the dryer.
Hot air dryer Dryer with
Basket for part handling :
Drying parts in a vacuum dryer : Water boils
at 5 C when the pressure is very low. A vacuum dryer is most efficient for quick drying of
0

parts at lower temperature.Pressure is lowered in a vacuum dryer such that water boils at
400 C. Parts become dry in 10 minutes at 400C, which is ideal for direct penetrant
application. A medium size part or a number of small parts can be dried in the vacuum
oven.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Part surface after cleaning and drying.
Peening
Peening
Peening
Part surface after cleaning and drying.
Part surface cleaned and dried.
Part cleaned for penetrant application :
cleaned part showing crack opening.
Penetrant sprayed on the part . The surface
excess penetrant have to be removed after the dwell time. Then a developer can be applied to
complete the process.
Appearance of a defect free part after developer application.
Penetrant indication of the defect in the part after developer application.
Capillary Action :
Principle of Liquid penetrant
testing.
Liquid enters narrow openings due to capillary action.

Liquid rises through the cavity of

a fine bore tube against the
gravity. This is known as capillary
action.
The finer the bore, the more is the
capillary force.
Liquid enters narrow
discontinuities because of
capillary forces.
A plant takes in water through
capillary action.
Contact Angle :A good penetrant must easily spread on the test surface and enter tight
discontinuity openings.

Low surface tension and low

contact angle allow liquids to
spread on the surface easily.
Liquid penetrants are formulated to
have low surface tension, low
contact angle and low viscosity.
Higher viscosity reduces the speed
of penetration.
Types of Penetrants :Liquid penetrants are available in three types.
Type 1 : Fluorescent dye, visible only under Ultra Violet light.
Type 2 : Color contrast, visible in ordinary light, usually Red color.
Type 3 : Dual sensitivity. Combination of fluorescent and color dye. Examined
under ultra violet as well as ordinary light. Used for special applications.
Penetrant is a solution of brightly colored visible or fluorescent dye in a colorless non
volatile liquid, usually highly refined hydrocarbon distillates. The penetrant possesses
many controlled properties for its successful operation.

Visible dye used in the penetrant is bright red or magenta in color.

Fluorescent dye is a pale yellow liquid which fluoresces brilliant yellow-green in color
under ultraviolet illumination.
Penetrant is a solution of brightly colored visible or fluorescent dye in a colorless non
volatile liquid, usually highly refined hydrocarbon distillates. The penetrant possesses
many controlled properties for its successful operation.

Visible dye used in the penetrant is bright red or magenta in color.

Fluorescent dye is a pale yellow liquid which fluoresces brilliant yellow-green in color
under ultraviolet illumination.
Penetrant is a solution of brightly colored visible or fluorescent dye in a colorless non
volatile liquid, usually highly refined hydrocarbon distillates. The penetrant possesses
many controlled properties for its successful operation.

Visible dye used in the penetrant is bright red or magenta in color.

Fluorescent dye is a pale yellow liquid which fluoresces brilliant yellow-green in color
under ultraviolet illumination.
 Fluorescent indication Color contrast indication
Fluorescent Type 1 : These penetrants contain a fluorescent dye and are visible only
under ultraviolet illumination in a darkened area. The penetrants have high sensitivity
and used for sensitive applications.
Color contrast Type 2 : These penetrants use a color dye visible under ordinary light. The
penetrants have lower sensitivity compared to fluorescent types and is used when high
sensitivity is not required.
Color contrast Process :
These penetrants use a brightly colored red dye visible under ordinary light.
These penetrants are recommended ;
when the part can not be inspected in a darkened area
when electrical supply is not available.
When high sensitivity is not required.
Fluorescent Process :
These penetrants contain a fluorescent dye and are visible only under ultraviolet
illumination in a darkened area. These penetrants have high sensitivity and used for high
sensitivity examinations. Fluorescent penetrants are available in five different sensitivity
levels [ ½ to 4 ].The use of minimum sensitivity penetrant which is capable of detecting
the discontinuities of interest is recommended.
Pentrant materials are oftened packed in aerosol cans. The
materials are also available in bulk containers.
Penetrant application :* Before penetrant application part surface must be
thoroughly cleaned and dried.* The penetrant must cover the examination area in a thin
consistent layer.* Penetrant may be applied by dipping, spraying, flooding or
brushing.* Application by rubbing with a penetrant soaked cloth is not permitted.
Penetrant application by a
brush :For testing of a small area,
penetrant may be applied with a
brush.
Application of penetrant by brushing is
also preferred in a confined area where
fine spray floating in the air is
hazardous to the user. It is
recommended to use an exhaust system
if spray method is used in a confined
place.
Penetrant has been sprayed on to this small component.The component is placed on the grid
for dwell.
Use of breathing apparatus and an exhaust system is very essential for spray
applications in confined places.
Use of breathing apparatus and an exhaust system is very essential for spray
applications in confined places.
Use of breathing apparatus and an exhaust system is very essential for spray
applications in confined places.
Use of breathing apparatus and an exhaust system is very essential for spray
applications in confined places.
Use of breathing apparatus and an exhaust system is very essential for spray
applications in confined places.
For small parts, penetrant may be applied by dipping the part into a tank containing the
penetrant. Suitable baskets are available for
this application.The material of the basket shall not contaminate the penetrant materials.
A basket with some parts inside, is being lowered on to a fluorescent penetrant tank.
Parts of smaller size or a number
of small parts may be placed on a
basket and dipped in the penetrant
tank.
Large part may be lowered on to the
tank by chain hoist.
Dipped part should be removed
from the tank for draining.
If penetrant is applied by dipping, there must be a place for
draining excess surface penetrant from the part.
A number of small parts are being sprayed with fluorescent
penetrant from a spray can.
Penetrat spray using pocket size aerosol cans for spot testing in the
field:
Penetrat static spray using pocket size aerosol cans for spot testing in
the field:
Conventional method of penetrant application for solvent
removable penetrant process is to spray from an aerosol can.
A penetrant application booth with exhaust system over the
application table.
A spray application section with the exhaust system above.
A spray application section with the exhaust system above.
A spray application section with the exhaust system above.
A spray application section with the exhaust system above.
A spray application section with the exhaust system above.
A spray application section with the exhaust system above.
A booth for electrostatic spray
application :This method has
been reported to cause
slightly increase in the
sensitivity of examination.
Electrostatic spraying is
applicable both for penetrant
and developer applications.
Drain and Dwell :If immersion method of
application is used, It is not recommended
to leave the part dipped in the penetrant
tank during the dwell time.
After the dip applicationnt, the part is
allowed to drain the excess penetrant
throughout the dwell time.
Penetrant may be reapplied if there is
tendecy of the penetrant to dry.
A part covered with fluorescent penetrant has been placed on the
grid for draining during the dwell time.
Parts covered with fluorescent penetrant is placed on the grid to drain
during dwell time. If penetrant appears to be drying during the dwell
time, penetrant must reapplied.
Parts during dwell time.
Parts during dwell time.
The entire test area must be fully covered with a thin layer of penetrant. A Part covered
with visible penetrant is under dwell time :
Penetrant applied on welded joints.
Penetrant applied on welded joints.
Dwell time chart :Dwell time is the time allowed for penetrant to enter
discontinuities. Tight discontinuities require longer dwell time.Suggested timing
for some common product forms :
A cubicle for penetrant testing of precision parts.
Simple penetrant application table
with the exhaust system on top.
A Penetrant test cabin for spray application of aerospace
components.
Automatic penetrant application system :
Fully automatic penetrant test line :
Large scale Penetrant testing line 1 :
Penetrant test line 2 :
Final inspection booth :
Penetrant tank processing layout for a Lab :Applicable for
fluorescent and color contrast examination.
The tank systems in a small
laboratory setup.
A compact fluorescent processing set up. Black curtained area is the examination
zone. up.
Developer application and
Inspection booth with UV lamp
for the fluorescent process..
Exhaust line can be seen on the
top.
Darkened area for large scale fluorescent Inspection process.
Professional compact set up :
A compact professional setup with
Electrical power, Exhaust system,
Sprayer system, Ordinary and UV
lights, and water treatment system.
A simple container can be
set up for use with the
solvent removable test
process. Provision of
electrical supply and
darkening the inside area
permits fluorescent process
also.
Solvent Removable Method : uses
Solvents as penetrant remover.* Solvent method is highly sensitive, does not
require additional equipments.* Recommended for spot testing.* Most
suitable for field use.* Requires careful processing.* Shall not be used near
open flame.
Solvent removable Penetrnt test kit.
Solvent Penetrant set for portable use :The set consists of Cleaner, Penetrant
and Developer in Aerosol cans which can be used in most locations.

Cleaner is a volatile solvent for the

penetrant in use.
Penetrant for this process is
usually oil based and can not be
removed by water rinsing.
Developer is usually white
powders suspended in a volatile
solvent.
The aerosol cans have shelf life of
5 years. However, the loss of
pressure may affect the cans after
2 years.
Solvent process : step 1Precleaning

After the part surface is

prepared for the
examination, cleaner is
sprayed on to the test
surface to remove traces
of oiliness.
The surface is allowed to
dry by evaporation or
wiping.
Solvent process : step 2Penetrant
application

The part surface must be

completely dry before
penetrant application.
The penetrant is brushed /
sprayed on the entire test area
in a thin film.
The penetrant is then allowed
to dwell on the part surface for
the required time.
The penetrant must not dry
during the dwell time.
Penetrant may be reapplied
during the dwell time.
Solvent process : step 3Removal of excess
penetrant.

The part surface is wiped

with clean dry cloth,
followed by fresh solvent
dampened cloth.
Wiping is repeated until no
traces of penetrant is visible
on the rag.
Penetrant wiping shall be
done carefully otherwise it
will remove penetrant from
the discontinuities affecting
the sensitivity of
examination.
Solvent process : step 4

A developer is used to
complete the examination
process.
Developers are inert white
powders used dry or as a
liquid suspension.
The developer is sprayed
carefully to cover the entire
test area in a thin uniform
coating.
Avoid wet runny coating.
Solvent process : step 5
Gross discontinuities produce
immediate indications.
Tighter discontinuities take longer
time to produce indications.
A minimum of 7 minutes
development time is recommended.
The size of the indications gives
relative idea of the nature of the
discontinuities.
The solvent process summary :
The solvent process summary :
Incorrect application of developer : A wet runny
coating. Developer sprayed from a short distance without shaking the can. Excess liquid
run away without leaving sufficient developer particles.
Correct application of developer :A thin uniform and continuous coating must be applied.
Solid white coating is not required.
Correct application of developer :A thin uniform and continuous coating must be applied.
Solid white coating is not required.
Solvent penetrant must be removed by wiping :Excess loose penetrant is
wiped off by clean dry cloths. The remaining traces are removed using
solvent dampened new cloth. After one pass, the cloth is folded to expose clean surface,
dampened with the solvent, and the surface is wiped again. The surface of the cloth is
examined, if traces of penetrant is visible, the cloth is folded to expose clean surface,
dampened again with the solvent and the surface is wiped again. The process is continued
till no traces of penetrant is visible on the cloth surface. The solvent shall not be sprayed
directly on the test surface.Cleaning shall be along one direction only.
Lint free clean cloth for wiping solvent type penetrants.
Crack indication at the eye of a Lug, revealed by solvent removable color
contrast penetrant process.
Solvent type penetrant applied around the nozzle weld.
Excess penetrant removed and developer applied.
Color contrast indication from a crack. Pink
coloration of the developer is due to insufficient removal of excess penetrant. The applied
developer must not flow.
Solvent type penetrant is being sprayed on to the part.
Color contrast indication of cracks on the part.
Color contrast indication from a crack on the part. A small rounded indication can also be
seen.
Color contrast crack indication on a welded plate :[ Solvent removable
process ]
Crack indication on a blade, revealed by color contrast solvent removable
penetrant process.
Most simple penetrant test set for spot testing
[ penetrant Pens for field use ] :Fluorescent, Dual sensitivity, Remover and non
aqueous Developer.
Water washable Method :for fast and economical processing of large number of
parts. * These Penetrants can be washed directly with water. * Water washable penetrants
contain an emulsifier which make them water washable.* Emulsifier increases the
viscosity which calls for longer penetration time.* These penetrants can not enter very
tight discontinuity opening.* Because of easy washability, water washable method is not
suitable for wide shallow discontinuities. * These penetrants are used where high
sensitivity is not required.* Good for examination on rough surface, threads, keyways,
narrow grooves and where liquid has a tendency to accumulate.
Water washable method is less sensitive when
compared to solvent and post emulsification methods.
Water washable process : fast & economical * After the penetration time, the part is rinsed
with plain water to remove the excess surface penetrant.* Rinsing is performed with a
coarse water spray from a nozzle, at around 450 to the surface, from a distance of 6 to
12 inches.* Water pressure, nominal 40 PSI, max 50 PSI, temp 10 – 38 0 C* Maximum
rinsing time for any area shall not be more than 2 minutes.
A water spray gun for rinsing operation : Factory adjusted to 40 PSI pressure.For large
scale processing, pressure gauges are recommended to control the rinsing process.
A coarse water spray removes loose penetrant by scrubbing action :
A coarse water spray removes loose penetrant by scrubbing action :
A part being rinsed from a water spray gun :
Rinsing Tank.
Rinsing Tank : pressure gauges for controlling nozzle pressure. Uv lamp for washing
fluorescent penetrants.
Rinsing Tank.
Post Emulsification Method :Highly Sensitive penetrant examination.Uses an
external emulsifier to make the penetrant water washable .Two types of Emulsifiers are
usedLipophylic [ oil based ] work by diffusion process.Hydrophylic [ detergent based ]
works by scrubbing action.
Lipophylic [ oil based ] Emulsifier :works by diffusion process.
Emulsification time is critical and depends on roughness, viscosity of
emulsifier, temperature.

Once the penetration time is over, the part

is dipped into the emulsifier tank and
removed for draining.
With time, the emulsifier diffuses into the
penetrant layer and the resulting mixture
is water washable.
Excess penetrant is then removed by water
rinsing.
Emulsification time varies between 1 to 4
minutes and must be determined
practically for each type of parts.
Emulsifier can not be applied by a brush.
Lipophylic [ oil based ] Emulsifier :works by diffusion process. Emulsification
time is critical and depends on roughness, viscosity of emulsifier, temperature.

Once the penetration time is over, the part

is dipped into the emulsifier tank and
removed for draining.
With time, the emulsifier diffuses into the
penetrant layer and the resulting mixture
is water washable.
Excess penetrant is then removed by water
rinsing.
Emulsification time varies between 1 to 4
minutes and must be determined
practically for each type of parts.
Emulsifier can not be applied by a brush.
Lipiphylic Emulsifier process :oil based emulsifier, applied by dipping the part
in the emulsifier tank. The emulsifier is then allowed to act for a controlled period of
time. The resultant mixture is water washable and to be removed by water rinsing. The
emulsifier in the tank gradually gets contaminated by penetrant and is finally discarded
when contamination exceeds 20%.
Hydrophylic [ detergent based ] Emulsifier :Most used emulsifier
process. Loose penetrant is first removed by plain water rinse. The remaining penetrant
is then removed by spraying the part surface using 2.5 to 5% solution of emulsifier.
The emulsifier may also be used by immersing the part in a 10 to 30% emulsifier
solution with mild agitation. The part surface is then sprayed with plain water again to
remove residue of the emulsifier solution.These emulsifiers are less sensitive to
contact time and is easy to control than the lipophylic emulsifier process.
Hydrophylic Emulsifiersolution
Concentration :The concentration
plays an important role in excess penetrant
removal process. The concentration is
monitored using a refractometer.
Developers :there are 4 Forms of Developers :Dry developers.
[ Chemically inert white powders ]Aqueous [ water base ] Water solution
developers. [ water soluble particles ]Water suspension developers.
[ insoluble particles ] Non AqueousSolvent suspension developers.
[ insoluble particles ]
Devloper action [ blotting ] :Developer extracts penetrant from discontinuities by
blotting action.Provide contrasting background.Penetrant spreads through the developer
and magnifies the indication making it more visible to the eye.
Developer Spray :A thin uniform coat of developer is required to initiate the blotting
action. Thick coating masks weaker indications must be avoided.
Dry developer application : Dry developers
are normally used with fluorescent process only.Can be applied by dipping, scooping,
brushing and spraying. Electrostatic charged spraying or dust chamber application is
most suitable. The developer must cling to the surface in a fine film of dust.
Dry developer must be applied on a dry surface only.
Dry developer application by scooping :Dry developers are normally used on rough
surfaces.Applied by dipping, scooping and brushing. Excess developer is removed by
shaking and gentle air blast.
Dry developer application in a dust storm closed cabinet :Dried parts are placed on the
grid, the cabinet is closed and the powder is blown by moisture free compressed air or a
fan mounted at the bottom of the cabinet to form a cloud of dust. While settling the
powders coat the part surfaces.
 Water soluble developer :
Water soluble developer particles
dissolve in water to produce a clear working solution.
Water suspension developer is suspension of insoluble particles in
water. Suspension developer requires continuous agitation during use. Application by
spraying and dipping is recommended. [ dipping is not allowed for water washable type
penetrants ] After the application of developer, parts require drying in a temperature
controlled oven.
Non aqueous developer is being applied by spraying :The recommended method of
application of non aqueous developer is by spraying. A thin uniform coat is applied to the
part surface by spraying from a suitable distance. A wet runny coating must be avoided.
Non aqueous developer is being applied by spraying :The recommended method of
application of non aqueous developer is by spraying. A thin uniform coat is applied to the
part surface by spraying from a suitable distance. A wet runny coating must be avoided.
Non aqueous developer applied by spraying :A thin uniform coat has been applied. Solid
white coating is not required. Solid coating masks weak indications.
A part after developer application :The defect indications are highlighted with a red marker
pen.
Solvent suspension developer applied. Removing excess penetrant by manual wipe from a
large object is a tedious task. The pink traces are the residue of penetrant left out during
excess removal.
A large crane hook undergoing penetrant examination :
Summary of
penetrant processes.
Examination for indications :
the penetrant spreads and produce an enlarged indications.
Penetrant Indications :The penetrant bleeds in to the developer and produces
enlarged indications.
Discontinuity Indications :The dye spreads on the developer and the indication is
larger than the discontinuity opening.
Color contrast Indication :Crack at the junction of a weld visible under ordinary
lighting. Gross defects produce dark red indication because of good bleed out. Good bleed out
shows that the discontinuity has volume.
Color contrast Indication :Crack indication. Bleed out shows a gross defect.
Color contrast indication :Dark red indication shows a deep crack.
Color contrast indication :Dark red indication shows a deep
crack.
Crackindication :
The indication is less
bright because of penetrant
spread.
Color contrast Indications :
Bright red indications from deep cavities on a weld.
A long crack indication.
Penetrant indications :
[ Both rounded and linear indications ]
Penetrant indications from a
number of mostly shallow cracks
Penetrant testing of rail crossings.
Deep crack Indications obtained on the head of the rail.
Liquid Penetrant Indication :
Fluorescent indication of a Long crack.
When the pinholes are located
very close to each other,
indications overlap to produce
patches.
Numerous crack
Indications overlapped to
form patches.
Photograph of a Fluorescent Indication :
Fluorescent Indication : a crack originating from a hole.
Photograph of a Fluorescent Indication :
Photograph of a Fluorescent Indication :
Photograph of a Fluorescent Indication :
Color contrast Indication :Cracks at the head of a bolt.
Fluorescent Indication :Crack at the head of a bolt visible under ultraviolet
illumination.
Fluorescent Indication :The brilliant glow of the fluorescent dye can make small
indications clearly visible.
Inspection :* Indications are interpreted in terms of type and size.* Indications are
classified as Linear or Rounded.* Size of the indications are larger than the discontinuity
openings. * The size of the indications are the deciding factor.
Linear and Rounded indication :Linear ; Length greater than 3 times the width.
Rounded ; Length less or equal to 3 times the width. Accept – Reject
decision depends on the type of indication.
Rounded and Linear type of
penetrant indication :
Rounded : Length of the indication less or
equal to 3 times the width.

Linear : Length of the indication greater than

3 times the width.
Rounded penetrantant indications around the hole.
Numerous linear penetrantant indications on this machined part.
Linear indication, from a crack which is not very deep:
Rounded indication from deep cavities :
Linear [ crack ] indication, light coating of developer shows the indications clearly.
Linear indication / crack on the weld surface, indications from undercuts along the weld
edges can be seen.
Linear indications [ multiple cracks ] at ID of a tube.:
Example of Linear indication / Crack : A
medium deep crack at the edge of a weldLinear indication : Length
greater than 3 times the width.
A gear with no relevant surface indications.
Example of Linear indication / a long weld Crack :
Example of Linear indication / Crack :A light coating of developer is
required for detecting light indications.
Example of Linear indication : A long weld
Crack. Indications from undercuts can also be seen.
A heat exchanger tube to tube sheet welds under penetrant examination.
Heat exchanger tube to tube sheet welds, no relevant indication in this area..
Indications detected by penetrant examination is generally removed by a portable grinder.
After cutting through the defects, the area should be retested before repair
to ensure complete removal of the defects.
The indications removed by grinding.the ground area is retested to ensure that the defects
have been removed.
The re test of the ground area shows that the defects have been removed.
The re test of the ground area shows that the defects have been removed.
No relevant penetrant indications on theses cast parts.
No relevant penetrant indications on theses cast parts.
Black and white image of a crack indication in a cast part.
inspection booth
An examinar Looking for penetrant indications using UV illumination. Photo taken using
white light.
Cast Gear, no relevant indications.
Example of rounded indications / porosity cluster :rounded indication :
Length less than or equal to 3 times the width. 4 or more indications in a line with
a separation of less than 1.6 mm between each indication is unacceptable.
Example of Rounded indication / Porosity :Rounded indication : Length
less or equal to 3 times the width. Rounded indications are generally produced by
pinholes, cavities and crater cracks. Single indication larger than 4.8 mm is
unacceptable.
Black and white image of rounded indications.
Indications from impact loaded cracks in test samples :
Indications from radiating arms overlap to produce large round indication. A weld surface
crater crack produce such indications.
Example of indications :
Indication from lack of fusion in ERW joint
Linear indication : [ very
deep cracks ]
Linear indication : [ very
deep cracks ]
Linear indication : [ very
deep cracks ]
Linear indication : [ very
deep cracks ]
Non relevant indications :Non relevant indications can be produced by
failure to remove sufficient excess surface penetrant.
Patches of penetrants will appear if sufficient excess surface penetrant is not
removed.
Non relevant indications :Rough irregular surface makes removing excess penetrant
difficult and produce non relevant indications.
Non relevant indications :Non relevant indications can be produced by failure to
remove sufficient excess penetrant.
Non relevant indications :
Non relevant indications can be
produced by failure to remove
sufficient excess surface
penetran.Roughness and
irregularities make removal of excess
penetrant difficult.
Non relevant indications :
Non relevant indications can be
produced by failure to remove
sufficient excess penetrantSsurface
roughness and irregularities make
removal of excess penetrant difficult.
Over removal of penetrant produces
diffused indications.
Excess developer coating masks or produce light indications.
Non relevant indications :Insufficient removal of excess surface penetrant will
produce Interfering penetrant background.
A crack emanating from the hole. Heavy background because of residual
penetrant.
A crack emanating from the cornere. Reddish background because of residual penetrant.
Non relevant indications :failure to remove sufficient excess penetrant produces
reddish-white background.
Indications from
undercut, rough
surface etc.
Over removal of penetrant
produces diffused indication
Gross discontinuities have produced dark red indications.
Relevant from holes[ IP ] and and non relevant indications from
rough surfaces.
Relevant from holes[ IP ] and and non relevant indications from
rough surfaces.
Grooves are difficult to clean may produce non relevant
indications :
Crack indication in teeth and some non relevant indications:
Sources of Non relevant indications :

Tool marks.
Finger prints.
Penetrant patches at the table or
at the fingers of the operator.
Lint or dirt particles on surface.
Scales on surface.
Oily residue on surface when
fluorescent is performed.
Penetrant indications from surface blemishes.
Penetrant indications from surface blemishes and the one.
Penetrant residue at the fingers of the operator :
Removal of excess penetrant is difficult on rough and corroded
surfaces, show up as non relevant indications.
Improper processing may produce weak indications :
Effect of penetrant quality on indications - 1 :
Effect of penetrant quality on indications - 2 :
Effect of penetrant quality on indications - 3 :
Effect of penetrant quality on indications - 4 :
Effect of penetrant quality on indications - 5 :
Incorrect applications of developer: Developer shall
not flow on the part. A flowing developer will wash out indications.
Correct applications of developer.
Effect of penetrant sensitivity on indications 6 :
Monitoring performance of penetrant test process :
Cracked Aluminum Comparator Block :
2024 – T3 aluminum plate heated and quenched to produce crack
patterns. Crack size is uncontrolled. Used for side by side comparison of penetrants.
Indications from crack pattern
in the aluminum crack panels.
Comparing fluorescent penetrants by aluminium test blocks.
Penetrant Test panels :Ni - Cr
crack panels. These are matched test
panels for monitoring sensitivity and
comparing penetrants.The crack depth is
controlled.The blocks are supplied with
photograph or replica of the indications.
This 1st record is compared with
subsequent tests.The cracks open with
use and must be monitored.
Matched Ni – Cr panels and their replica indications.
Ni Cr matched test panels for
monitoring sensitivity.
Cross section of crack in Ni - Cr test panel. The width of the crack is 1 / 20 of the
crack depth. Sensitivity of crack
detection depends mainly on crack width and not on length.
Indications of the cracks in Ni – Cr crack panels.
KnownDiscontinuity
Standard[ KDS ]
Panels :
contains controlled
cracksof 5 different sizes and
rough surface for checking
wash ability.Two panels are
produced together for side by
side comparison of used and
fresh penetrants.
Indications from the cracks in the
KDS Panel :
sensitivity is compared by noting the smallest
crackdetected.
Two KDS panels are produced
together so that they are virtual
twins.
Fluorescent Indications of the cracks in the KDS Panel :
Testing and Maintenance [ TAM / PSM 5 ] Panel : Extensively
used in aerospace industries and fore runner of modern panels.
Contains 5 cracks of different sizes and rough surface forchecking
the washing characteristics of penetrants.
Two versions of the TAM / PSM5 Panels : Highly polished and rough
surface for testing the washability of penetrant.
Crack indications in the TAM Panel :
Ultraviolet Bulbs [ mercury vapor lamps ] :Low power [ 100 / 125 Watts ]
uses an internal deep purple coating as filter for short wave length ultraviolet radiation.
The dark color of the coating filters out visible light.High power bulbs uses external
[ Koop ] filter. With filter, the bulb transmits 300 to 400 nm wavelength ultraviolet light
with peak wavelength around 365 nm.
The florescent material coating absorbs this energy and re- emits yellow green light which
is highly visible.
1. Ultraviolet lamp external filters :2. Yellow UV filter glasses
for reducing eye-strain.
Bulbs with damaged filter or
coating must not be used.
Unfiltered ultraviolet light
burns the exposed skin and
the retina of the eye causing
blindness.
Portable UV Light :lamp head with igniter / ballast power supply. The system
operates from 110 / 220 v power supply. The bulb becomes very hot.
The head which houses the UV bulb. The head may use external filter if required by the
bulb. A plastic pistol grip is used to hold the head during use. An external ballast type
power supply provides power to the head. The lamp must be left on unless a long idle
period follows. Once switched off, the lamp does not switch on until it cools down
sufficiently.
Hand held UV lamp illuminates parts at any location.
Florescent pigments are used for preparing fluorescent penetrants. Under ordinary light,
fluorescent penetrants look pale yellow.Fluorescent materials glow brilliantly under
ultraviolet illumination. Fluorescent materials used in non destructive testing responds to
ultraviolet radiation around 365 nano meters.
The fluorescent dye used in the penetrant absorbs invisible ultraviolet radiation and emits
visible light in yellow – green color.
The eye has maximum sensitivity 525 – 575 nm..
Ultraviolet Light
illuminating fluorescent
materials:
A ring illuminated by ultraviolet light.
Fluorescent indications under ultraviolet illumination :
Appearance of white developer under
ultraviolet illumination.The white developer
produces a darker background and enhance
the indications :
Fluorescent Indications :Surface indications on a chain ring.
 An Inspection booth for fluorescent penetrant examination.
Fluorescent examination process requires darkened inspection area.
Requires light intensity of min 1000μW / Cm2 at the examination surface.
Back ground light must be limited to 20 Lux maximum.
Examination may be performed at normal light using very high power
lamps of min 3000μW / Cm2 intensity.
Fluorescent penetrant test process requires a darkened area which can be achieved by use
of black curtains. UV lamp is used ;1. Execcss
penetrant removal station for checking adequacy of the cleaning operation.2.
inspection station for viewing indications.
Battery operated ultraviolet light
For use in areas where electrical supply is not available.
The unit has limited intensity.
UV Light emitting diodes are also used for battery
lighting in remote areas.
High intensity ultraviolet flood
lamp, produces 7500 – 10,000
μW / Cm2 and allows fluorescent
examination without darkening the
test area.
The
END
Completed

Slides
Ultraviolet Light for Flourescent Process :
Material Failure :
A part covered with fluorescent penetrant is placed on the grid to
drain during dwell time.
A part covered with fluorescent penetrant is placed on the grid to
drain during dwell time.
A part covered with fluorescent penetrant is placed on the grid to
drain during dwell time.
Visible light
spectrum
Ultraviolet Bulbs [ mercury vapor lamps ] :Low power [ 100 W ]
uses internal coating as filter.High power uses external filter.
With filter, the bulb transmits 300
to 400 nm wavelength ultraviolet
light with peak wavelength of
365nm.
Bulbs with damaged filter or
coating must not be used.
Without filter if directly exposed it
damages human eye and the skin.
Fluoroscent penetratn testing
needs UV light
Non-relevant Indications :
Water washable Penetrants ;Water washable process : fast &
economical is used where high sensitivity is not required.Good for
examination of rough surface, threads, keyways and large number of parts
Fluorescent Examination Process :Discontinuities detected by a
penetrating colored liquid. This color is visible under ultraviolet
illuminations. This process is more sensitive than color contrast process.
Small indications are easily seen.Fluorescent penetrants are available in
five sensitivity levels.½, 1 – 4. Selection rule is to choose the lower
sensitivity penetrant which will provide the required sensitivity.
Liquid Penetrant Testing :Discontinuities detected by a penetrating
colored liquid.
Penetrant entered into
discontinuties and shows
indication
Linear indication is a
indication length greater
than three times of the width
Rounded indication is a
indication length atleast
equal to three times of width
Solvent Removable Method :
Solvent Removable Method :
Solvent Removable Method :
Solvent Removable Method :
Solvent Removable Method :* Solvent method is highly sensitive,
does not require additional equipments.* Recommended for spot
testing.* Most suitable for field use.
Fluorescent Indications :Pinholes indication in casting.
When the pinholes are close to
each other, indications overlap to
produce patches of indications.
Solvent Removable Method :
Solvent Removable Method :
Solvent Removable Method :
Penetrant application by brush :
Liquid Penetrant Testing :
Applicable to
ferro magnetic materials,
Iron, Cobalt, nickel and
their magnetic alloys.
For detection of surface
and sub surface flaws
Welding Cracks :Service induced defects
Liquid Penetrant Testing :defect removal by grinding
Water washable process : fast & economical is used where
high sensitivity is not required.Good for examination of
rough surface, threads, keyways and large number of parts
Water wash process :
Liquid Penetrant Testing :
Liquid Penetrant Testing :
Liquid Penetrant Testing :
Applicable to
ferro magnetic materials,
Iron, Cobalt, nickel and
their magnetic alloys.
For detection of surface
and sub surface flaws
Linear [ crack ] indication :
Linear [ crack ] indication :
Non relevant indications :Interfering penetrant background will be
produced by failure to remove sufficient excess penetrant.