Cleaning of test surface 2 :

Paint Removal : The paint film must be completely removed to expose

the surface of the examination area. Paint removers are chemical bond
release agents or solvent strippers for the removal of paint and
corrosion inhibitor coatings. They are applied by dipping or brushing
and work well with heat to accelerate the removal process. The paint
strippers is removed and the surface is cleaned by detergents or
solvents.
Ultrasonic Cleaning : is performed on large number of small parts by
immersion or dipping the part in a ultrasonic cleaning tank with almost
any kind of cleaning solution. Solvents and alcohol work well with
ultrasonic agitation. It is the most effective method for opening up Detergent
defects by removing contaminants imbedded in the discontinuity cavity. cleaning.
Ultrasonic cleaning has been found to be effective in removing
penetrant entrapped in discontinuities. Tight flaws require 2 hours of
cleaning. For geometrically complex components, huge benefits result
from combining the chemical action of a solvent with ultrasonic
agitation.
Ultrasonic cleaning is based on the principle of producing cavitations
in a liquid solvent in which the component to be cleaned is immersed.
Large quantities of tiny bubbles are created in the solvent [ cavitations ]
by high intensity compression waves. The collapsing pressure of the
bubbles forces them into crevices where the fluid penetrates between
contamination and the work piece surface. This action forces the
contaminant off the work piece leaving it totally clean. The frequency of
ultrasonic vibration is 30 to 40kHz although higher frequencies may
sometimes be used. Cleaners are available as static solvents or
ultrasonic types.
Etching : This process uses acids or alkaline solutions to dissolve
smeared metal from the surface. Etching is performed after any
operation that could mechanically remove material from the surface,
such as sand blasting, machining, grinding or power brushing, to
assure that the cracks are opened to the surface. These mechanical
operations tend to smear and close the discontinuity openings.
Etching on steel is accomplished using 5 to 20% of acid solutions or
20% solution of ammonium per sulphate. The solution is applied for a
specific period of time, neutralized and rinsed. The etching time is
depends on the amount of material that is to be removed.
Etching usually requires a separate certification because of the
inherent danger to the test operator and the component being used.
Acid entrapment from etching can have disastrous effects on the
penetrant inspection. Sodium hydroxide caustic often used to etch
aluminum parts does not affect penetrants but can reduce the
brightness of indications. Careful cleaning of both acid and caustic
etches before penetrant inspection is highly recommended.
Drying the Part’s surface : Components that require the use of Drying components before penetrant application
cleaning agents for the pre cleaning process must be dried completely may require heating them to 1200 C for at least
before penetrant application. When water based cleaners are used 1 hour in an oven operating at ambient
during pre cleaning, the final step is a wash with clean water and the pressure. The component must cool down to
parts are thoroughly dried. Water or cleaning liquid residue will hinder 400 C before the application of the penetrant. A
entrance of penetrant into discontinuities. vacuum drying oven can dry the component
The normal way of removing water from cleaned parts before within 10 minutes.
penetrant application is to heat them in a temperature controlled Vacuum drying ovens can maintain a working
re - circulating air oven for one hour at around 125 0 C. An alternative is pressure as low as 10 milli bars absolute and
to immerse the components in a dewatering fluid which is then itself this can be achieved within 2 minutes. At this
removed by vapor degreasing. pressure, water boils at a temperature below
The Part surfaces are to be dried again after removal of excess 50 C. However, atmospheric water vapor will
penetrant and the stage at which surfaces are dried depends on the condense on work pieces removed from a
type of developer to be used. When dry powders or non aqueous drying oven operating at this temperature.
solvent suspension developer is used, the surfaces must be completely Vacuum drying ovens equipped with external
dry before application. When water soluble or water suspended heating elements in their base and wall to
developer is used, the parts are dried after the application of the maintain a working temperature at nominal
developer. 400 C can reduce drying times to less than 10
Drying temperatures of 60 - 80°C [ 140 - 176°F ] is normal for oven minutes. The residual temperature of
drying. Ovens should be thermostatically controlled with supply of clean approximately 400 C is achieved after drying,
dry re - circulating air and should be capable of drying the parts in 10 which is ideal for penetrant application. The
minutes. Care should be taken so as not to raise the surface ovens are smaller in size and can
temperature of the part above 600 C. In an oven, drying of small and accommodate a single, relatively large work
large parts together is not recommended because of dissimilar drying piece, or many smaller components.
time. Excessive drying can damage the part as well as evaporation of With recommended care, the oven provides a
the penetrant, which can impair the sensitivity of the inspection. long and efficient service enhancing the drying
process after precleaning.
Compiled by K. Chatterjee, 75643 Center for NDT P 00 Rv 04 Self study material.