LIQUID PENETRANT

TESTING
MODULE 4
Interpretation of Liquid Penetrant Indications
Part 5
Visibility of Liquid Penetrant Test Indications
Probably the one factor most responsible for the effectiveness of a liquid
penetrant is its visibility, often referred to as brightness, contrast or
brilliance. Carefully conducted experiments with glass plates clamped
together and viewed (through the mating surfaces) under monochromatic
light have shown that liquid penetrant materials of only medium or low
performance can enter openings that are smaller in width than a half
wavelength of sodium light.
Visibility of Liquid Penetrant Test Indications
Liquid penetrant was determined to have entered a plate gap of only 130
nm (about 5 x 10-6 in.). Taking into consideration the extremely small
amount of liquid penetrant contained in a discontinuity of this size and
the fact that only a small portion of this liquid penetrant can be bled back
to the surface to become visible, it is obvious that everything that will
enhance visibility should be used if maximum liquid penetrant test
performance is to be obtained.
Visual Examination of Fluorescent Liquid Penetrant Test Indications

The inspector views the processed test surfaces under ultraviolet

radiation in a darkened test area when fluorescent liquid penetrant
systems are used: Indications of discontinuities fluoresce with an
intensity that provides contrast in proportion to the ambient darkness,
literally drawing the eye of the inspector to them. The darker the
inspection area and the more nearly dark adapted the eyes of the
inspector, the more reliable the inspection will be. If outdoor fluorescent
liquid penetrant testing is necessary, it is often done at night or the area
of interest is shielded as much as possible from visible radiation (white
light).
Formation and Bleeding of liquid Penetrant Indications
Liquid penetrant indications tend to bleed across the developer coating
as time progresses after their formation. Thus, as the developer action
progresses from the time of its application, discontinuity indications
appear gradually and then reach their optimum visibility and clarity.
Thereafter, as bleeding of liquid penetrant indications continues, the
liquid penetrant spreads laterally into the developer coating. This
gradually reduces the definition and intensity of the indications. The
optimum indications are typically reached with developing times in the
range from 2 to 10 min (Fig. 10). Excessive bleedout of entrapped liquid
penetrant may take 30 min or longer (Fig. 11).
Figure 10 Fluoreseent liquid penetrant indications of optimum resolution and
clarity, obtained without bleedout or excessive spreading of liquid penetrant
across developer film: (a) gears; (b) sprocket; (e) spindle; (d) links.
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Figure 11 Examples of fluorescent liquid penetrant indications with excessive
bleedout or spreading of liquid penetrant across developer film: (a) turbine
blade; (b and c) structural parts; (d) casting.
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Contrast of Visible Dye liquid Penetrant Test Indications
In the case of visible liquid penetrants, increasing indication visibility
means incorporating the largest possible quantities of dye in the liquid
penetrant vehicle and choosing the most intense dye colors with the
highest contrast with respect to the background against which they will
be viewed. In nearly all cases, this contrast is heightened by using the
developer in such a manner that developer (1) serves to bring liquid
penetrant out of the discontinuity and (2) also covers the surface with a
smooth, white coating against which the indication stands out sharply.
Contrast of Visible Dye liquid Penetrant Test Indications
All of the visible dye liquid penetrants presently in use make themselves
perceptible to the eye in one of two ways – either by reflecting a
considerably smaller amount of light than the background or by reflecting
light of a different color (usually red) than the background (color
contrast). The incident light is not all absorbed by the liquid penetrant,
nor does the background reflect all the light that strikes it. The actual
contrast ratios are extremely difficult to measure but have been
estimated at from 10:1 to 20:1, the maximum contrast theoretically
obtainable.
Contrast of Fluorescent Liquid Penetrant Test Indications
In the case of fluorescent liquid penetrant discontinuity indications, visual
perceptibility is enhanced by light emission mechanisms within the liquid
penetrant indications and conditions of viewing are quite different. Using
brightness contrast, the bright yellow-green indication is seen against a
nearly black or at least a very dark background. The indication itself is
actually a source of light which, even though small, is quite intense.
Contrast can be exceptionally high. Some estimates give it a value as
high as 100 to 1 or even much greater, because it is the presence of light
compared to absence of light.
Contrast of Fluorescent Liquid Penetrant Test Indications
With fluorescent liquid penetrants, the most effective way to increase
visibility (and improve resolution of fine discontinuities) is to increase the
fluorescent brilliance of the liquid penetrant material. The fluorescent
indications are generally viewed in the substantial absence of visible
light, so that the background remains unseen.
Contrast of Fluorescent Liquid Penetrant Test Indications
Visibility of Fluorescent Liquid Penetrant Indications
From the point of view of color contrast, most fluorescent liquid
penetrants provide yellow or yellow-green indications against a black
background. This has been proven by research into visibility of such
objects as highway signs to be one of the most seeable combinations
possible. The normal human eye has its highest sensitivity in the yellow
or yellow green wavelength range. In fluorescent testing, the eye looks at
a fine source of light of high brightness. Under this condition, probably
because of halation, the source size appears to be greatly exaggerated
whereas the dark background tends to be minimized.
Contrast of Fluorescent Liquid Penetrant Test Indications
Background Fluorescence Caused by Rough or Porous Surfaces
In some practical applications where the test object surface is porous or
rough, fluorescent liquid penetrant tends to be retained on the surface as
well as in discontinuities. This condition reduces contrast between the
background and indications and may impair discrimination. For this
reason, a compromise between the removability of surface liquid
penetrant and intensity of fluorescence is necessary to reduce the
background fluorescence to a practical limit.
Placement of Light Sources in Liquid Penetrant Testing Booth
Consideration should be given to the disposition of lights within an
inspection booth and to the effect on an operator of placement of light
sources. Although ultraviolet-A radiation will not damage the eye
permanently, some of the layers of the eyeball exhibit strong tendencies
to fluoresce. If the inspection light is placed so that its rays fall directly or
are reflected into the eyes of operators, this eyeball fluorescence can
become extremely annoying and will impair inspector effectiveness to a
very marked degree.
Placement of Light Sources in Liquid Penetrant Testing Booth
Use of special filtering eyeglasses will increase operator perception and
reduce fatigue. Yellow tinted eyeglasses filter out the ultraviolet radiation
before it reaches the eye, yet they do not reduce the visibility of
fluorescent indications.
Interpretation of Liquid Penetrant Indications
The interpretation of liquid penetrant indications is normally a matter of
considerable judgment. It might be said that it involves three phases:
(1) observation of indications, (2) verification of indication cause and
significance and (3) disposition of test objects in accordance with
applicable criteria for acceptance and rejection.
The first step is that of visually observing the indication and verifying that
it is relevant, Le., that it is indicating a discontinuity rather than a material
characteristic that is a normal condition of the surface under
investigation. Figures 12 and 13 show some typical liquid penetrant
indications.
Figure 12 Fluorescent liquid penetrant test indications under ultraviolet
radiation: (a) aluminum spar cap; (b) fatigue crack in bearing shell.
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Figure 13 Blowholes in casting shown by fluorescent liquid penetrant testing.

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Interpretation of Liquid Penetrant Indications
The American Society for Testing and Materials (ASTM) has issued
ASTM E 433, Standard Reference Photographs for Liquid Penetrant
Inspection. This publication contains reference photographs to be used
as a means of establishing and classifying type and characteristics of
surface discontinuities detectable by liquid penetrant test techniques.
They may be used as a reference for acceptance standards,
specifications and drawings. However, no attempt has been made to
establish limits of acceptability or the extent of the metallurgical
discontinuity.
Interpretation of Liquid Penetrant Indications
In the event of questions of interpretation, supplemental means of
observation may be necessary such as viewing liquid penetrant
indications under magnification or preparing metallographs of cross
sections of discontinuities encountered in production testing.
Interpretation of Liquid Penetrant Indications
When it has been determined that an indication is relevant, a further
judgment must be made as to the disposition of the test objects to
answer questions such as the following.
1. Should supplemental nondestructive tests such as ultrasonic or
radiographic testing be used to attempt more complete definition of the
discontinuity causing the liquid penetrant indication?
2. Can the surface be accepted as is or be reworked to eliminate the
indicating discontinuity?
3. Should the surface or part be discarded as unserviceable?
Establishing Criteria for Acceptance or Rejection
Specifications or drawings for the parts or surface under examination
should specify the nondestructive test method or methods required for
part acceptance. Moreover, instructions should specify the acceptance or
rejection criteria or refer the inspector to supplemental documents such
as applicable acceptance/rejection specifications. If liquid penetrant tests
are being made on critical parts such as nuclear hardware or a jet engine
component, an expert in evaluation of indications in the specific industry
may have to be called on for a judgment.
Establishing Criteria for Acceptance or Rejection
To establish acceptance/rejection criteria, it may be necessary to
conduct an extensive correlation study between nondestructive test
indications and destructive test results. This is the ultimate procedure but
even it may leave some doubt because discontinuities or indications do
not always occur in exactly the same place, with the same frequency or
to the same extent.
Factors Influencing Judgment of Test Object Serviceability
It should be obvious that a number of factors enter into the final
judgment. Some of these are as follows.
1. What metal or alloy is involved in test objects?
2. If the test objects have a nonmetallic surface, what is its composition?
3. Where are the indications? Are they in critical radii, on edges that will
be ground off, in parts designed for high strength applications or in thick
sections that may allow for removal of surface discontinuities without
sacrifice of function?
Factors Influencing Judgment of Test Object Serviceability
4. Are the surface or surfaces repairable by welding or other means?
5. What is the cost of the part? It may be that the cost of a new part is so
low that the expense of repair or rework of an anomalous part is not
warranted.
Conversely, of course, one would not want to discard an expensive piece
of hardware that could be reworked at a considerable savings over the
cost of a new part.
Specifications Covering Evaluation of liquid Penetrant Indications

Some industries have prepared standards for evaluation and

acceptance/rejection of hardware on the basis of liquid penetrant
indications. These standards vary from quite general to very detailed.
Liquid penetrant users may find some of these helpful or may prefer to
prepare their own. If they are working under a contract, it is mandatory
that they determine the specifications to which the contracting agency
intends to hold them accountable.
Specifications Covering Evaluation of liquid Penetrant Indications

Commonly, a general statement covering inspection policy may be

encountered, such as, the inspection department shall pass only those
parts that have no relevant liquid penetrant indications. Parts showing
liquid penetrant indications should be referred to the metallurgy or design
departments for disposition. The metallurgy or design department shall
decide which parts shall be accepted, reworked or rejected.
Specifications Covering Evaluation of liquid Penetrant Indications

There are many specifications covering the liquid penetrant products,

liquid penetrant processing procedures and certification of liquid
penetrant test personnel. Some specifications have been prepared by
government agencies and others by technical societies such as the
American Society of Mechanical Engineers (ASME), ASTM International
and SAE International (formerly the Society of Automotive Engineers, or
SAE). Numerous specifications have been developed by companies
using liquid penetrant testing.
Specifications Covering Evaluation of liquid Penetrant Indications

Because of frequent changes in requirements, test personnel and

facilities should always check to verify that they are using the revision or
amendment of the applicable test specifications called out under
contract.
Acceptance/Rejection Criteria for Critical Parts
Test acceptance/rejection criteria for parts or surfaces would normally be
referenced by an applicable specification, standard for a particular part
or some other governing document that would outline what type of
discontinuity would be cause for rejection. An extreme example of this
would be the approach taken by companies that are working with
fracture mechanics, whereby a particular structure or part is analyzed for
specific types of discontinuities that may or may not constitute a
rejectable discontinuity. Standards are then written for the items for
nondestructive test criteria, which may include liquid penetrant testing.
These would include minimum acceptable indication size and strict
uniform liquid penetrant processing.
Acceptance/Rejection Criteria for Critical Parts
The importance of carefully controlled liquid penetrant testing and the
necessity to record the exact techniques used to process the parts on
the specification document cannot be over emphasized. In a number of
specifications, porosity bleedout diameters are specified as accept/reject
criteria. The maximum acceptable size limits for liquid penetrant
indications apply to the bleedout indication immediately after wiping the
indication one time with a swab or brush dipped in solvent. Bleedback is
the recurrence of the liquid penetrant indication after once wiping away
the original indication.