Liquid Penetrant Testing Level II

The use of non-invasive techniques to

determine the integrity of a material,
component or structure
or
quantitatively measure some characteristic
of an object.
Inspect or measure without causing damage.
Definition of NDT
Methods of NDT

Visual
What are Some Uses of NDE
Methods?
Flaw Detection and Evaluation
Leak Detection
Location Determination
Dimensional Measurements
Structure and Microstructure Characterization
Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response
Measurements
Material Sorting and Chemical Composition
Determination

Fluorescent penetrant indication
When are NDE Methods Used?
To assist in product development
To screen or sort incoming materials
To monitor, improve or control
manufacturing processes
To verify proper processing such as heat
treating
To verify proper assembly
To inspect for in-service damage
There are NDE application at almost any stage
in the production or life cycle of a component.
Six Most Common NDT
Methods
Visual
Liquid Penetrant
Magnetic
Ultrasonic
Eddy Current
X-ray
Historically, Penetrant Inspection was called the Oil & Whiting
method as it used kerosene and a white powder for the inspection
of railroad parts.
Liquid Penetrant Testing
Method
A liquid with high surface wetting characteristics
is applied to the surface of the part and allowed
time to seep into surface breaking defects.
The excess liquid is removed from the surface
of the part.
A developer is applied to pull the trapped
penetrant out the defect and spread it on the
surface where it can be seen.
Visual inspection is the final step in the
process. The penetrant used is often loaded
with a fluorescent dye and the inspection is
done under UV light to increase test
sensitivity.
Liquid Penetrant Inspection
Common Application of NDT
Inspection of Raw Products
Inspection Following
Secondary Processing
In-Services Damage Inspection
Inspection of Raw Products
Forgings,
Castings,
Extrusions,
etc.
Machining
Welding
Grinding
Heat treating
Plating
etc.
Inspection Following
Secondary Processing
Cracking
Corrosion
Erosion/Wear
Heat Damage
etc.
Inspection For
In-Service Damage
Most widely used nondestructive evaluation (NDE) methods.
Two main factors, which are its relative ease of use and its
flexibility.
Limited by inability to test materials with discontinuity not open to surface
or having extremely porous surface
LPI can be used to inspect almost any material provided that
its surface is not extremely rough or porous.
Materials that are commonly inspected using LPI include the
following:
Metals (aluminum, copper, steel, titanium, etc.)
Glass
Many ceramic materials
Rubber
Plastics
Common Uses of Liquid Penetrant
Inspection
1. Surface Preparation
Free of oil, grease, water, rust, scale or other contaminants
that may prevent penetrant from entering flaws.
2. Penetrant Application
The penetrant material is applied by spraying, brushing, or
immersing the part in a penetrant bath.
3. Penetrant Dwell
The total time that the penetrant is in contact with the part
surface
Basic Steps Involved in LPT
5. Developer Application
A thin layer of developer is applied to the sample to draw
penetrant trapped in flaws back to the surface where it
will be visible. Developers come in a variety of forms that
may be applied by dusting (dry powdered), dipping, or
spraying (wet developers).

4. Excess Penetrant Removal
The excess penetrant must be removed from the surface
of the sample while removing as little penetrant as
possible from defects. Depending on the penetrant
system used, this step may involve cleaning with a
solvent, direct rinsing with water, or first treated with an
emulsifier and then rinsing with water.


Basic Steps Involved in LPT
6. Indication development
The developer is allowed to stand on the part surface for a
period of time sufficient to permit the extraction of the
trapped penetrant out of any surface flaws. This
development time is usually a minimum of 10 minutes
7. Inspection
Performed under appropriate lighting to detect indications
from any flaws which may be present
8. Post Cleaning
Final step in the process -- thoroughly clean the part
surface to remove the developer
Basic Steps Involved in LPT
Immersion tanks & Detergent Cleaning
Vapor degreasing effective for oil &
grease & similar organic contamination.
Care needs to be taken.
Steam cleaning large difficult to handle
Solvent cleaning
Acid or alkaline cleaners for rust &
surface scale removal.
Paint removal Hot tank paint strippers
Etching effective on articles that have
been ground or machined. Uses acid or
alkaline solution to open up burrs


Surface Preparation
Blast (shot blasting, sand grit or
pressure
Liquid honing
Emery cloth
Wire brushes and
Metal scrapers
Surface cleaning processes to be avoided
include
These tend to close the discontinuities by
peening
Surface Preparation contd
Spraying Pressurized spray cans or
low pressure circulation pump.
Brushing Not recommended for post
emulsified penetrant
Immersion Dipping the entire part into
a tank of penetrant.
Pouring
Penetrant Application
Penetrant Dwell
The total time that the penetrant is in contact with the part
surface is called dwell time.
It is the time elapsed between the application of penetrant
and removal of excess penetrant.
Normal time is between 5 to 30 minutes.
Very fine cracks may require in excess of 30 minutes
Temperature of specimen & penetrant can affect dwell
time. Temperature allowed is 16-52 C
Penetrant manufacturer provides suggested dwell times for
its products.
a Water washable penetrants.
The water spray should be at an angle of 45 at a distance
of minimum 12 inches. Pressure of water spray should be
20-30 psi. Grain size of spray should be coarse. Water
temperature < 43C

b Post-emulsified penetrants require two step removal
process - Application of emulsifier by dipping and
removal of resultant emulsifier- penetrant mixture by water
rinse as above.
Depending on the penetrant system used, this step may
involve cleaning with a solvent, direct rinsing with water, or
first treated with an emulsifier and then rinsing with water.
Excess Penetrant Removal
c Solvent removable penetrants
I Remove first with dry lint free cloth
ii Moisten cloth with solvent and rub the specimen.
iii Final removal by dry cloth.
Excess Penetrant Removal contd
Dry Wet
Aqueous
Non-Aqueous
Soluble Suspended Suspended
Types of developers
a) Blotting effect. Penetrant is drawn out of the
discontinuity by capillary action of developer.

b) Provides a contrast background.
Developer
Developer Application
Dry developer
Fluffy white powder not carried in a liquid.
Applied directly as powder by using slight air pressure
or by dipping into a container of dry powder.
Necessary to have the surface dry to get an even layer.
It is the least sensitive method.
Applied on rough surfaces sharp fillets, holes &
threaded articles.
Wet developer is applied on smooth surfaces.
Some time is to be given for drying by hot air T < 180F
Development time is 7-10 minutes.
Most sensitive developer is solvent suspended.
They are generally alkaline in nature.
Developer Application
Inspection
Visible penetrant
Illumination required at the surface 1000 lux = 100
candles/m
2
Fluorescent penetrant
Needs darkened environment with black light.
Not a field operation. Illumination required at the surface =
1000 watt/cm
2
measured at 15 inches from filter face.
Inspection should be over within 30 minutes.
Indication Development &
Inspection
The developer is allowed to stand on the part surface for
a period of time sufficient to permit the extraction of the
trapped penetrant out of any surface flaws. This
development time is usually a minimum of 10 minutes
Color
The color of the penetrant material in visible dye penetrant
inspection provides good contrast against the developer or
part being inspected.
Fluorescence
LPI materials fluoresce because they contain one or more
dyes that absorb electromagnetic radiation over a
particular wavelength. Since the molecules are not stable
at this higher energy state, they almost immediately re-
emit the energy (with some loss) at a slightly longer
wavelength which is in the visible range.
Color & Fluoresence
Black light (also known as Wood's light) is the common
name for a lamp emitting almost entirely long wave
ultraviolet radiation and very little visible light.
Requires warm-up time of 5-10 minutes, Adjustment time of
about 1 minute
280 320 400 800 nm
Violet
Red
Blacklight Peaks at 365 nm
Visible light 400-800nm
Blacklight
Electromagnetic Spectrum
475-550 nm yellowish green color
Lower energy
Black light intensity will be affected by voltage variations.

Black lights should never be used with a cracked filter as output of
white light and harmful (to eyes) black light will be increased.
Higher energy
Blacklight
Liquid penetrants used in LPT can be categorized by the type
of Dye they contain.

Penetrant Contains
1 Visible Dye Coloured (usually red) dye
2 Fluorescent Fluorescent dye
3 Dual sensitivity Combination dyes
Liquid penetrants must have the ability to
1 Hold a dye material in suspension
2 Spread the dye evenly over the surface.
3 Carry the dye into any discontinuity open to surface.
4 Be easily removed,
5 Bring up the dye back to the surface when required.
Liquid Penetrant Testing materials
Liquid penetrants can be categorized by the process used to
remove the excess penetrant from the specimen.
1 Water washable penetrants are either self emulsifying
or removable with plain water. Available with visible
or fluorescent dye.
2 Post-emulsified penetrants require a separate
emulsifier to make the penetrant water washable.
3 Solvent removable penetrants are oily penetrants that do
not contain an emulsifying agent. Removable by
specifically designed solvents.
Liquid Penetrant Testing materials
Advantages Disadvantages
Easily washed with water
Good for quantities of small
specimens.
Good on rough surfaces.
Good on keyways and threads
Fast, single step process.
Relatively inexpensive.
Not reliable for detecting scratches &
similar shallow surface discontinuities.
Not reliable on re-runs of specimens.
Not reliable on anodized surfaces.
Acids & chromates affect sensitivity.
Easily over washed.
Subject to water contamination.
Solvent removable
Advantages Disadvantages
Portability.
No water required.
Good on anodized specimens.
Good for spot checking.
Specimens can be re-run.
Flammable materials.
Removal of excess penetrant is time
consuming.
Materials cannot be used in open tanks.
Difficult to use on rough surfaces like
cast magnesium.
Penetrants
Advantages Disadvantages
High sensitivity for very fine
discontinuities.
Good on wide shallow
discontinuities.
Easily washed with water after
emulsification.
Short preparation time.
Cannot be easily over washed.
Two step process.
Equipment required for emulsifier
application.
Difficult to remove penetrant from
threads, keyways, blind holes and rough
surfaces.
Post emulsified penetrant
Penetrants


Contact Angle
The contact angle is the angle at which a liquid/vapor
interface meets the solid surface. The contact angle is
specific for any given system and is determined by the
interactions across the three interfaces.
Contact Angle
On extremely hydrophilic (water loving/ good at wetting)
surfaces, a water droplet will completely spread (an
effective contact angle of 0).

On many hydrophilic surfaces, water droplets will exhibit
contact angles of 10 to 30.
On highly hydrophobic surfaces, which are incompatible with
water, one observes a large contact angle (70 to 90).

Some surfaces have water contact angles as high as 150 or
even 180.

On these surfaces, water droplets simple rest on the surface,
without actually wetting to any significant extent.
Contact Angle
Capillary action is the ability of a narrow tube to draw a liquid
upwards against the force of gravity.
It occurs when the adhesive intermolecular forces between
the liquid and a solid are stronger than the cohesive
intermolecular forces within the liquid.
It causes surface tension, which causes the droplet to
behave as if a thin, flexible film covered its surface.
The effect causes a concave meniscus to form where the
liquid is in contact with a vertical surface. The same effect
is what causes porous materials to soak up liquids.
Capillary Action
Viscosity is a measure of the resistance of a fluid to
deformation under shear stress.
It is commonly perceived as "thickness", or resistance to
pouring.
Viscosity describes a fluid's internal resistance to flow and
may be thought of as a measure of fluid friction.
Thus, water is "thin", having a low viscosity, while vegetable
oil is "thick" having a high viscosity.
Viscosity has little effect on the ability of a penetrant
material to enter a defect but it does have an effect on speed
at which the penetrant fills a defect.
Viscosity
The deformation of the surface of water under the weight of a
paperclip

Developer Advantages Disadvantages
Dry Indications tend to remain
brighter and more distinct over
time.
Easy to apply.
Does not form contrast
background so cannot be used
with visible systems.
Difficult to assure entire part
surface has been coated.
Soluble Ease of coating entire part.
White coating for good
contrast can be produced
which work well for both
visible and fluorescent
systems.
Coating is translucent and
provides poor contrast (not
recommended for visual
systems).
Indications for water washable
systems are dim and blurred.
Advantages and disadvantages of the various developer types.

Developer Types
Suspendible Ease of coating entire part.
Indications are bright and
sharp.
White coating for good
contrast can be produced
which work well for both
visible and fluorescent
systems.


Indications weaken and
become diffused after time.
Non-aqueous Very portable.
Easy to apply to readily
accessible surfaces.
White coating for good
contrast can be produced
which work well for both
visible and fluorescent
systems.
Indications show-up rapidly
and are well defined.
Provides highest sensitivity.


Difficult to apply evenly to all
surfaces.

More difficult to clean part
after inspection.
Developer Advantages Disadvantages
Advantages and disadvantages of the various developer types.
Developer Types
Sensitivity Ranking (highest to lowest) Developer Form Application
Technique per the Nondestructive Testing Handbook.
Ranking Developer Form Method of Application
1 Nonaqueous Wet Solvent Spray
2 Plastic Film Spray
3 water-soluble Spray
4 Water Suspendible Spray
5 water-soluble Immersion
6 Water Suspendible Immersion
7 Dry Dust Cloud (Electrostatic)
8 Dry Fluidized Bed
9 Dry Dust Cloud (Air Agitation)
10 Dry Immersion (Dip)
Sensitivity Ranking of Developers
All indications found with LP method will be surface discontinuities.
False Indication
Poor washing/cleaning is the source of false indications.
Non-relevant indications
Surface discontinuities caused by some features that may be press
fitted, keyed or riveted. May also include loose scale or rough
surface on forging or casting.
Indications & Interpretations
True Indications called a discontinuity ( acceptable/ unacceptable )

Continuous line caused by cracks, cold shuts, forging laps,
scratches or die marks
Intermittent line Any of the above provided they were very tight or
where the part had been peened, machined or ground.
Round usually caused by a porosity - blow holes, pin holes
Small dots Porous nature of specimen, coarse grain structure or
micro shrinkage.
Indications & Interpretations
Inherent, Raw material stage
Conveniently sized lump cast from molten metal. The shape
varies according to practice. Steel ingots may be from a few kg to
over 500 tonnes.
Big molten mass solidifies as ingot. During solidification gases
are liberated from external surface. Gases rising to escape give
rise to cavities. An elongated cavity in the center is called a pipe.
It also undergoes shrinkage. Some material may segregate as
non-metallic inclusions.
One third of the top is discarded. Impurities may remain in the
bottom 2/3 portion.
Origin of Discontinuities
In-process
either Rolling, forging, casting, welding, machining,
grinding.
Semi-finished products Slab, Bloom & Billets
Slab
Rolled from an ingot. It has a rectangular cross section of approx
0.2m x 1.5m and 10 m long and is used for producing bars, billets
and rods.
Bloom
An ingot is rolled to produce a bloom, about 250 mm square, but
much longer and slimmer than a slab. It would be the intermediate
product for a much longer rolled product.
Billet
The intermediate, with cross-section of approx 75 to 125 mm square,
for long products of small cross section.
Origin of Discontinuities
Rolling
Application of pressure to flatten lamination inclusion spreading
in longitudinal direction we get stringers
When rollers are not matching a long overlap indication is called a
seam or crack.
Forging Give shape by application of force. Forging lap or burst (
not enough temp for metal to flow)
Cold shut
Lack of fusion between layers as a continuous line.
Hot tears change in section thickness.
Origin of Discontinuities
Welding
Porosity, Pin hole, Lack of penetration, Lack of root fusion, cracks
longitudinal, transverse, crater crack
Grinding cracks, Heat treatment cracks
In service, After being used
Fatigue crack, Stress corrosion crack
Origin of Discontinuities
Acceptance criteria ASME Section VIII Div I
Any indication < 1/16 of inch considered as irrelevant indication
An Indication > 1/16 inch may be linear ( L/W >= 3 ) or
rounded ( L/W < 3)
Any linear indication > 1/16 inch is not acceptable
Any rounded indication > 4.8 mm is not acceptable
Four or more linear indications separated by , 1/16 inch is not
acceptable.
Acceptance Criteria
1 Photographs
2 Special wax & plastic film developers that absorb & fix the
penetrant indication to give a permanent record.

a) Strippable lacquers are sprayed over the indication and when
dry can be lifted.
b) Special fixers are sprayed over the indication and when dry
are lifted with transparent tape.

Fixing & Recording Indications
Cold shut
A defect produced during casting, causing an area in the metal where two
portions of the metal in either a molten or plastic condition have come
together but have failed to unite, fuse, or, blend into a solid mass.
Lamination
A defect appearing in sheets or strips as a segregation or in layers. To
become divided, caused by gas pockets in the ingot. generally parallel to the
worked surface of the metal.
Lap
A surface defect appearing as a seam, caused by folding over hot metal, fins or
sharp corners and then rolling or forging them into the surface but not welding
them.
Seam
On the surface of metal a crack that has been closed but not welded; usually
produced by some defect either in casting or in working, such as blowholes
that have become oxidized or folds and laps that have been formed during
working. Similar to cold shut and laminations.
Penetrant properties

Flash point > 120F
Testing on Nickel, Titanium, Stainless steel Chloride & sulphide < 1%
Nickel poisonous to sulphur
Titanium poisonous to Sulphur + chloride
Stainless steel poisonous to Sulphur + chloride
Forging
is manufacturing process where metal is pressed, pounded or squeezed
under great pressure into high strength parts known as forgings. The
process is normally (but not always) performed hot by preheating the
metal to a desired temperature before it is worked. It is important to note
that the forging process is entirely different from the casting (or foundry)
process, as metal used to make forged parts is never melted and poured
(as in the casting process).