Liquid Penetration Test

Learning Outcomes :
We were able to learn the methods of Liquid Penetration Test and able to detect the the defect
of the material such as scratch and crack.

Equipment / Apparatus :
1. Metal Specimen ( After the liquid penetration test)

2. Cleaner Liquid Spray

3. Penetration Liquid Spray

4. Developer Liquid Spray

Safety and Health :

1. Make sure the students follows the laboratory or workshop safety regulators.
2. Experiment must be conducted by lectures or experienced lab assistance.
3. Always know the hazards associated with the materials that are being utilized in the lab.
4. Always wear appropriate protective clothing.
5. Never perform unauthorized work, preparations or exeperiments.
6. Be familiar with the location of emergency equipment fire alarm, fire extinguisher,
emergency eye washer, and safety shower. Know the appropriate emergency response
procedures.
7. Safety precaution when using liquid spray, do not inhale the fume that came out from the
liquid sprayer and make sure that your skin is not in contact with any liquid from this test. It
might be corrosive.

Introduction :
Liquid Penetrant Inspection is a nondestructive method of revealing discontinuities that are
open to the surfaces of solid and essentially nonporous materials. Indications of a wide
spectrum of flaw sizes can be found regardless of the configuration of the work piece and
regardless of flaw orientations. Liquid penetrants seep into various types of minute surface
openings by capillary action. Because of this, the process is well suited to the detection of all
types of surface cracks, laps, porosity, shrinkage areas, laminations, and similar
discontinuities. It is extensively used for the inspection of wrought and cast products of both
ferrous and nonferrous metals, powder metallurgy parts, ceramics, plastics, and glass objects.
In practice, the liquid penetrant process is relatively simple to utilize and control. The
equipment used in liquid penetrant inspection can vary from an arrangement of simple tanks
containing penetrant, emulsifier, and developer to sophisticated computer-controlled
automated processing and inspection systems. Establishing procedures and standards for the
inspection of specific parts or products is critical for optimum end results.
The liquid penetrant method does not depend on ferromagnetism (as does, for example,
magnetic particle inspection), and the arrangement of the discontinuities is not a factor. The
penetrant method is effective not only for detecting surface flaws in non-magnetic metals but
also for revealing surface flaws in a variety of other nonmagnetic materials. Liquid penetrant
inspection is also used to inspect items made from ferromagnetic steels; generally, its
sensitivity is greater than that of magnetic particle inspection.
The major limitation of liquid penetrant inspection is that it can detect only imperfections that
are open to the surface; some other method must be used for detecting subsurface flaws.
Another factor that can limit the use of liquid penetrants is surface roughness or porosity.
Such surfaces produce excessive background and interfere with inspection.

History :
The exact origin of liquid penetrant inspection is not known, but it has been assumed that the
method evolved from the observation that the rust on a crack in a steel plate in outdoor
storage was somewhat heavier than the rust on the adjacent surfaces as a result of water
seeping into the crack and forcing out the oxide it had helped to produce. The obvious
conclusion was that a liquid purposely introduced into surface cracks and then brought out
again would reveal the locations of those cracks.
The only material that fulfilled the known criteria of low viscosity, good wettability, and
ready availability was kerosene. It was found, however, that although wider cracks showed
up easily, finer ones were sometimes missed because of the difficulty of detecting, by purely
visual means, the small amounts of kerosene exuding from them. The solution was to provide
a contrasting surface that would reveal smaller seepages. The properties and availability of
whitewash made it the logical choice. This method, known as the kerosene-and-whiting test,
was the standard for many years. The sensitivity of the kerosene-and-whiting test could be
increased by hitting the object being tested with a hammer during testing. The resulting
vibration brought more of the kerosene out of the cracks and onto the whitewash. Although
this test was not as sensitive as those derived from it, it was quick, inexpensive, and
reasonably accurate. Thus, it provided a vast improvement over ordinary visual examination.
The first step leading to the methods now available was the development of the fluorescent
penetrant process by R.C. Switzer. This liquid, used jointly with a powder developer, brought
penetrant inspection from a relatively crude procedure to a more scientific operation. With
fluorescent penetrant, minute flaws could be readily detected when exposed to ultraviolet
light (commonly called black light). This development represented a major breakthrough in
the detection of surface flaws.
Switzer's work also included the development of the visible-color contrast method, which
allowed for inspection under white light conditions. Although not as sensitive as fluorescent
penetrant inspection, it is widely used in industry for noncritical inspection. Through the
developments described above, liquid penetrant inspection has become a major
nondestructive inspection method.

Theory :
Nondestructive testing (NDT) is the process of inspecting, testing, or evaluating materials,
components or assemblies for discontinuities, or difference in characteristics without
destroying the serviceability of the part or system. In other words, when the inspection or test
is completed the part can still be used.
In contrast to NDT, other tests are destructing in nature and are therefore done on a limited
number of samples, rather than on materials, components or assemblies actually being put
into service.
These destructive tests are often used to determine the physical properties of materials such
as impact resistance, ductility, yield and ultimate tensile strength, fracture toughness and
fatique strength but discontinuities and difference in materials characteristics are more
effectively found by NDT.
Today modern non-destructive tests are used in manufacturing, fabrication and

Conclusion :
Like all nondestructive inspection methods, liquid penetrant inspection has both advantages
and disadvantages. The primary advantages and disadvantages when compared to other NDE
methods are summarized below.
Primary Advantages

 The method has high sensitivity to small surface discontinuities.

The method has few material limitations, i.e. metallic and nonmetallic, magnetic and
nonmagnetic, and conductive and nonconductive materials may be inspected.
Large areas and large volumes of parts/materials can be inspected rapidly and at low
cost.
Parts with complex geometric shapes are routinely inspected.
Indications are produced directly on the surface of the part and constitute a visual
representation of the flaw.
Aerosol spray cans make penetrant materials very portable.
Penetrant materials and associated equipment are relatively inexpensive.
Primary Disadvantages

Only surface breaking defects can be detected.

Only materials with a relatively nonporous surface can be inspected.
Precleaning is critical since contaminants can mask defects.
Metal smearing from machining, grinding, and grit or vapor blasting must be removed

prior to LPI.
The inspector must have direct access to the surface being inspected.
Surface finish and roughness can affect inspection sensitivity.
Multiple process operations must be performed and controlled.
Post cleaning of acceptable parts or materials is required.
Chemical handling and proper disposal is required.