Penetrant testing (PT) level I slide No.

Penetrant testing
 Penetrant testing (PT) level I slide No. 2

I Working step Scheme Remarks

The defect must lie open towards the

Pre-cleaning
surface and be free if impurities

Apply suitable penetration agent;

capillarity effect cares for penetration of

Remove excess penetrant from the testing

surface, no "washing out" from the defect!
Excess penetrant Testing surface must be dry prior to
removal and developing (Solvent evaporates fast, water
drying takes a longer time); Residuals of solvent
and water influence the developing
Drocess

Penetrant will be sucked, thus defect will

be visible ("bleeding out")

Indication of the defect will be evaluated in

certain periods; suitable conditions (e. g.
Inspection illumination) are required. Notice: Bleed
out is larger than actual defect extent.

Post-cleaning is necessary, if residuals of

Post-cleaning the testing agent may impair the
component, e.g. by corrosion.
 Penetrant testing (PT) level I slide No. 3

General statements for Penetrant testing

Discontinuities have to be open to the surface

in principle independent to material but surface not

excessively porous

important additional test method to magnetic particle testing

which can only be used by ferromagnetic material

indication is not coming equal to the real size of defect, it is a

temporary bleedout
 Penetrant testing (PT) level 1 slide No. 4

Qualification and certification of personnel for non-destructive

testing

A level 1 person is able to carry out tests according to fixed

guidelines while being controlled by a level 2 or level 3
person

A level 2 person is qualified to carry out and to supervise

tests according to accepted standards and specifications.
Additional a level 2 person is able to interpret test results.

A level 3 person is qualified to supervise one or more

activities and to accept responsibilities. A level 3 person is
able to estimate other NDT methods.
 Penetrant testina IPT) level I slide No. 5

Minimum requirement of training hours

for penetrant testing according to EN 473

16h

24h

level 3: no lower limit specified

 Penetrant testinn (PT) level 1 slide No. 6

EN 473 does not specify the subjects of training and

examination - only a minimum of examination tasks is
specified.

Minimum of examination tasks for PT

special
practical part
art

- abilities according to level 1

- abilitytosupervise
15 personnel level 1
- give instructions for
~ersonnellevel 1
 Penetrant testinp 1PT) level 1 slide No. 7

certification

requirements for certification of personnel which is trained,

qualified, practical approved and also physical qualified (vision
of colours and clearness of vision)

The necessary time of experience for PT 1 certification is 1

month - for PT 2 additional 3 month.
 Penetrant testing (PT) level 1 slide No. 8

Each of the particles of a substance (molecule) is attracted by

its neighbouring molecules.

This attraction force is much lower with liquids than with solid
materials, with gases it is very much lower than with liquids.

Therefore, a liquid, e.g. takes every given room. in spite of this

there is a residual cohesion (attraction force) between the liquid
particles. If one is aware of this, a variety of facts can be
explained.
 Penetrant testing (PT) level I slide No. 9

Bikl I. Zum E&teben dtr Oberllkbeappannung.

+ wetting ability

bad + surface tension of the liquid high

+ surface tension of the test object low
 Penetrant testing (PT) level I slide No. 10

drops of water on a leaf - bad wetting ability

pond skater on the water - the surface tension

prevents that it dives into the water.
 Penetrant testing (PT) level 1 slide No. 11

Viscosity is the "toughness" of a liquid

3 highly dependent on the temperature

3 thermal limits of the penetration test

 Penetrant testing (PT) level I slide No. 12

Adhesion

Adhesion means a sticking of different substances one to the

other.

Formation of the drawn up border with water

 Penetrant testing (PT) level 1 slide No. 13

Capillarity

Capillarity with water

 Penetrant testing (PT)level 1 slide No. 14

vapor pressure

small particles (melecules) come out of the surface

of the liquid -the liquid evaporates

Liquid

I high vapor pressure quick evaporation

high temperature high vapor pressure

fl Vapor 1

solvent

solvent:
high vapor pressure
 Penetrant testing (PT) level I slide No. 15

flash point

,,lowest temperature that leads to a sufficient quantity of vapor so that an

ignition is possible"

solvent

low flash point

flammable!
 Penetrant testing (PT) level I slide No. 16

All impurities such as rust, scale, oil, grease, varnish or

contaminations covering the surface imperfections are to be
removed.

removal

or

chemical 3 no residuals which could

influence the testing media
 Penetrant testing (PT) level 1 slide No. 17

Penetration procedure

Immersion, spraying, brushing, pouring

Important: surface must be sufficiently wetted

The penetration time depends on the properties of the

penetrant, the testing temperature, the material and the
defect type:

5 - 60 minutes

testing temperature:
 Penetrant testing (PT) level 1 slide No. 18

removal of excess penetrant from the surface

penetrant from the surface discontinuities!

with water

with solvent

with water and solvent

three-step excess penetrant removal for post-emulsifiable

penetrants using hydrophilic emulsifiers

(emulsifier makes penetrant suitable to be cleaned using water)

3 steps:
coarse removal with H 2 0
application of the emulsifiers (Important: time of
emulsifying!)
cleaning with H20again

Two-step excess penetrant removal for post-emulsifable

penetrants using hydrophilic emulsifiers

2 steps:
Immersion in emulsifier
(Important: time of emulsifying!)
washing off with water
 Penetrant testing (PT) level I slide No. 19

Dwina of the surface

Important:

testing temperature max. 50•‹C

no pressurised air
 Penetrant testina 1PT) level 1 slide No. 20

too thin

Dry developers

Dry developers are to be applied in conibination with

fluorescent penetrant only!

electrostatic spraying, fluidisers ...

solvent based developers

(powder suspendable in a solvent)

spraying (spray tins) or electrostatically

Water soluble developers

developer is slurried in water

uniform concentration of the developer is important (stirring

and mixing processes)

application can be carried out by spraying or electrostatically

 Penetrant testing (PT) level I slide No. 21

the developing process starts as soon as the dry powder

enters into contact with the residual penetrant.

developing time between 10 and 30 minutes

(depending on the testing system used and the extend of the

defects to be proved!)
 Penetrant testina 1PT) level I slide No. 22

inspection

The inspection should be carried out at an illumination strength

of 500 Ix. Surface reflections as well as other reflections should
be avoided.

If fluorescent penetrants re used the surface should tested

using a UV-A radiation source and a radiation intensi f 1000
pWIcm2.

The surrounding radiation intensity should not exceed 20 lx

(darkened). Thus, a certain adaptation time is necessary for the
human eye that in the standards is indicated with 5 minutes.

During the inspection the surface is sought for indications. This

should be done directly after drying of the developer (larger
defects) and then after termination of the developing time
8smaler defects). In individual cases intermediate inspections
may be necessary.
 Penetrant testing (PT) level 1 slide No. 23

Penetrant Excess p e n e t r a n t Devel aper

remaver

Denomination Method Denomination Denomination

-
Fluorescent A Water
penetrant

Colour con- 0 Lipophilic Water s o l u b l e

t r a s t pene- emulsifier
t rant 1 Oil- based
emulsifier Water suspendable
Dual purpos 2 Rinsing
( f 1uoresceo with run-
c o l o u r con- ning water Solvent- based
t r a s t pene- fnon-aqueous w e t )
trant) c Sol v e n t
(liquid)
Water o r s o l v e n t
D Hydrbphi 1 ic based f o r s p e c i a l
emu1 s i f i e r application
1 Optional (e.g. p e a l a b l e de -
prerinse 1 oper)
(water)
2 emulsifier
(water- di-
1 uted)
3 Final rinse
(water)

E Water and
sol vent

NOTE: For s p e c i f i c cases, i t i s necessary t o use penetrant t e s t i n g product

complying with p a r t i c u l a r requirements w i t h r e g a r d s t o flamnabi 1 it y , s u l f u r ,
halogen and sodium c o n t e n t and o t h e r contaminants, see prEN 571-2.

From: EN 571-1
Penetrant testing (PT) level I slide No. 24
 side 1

Penetration Test (PT)

Level 1

Table of Contents

1. Field of application of the testing method

2. Testing personnel

3. Important physical fundamentals

3.1 Cohesion
3.2 Surface tension
3.3 Viscosity
3.4 Adhesion

Description of the process

4.1 General
4.2 Preparation, Pre-cleaning and drying of the test surface
4.3 Penetration procedure
4.4 Intermediate cleaning
4.5 Developing procedure
4.6 Developing time
4.7 Inspection (evaluation of the ...)
4.8 Recording
4.9 Post-cleaning

Testing media (Testing system)

Controlling indicator for determining of the sensitivity of testing

systems
6.1 Test indicator 1 according to EN 571-3
6.2 Test indicator 2 according to EN 571-3

7. General statements on a surface suitable to be tested according

to the penetration test
Enclosure

(1) Sketch control indicator 1

(ii) Sketch control indicator 2
(iii) Main steps of the penetration test
(iv) Example for a test report

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 side 2

1. Field of application of the testing procedure

The penetration test is suitable for proving incompletions such as cracks, pores, lacks of fusion, overlap-
pings etc. that are open towards the surface. The process can be applied on all materials whose surface is
not extremely porous and that are will be affected themselves by the penetration media. The process is
mainly applied on metallic materials such as weld seams, cast and forged components.
The penetration test is particularly applied in technology, on non- magnetisable materials such
as austenitic steels, aluminium alloys, titan etc. Therefore, it can be seen as a supplementary
testing method for magnaflux testing that - as you know - is limited on testing of ferromagnetic
materials only.
Principally, the process enables evaluation, the so called "bleed outs" that do not allow a direct
correlation to the actual extent of the defect and that are different according to time.

2. Testing personnel

For the interpretation of the results, but also for the correct and expert execution of the tests a "suitable"
person is required according to the standard. In Europe a person who has been certified and is qualified
according to EN 473 "Qualification and certification of personnel for non-destructive testing" is regarded
as "suitable".

Qualification can be carried out according to EN 473 depending on the formation, experience
and education in three qualification levels:

Thus, a level 1 person is capable to carry out testing procedures according to a test instruc-
tion and under supervision of personnel of the levels 2 or 3, respectively.

A level 2 person is qualified to carry out the testing procedures according to recognised
procedures and to control them and the to evaluate the test results.

A level 3 person is qualified to supervise one or several activities, to take the responsibility
for them as well as to evaluate the other non-destructive testing procedures.

For the qualification levels minimum requirements for the education are prescribed according to
EN 473. For the penetration test these are:

Level 1: 16 hours
Level 2: 24 hours
For level 3 no minimum education time is obligatory.

Moreover, according to the standards the educational and testing procedures are prescribed,
but also the minimum number of testing questions. For the penetration test the test consisting of
three parts is the following:

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 side 3

Minimum number of test questions:

General part Specific part Practical part

Level 1 30 20 Capability
- Make adjustments
- Operate test equipment
- Record test results

Level 2 - Capabilities like level 1

- Capability to elaborate
instructions for level 1
persons

The prerequisite for the certification of testing personnel is the above mentioned education with a passed
qualification examination, the proof of a practical experience and a physical approbation test (capability
to see close, capability to see colours).
The required experience for the PTI certification amounts to one month, for PT level 2 addi-
tional 3 months.

3. Important phvsical fundamentals

3. I Cohesion

Each of the particles of a substance (molecule) is attracted by the neighbouring molecules. This attraction
force is much lower with liquids than with solid materials, with gases it is very much lower than with
liquids. Therefore, a liquid, e.g. takes every given room. In spite of this there is a residual cohesion (at-
traction force) between the liquid particles. If one is aware of this, a variety of facts can be explained.

3.2 Surface tension

As already mentioned is every molecule of a substance attracted by its neighbouring molecules. Therefore
the molecule MI will equally exert a load to all sides, i.e. the forces acting on the molecule will compen-
sate each other. On each force a counterforce is exerted. The molecule M2 is not uniformly exerted any
more, because it is near to the surface, thus there are no neighbouring molecules for the counterbalance.
In this regard the molecule M3 is extreme because it is very close to the surface and therefore the attrac-
tion forces act on the interior only (tension). These traction forces are called surface tension. They try to
decrease the surface, a typical example for this being the droplet formation of water. Further, these proc-
esses explain the fact that e.g. an insect can walk on the water surface.

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 side 4

Fig. 1: Formation of surface tension

The wetting liquid of a testing liquid on a surface thus is dependent on the surface tension. A low surface
tension of a liquid is therefore the prerequisite for a good wetting ability. Further, the viscosity of a liquid
and the surface roughness are decisive for the wetting ability.

3.3 Viscosity

As viscosity the "toughness" of a liquid is meant. It is a dynamic property of a substance characterising

the flux resistance. Decisive for the penetration test is that the viscosity is highly dependent on the tem-
perature, thus explaining the thermal limits depending on the temperature for the process.

At the border surfaces to solid bodies, e.g. walls of a container, the molecules of a liquid are subject to
forces that are produced by the molecules of the walls. This "sticking" of different substances one to the
other is called adhesion. These adhesion forces are of importance e.g. with lubricants on metallic tread
surfaces, bearings etc.
If one observes the conditions of a liquid molecule at a wall of a container, the adhesion force acts to-
wards the exterior and the already described cohesion force towards the interior. Is the adhesion force
larger than the cohesion force, what is mostly the case, a meniscus will be formed (see figure).

Fig. 2. Formation of the border drawn up with water

In narrow tubes the effect can be as large as the liquid in the tube rises, i.e. according to the above men-
tioned the higher, the more narrow the tube is. Narrow tubes are also designated as capillaw tubes. The
rising of a liquid in a narrow aperture is called capillaritv. One example of this is the sucking effect of a
sponge or the capillar feeding system of a plant.

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 s side 5

Fig. 3 "capillarity" with water.

4. Description of the process

4.1 General

Prior to the penetration test a "surface suitable to be tested" must ble arranged, i.e. the surface is to be
cleaned and dried in such a way that all defects lie open towards the surface. After that a suitable penetra-
tion agent that has the property to penetrate in fine irregularities opened towards the surface ( e g pores,
cracks) will be applied. After a suitable penetration time, the penetration agent will be removed from the
surface (excess penetrant removal). Just this process has to be carried out both very carefully and cau-
tiously in order to avoid wash outs of the penetrant from the incompletions. After that the developer will
be applied that absorbs the residual penetrant thus making it apparent (bleed out !).
In order to secure that the surface is suitable for the penetration test, this procedure should always be ap-
plied as the first testing method used.
Principally the following working steps are required for the application of the testing method:

a) Preparation and pre-cleaning of the surface to be tested

b) Penetration procedure
c) Excess penetrant removal
d) Developing process
e) Inspection
f ) Recording
g) Post-cleaning

(see also enclosure (iii), scheme DIN 5 71-1, appendix A)

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Table 1 Testing procedure with penetration processes

Working step Scheme Remarks

The defect must lie open towards the sur-

Pre-cleaning
face and be free if impurities

Apply suitable penetration agent; capillar-

Penetration
ity effect cares for penetration of the test
procedure agent

Remove excess penetrant from the testing

surface, no "washing out" from the defect!
Excess penetrant Testing surface must be dry prior to devel-
removal and dry- oping (Solvent evaporates fast, water
ing takes a longer time); Residuals of solvent
and water influence the developing proc-

Penetrant will be sucked, thus defect will

Developing
be visible ("bleeding out")

Indication of the defect will be evaluated in

certain periods; suitable conditions (e. g.
Inspection illumination) are required. Notice: Bleed
out is larger than actual defect extent.

I Protokoll I
Recording
u
Post-cleaning is necessary, if residuals of
Post-cleaning the testing agent may impair the compo-
nent, e.g. by corrosion.

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 side 7

4.2 Pre~aration,Pre-cleaning and drying

- o.f the surface to be tested

All impurities or surface overlays such as rust, scale, oil, grease, varnish or contaminations covering the
surface imperfections sought for or influencing the testing media are to be mechanically orland chemi-
cally removed.
In particular with mechanical cleaning of the surface it has to be paid attention to the fact that the surface
will not be compacted like with e.g. blasting processes. The surface defects sought for must necessarily
lie open and be free of contaminations. With the chemical pre-cleaning it is important that all residuals
influencing the testing media as well as the residuals such as grease, oil, varnish or pickling agents are
removed (see also item 7).
By means of sufficient drying it must be obtained that neither water nor any kind of solvent have re-
mained inside the surface irregularities,

4.3 Penetration test

The penetration agent can be applied to the surface to be tested by means of immersion, spraying, brush-
ing or pouring to the surface to be tested. It is important that the surface is sufficiently wetted.
The penetration time is dependent on the properties of the penetrant, the testing temperature, the material
and the defect type and extent to be proved. It amounts to 5 - 60 minutes and should be determined either
in the test instructions or by means of sensitivity tests.
The testing temperature (the temperature of the surface to be tested is referred to) must neither be too low
(under 5•‹C) nor too high (over 50•‹C). With testing temperatures too low the water in the irregularities
may condense or the viscosity of the penetrant may be negatively influenced, with temperatures too high
drying out processes may occur.

4.4 Excess penetrant removal

The excess penetrant removal serves to remove the penetrant from the surface to be tested. The most im-
portant with this process is to avoid washing out processes of the penetrant from the surface irregularities.
An expert excess removal requires to consider the surface structure, the defect geometry and the proper-
ties of the testing agents. Smooth surfaces and flat defects with large openings require special care and
increase the peril of wash outs.

With relation to the penetrant used it is distinguished between:

4.4.1 Excess removal using water

Here, by means of careful spraying or wiping with a moist and suitable sloth the excess water soluble
penetrant must be removed.

4.4.2 Excess penetrant removal using a solvent

First, the penetrant should be coarsely removed from the surface using a lint free cloth. It can be post-
cleaned using a cloth soaked with a solvent. Special attention has to be paid, if the solvent is directly
sprayed to the surface to be tested (never vertically).

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 side 8

4.4.3 Excess penetrant removal using both, water and solvent

First, the penetrant will be removed using water, then using a lint free cloth, soaked with a solvent.

4.4.4 Three-step excess penetrant removal for post-emulszjiable penetrants using hydrophilic emulsiJi-
ers

Penetrants of this type are to be made suitable to be cleaned with water using an emulsifier. Also here a
coarse pre-cleaning with water make sense, in order to remove a large part of the excess penetrant. After
that the emulsifier will be applied. Here, it is important that the emulsifier does not operate too long. Also
here the emulsifying time should be kept according to the indications made by the manufacturer or it
should be determined by trials carried out prior to the test. After emulsifying it must be cleaned with wa-
ter again.

4.4.5 Two-step excess penetrant removal for post-emulsifiable penetrants using lipophilic emulszjiers

The contact with the emulsifier can be obtained here by immersion only. As already stated under 4.4.4 the
contact time is important here, too and should be prescribed or determined in pre-trials, respectively.
Immediately after emulsifying it must be washed off. Thus, the process contrary to 4.4.4 consists of two
steps only.

4.4.6 Control of a sufficient excess penetrant removal

After the excess penetrant removal it must be controlled that no penetrant removals remain on the test
surface. With a fluorescent penetrant this can be carried out using a UV-A radiation source (radiation
force > 300 pW / m2). With coloured penetrants control is more difficult (possibly using a clean cloth). It
is essentially better, however, to leave a small amount of penetrant on the surface than to take the risk to
have a wash out.

4.4.7 Drying of the surface prior to applying the developer

Drying of the surface important prior to the application of the developer in this case only where the de-
veloper is not based on water can be carried out using clothes, air flux, condensation, elevated tempera-
ture, or a combination of these. With pressurised air it has to paid attention to the fact that it is free from
water and oil and the pressure is as low as possible.
Drying over the max. Testing temperature of + 50•‹Cis not allowed.

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4.5 Developing ~rocedure

Directly after the expert excess penetrant removal as well as drying the developer will be applied uni-
formly thin onto the testing surface. The application of the developer layer too thick can lead to a bad
indication, an application too thin reduces the indication sensitivity.

--.-... - _...
....*-....,T

-T .T-
: . ; ; .+;

too thin right too thick

4.5.1 D v developers

Dry developers are only to be applied in combination with fluorescent penetrants. In this case, the devel-
oper will as uniformly as possible be powdered onto the surface. This can be done with the help of elec-
trostatic spraying appliances, fluidisers or similar systems.

4.5.2 Solvent based developers

In this case a uniform and thin application of the developer (a powder suspendable in a solvent) onto the
testing surface is necessary using spraying. This can be carried out using spray tins, refillable pressure
vessels or electrostatically.

4.5.3 Water soluble developers

With developers of this kind the developer powder is either solved in water or slurried. It is to paid atten-
tion to the fact that the concentration of the developer maintains uniform upon the stirring and mixing
processes. Application can also be carried out by spraying using air or electrostatically.

4.6 Developing time

The developing process starts as soon as the dry powder enters into contact with the residual penetrant,
i.e. the carrier liquid of soluble developers has evaporated or has been dried.
Usually, the developing time is between 10 and 30 minutes. In special cases longer developing times may
be agreed upon (depending on the testing system used and the extent of the defects to be proved).

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4.7 Inspection (Evaluation o f the indication)

The inspection should be carried out at an illumination strength of 500 lx, if colour contrast penetrants are
used. Surface reflexions as well as other reflexions should be avoided, if possible.

If fluorescent penetrants are used the surface should be tested using a UV a radiation source and a radia-
tion intensity of 1000 pW 1 cm2.

The surrounding radiation intensity should not exceed 20 lx (darkened). Thus, a certain adaptation time is
necessary for the human eye that in the standards is indicated with 5 minutes.

During the inspection the surface is sought for indications. This should be done directly after drying of
the developer (larger defects) and then after termination of the developing time (smaller defects). In indi-
vidual cases intermediate inspections may be necessary.

4.8 Recording

An example of the recording is proposed in EN 571-1, appendix B and should be regarded as a sample
record.
The testing results can be recorded by means of a sketch, using an adhesive tape, by photos or by videos.
It is important that the record beside of a clear identification of the component is designed in such a way
that it can be repeated under the same circumstances at any time. The verbal description of the indication
is often difficult. Here, a photography is often the better possibility to show the significance of an indica-
tion.

4.9 Post cleaning

Is to be expected that possible residuals of the testing media may have a negative impact on the compo-
nent or its application (e.g stress corrosion cracking or fatigue crack corrosion) a post cleaning of the
testing surface is required.

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 side 11

5. Testing devices (testing svstem)

The combination penetrant, excess penetrant remover, and developer is called the testing system. The
individual components of the testing system should match and be manufactured by the same supplier. The
testing systems are subject to a neutral sample testing according to EN 571-2.

Penetrant Excess p e n e t r a n t Developer

remover

Denomination Method Denomi na ti on Form Denomi n a t i o n

Fluorescent A Water
penetrant

C o l o u r con- 8 Lipophilic Water s o l u b l e

t r a s t pene- emulsifier
trant 1 Oil- based
emulsifier Water suspendable
Dual purposi 2 Rinsing
( f l uorescen. w i t h run-
c o l o u r con- ning water S o l vent- based
t r a s t pene- (non-aqueous w e t )
trant) C Solvent
(1i q u i d )
Water o r s o l v e n t
D Hydrophil i c based f o r s p e c i a l
emulsifier applic a t i o n
1 Optional (e.g. p e a l a b l e de-
prerinse 1o p e r )
(water)
2 emulsifier
(water-di -
1u t e d )
3 Final rinse
(water)

E Water and
sol vent

NOTE: F o r s p e c i f i c cases, i t i s necessary t o use p e n e t r a n t t e s t i n g p r o d u c t

complying w i t h p a r t i c u l a r requirements w i t h regards t o f l a m n a b i l i t y , s u l f u r ,
h a l o g e n and sodium c o n t e n t and o t h e r c o n t a m i n a n t s , see prEN 571-2.

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 side 12

Examples for testing device systems:

I1 - Colour contrast penetrant

E - Excess penetrant remover water and solvent
D - Solvent based developer

I1 - Colour contrast penetrant

A - Excess penetrant remover water
D - Solvent based developer

6. Reference block for determining the sensitivitv o f the testing svatems

6.1 Reference block 1 according- to EN 571-3 for controllina the sensitivity o f fluorescent and coloured
penetrants
(Reference block for sample testing)

The reference block 1 consists of one set of 5 brass plates that are coated with a Cr layer of 5, 10, 20, 30,
and 50 pm. By means of longitudinal stretching of the plates transversal cracks in the coating are gener-
ated.
 side 13

The sensitivity of fluorescent penetrants will be determined using plates with a coating thickness of 5, 10,
20, and 30 pm. The sensitivity of the colour penetrant systems can be tested using plates with a layer
thickness of 30 and 50 pm.

6.2 Reference block 2 according to EN 571-3 for periodical testing o f fluorescent and coloured pene-
trants.
(Reference block for the user)

The reference block 2 consists of a 2.5 mm thick basic plate made of X3 CrNiMo 17-12 (stainless steel).
One side of the plate consists of four fields that are treated at a different roughness, the other side is
coated using a NiCr layer (layer thickness 60 pm). From the counterpart of the coating semi-spherical
impressions using a Vickers hardness testing device or similar have been put into that depending on the
extent of the spherical impression generates differently large artificial cracks in the plating.

On the differently rough surfaces it can be tested at which roughness degree strong background indica-
tions exist during the liquid penetrant testing.

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 side 14

7. General remarks on a surface suitable to be tested according to the penetration test

Of course, it is difficult to describe a surface suitable to be tested in Ra values. One example in this regard
is the scaled weld joint with a certain undercut zone in the transition areas to the parent metal. Here, the
testing personnel has to decide whether the existing surface can be tested or if it has to be mechanically
optimised. Due to the fact that on the one hand these appearances are bad to be described verbally and on
the other hand cannot be indicated using Ra values, reference series of natural weld joint surfaces in the
shape of surface impressions are recommended.
Such a reference series exists e.g. as DVS sheet 0709 with a sample catalogue of weld joint surfaces.
Here, limit cases for the usability of the penetration test are shown with the help of weld joint surfaces.
Should it be necessary to post-treat a surface to be tested the working procedure has to be chosen in such
a way that no negative influence on the testing procedure will take place. A contact pressure of the tool
too high can lead to a plastic deformation of the surface and thus to a closure of the cracks. In this case, it
is possible to superficially close a crack using a blunt chisel. Moreover, it should always be paid attention
to the fact that the surface is always be ground perpendicular to the direction of the crack to be expected,
in order to avoid the risk of "smearing" the crack opening by grind dust etc.

O 2002 SLV Duisburg - Niederlassung der GSI mbH

No reproduction without prior permission!
 side 15

Enclosure (iii) Main stem of the ~enetrationtest

IP r e p a r a t i o n and p r e c f e a n i n g f
I

washable pene- s i f i a b l e pene- removable pene-

t r a n t and allow t r a n t and a l l o w t r a n t and a l l o w
contact time
I

1-1
[ Wate'r and s o l venq 1 1 solvin,t remover 1

Water spray r i n s e e m u l s i f i e r and

a l l o w contact

Apply hydrophilic
emu1 s i f t e r and

e
-
Excess e n e t r a n t remover check

r
DryI 1
I
Apply w a t e r Apply w a t e r
s o l ubl e suspendable
d e v e l o er [ developer I

& A1 l o w t o d r

Ins ect

j Clean I

O 2002 SLV Duisburg - Niederlassung der GSI mbH

No reproduction wlthout prlor perrn~ss~onl
 side 16

Enclosure (iv) Example for a test report

Test report
Company: Order No.:
Department: Sub-order no.:
Penetration test
Test report no.: Sheet
Project: Component:
Customer: Manuf. No.:
Order no. Customer: Drawing no.:

Part to be tested: (fbrther indications such as:

Welding plan no.: Testing sequence plan no.:
Welded joint no.: Sheet no.:
Block no.: Part no.:
Cast no.: Model no.:)
Surface quality:
Temper:
Pre-treatment:

Specification (e.g. testing instructions, conditions of supply)

Testing scope:
Penetration system:
Short character: (further indications such a e.g. free of corrosive constituents acc. to EN 571-2)
Manufacturer:
Product designation:
Penetrant: Charge no.:
Excess penetrant remover: Charge no.:
Developer: Charge no.:

Execution

Testing temperature: Excess penetrant removal: (Further indications such as e.g.

Conservation)
Precleaning: Emulsifying time:
Drying: Drying:
Penetration time: Developing time:
Postcleaning:

Deviations from the testing specification:

Deviations from EN 571-1

Test result: (e.g. indications on: Defect position, defect type, defect distribution, defect extent,
number of defects, sketch)

Test site: Test date: Tester:

Judgement according to: (Test specification) admissible: non admissible:

Remarks:

Responsible tester: Certification: Date: Signature:

Possibly
Ordering persodexpert: Date: Signature:
Possibly
Acceptance institute: Date: Signature:

O 2002 SLV Duisburg - Niederlassung der GSI rnbH

No reproduction without prior permission!