FAKULTI TEKNOLOGI KEJURUTERAAN

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MATERIAL TESTING AND FRACTURE ANALYSIS

BETP 3573 SEMESTER 2 SESSION 2015/2016

LAB 1: COLOUR CONTRAST PENETRANT TEST

NAME OF GROUP 1.
MEMBERS &
MATRIX NUMBER
2.

3.

4.

COURSE 3 BETP

DATE

NAME OF INSTRUCTOR 1. NOORIRINAH OMAR

2. MR. AZIZUL IKHWAN BIN MOHD

TOTAL MARKS VERIFICATION STAMP

RESULTS: / 25
DISCUSSION : / 15
CONCLUSIONS / 10
REFERENCES: / 15
QUESTIONS: / 35 EXAMINER’S COMMENT

TOTAL MARKS: / 100

 JTKP/ BETP 3573

1.0 OBJECTIVES

This experiment is aim to:

1. Perform visible Color Contrast Penetrant Test using Solvent Removable
Method on welded plates to detect surface discontinuities as per ASTM
E165.
2. Characterize the defect(s) of welded plates as per ASTM E165.

2.0 LEARNING OUTCOMES

At the end of this laboratory session, students should be able to:-

a) Carry out sample preparation to remove any kind of contaminants on test

samples.
b) Detect surface breaking discontinuities present on welded plates using
visible dye penetrant in the area of interest.
c) Report the surface breaking discontinuities by sketching at exact location
including size, length and location of defects detected.
d) Evaluate the parameters that affects the sensitivity and reliability of testing
method.

3.0 THEORY

Dye penetrant inspection (DPI), also called liquid penetrant inspection (LPI) or
penetrant testing (PT), is a widely applied and low-cost inspection method used to
locate surface-breaking defects in all non-porous materials (metals, plastics, or
ceramics). The penetrant may be applied to all non-ferrous materials and ferrous
materials; although for ferrous components magnetic-particle inspection is often
used instead for its subsurface detection capability. LPI is used to detect casting,
forging and welding surface defects such as hairline cracks, surface porosity, leaks
in new products, and fatigue cracks on in-service components.

The principle is to apply liquid penetrant on the surface and is drawn into surface
defects by capillary action. Once a preset dwell time has passed, excess penetrant

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is removed and developer is applied to draw out penetrant from defects. Visual
inspection is then performed to inspect the present of any discontinuities of defects.

The surface should be free from foreign materials and paint as it would significantly
affect the quality of the test results. Grease, oils and paint prevent penetration and
should be removed by pre-cleaning. Scale, sand, dirt will trap penetrant and hinder
penetrant removal, therefore wire brushing is necessary.

PT can be classified according to sensitivity level (type of penetrant), method of

penetrant removal and type of developer. It will generate the PT system that will suit
the type of application. One of the PT system available is Colour Contrast Penetrant
Test using Solvent Removable Method. It is a method that only requires adequate
visible light and the defect can be detected through the existence of red dye on a
white develoepr background. This method is very portable as all the consumables
are in a form of aerosol cans.

4.0 EQUIPMENT / MATERIAL

I. Mechanical wire brush,

II. Lint-free cloth/paper towel,
III. Solvent cleaner,
IV. Red dye penetrant,
V. Developer,
VI. Vernier caliper,
VII. Ruler,
VIII. Welded plates (DPT no 1, 14 and 21).

** CAUTION
Wear appropriate PPE such as safety shoe, safety glass, glove and dust mask
while handling the chemicals.

5.0 PROCEDURES

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1. Surface Preparation / Pre cleaning

i) Clean the part area of interest (Figure 1) with the suitable wire brush
within at least 25.4 mm from left and right of the weldment . The
weldment shall be free from dirt, loose scale and spot paint.
ii) All spatters, slag and any other extraneous matter shall be removed
within area of interest.
iii) Shake the solvent cleaner can gently; apply cleaner to the surface to
remove any contaminants eg. oil, grease.

Figure 1: Pre-cleaning of welded sample

2. Application of Penetrant
i) Shake the pentrant can gently and spray on the area of interest along
the weldment until uniform red thin layer formed on it.
ii) Allow for the penetrant to soak into any flaws. Record the dwell time.
(NOTE: Wait for almost 10 minutes)

3. Excess Penetrant Removal

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i) Spray the solvent removal on lint-free cloth.

ii) Wipe off all the visible penetrant.
iii) It is important that the solvent removal is not spray on the surface
directly as it can remove the penetrant from the defects.

4. Application of Developer
i) Shake the developer can gently and spray on the area of interest
along the weldment until uniform white thin layer formed on it.
ii) Allow for the developer to draw penetrant from defects out onto
surface until a visible red indication can be observed. Record the
developer time. (CAUTION: Do not wait more than 10 minutes)

5. Inspection
i) Bring the sample for visual inspection under adequate illumination
intensity.
ii) Observe and record the true indications for their size, length and
location from the reference point of the test piece.

6. Post-Cleaning
i) Clean with solvent cleaner the surface completely upon finished the
inspection until all the residues of the dye penetrant and white
contrast developer have been removed.
ii) Check the part of interest for any chemical residual left. The chemical
residues should be removed from the part by mechanical cleaning, if
necessary. Then dry the part of the specimen.
iii) Repeat step 1 to 5 for other specimen.

6.0 EXPERIMENTAL DATA

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Record the following details in your report (10 marks):-

i) Penetrant Type : …………………………………….
ii) Developer Type : ………………………………………
iii) Solvent Cleaner Type : ……………………………………………
iv) Pre-cleaning Method : ……………………………………………
v) Penetrant Application Method : ……………………………………..
vi) Dwell Time : ………………………………………….
vii) Removal Method : ……………………………………..
viii) Developer Time : ………………………………….
ix) Illumination Technique : ……………………………………
x) Post-cleaning Method : …………………………………………

SKETCH ** For better image, please use your handphone’s camera.

Sketch the diagram as depicted in Figure 1 and indicate the position, size and
length of defect(s) found on the welded plate (15 marks).

7.0 DISCUSSIONS ** Based on your experimental results (15 marks)

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Write your discussions about this experiment (Less than 200 words)
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8.0 CONCLUSION (10 marks)

Give the conclusion and summarize the main findings of this laboratory work.
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9.0 REFERENCES (15 marks)

List at least two references.

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10.0 QUESTIONS (35 marks)

1) What are the characteristics of color penetrant test?

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2) What is dwell time ?

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3) What is the advantages of using Color contrast penetrant test?

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4) Give the disadvantafes of using Color contrast penetrant test?

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