Introduction to Liquid Penetrant Testing

Nail W S / TVE 2
 Liquid Penetrant Testing
• Is a non destructive means of
locating surface discontinuities based
on capillarity (entry and exit)
• It can’t “see” what’s below but can
relatively assess the discontinuity by
measuring indications on the surface
and compare it with the manual
• Parts inspected must free of coating
and contaminant (dirt, grease, rust,
scale, acids, etc.) that can block
penetrant to penetrate into
discontinuity
 Liquid Penetrant Testing (continue)
• Penetrant testing can be applied to most of materials including
metallic and non metallic objects
• Metallic materials include aluminum, magnesium, titanium, cast iron,
stainless steel, powdered metal products, copper, brass, bronze, etc.
• Non metallic materials include ceramics, plastic, molded rubber,
composites, glass, etc.
• Penetrant testing can’t be applied on a porous surface
 Penetrant Testing History
• Penetrant first used in 1900s to detect cracks in locomotive parts
• The method was called oil and whiting
• The method used dirty lubricating oil that was thinned with kerosene followed
by application of chalk coating which absorbed oil from the cracks
• In 1940s fluorescent or visible dye was added to the oil
 Principles
• Clean & dry test object
• Apply penetrant and let it penetrate
• Remove excess penetrant
• Apply developer
• Evaluate indications
• Post clean test object
 Penetrant Categorization
By dye type:
• Visible dye
• Fluorescent
• Dual sensitivity
By process
• Water washable
• Post emulsifiable
• Solvent removable
 Penetrant Classification System
Type Method Sensitivity Level Developer Solvent Class
I, Fluorescent A, WW 1/2, Ultra low Form a, Dry powder 1, Halogenated
II, Visible B, Lipophilic PE 1, Low Form b, Water soluble 2, Non halogenated
C, SR 2, Medium Form c, Water suspendible 3, Special application
D, Hydrophilic PE 3, High Form d, Non aqueous type I
4, Ultra high Form e, Non aqueous type II
Form f, Special application
 Water Washable / WW
• Have a built in emulsifier,
easily removed by water
rinse
• Typical rinse procedure
are (refer to manual):
Pressure < 40 psi
Temperature 10o - 38o C
Angle 45o - 75o
 Water Washable / WW (continue)

• Use on articles with a rough

surface or if they contain
threads or keyways
• Poor reliability in detecting
wide or shallow discontinuities
 Post Emulsifiable / PE
• Not contain emulsifying agent, not
soluble in water
• Emulsifier applied to remove excess
penetrant by dipping, spraying, or
flowing
• Emulsifier dwell time is 1 - 4 minutes
(refer to manual)
• Penetrant – emulsifier mixture is
removed by water rinse
• There are 2 types of emulsifier,
lipophilic (method B) and hydrophilic
(method D)
 Lipophilic Emulsifier
• Mechanism of lipophilic emulsification is by diffusion
• Both molecules of emulsifier and penetrant penetrate each other to
form a washable mixture
• Rate of diffusion increases as concentration and temperature raised
 Hydrophilic Emulsifier
• Is a water based solution, mixture of chemical called surfactant
• Works based on principle of peeling the penetrant
• Need pre-rinsing prior to emulsifier application to help remove 60 –
80 % penetrant and provide an even surface
• Applied by immersion or spraying
 Solvent Removable / SR
• Use post-emulsification penetrant
• Instead of using emulsifier and water
wash, excess penetrant is removed by
solvent
• SR penetrant is portable and suitable for
field application
• Solvent is never applied directly to the
specimen as it might wash out the
penetrant inside the discontinuity
 Consideration in Choosing The Process
Selection of the process depends Penetrant sensitivity ranking:
upon: • PE - Fluorescent
• Sensitivity required • SR – Fluorescent
• Number of articles to be tested • WW – Fluorescent
• Surface condition of parts • PE – Visible
• Configuration of test specimen • SR - Visible
• Availability of water, electricity, • WW - Visible
compressed air, suitable testing
area, etc.
 Pre Cleaning
• Effectiveness of penetrant testing is based upon the ability of
penetrant to enter surface discontinuities
• All paint, carbon, oil, varnish, oxide, plating, water, dirt, etc. must be
removed before application of penetrant
• Typical cleaning methods are detergent cleaning, vapor degreasing,
steam cleaning, solvent cleaning, rust & surface scale remover, paint
removal, etching, UT cleaning, mechanical cleaning, etc.
 Penetrant Application
• Penetrants, either fluorescent or visible can be applied by spraying, brushing or
swabbing, dipping, or flowing. It depends on the process required in the manual.
 Penetration (Dwell) Time
• Is the period of time during which the penetrant is permitted to
remain on the specimen. It will be vary according to the manual.
• It’s influenced by material type, product form, type of discontinuity,
and method applied
• Tight, crack-like discontinuities may require in excess of 30 minutes
for penetration to an extent that an adequate indications appears
• Gross discontinuities may be penetrated in 3-5 minutes
• Warming the specimen to a limited heat can reduce dwell time
 Developers Application
• Developer is a highly absorbent
powder that will draw penetrant from
discontinuity with capillarity principle
• Some indications may be visible prior
to application of developer, this step
will ensure that all discontinuities
visible to naked eye
• There are 2 types of developer, dry &
wet
• Wet developer further divided into 2,
non-aqueous & water-base
 Developer Application Guidelines
Water-base wet Non-aqueous wet Dry Developer
• On very smooth surface • Spot check or field • On rough surface
application • On sharp fillets, holes, and
• When testing large number
of small, irregularly-shaped • On vertical surface, to give threaded articles
articles even film of developer • On very large articles
• To wide & shallow • When greatest sensitivity
discontinuities, to give even is needed
film of developer
 Indications Interpretation
• During interpretation, cause of bleed out and severity of indications
must be determined
• Indications are classified as false, non relevant, and relevant
False indications: Come from poor washing, poor processing, lack of
cleanliness in inspection booth, etc.
Non relevant indications: Caused by surface irregularities or parts
configuration / design (press-fitted, keyed, splined, riveted, scale,
rough surface, etc.)
Relevant: Caused by discontinuities. Must be evaluated according to
appropriate manual. Analysis should be made to correct and prevent
such discontinuities to repeat again in the future
 Example of Indications

Typical procedure required a UV light with minimum 38 cm intensity of 1000 μW/cm2 to be

used with white light not more than 20 lux inside inspection booth
 Post Cleaning
• A thorough post cleaning is necessary because penetrant and
developer residue tend to attract moisture which may cause
corrosion
• Post cleaning usually use same method as pre cleaning
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