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Rolls Royce - Aerospace Process Specification RRP 58003

Fluorescent Penetrant Inspection (FPI)

Scope:

The developer determines an indicator’s brightness to be applied. On the other hand, this
approach substitutes filter paper for the developer to measure the brightness of a penetrant.

Color-correcting the brightness measurement makes it more representative of what an average

human eye would see. This figure has greater practical relevance than a measurement in units of
energy output, as human eyes do the most evaluation. Due to the lack of an absolute measuring
technique, the comparisons are also presented as a % of the specified reference penetrant in this
test method of ASTM E1135.

Table of Content

 Importance of Fluorescent Penetrant Testing

 Selecting the Correct Penetrant Method per AMS 2644
 Differences Between Sensitivity
 Common Terms in Fluorescent Penetrant Testing
 Key Takeaways
 FAQs

Fluorescent Penetrant Testing (FPT), also known as Dye Penetrant Inspection (DPI) or Liquid
Penetrant Testing (LPT). It is a widely used NDT method used to detect surface defects in
various materials, including metals, plastics, and ceramics. This NDT method has been a
cornerstone in ensuring the integrity of various components and materials. Let's delve into the
significance of Fluorescent Penetrant Testing and explore how it plays a crucial role in
maintaining high-quality standards.

Importance of Fluorescent Penetrant Testing

Fluorescent Penetrant Testing is a crucial NDT Method used in various industries to detect
surface defects and discontinuities in materials and components. This technique involves
applying a liquid penetrant to a material's surface, wiping away any excess penetrant, and then
applying a developer. The penetrant seeps into any surface discontinuities, making them
visible for inspection.

Here, we will discuss the importance of Fluorescent Penetrant Testing, the selection of the
correct penetrant method according to AMS 2644 standards, differences in sensitivity, and
common terms associated with this technique.

1. Defect Detection

FPT is highly effective in detecting surface cracks, porosity, weld defects, and other surface
irregularities that may compromise the integrity of a material or component. Detecting these
issues early helps prevent catastrophic failures.

2. Cost-Effective
Compared to other methods like radiography testing or ultrasonic testing, LPI is generally more
cost-effective and can be applied to a wide range of materials.

3. Versatility

It can be used on various materials, including metals, plastics, ceramics, and composites,
making it a versatile method for quality control and inspection.

4. Non-Destructive

It is non-destructive, meaning it does not harm the inspected part, making it suitable for both
production and in-service inspection.

5. Surface and Subsurface Detection

While the Fluorescent Penetrant Test primarily detects surface defects, it can also identify
subsurface discontinuities when used in combination with other NDT Techniques.

Selecting the Correct Penetrant Method per AMS 2644

To make sure FPT works well and is reliable, AMS 2644 says you need to think about several
things when choosing the right penetrant method. AMS 2644 is a standard that provides
guidelines for choosing the appropriate penetrant method based on specific inspection
requirements. Here's a simplified guide to this selection process.

1. Material Type: Determine the type of material being inspected, as this can influence the
choice of penetrant. Some penetrants are better suited for specific materials, such as metals,
plastics, ceramics, or composites.

2. Defect Size and Type: Assess the expected size and nature of the defects you need to
detect. Larger defects may be visible with standard penetrants, while smaller or more subtle
defects may require fluorescent penetrants for enhanced sensitivity.

3. Sensitivity Requirements: Define the level of sensitivity required for your inspection. If you
need to detect very fine cracks or defects, a fluorescent penetrant with higher sensitivity may
be necessary. For larger, more visible defects, a visible penetrant may suffice.

4. Lighting Conditions: Consider the lighting conditions under which the inspection will be
conducted. If inspections will occur under normal white light, visible penetrants are
appropriate. For inspections conducted under ultraviolet (UV) or black light, fluorescent
penetrants are needed.

5. Regulatory or Customer Requirements: Ensure compliance with any specific regulations or

customer specifications that dictate the penetrant method to be used.

Some industries or applications may have strict requirements for NDT methods.

6. Compatibility: Confirm that the selected penetrant is compatible with the material being
tested and with any subsequent steps in the inspection process, such as the developer and
cleaner.

7. Environmental Considerations: Consider environmental factors such as temperature,

humidity, and cleanliness of the inspection area, as they can impact the choice of penetrant.
8. Operator Training: Ensure that the inspection personnel are adequately trained and
certified to perform LPI using the selected penetrant method.

Types of Penetrants as per AMS 2644:

Based on these considerations, you can choose between two primary types of penetrants as
per AMS 2644:

1. Type I (Visible Penetrant): These penetrants are colored and provide visible indications on
the surface. They are suitable for detecting larger defects and are used in inspections
conducted under normal white light.

2. Type II (Fluorescent Penetrant): These penetrants contain fluorescent dyes and are used in
conjunction with a UV (ultraviolet) light source. They offer higher sensitivity and can detect
smaller defects that may not be visible to the naked eye under standard lighting conditions. By
choosing the right FTP method according to AMS 2644, the inspection can be made to fit the
material and flaws being looked at. This gives accurate and reliable results for NDT.

Differences Between Sensitivity

The term "sensitivity" in the context of Liquid Penetrant Inspection (LPI) refers to the ability of
the inspection method to detect smaller or more subtle defects on the surface of a material or
component. Sensitivity levels can vary depending on the type of penetrant used and the
inspection conditions.

Here are the key differences between sensitivity levels in LPI:

1. Visible Penetrant (Type I)

Sensitivity: Visible penetrants, also known as Type I penetrants, have lower sensitivity
compared to fluorescent penetrants.

Detection Capability: They are effective in detecting larger defects and surface irregularities
that are visible to the naked eye under normal white light.

Inspection Lighting: Visible penetrants are used in inspections conducted under standard
white light conditions, which are similar to regular ambient lighting.

Indications: Defect indications created by visible penetrants are typically visible as coloured
markings on the surface. These indications can be seen without the need for special UV
lighting.

2. Fluorescent Penetrant (Type II)

Sensitivity: Fluorescent penetrants, or Type II penetrants, offer higher sensitivity compared to

visible penetrants.

Detection Capability: They can detect smaller defects and discontinuities that may not be
visible to the naked eye. This increased sensitivity makes them suitable for finding finer cracks
or flaws.
Inspection Lighting: Fluorescent penetrants require inspection under ultraviolet (UV) or black
light conditions. The fluorescence emitted by the penetrant when exposed to UV light makes
defects stand out more clearly.

Indications: Defect indications produced by fluorescent penetrants are typically glowing or

brightly coloured when viewed under UV light. This fluorescence enhances the visibility of
defects.

Common Terms in Fluorescent Penetrant Testing :

Here are the common terms in Fluorescent Penetrant Testing.

Background: The surface against which the indication is viewed can be the natural surface or
the developer coating.

Bleedout: The process where entrapped liquid penetrant rises to form visible indications.

Developer: A material applied to accelerate bleed-out and enhance indication contrast.

Developing Time: The time between developer application and part examination.

Dwell Time: The total time the penetrant is in contact with the test surface, including
application and drain time.

Inspection: The visual examination of the test part after liquid penetrant processing.

Liquid Penetrant Testing: A Non-destructive Testing using liquid penetrant materials to detect
surface discontinuities.

Liquid Penetrant: A solution of dye with the ability to penetrate fine openings.

Pre-cleaning: The removal of surface contaminants from the test part before examination.

Sensitivity Level: A descriptive term for the capability of a penetrant system to indicate
surface-connected discontinuities.

Result:

For ASTM E1135, preparation of a penetrant is an important part of the fluorescence process,
and it has a significant impact on how well an individual system performs. The penetrant must
penetrate the discontinuity, be removed from the portion surface but not from discontinuity, be
brought out by the developer, and ultimately be examined and spotted by the inspector. To
determine system sensitivity, the penetrant’s inherent brightness must be considered when all
processing parameters are tailored to the components being inspected and the examination
materials being used.
Because the eye reacts logarithmically rather than linearly to increases in brightness, substantial
alterations in brightness have to be rather big. 25% of the differences between the two are clear,
13% are noteworthy, and 6% are visible to the naked eye. Experts may be able to identify a 3%
chance, but the typical observer won’t see it.

A further factor influencing the relevance of a data set is the variation between measurements
made on the same material sample. Even if the same amount of penetrant is used to prepare
each piece, the readings will not be precisely the same. Penetrant migration and sample
variances in paper produce these variations. Statistical calculations must be made to estimate
the confidence limits for the test findings.

Conclusion:

The test method of ASTM E1135 uses the fluorescent dye penetrant procedure and uses a variety
of penetrant, all of which have varying degrees of brightness.

Key Takeaways

 Fluorescent Penetrant Testing is a vital NDT method used in various industries to

detect surface defects and discontinuities in materials and components.
 Fluorescent Penetrant Testing involves applying a liquid penetrant, removing excess
penetrant, and applying a developer.
 It is effective in identifying surface cracks, weld defects, porosity, and other
irregularities, preventing catastrophic failures.
 It is a cost-effective NDT method suitable for a wide range of materials.
 Does not harm the inspected part, making it suitable for production and in-service
inspection.
 It can detect subsurface discontinuities when combined with other NDT Techniques.
 Fluorescent Penetrant Testing is crucial for quality assurance because of its non-
destructive nature, where precision and safety are paramount.

Inspection Materials:
Non Ferrous Metal:

Ferrous Metal:

Ferrous metals are metals that contain iron as the primary element, such as stainless steel. They
are known for their mechanical properties, such as high tensile strength. They are also magnetic
and can be easily shaped or formed.

 It can also be applied to some non porous and Non metallic materials
 Non- Porous Materials Non- Metallic Materials

Defects :
Operations : Casting, forging, Welding

The testing methods detect cracks, fractures, laps, seams and other flaws that are open to the
surface that may have been caused by fatigue, impact, quenching, machining, grinding, forging or
overload.

Inspection Material, Penetrant” covers the qualification, classification, and test

procedures for all liquid penetrant test materials. QPL AMS-2644 is the Qualified
Products List of the penetrants, emulsifiers, cleaners, and developers that have been
qualified and approved to AMS 2644.

As per Specified in QPL AMS 2644-QPD: Materials can be used

 Fluorescent Water -Washable penetrant

 Fluorescent Hydrophilic post-emulsified penetrant
 Hydrophilic remover
 Dry powder developer
 Non Aqueous wet developer (NAWD)

Rolls Royce uses the same penetrant Classification as those Specifiedin AMS 2644

Type 1 :Fluorescent Penetrant

Method A :Water washable
Method D :Post emulsified/hydrophilic remover
Level2 :Medium Sensitivity
Level3 : High sensitivity
Level4 : Ultra high sensitivity
Form a : Developer,Dry powder
Form d : Developer, Non - Aqueous (solvent based)

Refractometer Reading in Relation to the Hydrophilic Emulsifier Concentration

This can be accomplished by preparing known concentrations of hydrophilic emulsifier,

measuring and recording refractometer readings of the known concentrations, and plotting a
graph of the refractometer readings vs. known concentrations.

Prepare several known concentrations of hydrophilic emulsifier in water. For example, if

hydrophilic emulsifier is used at 20% concentration, prepare known emulsifier concentrations of
5%, 10%, 15%, 20%, 25% and 30%.

Preparing the Known Concentration Samples :

Portable Refractometer

Preparing 100 ml of each known concentration will keep the calculations simple. Using a 100 ml
graduated cylinder, prepare the 5% emulsifier solution by adding 5 ml of hydrophilic emulsifier to
95 ml of water for a total of 100 ml of 5% emulsifier solution. Adding the hydrophilic emulsifier
to the water will facilitate the mixing of the solution. Pour the 5% emulsifier solution into a
labeled beaker. Follow this procedure to prepare the remaining known emulsifier
concentrations.

Known Concentrations of Hydrophilic Emulsifier

Graduated Cylinder

 Measure and record the refractive index of each prepared emulsifier concentration using
the same calibrated refractometer.

MEASUREMENT DISTANCE FOR LIGHT OUTPUT FOR SOURCES USED FOR INSPECTION

Light Source Measurement Distance

Hand held sources 380mm (15 inches)

Light Source in a set Position 380mm (15inches)

Light Source with a Light Guide 150mm(6inches)

Borescope 75mm(3inches)
FAQs

1. How to do the fluorescent penetrant inspection?

A: Fluorescent Penetrant Inspection (FPI) typically involves the following steps:

a. Pre-cleaning: The surface to be inspected is cleaned thoroughly to remove contaminants and

ensure better penetration of the fluorescent penetrant.

b. Application of penetrant: A fluorescent liquid penetrant is applied to the surface, either by

spraying, brushing, or immersion.

c. Dwell time: The penetrant is allowed to dwell on the surface for a specified period, during
which it seeps into any surface defects.

d. Excess penetrant removal: Excess penetrant is carefully wiped off or rinsed away.

e. Application of developer: A white, absorbent developer is applied to the surface. This helps
draw out the trapped penetrant from defects and forms a visible indication.

f. Inspection: The surface is examined under UV or visible light. Any indications of defects will
fluoresce, making them easily visible and allowing for evaluation.

g. Cleaning and reporting: After inspection, the surface is cleaned, and a report is generated
documenting the inspection results.

2. What are the three types of fluorescence?

There are primarily three types of fluorescence:

a. Natural Fluorescence: This occurs when a substance naturally exhibits fluorescence under
certain conditions without the addition of external agents.

For example, some minerals and biological materials exhibit natural fluorescence when
exposed to ultraviolet (UV) light.

b. Induced Fluorescence: This type of fluorescence occurs when a substance that does not
naturally fluoresce is made to do so by introducing external agents, such as fluorescent dyes or
markers. These agents are used in various scientific and medical applications.

c. Phosphorescence: Phosphorescence is similar to fluorescence but involves a delayed

emission of light after the excitation source (usually UV light) is removed. Glow-in-the-dark
materials exhibit phosphorescence.

When is Fluorescent / Liquid Penetration Testing required

 Quality control:

FPI is often used as a part of quality control procedures in manufacturing and maintenance
operations. It can help to ensure that components are free from surface cracks, porosity,
laps, and other discontinuities that could compromise their safety and reliability.
 Regulatory compliance:

FPI may be required by regulatory agencies such as the Federal Aviation Administration
(FAA), the Nuclear Regulatory Commission (NRC), and the Department of Defence (DOD).
These agencies may require FPI to be performed on critical components to ensure their
safety and reliability.

 Failure analysis:

FPI can be used to investigate the causes of component failures. By inspecting failed
components, FPI can help to identify the location and extent of any surface discontinuities
that may have contributed to the failure.