Non Destructive Testing

Liquid Penetrant – Level II

Presented By
Dr. Eng. Ismail A. Abdallah
EGAC Chairman
 Liquid Penetrant Tests procedure
We can summarize the procedure of
liquid penetrant testing as follow:
1. Pre-cleaning process.
2. Apply the penetrant material.
3. Waiting for penetration time (Dwell time).
4. Remove the excess penetrant.
5. Apply the developer material.
6. Carry out the inspection.
7. Post cleaning process.
 Liquid Penetrant Tests procedure
1- Pre-cleaning process
The effectiveness of liquid penetrant testing is based upon the ability of the
penetrant to enter surface discontinuities all paint oil, varnish, oxide, water, dirt,
and similar coating must be removed before application of the penetrant.
Liquid penetrant placed on the surface of a specimen does not merely seep into
discontinuities, it is pulled into them by capillary action this is the reason that
can cover the under surface of an item with a penetrant and still have a valid test.
 Liquid Penetrant Tests procedure
1- Pre-cleaning process

Proper cleaning is essential to liquid penetrant testing for two reasons :

1. If the specimen is not clean and dry, penetrant testing is ineffective.

2. If all traces of penetrant materials are not removed after the test. they may have a
harmful effect on the specimen. (chlorine and sulfur may affect some alloys ex:
ST.ST.)
 Liquid Penetrant Tests procedure
1- Pre-cleaning process
• Immersion tanks and detergent solutions are common means of
assuring that a specimen surface is both physically and chemically
clean.
• vapor degreasing is particularly effective in the removal of oil.
grease and similar organic contamination However certain alloys
have an affinity for specific elements used in vapor decreasing and
if exposed to them may become structurally damaged.
 Liquid Penetrant Tests procedure
1- Pre-cleaning process
• Steam cleaning is particularly adaptable to the cleaning of large
unwieldy articles.
• Solvent cleaning may be used in immersion tanks or may be used
in a wipe on and wipe off technique solvent cleaning is usually less
effective than the previous methods of cleaning.
 Liquid Penetrant Tests procedure

1- Pre-cleaning process
• Rust and surface scale can be removed by any good commercially
available acid or alkaline rust remover following manufacturer’s
directions.
• Paint removal is often done in dissolving type hot tank paint strippers,
bond release or solvent patent strippers.
 Liquid Penetrant Tests procedure

1- Pre-cleaning process
• Etching is effective for use on articles that have been ground or machined this
process uses an acid or an alkaline solution to open up grinding burrs and
remove metal from surface discontinuities.
• Surface cleaning processes to be avoided include blast (shot sand or pressure)
emery cloth, wire brushes, and metal scrapers, these processes tend to close
discontinuities by peening or cold working the surface of the specimen.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
Almost any liquid could be considered a penetrant but modern penetrants
must have:
1. The ability to hold a dye material in suspension.
2. The ability to spread the dye evenly over the surface.
3. The ability to carry the dye into any discontinuity open to the surface.
4. The ability to bring up the dye as it is back to the surface.
5. The ability when desired to be easily removed.
 Liquid Penetrant Tests procedure

2- Apply the penetrant material

a) Penetrant test equipment
 Stationary

 Portable
 Liquid Penetrant Tests procedure

2- Apply the penetrant material

a) Penetrant test equipment
 Stationary
- Stationary equipment used in liquid penetrant testing varies in size and is largely
dependent upon the test specimen. depending on the type and process used.
A station system could include the following :
1. Precleaning station (Usually in remove area).
2. Penetrant station (Tank).
3. Drain station.
4. Emulsification station (Tank).
5. Rinse station (Tank).
6. Developing station (Tank).
7. Drying station (Usually Oven)
8. Inspection station (Enclosed booth or table with proper lighting).
9. Post cleaning station (Usually in remove area).
 Liquid Penetrant Tests procedure

2- Apply the penetrant material

a) Penetrant test equipment
 Portable
- Both visible and fluorescent dye penetrants are available in kits which
can be used at a remote location or when testing a small portion of a large
article.

A visible dye penetrant kit usually obtains:

1. pressurized spray cans of cleaning or removal fluid.

2. pressurized spray cans of visible dye penetrant.
3. pressurized spray cans of nonaqueous developer.
4. wiping cloths and brushes.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
a) Penetrant test equipment
 Portable
A fluorescent dye penetrant kit usually contains:
1. A portable black light and transformer.
2. Pressurized spray cans of cleaning or removal fluid.
3. Pressurized spray cans of fluorescent dye penetrant.
4. Pressurized spray cans of nonaqueous developer.
5. Wiping cloths and brushes.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
a) Penetrant test equipment
• fluorescent dye penetrant kit
- Black-light equipment is required in fluorescent penetrant testing since it supplies
light of a correct wavelength to cause the penetrant to fluoresce.
- A deep red-purple filter is used to pass only those wavelengths of light that will
activate the fluorescent material.
- At least a five-minute heat up time is required to reach the correct arc the
temperature when using mercury arc lamps
 Liquid Penetrant Tests procedure

• The black light emits a special light with wavelengths that fall
between visible and ultraviolet.
• There is no danger of injury to the human eye it is suggested
that the filter be checked prior to each use.
• Line voltage fluctuation will decrease the life time of black light bulb.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
• You must measure the temperature of the weld before you apply the
penetrant materials
• The test surface must be between 50°F (10°C)
and 125°F (52°C).
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
• There are three types of dye used in modern penetrants:
1- Visible; a brightly coloured dye that is highly visible under normal lighting conditions
this type of dye is normally called visible dye.
2- Fluorescent; an almost colourless dye which emits visible light rays when reviewed
under black light.
3- Dual sensitivity, contains both a visible dye for examination in white light and a
fluorescent dye.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
Methods of applying the penetrants:
• Penetrants either fluorescent or visible , can be applied by any one of
the following means:
1. Spraying usually using a low pressure circulation pump or from pressurized
spray cans.
2. Brushing usually applied with rags cotton waste. or brushes.
3. Immersion the entire part is dipped into a tank of penetrant.
4. Pouring the penetrant is simply poured over the surface.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
• Penetrant materials are often restricted to specific groups, the established groups
of penetrant materials will use the following in a variety of combinations to obtain
the best results:
1- Water washable penetrants contain an emulsifying agent which makes them
easily removable by a water rinse or wash this penetrant material can be obtained with
either a visible or fluorescent dye.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
1- Water washable penetrants
- care must be taken to insure that the spray volume and force does not
wash penetrant out of the discontinuity.

Water temperatures above 110°F (43°C) are not recommended because

this may speed up the vaporization of the penetrant.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
1- Water washable penetrants
- Water-washable penetrants are usually preferred for use on items with a
rough surface or if they contain threads or keyways.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
2- Post emulsifiable penetrants are highly penetrating oily visible or
fluorescent penetrants which are not soluble in water.
these penetrants must be treated with an emulsifier before they can be
removed by a water rinse or wash. (tow dwell time)
• Post-emulsification penetrants require a two-step removal processes
emulsifier is usually applied by dipping or immersion. the amount of
dwell time in the emulsifier is in the range of one to four minutes in
accordance with manufacturers recommendations and the type of defects
expected.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
3. Solvent removable penetrants are oily penetrants that do not contain an
emulsifying agent and are removable only by solvents specifically designed
for that purpose.
• Have the advantage of portably and can be used outdoors without using
heavy complex equipment
• Excellent for many maintenance inspections and for checking parts of a larger structure.
 Liquid Penetrant Tests procedure
2- Apply the penetrant material
b) Penetrant testing materials
3. Solvent removable penetrants
 Liquid Penetrant Tests procedure
• The flow chart below illustrates the different material combinations, however, care
should always be taken to ensure that manufacturers specifications or company
procedures are closely followed.
 Liquid Penetrant Tests procedure
3- Waiting for penetration time (Dwell time).
The period of time during which the penetrant is permitted
to remain in the specimen is a vital part of the test.

• Light discontinuities like crack may require in excess of 30 minutes for

penetration that will give an adequate indication , however , gross
discontinuities may be suitably penetrated in 3 to 5 minutes.
• Dwell times are based on the assumption that the penetrant will remain wet
on the part surface.
• Additional penetrant may be applied during dwell time.
 The penetrant manufacturer will provide suggested dwell times for
the various penetrants that it produces.
 Liquid Penetrant Tests procedure
4- Remove the excess penetrant
solvents are designed to be used in conjunction with specific penetrants
typical removers are available in bulk or pressurized spray containers.
 Liquid Penetrant Tests procedure
4- Remove the excess penetrant
Solvent is never applied directly to the specimen as it might wash out or
dilute the penetrant in the discontinuity.
 Liquid Penetrant Tests procedure
5- Apply the developer material
• Some indications may be visible prior to the application of a developer, but
this step will ensure that all discontinuities are visible to the naked eye.
• Developing is accomplished when a highly absorbent powder is applied to
the item being tested after excess penetrant is removed the penetrant is
actually drawn out of the discontinuity by the strong capillary action of the
developer.
• The developer will actually be larger than the actual size of the discontinuity.
 Liquid Penetrant Tests procedure
5- Apply the developer material
• There are two common types of developers in use today wet and dry.
both use a white powder and the primary difference is in the method of
application.
a. Wet developers :
1- The non-aqueous developer is held in suspension in a solvent base (Fast
drying) and is usually supplied in pressurized cans.
2- Water base developer is another type of wet developer holds the white
powder in suspension in a water.

After application, a short time is allowed for the water to evaporate leaving a
thin layer of white powder if an oven test used.
 Liquid Penetrant Tests procedure
5- Apply the developer material
b. Dry developers :
- A dry developer is a fluffy white powder that is not carried in a liquid.
- Dry developers are applied directly to the item as a powder, this is usually
done with slight air pressure.
- It is very necessary to have a dry surface prior to application of a dry
powder. a wet surface will result in uneven layers of powder.
 Liquid Penetrant Tests procedure
5- Apply the developer material
C. Low sulphur and low chlorine penetrant materials must be specifically
designed to avoid the harmful effects caused on some St.St., nickel and
titanium alloys by the sulphur and chlorine content.
 Liquid Penetrant Tests procedure
6- Carry out the inspection
Proper lighting should be the first consideration in the inspection of an article :
1. If a fluorescent dye penetrant is used a room or booth with dim light and a
black light with proper intensity are required.

2. If a visible dye penetrant is used, adequate normal lighting is necessary.

 Liquid Penetrant Tests procedure
6- Carry out the inspection
 Indications:
a) True indications:
all indications found with the liquid penetrant method will be surface
discontinuities (crack, undercut and porosity).
b) False indications:
The most common source of false indications is poor washing (remove the
excess).
To avoid false indications , care should be taken so that no outside
contamination such as the following occurs :
1. Penetrant on operator's hands.
2. Contamination of developer.
3. Penetrant on inspection table.
 Liquid Penetrant Tests procedure
6- Carry out the inspection
 Indications:
a) True indications could be divided into five basic categories:
1. Continuous line this type of indication is often caused by cracks, cold
shuts forging laps scratches or die marks.
2. Intermittent line these indications could be caused by any of the
discontinuities mentioned above provided they were very tight or where the
part had been machined or grind.
3. Round usually caused by porosity open to the surface.
4. Small dots tiny round indications caused by the porous nature of the
specimen.
5. Diffused or weak these indications are difficult to interpret and
often the part must be cleaned and retested. in many cases the
diffused or weak indications turn out to be false indications caused by an
improper penetrant procedure.
 Liquid Penetrant Tests procedure
6- Carry out the inspection

The Types Of Discontinuities

 Liquid Penetrant Tests procedure
 The Types Of Discontinuities

Discontinuities can be divided into three general categories:

1) Inherent
2) Processing
3) Service.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
1. Inherent they are usually related to discontinuities found in
the molten metal.

Inherent wrought discontinuities relate to the melting and

solidification of the original ingot before it is formed into slabs ,
blooms and billets.
Inherent cast discontinuities caused by inherent variables such
as inadequate feeding, gating, excessive pouring, temperature
and entrapped gases.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
2. Processing discontinuities they are usually related to the
various manufacturing processes such as machining forming
extruding, rolling, welding, heat treating, and plating.

3. Service discontinuities they are related to the various service

conditions such as stress corrosion, fatigue, and erosion.

Remember, when you use the liquid penetrant method you can
find only those discontinuities which are open to the surface.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities

Remember that

Discontinuities are not necessarily defects any indication that is

found by the inspector is called a discontinuity until it can be
identified and evaluated as to the effect it will have on the service
of the part.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
When an ingot is further processed into slabs blooms and billets
it is possible for the discontinuities to change size and shape.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
1- lamination pipe, as a billet is flattened and spread out non-
metallic inclusions may cause a lamination, pipe and porosity
could also cause laminations in the same manner.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
2- Inclusions, Non-metallic impurities, such as slag and oxides that are
present in the original ingot.
as a billet is rolled into bar stock , inclusions are squeezed out into longer and
thinner discontinuities called stringers.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
3- Seams, Seams are surface discontinuities found in rolled bars
and plate.
compressing and elongating of cracks or tears on the surface of
the ingot during the rolling operation..
• Seams are generally long, straight and parallel to the longitudinal axis.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
4- Forging lap
• Forging discontinuities occur when metal is hammered or pressed into
shape usually while the metal is very hot.
• A forged part gains strength due to the grain flow taking the shape of the
die and the process
Forging lap is caused by folding of metal on the surface of the forging usually
when some of the forging metal is squeezed out
between the two dies.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
5- Forging burst, is a rupture caused by forging at improper
temperatures.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
6- Cold shut
Casting discontinuities occur when molten metal is poured into a
mould and allowed to solidify.
A cold shut is caused when molten metal is poured over
solidified metal
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
7- Hot tears (Shrinkage Cracks), due to difference
in cooling rates between thin and thick sections (a crack formed
while the casting is cooling).
Hot treat cracks have no specific direction and usually start at sharp
corners which act as stress concentration points.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
8- Shrinkage cavities, are usually caused by lack of enough
molten metal to fill the space created by shrinkage , similar to
pipe in the ingot.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
9- Micro-shrinkage, is usually many small subsurface holes that
appear at the gate of the casting.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
10- Blow holes, are small holes at the surface of the casting
caused by gas which comes from the mould itself. (many moulds
are made of sand) and when molten metal comes into contact
with the mould, the water in the sand is released as steam.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
11- Porosity, Due to gas bubbles being trapped in the material
prior to solidification.
• is usually subsurface out can occur on the surface depending
on the design of the mould.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
12- Grinding cracks, are a processing type discontinuity caused by
stresses which are built up from excess heat created between grinding wheel
and metal.

• Grinding cracks will usually occur at right angles to the rotation of the
grinding wheel.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
13- Fatigue cracks, are service type discontinuities that are usually open
to the surface where they start from concentration points.
 Liquid Penetrant Tests procedure
 The Types Of Discontinuities
14- welding discontinuities

• Undercut
• Lack of fusion
• Lack of penetration
• Inclusions
• Porosity
• Stress cracks
• Crater cracks
 Liquid Penetrant Tests procedure
6- Carry out the inspection
 Fixing and recording indications :

1. Photographs typical black and white and colour film are used
with the self developing films providing the most convenience.

2. Special wax and plastic film have been developed to absorb

and fix the penetrant indication to form a permanent record.
 Liquid Penetrant Tests procedure
7- Post cleaning process.
• After the specimen has been inspected it is very important that
it be thoroughly cleaned post-cleaning
• Usually will involve the same types of cleaning operations as
were used in precleaning.
 Liquid Penetrant Tests procedure
Quality control of penetrant test materials
1- Sensitivity tests while there have been no simple quantitative tests
developed for measuring penetrant sensitivity a simple comparative test is
usually adequate.
• A small sample of the penetrant from the testing area is placed on one side
of an aluminium test block, and a small sample of new penetrant on the
other side. by visual observation it is determined if the old penetrant is
contaminated to the point where it must be discarded.
 Liquid Penetrant Tests procedure
Quality control of penetrant test materials
• Aluminium test blocks they provide a good means of evaluating general
purpose penetrants they should be used for comparisons only and not for
absolute evaluations.
• The blocks are heated and quenched to produce an overall crack pattern.
 Liquid Penetrant Tests procedure
Quality control of penetrant test materials
2- Meniscus test provides a practical test for evaluating the dye
concentration in thin liquid films.
The test utilizes a flat glass platen and a convex lens. when a drop of solution
is placed between the lens and platen.
A colourless or non-fluorescent spot is formed around the point of contact ,
the resultant contact angle simply indicates the ability of a liquid to wet a
surface.

The diameter of the remaining ''spot" of colourless penetrant provides

a measure of film thickness which can be used to compare the dye
concentration of penetrants.
 Liquid Penetrant Tests procedure
Safety precautions
In general , the materials used in penetrant inspection can be flammable and
can cause skin irritations.
skin irritation can be avoided by preventing unnecessary contact and by the
use of gloves.
The developing powders are considered nontoxic but excessive inhalation
must be avoided. exhaust fans should be installed in any confined area where
dry developers or vapours from the penetrants are present.
 Liquid Penetrant Tests procedure
Safety precautions
In addition, the ultraviolet spectrum of light rays generated from the mercury
arc lamp can cause sunburn and may be injurious to the eyes.
However if the proper filter for fluorescent dye inspection is used the harmful
rays will be filtered out.
 Liquid Penetrant Tests procedure
Safety precautions
 Never perform a penetrant test alone when in a confined space.
 Do not breathe the vapors from chemicals used in PT.
 Do not allow penetrant chemicals to get into your eyes.
 Do not allow penetrant chemicals to contact your skin.
 Do not swallow any penetrant chemicals.
 Do not spray flammable vapors near any ignition sources.
 Do not store solvent cleaners around heaters or equipment that makes
flames or sparks.
 Liquid Penetrant Test
Advantages
• Simple process in principle and application.
• Complete surface of the test sample can be examined in one operation
• Indications are formed directly over discontinuities giving an outline of their
shape
• No limitation on the size and shape of the test article
• Almost any solid material can be tested, including metals, ceramics,
cements, glass and plastics
• Adaptable to mass production and automation
• Can be adapted to leak testing.
 Liquid Penetrant Test
Limitations
• Restricted to surface flaws only.
• Discontinuities are not detectable if covered or filled in with contaminants.
• Not suitable for highly porous materials.
• Penetrant products may react with some materials (St.St. some nickel and
titanium alloys ).
• High or low temperatures limit the normal operating range of penetrants
• Some of the chemicals used in penetrant testing can cause skin and eye
irritation
• Insufficient ventilation can cause respiratory effects (confined space).
 PENETRANT TESTING ACCEPTANCE CRITERIA
• The acceptance criteria given hereunder for relevant indications for various
codes shall be used in general throughout of Third Party.
• DYE PENETRANT INSPECTION - API 1104
 PENETRANT TESTING ACCEPTANCE CRITERIA
• DYE PENETRANT INSPECTION - API 1104
 PENETRANT TESTING ACCEPTANCE CRITERIA
• DYE PENETRANT INSPECTION - ANSI/ASME B31.1
 PENETRANT TESTING ACCEPTANCE CRITERIA
• DYE PENETRANT INSPECTION - ANSI/ASME B31.3

• DYE PENETRANT INSPECTION - ASME Section VIII Div. 1

PENETRANT TESTING ACCEPTANCE CRITERIA