BASIC PRINCIPLE

LOCATING SURFACE DISCONTINUITIES BASED ON

 CAPILLARY ACTION (PENETRANT)

 REVERSE CAPILLARY ACTION (DEVELOPER)

(OR)
BLOTTING ACTION
 INTRODUCTION
 Discontinuities at sub surface in one stage be open to
the surface at other stage after grinding or machining.

 LPT done successfully on metals such as aluminum,

magnesium, copper, ss etc.. And also on other
materials such as plastics, glass etc.

 Care should always taken to assure that manufacturers

specifications or company procedures are closely
followed.
 LIMITATIONS
 Can’t be detect discontinuity that are NOT open to the
surface.

 For extremely porous materials.(Bricks)

 LPT can’t be done when the temperature of the

specimen exceeds 52 degree Celsius. Because of
chemicals being used.
CLEANER, PENETRANT, DEVELOPER IN CANS
 CLEANING & CHEMICALS
 Proper cleaning is essential for two reasons

 If the surface is not clean and dry, testing is ineffective.

 If all traces of penetrant materials are not removed, may have

a harmful effect on the specimen.
 Types of cleaning methods

 SURFACE CLEANING
Process of cleaning the surface. But certain methods to be
avoided.(Shot & sand blasting, emery cloth, wire brushes and metal
scrappers etc..). Because these processes tend to close the
discontinuities.
 TYPES OF CLEANING
 VAPOUR DEGREASING
Particularly effective in the removal of oil and
grease(n- propyl bromide).

 STEAM CLEANING
Particularly adaptable to remove dust in big articles.

 SOLVENT CLEANING
Used in immersion tanks or may be used in
wipe-on and wipe-off technique.(Acetone)
 TYPES OF CLEANING
 RUST AND SURFACE SCALE
Can be removed by acid or alkaline rust remover
following manufacturers directions.

 PAINT REMOVAL
Often done in dissolving type hot tank paint strippers
or solvent paint strippers

 ETCHING
Used to remove smeared metal(coated) clean surface
or rust.(Machining components or grinding burns) Type of
etchant used depend upon the material being inspected.
Particularly chromic acid.
Low concentration 80% of water + 20% acid
(H2so4,HCL,HNO3)
 TYPES OF CLEANING
 ULTRASONIC CLEANING
Ultra sound usually from (20-40kHz) to agitate fluid, it can be
used with just water and use of a solvent appropriate for the object to
be cleaned.

 DETERGENT CLEANING
Acid or alkaline solution is used to remove a unwanted
contaminant of job
Small component are used in detergent cleaning.
 ACID PICKLING
Heavy concentration acid solution is used to remove a heavy scale
and rust in the job surface and it is used to remove paint, grease
content.
CLEANING USING SOLVENT
 PROPERTIES OF PENETRANT
BASIC PROPERTIES OR QUALITIES OF PENETRANT

 Ability to hold a dye material.

 Ability to spread the dye evenly (Dispersive agent).
 Ability to carry the dye into the discontinuity.
 Ability to bring up the dye when developer is applied.
 Ability to be easily removed.
 Not evaporate or dry too quickly.
 Odorless
 Non flammable
 Non toxic
 Low in cost
 PROPERTIES OF PENETRANT
 VISCOSITY
Affects the rate at which penetrant enters a defect.

 Flash point above 93oC

 VOLATILITY
High volatility = High rate of evaporation
A good penetrant has low volatility
TYPES OF PENETRANTS (DYE BASED)
 Penetrants are categorized based on the type of dye
they contain,

 FLOURESCENT DYE PENETRANTS

(YELLOWISH GREEN)

 VISIBLE DYE PENETRANTS

(RED)

 DUAL SENSITIVITY PENETRANTS

 FLOURESCENT DYE PENETRANT
 Kerosene based liquid is added with zinc sulphate(or)
calcium tungsate to obtain the fluorescence

 Basically yellowish-green in colour (Radium)

 Highly sensitive

 Can’t viewed in normal light.

 It fluorescence only to Ultra voilet light.

UV LAMP PROPERTIES AND CONDITIONS
 For fluorescent testing, DARK ROOM is required.

 Eye adoption time should given approx 5-8 Mins.

 Dark room light intensity should not exceed 20 LUX.

 Light intensity is measured in LUX.

 Light intensity is calculated by Lux meter.

 UV light Intensity should be 1000u w/cm^2.

UV LAMP PROPERTIES AND CONDITIONS
 In ancient days, Mercury arc lamp used for UV light.
 At least 5 mins start up time required to reach correct
arc temperature.
 It required 10 mins start up time once it turned off and
turned on.
 It supplies light of correct wavelength to cause the
penetrant to fluorescent.
 A deep RED-PURPLE filter is used.
 This UV lamp should be monitored periodically,
whether the filter is not broken or cracked.
FLUOROSCENT INSPECTION (UV LIGHT)
 VISIBLE DYE PENETRANT
 Moderate sensitive.
 Red colour dye is added to the penetrant(Reddish
brown)
 As red colour has the maximum wavelength red colour
is used.
 It can be seen in normal light.
 Inspection area light intensity should be 1000 LUX.
DUAL SENSITIVE
 Low sensitive.
 It can seen in normal and UV light.
 Mostly not used because of its low sensitivity.
VISIBLE INSPECTION (NORMAL LIGHTING)
 PENETRANT TESTING MATERIALS
 WATER WASHABLE PENETRANTS
Contain an emulsifying agent which makes them
easily removable by water rinse or wash.

 POST EMULSIFIABLE PENETRANTS

Which are highly penetrating penetrants, which are
not soluble in water. Must be treated with an emulsifier
before water rinse or wash.

 SOLVENT REMOVABLE PENETRANTS

Do not contain an emulsifying agent, and are
removable only by solvents.
 PENETRANT TESTING MATERIALS
 EMULSIFIERS
When applied to penetrant coated specimen, the
mixture of penetrant with emulsifier, will convert the
penetrant by water rinse or wash.

 REMOVERS (SOLVENT)
Solvent such as ACETONE type material used to
remove the penetrant.

 DRY DEVELOPERS
A fluffy(light & soft) absorbent white powder (calcium
powder) is used to draw the penetrant indications to the
surface.
 PENETRANT TESTING MATERIALS
 WET DEVELOPERS (AQUEOUS)
Mixture of dry powder and water.

 NON AQUEOUS WET DEVELOPER

Dry powder mixed with highly volatile
(rapid drying) liquid solvent.

 LOW SULPHUR AND CHLORINE

To avoid harmful effects on materials which is being
inspected.
For SS & Titanium- Chlorine content should be less
For Nickel based alloy- Sulphur content should be less in
penetrant
PRE-CLEANING OR SURFACE PREPARATION
 The effectiveness of LPT is based upon the ability of
penetrant to enter the surface discontinuities.

 All paint, carbon, oil, varnish, water, dirt and other

similar coating MUST BE REMOVED before the
application of the penetrant.

 There are several types of cleaning methods

(As discussed in types of cleaning topic).
SURFACE CLEANING
 APPLICATION OF PENETRANT
 Penetrant applied on the surface, does not merely
seep into discontinuities, it is pulled into them by
capillary action.

 Due to this action, one can cover the under surface of

an material with a penetrant and still have a valid test.

 Penetrants, either fluorescent or visible can be applied

in anyone of these methods.
 APPLICATION OF PENETRANT
 SPRAYING
Using a low pressure circulation pump or form of
pressurized spray cans.(Aerosol cans)

 BRUSHING
Usually applied with cotton waste or brushes.

 IMMERSION
The entire part is dipped into a tank of penetrant.

 POURING
The penetrant is simply poured over the surface.
APPLICATION OF PENETRANT
(SPRAYING & BRUSHING)
 PENETRATING (OR) DWELL TIME
 The most important part of this penetrant testing.

 The PERIOD OF TIME during which the penetrant is

permitted to remain on the specimen.

 During this dwell time, the penetrant on the specimen will

be pulled by the discontinuous by CAPILLARY ACTION.

 Approximate Dwell time for LPT is 8 – 10 Mins.

 If the dwell time is too high, then the part will be difficult
to wash and exhibit high background.
Dwell Time

31
 PENETRANT TESTING PROCESS
WATER WASHABLE PENETRANTS

A built in emulsifier, can easily removed by water rinse

or wash.

Water temperature above 110 F are not recommended.

W.W.P are usually preferred for rough surface or if

they contain threads or keyways.

Best penetrant removal from blind holes and other

hard to reach locations.
 WATER WASHABLE PENETRANT

ADVANTAGES DISADVANTAGES
 Useable on rough  Susceptible to over
surfaces washing
 Suitable for batch testing  Least sensitive method
 Cheaper than other  Requirement for a water
methods source
 PENETRANT TESTING PROCESS
SOLVENT REMOVABLE PENETRANTS

 Portability

 Can be used for outdoors without using heavy, complex

equipment.

 Excellent for maintenance inspections.

 Checking small portions of larger structure.

 Often applied from pressurized spray cans

 PENETRANT TESTING PROCESS
SOLVENT REMOVABLE PENETRANTS
 After specified dwell time, the excess penetrant is first
removed by wiping with absorbent towels.

 And then it should be cleaned with towels dampened

with solvent.

 It should never applied directly to the specimen,

because it might wash out or dilute the penetrant in the
discontinuity.
 SOLVENT REMOVEABLE
ADVANTAGES DISADVANTAGES
 Portability  Not suited to batch
 No water supply needed testing
 Requires hand wiping so
time consuming
 More expensive than
water washable
 Potentially hazardous
chemicals
 PENETRANT TESTING PROCESS
 POST-EMULSIFICATION PENETRANTS

 Emulsifier will break down the penetrant and make it

water washable

 Two step removal process

 Applied by dipping or immersion but never by

brushing, the bristle of the brush may enter into
discontinuity.

 Emulsification time 3-5 Mins should be given (or)

accordance with manufacturers recommendation.
 PENETRANT TESTING PROCESS
 POST-EMULSIFICATION PENETRANT

 If too short an emulsification time is used, NOT all

penetrants will be removed which cloud over
discontinuity.

 If long time is used, penetrant with in the discontinuity

will also become water soluble and be washed away.

 Post emulsification penetrant makes the water wash

less critical.
 POST EMULSIFIABLE
ADVANTAGES DISADVANTAGES
 Maximum penetrating  Not suited to rough
ability surfaces
 Greater control over  More expensive
penetrant removal  More time consuming
 EXCESS PENETRANT REMOVAL
 Penetrant in a test piece, other than inspecting
area(weld) is called Excess penetrant.

 It is necessary to remove the excess penetrant in a

test piece, because it may lead to false indications.

 There are certain methods to remove the excess

penetrant
 Water Washable
 Post emulsifiable ( Lipophilic)
 Solvent removable
 Post emulsifiable ( Hydrophilic)
 EXCESS PENETRANT REMOVAL
WATER WASHABLE

 Excess penetrant is generally removed from the surface in a

water washable system by dipping are spraying.

 Pressure of flowing water between 40-50 PSI

 Temperature of flowing water should be 16-40 degree

Celsius.

 After washing the job should be dried by natural air or by

oven
 EXCESS PENETRANT REMOVAL
POST EMULSIFIABLE
 Emulsifier will break down the penetrant and make it
water washable.( 2 Types)

POST EMULSIFIABLE (LIPOPHILIC)

 Emulsifier chemical + Oil base material, removed
excess penetrant by diffusion action

POST EMULSIFIABLE (HYDROPHILIC)

 Emulsifier chemical + Water base material, material
removed excess penetrant by detergent action
lipopholic hydropholic
 REMOVAL OF EXCESS PENETRANT
PRE RINSING
Pre rinsing is used to remove the 80% of the penetrant
and remaining penetrant is removed by emulsification
process
Emulsification time: 90 sec
POST RINSING
Water droplet size= coarse
Sprayed angle=45 degree
Sprayed pressure = 25-40psi
Water temperature= 10-40 degree
 EXCESS PENETRANT REMOVAL
SOLVENT REMOVABLE
 Excess penetrant is removed by wiping with lint free
cloth.
 Re-wiping the specimen using a clean cloth dampened
with a solvent remover recommended by a
manufacturer.
 Solvent such as Trichloroethylene, acetone.
 Care must be taken to just dampen not saturate the
cloth with the solvent. Excess solvent will remove the
penetrant from the discontinuity.
 Wiping should done in uni-directional only.
EXCESS PENETRANT ON THE SPECIMEN
EXCESS PENETRANT REMOVAL
TYPES OF DEVELOPER AND ITS APPLICATION
DEVELOPER
 A material that is applied to material surface after excess
penetrant has been removed.

 Developer has designed to enhance the penetrant bleed-out

to form indications.

 Developing time should be given to bleed back.

 Image of the indications will be larger than the actual size

3 TYPES
 DRY POWDER
 AQUEOUS WET DEVELOPER
 NON AQUEOUS WET DEVELOPER
TYPES OF DEVELOPER AND ITS APPLICATION
DRY POWDER

 Very fluffy and high density in nature.

 Developer is blown onto the surface.

 Excess powder will be blown off with air or shaking.

 It may be dipped into a developer tank or brushed over the

surface.

 Indication appear with in a few minutes (Developing time)

after application, as the penetrant bleed back into the
developer by REVERSE CAPILLARY ACTION.

 It will provide a sharper, less spreading indication.

 DRY POWDER DEVELOPER

ADVANTAGES DISADVANTAGES
 Easy to handle  Difficult to see if
 No hazardous vapours properly applied
 Easy to remove  Fine powders can be
hazardous
 Do not offer a high
degree of colour contrast
SPRAYING DRY DEVELOPER
(BLOWER & POWDER)
TYPES OF DEVELOPER AND ITS APPLICATION
AQUEOUS WET DEVELOPER

 Dry powder will be soluble in water and became water

soluble.

 These water soluble will be filtered called water

suspendable.

 This wet developer can be applied by dipping, brushing

or spraying.

 Wet developer provides a broader indication.

 AQUEOUS DEVELOPER

ADVANTAGES DISADVANTAGES
 No vapours or dust  Difficult to apply evenly
 Cheaper than non-  Requires drying after
aqueous application
 TYPES OF DEVELOPER AND ITS APPLICATION
NON AQUEOUS WET DEVELOPER

 Dry powder already suspended in a volatile solvent.

 Drying operation is not required.

 Ultimate in sensitivity.

 It is necessary to agitate, to ensure particles are fully suspended.

 Available only in aerosol cans.

 Readily available, can’t be used in open tanks.

 It will provide sharp indications with very good resolution.

 NON-AQUEOUS DEVELOPER
ADVANTAGES DISADVANTAGES
 Most sensitive  Hazardous solvents
 Useable with fluorescent  Higher cost
or colour contrast  Need to be correctly
applied
APPLICATION OF NON-AQUEOUS DEVELOPER
 INTERPRETATION AND EVALUATION
INTERPRETATION

 A defect is a discontinuity that exceeds the maximum

acceptability level.

 Proper lighting should be there.

 For fluorescent, Dark room and a Black light with proper

Intensity are required.(Below 20 LUX)

 For visible, adequate normal lighting is required.(Above 1000

LUX).

 Brightness, size, shape, location of an indication all provide

data to aid in the evaluation of the discontinuity.
 INTERPRETATION AND EVALUATION
INDICATIONS
 All indications found will be surface discontinuities.

FALSE INDICATIONS
 Most common source of false indications is POOR
WASHING.

REASON FOR FALSE INDICATIONS

 Penetrant on operator hands.
 Contamination of developer.
 Penetrant on inspection table.
 FALSE INDICATIONS
 Due to poor washing and non removal of excess
penetrant properly.
 INTERPRETATION AND EVALUATION
NON RELEVANT INDICATIONS

 These are actual surface discontinuities that are caused

by material design (Notches)

 Caused by press fitted, riveted etc..

 could also include loose scale (or) rough surface on a

forging (or)casting
 INTERPRETATION AND EVALUATION
TRUE INDICATIONS
 Are caused by surface discontinuities not being false or
non relevant.
DIVIDED INTO 5 BASIC CATEGORIES
CONTINUOUS LINE
 Often caused by cracks, cold shuts, forging laps,
scratches (or) die marks.

INTERMITTENT LINE
 Caused by very tight (or) where the parts had been
machined (or) ground.
 INTERPRETATION AND EVALUATION
ROUND
 Caused by porosity open to the surface.

SMALL DOTS
 Caused by the coarse grain structure or micro shrinkage.

DIFFUSED OR WEAK
 These indications are difficult to interpret and often the
parts must be cleaned and re-tested. Turned out to be
false indications caused by improper penetrant
procedure.
 INTERPRETATION AND EVALUATION

RELEVANT INDICATION

 It is due to discontinuity of the job

 Linear indication is L>3W(crack)
 Rounded indication L<3W(porosity)
RELEVANT INDICATION
RELEVANT INDICATION (CRACKED COMPONENT)
EVALUATION
 POST CLEANING

DEPTH DETERMINATION
 The greater the depth of the discontinuity, the more
penetrant it will hold, and the indications will be larger
and brighter.

POST CLEANING
 After Inspection, the specimen has to be thoroughly
cleaned.
 Same cleaning process as done in Pre cleaning.
 If all traces of penetrant materials are not removed,
may have a harmful effect on the specimen.
 QUALITY CONTROL OF PENETRANT TEST MATERIALS
ALUMINIUM TEST BLOCK

 This test block, used to check the strength of in-use

penetrants, by processing one half of the block with used
penetrant, and other half with fresh penetrant.

 Should be used for comparison only, not for absolute

solutions.

 Blocks are non uniform, the depth and width of cracks are
uncontrolled.

 Complies with ASTM E165 and ASME boiler and pressure

vessel code.
ALUMINIUM TEST BLOCK
QUALITY CONTROL OF PENETRANT TEST MATERIALS

SENSITIVITY TEST
 For measuring penetrant sensitivity.

 A simple comparison test is adequate.

 A small sample of penetrant is placed on one side of

aluminum test block, and small sample of new
penetrant on the other side.

 It can be examined by visual observation.

 If the old penetrant is contaminated to the point, then

it must be discarded.
QUALITY CONTROL OF PENETRANT TEST MATERIALS
MENISCUS TEST
 Test for evaluating the dye concentration in thin liquid
films.
CERAMIC BLOCK TEST
 Consists of unglazed ceramic disc which has thousands
of micro pores and cracks on its surface.
 A pencil mark is made on the block, small amount of
test penetrant on one side and reference penetrant on
other side.
 After correct dwell time, penetrants are compared by
visual examination.
 Brightness of pore indications should be observed.
CHROMIUM PLATED CRACKED TEST PANEL
QUALITY CONTROL OF PENETRANT TEST MATERIALS
WATER CONTENT TEST

 As per ASTM D-95, 100 ml of penetrant is placed in a

boiling flask with a similar quantity of moisture free
XYLENE(volatile liquid hydrocarbon).

 Condensate is collected in a graduated tube to show the

percent of water by volume.

 If the percent of water exceeds manufacturers

recommendations, then the penetrants is discarded.
QUALITY CONTROL OF PENETRANT TEST MATERIALS

VISCOSITY TEST
 A viscometer tube is used to measure the viscosity in
centistokes to determine if the penetrant is within the
range recommended by manufacturer.
FLUROSCENT PENETRANT FADE TEST
 Side by side comparison test using aluminum test block
 F.penetrant is placed on both sides, one half is exposed
to standard black light for one hour and other side is
covered with paper.
 Two sides of block is observed, if one side of penetrant
is less brilliant, then the penetrant will be discarded.
QUALITY CONTROL OF PENETRANT TEST MATERIALS
WATER WASHABILTY TEST

 To evaluate the efficiency of Emulsifier.

 By comparing two different percentage blends of

penetrant and emulsifier.

 A special steel block is placed at 70 degree angle, two

blends are allowed to flow separately.

 After five minutes of waiting period, the block is

washed and examined for the traces of remaining
penetrant.
QUALITY CONTROL OF PENETRANT TEST MATERIALS

DEVELOPERS
 Simply visually inspected.
 Dry developers should not be lumpy, instead of fluffy
and light.

WET DEVELOPERS
 Often checked by HYDROMETER to assure the density
of the powder with in the range recommended by the
manufacturer.
 SAFETY PECAUTIONS
 The liquids used are usually flammable.

FIRE
 Penetrant materials having very low flash points should
be avoided.
 Higher the flashpoint less the fire hazard.
 Penetrant materials used in open tanks have a
minimum flash point of 125F (52 C).
 Most penetrant materials burn rapidly.
 penetrant materials are never stored near heat or open
flame.
 SAFETY PECAUTIONS
SKIN IRRITATION

 The oil base of LPT materials has a drying action on the

skin.

 Because of this, the material may cause unpleasant

irritations.

 It can be avoided by preventing unnecessary contact.

 By using gloves, Aprons and protective hand creams.

 SAFETY PECAUTIONS
AIR POLLUTION

 Dust and vapors from materials used in LPT are non

toxic, but excess inhalation can be a health hazard.

 Exhaust fans are used in confined areas where dry

developers are used.

THERMOSTATS
 Items are required and used to control the temperature
of the dying oven and penetrant material.
 SAFETY PECAUTIONS
UV LAMP
 If the filter used in the UV lamp, is broken are cracked
then the harmful rays will cause sunburn and retina in
the eyes will burned.
UV wavelength( In Nanometer)
 365 Nanometer – Filtered
 315-400 Nanometer – Range
 312–334 Nanometer _ Unfiltered
UV wavelength( In Angstrom)
 3650 Angstrom - Filtered
 3200-4000 Angstrom - Range
 2000-3200 Angstrom - Unfiltered
 CODES AND STANDARDS

 ASTM E 165 : standard recommended practices for PT

 ASTM A 462: procedure for PT in steel forgings

 ASTM E 270: definition of terms related to PT

 ASME sec V- Article 6 – PT

 SE 165- standard practise for PT.

CONTROL CHECKS - FREQUENCY
OVERALL SYSTEM PERFORMANCE DAILY

WATER WASH TEMPERATURE &PRESSURE DAILY

COLOUR INTENSITY WEEKLY

PENETRANT REMOVER DAILY

DEVELOPER WEEKLY

UV LAMP OUTPUT MONTHLY

UV MONITOR ANNUALLY

WATER TOLERANCE WEEKLY

Thank you