NOT RAINING PROGRAM STUDENT'S GUIDE LUO PENETRANT METHOD INTRODUCTION To THE LIQUO PENETRANT TRAINING PACKAGE The tang meters ms packane ate denned fo crovde 2 Dasle Knowledge of he fundamentals of auc senerantYesing. The waning progam mal you ate panceatng wh cinta ie Tolower, Setrcom hous olnstcton Yo race’ Ine inlomaten suggasieg tne ASH psteaton SNT-7C-14 Love raring wil ude echres on af x lessons wt an average of sepionrly one hour ber Tesson Ereraas wil begun oscars 4 Leva rang wll ace lectures on al lessons whan verge of anetonaely to hours Der Tetson Soa wilbe gen fo lessone 6:7 ‘The siusent Sheu assume the reSs0rsBA lar reading al assigeants, ening ects, nd par hcpatng n ease decvesure. Shon exams wi be sare ser each lesson fe prowae the alos ‘ath afelornsibr progres nto stmuste sy CONTENTS OF TRAINING PACKAGE ‘Yur tong package wil conan ine lolowng maleate win speclc mstucters ane assignments 0 be ven bye course ratucte 1. STUDENT'S Package A. Students Guide wicn wit cutie e purpose. conten, pa seo! he rng atonal 8. 1 Glasroom Training Handbook whch wil sare a8 the mar txt for he wang course ___ er ©. india! lecture guide packets on te hrcameniae of Iqud generar esing he lecture ‘ude mata are eroded wih each leon and ena othe tana Uses Sy he ‘tutor aumng nis were. Durng me tecture the akdent shoud use ine gud fo make 933 tonal notes. andthe ce wi Men became alti t tty om ata te ©. 1 packet of quizzes. The nsicter may eect remove the uaz Yom your Saket ono! fe sig couse a eat yt aes tn Crees Agu wo unste o 2, INSTRUCTOR'S PACKAGE [A The esmucr's sactage wil conan af ofthe efaion that you have wih te aden of an ruc’ pace, lecture gage ransgarenoes ard que toys ©. Alte opton of the nsincier. a set of fnsbes may be used Yo proce aon th and Atte ooton of the struct. the progranmed iseucion hansbocks may De wc fr atonal ssrnanis. Sever 668 of contests ave avaaoie ram ASNT and may be issued a tte eoton ofthe5 OUTLINE OF L=SSONS ANO RELATED REAOING ASSIGNMENTS Cssroom Trang nanatoor (CT-62) oles tne lesane ne traning eoerte the fooweg oer PrLasson ‘Classroom Training Handbook Ch 1-2 (opto) P42 Penetrant Gn 1-2 Pr-.esson 2—Clasareom Trlaing Handbook Ch 9 Toatonal Pit? Panatrnt Gn PT-Lesson 3—Cissroom Training Handbook Cr loptonal Pie? Pnetrant On 348 Pr-Lasson 4—Clessroom Training Hanabook Cn {ostenal P12 Penara Ch ¢S rLesson Classroom Truning Hancbook Ch 6-6 (ootonal Pi? Peneram Ch 87 P7-Lesson 8—Classroom Truning Handbook Cn § [oatenal Pt integucton Ch 1.7 Pr4asson 7—Clesaroom Traning Handhoos Ch leotonal SNTTCTA, 90.110 OPTIONAL REFERENCE MATERIAL ‘The folowing mate's valle rom ASNT Hesacuaners and sugested where ne student wants at: ‘tena denn n the Luc Penetant Med (The ASNT Catalog lee ances tnd rdenng miomaton) 1 Programmed nsrucon nanatook Plt? Llguld Penetrant Testing) 2. Progranmed itstucion handbook Pt Unrodueton to NOT) 1 {3 Principles of Penetrants by Cov ate 4 Auta! course #1723 (Liguld Penetant Testing) 5. SNF-TC-1A Recommended Practice fer Personnel Qualiistion and Certietion In Non:UGUID PeNerRANT METHOD NOT Training Program Studenis Gude Tavie of Conients Page Introduction. Related Reading Outline wi Lesson 1 1 Quiz 8 Lesson 2. a ‘Quiz 7 Lesson 3. 19 ‘uz, 2 Lesson 4. 7 son ‘Quiz 35 Lesson 5, 37 __Quiz. : 43 Lesson 6, Quiz Lesson 7, 57 ‘Qui oer)LESSON | LIQUID PENETRANT TESTING IS A NONDESTRUCTIVE MEANS OF LOCATING SUA FACE DISCONTINUITIES BASED ON CAPILLARITY OR CAPILLARY ACTION. IN THE LIQUID PENETRANT METHOD, THE LIQUID IS APPLIED TO “HE SURFACE OF THE SPECIMEN, AND SUFFICIENT TIME IS ALLOWED FOR PENETRATION OF SUR: FACE DISCONTINUITIES, IF THE DISCONTINUITY IS SMALL OR NARROW. AS IN A CRACK OR PINHOLE, CAPILLARITY ASSISTS THE PENETRATION. AFTER SUFFICIENT TIME HAS PASSED FOR THE PENETRANT TO ENTER THE DISCONTINUITY, THE SURFACE OF THE PARTIS CLEANED. CAPILLARY-ACTION IS AGAIN EMPLOYED TO ACT AS A BLOTTER TO DRAW PENETRANT FROM THE DISCONTINUITY.TO INSURE VISIBILITY, THE LIQUID PENETRANT CONTAINS EITHER A COLORED DYE EASILY SEEN IN WHITE LIGHT, OR A FLUORESCENT DYE VISIBLE UNDER BLACK (ULTRAVIOLET) LIGHT A. PENETRANT APPLIED TO SURFACE, 8. TIME ALLOWED FOR PENETRANT TO SEP INTO THE OPENING. ©, SURFACE PENETRANT REMOVED. 0. DEVELOPER APPLIED TO DRAW. Saree PENETRANT OUT OF CPENING. E. SPECIMEN VISUALLY EXAMINED. F. POST-CLEANINGDISCONTINUITIES THAT ARE SUBSURFACE IN ONE STAGE OF PRODUCTION COULO BE OPEN TO THE SURFACE AT ANOTHER STAGE, SUCH AS AFTER GRINDING OR MACHINING. NONMETALLIC INCLUSIONS AND POROSITY IN THE INGOT MAY CAUSE STAINGEAS, SEAMS, FORGING LAPS, COLD SHUTS, AND THE LIKE AS THE BILLET OR SLAB IS PROCESSED IN THE MANNER SHOWN BELOW: adPr iectue Goce ANYTHING THAT COULD BLOCK THE PENETRANT FROM ENTERING THE DISCON- TINUITY MUST BE REMOVED. A LIST OF CONTAMINANTS THAT MUST 8E REMOVED WOULD INCLUDE DIRT, GREASE, RUST, SCALE, ACIDS, AND EVEN WATER. THE CLEANING SOLVENT USED MUST BE VOLATILE (READILY VAPORIZED) SO THAI IT EASILY EVAPORATES OUT OF THE DISCONTINUITY AND DOES NOT OILUTE THE PENETRANT. SURFACE PREPARATION BY SHOT OR SANDBLASTING IS NOT RECOMMENDED DISCONTINUMTES THAT WERE OPEN TO THE SURFACE MAY BE CLOSED BY THE SHOT OR SANDBLASTING. Yip cxose-ecrion ZI HISTORICALLY, PENETRANT INSPECTION WAS CALLED THE “OIL AND WHITING METHOD.” AS IT USED KEROSENE AND & WHITE POWDER FOR THE NSPECTION OF RAILROAD PARTS. HOWEVER, IN THE PAST 40 YEARS THE PROCESS HAS BEEN IM PROVED TREMENDOUSLY TO THE POINT WHERE IT IS A AELIABLE AND ACCURATE INSPECTION TECHNIQUE, THE LIQUID PENETRANTS USED IN NONDESTRUCTIVE TESTING CAN BE CATEGO- RIZED BY THE TYPE OF DYE THEY CONTAIN, 1, VISIBLE DYE PENETRANTS CONTAIN A COLORED (USUALLY FED) OVE 2. FLUORESCENT PENETRANTS CONTAIN A FLUORESCENT DYE. 3. DUAL SENSITIVITY PENETRANTS CONTAIN A COMBINATION OF VISIBLE ANO FLUORESCENT DYES,Fr Lecture Goce PENETRANTS CAN BE FURTHER CATEGORIZED BY THE PROCESSES USED TO REMOVE THE EXCESS PENETRANT FROM THE SPECIMEN 1. WATER-WASHABLE PENETRANTS ARE EITHER SELF-EMULSIFYING OR. REMOVABLE WITH PLAIN WATER 2. POST-EMULSIFIED PENETRANTS REQUIRE A SEPARATE EMULSIFIER TO MAKE THE PENETRANT WATER WASHABLE, 3. SOLVENT-REMOVABLE PENETRANTS MUST BE REMOVED WITH A SOLVENT WHICH IS TYPICAL WHEN USING VISIBLE DYE IN PRESSURIZED SPRAY CANS, THE FLOW CHART BELOW ILLUSTRATES THE PROCESSING SEQUENCE WITH VIS ‘BLE DYE AND FLUORESCENT PENETRANTS. : = ma —— veer StaDUAL SENSITIVITY PENETRANTS WOULD FOLLOW & PROCESSING SEQUENCE SIMILAR TO THAT SHOWN BELOW.THE SELECTION OF THE SEST PROCESS, AS LISTED ON PAGES 5 ANO 8, DEPENDS. UPON. SENSITIVITY REQUIRED. NUMBER OF ARTICLES TO BE TESTED. ‘SURFACE CONDITION OF PART BEING INSPECTED. CONFIGURATION OF TEST SPECIMEN. AVAILABILITY OF WATER, ELECTRICITY, COMPRESSED AIR, SUITABLE TESTING AREA, ETO. PENETRANT TESTING IS SUCCESSFULLY USED ON METALS SUCH AS’ ALUMINUM MAGNESIUM, BRASS, COPPER, CAST IRON, STAINLESS STEEL, TITANIUM. AND MOST OTHER COMMON ALLOYS. IT CAN ALSO BE USED TO TEST OTHER MATERIALS, INCLUDING CERAMICS, PLASTICS, MOLDED RUBBER, POWDERED METAL PRODUCTS, OR GLASS. PENETRANT TESTING IS LIMITED BY ITS INABILITY TO TEST MATERIALS WITH DISCONTINUITIES THAT ARE NOT OPEN TO THE SURFACE OR HAVING AN EX: TREMELY POROUS SURFACE.ane LESSON uz omnis nuns a say te! como ns ng a pvarnt “ype l panetens, according lo ou" es, st6 ase containing afhoescent dy Because of he capilry action of peneans, his 2recess of aspecton warks wo on pais ‘wim very porous suaces ‘nen dong a aud pentane, he confit ol he specie hs ite efact on the a {ctvenesso he test. Luau pentrantnsoecon can be used ely on metals Such a summa and st ‘Tn penetran nepection method s used ony n he fess produc: Ct and wing ar the names a he two men who vented the pendant test metho. The feat meant step peneratlesing is srtce preperation. ‘one of the moat comman contaminant inte panatrant meth water. ‘The moat comenan mete of surtace preperation or penetan esi is sanding, Chemical etting it sometmas used o remove smeared metal rom = surace to open dlscon: Some svosurace defects cn be lcs wih te hry senave Type I panera’ ‘low hoes and ges porsty may be detected wih the penstran meted Salvent cionng ie commen method of suace Searing parts bors penetra! tesing. ‘The one major iation o peetrant esting thane pat must be net (Grease and st woud usualy be considered a contaminant onthe sacs ofa oleate «detect wih penerat esting, he elect must be open othe surface is considered advantagecus fora eu penetra mater have ew tension an igh csptoty 1 ace,LESSON 2 THIS LESSON DISCUSSES THE EQUIPMENT AND MATERIAL REQUIRED TO PERFORM THE VARIOUS PENETRANT TESTS AND THE REQUIRED PRE- AND POST-TEST CLEAN: ING. PROPER CLEANING IS ESSENTIAL TO LIQUID PENETRANT TESTING FOR TWO REASONS 1. If THE SPECIMEN IS NOT CLEAN AND DAY, PENETRANT TESTING IS INEFFEC- TWE. 2. IF ALL TRACES OF PENETRANT MATERIALS ARE NOT RENOVED AFTER THE TEST. THEY MAY HAVE A HARMFUL EFFECT ON THE SPECIMEN. (CHLORINE ANO SULFUR MAY AFFECT SOME ALLOYS } IMMERSION TANKS AND DETERGENT SOLUTIONS ARE COMMON VEANS OF ASSUR: ING THAT & SPECIMEN SURFACE IS SOTH PHYSICALLY ANO CHEMICALLY CLEAN. VAPOR DEGREASING IS PARTICULARLY EFFECTIVE IN THE REMOVAL OF OlL. GREASE, AND SIMILAR ORGANIC CONTAMINATION. HOWEVER, CERTAIN ALLOYS HAVE AN AFFINITY FOR SPECIFIC ELEMENTS USED IN VAPOR DEGREASING AND IF EXPOSED TO THEM MAY BECOME STRUCTURALLY DAMAGED. ‘STEAM CLEANING IS PARTICULARLY ADAPTABLE TO THE CLEANING OF LARGE, UN: WIELOY ARTICLES SOLVENT CLEANING MAY BE USED IN IMMERSION TANKS OR MAY BE USEO IN A \WIPE-ON ANO WIPE.OFF TECHNIQUE. SOLVENT CLEANING IS USUALLY LESS EFFEC. TIVE THAN THE PREVIOUS METHODS OF CLEANING a RUST AND SURFACE SCALE CAN BE REMOVED BY ANY GOOD COMMERCIALLY AVAILABLE ACIO OR ALKALINE RUST REMOVER FOLLOWING MANUFACTURER'S DIRECTIONS: PAINT REMOVAL IS OFTEN DONE IN DISSOLVING-TYPE HOT-TANK PAINT STRIPPERS, BOND RELEASE, OR SOLVENT PAINT STRIPPERS. ETCHING IS EFFECTIVE FOR USE ON ARTICLES THAT HAVE EEEN 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, GAIT, OR PRESSURE), LIQUID HONING, EMERY CLOTH, WIRE BRUSHES AND METAL SCRAPERS. THESE PROCESSES TEND TO CLOSE DISCONTINUITIES BY PEENING OR COLD WORKING THE SURFACE OF THE SPECIMEN. PENETRANT TEST EQUIPMENT (STATIONARY) STATIONARY EQUIPMENT USED IN LIQUID PENETRANT TESTING VARIES IN SIZE AND IS LARGELY DEPENDENT UPON THE SIZE OF THE TEST SPECIMEN. DEPENDING ON THE TYPE AND PROCESS USED. A STATIONARY SYSTEM COULD INCLUDE THE FOLLOWING. 1, PRECLEANING STATION (USUALLY 7, DRYING STATION (USUALLY OVEN) IN REMOTE AREA) 8. INSPECTION STATION (ENCLOSED 2. PENETRANT STATION (TANK) BOOTH OR TABLE WITH PROPER 3, DRAIN STATION UHTING) |4, EMULSIFICATION STATION (TANK) 9, POSTCLEANING STATION (USUALLY 5, RINSE STATION [TANK] IN REMOTE AREA) 6. DEVELOPING STATION (TANK)nN enon 8 PENETRANT TEST EQUIPMENT (PORTABLE) GOTH VISIBLE AND FLUORESCENT DYE PENETRANTS ARE AVAILABLE IN KITS WHICH CAN BE USED AT A REMOTE LOCATION OR WHEN TESTING & SMALL POR- TION OF A LARGE AATICLE, A VISIBLE DYE PENETRANT KIT USUALLY CONTAINS: |. 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 ANO BRUSHES. ‘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 PENETFANT. 4. PRESSURIZED SPRAY CANS OF NONAQUEOUS DEVELOPER, 5. WIPING CLOTHS AND BRUSHES, BLACK LIGHT EQUIPMENT IS REQUIRED IN FLUORESCENT PEN:TRANT TESTING SINCE (T SUPPLIES LIGHT OF 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 TEMPERATURE WHEN USING MERCURY ARC LAMPS. THE BLACK LIGHT EMITS A SPECIAL LIGHT WITH WAVELENGTHS THAT FALL BE: TWEEN VISIBLE AND ULTRAVIOLET. PROVIDED THAT THE FILTER IS NOT BROKEN (OR CRACKED, THERE IS NO DANGER OF INJURY TO THE HUMAN EYE. IT IS SUG- GESTED THAT THE FILTER 8E CHECKED PRIOR TO EACH USE.PENETRANT TESTING MATERIALS CAN BE USED IN A VARIETY OF COMBINATIONS. MOST MATERIALS AAE AVAILASLE IN EITHER PRESSURIZED SPRAY CANS OR IN BULK QUANTITIES. THE FLOW CHART BELOW ILLUSTRATES THE DIFFERENT MATERIAL COMBINATIONS. HOWEVER, CARE SHOULD ALWAYS BE TAKEN TO ASSURE THAT MANUFACTURERS SPECIFICATIONS OR COMPANY PROCEDURES ARE CLOSELY FOLLOWED [Pr Leste Gace Cesson 2 PENETRANT TESTING MATERIALS PENETRANT MATERIALS ARE OFTEN AESTRICTED TO SPECIFC GROUPS, THE ESTABLISHED GROUPS OF PENETRANT MATERIALS WILL USE THE FOLLOWING IN A VARIETY OF COMBINATIONS TO OBTAIN THE 8EST RESULTS: 1. WATER-WASHABLE PENETRANTS—CONTAIN AN EMULSIFYING AGENT WHICH MAKES THEM EASILY REMOVABLE BY A WATER AINSE OR WASH, THIS PENETRANT MATERIAL CAN BE OBTAINED WITH EITHER A VISIBLE OR FLUORESCENT OVE 2. POST-EMULSIFIABLE PENETRANTS—ARE HIGHLY PENETRATING, OILY VISIBLE OR FLUORESCENT PENETRANTS WHICH ARE NOT SOLJBLE IN WATER, THESE PENETRANTS MUST BE TREATED WITH AN EMULSIFER BEFORE THEY CAN BE REMOVED BY A WATER RINSE OR WASH 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. 4, EMULSIFIERS—WHEN APPLIED TO A PENETRANT-COATED SPECIMEN MAKE THE RESULTANT MIXTURE REMOVABLE BY WATER RINSE OR WASH EMULSIFIERS HAVE LOW PENETRANT CHARACTERISTICS AND UO NOT REMOVE INDICATIONS FROM THE SPECIMEN SURFACE. 5. REMOVERS (SOLVENT)—ARE DESIGNED TO BE USED IN CONJUNCTION WITH ‘SPECIFIC_PENETRANTS.-TYPICAL-REMOVERS -ARE-AVAILABLE IN-BULK-OR PRESSURIZED SPRAY CONTAINERS. 6. DRY DEVELOPERS—ARE A FLUFFY, ABSORBENT WHITE FOWDER THAT IS USED IN BOTH FLUORESCENT AND VISIBLE DYE PENETRANT TESTS. IT FUNC. TIONS TO DRAW THE PENETRANT INDICATIONS TO THE SURFACE THUS MAK- ING THEM VISIBLE 7. WET DEVELOPERS—FUNCTION SIMILARLY TO ORY DEVELOPERS EXCEPT THAT THEY ARE A MIXTURE OF A DEVELOPING POWDER AND WATER,Teston 2 8 NONAQUEOUS WET DEVELOPERS—OIFFER FROM WET DEVELOPERS IN THAT THE DEVELOPER POWDER IS MIXED WITH A AAPIO-CRYING LIQUID SOLVENT 9. LIQUID OXYGEN (LOX) COMPATIBLE MATERIALS—MUST BE USED WHEN AR- TICLES INSPECTED ARE SUBJECTED TO CONTACT WITH ETHER LIQUID OR GASEOUS OXYGEN. THESE MATERIALS ARE SPECIFICALLY DESIGNED TO BE INERT WHEN IN THE PRESENCE OF LOX. 10. LOW SULFUR AND LOW CHLORINE—PENETRANT MATERIALS MUST E SPECIFICALLY DESIGNED TO AVOID THE HARMFUL EFFECTS CAUSEO ON ‘SOME NICKEL AND TITANIUM ALLOYS BY THE SULFUR ANC CHLORINE CON. TENT. SAFETY PRECAUTIONS. IN GENERAL, THE MATERIALS USED IN PENETRANT INSPECTION CAN BE FLAM- MABLE AND CAN CAUSE SKIN IRRITATIONS. IN ADDITION, THE ULTRAVIOLET SPECTRUM OF LIGHT RAYS GENERATED FROM THE MERCURY ARC LAMP CAN CAUSE SUNBURN AND MAY BE INJURIOUS TO THE EVES HOWEVER, IF THE PROPER FILTER FOR FLUORESCENT DYE INSPECTION IS USED, THE HARMFUL RAYS WILL BE FILTERED OUT. FIRE—MANY PENETRANT MATERIALS ARE FLAMMABLE, SAFE PRACTICE REQUIRES THAT PENETRANT MATERIALS USED IN OPEN TANKS HAVE 4 FLASHPOINT OF GREATER THAN 120° F - — SKIN IRRITATION-SKIN IRRITATION CAN BE AVOIDED BY PREVENTING UN NECESSARY CONTACT AND BY THE USE OF GLOVES. APRONS. AND PROTECTIVE HAND CREAMS. AIR POLLUTION—THE DEVELOPING POWDERS ARE CONSIDERED NONTOXIC BUT EX: CESSIVE INHALATION MUST BE AVOIDED, EXHAUST FANS SHOULO SE INSTALLED IN ANY CONFINED AREA WHERE DRY DEVELOPERS OR VAPORS FROM THE PENETRANTS ARE PRESENTawe. Lesson 2 enon a aecetate method 0! sutace cleming a tet pata to be ‘good exhaust aystsm is ecommended whan working with cleaning solvents. \Yanercegreasing' ctlen usd remove oxton, ust, and acne Deore a pat panetant Pars iat nave been painted ususty cannot be inepacied wih pensrants because sub ein ‘removing techniques Fave not been develope. Detergent sng is accesaie lor posing but should never e use lor pracieaning because tim ast the emulster gurng ne penetra est, ona ie olen alive Beclring a par tat has ben machired fo apecilciclerance by sautace ging Cony waible aye penarants ae avaible portble Ks because Murescent des wilt fe: Dry eeveloers are usualy only used wih vsble dye penevants Enmulsiors and solvents are both commony ued in penevant esty es postcleanee Wet dveionars should neve be used when hay wil come nto coract wih gaseous or fauié ‘nigen becouse ofthe rele eaoted by oxygen and water mixing, [Emusilers must have high penevatng cheracanstes lo ema penetants Ina ein lets and tne covet ers pace an no broken or wacked, Peneirnt materi ae often placed in grouings tat wl assure aad lst wh materi that Noraqueo - Postemusiiable poneans are usualy soubien wale aller he soeiaton olan musi. Water washable pencvants ae cammoly uted wih either a vita of rescence, Fasnoont rele othe lonest tenperaie at which vapors wit ile when expose to tneogee APPLICATION OF PENETRANTS ALMOST ANY LIQUIO COULD BE CONSIDERED A PENETRANT, BUT MODERN PENETRANTS MUST HAVE: 1, THE ABILITY TO HOLD A DYE MATERIAL IN SUSPENSION. THE ABILITY TO SPREAD THE DYE EVENLY OVER THE SURFACE THE ABILITY TO CARRY THE DYE INTO ANY DISCONTINUITY OPEN TO THE SUR- FACE, 4. THE ABILITY TO BRING UP THE DYE AS IT IS “COAXED” BACK TO THE SUR. FACE. 5. THE ABILITY, WHEN DESIRED, TO BE EASILY REMOVED. THERE ARE TWO TYPES OF DYE USED IN MODERN PENETRANTS 1. VISIBLE—A BRIGHTLY COLORED DYE THAT IS HIGHLY VISIBLE JNDER NORMAL LIGHTING CONDITIONS, THIS TYPE OF OYE IS NORMALLY CALLED VISIBLE OYE. 2. FLUORESCENT—AN ALMOST COLORLESS OYE WHICH EMITS VISIBLE LIGHT RAYS WHEN REVIEWED UNDER BLACK LIGHT A DYE WITH DUAL SENSITIVITY CONTAINS BOTH A VISIBLE DYE FOR EXAMINA: TION IN WHITE LIGHT AND A FLUORESCENT DYE FOR A MORE SENSITIVE EVALUA- TION OF SMALL DISCONTINUITIES. PENETRANTS. EITHER FLUORESCENT OR VISIBLE, CAN 8E APPLIED BY ANY ONE OF _ THE FOLLOWING MEANS: 1. SPRAYING—USUALLY USING A LOW PRESSURE CIRCULATION 2UMP OR FROM PRESSURIZED SPRAY CANS, BRUSHING—USUALLY APPLIED WITH RAGS, COTTON WASTE, OR GRUSHES IMMERSION—THE ENTIRE PART IS DIPPED INTO A TANK OF PENETRANT POURING—THE PENETRANT IS SIMPLY POURED OVER THE SURFACEPENETRATION (OWELL) TIME THE PERIOD OF TIME OURING WHICH THE PENETRANT IS PERMITTED TO REMAIN ON THE SPECIMEN IS A VITAL PART OF THE TEST TIGHT CRACKLIKE DISCONTINUITIES 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 THE TEMPERATURE OF THE SPECIMEN AND TEMPERATURE OF THE PENETRANT CAN AFFECT THE REQUIRED DWELL TIME WARMING THE SPECIMEN TO 70°F OR HIGHER ACCELERATES PENETRATION AND SHORTENS OWELL TIME. HOWEVER, CARE SHOULD BE TAKEN NOT TO OVERHEAT THE SPECIMEN SINCE TOO MUCH HEAT MAY CAUSE EVAPORATION (OF THE PENETRANT FROM THE DISCONTINUITY. WELL TIMES ARE BASED ON THE ASSUMPTION THAT THE PENETRANT WILL RE: MAIN WET ON THE PART SURFACE, ADDITIONAL PENETRANT MAY BE APPLIED DURING DWELL TIME, ‘THE PENETRANT MANUFACTURER WILL PROVIDE SUGGESTED OWELL TIMES FOR THE VARIOUS PENETRANTS THAT IT PRODUCES. PENETRANT TESTING PROCESSES WE PREVIOUSLY MENTIONED THE TWO TYPES OF PENETRANTS, VISIBLE AND FLUORESCENT. FOR BOTH CATEGORIES THERE IS A FURTHER BREAKDOWN: 1. WATER-WASHABLE (VISIBLE OR FLUORESCENT) 2, POST-EMULSIFICATION (VISIBLE OR FLUORESCENT) 3, SOLVENT-REMOVABLE [VISIBLE OR FLUORESCENT) WATER-WASHABLE PENETRANTS HAVE A BUILT-IN EMULSIFIER ANO THE PENETRANT IS EASILY REMOVED BY A WATER RINSE, CARE MUST BE TAKEN TO INSURE THAT THE SPRAY VOLUME AND FORCE DOES NOT WASH PENETAANT OUT OF THE DISCONTINUITY. WATER TEMPERATURES ABOVE 110° F ARE NOT RECOMMENDED SECAUSE THIS MAY SPEED UP THE EVAPORIZATION OF THE PENETRANTCoston THE SKETCH BELOW REPRESENTS THE STEPS IN A WATER-WASHABLE PENETRANT Test. WATER-WASHABLE PENETRANTS ARE USUALLY PREFERRED FOR USE ON AR. TICLES WITH A ROUGH SURFACE OA IF THEY CONTAIN THREADS OR KEYWAYS. THE BUILTN EMULSIFIER PROVIDES THE BEST PENETRANT REMOVAL FROM BLIND HOLES AND OTHER HARD-TO-REACH LOCATIONS SUT HAS THE DISADVAN. TAGE OF POOR RELIABILITY IN DETECTING WIDE OR SHALLOW DISCONTINUITIES. (SEE PAGE 6 FOR ADVANTAGES AND DISADVANTAGES)SOLVENT-REMOVABLE PENETRANTS—THEY HAVE THE ADVANTAGE OF PORTABIL: ITY AND CAN BE USED OUTDOORS WITHOUT USING HEAVY. COMPLEX EQUIPMENT THEY ARE EXCELLENT FOR MANY MAINTENANCE INSPECTIONS AND FOR CHECK. ING PORTIONS OF A LARGER STRUCTURE PENETRANT IS OFTEN APPLIED FROM A rican PRESSURIZED SPRAY CAN WHICH MAKES . THE SYSTEM VERY PORTABLE AFTER THE SPECIFIED OWELL TIME, THE EXCESS PENETRANT IS FIRST REMOVED é BY WIPING WITH ABSORBENT TOWELS = AND THEN CLEANED WITH TOWELS DAMPENED WITH SOLVENT. SOLVENT IS NEVER APPLIED DIRECTLY TO THE SPECIMEN AS IT MIGHT WASH (OUT OA DILUTE THE PENETRANT IN THE DISCONTINUITY. (SEE PAGE 6 FOR ADVANTAGES AND DISADVANTAGES OF SOLVENT-REMOVASLE PENETRANTS) POST-EMULSIFICATION PENETRANTS AEQUIRE A TWO-STEP REMOVAL PROCESS, THE EMULSIFIER IS USUALLY APPLIED BY DIPPING OR IMMERSION. THE AMOUNT OF DOWELL TIME IN THE EMULSIFIER IS IN THE RANGE OF ONE TO FOUR MINUTES IN AC- CORDANCE WITH MANUFACTURERS’ RECOMMENDATIONS AND THE TYPE OF DEFECTS EXPECTED THE RESULTANT EMULSIFIER-PENETRANT MIXTURE IS REMOVED 8Y WATEA RINSE (EMULSIFICATION WILL BE COVERED IN MORE DETAIL IN LESSON 4)1_WATER-WASHABLE Tessar 3 | seuvwevemsrene 2. SOLVENT-REMOVABLE JA Aaa 3. POST-EMULSIFICATIONLEAK-THROUGH TECHNIQUE—THE USE OF LIQUID PENETRANT IN THIS METHOD IS ‘SUITED FOR FINDING LEAKS IN SUCH ARTICLES AS TANKS. PIPING, TUBING, AND, HOLLOW CASTINGS. THE SKETCH BELOW ILLUSTRATES THE LEAK-THROUGH TECHNIQUE FIXING AND RECORDING INDICATIONS. 1. PHOTOGRAPHS—TYPICAL BLACK AND WHITE AND COLOR FILM ARE USED WITH THE SELF-DEVELOPING FILMS PROVIDING THE MOST CONVENIENCE 2, SPECIAL WAX AND PLASTIC FILM DEVELOPERS HAVE SEEV DEVELOPED TO ABSORB AND FIX THE PENETRANT INDICATION TO FORM A PERMANENT RECORD, A, STRIPPABLE LACQUERS ARE SPRAYED IN SEVERAL COATS OVER THE IN: DICATION AND WHEN ORY CAN BE “LIFTED” TO PROVIDE A PERMANENT RECORD, B, SPECIAL “FIXERS” ARE SPRAYED OVER THE INDICATION ANO WHEN DAY ARE LIFTED WITH TRANSPARENT TAPELESSON 3 uz, 2 chal sensitty panetant conlahs 8 spec ye Ia sible whe Hoh and wi Roresc® ‘etnout he ee o blak hh A par being penetantmspacted must stay Immersed hth pera ank fr te eniro peeled due ime The qu penetra’ eakstvough lst rare fo he aby of «pene ry ceveloper every. Viable dye penetans are usvsly considered lobe lets sane than herent pentrants. ‘Walerwashatio poneiranis havea buit-n enusiier that permis 900 resus penetra removal Wom parts suapeced of hing wide e slow Gacontvuts, Sohventemovabie penetanis are aveate m both vin and Murescent dye, Excess poat-eruisiibia penetra! i commonly removed by spreyng the ata ole pr wih leaner (sven) and then wing wah n-eelowel Waterwasnabe penetant ays ar usutly very porate because ne materials are com- monly used in pressurized spray cane Waring ihe soecimen lo temperatures upto about 70°F tds to accelerate penetration and shortens de ine, For the dw tne lobe accurate, he sacs ol the soecimen must say wet with penarat for the ene inspected he typical awa tne for mos! penetra iapecton Is About 20-20 minutes. 12, Ust two (2) of he conmenty used methods of aopyeg penetrant lo specimen ‘halt to Be mapecie, {o sereag rrough the 18. Lst-towr ofthe -commeny uted: methods of preciearing the spechnen bere penetrantinspacion oboe, each XX 3 inches wit fled hres, whic 11 you were asked lo examine 200 natant method would you chooes? (2) post emuttestin (b) water washableLESSON 4 THIS LESSON DISCUSSES EMULSIFICATION, PENETRANT REMOVAL, AND DEVEL. OPER APPLICATION POST-EMULSIFICATION PENETRANT [P. £, PENETRANT} THIS TYPE OF PENETRANT EMULSIFICATION IS ACCOMPLISHED BY DIPPING THE PART IN A CHEMICAL EMULSIFIER PRIOR TO WASHING. THE EMULSIFIER WILL BREAK DOWN THE PENETRANT AND MAKE IT WATER SOLUBLE. THE EMULSIFIER CAN SE APPLIED BY DIPPING OR SPRAYING, BUT NOT BY BRUSHING. THE BRISTLES OF THE SRUSH MAY ENTER THE DISCONTINUITY SN XD SSD) = vipDp cinIF TOO SHORT AN EMULSIFICATION TIME IS USED. NOT ALL PENETRANT WILL BE REMOVED, WHICH WILL CLOUD OVER CISCONTINUITIES, IF TOO LONG A TIME IS USED, PENETRANT WITHIN THE DISCONTINUITIES WILL ALSO BECOME WATER SOLUBLE AND BE WASHED AWAY WITH EXCESS PENETRANT. THE PE PENETRANT MAKES THE WATER WASH LESS CRITICAL, THE SKETCHES BELOW COMPARE THE EFFECTS OF WATER-WASHABLE ANO POST- EMULSIFICATION PENETRANTS Wow ss isconTINuIcs. A SOOM - merece «eae (A) WATER-WASHABLE. (8) POST-EMULSIFICATIONDEVELOPER APPLICATION ‘SOME INDICATIONS MAY BE VISIBLE PRIOR TO THE APPLICATION OF & DEVELOPER, SUT 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 QUT OF THE DISCONTNUITY BY THE STRONG CAPILLARY ACTION OF THE DEVELOPER AS SHOWN ABOVE, THE IMAGE OF THE DISCONTINUITY IN THE OEVELOPER WILL ACTUALLY BE LARGER THAN THE ACTUAL SIZE OF THE DISCONTINUITY THERE ARE TWO COMMON TYPES OF DEVELOPERS IN USE TODAY—WET AND DRY. OTH USE A WHITE POWDER AND THE PRIMARY DIFFERENCE IS IN THE METHOD OF APPLICATION, oe es 1. WET DEVELOPERS: ‘A, THE NONAQUEOUS DEVELOPER IS HELO IN SUSPENSION IN A SOLVENT. BASE AND IS USUALLY SUPPLIED IN PRESSURIZED CANS, ANOTHER TYPE OF WET DEVELOPER HOLDS THE WHITE POWDER IN SUSPENSION IN A WATER BASE. THIS TYPE OF WET DEVELOPER IS GENERALLY USED WITH WATER: WASHABLE OR P. E. PENETRANTS ANO IS APPLIED BY DIPPING OR SPRAY. ING. AFTER APPLICATION, A SHORT TIME 1S ALLOWED FOR THE WATER TO EVAPORATE LEAVING A THIN LAYER OF WHITE POWDER IF AN OVEN IS USED, THE TEMPERATURE SHOULD NOT EXCEED ABOUT 225 F AS THIS COULD EVAPORATE PENETRANT IN THE DISCONTINUITY2. DRY DEVELOPERS [A DRY DEVELOPER IS A FLUFFY WHITE POWDER THAT (S NOT CARRIED IN A uu, DRY DEVELOPERS ARE APPLIED DIRECTLY TO THE ARTICLE AS A POWDER. THIS IS USUALLY CONE WITH SLIGHT AIR PRESSURE OR ARTICLES MAY BE DIPPED INTO A CONTAINER OF DRY DEVELOPER, ITIS VERY NECESSARY TO HAVE A DRY SURFACE PRIOR TO APPLICATION OF ‘A DRY POWDER. A WET SURFACE WILL RESULT IN UNEVEN LAYERS OF POWDER - DRY DEVELOPER IS USUALLY USED ON FLUORESCENT PENETRANTS. ‘ADVANTAGES OF ““WET"" DEVELOPERS BETTER ON SMOOTH SURFACES WHERE THE ORY DEVELOPER WILL NOT ADHERE. WHEN A WIDE, SHALLOW DISCONTINUITY IS SOUGHT, A WET DEVELOPER WILL LEAVE A MORE EVEN COAT OF DEVELOPER ADVANTAGES OF "DRY" DEVELOPERS ON ROUGH SURFACES, AND ON SHARP FILLETS, HOLES, AND THREADED AR. TICLES, THE WET DEVELOPER TENDS TO LEAVE TOO MUCH DEVELOPER,LESSON 4 mung seamed onan too kng ane sadam, ptt uring the rns cycle, an emus ie ace lo &savenremovabb penetant 0 make it water Waler-washable peneants havea bull envi Pos emulsification penetrants are commonly avaabe n bol vable and WMorescent dyes ‘Te penevan removal oracess win waterwashable peneirans i very ec! because of he anger suowensah salle SoWvaniramonatie penetans ae common utes because tay wl withstand & very force water wash winou! Ie cenge of over wasn, 7 lpeng the pal a tank o soventsouon, Wet daveloners are usualy chosen ove a dry dovelope or use cma smooth sce A major advaniage one ory developer over wet fat i wil no owe the sre arti of ex: ets buloup m Bveads and ‘The emsteaion me requred io dete! wid or shalow cicontndes is wsuaty lenge ha To avoid overwash whan usig water washable peetrans the wale soraynozl is wsialy nel a 3 80" angi tothe srlace. len using a waterwashablepereanl the pat must be completes died # a oven ino ‘rcets of 226° F belore the wet dveope Care apmies ‘A mejor edvniage of 2 nonaqueous developer i al # can be spo 0 stats heated shove 225" FwiPou! evaporation on he devloze vehcl Soventremowable horescent pentrants reque he ute o 2 ater me-corsumng meth of Posters visti dye penevants commonly ute both wel and oy developersLESSON 5 THIS LESSON DISCUSSES THE FINAL STEPS IN THE PENETRANT PROCESS: INSPEC. TION, EVALUATION, POSTCLEANING, AND MATERIAL CONTROL. INSPECTION PROPER LIGHTING SHOULO BE AN ARTICLE, |. 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. {E FIRST CONSIDERATION IN THE INSPECTION OF TYPICAL INDICATIONS IN PENETRANT INSPECTION __ALL INDICATIONS FOUND WITH THE LIQUID. PENETRANT. METHOD WILL BE SUR- FACE DISCONTINUITIES, BUT THE INDICATIONS MAY OR MAY NOT AFFECT THE USEFULNESS OF THE ARTICLE, FALSE INDICATIONS. THE MOST COMMON SOURCE OF FALSE INDICATIONS IS POOR WASHING. THE OPERATOR CAN EASILY TELL WHEN A GOOD RINSE IS OBTAINED BY US- ING A BLACK LIGHT DURING AND AFTER THE FLUORESCENT PENETRANT REMOVAL PROCESS,seentason § 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 TRANSFERRED TO CLEAN SPECIMEN FAOM OTHER INDICATIONS 4 PENETRANT ON INSPECTION TABLE, ‘Typleal False ts NONRELEVANT INDICATIONS, NONAELEVANT INDICATIONS ARE ACTUAL SURFACE DISCONTINUITIES THAT IN MOST CASES ARE THERE BY DESIGN. THEY ARE CAUSED BY SOME FEATURE OF ASSEMBLY SUCH AS ARTICLES THAT ARE PRESS-FITTED, KEYED. SPLINED, OR IVETED, NONRELEVANT INDICATIONS COULD ALSO INCLUDE LOOSE SCALE OR A ROUGH ‘SURFACE ON A FORGING OR CASTING,TRUE INDICATIONS (SOME TYPICAL INDICATIONS ARE SHOWN IN CHAPTER 6, PAGES 8-19 IN THE TRAINING HANDBOOK) TRUE INDICATIONS ARE THOSE CAUSED BY SURFACE DISCONTINUITIES THAT HAVE BEEN INTERPRETED AS NOT BEING FALSE OR NONRELEVANT. TRUE INDICATIONS ARE SUBJECT TO EVALUATION AS TO THE CAUSE AND THE EFFECT THEY WILL HAVE ON THE SERVICE LIFE OF THE ARTICLE TRUE INDICATIONS-COULD -8E-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 PEENED, MACHINED, OR GROUND. 3, ROUND—USUALLY CAUSED 8Y POROSITY OPEN TO THE SURFACE. 4. SMALL DOTS—TINY ROUND INDICATIONS CAUSED BY THE 20ROUS NATURE OF THE SPECIMEN, COARSE GRAIN STRUCTURE, OR MICRCSHRINKAGE, 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, DEPTH DETERMINATION OF PENETRANT DISCONTINUITIES THE GREATER THE DEPTH OF A DISCONTINUITY, THE MORE PENETRANT IT WILL. HOLD AND THE LARGER AND BRIGHTER THE INDICATION. POSTCLEANING AFTER THE SPECIMEN HAS BEEN INSPECTED IT |S VERY IMPORTANT THAT IT BE THOROUGHLY CLEANED, POSTCLEANING USUALLY WILL INVOLVE THE SAME TYPES OF CLEANING OPERATIONS AS WERE USED IN PRECLEANING.son's QUALITY CONTROL OF PENETRANT TEST MATERIALS ALUMINUM TEST BLOCKS—THEY PROVIDE & GOOD MEANS 2F EVALUATING GENERAL PURPOSE PENETRANTS. THEY SHOULD BE USED FOR COMPARISONS ONLY AND NOT FOR ABSOLUTE EVALUATIONS, THESE 8LOCKS ARE NONUNIFORM, AND THE OEPTH AND WIDTH OF CRACKS ARE UNCONTROLLED THE SIZE OF THE BLOCKS MAY VARY BUT ARE ABOUT 3/8 BY 2 INCHES OF 2024.T-3 ALUMINUM, ABOUT 3 INCHES LONG. THE BLOCKS ARE HEATED AND QUENCHED TO PRODUCE AN OVERALL CRACK PAT: TERN. THEY CAN BE REUSED BY REHEATING, QUENCHING. ANO CAREFUL CLEAN. ING PENETRANT 2 PENETRANT SLOT IN Test BLOCK SENSITIVITY TESTS—WHILE THERE HAVE SEEN 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 ALUMINUM 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.tesisn § MENISCUS TEST—FROVIDES A PRACTICAL TEST FOR EVALUATING THE DYE CON: (CENTRATION IN THIN-LIQUIO FILMS. THE TEST UTILIZES A FLAT GLASS PLATEN AND A CONVEX LENS WHEN A OROP OF SOLUTION IS PLACED BETWEEN THE LENS AND PLATEN, A COLORLESS OA NONFLUORESCENT 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 COLORLESS PENETRANT PROVIDES ‘A MEASURE OF FILM THICKNESS WHICH CAN BE USED TO COMPARE THE DYE ~~ GONCENTRATION OF PENETRANTS. PROLONGED EXPOSURE OF A FILM TO ULTRAVIOLET LIGHT OR ACCIDENTAL CONTAMINATION BY ACIOS OR ALKALIS WILL AFFECT THE DYE CONCENTRATION AND THEREFORE CHANGE THE SPOT DIAMETER, contact spot, angle Tens a Tater CERAMIC BLOCK TEST—CONSISTS OF AN UNGLAZED CERAMIC DISC WHICH HAS THOUSANDS OF MICROPORES AND CRACKS ON ITS SURFACE A PENCIL MARK IS MADE ON THE BLOCK AND A SMALL AMOUNT OF A TEST ~PENETRANT IS PLACED ON ONE SIE AND A REFERENCE PENE-RANT IS APPLIED TO THE OTHER SIDE. AFTER THE CORRECT DWELL TIME, THE TWO PENETRANTS ARE COMPARED IN A SIDE-BY-SIDE VISUAL EXAMINATION. ‘A REDUCTION’IN THE NUMBER OR APPARENT BRIGHTNESS OF PORE INDICATIONS SHOULD BE OBSERVED WHEN COMPARING A FRESH AND OLD BATCH OF PENETRANT. WATER CONTENT TEST—THE ASTM STANDARD 0-95 DESCRIBES A TEST WHERE 100 ML OF PENETRANT IS PLACED IN A BOILING FLASK WITH A SMILAR QUANTITY (OF MOISTURE-FREE XYLENE. THE CONDENSATE IS COLLECTED IN A GRADUATED TUBE TO SHOW PERCENT OF WATER BY VOLUME IF PERCENT OF WATER EXCEEDS MANUFACTURERS’ RECOMMENDATIONS, THE PENETRANT IS DISCARDED.VISCOSITY TEST—A VISCOMETER TUBE IS USED TO MEASURE THE VISCOSITY IN CENTISTOKES TO DETERMINE IF THE PENETRANT IS WITHIN THE RANGE RECOM: MENDED BY THE MANUFACTURER. A TYPICAL STANDARD IS ASTM 0-445. FLUORESCENT PENETRANT FADE TEST—THIS TEST INVOLVES THE USE OF THE ALUMINUM TEST BLOCKS IN A SIDE-BY-SIDE COMPARISON TEST "THE FLUORESCENT PENETRANT IS PLACED ON BOTH SIDES OF THE BLOCK AND PROCESSED NORMALLY. ONE HALF OF THE BLOCK IS THEN EXPOSED TO A STAN: DARD BLACK LIGHT FOR ONE HOUR, WHILE THE OTHER SIDE 1S COVERED WITH PAPER, THE FLUORESCENT BRILLIANCE OF THE TWO SIDES IS OBSERVED AND, IF ONE SIDE IS NOTICEABLY LESS BRILLIANT, THE PENETRANT IS DISCARDED. WATER WASHABILITY TEST—THIS TEST EVALUATES THE EFFICIENCY OF THE EMULSIFIER BY COMPARING TWO DIFFERENT PERCENTAGE BLENDS OF PENETRANT AND EMULSIFIER A SPECIAL STEEL BLOCK IS PLACED AT A 75° ANGLE AND THE TWO BLENDS ARE ALLOWED TO FLOW SEPARATELY DOWN THE BLOCK, AFTER A FIVEMINUTE "WAITING PERIOD. THE BLOCK IS WASHED AND EXAMINED FOR TRACES OF REMAIN. ING PENETRANT. DEVELOPERS—DRY DEVELOPERS ARE SIMPLY VISUALLY INSPECTED TO SEE THAT THEY ARE NOT LUMPY OR CAKED INSTEAD OF FLUFFY ANO LIGHT. WET DEVELOPERS ARE OFTEN CHECKED USING A HYDROMETER TO ASSURE THAT THE DENSITY OF THE POWDER IN THE VEHICLE IS WITHIN THE RANGE RECOM. MENDED BY THE MANUFACTURER, FILTERED PARTICLE METHOD OF PENETRANT INSPECTION—WHEN TESTING & POROUS SURFACE WITH FILTERED PARTICLES, THE INCREASED AREA CREATED BY A CRACK WILL “FILTER" THE PENETRANT, LEAVING THE PARTICLES ON THE SUR FACE7) aa ane Lesson 5 ‘type! face inca could be cause By an assemay tht requres in component o be Nenvelvantneiotons cous be caused by he rough surtace ona easing Postlering necessary eny when the part mus Be rlesed by te quid penerant mato, [A typcal te incaton producing round ication common ceed by nora, Diluted or weak indeatens ere ton causes by subsurace lsconinuties, andthe pat must be ralesieg using a ighy seraive pnelan hl wit penetrate gra true, rue iniceons ar usualy hase el requ evaluation Yo delorine Wer act onthe wervies He othe pa “Te aun tes Blocks uses penevant evasion are ested ra avenchad wale 0 ro: ‘The senaivy tests used in enetrant inpecton ar riatvely imo, nanquanistve, and ure sie-by sce viva observation, The meniscus ost utes lt glass ten and convex len fo determine the ae concent: ton of vise o Huorescentpenevant ‘Te ceramic block lest uses an unfired ceramic dsc le deteming the apcerent brightness o he | spac steel block, paced ata 7 angi Dry developers ae often checkad with a nyerometer one tal hay are ei ight and lly ‘and not sete io a Gense mature ‘Te tuorscont penetran tide ist usualy makes use ofthe amin aa blocks 10 pet he tered partie meio of penevant inspection used eta fa INorescent patil na wil not pass tough a #120 seve, ‘The daptn oa dlscontnuty can be comoared by cbservng the relate iz or beghiness of he incaton Penetrant that has been wransfered to a clean ari rom the cation on anata aie can cause ase ateaton Nenslevantneeation olten are ati! scace dscontenies, If ascominaty i avatisted 98 being a Yue hatin, the ate shoud auomacahy bere: inci a used 1 check the actvaness oftheLESSON 6 THIS LESSON DISCUSSES TYPES OF DISCONTINUITIES THAT CAN BE EVALUATED WITH THE LIQUID PENETRANT METHOD. DISCONTINUITIES CAN BE DIVIDED INTO THREE GENERAL CATESORIES: INHERENT. PROCESSING, AND SERVICE. 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 RELATE TO THE MELTING, CASTING, AND SOLIDIFICATION OF A CAST ARTICLE. USUALLY CAUSED BY INHERENT VARIABLES SUCH AS INADEQUATE FEEDING, GATING, EXCESSIVE POURING TEMPERATURE, AND ENTRAPPED GASES, 2. PROCESSING DISCONTINUITIES—THEY ARE USUALLY RELATED TO THE VARIOUS MANUFACTURING PROCESSES SUCH AS MACHINNG, FORMING, EX: TRUDING, ROLLING, WELDING, HEAT TREATING, AND PLATING 3. SERVICE DISCONTINUITIES—THEY ARE RELATED TO THE VARIOUS SERVICE CONDITIONS SUCH AS-STRESS- CORROSION: FATIGUE” ANO-EROSION-— REMEMBER, WHEN YOU USE THE LIQUID PENETRANT METHOD. YOU CAN FIND ONLY THOSE DISCONTINUITIES WHICH ARE OPEN TO THE SURFACE. HOWEVER, DURING THE MANUFACTURING PROCESS, MANY DISCONTINUITIES THAT WERE SUBSURFACE CAN BE MADE OPEN TO THE SURFACE SY NACHINING, GRIND: ING, ANO THE LIKE, REMEMBER THAT DISCONTINUITIES ARE NOT NECESSARILY DEFECTS. ANY INDICA. TION 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.LISTED BELOW ARE SOME TYPICAL DISCONTINUITIES THAT SHOULD SE RECOG. NIZED WHEN OOING ANY TYPE OF NONDESTRUCTIVE TEST. (& MORE DETAILED STUDY OF TYPICAL DISCONTINUITIES CAN BE OBTAINED EY READING PRO. GRAMMED INSTRUCTION HANDBOOK Pi-4-1.) DISCONTINUITIES-TRAPPED-IN-THE-INGOT-OURING-THE-STEELMAKING PROCESS MAY CAUSE ADDITIONAL TYPES OF DISCONTINUITIES AS THE STEEL IS USED IN THE MANUFACTURE OF AN ARTICLE, THERE ARE THREE MAIN TYPES OF DISCONTINUITIES FOUND IN INGOTS. 1. PoRosiTy—causED ay ENTRAPPED GAS IN THE MOLTEN a a 2. NONMETALLIC INCLUSIONS—CAUSED fnfcitsows BY IMPURITIES ACCIDENTALLY IN- CLUDED IN THE MOLTEN METAL. IPE—CAUSED BY SHRINKAGE AT THE ‘CENTER OF THE INGOT AS THE MOLTEN METAL SOLIDIFIES. THE "HOT TOP" IS USUALLY CROPPED OFF TO REMOVE MOS" OF THE ABOVE DISCONTINUITIES,WHEN AN INGOT IS FURTHER PROCESSED INTO SLABS, SLOOMS, AND BILLETS, 1T 'S POSSIBLE FOR THE DISCONTINUITIES TO CHANGE SIZE AND SHAPE. AS A BILLET IS FLATTENED AND SPREAD OUT, NONMETALLIC INCLUSIONS MAY CAUSE A LAMINATION. PIPE AND POROSITY COULD ALSO CAUSE LAMINATIONS INV THE SAME MANNER AS SHOWN BELOW: AS A BILLET IS ROLLED INTO BAR STOCK, NONMETALLIC INCLUSIONS ARE SQUEEZED OUT INTO LONGER AND THINNER DISCONTINUITIES CALLED STRINGERS,Pr Lecture cuce AS A BILLET IS ROLLED INTO ROUND BAR STOCK, SURFACE IRAZGULARITIES MAY CAUSE SEAMS. SEAMS ARE CAUSED BY FOLDING OF METAL OUE TO IMPROPER, ROLLING OR BY A CRACK IN THE BILLET AS SHOWN BELOW: ‘A SEAM COULD ALSO OCCUR WHEN THE BILLET IS FORMED INTO A RECTANGULAR BAR AS SHOWN BELOW:Pr Leche Gace FORGING DISCONTINUITIES OCCUR WHEN METAL IS HAMMERED OR PRESSED INTO SHAPE, USUALLY WHILE THE METAL IS VERY HOT. ‘A FORGED PART GAINS STRENGTH OUE TO THE GRAIN FLOW TAKING THE SHAPE OF THE DIE, AND THE PROCESS IS SHOWN BELOW. ‘A FORGING LAP IS CAUSED BY FOLDING OF METAL ON THE SUFACE OF THE FORGING, USUALLY WHEN SOME OF THE FORGING METAL IS SQUEEZED OUT BETWEEN THE TWO DIES. GZ A FORGING BURST IS A RUPTURE CAUSED BY FORGING AT IMPROPER TEMPERATURES. BURSTS MAY. BE EITHER INTERNAL OR-OPEN-"O-THE SURFACE |AS SHOWN BELOW. “or cer on etaCASTING DISCONTINUITIES OCCUR WHEN MOLTEN METAL IS POURED INTO A MOLD. AND ALLOWED TO SOLIDIFY. A COLD SHUT IS CAUSED WHEN MOLTEN METAL IS POURED OVER SOLIDIFIED METAL AS SHOWN BELOW: HOT TEARS (SHRINKAGE CRACKS) OCCUR WHEN THERE IS UNEQUAL SHRINKAGE BETWEEN LIGHT AND HEAVY SECTIONS AS SHOWN BELOW:SHRINKAGE CAVITIES ARE USUALLY CAUSED BY LACK OF ENOUGH MOLTEN METAL TO FILL THE SPACE CREATED BY SHRINKAGE, SIMILAR “O PIPE IN THE IN Gor. [esse MICROSHRINKAGE IS USUALLY MANY SMALL SUBSURFACE HOLES THAT APPEAR AT THE GATE OF THE CASTING. MICROSHRINKAGE CAN ALSO OCCUR WHEN. THE MOLTEN METAL MUST FLOW FROM A THIN SECTION INTO THICKER SECTION OF A CASTING. BLOW HOLES ARE SMALL HOLES AT THE SURFACE OF THE CASTING CAUSED BY GAS WHICH COMES FROM THE MOLD ITSELF, MANY MOLDS ARE MADE OF SAND, AND WHEN MOLTEN METAL COMES INTO CONTACT WITH THE MOLD, THE WATER IN THE SAND IS RELEASED AS STEAM. POROSITY IS CAUSEO BY ENTRAPPED GAS. POROSITY IS USUAL.Y SUBSURFACE BUT CAN OCCUR ON THE SURFACE DEPENDING ON THE DESIGN OF THE MOLD.GRINDING CRACK. ARE A PROCESSING-TYPE DISCONTINUTY CAUSED BY STRESSES WHICH ARE QUILT UP FROM EXCESS HEAT CREATED BETWEEN GRINO- ING WHEEL AND METAL. GRINDING CRACKS WILL USUALLY OCCUR AT RIGHT ANGLES TO THE ROTATION OF THE GRINDING WHEEL HEAT TREAT CRACKS ARE OFTEN CAUSED SY THE STRESSES BUILT LS OURING HEATING AND COOLING. UNEQUAL COOLING BETWEEN LIGHT AND HEAVY SEC. TIONS MAY CAUSE HEAT TREAT CRACKS. HEAT TREAT CRACKS HAVE NO SPECIFIC DIRECTION AND USUALLY START AT SHARP CORNERS WHICH ACT AS STRESS CONCENTRATION POINTS. FATIGUE CRACKS ARE SERVICE-TYPE OISCONTINUITIES THAT ARE USUALLY OPEN TO THE SURFACE WHERE THEY START FROM CONCENTRATION POINTS, FATIGUE CRACKS ARE POSSIBLE ONLY AFTER THE PART IS PLACED INTO SERVICE, BUT MAY BE THE RESULT OF POROSITY, INCLUSIONS OR OTHER OSCONTINUITIES IN A HIGHLY STRESSED METAL PART. =WELDING DISCONTINUITIES—THE FOLLOWING ARE TYPES OF “PROCESSING DISCONTINUITIES. CRATER J ceaysverse cracks STRESS CRACK POROSITY SLAG INCLUSIONS TUNGSTEN INCLUSIONS SSS SE Lack oF PENETRATION S&S LACK OF FUSION CL EE UNDERCUT LLL os DAestan ? AFTER REVIEWING THE PHOTOGRAPHS AND DESCAPTIONS OF TYPICAL DISCON- TINUTIES I> SHOULD BE OBVIOUS THAT LIQUD PENETRANT INSPECTION 18 NOT THE BEST METHOD IN ALL CASES. THE SELECTION OF ONE TESTING METHOD OVER ANOTHER IS BASED UFON VARIABLES SUCH AS {TYRE AND ORIGIN OF DISCONTINUITY 2. MATEFIAL MANUFACTURING PROCESS. 9. ACCESSIBILITY OF ARTICLE 4. LEVEL OF ACCEPTABILITY DESIRED 5. EQUIPMENT AVAILABLE 6. cost TRAINING AND CERTIFICATION IT IS IMPORTANT THAT THE TECHNICIAN AND SUPERVISOR SE QUALIFIED IN THE UQUID PENETRANT METHOD SEFORE THE TECHNIQUE IS USED ANC TEST RESULTS EVALUATED, THE AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING RECOMMENDS THE USE OF ITS DOCUMENT RECOMMENDED PRACTICE NO. SNT-TC-1A. THIS DOCUMENT PROVIDES THE EMPLOYER WITH THE NECESSARY GUIDELINES TO PROPERLY QUALIFY AND CERTIFY THE NOT TECHNICIAN IN ALL METHODS, TO COMPLY WITH THIS DOCUMENT THE EMPLOYER MUST ESTABLISH A ““WRIT- TEN PRACTICE” WHICH DESCRIBES IN DETAIL HOW THE TECHNICIAN WILL BE ‘TRAINED, EXAMINED, AND CERTIFIED, THE STUDENT IS ADVISED TO STUDY PAGE 6 OF THE JUNE 1975 EDITION OF SNT- TO-18 TO DETERMINE THE RECOMMENDED NUMBER OF HOURS OF CLASSROOM INSTRUCTION AND MONTHS OF EXPERIENCE NECESSARY TO BE CERTIFIED AS A LIQUID PENETRANT TESTING TECHNICIAN.Cosson? CERTIFICATION OF NDT PERSONNEL IS THE RESPONSIBILITY OF THE EMPLOYER AND IS USUALLY AT THREE LEVELS. LEVEL IIS QUALIFIED TO PERFORM SPECIFIC CALIBRATIONS, SPECIFIC TESTS, AND SPECIFIC EVALUATIONS ACCORDING TO WRITTEN INSTRUCTIONS, I-18 QUALIFIED TO SET UP AND CALIBRATE EQUIPMENT AND TO INTER: PRET AND EVALUATE RESULTS WITH RESPECT TO CODES, STAN. DARDS, AND SPECIFICATIONS, MUST BE ABLE TO, PREPARE WRITTEN INSTRUCTIONS AND REPORT TEST RESULTS. LEVEL: I=MUST BE-CAPABLE “ANO”RESPONSIBLE FOR ESTABLISHING TECH: NIQUES, INTERPRETING CODES, AND OESIGNATING THE TEST METHOD AND TECHNIQUE TO BE USED. MUST HAVE A PRACTICAL BACK- GROUND IN THE TECHNOLOGY AND BE FAMILIAR WTH OTHER COM. MONLY USED METHODS OF NOT. LeveL THE SNT-TC-1A DOCUMENT RECOMMENDS THAT THE NOT TECHNICIAN BE EXAMINED IN THE FOLLOWING AREAS: ‘A. GENERAL EXAMINATION 8. SPECIFIC EXAMINATION . PRACTICAL EXAMINATIONASNT PROVIDES A SERVICE TO THE INOUSTRY BY PROVIDING LEVEL Ill EXAMINA. TIONS IN THE GENERAL AND PRACTICAL AREAS. BECAUSE OF THE INDIVIDUAL 7E. QUIREMENTS OF THE MANY INDUSTRIES USING NOT, THE SPECIFIC EXAMINATION 'S STILL THE RESPONSIBILITY OF THE EMPLOYER, THE FOLLOWING FLOW CHART INDICATES THE PATHS THAT CAN BE TAKEN TO BE CERTIFIED ACCORDING TO THE ‘SNT-TO-1- DOCUMENTLesson 7 ure ‘tod over another i usualy Ihe decision! he Level eeticisn percrmig net ASNT pronces a ‘he tesponsbilly of ssing a ceria fo he NDT lectin i nays given to fe employer the SHTTC-1A documento bs comied wih, ce ler examining Level, andl personna nthe Genera and Specie {the SNT-TC-1A docuren! iso be used a0 a racommended guideline, he Willen Practice ‘rus be submited to ASNT lor sporva the SNT-TC-1A guidlines ae 1s be Lowes, Ine Lovell tecnico sould havea knows ‘toler commonly used methods of NOT eventhough carillon i needed! ey fe Vad ‘A Levelt tecnica performing» laud peneban! esis permite to acepl or alec he part povided ta wile msiuctons 2 recede we given Io hm bya Lever Lave! er ed ina ‘To comly wih the guidelines of SNI-TC:1A, al tre levele ol tecticons must tke a General, Practcal, and Specie lel exarinatons are used to determine cetieion ‘he June 1978 econ of SNT-TC:1A permis the employer lo waive an mxaninaion for Level bersomel provided tal docimeniatn sn ile showing the lechnicar’squaifintons Ni sent! hat every employer using the SNT-TC-1A document eslaish a Wien Pract, {1 an employer does not have a Level lachien a ie company, he ea lan the services of te eutede agency to ertrm these hnclonsLESSON 7 IDENTIFICATION AND COMPARISON OF DISCONTINUITIES THAT CAN BE FOUND WITH THE LIQUID PENETRANT PROCESS. THE STUDENT IS ASKED TO STUDY THE PHOTOGRAPHS AND DESCRIPTIONS OF TYPICAL DISCONTINUITIES AS PRINTED IN THE PT CLASSROOM TRAINING HAND- BOOK (CT-6-2), EACH OF THE SPECIFIC DISCONTINUITIES ILLUSTRATED ARE DIVIDED INTO THREE GENERAL CATEGORIES: INHERENT, PROCESSING, AND SERVICE. : cou sHuT PAGE 7-10 FILLET CRACK PAGE 7-12 GRINDING CRACKS PAGE 7-15 HEAT-AFFECTED ZONE CRACKING .... PAGE 7-19 HEAT TREAT CRACKS PAGE 7-21 ‘SHRINKAGE CRACKS PAGE 7.24 THREAD CRACKS PAGE 7-26 HYDROGEN FLAKE PAGE 7-31 LACK OF PENETRATION PAGE 7-40 LAMINATIONS vanes PAGE 7-42 LAPS AND SEAMS PAGE 7-44 LAPS AND SEAMS PAGE 7-46 MICROSHRINKAGE PAGE 7-49 STRESS CORROSION PAGE 7-55 HOT TEARS PAGE 7-63 INTERGRANULAR CORROSION PAGE 7-68Lesson 6 ove 1. The genes category of processing scontmutas telat isconntis case aura imanuactunng processes uch 88 wetng,extuag and Neal Weatng 2, Darn the staimaking arocess the to a ne mgot fuel roves 19 Mele elmeate such Secontmutes apne, pore and nonmetlic neers 2. wana iets roted ino ba sock, @nanmetaie nlesion could be Yeed ine &nger ane 44 Porosity abit ould cause a laraon ihe metal were lores a Fat pte 5, Seams are usu subswtacesacontnutns caused by proper raing of ial no round —— 6. Dering the roling ofa bet int ound bar stock, the gran in he metal ams perpendioula 1 the arecton of ing, 7. Inthe tering eperaten, under ©. Forging brats te conscere subeirtace eacontnuties and can never be mspectad with haus 9. Colt shuts are common decontuites found nthe lorgng process anf are caused by hace: (uate nealing af Ihe lrged pat 10. Blow roles a0 seurace dacontuiies common found neat part 11, Because cold meta! accuses more space nan hol mata here is ne cngar of “ha ees” ou fg the eating process 12, Porosity is often caused by entapped gBs thats expended during he nating and pressing the orang process. 13. Meroetvinkage i often found at he gate o casing and is vel subetace. 1 Gini ace are usualy at AEN angi lo ha dracton of grncng a ae caused by ne heal Buicup belweea the grncing whee and meta, 15, Heat eat cracks are olten associate with tess concent 16. Porosty may lado aiue crack na igh sessed part 17. crater cracks and tngsien incisions are botn aesoctee with dacontmties formes ang he wang process 16. Lack of penetration and inc o! fusion both rlar othe same type of weksng agcontnuty 1 atl wl nt low Ihe metal to few propery and may ito poets an the pat being Meat