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2
H A P T E R
Principles of Liquid
Penetrant Testing
FIGURE 3. Postemulsifiable liquid penetrant processes: (a) lipophilic; (b) hydrophilic. Shaded areas indicate
steps that differ between lipophilic and hydrophilic techniques.
(a) (b)
Clean
Dwell Prerinse
Dwell Dwell
Aqueous Aqueous
Dry Dry Dry Dry
developer developer
Nonaqueous Nonaqueous
Dry developer Dry Dry developer Dry
developer developer
Dwell Dwell
Inspect Inspect
Postclean Postclean
(c)
Clean
Emulsified liquid penetrant
Dwell
Emulsifier reaction zone
movement is stopped at
part surface (before it can Initial dry wipe
Liquid penetrant enter entrapment by careful
entrapped in defect timing before rinse starts
not emulsified Solvent wipe
(d)
Room temperature water spray at 45 degrees Final dry wipe
removes emulsified surface liquid penetrant only MOVIE.
Nonaqueous developer Developer is
applied.
Dwell
Inspect
Nonemulsified liquid
penetrant within
Postclean
entrapment is not
removable
(a)
(b)
Water spray
Entrapped
(b) liquid
penetrant
(c)
Water spray
Entrapped
Lost liquid liquid
penetrant penetrant
MOVIE.
Nonaqueous
Nonaqueous Wet
wet developer Developer
enhances Another common developer type is the so
visible dye called nonaqueous wet developer whose
contrast. developer solids come premixed and
suspended in a volatile solvent. The
volatile solvent tends to pull liquid
penetrant from indications by solvent
action. It also accelerates drying so that a
supplementary drying operation is not
(b) (b)
(c)
(c)
(d) (d)
Contrast of Fluorescent
Liquid Penetrant Test Placement of Light Sources
Indications in Liquid Penetrant Testing
In the case of fluorescent liquid penetrant Booth
discontinuity indications, visual Consideration should be given to the
perceptibility is enhanced by light disposition of lights within an inspection
emission mechanisms within the liquid booth and to the effect on an operator of
penetrant indications and conditions of placement of light sources. Although
viewing are quite different. Using ultraviolet-A radiation will not damage
brightness contrast, the bright the eye permanently, some of the layers of
yellow-green indication is seen against a the eyeball exhibit strong tendencies to
nearly black or at least a very dark fluoresce. If the inspection light is placed
background. The indication itself is so that its rays fall directly or are reflected
actually a source of light which, even into the eyes of operators, this eyeball
though small, is quite intense. Contrast fluorescence can become extremely
can be exceptionally high. Some estimates annoying and will impair inspector
give it a value as high as 100 to 1 or even effectiveness to a very marked degree.
much greater, because it is the presence of Use of special filtering eyeglasses will
light compared to absence of light. increase operator perception and reduce
With fluorescent liquid penetrants, the fatigue. Yellow tinted eyeglasses filter out
most effective way to increase visibility the ultraviolet radiation before it reaches
(and improve resolution of fine the eye, yet they do not reduce the
discontinuities) is to increase the visibility of fluorescent indications.
fluorescent brilliance of the liquid
penetrant material. The fluorescent
indications are generally viewed in the
substantial absence of visible light, so that Interpretation of Liquid
the background remains unseen. Penetrant Indications
The interpretation of liquid penetrant
Visibility of Fluorescent Liquid indications is normally a matter of
Penetrant Indications considerable judgment. It might be said
From the point of view of color contrast, that it involves three phases:
most fluorescent liquid penetrants provide (1) observation of indications,
yellow or yellow-green indications against (2) verification of indication cause and
a black background. This has been proven significance and (3) disposition of test
by research into visibility of such objects objects in accordance with applicable
as highway signs to be one of the most criteria for acceptance and rejection.
seeable combinations possible. The The first step is that of visually
normal human eye has its highest observing the indication and verifying
sensitivity in the yellow or yellow green that it is relevant, i.e., that it is indicating
wavelength range. In fluorescent testing, a discontinuity rather than a material
the eye looks at a fine source of light of characteristic that is a normal condition
high brightness. Under this condition, of the surface under investigation.
probably because of halation, the source Figures 12 and 13 show some typical
size appears to be greatly exaggerated liquid penetrant indications.
whereas the dark background tends to be The American Society for Testing and
minimized. Materials (ASTM) has issued ASTM E 433,
Standard Reference Photographs for Liquid
Penetrant Inspection.5 This publication
Background Fluorescence Caused contains reference photographs to be used
by Rough or Porous Surfaces as a means of establishing and classifying
In some practical applications where the type and characteristics of surface
test object surface is porous or rough, discontinuities detectable by liquid
fluorescent liquid penetrant tends to be penetrant test techniques. They may be
retained on the surface as well as in used as a reference for acceptance
discontinuities. This condition reduces standards, specifications and drawings.
contrast between the background and However, no attempt has been made to
indications and may impair establish limits of acceptability or the
discrimination. For this reason, a extent of the metallurgical discontinuity.
compromise between the removability of
(a) (b)
FIGURE 13. Blow holes in casting shown by fluorescent liquid penetrant testing.
Acceptance/Rejection
Criteria for Critical Parts
Test acceptance/rejection criteria for parts
or surfaces would normally be referenced
by an applicable specification, standard
for a particular part or some other
governing document that would outline
what type of discontinuity would be cause
for rejection. An extreme example of this
would be the approach taken by
companies that are working with fracture
mechanics, whereby a particular structure
or part is analyzed for specific types of
discontinuities that may or may not
constitute a rejectable discontinuity.
Standards are then drawn up for the items
for nondestructive test criteria, which may
include liquid penetrant testing. These
would include minimum acceptable
indication size and strict uniform liquid
penetrant processing.
The importance of carefully controlled
liquid penetrant testing and the necessity
to record the exact techniques used to
process the parts on the technique card or
other applicable document cannot be over
emphasized. In a number of
specifications, porosity bleedout diameters
are specified as accept/reject criteria. The
maximum acceptable size limits for liquid
penetrant indications apply to the
bleedout indication immediately after
wiping the indication one time with a
swab or brush dipped in solvent.
Bleedback refers to the recurrence of the
liquid penetrant indication after once
wiping away the original indication.
(a)
Field Application of
Nonaqueous Developers
A convenient developer for use under
field conditions is nonaqueous developer
applied from an aerosol container.
Before applying the developer, the
container should be shaken vigorously to
make certain the materials are well mixed
and all solids are brought into suspension.
The developer should be used sparingly.
Just enough developer is applied with a
spray can to cover the part thinly and
evenly. The proper developer thickness
will dry to a thin, translucent layer. Too
much developer may mask indications.
Care should be taken to use a short
distance of up to 0.3 m (12 in.) between
spray nozzles and test parts to ensure
application of a wet developer coat.
(b) Excessive spraying distances result in
solvent flashoff so that the benefits of a
nonaqueous developer that aids liquid
penetrant from entrapments to reach the
test surface will be lost. The user should
exercise caution because some developers
sprayed from aerosol cans are flammable.
Viewing of Fluorescent
Liquid Penetrant
Indications
For field inspection under ultraviolet
radiation, curtains or other means of
shutting out the natural light are
recommended. The darker the inspection
area, the more reliable the inspection will
be. Outdoor testing is often done at night.
Inspectors should accommodate their eyes
to darkness before inspection.
Maintaining Cleanliness in
Control of Atmospheric Liquid Penetrant
Pollution from Liquid Processing and Test Areas
Good housekeeping in and around liquid
Penetrant Testing Systems penetrant test units should be observed at
Air sampling to ensure that the area all times. A clean piece of equipment not
surrounding the liquid penetrant only looks better but also provides a
processing is being maintained at safe much better inspection. Accumulations of
health levels is an advisable precaution, expendable test materials on equipment
particularly if toxic solvents are known to should be avoided. Liquid penetrant,
be involved. The Environmental either visible or fluorescent, can be
Protection Agency (EPA) has placed especially bad if allowed to collect on
restrictions on the concentrations of work surfaces. It can be picked up by parts
certain volatile solvents in the and may lead to false indications or, at
atmosphere,6 and the Occupational Safety least, confusion to the inspector.
and Health Administration administers Collection of quantities of fluorescent
regulations that limit the accumulated liquid penetrant on interior surfaces of
exposures of personnel to toxic gases or the ultraviolet radiation inspection booth
vapors.7 Continued monitoring of the can be particularly bad. Under the
atmosphere in work areas and of influence of the ultraviolet radiation
emissions from exhaust systems into the always present in the inspection booth,
environmental atmosphere may be masses of fluorescent material can easily
necessary to ensure compliance with these emit enough visible light to affect the
requirements. Some liquid penetrant inspectors darkness adaptation, thereby
processing materials have been specifically lowering the overall sensitivity of the
formulated to abide by air pollution entire liquid penetrant testing process.
restrictions such as those in Los Angeles Precautions must also be taken to
and San Francisco. Because of the rapid ensure that developer powder is free from
changes in environmental and health liquid penetrant contamination.
regulations, users of liquid penetrants and Fluorescent or color dyes in the developer
solvent materials should check their may be carried onto part surfaces with the
compliance with federal, state and developer to produce false indications.
municipal or other applicable codes and Bright fluorescent spots in tank developers
regulations on a continual basis. may also emit light that may interfere
with the inspectors dark adaptation.
Another common source of trouble is the
accumulation of dust behind the filter of
Ultraviolet Lamp the ultraviolet lamp. The filter should be
Maintenance removed and the back of the filter and the
face of the ultraviolet lamp bulb should
An integral part of the fluorescent liquid both be wiped clean whenever dust
penetrant system is the ultraviolet accumulates.
radiation source (ultraviolet lamp), the
intensity of which is vital to a reliable
result. It is recommended that this
intensity be checked weekly or more often
if the light is being operated at an
intensity level close to the minimum.
Ultraviolet radiation intensity should be
measured with a meter calibrated to
requirements of the National Institute of
Standards and Technology. On a
commercially available ultraviolet
radiation meter, measurements are taken
at distances of 380 mm (15 in.) from the
face of the filter on the ultraviolet lamp,
Summary of Ultraviolet
Radiation Safety
With appropriate precautions, fluorescent
penetrant testing can be performed in a
safe and effective manner.
The general rules of ultraviolet safety
are designed to protect the people who
may be exposed to such radiation, directly
or accidentally.
The first level of protection includes
posting areas where ultraviolet radiation
exists in excess of safe limits. Legal
signage must display standard caution
ultraviolet radiation warnings and may
contain additional health protection
information. The color and size of such
signs should meet Federal and state
requirements (see 29 CFR 1910.115).7
Control of the environment is another
critical safety measure.
Equipment that produces ultraviolet
radiation should be enclosed by
partitions, screens or walls painted with
nonreflective paint. Paint containing
metallic particles should not be used. In
addition, this equipment must be labeled
to inform individuals of its potential
health and safety hazards.
Contact the Occupational Safety and
Health Administration (OSHA), the
American National Standards Institute
(ANSI), the American Conference of
Governmental Industrial Hygienists
(ACGIH) and the National Institute for
Occupational Safety and Health (NIOSH)
before performing any fluorescent liquid
penetrant test procedure.