FAILURE MODE AND ACTIONS IN A PENETRANT INSPECTION PROCESS

Rubén Olmeda Sanz

Level 3 PT EN 4179
MPB AEROSPACE S.L.

This article describes, as example, some of the most common failure modes that can occur in a Penetrant Inspection process (water washable penetrant) and corrective and preventive actions to be
performed. This can be useful to be included in the Penetrant Inspection procedure to be available to the inspectors in order to facilitate a quick response to a failure.

FAILURE CAUSES CORRECTIVE ACTION PREVENTIVE ACTION

Check beforehand that the attack factor calculation and time in tank
During pre cleaning etching of 5 microns (or
Time inside the tank or incorrect Repeat pre-cleaning and etching removing the is correct
indicated in each case) is not performed or
installation malfunction number of microns necessary Preventive maintenance of the installation
insufficient
Calibration and periodic checks of the process control software

In case of parts with complex geometry, increasing the drying time

The parts have humidity before penetrant Continue drying to ensure that the parts are
Drying insufficient Preventive maintenance. Calibration and periodic checks of the
application completely dry
process control software

After the application of the penetrant it is Apply the penetrant manually in the areas that
Faulty installation Preventive maintenance. Calibration and periodic checks of the
observed that it does not completely cover require it, respecting again the corresponding
Parts placed improperly process control software Place the parts properly avoiding masks
the parts. penetration time

The maximum penetration time has been Preventive maintenance. Calibration and periodic checks of the
exceeded or dry penetrant is observed on the Faulty installation or human error Clean the parts again and reprocess process control software
surface of the parts. Apply more penetrant preventing drying as often as necessary

Preventive maintenance. Respect the guidelines established and

Improper wash or wash conditions
Overwashing during the penetrant removal Wash with water and re-reprocess the parts controlling pressure washing and wash temperature before
(pressure / temp) unfulfilled
processing each batch.

Temperature or maximum time of drying is Preventive maintenance. Calibration and periodic checks of the
Faulty installation Clean the parts again and reprocess
exceeded after penetrant removing process control software
 FAILURE
The maximum application time of developer has been
exceeded
During the inspection parts have excessive
background fluorescence
The dry developer does not cover all the areas to be
inspected with a thin and uniform layer
After post cleaning are detected rests of product
(penetrant or developer) on the parts.
Equipment out of calibration are detected
The intensity of light (UV or white) is out of maximum
or minimum values required
The control process efficiency results non conform
The condition of developer does not comply with the
requirements
CAUSES
Faulty installation
Improper wash or penetrant
deteriorated
Faulty installation
Parts placed improperly
Improper wash
Human Error
Failure or exhaustion of the light
sources
Tam Panel dirty, processed
incorrectly or damaged.
Penetrating deteriorated
No efficient process
Product expired or
deteriorated.
Contamination by penetrant
trawls (baskets / frame or
parts) or wet (incorrect drying)
CORRECTIVE ACTION
Clean the parts again and reprocess
Clean the parts again and reprocess
In case of repeated failure perform washability test
Apply developer manually in areas with lack of
coverage or change the position of the parts and
reapply the developer using the fluid tank bed
Manual cleaning with solvent and repeat the
washing process and dry
Interrupt the process and immediately report to
Quality Assurance
Interrupting and repair or replace the light sources.
Immediately notify the Quality Assurance
Carefully clean again Tam Panel and re-process. If
the result is still negative, the process is
interrupted and immediately communicated to
Quality Assurance to perform root cause analysis
(which must include completion of the testing
process sensitivity and washability).
If it detects that the Tam panel is damaged,
replace and repeat the test with a new Tam Panel.
Interrupt the process, discard the developer, clean
tank and replenish new developer
PREVENTIVE ACTION
Preventive maintenance. Calibration and periodic checks
of the process control software
Respect washing guidelines established Performing
periodic test of washability
Preventive maintenance. Calibration and periodic checks
of the process control software. Place the parts properly
avoiding masks
Respect washing guidelines established
Adequate monitoring of calibrations plan
Preventive maintenance. Proper review of cleanliness and
integrity of filters. Have a safety stock of bulbs / lamps
Maintenance and proper cleaning of Tam Panel. Correct
processing of Tam Panel Robustness in the process
Properly control expiration and storage of the product.
Remove excess of penetrant correctly both as parts of
baskets and racks to avoid dragging. Drying the parts
correctly
 FAILURE CAUSES CORRECTIVE ACTION PREVENTIVE ACTION

Penetrant in use does not comply with the Product expired or

requirements (features, separation of constituents,
pollution, washability, water content, fluorescence
intensity, ..)
Interrupt the process, replace the penetrant. In the
deteriorated. Properly control expiration and storage of the product.
event of affected parts, immediately report to
Contamination by moisture or Prior cleaning and drying the parts correctly performed
Quality Assurance
other contaminants.

Carefully clean again Tam Panel (as shown in

Tam Panel dirty, processed Annex 4) and repeat the measurement. If the result Maintenance and proper cleaning of Tam Panel. Correct
Tam Panel degradation exceeds the required ± 30%
incorrectly or damaged. is still negative, the Tam panel is replaced by a processing of Tam Panel
new Tam Panel.

Rubén Olmeda Sanz

Level 3 PT EN 4179
MPB AEROSPACE S.L.