Lec9 DyePenetrationTest

INSPECTION AND MATERIALS ENGINEERING
SKG-15

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SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

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Course Objective :
At the end of the programme, participants will be able to : Describe the methods and basic applications of conventional NDT techniques Identify conventional and specialised NDT techniques performed during inspection

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Introduction Definition of NDT :

The development and application of technical method to materials and/or components in ways that DO NOT impair future usefulness and serviceability in order to detect, locate, measure, interpret and evaluate discontinuities

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Definition of DEFECT :
A flaw (imperfection or unintentional discontinuity) of such size, shape, orientation, location, or properties as to be rejectable

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Definition of DISCONTINUITY :
A lack of continuity or cohesion; An interruption in the normal physical structure of material or a product

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Definition of FLAW :
An imperfection or unintentional discontinuity which is detectable by a nondestructive examination

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Definition of IMPERFECTION :
A condition of being imperfect; A departure of a quality characteristic from its intended condition

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Definition of INDICATION :
The response or evidence from the application of a nondestructive examination

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Conventional NDT :
1 Dye / Liquid Penetrant Testing (DPT) 2 Magnetic Particle Inspection (MPI) 3 Ultrasonic Testing (UT) Thickness Gauging (UTTG) Flaw Detection (UTFD) 4 Radiography Testing (RT) 5 Eddy Current Testing (ECT)


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Specialised NDT :
1 Tubular Inspection Remote Field Electromagnetic Testing (RFET) or Remote Field Eddy Current (RFEC) Magnetic Flux Leakage (MFL) Internal Rotary Inspection System (IRIS) 2 Infrared Thermography 3 Time of Flight Diffraction (TOFD)


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Specialised NDT :
4 Acoustic Emission Testing (AE) 4 Ultrasonic C-scanning 5 Gamma Scanning 6 Long Range Ultrasonic 7 Pulse Eddy Current (PEC) 8 Small Concentrated Area Radiography (SCAR) 9 Radioisotope Tracer

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DYE PENETRANT TESTING (DPT)

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Application of DPT :
To detect Surface Discontinuity Discontinuities which are open to the surface of nonporous metals and other materials

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DPT Subject Content :

1 Theory of DPT Technique aAdvantages bDisadvantages cWorking Principle 2 Basic Application dApplication Method eLiquid Penetrant Materials f Liquid Penetrant Methods gDevelopers 3 Results Interpretation

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1. Theory of Dye Penetrant Testing (DPT) Technique

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1 Theory of DPT Technique aAdvantages bDisadvantages cWorking Principle

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A.
Advantages of DPT :
Portable Able to inspect on a small area Simple and fast Sensitive for very fine cracks Any defect size, configuration, internal structure or chemical composition Any material, ferrous and nonferrous metals Not affected by material magnetic properties Orientation of the discontinuity is not a factor

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B.
Disadvantages of DPT :
External / surface defects only Surface coating, grease, oil, dirt, and paint must be removed Poor or rough surface affects result Not applicable to porous material No direct information on depth of defect Method is often abused if not fully understood

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C.
Working Principle of DPT :
Migrating by Capillary Action into discontinuities or cavities that are open to the surface Reverse Capillary due to equilibrium action Blotter effect by Developer Contrast between the Liquid Dye and the Developer Colour contrast (visible under white light) Fluorescent (visible under Ultraviolet light)

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Capillary Action Forces :

Cohesive Force Forces of attraction between molecules within a single phase Adhesive Force Forces of attraction between molecules of two different phases Adhesive > Cohesive Surface Tension Interfacial tension between two phases

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2. Basic Application

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Basic Application
aApplication Method bLiquid Penetrant Materials cLiquid Penetrant Methods dDevelopers

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A.
Application Method :
i. Surface Preparation ii. Apply Liquid Penetrant to surface iii. Allow time for penetration iv. Remove excess Penetrant v. Apply Developer to surface vi. Perform inspection and review result vii. Post cleaning

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(i). Surface Preparation :

Cleaning Ensure crack is not filled or blocked by debris Ensure no surface contaminant would prevent Capillary action from taking place mask or disturb development of indications

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Method of Precleaning :
Mechanical cleaning metal removing processes such as filing, buffing, scraping, grinding, etc. are often used to remove carbon, rust and scale, sands, etc. these processes may decrease the effectiveness of the Penetrant testing by smearing or peening over metal surfaces and filling discontinuities open to the surface. Detergent cleaning may be alkaline, neutral or acidic in nature, but must be non-corrosive

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Vapour degreasing removes oil and grease-type soils from surface will not remove inorganic-type soils such as dirt, corrosion, salts, etc. Steam cleaning a type of hot-tank alkaline cleaning method will remove inorganic/organic soils, but may not reach the bottom of deep discontinuities

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Solvent cleaning used to dissolve soils such as grease, oily films, waxes, sealants, paints, etc. must be residue free Acid etching inhibited acid (pickling) solutions used to remove oxide scales (descaling) caution for possibility of hydrogen embrittlement

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Paint stripping removed by bond release solvent paint remover paint film must be completely removed to expose the surface of the metal Ultrasonic cleaning adds ultrasonic agitation to solvent or detergent cleaning to improve cleaning efficiency and decrease cleaning time

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(ii). Apply Liquid Penetrant to Surface :

Soaking with Penetrant Provide a method for Capillary Action to occur Provide a contrast for detection of indication Application : Spraying, Immersion, Pouring Apply in excess to ensure full coverage

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Temperature of Surface :
Not less than 15C (60F) Not more than 50C (125F) If temperature exceeds the above, the test will require a qualification procedure Liquid Penetrant Comparator block : Quenched cracked aluminum block 2 " x 3" face, 3/8" thick

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(iii). Allow Time for Penetration :

Allow time for Capillary Action to seep into cracks Dwell Time Typically 5 ~ 15 minutes Not applicable to porous or absorbing material May be affected by temperature of specimen Maintain penetrant in its liquid stage Do not allow time too long for it to dry up

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(iv).
Remove Excess Penetrant :
Remove excess Penetrant that is not relevant to crack indication during development For Solvent Removal Penetrant : Wipe with lint free cloth Follow by cloth dampened with Solvent Avoid direct spraying from pressurised can Avoid over washing or flushing of Penetrant For Fluorescent Penetrant, view under blacklight during cleaning

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(v). Apply Developer to Surface :

Provide a medium for Capillary Action to take place in reverse direction Provide colour contrast to indication eg. white powder against red dye Enlargement of indication Essential to observe developing process Developing time is dependent on type and size of discontinuities big wide cracks : immediate results tight cracks : takes time

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(v).
Apply Developer to Surface :
Dipping in tank, followed by drying Spraying from pressurised can Apply with powder puff Ensure thin and even layer of coverage Excessive developer masks small indications Insufficient developer will not provide sufficient capillary force to draw penetrant

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(vii). Post Cleaning :

Remove Penetrant and Developer after test Penetrant may be acidic or alkaline Avoid corrosion

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Basic Application

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Liquid Penetrant Materials
Visible-Dye
Fluorescent
Emulsifier Liquid Penetrant Methods Water Water Solvent
Developers
Wet Water Suspended Particle
Dry
Non-Aqueous Wet
Water Soluble

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B. Liquid Penetrant Materials :

Fluorescent Fluoresce brilliantly under Ultraviolet Light Visible-Dye Usually red in colour Produce vivid indications in contrast to the white background of Developer

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Restrictions of Penetrants :
A Fluourescent Penetrant examination SHALL NOT follow a Visible-Dye (Colour Contrast) Penetrant examination Intermixing of Penetrant materials from different families or different manufacturers is NOT permitted

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Property of Penetrants :
Ability to hold a Dye Ability to spread the Dye evenly over the surface Ability to bring out the Dye during developing Easy to remove

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Good Characteristics of Penetrants :

High Surface Tension Low Density High Wetting properties Non-toxic High flash point and low volatility Viscosity is NOT a criteria

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Basic Application

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Visible-Dye
Fluorescent
Developers
Wet Water Suspended Particle
Dry
Non-Aqueous Wet
Water Soluble

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C. Liquid Penetrant Methods :

i. ii. iii. Water Washable Post Emulsifiable Solvent Removable

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(i). Water Washable Method :

Fluorescent or Visible-Dye Penetrants have a built-in Emulsifier Penetrants are directly Water Washable from the surface, ie. water rinsing Low penetrating characteristics Designed for use at temperature range of 15~50C Loses sensitivity below 2C

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(i)a.
Water Washable Fluorescent :
Fastest of the three Fluorescent methods Least sensitive of the three Fluorescent methods Not reliable to reveal open and shallow discontinuities Unable to detect the very tightest cracks

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(i)b.
Water Washable Visible-Dye :
Fastest and simplest of all Penetrant methods Least sensitive of all Penetrant methods Penetrant may be removed from wide, shallow discontinuities Least sensitive to locate tight cracks

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(ii). Post Emulsifiable Method :

Fluorescent or Visible-Dye Penetrants are Oil Based High penetrating characteristics Penetrant contains no emulsifier, requires a separate emulsifying step to facilitate water rinse removal of penetrant Penetrants require a Post Emulsifier to form a water soluble mixture that can be rinsed with water

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(ii)a.
Post Emulsifiable Fluorescent :
Two types of Emulsifier : Oil Base Emulsifier (Lipophilic) function by diffusion, no longer used Water Base Emulsifier (Hydrophilic) function by displacement Most sensitive of all Penetrant methods Able to detect wide, shallow discontinuities as well as tight cracks Requires only a short penetration time

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(ii)b.Post Emulsifiable Visible-Dye :
More sensitive than the Water Washable Visible-Dye method

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(iii). Solvent Removable Method :

Fluorescent or Visible-Dye Penetrants are Solvent based Able to use at site for a small surface area Solvent cleaners remove excess Penetrant by direct solvent action Flammable solvents have low toxicity but may be fire hazards Non-flammable solvents require well ventilated areas as they are often toxic

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Basic Application

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Visible-Dye
Fluorescent
Developers
Wet Acqueous Water Suspended Particle Water Soluble
Dry
Wet Non-Aqueous

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Good Characteristics of Developers :

Absorbent to draw penetrant out of a defect Fine grained and not lumpy Able to mask the background but not thick enough to mask a defect Light and easily applicable Easily wet by penetrant Easily removed from the specimen Inert and non-toxic

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D. Developers :
i. ii. iii. iv.
Dry Water Suspendible (wet acqueous) Water Soluble (wet acqueous) Solvent Suspendible (wet non-acqueous)
The visible evidence on presence of Penetrants must be enhanced by the Developer

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(i). Dry Developers :

Used with Fluorescent Penetrants, rarely used with Visible-Dye Penetrants Highly absorptive, light and fluffy Applied by dipping parts in the powder or by a hand scoop, followed by shaking off the excess

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(ii).
Water Suspendible Developers :
Applied just after excess Penetrant is washed and immediately before drying Reduced developing time as developing action proceeds as it is drying Provides good sensitivity Easy application by dipping or flowing from a nozzle or paint spray gun Amount of powder must be carefully controlled to avoid reduced sensitivity

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(iii).
Water Soluble Developers :
Less sensitive than the Water Suspendible types No need to maintain proper powder content A solution of salts in the form of fine granules which can be dissolved in water

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(iv).
Solvent Suspendible Developers :
Provides maximum Developer sensitivity Provides a smooth uniform coating Quick drying No dripping even on vertical surface Portable kits with spray cans Often used with Visible-Dye Penetrants Effective in revealing very fine cracks if sprayed lightly and rapidly over the surface

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Pre-Clean
Penetrant Application
Fluorescent
Visible-Dye
Water Wash Rinse Dry Parts
Developer Application
Apply Dry Developer
Apply NonAqueous Developer
Apply Aqueous Developer
Dry Parts
Inspection
Fluorescent Inspection
Visible-Dye Inspection
Post Clean
Type 1 - Water Washable Penetrant Inspection Processing Procedures ASME Section V - Nondestructive Examination

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Pre-Clean
Fluorescent Visible-Dye
Emulsification Water Wash Rinse
Dry Parts
Apply Aqueous Developer
Apply Dry Developer
Dry Parts
Inspection
Post Clean
Type 2 - Post Emulsifiable Penetrant Inspection Processing Procedures ASME Section V - Nondestructive Examination

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Pre-Clean
Fluorescent
Visible-Dye
Solvent Wipe-Off
Dry Parts
Apply Dry Developer
Inspection
Post Clean
Type 3 - Solvent Removable Penetrant Inspection Processing Procedures ASME Section V - Nondestructive Examination

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3. Results Interpretation

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Viewing Results :
Final interpretation shall be made within 7 ~ 30 mins after the developing requirements are satisfied Ensure proper and sufficient lighting Avoid glare For Fluorescent method : Ultraviolet (Black Light) illuminance Warmed up minimum 5 mins before use Dim environment

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Indications :
False Indications : Incomplete removal of excess Penetrants Contamination by hands, equipment and surface debris Non-Relevant Indications : Actual surface discontinuities that existed due to the design Rough surface on forging or casting materials

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Evaluating Indications :
Typical discontinuities detectable are cracks, seams, laps, laminations, and porosity Relevant Indications : Continuous Lines Intermittent Lines Rounded Indications Small Dot Indications Diffuse Indications Retest any diffused or weak indications

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Evaluating Indications :
Edges of Indications Brilliance and extent of Indications Time for Indication to develop Persistence of Indication

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Precautionary Requirements :
Chemical contaminants : Halide content on Stainless Steel and Titanium Chloride, Fluoride, Bromide Sulfur content on Nickel alloys Content limited to 1 wt %

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Reporting :
5 D's : Datum points from which measurements taken Dimensions of defects Distances of defects from datum points Defect types Drawings to show location and dimension of defects

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4. Questions & Answers

Lec9 DyePenetrationTest

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INSPECTION AND MATERIALS ENGINEERING

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

Introduction Definition of NDT :

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

DYE PENETRANT TESTING (DPT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

DPT Subject Content :

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

1. Theory of Dye Penetrant Testing (DPT) Technique

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

1 Theory of DPT Technique aAdvantages bDisadvantages cWorking Principle

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

Working Principle of DPT :

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

Capillary Action Forces :

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

(i). Surface Preparation :

INSPECTION AND MATERIALS ENGINEERING

SKG 15-2 : NON DESTRUCTIVE TESTING (NDT)

INSPECTION AND MATERIALS ENGINEERING