LIQUID PENETRANT TESTING

Dita Nursafitri, S.ST

YOU SHOULD KNOW

 GENERAL KNOWLEDGE
 Definition and importance of NDT
 Types of NDT methods

 PHYSICAL PRINCIPLES OF THE TEST

 PROCESSING
 TEST EQUIPMENT AND MATERIALS
 CODES, STANDARDS, PROCEDURES AND
SAFETY
 PRESENTATION AND RECORDING OF RESULTS
 INTERPRETATION OF RESULTS, LIMITATIONS
GENERAL KNOWLEDGE
Definition
Non-destructive testing is the use of physical
methods which will test materials, components and
assemblies for flaws in their structure without damaging
their future usefulness.
NDT is concerned with revealing flaws in the
structure of a product. It, however, cannot predict where
flaws will develop due to the design itself.
All NDT methods have the following common
characteristics:
1. The application of a testing medium to the product to
be tested.
2. The changes in the testing medium due to the defects
in the structure of the product.
3. A means by which it detects these changes.
4. Interpretation of these changes to obtain information
about the flaws in the structure of the product.
GENERAL KNOWLEDGE
 Importance of NDT

NDT plays an important role in the quality control of a product. It

is used during all the stages of manufacturing of a product. It is used to
monitor the quality of the:
1. Raw materials which are used in the construction of the product.
2. Fabrication processes which are used to manufacture the product.
3. Finished product before it is put into service.

Use of NDT during all stages of manufacturing results in the following

benefits:
1. It increases the safety and reliability of the product during operation.
2. It decreases the cost of the product by reducing scrap and conserving
materials, labour and energy.
3. It enhances the reputation of the manufacturer as producer of quality
goods.

All of the above factors boost the sales of the product which bring
more economical benefits to the manufacturer.
NDT is also used widely for routine or periodic determination of
quality of the plants and structures during service. This not only increases
the safety of operation but also eliminates any forced shut down of the
plants.
GENERAL KNOWLEDGE

Types of NDT methods

-Visual testing (VT)
-Liquid penetrant testing (PT)
-Magnetic particle testing (MT)
-Eddy current testing (ET)
-Radiographic testing method
(RT)
-Ultrasonic testing (UT)
GENERAL KNOWLEDGE
PHYSICAL PRINCIPLES OF THE TEST
(PT)

Liquid penetrant testing is one of the oldest and

simplists NDT methods where its earliest versions
(using kerosene and oil mixture) dates back to the
19 th century. This method is used to reveal
surface discontinuities by bleedout of a colored or
fluorescent dye from the flaw. The technique is
based on the ability of a liquid to be drawn into a
"clean" surface discontinuity by capillary action.
After a period of time called the "dwell time",
excess surface penetrant is removed and a
developer applied. This acts as a blotter that draws
the penetrant from the discontinuity to reveal its
presence.
PHYSICAL PRINCIPLES OF THE TEST
(PT)

Liquid penetrant testing is one of the most

widely used NDT methods. Its popularity can be
attributed to two main factors: its relative ease of
use and its flexibility. It can be used to inspect
almost any material provided that its surface is not
extremely rough or porous. Materials that are
commonly inspected using this method include;
metals, glass, many ceramic materials, rubber and
plastics.
However, liquid penetrant testing can only be
used to inspect for flaws that break the surface of
the sample (such as surface cracks, porosity, laps,
seams, lack of fusion, etc.).
PHYSICAL PRINCIPLES OF THE TEST
(PT)
Penetrant inspection consists essentially of the following
sequence of operations:
(1) The surface of components to be inspected is prepared by
cleaning, creating a clean dry surface.
(2) Penetrant is applied to the prepared surface to be inspected.
(3) A period of time is allowed for it to enter any discontinuity open
to that surface.
(4) The excess penetrant is removed in such a manner that will
ensure retention of penetrant inside of the discontinuity.
(5) A developer agent is applied to draw the penetrant liquid from
the discontinuities out to the surface and thereby give an
enhanced indication of such discontinuities.
(6) The discontinuities are then visually examined and assessed
under appropriate viewing conditions.
(7) The part is then cleaned and, as necessary, a corrosion
preventative is applied.
PHYSICAL PRINCIPLES OF THE TEST
(PT)
PROCESSING
(PT)
Standard specifications classify penetrant materials
according to their physical characteristics and their
performance.
1. Penetrant materials come in two basic types:
- Fluorescent Penetrants: they contain a dye or several
dyes that fluoresce when exposed to ultraviolet radiation.
- Visible Penetrants: they contain a red dye that provides
high contrast against the white developer background.

Fluorescent penetrant systems are more sensitive than

visible penetrant systems because the eye is drawn to the
glow of the fluorescing indication. However,visible penetrants
do not require a darkened area and an ultraviolet light in
order to make an inspection.
PROCESSING
(PT)
2. Penetrants are then classified by the method used to remove
the excess penetrant from the part. The four methods are:

 Water Washable: penetrants can be removed from the part

by rinsing with water alone. These penetrants contain an
emulsifying agent (detergent) that makes it possible to wash
the penetrant from the part surface with water alone. Water
washable penetrants are sometimes referred to as self-
emulsifying systems.
 Post-Emulsifiable, Lipophilic: the penetrant is oil soluble
and interacts with the oil-based emulsifier to make removal
possible.
 Solvent Removable: they require the use of a solvent to
remove the penetrant from the part.
 Post-Emulsifiable, Hydrophilic: they use an emulsifier that
is a water soluble detergent which lifts the excess penetrant
from the surface of the part with a water wash.
PROCESSING
(PT)
3. Penetrants are then classified based on the strength
or detectability of the indication that is produced for a
number of very small and tight fatigue cracks. The five
sensitivity levels are:
 Level ½ - Ultra Low Sensitivity
 Level 1 - Low Sensitivity
 Level 2 - Medium Sensitivity
 Level 3 - High Sensitivity
 Level 4 - Ultra-High Sensitivity

The procedure for classifying penetrants into one of

the five sensitivity levels uses specimens with small
surface fatigue cracks. The brightness of the indication
produced is measured using a photometer.
STEPS OF LIQUID PENETRANT TESTING
1. Surface Preparation: One of the most critical steps of a liquid
penetrant testing is the surface preparation. The surface must
be free of oil, grease, water, paints, varnishes, plating, heavy
oxides or other contaminants that may prevent penetrant from
entering flaws. The sample may also require etching if
mechanical operations such as machining, sanding, or grit
blasting have been performed. These and other mechanical
operations can smear metal over the flaw opening and prevent
the penetrant from entering.
2. Penetrant Application: Once the surface has been thoroughly
cleaned and dried, the penetrant material is applied by
spraying, brushing, or immersing the part in a penetrant bath.
Once the part is covered in penetrant it must be allowed to
dwell so the penetrant has time to enter any defect that is
present.

There are basically two dwell mode options:

- Immersion-dwell: keeping the part immersed in the penetrant
during the dwell period.
- Drain-dwell: letting the part drain during the dwell period (this
method gives better sensitivity).
STEPS OF LIQUID PENETRANT TESTING
3. Penetrant Dwell: The penetrant is left on the surface for
a sufficient time to allow as much penetrant as possible to
be drawn from or to seep into a defect. Penetrant dwell
time is the total time that the penetrant is in contact with
the part surface. Dwell times are usually recommended
by the penetrant producers or required by the
specification being followed. The times vary depending on
the application, penetrant materials used, the material,
the form of the material being inspected, and the type of
discontinuity being inspected for. Minimum dwell times
typically range from five to 60 minutes. Generally, there
is no harm in using a longer penetrant dwell time as long
as the penetrant is not allowed to dry. The ideal dwell
time is often determined by experimentation and may be
very specific to a particular application. Penetrant
Application: Once the surface has been thoroughly cleaned
and dried, the penetrant material is applied by spraying,
brushing, or immersing the part in a penetrant bath.
Once the part is covered in penetrant it must be allowed
to dwell so the penetrant has time to enter any defect that
is present.
STEPS OF LIQUID PENETRANT TESTING

The time required to fill a flaw depends on a number of

variables which include:
 The surface tension of the penetrant.
 The contact angle of the penetrant.
 The dynamic shear viscosity of the penetrant.
 The atmospheric pressure at the flaw opening.
 The capillary pressure at the flaw opening.
 The pressure of the gas trapped in the flaw by the penetrant.
 The radius of the flaw or the distance between the flaw walls.
 The density or specific gravity of the penetrant.
 Microstructural properties of the penetrant.

The ideal dwell time is often determined by experimentation

and is often very specific to a particular application. For example,
the table shows the dwell time requirements for steel parts
according to some of the commonly used specifications.
STEPS OF LIQUID PENETRANT TESTING
STEPS OF LIQUID PENETRANT TESTING
4. Excess Penetrant Removal: This is the
most delicate part of the inspection procedure
because the excess penetrant must be
removed from the surface of the sample while
removing as little penetrant as possible from
defects. Depending on the penetrant system
used, this step may involve cleaning with a
solvent, direct rinsing with water, or first
treating the part with an emulsifier and then
rinsing with water.
STEPS OF LIQUID PENETRANT TESTING
Removal Method
 Water-Washable : the most economical to apply
of the different methods and it is easy to use.
Water-washable or self-emulsifiable penetrants
contain an emulsifier as an integral part of the
formulation. The excess penetrant may be
removed from the object surface with a simple
water rinse.
 Solvent Removable : For small localized areas.
This method requires hand wiping the surface
with a cloth moistened with the solvent remover,
and is, therefore, too labor intensive for most
production situations.
STEPS OF LIQUID PENETRANT TESTING
Removal Method
 Post-Emulsifiable : When removal of the penetrant from the
defect due to over-washing of the part is a concern.
 Post-emulsifiable : - Lipophilic
- Hydrophilic
 Post-emulsifiable penetrants require a separate emulsifier
to breakdown the penetrant and make it water washable.
The part is usually immersed in the emulsifier but may also
be sprayed on the object. Brushing is not recommended.
The emulsifier is aloowed sufficient time to react with the
penetrant on the surface of the part but not given time to
make its way into defects to reacht with the trapped
penetrant.
 The hydrophilic post-emulsifiable method (Method D) is
more sensitive than the lipophilic post-emulsifiable method
(Method B). The major advantage of hydrophilic emulsifiers
is that they are less sensitive to variation in the contact and
removal time.
STEPS OF LIQUID PENETRANT TESTING

When using an emulsifiable penetrant is used, the

penetrant inspection process includes the following steps
(extra steps are underlined):
1. pre-clean part,
2. apply penetrant and allow to dwell,
3. pre-rinse to remove first layer of penetrant,
4. Apply hydrophilic emulsifier and allow contact
for specified time,
5. rinse to remove excess penetrant,
6. dry part,
7. apply developer and allow part to develop, and
8. inspect.
STEPS OF LIQUID PENETRANT TESTING
5. Developer Application: A thin layer of
developer is then applied to the sample to
draw penetrant trapped in flaws back to the
surface where it will be visible. Developers
come in a variety of forms that may be
applied by dusting (dry powders), dipping, or
spraying (wet developers).

Nonaqueous developers are generally recognized as

the most sensitive when properly applied. However, if
the thickness of the coating becomes too great, defects
can be masked.
STEPS OF LIQUID PENETRANT TESTING
STEPS OF LIQUID PENETRANT TESTING
STEPS OF LIQUID PENETRANT TESTING
6. Indication Development: The developer is
allowed to stand on the part surface for a
period of time sufficient to permit the
extraction of the trapped penetrant out of
any surface flaws. This development time is
usually a minimum of 10 minutes.
Significantly longer times may be necessary
for tight cracks.
7. Inspection: Inspection is then performed under
appropriate lighting to detect indications from any
flaws which may be present.
8. Clean Surface: The final step in the process is to
thoroughly clean the part surface to remove the
developer from the parts that were found to be
acceptable.
TEST EQUIPMENT AND MATERIALS
 Viscosity : The change in viscosity affects the
speed of washing characteristics. The increase in
penetrant viscosity will increase dragout on test
parts, slow penetration into discontinuities, and
change the wash characteristics.
 Temperature Control : Temperatures from 27
to 49°C are reported in the literature to produce
optimal results. Many specifications allow testing
in the range of 4 to 52°C.
TEST EQUIPMENT AND MATERIALS
 Penetrant Quality Control : The quality of a
penetrant inspection is highly dependent on the
quality of the penetrant materials used.
 Dwell Quality Control : The only real quality
control required in the dwell step of the process is
to ensure that a minimum dwell time is reached.
There is no harm in allowing a penetrant to dwell
longer than the minimum time as long as the
penetrant is not allowed to dry on the part.
TEST EQUIPMENT AND MATERIALS
 Emulsifier Path Quality Control
1. Lipophilic Emulsifiers : when the concentration
of penetrant contamination in the emulsifier
becomes too great, the mixture will not function
effectively as a remover. Standards require that
lipophilic emulsifiers be capable of 20%
penetrant contamination without a reduction in
performance. When the cleaning action of the
emulsifier becomes less than that of new
material, it should be replaced.
TEST EQUIPMENT AND MATERIALS
 Emulsifier Path Quality Control
2. Hydrophilic Emulsifiers : have less tolerance
for penetrant contamination. The penetrant
tolerance varies with emulsifier concentration
and the type of contaminating penetrant. In
some cases, as little as 1% (by volume)
penetrant contamination can seriously affect
the performance of an emulsifier.
TEST EQUIPMENT AND MATERIALS
 Emulsifier Concentration and Contact Time
: The optimal emulsifier contact time is
dependent on a number of variables that include
the emulsifier used, the emulsifier concentration,
the surface roughness of the part being inspected,
and other factors. Usually some experimentation
is required to select the proper emulsifier contact
time.
TEST EQUIPMENT AND MATERIALS
 Wash Quality Control : The wash temperature,
pressure and time are three parameters that are
typically controlled in penetrant inspection
process specification When the spray method is
used, the water pressure is usually limited to 276
kPa. The temperature range of the water is
usually specified as a wide range (e.g., 10 to
38°C). The wash time should only be as long as
necessary to decrease the background to an
acceptable level.
TEST EQUIPMENT AND MATERIALS
 Drying Process Quality Control : To prevent
harming the penetrant material, drying
temperature should be kept to less than 71°C.
Also, the drying time should be limited to the
minimum length necessary to thoroughly dry the
component being inspected.
 TEST EQUIPMENT AND MATERIALS
 Developer Quality Control :
1. Dry Powder Developer : should be checked daily to ensure that it
is fluffy and not caked. It should also be relatively free from specks
of fluorescent penetrant material from previous inspection.
2. Wet Soluble/Suspendable Developer : The concentration should
be checked at least weekly using a hydrometer to make sure it
meets the manufacturer's specification. To check for contamination,
the solution should be examined weekly using both white light and
UV light. They should never be applied with a brush.
3. Solvent Suspendable : typically supplied in sealed aerosol spray
cans. The way that the developer is dispensed must be monitored.
Make sure the can is well shaken and apply a thin coating to a test
article. If the spray produces spatters or an uneven coating, the can
should be discarded. With a visible penetrant system, the developer
coating must be thick enough to provide a white contrasting
background but not heavy enough to mask indications. When using
a fluorescent penetrant system, a very light coating should be used.
4. Development Time : Parts should be allowed to develop for a
minimum of 10 minutes and no more than 2 hours before
inspecting.
TEST EQUIPMENT AND MATERIALS
 TEST EQUIPMENT AND MATERIALS
 Lighting Quality Control
1. Lighting for Visible Dye Penetrant Inspections :
Inspections can be conducted using natural lighting or
artificial lighting. the use of artificial lighting is
recommended to get better uniformity. The light
intensity is required to be100 foot-candles at the surface
being inspected. (white)
 TEST EQUIPMENT AND MATERIALS

 Lighting Quality Control

2. Lighting for Fluorescent Penetrant Inspections :
excited by UV light of 365nm wavelength and emit
visible light somewhere in the green-yellow range
between 520 and 580nm, often a mercury arc lamp with
a filter, remove all but the UV and a small amount of
visible light between 310 and 410nm, should be clean
and the light should never be used with a cracked filter,
warmed up prior to use, accepted intensity is 1000
µW/cm at 38cm distance from the filter face, The
required check should be performed when a new bulb is
installed, at startup of the inspection cycle, if a change
in intensity is noticed, or every eight hours of
continuous use. It is important to keep white light to a
minimum. Light levels of less than 2 foot-candles are
required by most procedures
 TEST EQUIPMENT AND MATERIALS

 Lighting Quality Control

3. Light Measurement : are made using a radiometer (an
instrument that transfers light energy into an electrical
current), the sensing area should be clean and free of
any materials that could reduce or obstruct light
reaching the sensor, calibrated at least every six
months.
 TEST EQUIPMENT AND MATERIALS

 System Performance Check : typically required daily,

at the reactivation of a system after maintenance or
repairs, or any time the system is suspected of being out
of control, test specimen with known defects, same
procedure used to process production parts, The ideal
specimen is a production item that has natural defects of
the minimum acceptable size, each operator should
process a test specimen, universal test specimens that can
be used if a standard part is not available, commonly used
test specimen is the TAM or PSM panel which is used for
fluorescent penetrant systems, five impacted areas with a
range of different crack sizes.
TEST EQUIPMENT AND MATERIALS
NATURE OF THE DEFECT
 Sensitivity is defined as the smallest defect that
can be detected with a high degree of reliability.
 Typically, the crack length at the sample surface
is used to define size of the defect.
 The volume of the defect is likely to be the more
important feature
NATURE OF THE DEFECT
NATURE OF THE DEFECT
In general, penetrant testing is more effective at
finding:
 Small round defects than small linear defects.
 Deeper flaws than shallow flaws.
 Flaws with a narrow opening at the surface than
wide open flaws.
 Flaws on smooth surfaces than on rough
surfaces.
 Flaws with rough fracture surfaces than smooth
fracture surfaces.
 Flaws under tensile or no loading than flaws
under compression loading.
HEALTH AND SAFETY PRECAUTIONS
 Chemical Safety : Some of the penetrant materials
are flammable and, therefore, should be used and
stored in small quantities. They should only be used
in a well ventilated area and ignition sources avoided.
Eye protection should always be worn to prevent
contact of the chemicals with the eyes. Gloves and
other protective clothing should be worn to limit
contact with the chemicals.
 Ultraviolet Light Safety : too much exposure can
be harmful to the skin and eyes. Skin and eye damage
occurs at wavelengths around 320 nm and shorter
which is well below the 365 nm wavelength, where
penetrants are designed to fluoresce. Therefore, UV
lamps sold for use in penetrant testing are almost
always filtered to remove the harmful UV
wavelengths.
ADVANTAGES AND DISADVANTAGES
Advantages
 High sensitivity (small discontinuities can be detected).

 Few material limitations (metallic and nonmetallic,

magnetic and nonmagnetic, and conductive and
nonconductive materials may be inspected).
 Rapid inspection of large areas and volumes.

 Suitable for parts with complex shapes.

 Indications are produced directly on the surface of the

part and constitute a visual representation of the flaw.
 Portable (materials are available in aerosol spray
cans)
 Low cost (materials and associated equipment are
relatively inexpensive)
ADVANTAGES AND DISADVANTAGES
Disadvantages
 Only surface breaking defects can be detected.
 Only materials with a relatively nonporous surface can be
inspected.
 Pre-cleaning is critical since contaminants can mask
defects.
 Metal smearing from machining, grinding, and grit or vapor
blasting must be removed.
 The inspector must have direct access to the surface being
inspected.
 Surface finish and roughness can affect inspection
sensitivity.
 Multiple process operations must be performed and
controlled.
 Post cleaning of acceptable parts or materials is required.
 Chemical handling and proper disposal is required.
CODES, STANDARDS, PROCEDURES
 ASME - American Society of Mechanical Engineers.
 ASTM - American Society for Testing Materials.
 IIW - International Institute of Welding.
 ISO - International Organization for
Standardization.
 DIN - German Standardizing Body.
 BSI - British Standards Institution.
 JIS - Japanese Industrial Standards.
 SAA - Standards Association of Australia.
 SAE - Society of Automotive Engineers USA
 DOD - Department of Defence USA
 API - American Petroleum Institution.
CODES, STANDARDS, PROCEDURES
 Mil-STD-410 — Qualification of inspection
personnel (Magnetic Particle and Liquid
Penetrant).
 ISO/DIS/9712 — Non Destructive Testing-
Qualification and Certification of personnel.
 BS EN 473-93 — General principles for
qualification and certification of NDT personnel.
 SNT-TC-1A — Recommended practice for
Qualification and Certification of NDT personnel.
This document was developed by the American
Society for Non-destructive Testing (ASNT).
FORMULATION OF INSTRUCTIONS FOR THE TEST
 The materials, types, shapes, or sizes to be examined, and the extent
of the examination;
 Type (number or letter designation if available) of each penetrant,
penetrant remover,emulsifier, and developer;
 Processing details for pre-examination cleaning and drying,
including the cleaningmaterials used and minimum time allowed for
drying;
 Processing details for applying the penetrant; the length of time that
the penetrant willremain on the surface (dwell time) and the
temperature of the surface and penetrant during the examination if
outside 60°F to 125°F (16°C to 52°C) range;
 Processing details for removing excess penetrant from the surface,
and for drying thesurface before applying the developer;
 Processing details for applying the developer, and length of
developing time beforeinterpretation;
 Processing details for post-examination cleaning.
INSPECTION, INTERPRETATION, AND
EVALUATION
 Interpretation : The process of detecting an
indication and the process of determining
whether an indication is relevant, nonrelevant, or
false.
 Relevant : One resulting from a discontinuity,
while nonrelevant is non associated with a parts
structural condition or discontinuity. (continuous
line, intermittent line, rounded, small dots, and
diffused or weak)
INSPECTION, INTERPRETATION, AND
EVALUATION
 Nonrelevant : can
result form an
intentional
change in part
shape such as
threads or small
radii, whether
they mask or
cover a true
discontinuity
indication.
INSPECTION, INTERPRETATION, AND
EVALUATION
 Service-induced discontinuities : the most
frequently discontinuities detected by penetrant
are fatigue cracks, stress corrosion, and overload
cracking.
 Evaluation of indication : Carefully wipe the
indication area once with a afast drying solvent.
EVALUATION
 Hanya indikasi yang memiliki dimensi yang
lebih besar dari 1/16 inchi akan
dianggap relevan. Indikasi apapun yang di
pertanyakan atau meragukan akan dikaji ulang
untuk menentukan apakah relevan atau
tidak relevan.
EVALUATION
 Relevant linier indication
Suatu cacat dikatakan memiliki indikasi linier dan akan
direject apabila pada cacat tersebut memiliki panjang lebih
dari 3 kali lebarnya dan yang besarnya lebih dari 1/16 in.
(1,6 mm).

 Relevant rounded indication

Suatu cacat dikatakan memiliki indikasi lingkaran
apabila pada cacat tersebut memiliki panjang kurang dari 3
kali lebarnya.

 Material tersebut akan direject apabila memiliki panjang

atau lebar indikasi lingkaran lebih dari­­­ 3/16 (4,8 mm).
 Material tersebut akan direject apabila memiliki 4 atau
lebih indikasi lingkaran yang tersusun dalam satu baris,
dengan jarak antara indikasi lingkaran kurang dari 1,6
mm.
THANK YOU