Penetrant Testing, or PT, Is A Nondestructive

Introduction
• Penetrant Testing, or PT, is a nondestructive

testing method that builds on the principle
of Visual Inspection.
• PT increases the “seeability” of small
discontinuities that the human eye might
not be able to detect alone.
How does it work
• In penetrant testing, a liquid with high surface wetting
characteristics is applied to the surface of a component under
test.
• The penetrant “penetrates” into surface breaking
discontinuities via capillary action and other mechanisms.
• Excess penetrant is removed from the surface and a
developer is applied to pull trapped penetrant back
the surface.
• With good inspection
technique, visual
indications of any
discontinuities present
become apparent.
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, 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.
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.
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.
Penetrants are also classified by the method of removing the excess penetrant.
• Solvent Removable penetrants are removed by wiping with a cloth dampened with solvent. They are
supplied in aerosol cans for portability and are primarily used for spot checks.
• Water Washable penetrants are removed with a course spray of water. They are the easiest to employ and
most cost effective when inspecting large areas.
• Post-Emulsifiable penetrants are water-washable only after they have reacted with an emulsifier solution.
A post-emulsifiable system is used when washing the penetrant out of the defect is a concern. The emulsifier
is given time to reacts with the penetrant on the surface but not the penetrant trapped in the flaw.
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).
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. Post Cleaning: 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.
Advantages
1. High sensitivity (small discontinuities can be detected).
2. Few material limitations (metallic and nonmetallic, magnetic
and nonmagnetic, and conductive and nonconductive materials
may be
inspected).
3. Rapid inspection of large areas and volumes.
4. Suitable for parts with complex shapes.
5. Indications are produced directly on the surface of the part
and constitute a visual representation of the flaw.
6. Portable (materials are available in aerosol spray cans)
7. Low cost (materials and associated equipment are relatively
inexpensive)
Disadvantages
1. Only surface breaking defects can be detected.
2. Only materials with a relatively nonporous surface can be
inspected.
3. Pre-cleaning is critical since contaminants can mask defects.
4. Metal smearing from machining, grinding, and grit or vapor
blasting must be removed.
5. The inspector must have direct access to the surface being
inspected.
6. Surface finish and roughness can affect inspection sensitivity.
7. Multiple process operations must be performed and controlled.
8. Post cleaning of acceptable parts or materials is required.
9. Chemical handling and proper disposal is required.
Choices of Penetrant Materials
Penetrant Type
I Fluorescent
II Visible
Method
A Water Washable
B Postemulsifiable
C Solvent Removable
Developer Form
Dry Powder
Wet
Penetrant Materials
Penetrants are formulated to possess a number of
important characteristics. To perform well, a penetrant
must:
– Spread easily over the surface being inspected.
– Be drawn into surface breaking defects by capillary action or
other mechanisms.
– Remain in the defect but remove easily from the surface of the
part.
– Remain fluid through the drying and developing steps so it can
be drawn back to the surface.
– Be highly visible or fluoresce brightly to produce easy to see
indications.
– Not be harmful to the inspector or to the material being tested.

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Introduction

• Penetrant Testing, or PT, is a nondestructive

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