Liquid Penetrant Testing

Compiled for ASNT by

David Quattlebaum, Jr.
Quattlebaum Consultants
 Level II

Liquid Penetrant Testing

 Lesson 5

Selection of Penetrant
Testing Method
 Introduction

1. Combinations of penetrant,
emulsifiers, penetrant removal
methods and forms of
developers must be made in
accordance with the penetrant
material manufacturer’s
recommendations and
instructions or an applicable
qualified products list.
 Introduction

2. Penetrant type and method are

sometimes decided by the
contractor, customer, Level III
technician or design engineer.
Selection of Penetrant Type

Selection of a suitably efficient, cost

effective penetrant type and process
for a particular application depends
on several factors.
1. Customer requirements.
2. Specification requirements.
3. Sensitivity required.
4. Size and number of test objects.
Selection of Penetrant Type

5. Surface condition of the test

objects.
6. Configuration of the test objects.
7. Cost of equipment and
materials.
8. Availability of water, electricity,
compressed air and suitable
testing area.
 Advantages

1. The advantage of using

fluorescent penetrant is that
fluorescent indications are easier
to see.
2. The advantage of the water
removable penetrant is that it is
much faster, safer, ecologically
friendly and inexpensive.
 Disadvantage

1. The disadvantage of water

removable penetrant is the
danger of over washing if the
technician does not use proper
techniques. Over cleaning can
occur with any type, method or
sensitivity level if technicians fail
to follow the appropriate work
practices.
Penetrant versus Other Methods

1. The penetrant method is limited

to surface discontinuities.
2. The penetrant method is an
economical, excellent field
testing method.
Penetrant versus Other Methods

3. The penetrant method does not

require special equipment, and
does not always require
electrical power.
4. The penetrant method has lower
training and experience
requirements than most other
methods.
Penetrant Examination as a
Complimentary Method
1. The penetrant method may be
used as a primary method for
detecting surface discontinuities.
2. The penetrant method is
effective as a means of verifying
surface indications detected by
other methods.
Selection of Penetrant Method

When selecting a penetrant method,

the following information should be
considered.
1. Material to be tested.
2. Location of testing.
3. Number, weight and size of the
test objects.
Selection of Penetrant Method

4. Type of discontinuities.
5. Surface condition of the test
object.
6. End use of the test objects.
7. Selection of developer.
8. Acceptance and rejection
criteria.
 Portability
1. Field liquid penetrant tests can
be effectively and efficiently
completed using portable, Type I
(fluorescent) or Type II (visible)
penetrant kits and either water or
solvent wipe.
2. Aerosol liquid penetrant testing
kits are portable, and if Type II
solvent removable is chosen, no
power or water supply is needed.
 Portability

3. The advantage of aerosol kits is

their portability, and very little
set-up time is required.
4. The disadvantage of manual
wipe is that the method is slow.
 Postemulsification

1. When postemulsification processes

are required, appropriately
formulated penetrant materials and
postemulsification methods must be
used.
2. Small test objects can be dipped in
a tank of Method B (lipophilic)
emulsifier, the emulsification time
monitored and excess penetrant
rinsed off.
 Postemulsification

3. For large test objects,

equipment that sprays water
and Method D (hydrophilic)
emulsifier mix may be more
efficient.
4. The advantage of the
postemulsified method is the
elimination of worry that
penetrant may be rinsed out of
shallow discontinuities.
 Postemulsification

5. The disadvantage of the

postemulsified method is the
cost of the emulsifier and
equipment, the extra timed
step for emulsification and the
maintenance checks for the
emulsifier.
6. Method B (emulsification)
method is not permitted by some
industry specifications.
 Postemulsification

7. The choice of developer for all

the methods is regulated by
specifications and the
manufacturers’
recommendations.
 Dry Developer

1. Dry developer is best for rough

surfaces, such as castings or
test objects with fine threads or
corners, such as keyways.
2. Dry developer is also easy to
handle and easy to apply.
 Dry Developer

3. Dry developer leaves no film,

thus no special cleaning is
required for subsequent
processing operations.
4. Excessive drying time should be
avoided, as this will reduce
sensitivity.
 Dry Developer

5. Dry developer is the least

sensitive type of developer and
should not be used for visible
penetrant.
 Wet Developers

1. Aqueous developers can be

applied immediately after the
water rinse, before drying.
2. Both water suspendible and
water soluble developers may be
applied by dipping, spraying or
flowing.
 Wet Developers

3. Aqueous developers give off no

flammable vapors, no dust and
have no odor.
4. Since aqueous developer
leaves a thicker coverage,
complete coverage with
aqueous developer is easier to
monitor than with dry developer.
 Wet Developers

5. Both types of wet developers

leave a thicker buildup of
developer on rough surfaces,
such as castings, or test objects
with fine threads or corners,
such as keyways.
 Wet Developers

6. The water suspendible

developer requires agitation,
and both types require daily
maintenance checks when
used in tanks.
7. When a nonaqueous wet
developer is used, the test
object must be completely dry
before the developer is applied.
 Wet Developers

8. Nonaqueous wet developer is

the most sensitive developer
because it can be sprayed in a
very controlled, thin layer.
 Wet Developers

9. The solvent carrier dissolves in

the penetrant, slightly reducing
the viscosity, increasing the
volume of the penetrant in the
discontinuities and leaching the
indications to the surface as the
volatile liquid evaporates.
 Wet Developers

10. There are also wax and plastic film

developers that absorb and fix
penetrant indications to provide
records. The selection and usage of
these materials is largely
dependent on the particular process
used, the controlling specifications
or standards and the company
policy regarding recording of test
indications.
 Lesson 6

Interpretation and Evaluation

of Indications
Discontinuity Categories

Specific discontinuities are divided

into three general categories.
1.Inherent.
2.Processing.
3.Service.
Discontinuity Categories

No matter what type of

discontinuity may be present in
the test object, only those open
to the surface may be detected
with liquid penetrant testing.
 Discontinuities

1. In metals, inherent discontinuities

are those that are related to the
melting and original solidification
of the molten metal, ingot or
casting.
 Discontinuities

2. Processing discontinuities are

related to the various
manufacturing processes, such
as forging, machining, forming,
extruding, rolling, welding, heat
treating and plating.
3. Service discontinuities are
related to inservice conditions of
test objects.
Inherent Discontinuities

Inherent discontinuities in ingots are

formed during the processing and
solidification process and include the
following.
1. Inclusions (slag, impurities, etc.).
2. Porosity (entrapped gas).
3. Pipe (shrinkage).
4. Cracks.
Inherent Discontinuities

Inherent cast discontinuities are those

related to the melting, casting and
solidification of the cast test object and
include the following.
1. Porosity (entrapped gas).
2. Shrinkage.
3. Hot tears.
Inherent Discontinuities

4. Inclusions (slag, impurities, etc.).

5. Cracks.
6. Blowholes.
Processing Discontinuities

Forging discontinuities include the

following.
1. Burst: Appear as scaly,
ragged cavities when open to
the surface.
2. Laps: Folded flap of metal,
forced on the surface. Appear
as oddly-shaped cracks.
Processing Discontinuities

3. Cracks: Unlike laps, follow

stress distribution. Appear as
thin, jagged, linear indications.
Processing Discontinuities

Rolling discontinuities include the

following.
1. Pipe (shrinkage): Normally result
in internal lamination.
2. Porosity and inclusion: Result in
internal laminations.
3. External seams, stringers or
cracks.
Processing Discontinuities

Lamination characteristics include

the following.
1. They appear on the end of pipe
and plate.
2. They are linear and parallel with
top and bottom surfaces.
3. On rolled shapes (for example,
I-beams), they are parallel to the
rolling direction.
Processing Discontinuities

Seam characteristics include the

following.
1. They appear on the surface of the
test object.
2. They follow the direction of rolling.
3. The appearance depends on the
inherent discontinuity.
Processing Discontinuities

Stringer characteristics include the

following.
1. They appear on the surface of the
test object.
2. They follow the direction of rolling.
3. The appearance depends on the
inherent discontinuity.
4. They are usually deep in
comparison to seams.
Processing Discontinuities

Crack characteristics include the

following.
1. They appear on the surface of the
test object.
2. Those resulting from inherent
discontinuities follow the rolling
direction.
Processing Discontinuities

Drawing, extruding and piercing

discontinuities are visible on the
surface.
1. Drawn products: Gross failure,
normally through-wall.
2. Extrusions: Scabs (scraped or
torn surface).
3. Piercing: Scoring or mandrel
drag, sluggish.
Casting Discontinuities
Even though casting is a primary
process, casting discontinuities are
inherent and include the following.
1. Inclusions.
2. Hot tears.
3. Porosity.
4. Unfused chills.
5. Unfused chaplets.
6. Cold shuts.
Service Induced Discontinuities

Service discontinuities are

related to service conditions
such as cycles of loading, stress
corrosion, fatigue and wear.
 Cracking

There are many causes of cracking.

1. Material types.
2. Exposure circumstances.
3. Equipment type.
 Cracking

The stages of cracking include the

following.
1. Initiation (crack forms).
2. Propagation (crack moves).
3. Final failure (overload due to
loss of sound supporting
material).
Typical Penetrant Indications

Large crack Tight crack

or opening or cold shut

Partially Pits or
welded lap porosity
Forming of Indications

1. After the proper precleaning,

drying and application of
penetrant for the proper dwell
time (reference applicable
procedure), capillary action
forces the penetrant into the
discontinuity.
Forming of Indications

2. The excess surface penetrant is

removed either by wiping or with
a water spray rinse, with the aid
of an emulsifier for
postemulsifiable penetrants.
Time for Indications to Appear

1. After removal of excess surface

penetrant and application of
developer, penetrant will migrate
to the surface aided by capillary
action and the blotting action of
the developer.
Time for Indications to Appear

2. Deep indications will begin to

appear first since indications
with a large reservoir of
penetrant will bleed out faster
than a small indication with a
smaller reservoir.
Time for Indications to Appear

3. Typical time to allow indications

to form before measuring and
evaluation is specified in the
written procedure.
4. Standard times for evaluation
are important so different
technicians and testing facilities
will get standard results.
Effects of Temperature

1. Colder temperatures will

increase the viscosity of the
penetrant and slow the capillary
action.
2. Temperatures higher than
approved may cause the
penetrant to dry and reduce
sensitivity.
Effects of Temperature

3. High temperature materials

require special procedures and
special training.
 Lighting

1. The standard lighting, referred to

as ambient (white) light, for
viewing and evaluating visible
dye penetrant indications should
be verified at the test surface
using calibrated equipment.
 Lighting

2. For fluorescent penetrant

indications, the standard lighting
should be verified with a
calibrated ultraviolet radiation
meter at the test surface, and a
darkened test area of less than
20 lux (2 ftc) ambient light.
Effects of Metal Smearing

1. Power wire brushing or sand

blasting can smear metal and
close the surface opening of
discontinuities.
2. If allowed by the governing
procedure, the surface should be
etched to remove the smeared
metal.
 Sequence

1. Inservice tests are sometimes

used for the root pass of welds,
or before final machining.
2. Final liquid penetrant testing is
performed on a test object in the
final machined and/or heat
treated condition after proper
precleaning, as required.
Factors Affecting Indications

Penetrant selection depends on the

following factors.
1. Sensitivity requirements.
2. Component location.
3. Ultraviolet radiation availability.
4. Water availability.
5. Power availability.
Factors Affecting Indications

Fluorescent indications are

easier to see. The postemulsified
method is the most sensitive for
small, shallow indications.
 Prior Processing

1. The method of precleaning may

depend on prior processing of
the test object.
2. If a test object or weld has never
been exposed to machine oils or
lubricants, some specifications
will allow reduction of penetrant
dwell time.
 Prior Processing

3. Ultrasonic testing using couplant

should only be performed after
final penetrant testing because
the couplant may hinder
penetrant penetration into
discontinuities.
 Prior Processing

4. Visible penetrant should never

be used before a fluorescent
penetrant test because the red
penetrant may still be present in
discontinuities and could
interfere with indication
luminosity.
 Prior Processing

Factors affecting indications also

include the following.
1. Previous examinations.
a. Magnetic particles may fill or
bridge discontinuities.
b. Visible versus fluorescent
penetrants.
2. Surface conditions.
 Prior Processing

3. Temperature.
4. Dwell time.
5. Developer application.
6. Examination conditions.
 Prior Processing

7. Surface conditions.
a. Surface openings may be
closed.
b. Rough or porous area may
retain penetrant.
 Prior Processing

c. Deposits on the surface or in

openings may dilute the
penetrant.
d. Moisture within the discontinuity
can prevent penetrant from
entering.
 Prior Processing

8. Temperature.
a. Viscosity of most liquids
increases at low
temperatures.
b. Volatile components may
evaporate if too hot.
 Prior Processing

9. Dwell time and washing.

a. Fine indications could be caused
by insufficient penetrant dwell time.
b. Diffused indication may imply
incomplete washing.
c. Excessive washing can remove
penetrant from large or shallow
discontinuities, resulting in less
intense indications.
 Prior Processing

10. Developer application.

a. Excessive developer may
mask fine discontinuities.
b. Contrast may be reduced.
 Prior Processing

11. Examination conditions.

a. Good eyesight is required.
b. Proper lighting.
c. Darkened area for fluorescent
penetrants.
 Prior Processing

d. Adequate ultraviolet radiation

intensity for fluorescent
penetrants.
e. Adequate ambient light intensity
for visible dye.
f. Allow eyes to adjust to booth
according to specifications.
 Crack Indications

Cracks can occur as:

1. Solidification cracks.
2. Processing cracks.
3. Service cracks.
Indications from Specific
Material Forms
Surface indications can appear
on many of the following
processes.
1. Forgings.
2. Castings.
3. Plates.
4. Welds.
5. Extrusions.
Indications from Specific
Material Forms
Each indication requires
evaluation against an approved
specification or procedure.
Indications from Discontinuities

1. Continuous linear indications.

a. Cracks.
b. Cold shuts.
c. Forging laps.
d. Seams.
Indications from Discontinuities

2. Intermittent linear indications.

a. Partially filled cracks, seams,
or forging laps.
3. Rounded area indications.
a. Gas holes.
b. Pin voids.
c. Deep crater cracks.
Indications from Discontinuities

4. Small dot indications.

a. Porosity.
b. Excessive coarse grains
(castings).
Indications from Discontinuities

5. Diffused indications.
a. Widespread porosity.
b. Excessive developer.
c. Pockets or shrinkage that
come to the surface.
d. Wide cracks.
Indications from Discontinuities

Insufficient cleaning/incomplete
penetrant removal can also
cause diffused indications.
Evaluation of Indications

To evaluate an indication is to
decide if the indication is
acceptable, requires rework or
causes the test object to be
rejected.
Evaluation of Indications

1. Determine if the indication is

linear or rounded by procedure
definition.
2. Determine if the indication is a
crack, seam, lap, porosity or lack
of fusion.
3. Measure each indication and
compare to acceptance criteria.
Evaluation of Indications

4. Create a detailed report.

5. Generate a sketch of the
indication and location.
6. Identify the test object as
acceptable or unacceptable, and
segregate it from the lot.
 False Indications

1. Poor washing of water washable

and postemulsifiable penetrants.
2. Inadequate ultraviolet radiation
during the washing process.
3. Poor technique.
 False Indications

4. Contaminants
a. Penetrant on the hands of the
technician.
b. Contamination of wet or dry
developer.
 False Indications

c. Penetrant rubbing off of one test

object to a clean portion of the
surface of another test object.
d. Penetrant spots on the testing
table.
e. Improper handling techniques.
Relevant and Nonrelevant
Indications
1. Relevant indications are true
discontinuities.
2. Nonrelevant indications are
accumulations of penetrant
commonly caused by the
following factors.
Relevant and Nonrelevant
Indications
a. Poor washing or cleaning.
b. Test object configuration,
features or irregularities.
c. Press-fitted test objects.
 Lesson 7

Liquid Penetrant
Process Control
 Introduction

1. The reliability of any penetrant

test is determined in large part
by the condition of the material
used.
2. Inservice checks are used to test
penetrant materials held in open
tanks and subjected to
contamination or evaporation.
Quality Control of Test Materials

Many quality control procedures

are required for determination of
the following components.
1. Sulfur and chlorine content.
2. Liquid oxygen compatibility.
3. Temperature stability.
4. Water tolerance.
Quality Control of Test Materials

5. Viscosity.
6. Flash point.
7. Toxicity.
8. Developer precipitation rate.
Test Material Control Samples
1. Control samples are taken at the
time penetrant materials are
received from the supplier – this
includes developers.
2. Samples are kept in sealed
containers and stored where they
are not subject to deterioration
from heat, light or evaporation.
3. Samples should be sufficient for life
of the penetrant materials.
 Reference Blocks

1. Reference blocks, plates or

panels are often specified in the
procedures for quality control of
liquid penetrant materials.
2. These standards are often called
known defect test specimens
(KDTS).
 Reference Blocks

3. The materials used in the

manufacture of reference blocks
include aluminum, steel, nickel,
glass and ceramic.
4. Some of the blocks are
designed primarily for the
following functions.
 Reference Blocks

a. Checking penetrant system

sensitivity.
b. Performing comparison tests.
c. Penetrant or emulsifier
washability.
 Test Panels

1. Cracked nickel-chromium plated

panels.
2. Penetrant system monitor (PSM)
panel.
3. Quench cracked aluminum
block.
System Monitor Panels

System monitor panels are

commercially manufactured and can
be used to detect major changes in
the following.
1. Visible and fluorescent systems.
2. Water washable and
postemulsified systems.
System Monitor Panels

System monitor
panel includes five
crack centers of
different sizes for
evaluation of
sensitivity and grit
blast side for wash
characteristics.
Aluminum Reference Blocks

1. Aluminum reference blocks

measure about 5 by 7.5 cm
(2 by 3 in.), and are cut from
0.8 cm (0.3 in.) thick bare
2024-T3 aluminum alloy plate,
with the 7.5 cm (3 in.) dimension
in the direction of rolling. The
dimensions are for guidance
only.
Aluminum Reference Blocks

2. The blocks are heated and water

quenched to produce thermal
cracks. This is accomplished by
supporting the block in a frame
and heating it nonuniformly with
the flame of a gas burner or
torch in the center on the
underside of the block.
Aluminum Reference Blocks

3. A groove about 0.15 by 0.15 cm

(0.06 by 0.06 in.) deep is cut in
the 5 cm (2 in.) direction across
the center of the heat affected
zone.
4. This forms two test areas, and
permits the side-by-side
application and comparison of
two penetrants without cross
contamination.
Aluminum Reference Blocks

5. This type of block is widely used for

comparing the performance of
penetrants in field conditions.
Aluminum Reference Blocks

6. After a reference block has been

used, it is cleaned before reuse.
The block is heated slowly with a
gas burner to
426 °C (800 °F), as determined
by a 426 °C (800 °F)
temperature indicating medium,
after which the block is
quenched in cold water.
Aluminum Reference Blocks

7. It is then heated to about 71 °C

(160 °F) for 30 min to drive off
any moisture in the cracks, and
is then allowed to cool to room
temperature.
Aluminum Reference Blocks

Typical
aluminum 2024-
T3 reference
block after
heating/
quenching and
grove cut. Note
the HAZ in the
center.
Ceramic Reference Blocks

1. Ceramic reference blocks are

flat, circular disks of unglazed
ceramic that, although quite solid
and impervious to liquids, have
micropit surfaces that entrap
liquid penetrants.
Ceramic Reference Blocks

2. The micropit structure provides a

range of pore sizes, and a
performance comparison can be
made of two or more penetrants
merely by noting the number or
distribution of porosity indications
and their intensity in a side-by-
side comparison test.
Ceramic Reference Blocks

3. Indications appear as a large

number of microscopic specks of
fluorescence or color, the
number increasing as the
sensitivity of the penetrant
increases.
Ceramic Reference Block Use

1. Using a small applicator, a drop of

each penetrant to be tested is
applied to the flat surface of the
reference block.
2. Immediately following application,
the penetrants are blotted with a
piece of soft tissue by pressing
the tissue against the block using
a flat object.
Ceramic Reference Block Use
3. The tissue and cover also hold the
penetrants in proper contact with
the reference block and prevent
excessive bleeding and possible
cross contamination.
4. Following the required dwell period
(usually 10 min), the penetrants are
processed in accordance with the
penetrant manufacturer’s
recommendations.
Ceramic Reference Block Use

5. A developer is not used.

6. In making visual comparisons,
both the number of indications
observed and the intensity of
indications are noted.
Anodized and Plated Test Panels
1. Stress cracked anodized aluminum
and chrome plated nickel test
panels are frequently used for
comparing penetrant sensitivity and
washability.
2. The panels are classified according
to the size cracks they contain.
3. The grades are coarse, medium and
fine, providing low, medium and
high sensitivity levels.
Anodized and Plated Test Panels

Coarse cracks Medium cracks Fine cracks

Plated Test Panels Usage

1. A line is usually drawn along the

centerline (length) of the panel
using a wax pencil or narrow
vinyl tape.
2. This forms two test areas and
permits the side-by-side
application and comparison of
penetrant materials without cross
contamination.
Low Cycle Fatigue Blocks

1. Titanium or NiCrFe plates are

commonly used to manufacture
standards with low cycle fatigue
blocks (LCF) cracks in various size
ranges.
2. The cracks are started from
electrical discharge machined
(EDM) notches or spot welds,
which are later ground away after
the starter cracks are grown.
Low Cycle Fatigue Blocks

3. Tensile stressing or reverse

bending of the plates achieves
additional crack length
extension.
4. Titanium or NiCrFe plates are
commonly sold in a set of three
plates, with a total of eighteen
possible cracks in the set.
Low Cycle Fatigue Blocks Usage

1. Low cycle fatigue blocks are

used like other known
discontinuity standards, except
that the total number of detected
cracks per inspection of the plate
set is recorded and monitored in
a running summary per
procedure supplied with the
plates.
Low Cycle Fatigue Blocks Usage

2. When fewer cracks are detected,

the technician is warned that
something has shifted in the
process capability, or that the
cracks have been improperly
cleaned.
Tests of Penetrant Materials

Inservice quality of the materials used

in liquid penetrant testing is
determined by a check of the
following components.
1. Sensitivity.
2. Water content.
3. Contamination.
Tests of Penetrant Materials

4. Washability.
5. Fading of the penetrant dyes
(checked by a simple
comparison test).
5. Fluorescent luminance.
Tests of Penetrant Materials

a. The fluorescent luminance test is

a comparison of the luminance of
the control penetrant sample to
the used penetrant in the tanks.
b. Samples are alternately read on
a fluorometer and the results
compared.
Tests of Penetrant Materials

c. If the fluorescent intensity of the

penetrant should drop below
90% of the reference penetrant,
the penetrant is discarded.
 Emulsifier Tests

Emulsifiers are usually tested for

the following components.
1. Sensitivity.
2. Washability.
3. Water content.
4. Amount of contamination
from penetrants.
 Emulsifier Tests

The sensitivity test, water

washability test and the water
content test for emulsifiers are
identical to the tests used for
penetrants.
Dry Developer Tests

1. Dry developers used in open

containers or chambers are
usually tested by observation.
2. Dry developers are not
hygroscopic, they do not absorb
moisture from the air and they
are relatively trouble free if they
do not come in contact with
water.
Dry Developer Tests

3. Any dry developer that is found

lumpy or caked instead of light
and fluffy, or that shows any
other sign of having been wet, is
discarded.
Dry Developer Tests

Dry developer is checked daily for

the following.
1. Cracking.
2. Dirt.
Should either condition exist, the
developer is discarded.
Wet Developer Tests

1. Wet (aqueous) developers are

usually tested for proper
concentration and possible
contamination from dirt or
penetrant.
2. Solution concentration is tested
by measuring the specific gravity
with a hydrometer.
Wet Developer Tests

3. If the hydrometer reading differs

from manufacturer’s
requirements, either powder or
water is added to the developer
in sufficient quantities to bring
the concentration within
acceptable limits.
Wet Developer Tests

4. A small, smooth test plate with

no indications is dipped in the
developer tank and visually
examined for dirt.
Wet Developer Tests

5. The tank and the plate are

checked for fluorescence or
penetrant contamination under
ultraviolet radiation. If either
condition is evident, the
developer is discarded.
 Typical Hydrometer

Ballast
Stem

Scale
Body
 Lesson 8

Test Procedures and Standards

 Introduction

There are three types of written

documents that control penetrant
tests.
1. Standards.
2. Specifications.
3. Written practices.
 Standards

A reference document that

controls and standardizes
generally accepted practices for
a nondestructive testing method.
Examples include the following.
 Standards

1. MIL-STD-6866, Inspection,
Liquid Penetrant.
2. ASTM E-1417, Standard
Practice for Liquid Penetrant
Examination.
 Specifications

1. Specifications are written by a

company for a specific process.
2. Specification is a tool used by
engineering, management and
purchasing for contractual
documents and procedure
development. They will normally
contain the following sections.
 Specifications

a. Reference documents.
b. Materials.
c. Equipment.
d. Personnel qualifications.
e. Process control.
f. Written procedure requirements.
 Written Practices

Written practices provide specific

guidance on the performance of the
penetrant test and should contain the
following information.
1. Penetrant materials to be used.
2. Details of precleaning the test
object.
3. Complete processing parameter.
 Written Practices

4. Testing and evaluation

requirements.
5. Specific test object information.
6. Acceptance/rejection criteria.
7. Postcleaning procedures.
8. Documentation requirements.
9. Safety requirements.
 Lesson 9

Safety, Health and Disposal

General Safety Precautions

1. Use eye and face protection.

2. Keep clothing free of penetrant
material and change immediately if
cloth is contaminated.
3. Clean penetrant material off skin as
soon as possible.
4. Avoid or limit exposure to penetrant
materials in confined areas.
General Safety Precautions

5. Wear safety shoes to protect

feet.
6. Use proper lifting techniques.
7. Have proper fire extinguishers.
8. Wear proper protective clothing.
9. Know the direction of sprays.
10. Know the work environment.
General Safety Precautions

11. Observe all safety rules.

12. Know the proper method of
disposal of aerosol cans.
13. Do not smoke around
penetrant materials.
14. Properly dispose of used
wiping cloths and paper towels.
 Flammability

1. Only approved ultraviolet lights

should be used in areas where
flammable vapors are present.
2. Dispose of all cloths and paper
towels in a metal container.
3. All penetrant materials should
be stored away from sources of
flame and heat.
Flammability: Flash Point

1. Lowest temperature at which the

vapors in sufficient concentration
will ignite in air if exposed to a
source ignition.
2. Minimum of 200 °F OSHA
established for liquids in open
tanks without special ventilation.
3. Aerosol cans/materials can have
a flash point as low as 40 °F.
Flammability: Penetrants

Penetrant vapors may

concentrate above the liquid
penetrant surface.
Flammability: Emulsifiers

1. Emulsifiers have many of the

same hazards as penetrant.
2. Check the Material Safety Data
Sheet (MSDS) before use for
safe handling.
Flammability: Solvent Removers

1. Solvent removers can have a

very low flash point.
2. Do not spray around sources of
flame such as welding and
grinding operations.
Flammability: Dryers

3. Designed for drying parts.

4. Do not use combustible
materials in dryers.
Skin Irritation and Allergies

1. When used according to the

manufacturers’ instructions,
penetrant materials do not
normally pose any problems.
2. In most cases, skin irritation is a
form of dermatitis that appears on
the hands and arms.
3. Rubber gloves will prevent most
cases of skin irritation.
Respiratory Considerations

1. Respiratory equipment is not

normally needed as long as
adequate ventilation for fumes
and vapors is maintained.
2. Dry developers should only be
applied in hood equipment or
adequately ventilated work
areas.
Physiological Effects of
Ultraviolet Radiation
1. The National Institute for
Occupational Safety and Health
(NIOSH) recommends personnel
working with ultraviolet radiation
between 310 to 400 nm limit
exposure of their eyes and
unprotected skin to 1000
µW/cm2.
Physiological Effects of
Ultraviolet Radiation
2. Personnel using ultraviolet
radiation bulbs should consider
special yellow glasses that block
most ultraviolet radiation.
Disposal of Penetrant Materials

1. Special rules set by federal,

state and local laws must be
followed.
2. General rule: Penetrant testing
material cannot be disposed of
through normal sewer lines.
Controlling Penetrant Usage

1. Use equipment that limits the

amount of penetrant.
2. Increase penetrant drain time.
3. Use equipment that separates
penetrant and emulsifier from
the waste water.
4. Use biodegradable penetrants.