Beruflich Dokumente
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H A P T E R
162
Surface Conditions
Interfering with Liquid
Penetrant Testing
Test material surface conditions that may
interfere with the application of liquid
penetrants or their entry into surface
connected discontinuities may be
classified into two groups:
(1) contaminants on the surface or within
discontinuities that prevent surface
wetting and capillary flow of the liquid
penetrants; (2) contaminants or surface
conditions that physically block the
entrances to discontinuities so that liquid
penetrants cannot enter.
Similarly, surface conditions or
contaminants that trap liquid penetrant
or tracer liquids to produce false
indications or inhibit or prevent
extraction of liquid penetrant retained in
leaks or discontinuities during
development, can be classified into two
groups: (1) porous, adherent coatings or
contaminants providing interstices that
retain liquid penetrants on test object
surfaces or impede their entry into
underlying discontinuities or leaks; and
(2) coatings on interior surfaces of
discontinuities or leaks that have high
surface energies and resist extraction of
the liquid penetrant from the
discontinuities into the developer coating.
Types of Surface
Contamination Found on
Test Objects
Surface contamination and contamination
within leaks or surface connected
discontinuities can be of many types,
including (1) preservative, forming,
machining or lubricating oils and other
liquids containing organic constituents;
(2) carbon, varnish and other tightly held
soil; (3) scale, rust, oxides, corrosion
products and weld metal and weld flux
residues; (4) paint and organic protective
coatings; (5) water, hydrates or other
TABLE 1. Contaminants that are on the test object surface or contained in voids or discontinuities and that interfere
with liquid penetrant action during processing, with removal procedures or corrective treatments.
Types of Contaminants
Interference Effects
1. Preservative, forming,
machining or lubricating
oils
1.
2.
3.
4.
5.
6.
vapor degreasing
hot tank alkaline cleaning
steam cleaning
solvent emulsion cleaning
water emulsion cleaning
solvent washing
1.
2.
3.
4.
1.
2.
3.
4.
4. Paint coatings
1.
2.
3.
4.
5. Water
1. air dry
2. force dry with dry air
3. oven dry at elevated temperature
a. Agitation such as used in ultrasonic cleaning may be beneficial with this surface treatment.
b. Mechanical processes that peen or smear surface material may act to close openings into discontinuities so that liquid penetrant indications cannot form.
Such abrasive cleaning techniques are often prohibited or require a subsequent acid etching treatment to reopen the discontinuity to the part surface so that
penetrant can enter.
163
TABLE 2. Test object surface irregularities and conditions interfering with liquid penetrant action during processing, with
removal procedures or corrective treatments.
Types of Contaminants
Interference Effects
1. Surface roughness
1. abrasive polishinga
2. electropolishing
1. acid etching
2. electropolishing
a. Mechanical processes that peen or smear surface material may act to close openings into discontinuities so that liquid penetrant indications cannot form. Such
abrasive cleaning techniques are often prohibited or require a subsequent acid etching treatment to reopen the discontinuity to the part surface so that
penetrant can enter.
Effects of Contamination by
Carbon, Engine Varnish or Tightly
Held Soil
Tightly bonded contaminants such as
layers of carbon, engine varnish and other
soils are difficult to remove from test
surfaces. They can interfere seriously with
liquid penetrant testing. They typically
impede surface wetting by liquid
penetrant and may bridge over or obstruct
entry of liquid penetrant into
discontinuities. Such contaminant layers
on the test part surface tend to absorb or
collect liquid on their surface; they may
also absorb or assimilate liquid into the
interior of the contaminant layer. This
leads to background fluorescence or
visible dye staining of the surfaces of test
objects, reducing indication contrast and
visibility. For these reasons such
contaminants should be removed from
test parts before application of liquid
penetrant.
164
Effects of Contamination by
Strong Acids or Alkalis
Strong acids or alkalis used to clean test
parts before liquid penetrant or leak
testing can impede surface wetting and
penetration of test media into surface
discontinuities if proper water rinsing and
drying are not performed. These acids and
alkalis may react to decompose or degrade
dyes or other active constituents of liquid
penetrants. In particular, acid and
chromate residues may adversely affect
the dyes by decomposing them, resulting
in weak or faint test indications.
Chromate residues also absorb ultraviolet
radiation, which leaves less radiation to
excite fluorescence in the liquid
165
Effects of Lack of
Cleanliness in Liquid
Penetrant Processing Areas
Lack of cleanliness in liquid penetrant
testing areas is a potential source of test
object contamination. If test objects are
placed on surfaces or in containers that
have previously been used for parts in
process, they may be contaminated by
liquid penetrants, emulsifiers, solvents,
water or developers. If, before the test
process, the test operator handles test
parts with hands contaminated with
materials used in the liquid penetrant
testing, these contaminants may be
deposited on the surfaces of the
previously cleaned test parts. Any such
prior contamination of the test objects
can interfere with the proper functioning
of the liquid penetrants and either can
lead to false indications or can obscure
valid indications. When doubt exists, it
may be preferable to subject test objects
suspected of being contaminated to
thorough recleaning and retesting.
166
Techniques of Precleaning
Test Objects for Liquid
Penetrant Testing
Both precleaning (before testing) and
postcleaning (following liquid penetrant
testing) are vital steps in the test process
(Fig. 1). Methods for precleaning of test
objects include (1) detergent cleaning,
(2) vapor degreasing, (3) steam cleaning,
(4) solvent cleaning, (5) acid or alkaline
cleaning, (6) abrasive cleaning, (7) paint,
varnish and carbon removal,
(8) electrocleaning, (9) agitation or
FIGURE 1. Flowsheet for cleaning processes used with liquid penetrant testing.
Incoming parts
Alkaline
Vapor degrease
Steam
Solvent wash
Chemical
Preclean
Mechanical
Paint stripper
Ultrasonic
Dry
Etch
(optional)
Inspect
Inspect
Mechanical wash
Water rinse
Postclean
Dry
Vapor degrease
Solvent soak
Ultrasonic clean
Outgoing parts
167
Selection of Cleaning
Processes
Selection of cleaning processes for
removal of soils and other contaminants
from metallic test objects is influenced by
the following factors: (1) types of
contaminants to be removed
(2) composition or alloy of the test object,
(3) degree of cleanliness required for
proper operation of liquid penetrant tests
and (4) cost and time factors.
In addition, the quantity of similar test
objects to be cleaned, their size and shape
and the ease with which they can be
handled are factors to be considered.
Multiple small test objects can often
best be cleaned by immersion in liquid
cleaners or by mechanized processes such
as vapor degreasing, dipping or spraying
of parts carried by conveyor lines. Large
parts that cannot be placed in cleaning
tanks may be cleaned by spraying both
cleaners and rinsers onto part surfaces.
Parts to be cleaned in the field or at
fixed locations in shops or test
laboratories can often be handled by
wipe-on, wipe-off techniques. In wiping
techniques, cleaning or removal fluids are
applied by lintfree rags moistened or
wetted and wiped over test surfaces.
Excess fluids and contaminants are
removed by wiping with dry rags or
lintfree paper towels. In each case, caution
is required to ensure that cleaning and
rinsing fluids are free from excessive
contamination that could reduce their
effectiveness. Hazards to personnel from
toxic or flammable materials must be
controlled or prevented. The cleaning
agents must also be selected to be
nondamaging to test object materials and
surfaces. Wiping material that is lint free
or has lint that does not fluoresce should
be used.
Precautions in Cleaning of
Metallic Surfaces
Although liquid penetrant testing is
applicable to a wide variety of test
materials, metal surfaces are by far the
most commonly tested. Various metals
may be involved, including aluminum,
magnesium, titanium, carbon and low
alloy steels, stainless steels, high
temperature nickel base alloys and copper
alloys. The choice of cleaning chemicals
should be specific to the method to be
cleaned. For example, a highly alkaline or
caustic solution may be effective for
168
Precautions in Cleaning
and Processing of
Nonmetallic Surfaces
Nonmetallic surfaces such as plastics and
elastomers or ceramics and glass can have
different wetting characteristics than
surfaces of metals. The nonmetallic
chemistry may resist removal of
contaminants. In addition, damaging
effects can occur from the liquid
penetrant materials. For example, liquid
penetrant testing of acrylic plastics might
result in crazing. Preliminary trials on
reject or scrap surfaces and/or
consultation with the supplier of the test
object materials or the liquid penetrant
test materials is advisable in questionable
cases. The same precautions for cleaning
metallic surfaces apply to cleaning of
nonmetallic surfaces because cleaning
techniques used for metallic surfaces may
be ineffective or may damage the
nonmetallic material. Because liquid
penetrant testing of nonmetallics is a
minor application, the following
discussion deals with metals.
Problems Requiring
Complex Cleaning
Procedures
Complex problems encountered in
precleaning of test objects for liquid
penetrant tests may require several
contaminant removal techniques. For
example, scale removal by acid treatment
must normally be preceded by alkaline
cleaning or by some other technique that
removes the oil so that the acid can react
with surface contamination. Acids are not
generally good cleaners for oily soils.
The removal of scale and carbonaceous
deposits such as those on used jet engine
blades usually requires a multistage
cleaning process. Procedures for cleaning
highly critical products may necessitate
careful processing with pure cleaning
products, followed by rinsing with
deionized or distilled water. Such critical
applications are best considered on an
individual basis.
Types of Soil
The term soil refers to undesired material
on a surface that is not an integral part of
the surface. Oil, grease, dirt and loose
scale are soils. On the other hand, a
decarburized skin or excess hard
chromium are not considered to be soils.
Soil can be classified into seven broad
groups: (1) pigmented drawing
compounds, (2) unpigmented oil and
grease, (3) chips and cutting fluids,
(4) polishing and buffing compounds,
(5) rust and scale, (6) carbonaceous
deposits and (7) miscellaneous
compounds such as lapping compounds,
ultrasonic test couplants and residue from
magnetic particle testing.
Avoidance of Abrasive
Methods That Peen, Smear
or Cold Work Metals
Surface preparation by severe abrasion
that peens, smears or cold works metallic
surfaces should be avoided in precleaning.
Peening or cold working of metal surfaces
tends to close discontinuities. Thus
techniques such as grit blasting, sand
blasting, emery cloth, wire brushing or
metal scraping should be used only with
caution and only when no other
technique will suffice. Specifications
usually prohibit such abrasive cleaning
169
Restrictions on Halogen,
Sulfur, Potassium or
Sodium Cleaning
Compounds
Some metals and alloys are sensitive to
certain elements such as halogens, sulfur,
sodium and potassium. The aerospace and
nuclear industries have been concerned
about effects of halogenated solvents such
as have been used in vapor degreasing,
which can have damaging effects on
halide sensitive materials, particularly
titanium and its alloys. (Some companies
forbid vapor degreasing with halogenated
solvents to eliminate any possible effects
of chlorides or fluorides from the
decomposition products.) Cleaning
compounds that contain sulfur should
not be used with nickel or nickel base
alloys. Restrictions are placed on halogen
containing compounds on stainless steels
and on both halogen and sulfur
containing compounds for use on nickel
base alloys for nuclear power industrial
applications. Restrictions on surface
treatments of metals for military
equipment are cited in applicable
specifications.
In the United States, precautions on
halogenated solvents are moot in light of
170
Vapor Degreasing
One of the most common techniques of
preparing test parts for liquid penetrant
testing is vapor degreasing. This process is
particularly suitable for removal of soluble
organic contaminants such as mineral oils
and greases. Unfortunately, vapor
degreasing is not effective for removal of
solid contaminants such as carbon,
varnish, paints, scale, corrosion products
or oxides. Other means of removal are
required. In some cases, restrictions are
placed on vapor degreasing of chloride
sensitive metals and alloys with
halogenated solvents (see discussion
elsewhere on restrictions on halogen,
sulfur, potassium or sodium compounds).
When steel or other ferrous metal parts
are vapor degreased, the metal is usually
171
Precleaning by Spraying or
Wiping of Solvent Cleaners
Test objects that are located in the field or
are too large to be immersed in tanks can
be cleaned by spraying or wiping the
surfaces with solvent.
Caution. When spraying a flammable
solvent, dispersion of low flash point
liquids creates an explosion hazard.
Spraying is typically done with
conventional paint spraying equipment,
airless spray, small bench type sprayers or
by aerosol spray cans. Where feasible, the
sprays should be directed into a vented
fume collecting hood. Solvent cleaning is
also often used as a preliminary step
before acid or alkaline cleaning to remove
soils that could interfere with the action
of these chemical means of
decontamination.
172
(F)
LL1
mgm3
65
15
45
10
40
(150)
(59)
(110)
(50)
(105)
___
___
___
300
100
___
___
___
2000
525
none
none
none
none
none
none
none
none
none
none
none
none
10
50
50
350
50
1000
49
174
339
1900
269
7600
(57)
(54)
(54)
1000
400
200
1900
980
260
(0)
(12)
(110)
(46)
750
1f
5
50
1780
___
18
188
14
12.7
12
18
11
44
8
173
Removal of Paint
Paint can obscure or bridge surface
discontinuities in underlying metals of
test objects and must be removed before
liquid penetrant testing to obtain effective
liquid penetrant test indications. Paint
removers are commercially available from
various manufacturers for both in-place
and dip tank application. Because paint
removal technology is somewhat
complex, the recommended approach is
to enlist assistance from a supplier of
good paint removers. Recent advances in
paint technology have resulted in finished
systems removable only with special
products. Factors that influence the ease
of paint removal include (1) surface
preparation before painting, (2) type of
paint primer, (3) type of paint used,
(4) number of paint coats, (5) age or cure
of the paint finish, (6) type of paint
removers used and (7) nature of the
substrate.
The treatments for paint removal from
test objects before liquid penetrant testing
include (1) solvent type paint removers,
(2) alkaline or acid type paint removers,
(3) abrasive removal procedures and
(4) burning or ignition.
Critical structures cannot tolerate the
use of any products or paint removal
procedures that may be damaging to their
metals or alloys. This requires careful
attention when abrasive techniques are
used for paint removal. Ignition or
burning off of paint layers should never
be used on aircraft. When solvent
cleaning techniques are used, it is
essential to remove traces or residues from
solvents and other contamination by
techniques such as have been
recommended for unpainted metallic
parts.
Removal of Carbon,
Varnish and Other Tightly
Held Soil
Carbon and varnish removal is similar to
paint removal and many of the
procedures and products used for removal
of paint are also used for removal of
carbon and varnish. Solvent carbon
removers are available for brush or spray
application or for use in dip tanks. Dip
tank carbon removers are available that
operate at ambient or elevated
temperatures. Carbon can also be
removed by alkaline products, depending
on the conditions and the nature of the
carbonaceous deposits. Mechanical means
are also used for removal of this type of
soil.
174
Alkaline Cleaning
Alkaline cleaners remove oily soils from
metals by detergent action that reduces
surface and interfacial tensions and
permits the cleaning compound to wet
the soils, seep under them and displace
them. This action is attributed to builders
(usually sodium compounds) that provide
alkalinity. They loosen, disperse and
emulsify soils removed from the metal
surface. In water solution, alkaline
cleaners reduce the viscosity of the soil
and the water transmits agitation to the
work surface and flushes away the soils.
Cleaning action is provided by soaps and
detergents added to the cleaning
compounds that act as surface active or
wetting agents.
The cleaner may function by the
mechanism of high alkalinity needed for
saponification reactions and must
dissociate to provide ions. Most soaps or
synthetic detergents are more efficient at
pH values from 7 to 13. This active
alkalinity is one of the working agents
and is continually lost by saponification
and neutralization reactions and by
dragout on parts removed. This type of
cleaner should provide alkalinity that is
continuously available and ionized to
replace the losses in active alkalinity.
The alkaline cleaner must also disperse
soils removed from the test objects so that
fluid close to the part surface does not
become so highly contaminated as to
redeposit soils on the surfaces being
cleaned. The builders should be soluble in
cold water and have no affinity for the
object being cleaned. Traces of cleaner or
alkali remaining on test objects after
rinsing are objectionable because they
might cause dermatitis or other health
hazards or interfere with the action of
liquid penetrants during the later test
operations.
175
Emulsion Precleaning
Emulsion cleaning can remove many
types of soils from test objects, including
pigmented drawing lubricants,
unpigmented oils and greases, cutting
fluids and residues from polishing, buffing
or magnetic particle testing. Emulsion
cleaning provides rapid superficial
cleaning and typically leaves on the work
a thin film of oil that provides some
protection against rusting. This oil can be
removed by subsequent vapor degreasing
or by two stage rinsing with an initial
rinse (typically in agitated cold water) and
a final rinse with hot water at 65 to 95 C
(150 to 200 F) to preheat the test objects
and aid in drying.
In some cases, emulsion cleaning
following alkaline cleaning is used to
provide temporary protection against
rusting of ferrous parts. However, unless
the residual oil film is completely
removed before liquid penetrant testing,
careful tests might be required to ensure
that it could not interfere with liquid
penetrant action.
The emulsion cleaner system typically
involves stable emulsions of two
immiscible liquids, such as a hydrocarbon
and water, whose stability is aided by
addition of a suitable emulsifying agent.
Depending on the nature of the
hydrocarbon solvent, the cleaning is done
at temperatures of 60 to 80 C (140 to
180 F). The solvent is often of petroleum
compounds of naphthenic, paraffinic or
aromatic types. The low boiling solvents
are usually more effective in removing
soils but increase hazards of fire or
evaporation loss as boiling and flash
points are approached. Both stable single
phase and unstable multiphase emulsion
cleaners exist. The latter are used for the
most difficult to remove hydrocarbon oils
176
Removal of Fingerprints
from Test Surfaces
Most cleaning techniques will remove
fingerprint contamination on test objects.
However, in critical applications, it may
be necessary to use special procedures
such as electrocleaning or special
fingerprint removal products. The
mandatory use of cotton gloves for
handling test parts may be justified where
contamination from fingerprints, during
test handling or operations, is suspected
of causing trouble.
177
178
MOVIE.
Postcleaning.
Postcleaning to Remove
Liquid Penetrant Residues
The cleanliness condition following
testing will vary with processing
techniques, liquid penetrant materials and
surface texture. Some liquid penetrants
such as water washable liquid penetrants
with a low level of water solubility may be
apt to leave a film of surface liquid
penetrant on test objects. However, some
water washable liquid penetrants, when
properly washed off, leave a cleaner
surface than lipophilic (oil base)
emulsifiers. Rough surfaces such as sand
casting surfaces tend to retain liquid
penetrant in a multitude of pores. Some
test processors, fearing washout of liquid
penetrant from relevant wide open
discontinuities, favor underwashing. They
intentionally leave a surface film of liquid
penetrant. However, where the test
Liquid Penetrant
Emulsifiers in Postcleaning
of Liquid Penetrant
Residues
Although not a common practice and not
as thorough as many other procedures,
the emulsifier used to remove
postemulsifiable liquid penetrants can be
used for removing residual surface liquid
penetrant during postcleaning. The parts
are subjected to a prolonged emulsifier
dwell time. This procedure may be
relatively inexpensive, depending on the
cost of the emulsifier and the rate at
which it becomes contaminated. In some
instances, such as in field testing of only a
few parts, emulsification may be the most
practical postcleaning technique. When
the volume of testing is low and the
requirement for a special cleaning
procedure is absent, the emulsifier
approach may be preferable.
179
180
Disassembly of Aircraft
and Engine for Rework
and Inspection
Aircraft returning for rework or repair are
disassembled to the degree necessary to
provide an airworthy product for another
service tour. This disassembly includes
both the aircraft and engines. The amount
of disassembly an aircraft component
receives will govern its techniques of
precleaning for the fluorescent liquid
penetrant test. In general, the precleaning
may be divided into two major categories:
(1) precleaning of components that are
completely disassembled and processed
through feeder shops and their
fluorescent liquid penetrant test stations;
(2) precleaning of components and
structures that are fluorescent liquid
penetrant tested only in selected areas.
Each of these categories entails different
precleaning processes.
Preparation of
Components for
Inspection
Before induction into rework facilities, the
aircraft and engines(s) are cleaned by
detergents, solvents, steam or other
techniques to remove soils, greases etc.
Chemical Cleaning of
Components Scheduled for Feeder
Shops
Components scheduled for feeder shops
are removed from the engine or aircraft
and disassembled and their parts are
cleaned and tested separately. Chemical
cleaning is a preferred technique and is
used as much as practical for paint
stripping, derusting and descaling of
parts. However, mechanical cleaning is
required on some parts.
As most parts and components on
aircraft are painted as protection against
the operating environment, paint
stripping is usually the first precleaning
process used. Parts are then chemically
cleaned to remove corrosion products,
grease, carbon, dirt etc. This aids in
ensuring that surfaces are free of any
foreign materials that would either
prevent the liquid penetrants entry into
discontinuities or would hold the liquid
penetrant on the surface, causing false
indications or masking relevant
indications. Etching of turbine blades is
but one example of the variety of
precleaning required to condition a part
for liquid penetrant testing.
Restrictions on Mechanical
Cleaning of Components of
Inservice Aircraft
Even though chemical cleaning is the
preferred technique, mechanical cleaning
181
Precleaning of Selective or
Localized Areas of Aircraft
or Components
Preparation of selected, localized surface
areas can range from cleaning a complete
wing spar to a small attach fitting. Some
large helicopter transmission housing and
engine accessories cases also fall into this
category. Because these parts cannot be
taken into the cleaning tanks, the
precleaning techniques are much more
restrictive.
Again, precleaning usually starts with
paint stripping. Chemical stripping is
generally used but mechanical stripping is
substituted for some components having
phenolic resins or baked enamels.
Mechanical stripping is usually grit
blasting of the approximate area to be
tested. Many areas will have sealants
applied that must be removed, usually by
182
Conditions Interfering
with Liquid Penetrant
Testing of Inservice
Aircraft
Conditions listed below and many others
interfere with fluorescent liquid penetrant
testing for the reasons given.
1. Remaining scale, rust and paint
residue will absorb liquid penetrant
and thereby give false indications or
mask relevant indications.
2. Residue remaining around fasteners
presents an additional masking
problem and causes such excessive
bleedout that cracks extending from
these areas have to propagate from
3 to 6 mm (0.125 to 0.25 in.) to be
identified.
183
Types of Mechanical
Processing Preceding
Liquid Penetrant Testing
During the fabrication of components
such as in aircraft, a number of
mechanical processes may be applied to
the part. Titanium and aluminum parts
are frequently machined to their final
configuration. Steel parts are often grit
blasted to remove heat treat scale.
Titanium and aluminum parts are
commonly tumble deburred or liquid
honed to improve the surface condition
and remove burrs resulting from previous
operations. Shot peening is used to induce
a favorable stress pattern in the surface of
some parts. Many parts are machined and
then sanded to remove machining marks.
Liquid penetrant testing often is applied
at several stages in the fabrication
sequence and may directly follow any of
the above mechanical processes.
184
Examples of Mechanical
Obliteration of Crack
Indications in Aluminum
Alloys
McFaul has reported unique photographic
evidence of obliteration of liquid
penetrant indications of surface cracks in
aluminum alloys.5 These tests indicated
that obliteration of cracks by mechanical
surface processing (except for shot
peening) can be overcome by a mild etch,
if a postemulsifiable liquid penetrant
system is used. The postemulsifiable
liquid penetrant, compared to a water
washable liquid penetrant, is more
impervious to the nullifying effects of
possible residual acids and other
contaminants.
To conduct the tests, patterns of tight
cracks with depth of 0.2 to 3 mm (0.01 to
0.125 in.) were generated in 10 mm
(0.375 in.) thick blocks sliced from 75
100 mm (3 4 in.) aluminum alloy bars
by repeated heating to 540 C (1000 F)
and quenching in ice water. After about
the fifth quench, a network of high
thermal stress, low cycle fatigue cracks
appeared. These crack specimens were
milled sufficiently to clean up both top
and bottom surfaces of the blocks to a
0.8 mm (0.03 in.) root mean square (rms)
surface finish.
Liquid penetrant tests were made with
a lipophilic postemulsifiable liquid
penetrant system and a nonaqueous
developer. Liquid penetrant dwell time
was 15 min. Excess liquid penetrant was
then flushed off with water to reduce the
subsequent emulsification time,
established at 1 min. After emulsification,
the parts were again thoroughly washed
with a spray rinse and checked with
ultraviolet radiation. Specimens were then
dried for 10 min in an 80 C (180 F)
FIGURE 2. Effect of honing or lapping on liquid penetrant indications in cracked aluminum test specimens: (a) original crack
pattern of standard quench cracked block; (b) crack pattern after removal of 0.06 mm (0.0025 in.) of material using 30 grit
wheel with coolant and controlled feed and speed; (c) crack pattern after removal of 25 m (0.001 in.) by simulated cylinder
honing operation; (d) crack pattern after removal of 0.008 mm (0.0003 in.) per side by standard preanodic etch method;
(e) crack pattern after removal of 0.06 mm (0.0025 in.) by milling.
(b)
(a)
(d)
(c)
(e)
185
FIGURE 3. Effect of hand sanding using 180 grit on liquid penetrant indications in cracked aluminum alloy test block:
(a) original crack pattern of standard quench cracked block; (b) crack pattern after removal of 0.05 mm (0.002 in.) by hand
sanding using 180 grit aluminum oxide paper; (c) crack pattern after 10 min preanodic etch, removing about 0.005 mm
(0.0002 in.) per side; (d) crack pattern after additional 5 min etch, making total of 0.008 mm (0.0003 in.) material removed
per side; (e) crack pattern after 0.06 mm (0.0025 in.) was removed by milling.
(c)
(b)
(a)
(d)
(e)
FIGURE 4. Effect of hand sanding using 240 grit on liquid penetrant indications in cracked
aluminum alloy test block: (a) original crack pattern of standard quench cracked block;
(b) crack pattern after removal of 0.05 mm (0.002 in.) material by hand sanding using 240
aluminum oxide grit paper; (c) crack pattern after removal of 0.008 mm (0.0003 in.) per side
by standard preanodic etch method; (d) crack pattern after removal of 0.06 mm (0.0025 in.)
material by milling. Note that crack obscuring effect of 240 grit is noticeably more than that
indicated by use of coarser 180 grit.
186
(a)
(b)
(c)
(d)
FIGURE 5. Effect on liquid penetrant indications from combination of hand sanding of cracked
aluminum alloy test block with 80 grit paper and finish grind using motor driven 240 grit
quill: (a) original crack pattern of standard quench cracked block; (b) crack pattern after finish
grind; (c) crack pattern after removal of 0.008 mm (0.0003 in.) material per side by standard
preanodic etch; (d) crack pattern after removal of 0.06 mm (0.0025 in.) material by milling.
(a)
(b)
(c)
(d)
FIGURE 6. Effect of hand scraping using carbide tip scraper on liquid penetrant indications in cracked aluminum alloy test
block: (a) original crack pattern of quench cracked block; (b) crack pattern after removal of 0.12 mm (0.005 in.) by hand
scraping entire surface; (c) crack pattern after removal of 0.008 mm (0.0003 in.) per side by preanodic etch. Note that some
streaking and slight loss of crack pattern is evidenced in Fig. 5b due to variations in scraping technique.
(a)
(b)
(c)
187
Investigation of
Mechanical Processes
Reducing Liquid Penetrant
Sensitivity
An investigation has been reported6
whose objectives were to (1) identify
several mechanical processes that reduce
the effectiveness of subsequent liquid
penetrant testing of aluminum, titanium
and steel and (2) determine techniques to
restore liquid penetrant sensitivity after
those mechanical processes. Quench
cracked steel and stress corrosion cracked
FIGURE 7. Effect of standard shot peen process on liquid penetrant indications in cracked aluminum alloy test block:
(a) original crack pattern of standard quench cracked block; (b) crack pattern after shot peen; (c) crack pattern after removal
of 0.008 mm (0.0003 in.) material per side by standard preanodic etch process; (d) crack pattern after removal of 0.12 mm
(0.005 in.) material by milling; (e) crack pattern after removal of an additional 0.12 mm (0.005 in.) by milling.
(b)
(a)
(d)
188
(c)
(e)
(a)
(a)
(b)
(b)
(c)
(c)
(d)
(d)
189
FIGURE 10. Effect of grit blasting using 150 alum oxide grit on liquid penetrant indications in cracked
aluminum alloy test block: (a) original crack pattern of quench cracked block; (b) crack pattern after grit blast;
(c) crack pattern after 0.008 mm (0.0003 in.) per side was removed by standard preanodic etch. Note that
textured surface of block in Fig 5c definitely affected spread of liquid penetrant during development period.
Because liquid penetrant pattern was returned in its entirety, no further work was done with this example.
(c)
(b)
(a)
FIGURE 11. Effect of chromic anodic anodize treatment on liquid penetrant indications in cracked aluminum
alloy test block: (a) original crack pattern as developed in 7075-T6 block by quench crack method;
(b) chromic acid bleed back stain after anodizing; (c) crack pattern as developed by liquid penetrant process
after anodizing. Note that here, as in grit blasted specimen, surface texture promoted increased spreading of
liquid penetrant during development.
(c)
(b)
(a)
TABLE 4. Amount of surface material to be removed by etching to restore liquid penetrant indications.
Surface Material to Be Removed
4340 Steel
300M Steel
m (in. 106) m (in. 106)
______________________________________________________________________________________________________________
Process
No. 120 aluminum oxide grit blasting
No. 50 aluminum oxide grit blasting
Liquid honing
Shot penning
Tumble deburring
Sanding, 100 grit
Sanding, 180 grit 2.5
100
Finish sanding of O-ring grooves
Conventional machining
Titanium
m (in. 106)
7.5
300
100.0 4000
2.5
100
100.0 4000
2.5
100
no effect
70
1.8a
___
___
___
___
190
1.8
70
1.5
60
1.8
70
4.5 180
1.5
60
1.5a
60
no effect 5
___
___
___
___
0.8
30
0.5
20
0.8a
30
2.5
100
40
1.0a
no effect
___
___
___
___
Aluminum
m (in. 106)
___
___
___
___
5
5
1.3
5
___
___
___
___
(200)
(200)
(200)
(30)
(200)
Evaluation of Effect of
Mechanical Processing of
Aluminum on Liquid
Penetrant Sensitivity
Quench cracked 2024 aluminum alloy
specimens were investigated using the
procedures shown in Figs. 12 and 13. The
liquid penetrant materials used in the
evaluation were (1) a water washable
fluorescent liquid penetrant and (2) a
lipophilic fluorescent postemulsifiable
liquid penetrant system used with two
types of wet developer. The specimens
were cleaned after each liquid penetrant
test by vapor degreasing to remove
residues of liquid penetrants and
processing materials before retesting.
The effects of four mechanical
processes were investigated: (1) tumble
deburring, (2) sanding with 100 grit
emery cloth sanding disks with an air
motor unit in the same manner as
standard milled part, (3) sanding with
30 s etch
(remove
1.3 m or
0.00005
in.)
Etch with
nitric-chromic-hydrofluoric
acid etch (1 L nitric acid,
0.1 L hydrofluoric acid and
0.5 kg chromic acid)
10 min
20 min
5 min etch
etch
etch
(remove
(Remove
(remove
2.5 m or
5 m or
7.5 m or
0.0001 in.) 0.0002 in.)
0.0003 in.)
191
(b)
(b)
(c)
192
Evaluation of Effect of
Mechanical Processing of
Steel on Liquid Penetrant
Sensitivity
Specimens of AISI 4130 and AISI 1018
steels were cracked by carburization and
(b)
Recommended Metal
Removal by Etching of
Sanded Aluminum Parts
These results indicate that aluminum
parts subjected to (1) a sanding operation
with 180 grit butterfly type sanding units
or (2) a sanding operation with 100 grit
emery cloth sanding disks or (3) tumble
193
Specimen B
End
(b)
End
FIGURE 19. Typical grinding crack pattern in carburized AISI 1018 steel.
194
Effects of Mechanical
Processing of Steels on
Liquid Penetrant
Indications
Parameters
Tumble deburring
TABLE 6. Summary of mechanical processing effects on liquid penetrant indications. Blank boxes indicate that tests were
not performed under those conditions.a
Operation
Grit blasting, 120 grit aluminum oxide
Grit blasting, 50 grit aluminum oxide
Liquid honing
Shot peening
Tumble deburring
Sanding, 100 grit
Sanding, 180 grit
Finish sanding O-ring grooves
a.
b.
c.
d.
e.
Aluminum
not performeda
not performeda
not performeda
not performeda
masked someb
masked someb
masked someb
masked mostc
4340 Steel
masked someb
masked someb
masked someb
masked mostc
masked someb
reduced strengthd
reduced strengthd
not performeda
1018 and
4130 Steel
300M Steel
masked someb
masked someb
reduced strengthd
masked mostc
reduced strengthd
no effecte
no effecte
not performeda
not performeda
not performeda
masked mostc
not performeda
not performeda
not performeda
not performeda
not performeda
Titanium
(6AI-4V)
masked mostc
masked mostc
masked someb
masked mostc
masked someb
no effecte
masked someb
not performeda
195
Recommended Metal
Removal by Etching to
Restore Indications in Steel
The amount of etching required to restore
masked liquid penetrant indications also
varied depending on the mechanical
process and the material (see Table 4). For
example, the average required amount of
etching varied from 0.5 to 5 m (7 105
to 2 104 in.) for 300M steel. Etching of
high strength steels is not always feasible
because of the possibility of
embrittlement. Consequently, when it is
not feasible to etch, these test results
indicate that it may be necessary to use a
supplementary testing such as magnetic
particle testing along with liquid
penetrant testing if parts are to be tested
after grit blasting or liquid honing.
FIGURE 21. Effect of liquid honing on liquid penetrant indications in 300 M steel (water
washable liquid penetrant without developer): (a) before liquid honing; (b) after liquid
honing.
(a)
(b)
196
Evaluation of Effect of
Mechanical Processing of
Titanium on Liquid
Penetrant Testing
Sensitivity
Stress corrosion cracked specimens of
annealed Ti-6Al-4V titanium alloy were
also investigated for effects of mechanical
FIGURE 22. Effect of shot peening on liquid penetrant indications in 300M steel: (a) as
cracked; (b) after shot peening; (c) after etching.
(a)
(b)
(c)
197
Parameters
Tumble deburring
FIGURE 23. Effect of grit blasting on liquid penetrant indications in 300M steel: (a) as cracked;
(b) after grit blasting; (c) after etching.
(a)
(b)
(c)
198
(b)
(b)
(c)
Effects of Mechanical
Processing of Titanium on
Liquid Penetrant
Indications
The effect of mechanical processing on
titanium can be seen in Table 6. The effect
on the liquid penetrant indications varied
depending on the mechanical process. For
example, grit blasting and shot peening
resulted in a total loss of liquid penetrant
indications (see Fig. 24) and were the
most detrimental processes. Consequently,
it can be seen that if liquid penetrant
testing of titanium is performed
immediately after grit blasting or shot
peening without etching, the test would
be highly ineffective. The effectiveness of
the liquid penetrant testing was reduced
to a lesser degree by liquid honing,
tumble deburring and 180 grit sanding
(see Fig. 25). For those processes, finer
indications were lost but the larger
indications remained. Finally, 100 grit
sanding had no observable effect on
either the number of liquid penetrant
indications or their strength.
Recommended Metal
Removal by Etching to
Restore Indications in
Titanium
The amount of etching required to restore
masked liquid penetrant indications also
varied depending on the mechanical
process and the material (see Table 4). The
average required amount of etching for
Ti-6Al-4V alloy varied from 2.5 to 100 m
(0.0001 to 0.004 in.).
199
References
200