Liquid Penetrant Testing Procedure

Specific Examination for the Computer Based Training Program TABLE OF CONTENTS 1.0 2.0 2.1 2.2 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5.0 5.1 5.2 Requirements . . . . . Inspection Facilities . . . . Processing . . . . . Viewing . . . . . . System Performance . . . . Open Tank System . . . . Penetrant System Check . . . . Automated Systems . . . . Penetrants. . . . . . Brightness . . . . . Water Content . . . . . Separation of Constituents . . . Removability Method A Only . . . Removability Method B Only . . . Sensitivity . . . . . Emulsifier Water Content (Lipophilic) . . Emulsifier Concentration (Hydrophilic Emulsifier) Emulsifier Removability . . . . Developers . . . . . Dry Developer . . . . . Wet Developer (Soluable & Suspendable) . Nonaqueous Wet Developer . . . Black Lights . . . . . Final Inspection . . . . . Bulb Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 .4 .4 .4 .4 .4 .4 .4 .5 .5 .5 .5 .5 .5 .5 .6 .6 .6 .6 .6 .6 .6 .6 .6 . .6 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7

5.3 Lens . . . 5.4 Lens Casing . . 5.5 Black Light Warm-up . 5.6 Black Light Lens Distance 5.7 Black Light Intensity . 5.8 Dispersal . . . 5.9 Daily Inspection . . 5.10 Line Voltage . . 5.11 Lamp Assembly . . 5.12 Light Meter . . 5.13 Light Meter Calibration . 6.0 Dryers . . . 6.1 Dryer Type . .

6.2 6.3 6.4 6.5 7.0 7.1 7.2 7.3 8.0 9.0 9.1 9.2 9.3

Thermostat Accuracy . Thermostat Accuracy . Dryer Temperature . Part Temperature . . Restrictions . . Final Fabrication . . Shot Peening . . Etching . . . Cleaning . . . Penetrant Inspection Process Cleaning Methods . Penetrant Family . . Developer Family .

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9.4 Penetrant Coverage . 9.5 Masking/Plugging . 9.6 Penetrant Applications . 9.7 Welded Components . 9.8 Part Temperature . . 9.9 Pooling of Penetrant . 9.10 Penetrant Dwell Time . 9.11 Immersion . . 9.12 Penetrant Drying . 9.13 Penetrant Removal . 9.14 Rinsing . . . 9.15 Spray Removal . . 9.16 Examination . . 9.17 Excessive Fluorescence . 9.18 Method C Process . 9.19 Method C Removal . 9.20 Method C Illumination . 9.21 Over-removal . . 9.22 Method D Process . 9.23 Method D Rinse . . 9.24 Post-rinse . . 9.25 Over-rinse . . 9.26 Excessive Background . 9.27 Drying . . . 9.28 Drying Parameters . 9.29 Dry Developers . . 9.30 Development Time . 9.31 Nonaqueous Developers 9.32 Aqueous Developers . 10.0 Inspection . . 10.1 Corrective Lens . .

10.2 10.3 10.4 10.5 10.6 11.0 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 12.0 12.1 12.2

Booth Inspection . . . Dark Adaptation. . . . Inspection Surface Light Intensity . Black Light Intensity without Developer Final Inspection . . . . Accept/Reject Criteria . . . Certified Personnel . . . Raw Stock . . . . Improper Cleaning . . . Evaluation . . . . Redevelopment Time . . . Rounded Indications Defined . . Rounded Indications Accept/Reject . Cracks . . . . . Inspecting Installed Parts . . Method A (Water Washable) . . Method C (Solvent Removable) .

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1.0 Requirements 1.1 All materials used for penetrant inspection shall conform to and be qualified per MIL-I-25135. 1.2 Water soluble developers shall not be used with water washable penetrants. 1.3 Type II penetrants shall not be used prior to a Type I penetrant inspection of the same component. 1.4 Penetrant inspection without a developer shall be allowed only for those penetrant systems which have met the appropriate sensitivity level requirement without a developer. 2.0 Inspection Facilities 2.1 Processing - The penetrant inspection processing equipment shall be designed in order to permit a uniform and controlled operation. The equipment shall meet all applicable national and local safety requirements as well as the requirements specified herein. 2.2 Viewing - When performing a final inspection for fluorescent penetrants, the ambient white light background shall not exceed 2 foot-candles. 2.2.1 Viewing - Black lights shall provide a minimum of 1,000 micro-watts/cm2 when measured 15 inches from the front face of the black light filter or bulb. 3.0 System Performance 3.1 Open Tank System - The penetrant system shall be checked daily or when first operated for performance. The check shall be made with known defect standards (PSM-5 Panel, N410721001 Test Panel Set, 198055 TAM Panel. 3.2 Penetrant System Check - The penetrant system check shall be performed by processing a known defect standard through the penetrant system using appropriate processing parameters and comparing the indications obtained to those obtained with unused samples of the same materials. 3.2.1 When the performance of the in-use materials falls below the performance of the unused materials, the in-use material quality shall be checked with the appropriate tests anc corrected or discarded prior to conducting any further penetrant inspections. 3.3 Automated Systems - Automated penetrant systems that incorporate deviations from manual operating procedures may be used.

3.3.1 The system shall be checked weekly, or whenever it is adjusted or shutdown for maintenance reasons. 3.3.2 Known defects standards shall be processed through the penetrant system and compared to results of the same specimens after being processed manually. Any noticeable reduction in sensitivity shall require system adjustment. 3.4 Penetrants - The following checks on in-use penetrants shall be conducted before replenishment or when quality may have degraded. 3.5 Brightness - The brightness of in-use penetrants shall be conducted monthly in accordance with MIL-I-25135 or ASTM-E-1135. 3.5.1 A sample on unused penetrant shall be used as a reference. Brightness values less than 90 percent of the unused penetrant are unacceptable and shall be replaced. 3.6 Water Content - (Method A Penetrants Only) - The water content of in-use Method A penetrants shall be conducted monthly in accordance with ASTM-D-95. Water content in excess of 5 percent by volume of the original penetrant shall be replaced. 3.7 Separation of Constituents - Tank penetrants shall be observed for separation of constituents (layering). The test shall consist of taking a sample of the penetrant material, at the beginning of the shift, utilizing a clear container. The sample shall stand for a minimum of four hours and viewed to determine if there is separation of constituents. If separation is identified the penetrant shall be replace. 3.8 Removability - (Method A Penetrants Only) - The removability of Method A penetrants shall be tested monthly in accordance with MIL-I-25135 with a sample of the unused penetrant as a reference. 3.8.1 If the removability is noticeably less than the test performed with the unused penetrant sample, the in-use penetrant shall be replaced. 3.9 Removability - (Method B Penetrant Only) - The removability of Method B penetrants shall be tested monthly in accordance with MIL-I-25135 with a sample of the unused penetrant as a reference. 3.9.1 If the removability is noticeably less than the test performed with the unused penetrant sample, the un-use penetrant shall be replaced. 4.0 Sensitivity

4.0 Sensitivity - The sensitivity on in-use penetrants shall be checked weekly using a known defect standard. 4.1 Emulsifier - Water Content (Lipophilic Emulsifier) - Water content shall be checked monthly in accordance with ASTM-D-95. Water content in Excess of 5 percent of the original unused emulsifier shall be replaced. 4.2 Emulsifier - Concentration (Hydrophilic Emulsifier) - The concentration of immersion solutions shall be checked weekly with a refractometer. 4.2.1 A concentration greater than three percentage points from the initial reading shall result in the replacement of the emulsifier. 4.3 Emulsifier Removability - Removability of the in-use tank emulsifier shall be checked weekly by normal wash parameters used when processing parts. 4.3.1 Removability less than that of the reference system is unacceptable and the emulsifier shall be replaced. 4.4 Developers - The following checks on in-use developers shall be performed as specified. Unacceptable performance shall be cause for replacement or corrective action. 4.5 Dry Developer - Dry developer shall be checked daily to ensure its fluffy and not caked. Caked dry developer is unacceptable and shall be replaced. 4.6 Wet Developer (Soluble and Suspended) - Wet developers shall be checked daily for fluorescence, as appropriate, and coverage. Immerse a clean aluminum panel, about 3 inches x 10 inches and remove for drying and observation under a black light. 4.6.1 Failure of the wet developer to uniformly wet the panel or observed fluorescence is unacceptable. 4.6.2 Concentration of the wet developer shall be checked weekly with a hydrometer and shall be in accordance with the developer supplier recommended concentration. 4.7 Nonaqueous Wet Developer - Applications shall wet the surface to be inspected with the lightest possible coating by any suitable spray method. 5.0 Black Lights 5.1 Final Inspection - Ultraviolet (black light) final inspection lights shall be not less than 100 watts. 5.2 Bulb Type - the bulb shall be a flood or spt-type with a wavelength of 3,200-3,800 angstrom units.

5.3 Lens - The lens shall be cleaned a maximum every 14 days. 5.4 Lens Casing - The lens and casing shall be inspected for leakage of visible white light due to damaged or defective masking. 5.4.1 White Light Leakage - If any white light is visible, the lens or casing shall be repaired or replaced. 5.5 Warm-up - Allow the black light to warm up a minimum of 15 minutes before performing an inspection. 5.6 Lens Distance - With a black light held by a fixture, adjust its height to 15 inches from the face of the lens fixture to the sensor cell of the ultraviolet meter. 5.7 Intensity - The black light intensity shall be not less than 1,000 mW/cm2. 5.8 Dispersal - Ensure that the bulb and filter combination provides an even light dispersal in the projected beam. 5.9 Daily Inspection - Black light reflectors and filters shall be inspected daily for cleanliness and integrity. Damaged or dirty reflectors or filters shall be repaired ro replaced. 5.10 Line Voltage - Constant line voltage is required for consistent light performance. Where fluctuations exist, a constant voltage transformer shall be used. 5.11 Lamp Assembly - Lamp assemblies or components that do not meet the foregoing requirements shall be repaired ro replaced. 5.12 Light Meter - The black and/or white light meter shall be calibrated at intervals not exceeding one year. 5.12.1 I f the black or white light meter is dropped, it shall be recalibrated before reuse. 5.13 Light Meter Calibration - The black and white light meters shall be calibrated using a method traceable to the National Institute of Standards and Technology (NIST). 6.0 Dryers

6.1 Dryer Type - Dryers shall be the circulating air type and shall be provided with thermostatic controls that will maintain stable temperatures throughout the oven up to 160 degrees Fahrenheit. maximum. 6.2 Thermostat Accuracy - The thermostat shall be checked at intervals not exceeding six months.

6.3 Thermostat Accuracy - The thermostat shall be accurate within 10 percent of the operating temperature. 6.4 Dryer Temperature - The dryers used in automated systems may generate temperatures up to 200 degrees Fahrenheit. 6.5 Part Temperature - The surface temperature of the parts shall not exceed 160 degrees Fahrenheit at any time. 7.0 Restrictions 7.1 Final Fabrication - Penetrant inspection shall be performed after final fabrication of parts. 7.2 Shot Peening - Parts which have been shot peened prior to penetrant inspection shall be rejected. 7.3 Etching - Castings shall not be etched prior to penetrant inspection unless otherwise specified. 8.0 Cleaning 8.1 Parts and materials to be inspected by fluorescent penetrant methods shall be free from contaminants and foreign materials which would mask defects or produce irrelevant or false indications. 9.0 Penetrant Inspection Process 9.1 Cleaning Methods - Cleaning methods, including etching, selected for a particular part shall be consistent with the contaminants to be removed and shall not damage the part or its intended function. 9.2 Penetrant Family - Approved penetrants and emulsifiers shall be used as a family group from one manufacturer. 9.2.1 Products from different manufacturers shall not be mixed.

9.3 Developer Family - Nonaqueous developers from a different manufacturer (family) can be used . 9.6 Penetrant Coverage - Unless otherwise specified, the entire surface of the part shall be covered with penetrant.

9.7 Masking/Plugging - Those areas not to be covered with penetrant shall be masked, plugged or otherwise protected. 9.8 Penetrant Applications - Penetrant shall be applied by spraying, dipping, brushing, or other methods which shall provide coverage as required. 9.9 Welded Components - Welded components having openings where residual penetrant cannot be removed shall not be tank dipped or sprayed. The penetrant shall be applied by brush or swab. 9.10 Part Temperature - The part, penetrant, and ambient temperature shall all be in the range of 50-100 degrees Fahrenheit. 9.11 Pooling - The part shall be rotated or otherwise positioned in order to prevent pooling of the penetrant during the dwell time. 9.12 Penetrant Dwell Time - The dwell time shall be a minimum of 10 minutes and a maximum of 2 hours. 9.13 Immersion - Parts shall not be left immersed in the penetrant tank for longer than one-half the dwell time. 9.14 Penetrant Drying - If the penetrant dries, the component shall be cleaned and retested. 9.15 Penetrant Removal - After the required penetrant dwell time, the penetrant shall be removed by the applicable method. 9.16 Rinsing - After the required emulsifier dwell time, emulsification shall be stopped by immersion or water spray. 9.17 Spray Removal - For spray removal of the penetrant or emulsifier, rinsing shall be the minimum required to remove the emulsifier or penetrant from the surface of the part.

9.18 Excessive Fluorescence - Clean and reprocess those parts with excessive background fluorescence. 9.20 Method C Process - Solvent removable penetrants are removed by first wiping the excess penetrant with a clean, lint-free, dry cloth or absorbent toweling.

9.21 Method C Removal - The remainder of the surface penetrant shall be removed with a solvent-dampened lint-free cloth or towel. 9.21.1 The surface of the component shall not be flushed with solvent and the cloth or towel shall not be saturated with solvent. 9.22 Method C Illumination - The component and cloth or toweling shall be observed under appropriate illumination to assure adequate removal of the surface penetrant. 9.23 Over-removal - Over-removal of the surface penetrant shall require the component to be cleaned and reprocessed. The surface shall be dried by blotting with a lint-free, dry cloth or towel, or by evaporation. 9.24 Method D Process - Hydrophilic post emulsifiable penetrant shall be removed with a water pre-rinse application of the hydrophilic emulsifier followed with a post-rinse. 9.25 Method D Rinse - the water pre-rinse shall be applied by immersion, flowing, foaming, or spray. 9.25.1 For immersion applications, the concentration, percent volume, shall be no higher than specified by the penetrant system supplier and shall not exceed that for which the system is qualified. 9.25.2 For immersion applications, the emulsifier or part may be mildly agitated. 9.25.3 Dwell time shall be the minimum required for adequate surface penetrant removal, but unless otherwise specified, shall not exceed 2 minutes. 9.25.4 For spray applications, the concentration shall not exceed 5 percent.

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9.26 Post-rinse - After the application and dwell of the hydrophilic emulsifier, the component under test shall be rinsed with water. 9.27 Over-removal - Evidence of over-removal shall require the part to be cleaned and reprocessed. 9.28 Excessive Background - Excessive background may be removed by additional (touch-up) application of the hydrophilic emulsifier provided its maximum allowable dwell time is not exceeded. 9.28.1 Additional rinsing of the touch-up area will be required after application and dwell of the hydrophilic emulsifier.

9.28.2 If the touch-up application of the hydrophilic emulsifier does not produce an acceptable background, the part shall be cleaned and reprocessed. Manual systems shall require the use of appropriate illumination to assure adequate penetrant removal. 9.29 Drying - all parts shall be dried prior to the application of dry developer, nonaqueous developer, or examination without developer. 9.29.1 The components should be drained of excess water but not dried before the application of aqueous soluble or suspendable developer. 9.29.2 The components shall be dried after the application of aqueous developers. 9.30 Drying Parameters - Components shall be air dried at room temperature or in a drying oven. 9.30.1 Oven temperature shall not exceed 160 degrees Fahrenheit maximum or 200 degrees Fahrenheit for automated systems. 9.30.2 Drying time shall not exceed 30 minutes, or that necessary to adequately dry the part, whichever is less. 9.30.3 Components shall not be placed in the oven with pooled water. 9.31 Dry Developers - Components shall be dry before the dry developer is applied. Dry developer shall be applied in such a manner as to contact all surfaces to be inspected. 9.31.1 Excessive dry developer may be removed after the development time by light tapping or light air blow.

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9.32 Development Time - Development time shall be between a minimum of 10 minutes and a maximum of 4 hours. 9.33 Nonaqueous Developers - Components, or areas requiring examination, shall be dry before application of the nonaqueous developer. 9.33.1 Nonaqueous developer shall be applied by spraying with a uniform thin coating over the entire surface to be inspected. 9.33.2 If the developer coating thickness is too heavy such that the metallic surface is completely masked, the component shall be cleaned and reprocessed. 9.33.3 The minimum developer time shall be 10 minutes. The maximum developer time shall not exceed 1 hour.

9.34 Aqueous Developer - Aqueous soluble developers shall not be used with Method A penetrants. 9.34.1 Aqueous suspendable developers can be used with Type I penetrants. 9.34.2 Aqueous developers may be applied to the component after rinsing. The aqueous developers shall be applied by spray, flowing or immersion. 9.34.3 The applied developer shall not be allowed to puddle and shall completely cover all surfaces of the part. 9.34.4 Oven temperature shall not exceed 160 degrees Fahrenheit maximum or 200 degrees Fahrenheit maximum for automated systems. 9.34.5 Drying time shall not exceed 30 minutes, or that necessary to adequately dry the part, whichever is less. 10.0 Inspection 10.1 Corrective Lens - All inspectors using light sensitive lenses are restricted from performing inspections while wearing corrective lenses. 10.2 Booth Inspection - Parts shall be inspected in a booth or darkened area where ambient and incident white light does not exceed two foot-candles.

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10.3 Dark Adaptation - Inspectors shall accustom their eyes to darkness for not less than 3 minutes prior to evaluation parts. 10.4 Inspection Surface light Intensity - When inspecting internal surfaces, a minimum black light intensity of 500 mW/cm2 shall be maintained at the inspection surface. 10.5 Black Light Intensity without Developer - When using approved Class 2 or 3 penetrants without developer, the black light intensity shall not be less than 3,000 mW/cm2 at the test part surface. 10.6 Final Inspection Limitations - When conditions do not permit inspection immediately, a maximum time of two hours may be allowed, provided the parts have been adequately protected from contamination and not exposed to direct sunlight.

11.0 Accept/Reject Criteria 11.1 Certified Personnel - Only appropriate, certified personnel can accept parts or raw stock as passing a penetrant inspection based on this procedure. 11.2 Raw Stock - All parts and raw stock free of penetrant indications shall be accepted. 11.3 Improper Cleaning - Material containing indications caused by faulty rinsing, rough surface conditions or improper cleaning shall be retested and evaluated. 11.4 Evaluation - Indications may be evaluated by wiping the indication with a solvent dampened swab, allowing the area to dry, and redevelop. 11.5 Redevelopment Time - Redevelopment time shall be as long as the original development time. If no indication reappears, the original indication shall be considered false. 11.6 Rounded Indications Defined - Rounded indications include those obtained from voids (cavities) or porosity. Rounded indications are circular or elliptical with there length less than three times there width. 11.7 Rounded Indications Accept/Reject - Rounded indications are rejectable when they exceed one or more of the following:

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The longest dimension is 1/16 inch or greater Six or more in line and any two separated by less than 1/16 inch. Ten or more scattered (not in line) in any one square inch or surface. 11.8 Cracks - Parts shall be rejected for crack indications or other continuous linear, or irregular indications where the length is greater than 1/16 inch. 12.0 Inspecting Installed Parts 12.1 Installed Parts Inspection - A Type II dye penetrant inspection shall be substituted for fluorescent penetrant inspection when the inspection area cannot be darkened adequately for a fluorescent penetrant inspection. 12.2 Method A (Water Washable) 12.2.1 Apply penetrant using a brush. Reapply as necessary to maintain a constant wet film on the surface.

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12.2.2 Penetrant dwell time shall be a minimum of 10 minutes and a maximum of 2 hours. 12.2.3 Remove surface penetrant by water wash or with clean dampened cloth. 12.2.4 Use portable black light to determine if cleaning is complete. 12.2.5 Dry evaporation or wipe with a clean cloth. 12.2.6 Spray a thin even coat of nonaqueous developer. 12.2.7 The minimum developer time shall be 10 minutes. The maximum developer time shall not exceed 1 hour. 12.2.8 Examine under black light in a darkened area. 12.3 Method C (Solvent Removable) 12.3.1 Apply Level 2 or 3 penetrant using a brush. Reapply as necessary to maintain a constant wet film on the surface. 12.3.2 Penetrant dwell time shall be a minimum of 10 minutes and a maximum of 1 hour. 12.3.3 Apply cleaner/remover to a clean cloth and wipe the surface of the part. 12.3.4 Inspect the surface with a black light to ensure complete removal of the penetrant. 12.3.4 Spray a thin coat on nonaqueous developer. 12.3.6 The minimum developer time shall be 10 minutes. The maximum developer time shall not exceed 1 hour.