0 Bewertungen0% fanden dieses Dokument nützlich (0 Abstimmungen)
60 Ansichten68 Seiten
Liquid penetrant inspection is a non-destructive testing method used to detect surface-breaking defects in non-porous materials. It involves cleaning the surface, applying a penetrant that is drawn into defects via capillary action, removing excess penetrant, applying a developer to draw the penetrant out of defects, and inspecting under appropriate lighting. The type of penetrant, removal method, and developer used define the inspection system and can be selected based on defect characteristics, part geometry, and test requirements.
Liquid penetrant inspection is a non-destructive testing method used to detect surface-breaking defects in non-porous materials. It involves cleaning the surface, applying a penetrant that is drawn into defects via capillary action, removing excess penetrant, applying a developer to draw the penetrant out of defects, and inspecting under appropriate lighting. The type of penetrant, removal method, and developer used define the inspection system and can be selected based on defect characteristics, part geometry, and test requirements.
Liquid penetrant inspection is a non-destructive testing method used to detect surface-breaking defects in non-porous materials. It involves cleaning the surface, applying a penetrant that is drawn into defects via capillary action, removing excess penetrant, applying a developer to draw the penetrant out of defects, and inspecting under appropriate lighting. The type of penetrant, removal method, and developer used define the inspection system and can be selected based on defect characteristics, part geometry, and test requirements.
Surface inspection method Applicable to all non-porous, non- absorbing materials
Dye Penetrant Inspection(DPI) Penetrant Flaw Detection (PFD) Penetrant Testing (PT) 6 Steps in Penetrant flaw detection Surface preparation Penetrant application Removal of excess penetrant Application of developer Inspection Post cleaning and protection 1. Surface Preparation Physical Methods Chemical Methods Scale Slag Corrosion products Oils and Greases Paints Chemical Methods Vapour Degreasing Hot Solvent Degreasing Cold solvent Degreasing Solvent materials with Emulsifiers Acid / Alkaline Cleaning Steam cleaning Paint Removal
2. Penetrant Application Penetrating fluid applied to component and drawn into defect by capillary action Penetrant Application
Critical factors Penetration / Dwell time
Component Temperature
Principle : Capillary Action Interaction of adhesive and cohesive forces Principle : Capillary Action Interaction of adhesive and cohesive forces Penetrant Properties Good Wetting Ability High Surface Tension Viscosity Wetting Ability Liquids having good wetting ability have a low contact angle. Liquids having a contact angle of 90 or less will act as penetrants. Contact angle is strongly affected by surface cleanliness. Contact Angle Contact Angle LOW HIGH Contact Angle Surface Tension HIGH LOW Surface Tension Strongly affected by contamination Viscosity Viscosity is a measure of internal friction It affects the rate at which a liquid flows Viscosity has a strong effect on the time taken for capillary action to work A high viscosity penetrant will require a longer contact time and a longer development time A low viscosity penetrant may drain too quickly from vertical or overhead surfaces Types of Penetrant Colour Contrast Fluorescent All other factors being equal, fluorescent penetrants provide the best sensitivity Each of the above may be water washable, solvent removable or post-emulsifiable (in order of increasing sensitivity) 2. Penetrant Application Methods Spraying Brushing Immersion Preceded by a visual inspection Penetrant application Special Methods Thixotropic penetrants Electrostatic spraying 3. Removal of Excess Penetrant Penetrating fluid applied to component and drawn into defect by capillary action Penetrating fluid removed from component surface (but not from defect) Removal of Excess Penetrant Water washable Solvent Removable Post Emulsifiable Penetrants are formulated for removal by one or sometimes more than one of the above. Removal of Excess Penetrant Water Washable Penetrant Spray wash Minimise mechanical action Pressure as low as possible Temperature less than 50C Water Washable Penetrant ADVANTAGES Usable on rough surfaces Suitable for batch testing Cheaper than other methods DISADVANTAGES Susceptible to over washing Least sensitive method Requirement for a water source Post Emulsifiable Penetrant Stages Immerse component in penetrant Immerse component in emulsifier Emulsifier diffuses into the penetrant making it water washable Water wash removes excess penetrant / emulsifier Penetrant in defects left unaffected Removal of Excess Penetrant 2 Post emulsification systems Hydrophilic
Lipophilic Contact time critical Determined by experimentation Post emulsifiable ADVANTAGES Maximum penetrating ability Greater control over penetrant removal DISADVANTAGES Not suited to rough surfaces More expensive More time consuming Removal of Excess Penetrant Clean off the excess with a lint free cloth.
Wipe with a solvent dampened rag.
Solvent Removable Thou shalt not spray the cleaner directly onto the item under test.
Solvent Removable ADVANTAGES Portability No water supply needed DISADVANTAGES Not suited to batch testing Requires hand wiping so time consuming More expensive than water washable Potentially hazardous chemicals Drying Hot air recirculating oven (max 80C) Forced warm air Dry clean compressed air Component temperature shall not exceed 50C 4. Development Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface Developer Properties Absorptive Fine texture Able to mask out background colour Evenly and easily applicable Light and even coat Non-fluorescing Easily wetted Contrasting colour Easily removed Non-toxic and Non- irritant Developer action Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface Penetrant drawn back out of the defect by reverse capillary action Developer action Capillary Action - Increases the size of an indication far beyond the actual defect size; increases the thickness of an indication, thereby increasing its colour brilliance. Light scattering - Aids the conversion of UVA to visible light when using fluorescent systems; reduces background glare when using visible systems. Solvent Action - Solvent combines with penetrant, reducing penetrant viscosity, thereby inducing a more rapid, more efficient bleed-out. Light Scattering I 0
I f
I f
I f
I f
No Developer With Developer No Developer With Developer Development Dry powder Component must be dry Applied by Dipping Blowing Dust storm cabinet Aqueous liquid Dry after application Applied by Immersion Spraying Brushing Non-Aqueous liquid Applied by Aerosol Dry powder developer ADVANTAGES Easy to handle No hazardous vapours Easy to remove DISADVANTAGES Difficult to see if properly applied Fine powders can be hazardous Does not offer the best degree of colour contrast Aqueous Developer Solutions Aqueous Developer Solutions Suspensions Aqueous Developer ADVANTAGES No vapours or dust Cheaper than non- aqueous DISADVANTAGES Difficult to apply evenly Requires drying after application Non-Aqueous Developer ADVANTAGES Most sensitive Usable with fluorescent or colour contrast DISADVANTAGES Hazardous solvents Higher cost Need to be correctly applied Developer Sensitivity Dry powder 100 - 140 % Aqueous solution 110 - 150 % Aqueous suspension 120 - 200% Non-Aqueous 120 - 240% System Classification Type of penetrant Method of penetrant removal Type of developer System classification PENETRANT Colour contrast Fluorescent Dual REMOVAL Water washable Solvent Post emulsifiable DEVELOPERS Dry powder Aqueous Non-Aqueous 5. Inspection Indications viewed as soon as practicable after developer application with final assessment taking place after a minimum development time has elapsed. 30 Seconds 1 Minute 15 Minutes 5. Inspection Colour Contrast White light above 500 lux Fluorescent White light below 20 lux UV-A above 1000W / cm 2 Lighting levels critical 5. Inspection Fluorescent Allow 15 minutes lamp warm-up Allow 5 minutes dark adaptation Do not wear photo-chromatic spectacles
6. Post Cleaning DPI residues are required to be removed because They may be harmful to the component or They may impair subsequent processing Advantages of DPI Applicable to all non-porous materials Able to test large parts with a portable kit Batch testing Applicable to small parts with complex geometry Simple,cheap, easy to interpret Good sensitivity Training requirements typically less than for other NDT methods. Disadvantages of DPI Will only detect defects open to the surface Careful surface preparation required Not applicable to porous materials Temperature dependent Cannot retest indefinitely Compatibility of chemicals Penetrant Systems PENETRANT
Colour contrast Fluorescent
Dual REMOVAL
Solvent
Water washable
Post emulsifiable DEVELOPERS
Dry powder
Aqueous
Non-Aqueous Selection of System Nature of discontinuities (size and type) Geometry and intricacy Surface condition Component material and application Size and position Equipment and expertise available Cost Number of components to be tested Control Checks Tank levels Overall system performance Overall System Performance Chromium plated cracked test panel Cracked test piece Quench cracked aluminium alloy block Control Checks Tank levels Overall system performance Rinse water temperature Oven temperature Equipment cleanliness Airline filters UV-A filters
Control Checks UV-A / visible light levels Fluorescent / colour intensity Suppliers check Hydrophilic remover dilution Developer Meter / gauge calibrations Control Checks - Frequency Tank levels Overall system performance Rinse water temperature Oven temperature Equipment cleanliness Airline filters UV-A filters UV-A / visible light levels
Daily Daily Daily Daily Daily Weekly Daily Monthly Control Checks - Frequency Fluorescent / colour intensity Suppliers check Hydrophilic remover dilution Developer Meter / gauge calibrations
Monthly Annual when fresh Daily Annual UV(A) Electromagnetic Spectrum 10 -10 10 -8 10 -6 10 -4 10 -2 1cm 10 2 10 4 10 6 10 8 Wavelength Electric Waves TV Microwaves Infra red Ultra violet X-rays & Gamma Light 10 100 200 300 400 500 600 700 ULTRAVIOLET VISIBLE LIGHT LIGHT A Damaged Black Light Emits UV-A UV-B UV-C Electromagnetic Spectrum Fluorescence UV-A Source : Mercury vapour arc lamp + Filter Precautions Avoid looking directly at the lamp Do not use if filter is cracked, damaged or incorrectly fitted Fluorescence and the
Electromagnetic Spectrum 10 100 200 300 400 500 600 700 ULTRAVIOLET VISIBLE LIGHT LIGHT Emits Dual Absorbs Fluorescent v Colour Contrast Fluorescent more sensitive Less operator fatigue with fluorescent More difficulty in monitoring fluorescent penetrant removal Fluorescence may degrade under UV(A), when exposed to acid and high temperatures