ETT LIQUID PENETRANT TESTING CLASSROOM TRAINING BOOK The American Society for Nondestructive Testing, Inc.IPUBLICATIONS a LIQUID PENETRANT TESTING CLASSROOM TRAINING BOOK Written for ASNT by Duane Badger NDT Assistance ‘The American Society for Nondestructive Testing, GeyPublished by The American Society for Nondestructive Testing, Ine. 1711 Arlingate Lane Columbus, OH 43228-0518 Copyright © 2005 by The American Society for Nondestructive Testing, Inc. All rights reserved. ASNT is not responsible forthe authenticity or accuracy of information herein, and published opinions or statements ‘do not necessarily roflect the opinion of ASNT. Products or services that are advertised or mentioned do not catty the endorsement or recommendation of ASNT. IRRSP, Level IH] Study Guide, Materials Evaluation, NDT Handbook, Nondestructive Testing Handbook, The NDT Technician and <[Link]> are service marks of The American Society for Nondestructive ‘Testing, Inc. ACCP, ASNT, Research in Nondestructive Evaluation and RNDE are registered trademarks of ‘The American Society for Nondestructive Testing, Inc. ASNT exists to create a safer world by promoting the profession and technologies of nondestructive testing. ISBN 1-$7117-121-5 Printed in the United States of America Library of Congress Cataloging-in-Publication Data Liquid penetrant testing : classroom training book / written for ASNT by Duane Badger, [Link].~ (Personnel training publications series) Includes bibliographical references and index ISBN 1-57117-121-5 (pbk.) 1. Penetrant inspection. I. American Society for Nondestructive Testing. I Titl. Ill. Series. ‘TAAI7.55.833 2004 620.1127-de22 2004028159 First printing January 2005 Second printing 06107Acknowledgments A special thank you goes to the following technical reviewers who helped with this publication James Borucki, Gould Bass NDT. Gina Caudill, United States Coast Guard Nat Faransso, KBR Art Gallant, Elite Inspection Services Vilma Holmgren, Magnaflux ‘Teery Kessler, TK Consulting, LLC Brian MacCracken, Pratt and Whitney Joe Mackin, International Pipe Inspectors Association David Moore, Sandia National Laboratories William Mooz, Met-L-Chek Company Jemy Nelson James Waugh, ilobal Technical Services A special thank you goes to the following corporate reviewers who helped with this publication: John Brausch, Air Force Research Laboratory Jerry Fulin, Tenmessee Gas Pipeline Jim Houf, The American Society for Nondestructive Testing, Inc. Scott Huddleston, Huddleston Technical Services, Stephen Lakata, Norfolk Southern Corporation S.0. MeMillan, BAY Quality Assurance Joseph E, Monroe, Easter NDT David R. Quattlebaum, Quattlebaum Consultants Frank Sattler, Satter Consultants, Ine. Stephen Senne, Senne Technical Services Noel Tracy, Universal Technology Corporation Ron VanArsdale, Inspection Training and Consulting Albert M. Wenzig, J, Industrial Testing Laboratory Services, LLC ‘The Publications Review Commitiee includes: Chair, Sharon I. Vakelich, University of Dayton Research Institute B. Boro Djordjevie, Johns Hopkins University Mark A. Randig, Cooperheat-MQS, Inc, ‘Ann E, Spence Educational Materials EditorForeword ‘The American Society for Nondestructive Testing, Inc. (ASNT) has prepared this series of Personnel Training Publications to present the major areas in each nondestructive testing method. Each classroom training book in the series is onganized to follow the Recommended Training Course Outlines found in Recommended Practice No. SNT-TC-1A. The Level Land Level It candidates should use ths classroom ‘raining book as a preparation tool for nondestructive testing certification. A Level I or Level If may be expected to know additional information based on industry or employer requirements. ivTable of Contents Acknowledgments 7 ii Foreword .... “ sin 8 iv Table of Contents ane paiada aeaaV: Level I Liquid Penetrant Testing ........... Chapter I Introduction to Liquid Penetrant tTesting - History fe iF scene geen =: oecsee ‘The Purpose of Liquid Penetrant Testing Basic Principles... a ‘Commercially Available Liquid Penetrant Materials “| Personnel Qualification and Certification. . . Employee Certification .......... Training Experience Examination . Certification Safety Precautions Fire <.. Skin Irritation. Air Pollution - Ultraviolet Radiation... Chapter 2 - Liquid Penetrant Processing Procedures and Techniques Preparation of Test Objects. Precleaning of Test Objects - - Begeleaning and Postcleaning, Equipment a Solvent Cleaning .. Detergent Cleaning Vapor Degreasing. . Steam Cleaning... Ultrasonic Cleaning. .: Rust and Surface Scale Removal Paint Removal .......... Etching . Precleaning Processes to be Avoided Precleaning and Postcleaning Materials... Drying Test Objects... Dwell Time : seat Application of Penetrant s+... Removal of Excess Surface PenetrantAdequate Illumination ‘ Water Rinse (Method A, Band D) ..... Manual Wipe (Method C) .. Developer Application and Drying - Dry Powder ....... Water Soluble |<... Water Suspendible Nonaqueous Development Time. - Interpretation and Evaluation Interpretation © uation .. Indications False Indications Nonrelevant Indications Relevant Indications... Categories of Relevant Indications Continuous Linear Intermittent Linear... . 2. Round... ol Diffused or Weak... se secs eevee Discontinuity Depth Determination Typical Indications . Postcleaning . — Postcleaning Materials 1.2... Chapter 3 ~ Liquid Penctrant Testing Methods Standard Methods ........ Method Characteristics» Fluorescent or Visible Solvent or Water Removable Inline Penetrant Systems Lipophilic Emulsification +>. - Hydrophilic Emulsification .. . Chapter 4 - Liquid Penetrant Testing Equipment Liquid Penetrant Testing Units . . Stations SAT ‘Auxiliary Equipment "2. .) Pumps . : Sprayers and Applicators” —— Lights. . Timers ‘Thermostats and Thermometers Exhaust Fans = Refractometer Hydrometer. . Portable Equipment Visible Dye Penetrant Kit vi Personnel Training PublicationsFluorescent Penetrant Kit ............. Ultraviolet Radiation... Tubular Fluorescent Cold Discharge Sources . ‘Testing in Subdued White Light Light Meters bee eee vena Materials for Liquid Penetrant Testing Precleaning and Postcleaning Materials Water Washable Penetrants ........ Postemulsification Penetrants . . . Emubsifiers .........0. Solvent Removers . Dry Developer. Nonaqueous Wet Developer” ‘Water Based Developers... Special Purpose Penetrant Materials Precautions .........++ Level I Liqui Chapter 5 ~ Selection of Liquid Penctrant Testing Method. Selection. Advantages and Disadvantages 21)! Portability Postemulsification Dry Developer Wet Developers | 1)! sean swiSS Chapter 6 ~ Interpretation and Evaluation of Indications . Discontinuity Categories Inherent Discontinuities . Processing Discontinuities .. . Service Discontinuities Indications ...... Forming of Discontinuity Indications ‘Time for Indications to Appear Persistence of Indications Effects of Temperature. . Lighting : Effects of Metal Smearing Operations. Sequence... ‘Test Object Preparation Factors Affecting indications Penetrant Used ...... Prior Processing rack Indications Solidification Cracks” Processing Cracks Service Cracks .. Porosity Indications... Indications from Specific Material Forms” | + Liquid Penetrant Testing Classroom Training Book viiForgings Castings Plate... Welds. Extrusions . Evaluation of Indications False Indications .. Relevant Indications Nonrelevant Indications . . Chapter 7 - Liquid Penetrant Process Control cece coe 67 Quality Control of Test Materials ee rome ‘Test Material Control Samples Reference Blocks . System Monitor Panels 2 Aluminum Reference Blocks... .. Preparation for Use .......... Preparation for Reuse Ceramic Reference Blocks. Preparation for Use .. Usage ..... Cleaning After Use. : Anodized and Plated ‘Test Panels... -. - Preparation for Use .....0.se0eeee Usage... ei ‘Twin NiCr Sensitivity Panels’ | Stainless Steel Test Panels Preparation for Use .... Low Cycle Fatigue Blocks x ‘Tests of Liquid Penetrant Materials. Sensitivity Comparison Test. ....... Water Washability Test... . : Water Content Test .. .- Fluorescent Luminance Test Emubsifier Tests 20... 0.066 Developer Tests Dry Developer... cess eee eee Wet Developer ‘ Chapter 8 ~ Test Procedures and Standards. . Procedures, Standards and Codes... Acceptance Criteria... Basic Methods of Instruction... Condusion ......... é CREF wenesnegronn 279 Bibliography and Figure Sources 4 Index® desCowsarTern ee vill Personnel Training Publications