Test Equipment and Materials

TEST EQUIPMENT AND
MATERIALS
MUKHTAR ALI, NCNDT
SM1 CH 4
Jun 17, 2015
EVALUATION OF THE MATERIALS FOR TESTING

For appropriate selection of inspection
procedure following information shall be

considered:
Materials and desired objectives
Surface Condition
Shape of the product
Type of the product
Size of the product
Availability of the equipment
Sensitivity desired
SM1 CH 4
Jun 17, 2015
PROCESS SELECTION GUIDE

TESTING PROBLEM
PREFERRED
PROCESS
High production of many

small articles required
Water washable
Small articles handled

in baskets
Highest sensitivity to fine

discontinuities
Post emulsified
Brightest indication.
Most sensitive
Shallow discontinuities
scratches, etc., must be
detected
Post emulsified
Depth of emulsification
can be controlled
Articles having a rough

surface
Water washable
Articles having threads

and keyways
Water washable
Post emulsified
penetrant might lodge
in corners
SM1 CH 4
REMARKS
Jun 17, 2015
PROCESS SELECTION GUIDE

TESTING PROBLEM
PREFERRED
PROCESS
REMARKS
Articles having medium

rough surfaces
Water washable or
post emulsified
Choice depends upon

production and sensitivity
requirements
Spot testing of local areas

desired
Solvent removed
Best choice for an efficient

& sensitive method.
Portable equipment
necessary
Solvent removed
Best choice for an efficient

& sensitive method.
Water and electricity not

available
Solvent removed
Most appropriate choice.
Anodized articles, cracks

after anodizing, to be tested
1. Solvent removed
2. Post emulsified
3. Water washable
Order of preference
indicated
Repeated application of
process is desired
Solvent removed
Four to five times

inspection, results
reliable.
SM1 CH 4
Jun 17, 2015
Characteristic properties
Each process of inspection by liquid
penetrant method has typical

characteristic associated with it. They
have thus certain advantages and
disadvantages depending on the state
of the samples and conditions of
inspection.
SM1 CH 4
Jun 17, 2015
SOLVENT REMOVABLE VISIBLE DYE-PENETRANT PROCESS
S/No
ADVANTAGES
DISADVANTAGES
1.
Has greater portability, requires no Some materials are flammable.

black light.
2.
Can be used on suspected local

areas of large parts, aids in rework or
repair.
Expensive in man-hours.
3.
Can be used on parts where contact

with water is not permissible or
water is not available.
Indications are less visible than

fluorescent indications.
4.
Can be used on anodized surfaces.
Difficult to
use on rough
surfaces, especially on sand
castings.
5.
Material should not be used in

open tanks.
SM1 CH 4
Jun 17, 2015
WATER WASHABLE VISIBLE DYE PENETRANT PROCESS.

S/No.
ADVANTAGES
DISADVANTAGES
1.
Has greater portability, requires no

black light source.
Not a reliable process for finding

scratches
and
wide
shallow
surface discontinuities.
2.
Susceptible to overwashing.
3.
Fast economical of time.
4.
Easily washed with water.
5.
Good on rough surfaces.
6.
Good on threads & keyways.
7.
Relatively inexpensive.
SM1 CH 4
Not reliable for second or third

running of parts.
Jun 17, 2015
WATER WASHABLE FLUORESCENT PENETRANT PROCESS.
S/No.
ADVANTAGES
DISADVANTAGES
1.
Has fluorescence for greater visibility.
May be difficult to rerun parts.
2.
Easily washed with water.
Anodizing may affect sensitivity.
3.
Good on rough surfaces such as large Chromate

forgings and castings.
sensitivity.
4.
Good for quantities of small parts.
Requires inspection in dark areas

with black light.
5.
Good in keyways and threads.
Not reliable for detecting scratches

and similar shallow-surface
discontinuities.
6.
High speed, economical of time, and For black

good on wide range of defects.
required.
SM1 CH 4
Jun 17, 2015
finish
light
may
affect
electricity
is
POST-EMULSIFIABLE FLUORESCENT PENETRANT PROCESS.

S/No.
ADVANTAGES
DISADVANTAGES
1.
Has fluorescence for greater visibility.
Application
operation.
2.
Highest sensitivity to very fine defects.
Requires inspection in dark areas with black

light.
3.
Can show wide, shallow defects.
Sometimes difficult to wash penetrant from:

a. Threaded parts.
b. Keyways.
c. Blind holes.
4.
Easily
washed
emulsification.
with
water
after
5.
of
emulsifier
is
separate
Some materials are flammable.

Difficult to use on rough surfaces.
6.
High production, especially with large

parts.
Requires a rinsing aid.
7.
Can be used on anodized surfaces.
Emulsification time control is critical.
8.
Can be used on chromate surfaces.
9.
Parts can be rerun satisfactorily.
SM1 CH 4
Jun 17, 2015
SOLVENT REMOVABLE FLUORESCENT PENETRANT PROCESS.
S/No.
ADVANTAGES
DISADVANTAGES
1.
Fluorescence ensures visibility.
Requires darkened area for inspection.
2.
Portability.
Flammable materials.
3.
No water required.
Removal of excess penetrant is time

consuming.
4.
Good on anodized specimens.
Materials cannot be used in open

tanks.
5.
Good for spot checking.
Difficult to use on rough surfaces such

as cast magnesium.
6.
Specimen can be rerun.
10
SM1 CH 4
Jun 17, 2015
BEHAVIOUR PROPERTIES
Evaluation of the Behaviour of
penetrant materials
Use of aluminium comparator blocks
Behaviour of used materials
Behaviour of fresh stock
Behaviour of materials at low
temperature
Behaviour of materials at high
temperature
11
SM1 CH 4
Jun 17, 2015
Preparation of cracks in aluminium alloy

blocks
Three-inch (75 mm) lengths are cut from a 3/8
x 2 inch (9.5 mm x 50.8 mm) bar of 2024

aluminium alloy
Temperature 525C
Heating time at least 4 minutes
Quenching Temperature 50F or less.
12
SM1 CH 4
Jun 17, 2015
RENEWAL OF ALUMINIUM
COMPARATOR BLOCKS
Vapour phase degrease
Scrub with stiff brush, soap and water
Soak in acetone at least overnight
Rinse with water
Heat slowly with a gas burner to 800 F
(425 C) and quench in cold water
Reheat moderately to drive off any water
in cracks and allow to cool to room
temperature
13
SM1 CH 4
Jun 17, 2015
USE OF CRACKED BLOCKS

The ASME code prescribes various uses of aluminium
comparator blocks
The block is used for qualifying a liquid penetrant
technique at a temperature of less than 50 F (10 C) or
above 125 F (52 C).
The penetrant materials in use are applied to half of the
block on one side of the slot, and control materials
(fresh in stock) are applied to the other half in an
identical fashion
Processing of the two halves should be made
simultaneously and then a direct visual comparison of
the results should be made
14
SM1 CH 4
Jun 17, 2015
If the comparison of the observed crack pattern reveals
no outstanding difference in two halves, it can be

assumed that all the materials under use are suitable
and their behaviour is normal
15
SM1 CH 4
Jun 17, 2015
LIMITATION OF ALUMINIUM ALLOY

BLOCKS TESTS
The artificial cracks in aluminium alloy are non-uniform
by nature and as such it is impossible to make two

blocks identical
It is important therefore to make a series of tests before
reaching conclusions for critical results
The difference may be quite subtle, hence the
interpretation of the results should be done by
personnel experienced at least in use of block
themselves
Other forms of test blocks such as made of ceramic
stress-cracked anodized, aluminium and chrome plated
nickel test panels are also used to check the overall
performance of the penetrant materials
16
SM1 CH 4
Jun 17, 2015
CONTROL OF CONTAMINANTS
Mostly affective materials, Austenitic
stainless steels, Titanium or Nickel base

alloys
Affective contaminants are Sulphur,
Chlorine and Fluorine
Contamination limits 1% by weight
17
SM1 CH 4
Jun 17, 2015
CLEANING EQUIPMENT
Ultrasonic Cleaning
Use of ultrasonic cleaning equipment is often combined
with a solvent or detergent bath to improve cleaning

efficiency and reduce cleaning time
The method works well with water and detergent
cleaning when contaminants to be removed are

inorganic, and with solvents for organic type of
contamination
It is recommended to heat the test articles after the
cleaning process to aid in the evaporation of cleaning
fluids
18
SM1 CH 4
Jun 17, 2015
Degreasing Steam
Cleaning by vapour degreasing is particularly effective
in the removal of oil, grease and similar organic

contamination
There are certain restrictions as to its use as a precleaning or post-cleaning method
Nickel alloys, certain stainless steels, and titanium have
an affinity for specific elements e.g. chlorine or sulphur,
and if exposed to them will become structurally
damaged
Degreasing must be limited to those materials that have
been approved for this method of cleaning
19
SM1 CH 4
Jun 17, 2015
PULVERIZERS AND AEROSOLS

Safe from outside contamination
Easy in Lab and field use
Storage is not a problem
Good and uniform performance
20
SM1 CH 4
Jun 17, 2015
INSTALLATIONS FOR PROCESSING BY IMMERSION
The stationary equipment used in liquid
penetrant testing ranges from simple to

fully automatic systems and varies in
size depending on the requirements of
specific tests
21
SM1 CH 4
Jun 17, 2015
Visible dye and fluorescent penetrant

process
22
SM1 CH 4
Jun 17, 2015
Dual sensitivity penetrant

processes
23
SM1 CH 4
Jun 17, 2015
Small-size fluorescent post-emulsified penetrant and

dry developer test equipment
24
SM1 CH 4
Jun 17, 2015
Medium-size fluorescent water-washable penetrant

and wet developer test equipment
25
SM1 CH 4
Jun 17, 2015
Large-size fluorescent water-washable penetrant

and wet developer test equipment
26
SM1 CH 4
Jun 17, 2015
Medium-size visible dye water-washable

penetrant and dry developer test equipment
27
SM1 CH 4
Jun 17, 2015
Medium size visible dye post-emulsified

penetrant and dry developer test equipment
28
SM1 CH 4
Jun 17, 2015
Stations
Pre-cleaning station
Penetrant station (tank)
Drain station
Emulsifier station
Rinse station
Developer station
Dryer station
Inspection station
Post cleaning
29
SM1 CH 4
Jun 17, 2015
AUXILIARY EQUIPMENT
Pumps
To agitate different penetrant materials

Sprayers and applicators
Used to spray penetrant, emulsifier and water rinsing
Reduce inspection time
Lights
Visible and Ultraviolet lights are installed at inspection
station
Timers
Timers are used to control the time at different stages
during process
30
SM1 CH 4
Jun 17, 2015
Thermostats and thermometers
To check the temperature of drying oven and penetrant

materials
Exhaust fans
Exhaust fans are used to remove fumes and dust
Hydrometers
Used to check the specific gravity of aqueous
developers
31
SM1 CH 4
Jun 17, 2015
LIGHTING
Measuring equipment and units
Measurement of black light intensity requires the use of
a special meter calibrated in watts per square metre or

microwatt per square centimetre
Meter is filtered so that it responds only to black light
It is also filtered so as not to read short wave ultraviolet
The meter scale runs up to 6000 watt/cm2, which is
expandable up to 25000 watt/cm2 by attaching a

multiplier screen supplied with the meter
32
SM1 CH 4
Jun 17, 2015
33
SM1 CH 4
Jun 17, 2015
ULTRAVIOLET RADIATION LAMPS

(BLACK LIGHT)
Incandescent lamps
Metallic or carbon arcs
Tubular `BL' fluorescent lamps
Tubular `BLB' fluorescent lamps
Enclosed mercury vapor arc lamps
34
SM1 CH 4
Jun 17, 2015
Mercury vapour arc lamp sources of black light
Mercury vapour lamps are gaseous discharge devices in
which an electric arc takes place in a controlled

atmosphere and emits light whose characteristics
depend on the nature of the atmosphere
MC represents a quartz or hard-glass cartridge in which
the mercury vapour is confined
E1 and E2 are the main electrodes that carry current to
the arc stream which takes place along the length of the
cartridge. E3 is an auxiliary starting electrode. R
represents a current limiting resistor
The entire assembly is sealed in an outer protective
bulb, B, which may be either evacuated or filled with air
or an inert gas, depending on the design of the bulb
35
SM1 CH 4
Jun 17, 2015
36
SM1 CH 4
Jun 17, 2015
The lamp is fed from a current regulating ballast
reactance or transformer
This is required because the arc tube shows negative
resistance characteristics and would quickly destroy

itself if not throttled by an external device
37
SM1 CH 4
Jun 17, 2015
A black light mercury arc bulb requires a housing and
fixture:i)
to support the filter.
ii) to prevent leakage of unwanted visible light and to
permit the operator to direct the beam onto the area to
be inspected. Mercury vapour arc lamps up to an
intensity of 400 watt are also commercially available,
but are normally not portable
38
SM1 CH 4
Jun 17, 2015
Tubular fluorescent cold discharge black

light sources
39
SM1 CH 4
Jun 17, 2015
These are standard fluorescent bulbs that come in sizes
from 2 to 60 input watts and over

These cold discharge tubular lamps contain lowpressure mercury vapour glow discharges
Their primary radiation is hard ultraviolet of 253.7 nm
(2537 A) wavelength
This is used to excite a special cerium-activated calcium
phosphate phosphor which is coated on the inside of the
tube
This phosphor, when activated by the ultraviolet, emits
black light with a range of 320 to 440 nm wavelengths
peaking at 360 nm
40
SM1 CH 4
Jun 17, 2015
Because a significant amount of visible light is emitted
along-with the black light, these bulbs are often made of

a purple-red filter glass similar to that used over the
high-pressure arc lamps previously described
This greatly reduces the black light emitted, but still
leaves what is often an excessive amount of visible blue

light, considering the relatively low intensity of the black
light produced
41
SM1 CH 4
Jun 17, 2015
Advantages and limitations of fluorescent

tubular black light sources
Advantages
Instant starting
Cool Operation
Low cost
Limitations
Low Intensity
Cannot easily focused
Not suitable for critical inspection
42
SM1 CH 4
Jun 17, 2015
Incandescent filament black light

sources
This type of source of black light comes in 75 and 150
watt sizes
It comes as standard incandescent bulb with a filter
glass envelope
These sources give a considerable portion of visible light
along with black light, as such are thus even less usable
and suitable than the fluorescent black light sources
43
SM1 CH 4
Jun 17, 2015
MEASUREMENT OF LIGHT
Visible Light
Ultraviolet Light
Visible light intensity at inspection site 50 foot candle or
500 Lux
Ultraviolet light intensity at inspection site 1000 W/cm2
Measurement of visible light intensity by visible light
meter
Measurement of UV light intensity by UV light meter
J221
44
SM1 CH 4
Jun 17, 2015
THANK YOU
45
SM1 CH 4
Jun 17, 2015

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TEST EQUIPMENT AND

MUKHTAR ALI, NCNDT

Jun 17, 2015

EVALUATION OF THE MATERIALS FOR TESTING

procedure following information shall be

Jun 17, 2015

PROCESS SELECTION GUIDE

High production of many

Small articles handled

Highest sensitivity to fine

Articles having a rough

Articles having threads

Jun 17, 2015

PROCESS SELECTION GUIDE

Articles having medium

Choice depends upon

Spot testing of local areas

Best choice for an efficient

Best choice for an efficient

Water and electricity not

Most appropriate choice.

Anodized articles, cracks

Four to five times

Jun 17, 2015

penetrant method has typical

Jun 17, 2015

SOLVENT REMOVABLE VISIBLE DYE-PENETRANT PROCESS

Has greater portability, requires no Some materials are flammable.

Can be used on suspected local

Can be used on parts where contact

Indications are less visible than

Can be used on anodized surfaces.

Material should not be used in

Jun 17, 2015

WATER WASHABLE VISIBLE DYE PENETRANT PROCESS.

Has greater portability, requires no

Not a reliable process for finding

Fast economical of time.

Easily washed with water.

Good on rough surfaces.

Good on threads & keyways.

Not reliable for second or third

Jun 17, 2015

WATER WASHABLE FLUORESCENT PENETRANT PROCESS.

Has fluorescence for greater visibility.

May be difficult to rerun parts.

Easily washed with water.

Anodizing may affect sensitivity.

Good on rough surfaces such as large Chromate

Good for quantities of small parts.

Requires inspection in dark areas

Good in keyways and threads.

Not reliable for detecting scratches

High speed, economical of time, and For black

Jun 17, 2015

POST-EMULSIFIABLE FLUORESCENT PENETRANT PROCESS.

Has fluorescence for greater visibility.

Highest sensitivity to very fine defects.