In Use Penetrant Materials Process Controls

Presented by

Kevin Walker

Why?• Aid in controlling your process• A well monitored system will

prevent costly and painful corrections

PENETRANT MATERIALS

• High quality• Has the capacity to withstand

abuse• Not fail-safe

In Use Material Checks

• Inspectors must be aware of:–Changes of performance–Color –Consistency

• Cost associated with this testing

Testing (In most cases)• Simple tests• Uses minimum equipment• Can be run in inspection area• Personnel should be familiar with

inspection process• Save a new standard sample at the

time tanks are filled in a closed container

Storing Sample Materials

• Plastic containers should NOT be used for Long term storage

• Use metal or glass containers

• Should not be stored in high temperatures

Specifications

• Establish point of performance loss

• Determine exact point of material failure

• These limits apply mainly for critical applications

In Use Material Checks

• ASTM 1417-05– 7.8.2 Material Checks (In Use)

• Does not apply to materials that are not recovered or reused, i.e. aerosols, some spray systems

• Records must be maintained at location for audit.

Each Shift

• Water wash pressure and temperature-7.8.4.6

• Inspection area – 7.8.4.5– Clean and free from excessive

fluorescent contamination – Free of white light background

• Not exceed 2 fc (21.5 lx)

Daily Tests• Penetrant contamination

– 7.8.2.1– Look for waxy deposits,

white coloration, any separation, scum, or any other evidence

– Modify per manufacturers instructions

– Discard

• System performance – 7.8.3– Processing a known defect standard

through the system using in-use materials

• Comparative Penetrant Sensitivity –7.8.3.4– Process with unused emulsifier and

developer– TAM Panel

• Not for determining sensitivity level of the penetrant

– NiCr Panels– Or part known defect

Daily Tests - Continued

Daily Tests• Method A penetrant 7.8.3.2 and

Emulsifier Removability 7.8.3.3– Test piece specified in AMS-2644

(Stainless steel test block with rough surface)

– Use normal wash parameters to process part

Daily Tests cont.

• Dry Developer condition – 7.8.2.7– For recycled

material only– Spread thin layer in

4” (10 cm) circle if TEN or more fluorescent specks discard

4”

• Developer contamination (aqueous -soluble and suspendable) – 7.8.2.8– Immerse 3” (7.6 cm)x10” (25.4 cm)

aluminum panel, dry– Look for fluorescence and uniform

coverage

Daily Tests – Cont.

• Black Light Intensity - 7.8.4.1– Minimum 1000 mW/cm2 at 15” from

front of filter to the face of the sensor

Daily Tests - Continued

• Black Light Intensity - 7.8.4.1– All types used to inspect parts

(portable, hand-held, mounted or fixed)

Daily Tests - Continued

• Black Light Integrity – 7.8.4.1 (Weekly)– Clean, repair or replaced as needed

Daily Tests - Continued

• Special UV Lighting –7.8.4.2– Pencil lamps, borescopes

or remote UV inspection equipment

– Measured at expected working distance at1000 mW/cm2

– For borescopes & remote video equipment, the image must have enough resolution for proper inspection & evaluation

Daily Tests - Continued

Weekly Tests

• Developer concentration (Aqueous: Soluble & Suspendible) – 7.8.2.9– Check with Hydrometer– Concentration no higher

than specified by supplier

Weekly Tests

• Emulsifier (hydrophilic) concentration –7.8.2.6– Concentration checked

with refractometer– Concentration no higher

than specified by supplier, for spray applications no higher than 5%

Weekly Tests – Continued

• Water Content – (Water-Based, Water-Washable penetrants only) - 7.8.2.3– Use refractometer– Maintained according to manufacturer

recommendation

Monthly Tests

• Water content – 5% max. (Non-water-based, Method A only) - 7.8.2.4

• Emulsifier water content (lipophilic only)-7.8.2.5

Quarterly• Fluorescent brightness (ASTM E-1135-Test Method for

Brightness of Penetrants)-7.8.2.2– Measured with Fluorometer– Brightness less than 90% of standard should be discarded or

corrected

Quarterly

• Calibrate Drying Oven – 7.8.4.7– Calibrate temperature control and indicator

Semi-Annual• Calibrate light

meter – 7.8.4.4– Black Light and

White Light meters

• Calibrate water temperature indicator and pressure gages –7.8.4.6

Contamination

• Penetrants can absorb large amounts of solvents or oils, but…

• Usually will decrease fluorescence• Some cleaning solvents, degreasers,

acids, alkaline cleaners can destroy fluorescence

• Effect washability

Contamination•Some aqueous cleaners contain

metasilicates which may prevent penetrant from entering crack

•Incomplete cleaning of oil can also hinder penetrant from entering crack

CONTAMINATES

•Will cause loss of fluorescence in penetrant

•May enter a little at a time as residue on parts or…

•All at once when foreign material is added accidentally

Types of Contaminates•Water

– The most common contaminate– Not harmful until water tolerance

is met– Small amounts of water may

change viscosity and washability– Contamination in PE penetrants

causes separation

STANDARD ZL-60D - 16% water Contamination!

STANDARD ZL-60D – 20% water tolerance

Types of Contaminates

• Dirt, soil, other insoluble solids–Result of improper cleaning or

matter falling into tank• Organic material• Organic solvents• Acid • Alkaline materials

Standard 10% conc. alkaline cleaner

Emulsifier Contamination

• Penetrant contamination• Will slow emulsifying action• Small amounts of contamination

can be tolerated• Emulsifier should be replaced

based on performance rather than penetrant content

Heated Parts• In some cases, used to speed up

penetration• Some fluorescent dyes decompose

around 1600F (710C)• Long term exposure to heated parts

will effect fluorescence in tank

Standard Panel Heated to 1800F(820C)

Brightness Case StudyLEVEL 3 POST EMULSIFIABLE - 90% minimum

86

88

90

92

94

96

98

100

102

104

106

1 / 3 / 2 0 0 1 3 / 3 / 2 0 0 1 5 / 3 / 2 0 0 1 7 / 3 / 2 0 0 1 9 / 3 / 2 0 0 1 1 1 / 3 / 2 0 0 1 1 / 3 / 2 0 0 2

DAT E COMPANY ONE

Water Content Case StudyLevel 3 Water Wash - 5% maximum water content

0

0.5

1

1.5

2

2.5

3

3.5

4

1/02 2/02 3/02 4/02 5/02 6/02Date

Wat

er C

onte

nt(%

)

Company 2

THANK YOU