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DOWTY PROPELLERS STANDARD PRACTICES MANUAL
NDT 8 DAP
PENETRANT FLAW DETECTION
1. Scope
A. NDT 8DAP supersedes NDT 8 for all future Dowty Propellers contracts.
Where existing drawings/documents call up NDT 8, NDT 8DAP must be used in lieu.
B. This specification covers requirements for penetrant inspection being performed during manufacture
at Dowty Propellers (DP) or Sub-contractors (hereinafter ‘at DP’ includes Sub-contractors).
Deviation from the requirements may only be authorised in writing by Dowty Propellers.
C. Penetrant flaw detection procedure is suitable for the detection of defects open to the surface in all
metallic materials and in certain non-metallic materials such as carbon, plastics etc. Magnetic flaw
detection, NDT 2DAP, should be employed for surface flaw detection of Ferro-magnetic materials,
i.e. all steels, (except austenitic stainless steels and some nickel alloys). Parts made from such
magnetic materials should not normally be inspected using a penetrant procedure.
D. This specification requires the use of post emulsified fluorescent penetrant to specification
AMS 2644, production parts processing call-up is Type 1 penetrant, method D or B emulsifier, level
2 sensitivity and form a or d developer. For parts undergoing overhaul the call-up is Type 1
penetrant, method D or B emulsifier, level 3 sensitivity and form A or D developer. Water washable
penetrants are not permitted unless specifically agreed by DP. Portable ‘aerosol’ type systems may
be used for localised areas. The relative sensitivity requirements are the same as quoted above. In
all cases portable systems must be used in accordance with the manufacturers recommended
procedure. The portable system in use at DP is detailed in procedure NDT 27DAP.
E. Inspectors operating this procedure must have access to a copy of this Specification for reference
and guidance.
F. Penetrant flaw detection Inspectors employed by DP must be approved in accordance with the
requirements of NDT 10DAP. Subcontracting agencies must maintain their own personnel
certification scheme. This scheme must be approved by DP.
G. This Specification conforms to and exceeds the requirements for BSI Aerospace Standard M39 and
Specification ASTM E1417. Where it is required by contract to inspect in accordance with other
specifications, copies of these documents shall be held at the test station.
H. Where a suitable Level 3 NDT Technician is required he/she must be an ASNT Level 3, or a
company Level 3 approved in accordance with NDT 10DAP, holding certification in the appropriate
discipline.
2. Applicability
A. Final Clearance and Intermediate Inspections.
(1) All Class 1 components produced from non-ferromagnetic materials must be final clearance
inspected by this process. Class 2 and 3 parts may be inspected on a batch sampling plan,
reference PS 51000.
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(2) The final clearance inspection must be accomplished after completion of all heat treatment,
forming, machining, welding, and major de-burring operations, but must be carried out before
shot peening, anodising, painting or polishing. The final clearance inspection may precede
minor filing operations, sanding, honing, buffing or grit blasting. Final clearance inspection is
required to be carried out after any process which may cause or expose defects, and before any
surface treatment that will close surface openings or leave unremovable residue within them.
(3) An intermediate penetrant flaw detection is advisable on parts where considerable machining is
involved. This is best carried out after heat treatment on parts which are part machined before
heat treatment, but see paragraph 2.B.
B. Aluminium Alloy Forgings Class 1.
(1) When forgings are supplied not fully heat treated, etch and penetrant flaw detection to
NDT 8DAP will be carried out at a stage between final heat treatment and the production of any
final close limit dimensions. The Forger will work to the agreed procedure on the DP Inspection
Schedule.
(2) When forgings are supplied in the fully heat treated condition and the Inspection Schedule
specifies ‘Etch and Penetrant Flaw Detect to NDT 8DAP’ the Forger will perform this operation
after heat treatment. DP will not normally carry out etching immediately prior to the final
penetrant inspection to NDT 8DAP.
(3) When a forging supplier is unable to carry out etch and penetrant flaw detection to NDT 8DAP,
he will apply an agreed alternative which will be specified on the Inspection Schedule. In
addition the Inspection Schedule will specify ‘Etch and Penetrant Flaw Detection to NDT 8DAP’
to be carried out by DP.
(4) The final clearance inspection, specified in paragraph 2.A. must be carried out in addition to the
etch and penetrant requirement, unless the machining tolerances permit both inspections to be
performed concurrently at the final stage.
C. Components Undergoing Overhaul.
(1) After disassembly and cleaning, the paint must be removed prior to flaw detection.
(2) When the paint has been stripped, this must be complete, including all greasy residues. In the
case of parts which have been paint stripped the normal vapour degreasing procedure should
be carried out.
(3) Parts which have been subjected to engine oils in service are to be immersed in a cold
hydrocarbon or chlorinated hydrocarbon degreasing fluid for not less than 30 minutes prior to
vapour degreasing. When vapour degreasing cannot be used, the soak period is to be
increased to 45 minutes followed by a drain period. Parts must be dry prior to the application of
fluorescent penetrant.
(4) Components or assemblies undergoing Life Assessment or structural integrity survey must
normally be paint stripped to PS 5211. Parts exempted are those which a special finish which
precludes removal, e.g. Protection of Magnesium Alloy Castings. Other examples must be
agreed with the inspection authority, e.g. where paint removal may be considered impractical or
injurious on a partially disassembled unit assembly.
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(5) When it is necessary to remove damage, defects or corrosion, the re-work procedures given in
Part 7 must be applied. In addition, particularly in the case of corrosion, reference should be
made to Drawing Number 450000000, titled General Repair Notes. Once the defect has been
removed to the requirements of Para 7, a further 0.010" of material must be removed. The
component must then be reviewed by the design authority.
3. Associated Specifications
BS M39 - Penetrant Inspection of Aerospace Materials and Components.
PS 5102 - Anodising of Aluminium and Aluminium Alloys.
PS 5202 - Temporary Protection of Parts.
PS 5203 - Degreasing with Trichloroethylene.
PS 5211 - Paint Stripping.
PS 51000 - The Use of Specifications in Manufacturing.
NDT 2DAP - Flaw Detection by the Wet Magnetic Particle Method.
NDT 10DAP - The Approval of Personnel for Non-Destructive Testing.
NAS410 - Certification of Penetrant and Magnetic Particle Inspection Personnel.
A-A-58050 - Fluorescent Penetrant Inspection Units.
ASTM E 1417 - Practice for Liquid Penetrant Examination.
AMS 2644 - Inspection Materials - Penetrant.
BS 3683 Part 1 - Terms used in Non-Destructive Testing (Penetrant Flaw Detection).
BS EN ISO 3059 - Method for Assessing Black Light used in Non-Destructive Testing.
ISO 10012-1 - Quality Assurance Requirements for Measuring Test Equipment.
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4. Equipment and Materials
A. Trichloroethylene degreaser and supply of trichloroethylene to ISO 2212: PS 5203 refers or any
other pre-cleaning/degreasing system acceptable to a suitable level 3 NDT engineer.
B. Tank for immersion application of penetrant to the requirements of paragraph 8.A.(1) and a drain
facility for components. Alternatively, electro static application may be used where approved by DP.
C. A supply of Ardrox 985 P.13 fluorescent penetrant, or other penetrant conforming to paragraph 1.D.
Note that all material must be of the same group or family, reference AMS 2644.
D. A wash tank with provision for air agitation if required. The wash tank may be connected to a
decolorising sump or to an activated carbon filter/pump system.
E. A compressed air/water spray gun (Ardrox BCP 65 or similar) connected to a compressed air
supply, with a regulator and calibrated pressure gauge, and mains water supply. Alternatively a
water wash spray gun may be used. (See Para 8.A.(3) and (4)).
F. Tank for immersion application of emulsifier solution to the requirements of paragraph 8.A. (1).
Alternative methods of application may be used where approved by DP.
G. A supply of 9 PR12 Ardrox emulsifier made up to 10% mix by volume in water.
H. A wash tank as 4.D., with spray gun as 4. E., if black light background illumination to the
requirements of this specification is provided over the tank. In other cases the second wash stage
shall be an agitated hot or cold water tank (without spray gun) used with a timed dip cycle system:
see procedure paragraph 5.B.(8)(b).
I. A hot air blast drying oven with calibrated temperature control regulator to operate reliably at not
more than 66 °C (150 °F) maximum.
J. An automatic cycle dust storm developer cabinet.
K. A supply of 9D4A Ardrox dry powder developer. Also a supply of non-aqueous wet developer 9D6
or equivalent.
L. A viewing darkroom or booth, fitted with approved ultra-violet lamps, capable of meeting the
requirements of this Specification.
M. Tank for de-watering oil.
N. A supply of de-watering oil: PS 5202 refers.
O. UV.A (black light) (ultra-violet) inspection lamps which satisfy BS EN ISO 3059, Special Viewing
Equipment, will be required for bores and cavities. This does not need to meet the Control
Requirements of this specification.
P. A supply of acids to make up the etch solutions.
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Q. A supply of test panels and blocks to meet the Control Requirements of this specification,
washability fixture, light meters and other control equipment as required by the specification, see
Part 8.
R. All tanks shall be identified as to contents and special instructions shall be posted in a prominent
position.
S. Calibrated timers: II No. 26 refers.
5. Procedure
A. Pre-Penetrant Etch Treatment.
NB. Pre-Penetrant Etch Treatment is not required on parts for overhaul. It is only to be used when called
for by CMM’s, TO’s etc or prior to penetrant inspection to remove smeared metal, when a component has
been machined or otherwise reworked.
(1) Before the treatment starts the solution should be at shop temperature, 15 to 24 °C (59 to 75
°F).
(2) This treatment will normally be carried out in acid solution of 10% v/v Sulphuric Acid SG 1.84
and 1% v/v (Note in UK 40% v/v Hydrofluoric acid is the maximum available concentration.)
Hydrofluoric Acid 50 -60%. This conforms to DEF STAN 03-24, Annex C. DP approval is
required for alternative solutions. This treatment converts non-weeping (black line) defects to
weeping (open) defects, and removes smeared metal and corrosion products. In the process
some material is removed from the surface, making masking necessary should close limits be
involved. It is necessary to ensure that no anodic film is present before the etch treatment.
Remove anodic film to PS 5102 or by immersion in the etch solution until effervescence
commences in the anodised areas. In the latter case, etch time will start when effervescence
commences. After etching and rinsing, parts are to be immersed in a de-oxidiser to remove
smut. The solution is I.C.I. De-oxidiser Number 1, 20-30 g/1 and Sulphuric Acid 40-50 g/1. In
the absence of a de-oxidiser, remove the smut with a soft wet cloth.
(3) Etch Process.
WARNING: IF HYDROFLUORIC ACID CONTACTS THE SKIN APPROPRIATE ANTIDOTE GEL

OR CREAM [CALCIUM GLUCONATE IS RECOMMENDED] MUST BE APPLIED,
WATER IS NOT SUFFICICENT.
DO NOT GET ACID SPLASHES ON THE SKIN OR IN THE EYES. DO NOT INHALE
THE ACID FOG THAT RISES FROM THE SOLUTION DURING THE PROCESS.
WEAR A FACE MASK AND RUBBER GLOVES. SWITCH ON THE EXHAUST FAN
BEFORE STARTING THE ETCH PROCESS AND DO NOT SWITCH THE FAN OFF
UNTIL AT LEAST ONE HOUR AFTER COMPLETION OF THE PROCESS.
(a) Degrease to PS 5203 (ISO 2212) and allow parts to cool to shop temperature. Immersion
in clean cold water at shop temperature is permissible to achieve this.
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(b) Unless otherwise stated on the drawing or manufacturing layout, immerse parts in new etch
solution at shop temperature. If the areas to be treated are small, a local etch may be
carried out using cotton wool swabs. As the solution ages, times must be adjusted as
indicated by the Control Check result reference paragraph 8.B. (7)(b). As the temperature
increases the time must be reduced and vice-versa. A good indication of the correct effect
of the acid is the degree of effervescence that takes place when parts are immersed.
(c) After lifting from the acid solution, manipulate parts as necessary to empty acid from bores
and blind holes.
(d) Immediately immerse in the water wash tank with the air agitation on. Lift out of the tank
and wash off with the air/water spray gun.
(e) Immerse in the de-oxidiser for 2 minutes to remove discoloration and smut.
If a de-oxidiser dip is not available, remove smut using a soft wet cloth. Manipulate as in
paragraph (c) to remove water.
(f) Place in a hot water dip to remove the de-oxidiser residue and blow dry with filtered air.
(g) Inspect the parts under white light of 2000 lux minimum for obvious flaws revealed by the
etch process. These should be dressed out and the area re-etched locally prior to the
penetrant process - see Part 7.
(4) The etched parts should proceed to the Penetrant Process (paragraph 5.B.) with the minimum
delay.
(5) If parts are delayed for more than 3 hours, or if they have to be moved to another location at risk
of contamination, they must be immersed in de-watering oil. Parts to be moved must be
adequately protected from damage and contamination.
NOTE: Wash water effluent is to be neutralised by the addition of appropriate quantities of

sodium carbonate. This is to be applied by a drip feed system attached to the
drain. A half to one pound per gallon of water solution should give satisfactory
results.
(6) Dry the components in a re-circulating oven at 80°C.
B. Penetrant Treatment.
(1) Clean thoroughly. Parts shall be free from paint, oil, grease, scale, swarf, water and all other
contaminants. There should be no burrs, smeared metal or marking dye on the part surfaces.
(Titanium alloy parts may be de-scaled by grit blasting if necessary).
(2) Treat in trichloroethylene vapour degreaser to PS 5203 or any other pre-cleaning/degreasing

system acceptable to a suitable level 3 NDT engineer. (Parts which have been previously non
fluorescent penetrant treated will require special cleaning treatment).
(3) Cool to shop temperature.
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(4) Dip in penetrant for 10 minutes minimum (20 minutes minimum for Titanium alloys).
Manipulating to ensure that no air pockets prevent complete contact with the penetrant.
(5) Stand to drain for 15 minutes. Ensure that any wells of penetrant are drained off by
manipulating the component.
(6) Dip in the wash tank and then suspend or place parts over the tank for overall thorough washing
with the spray gun. All surfaces must be thoroughly washed so that all ‘loose’ penetrant is
flowed off.
NOTE: At the conclusion of this process the parts will have a slightly oily, thin surface film
of penetrant remaining.
(7) Immerse in the emulsifier, taking care that all surfaces are wetted by the emulsifier. After
dipping for the specified time - which must be rigidly adhered to with the aid of a suitable
seconds timer - the component is lifted out and drained off. Manipulation may be necessary to
drain out wells of emulsifier in blind holes or recesses.
(a) The total contact period is adjusted to suit the component finish. See 5.C. This period
should be the minimum time required for removal of all excess penetrant so that all
background fluorescence is eliminated.
(8) Perform second water wash operation:
(a) UV.A (black light) illumination of 300μW/cm2 is required with no more than 300 lux of
ambient white light. :
1 Immediately after completion of the emulsifier time, dip in the wash tank and then
suspend or place over the tank and thoroughly spray wash with the air/water or water
spray gun until surface fluorescence is just removed using UVA of at least 300μW/cm2
at 300nm.
(9) Water in blind holes and recesses should be blown off with dry compressed air. The
components are finally dried in the air circulating oven. The drying time depends upon the
mass of the component or load and must be kept to the minimum required to dry the parts.
(10) Apply developer by placing in the dust storm cabinet for storm cycle. After completion, any
excess powder on upper surfaces should be gently blown off into the cabinet using dry
compressed air.
NOTE: Dust storm cycling shall be as follows for manually operated cabinets:
(a) Load parts - close and lock lid.
(b) Agitate dust with storm fans for approximately 15 seconds.
(c) Dwell time - approximately 4 minutes.
(d) Operate extraction for at least 30 seconds.
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(e) With extraction running, open lid and unload parts.
1 The extraction should be reverse operated during storm period to empty the hopper.
(11) Stand for 15 minutes minimum, 1 hour maximum.
(12) Carry out inspection in the darkroom or booth using ultra-violet lamps:
WARNING: ULTRA VIOLET LIGHT CAN DAMAGE YOUR EYES. DO NOT LOOK INTO THE
ULTRA-VIOLET LAMPS, OR AT DIRECT REFLECTIONS.
(a) Switch on ultra-violet lights at least 10 minutes before they are required to be used. They
are best left on during working periods.
(b) No inspection is to be carried out until dark light acclimatisation has been achieved.
Inspectors must allow at least 5 minutes in the darkroom, in black light conditions, before
commencing inspections.
(13) Difficulties in interpretation should be referred to Supervision. Parts containing defects should
be referred to Supervision before rectification is commenced, unless previous acceptance
standards have been laid down. Suspect parts shall be segregated and marked. Paperwork
must be endorsed by the qualified Inspector.
(14) Parts which have passed inspection are to be coated with de-watering oil.
(15) Processing Notes.
(a) The time cycle laid down must be rigidly adhered to. Timing is particularly critical at the
acid etching stage, if required, and the emulsifier stage.
(b) A proper flow of work must be maintained, work must not be allowed to stand between
stages. Work must not be started on components if there is not time to complete their
treatment and inspection without hold-up.
(c) If work becomes delayed or spoiled for any reason, the process must be recommenced
from the degreasing stage. Re-etching, where applicable, will not normally be necessary,
provided the requirements of paragraph 5.A.(5) have been satisfied.
(d) Absolute cleanliness must be maintained. Solutions must not be allowed to splash over,
and carry-off must be kept to a minimum by careful draining of parts.
(e) All parts, must be subjected to the minimum handling necessary. Inspectors should ensure
that their hands are clean at all times.
(f) If lifting hooks or wire baskets are use, these should be included in washing and remover
treatment. Alternatively, change hooks between stages to reduce carry-off. The use of
fibre rope slings is prohibited.
(g) When placing parts in a basket, care must be taken to ensure that parts do not overlap
each other and cause ‘masking’ during washing stages.
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C. Procedure
(1) The summary procedure shall be displayed in the test facility:
PENETRANT PROCEDURE SUMMARY

(a) Clean, etch (if required), dry and apply de-watering oil (if required).
(b) Degrease and cool. (Not parts with self lubricating bearings).
(c) Penetrant dip for 10 minutes (20 minutes minimum for Titanium, parts).
(d) Drain for 15 minutes.
(e) Wash 1.
(f) Emulsifier treatment - total contact time to be as shown:
Materials Surface Finish Emulsifier Contact

Time
Wrought Smooth-polished and fine finished ½ - 1 minute
Wrought Fine - scurfed and fine turned 1 - 2 minutes
Wrought Medium - grit blast, coarse machined 2 - 3 minutes
Cast and Coarse - anodised, as forged, machined castings, shot peened 3 - 4 minutes
Wrought surface
Cast Porous - raw castings, very rough scaly surfaces
4 - 5 minutes
Chromium Ground - (5 seconds immersion)
20 seconds
Plate
Attention is drawn to the need to employ minimum times.
(g) Wash 2
(h) Blow off and dry
(i) Developer application
(j) View after 15 minutes, but not later than after 60 minutes. (If time before viewing is
exceeded, re-process from degreasing stage).
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6. Acceptance Standards
A. False indications shall be identified and ignored. False indications may be caused by rough or
absorptive surfaces, drying runs or faulty washing. False indications can often be wiped off without
re-appearing after re-development and generally do not show the brilliance of flaw indications.
However, some defects, e.g. black lines in forgings, often result in poor brilliance. Such indications
should be re-etched to Part 7.
B. All flaw indications must be referred to a DP Qualified level II or III technician. This person will
decide on acceptance, rework/Materials Laboratory action or scrap. Exceptions arise only in the
case of cast parts:-
Castings are unlikely to be totally free of indications and the following may be applied in determining
the acceptability of the parts in which any indications are found.
No cracks, cold shuts, inclusions, segregation, through or linear indications are allowed.
Isolated fine rounded porosity is acceptable.
Other rounded indications up to 0,4 mm diameter are acceptable if the void cannot be seen at x 10
magnification under good white light conditions.
Voids up to 0,4 mm that can be seen at x 10 magnification under white light are acceptable providing
that the void is separated from an adjacent void by a distance of at least 8 times the diameter and
there are no more than 15 indications in an any 25 mm x 25 mm area.
Indications which exceed the above limits should be referred to a DP qualified level II or III
technician for a decision as to their possible acceptance.
C. Defects which will not be removable within drawing or concession limits are cause for immediate
rejection.
D. Where defects may be removable within actual or possible limits, re-work procedure shall be
applied.
7. Re-Work Procedure
A. Attempts to remove defects may be made by grinding, filing or machining, but not by polishing,
heavy abrasive blast, or other processes which cause smearing of surface metal. Whenever
possible, removal of defects shall be performed by cutting along the length of the defects to reduce
the danger of rendering defects invisibly by flowing of the surface metal.
B. All re-work areas must be etched prior to re-application of the penetrant process, using the following
solution applied by swabbing for 5 minutes. Temperature of the part should be 15°C (60°F) or
above.
C. Etch Solution for Aluminium Alloys
NOTE: Other alloys to be referred to the Materials Laboratory.
Hydrofluoric Acid, HF 40% 2,5 ml

Hydrochloric Acid, HCl 1.18 SG 3,5 ml
Nitric Acid, HN03 1.42 SG 5,0 ml
Water, H20 89,0 ml
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D. Procedure
(1) After machining the defect area, clean off all dirt and grease.
WARNING: ETCHING REAGENTS ARE DANGEROUS AND SHOULD NOT BE ALLOWED TO

CONTACT THE SKIN; RUBBER GLOVES MUST BE WORN. IF ANY OF THE
LIQUID IS SPILT, IT MUST BE WASHED AWAY WITH WATER.
(2) Apply the etch to the re-worked surface as described in paragraph 7.B. Wash off with water or
methylated spirit and dry.
NOTE: It is desirable to guard against runs of the etching reagent over the sound surfaces
of the component.
(3) Examine the etched surface and if the defect appears to have been removed, re-inspect with
penetrants.
(4) If the depth of the groove produced by eliminating the crack renders the component
dimensionally unacceptable, it should be rejected at this stage. If however, the defects appear
to have been removed, the relevant area should be re-inspected.
(5) Subject to design and quality consideration, the relevant area from which the defect has been
removed must be suitably blended and polished.
8. Control Requirements
A. Equipment
(1) All plant and handling equipment shall be kept clean. Precautions shall be taken to prevent
ingress of foreign matter into the tanks. Cover tanks when not in use for long periods.
(2) Tanks, ovens and dust cabinets shall be clearly labelled. Wash gun setting procedure shall be
shown at, or near, wash tanks.
(3) Where combined water/air guns are used, the pressure is to be set by the following procedure:
(a) Adjust with water on, only so that when the jet is pointed horizontally there is a fall of
approximately 0,25 metre, at the 1 metre position measured horizontally from the jet orifice.
Air should then be applied at a controlled pressure of 30 lbf/in2.
(4) Water wash guns without an air line attached shall operate with a water pressure of 40 lbf/in2
and recorded daily.
(5) Air and water pressure gauges shall be calibrated and tagged six monthly IAW II No. 8.
(6) Compressed air moisture traps shall be inspected frequently and emptied whenever more than
one quarter full.
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(7) The drying oven shall be surveyed at 3 monthly intervals using a calibrated thermometer and
probe at the point nearest each heater. A minimum of 3 readings shall be taken at each
surveyed point. The thermostat cut-out temperature shall be a maximum of 66 °C (150 °F).
Where an additional thermostat is fitted, its cut-out temperature should not exceed 66 °C
(150 °F).
(8) Timers shall be calibrated 6 monthly (Analogue) or 12 monthly (Digital) with an accuracy of ± 15
seconds over 15 minutes. (II No. 26 refers)
B. Materials
(1) The appearance of the penetrant shall be checked daily. There shall be no surface scum or
evidence of separation or cloudiness.
(2) The emulsifier shall be checked daily under black light for evidence of separation, cloudiness or
excessive fluorescence due to contamination.
(3) The developer powder shall be checked daily under black light for fluorescence contamination
and under white light for caking and foreign matter. The dust cabinet shall be kept clean and
dry.
(4) The penetrant stability and brilliance shall be checked on a 3 monthly basis by the manufacturer
or by the following procedure:
(a) Procedure requires standard dropper, Watman Number 1 Filter paper and a supply of
Analar Methylene Chloride of Analar Isopropyl Alcohol.
1 Place identical quantities of in-plant used penetrant and new penetrant, diluted 10%
with Analar Isopropyl Alcohol. Dry for 15 minutes.
2 Place the samples over the screen/reflector of a black light monitor and expose to a
black light at half a metre. Record the readings. The fluorescent brightness shall not
be less than 85% of the appropriate reference penetrant.
3 Place identical quantities of in-plant used penetrant diluted 10% with Analar Methylene
Chloride on two papers. Alternatively the penetrant maybe diluted 50% with Analar
Isopropyl Alcohol.
4 Place one paper under a standardised 125 W ultraviolet lamp at 0,5 metre and expose
for 1 hour. Place the remaining paper in a location protected from strong light, heat
and air currents. After the exposure compare the specimens using the black light
monitor method in Para 2. The fluorescent brightness difference of samples shall not
exceed 50%.
5 If it is observed that there is a noticeable drop-off in stability or brilliance, send a

sample off the penetrant to the supplier for analysis.
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(5) Where in-use penetrant quantity exceeds 30 gallons, a 6 monthly analysis shall be carried out.
This should include a corrosion test to DTD 929. Some material suppliers will provide this
service. A washability test is to be performed monthly (MIL-I-26135 refers) to the following
procedure:
(a) Pour 2 ml of the penetrant onto 3 panels and leave to drain at 45° angle for 15 minutes.
(b) Ensure the fixture has 6 to 7 pints of water in the container and that air pressure regulated
to 5 lbf/in2 is available.
(c) Immerse the panels in the emulsifier for 2 minutes.
(d) Position a panel on the fixture at 12 inches from and 90° to the nozzle. Rinse the panel for
30 seconds. Likewise rinse the other 2 panels.
(e) Dry the panels in the drying oven.
(f) Apply developer to each panel.
(g) After 15 minutes, examine under a black light. To pass the test, there should only be a light
background fluorescent on the test panels.
(h) Degrease and sandblast the panels (100 mesh grit) after each use.
(6) The penetrant line materials shall be checked each month as follows:
(a) Penetrant materials in-use shall be compared to an unused sample. These shall be in
sealed containers standing upright for 16 hours minimum prior to examination under white,
then black light. Should there be evidence of separation or precipitation, cloudiness or loss
of fluorescent brightness in the used material in comparison to the new, a sample shall be
submitted for further investigation. Any corrective action resulting shall be recorded in the
NDT Materials Log.
(b) A sample of the in-use emulsifier shall be checked for water content which should not
exceed the manufacturer’s recommendation, e.g. 90% maximum for Ardrox 9PR12.
(c) The emulsifier shall be compared in appearance with a new sample for evidence of dirt,
separation or cloudiness. When emulsifier is maintained for periods in excess of 3 months,
this check shall be carried out weekly after the 3 month period.
(7) Etch Table Control
(a) The solution strength shall be checked by the Materials Laboratory.
(b) Before each use, 2 aluminium alloy test pieces shall be processed through the etch solution
at 20 °C (68 °F) to determine the etch time required to remove .0002 in (0,005 mm) per
surface. When the time exceeds 1.7 times the original time the etch solution must be
changed. Test piece materials shall be 7075 T73 and L77 (or L168) in the fully heat treated
condition. For propeller blade forgings a test piece in MAT 5205, MAT 5201 or
DTD 150 shall be used.
NDT 8DAP
Page 13
60-00-00 Aug 31/10
ABC
C. Performance Tests
(1) The effectiveness of the process, of both Manual and Automatic Penetrant lines, is to be
checked daily using the PSM-5 (TAM) Panels, one of which along with its comparison
photograph is allocated to each line.
NOTE: Under no circumstances is a panel to be processed through a penetrant line other

than the line it has been specifically allocated to.
(2) The panels are to be processed through each penetrant line from the degreasing stage in the
normal way, using an emulsifier time of 2 minutes.
(3) After application of the appropriate powder developer, providing a satisfactory indication of the
‘crack pattern’ exists when compared to the panel’s photographic record, the effectiveness and
therefore, the sensitivity of the process is acceptable.
(4) The temperature of the mains water to the spray gun at the final wash shall be checked daily
and recorded.
(5) Cleaning Procedure for Quench Blocks, Chromium Plated Panels and Washability Panels:
(a) Blocks or panels are to be immersed in a cold degreasing fluid (see Para 2.C.(3)) until
there is no evidence of fluorescence after drying and application of developer.
(b) After cleaning, blocks are to be stored immersed a solvent solution in a closed container.
Plated panels and washability panels must be stored wrapped in dry tissue paper.
(c) Prior to re-use, blocks are to be re-checked for cleanness by examination under black light.
Any sign of indications are cause for repeat cleaning and re-check or scrap.
(d) Blocks or panels which have been damaged, or whose performance is suspect, are to be
scrapped.
D. Lighting
(1) Background ultra-violet lighting shall be checked with a meter each month and shall be at least
300μW/cm2 at the work position and over the second wash tank if applicable.
(2) White light ambient levels shall be checked in black light viewing areas with a meter each month
and shall not exceed 20 lux (2 ft candles) at the work position.
(3) UV.A (Black light) inspection lamps shall be checked daily and recorded weekly. The distance
(d) from the external datum on the monitor to the front face of the black light shall be 15 inches.
The minimum reading permitted is 1000μW/cm2 at 15 inches IAW ASTM E 1417.
(4) White light intensity viewing levels shall be 2000 lux (200 ft candles) at the viewing surface, and
shall be checked monthly.
NDT 8DAP
Page 14
60-00-00 Aug 31/10
ABC
E. Light Monitors
(1) UV.A (Black light) monitors shall be calibrated 6 monthly to BS EN ISO 3059. Certificates are to
be kept on file.
(2) UV.A (Black light) monitor fluorescent screens shall be checked at 6 monthly intervals to BS EN
ISO 3059 and recorded on file.
(3) White light meters shall be calibrated 6 monthly. Certificates are required to be kept on file.
NDT 8DAP
Page 15
60-00-00 Aug 31/10
ABC
MONTH AND YEAR .......................................................... NDT 8DAP
SITE .................................................................................. CONTROL SHEET J

PENETRANT CONTROLS
Penetrant - (Stability & Brilliance)

MONTHLY (Precipitation
(Separation
Emulsifier - (Water content check
(Comparison
Penetrant - (Check
Water Washability Test

Backgroup White Light ................. ft Candles
3 MONTHLY Due Date .................. ANNUAL Due Date ..................
Oven Check Air Gauges
Temperature ............. Water Gauges
DAILY CHECKS (DATE)

1 2 3 4 5 6 7
8 9 10 11 12 13 14
15 16 17 18 19 20 21
22 23 24 25 26 27 28
29 30 31
DAILY
Penetrant - scum or separation

Emulsifier - fluorescence, contamination
Developer - fluorescence, caking
PSm 5
(TAM) Panel - process
Spray Gun - water regulator 40 lbf/in² )
)
Water ) Record in
Temperature - final wash ) Date Block
NDT 8DAP
Page 16
60-00-00 May 31/08
ABC
YEAR ............................... BLACK LIGHT INSPECTION LAMPS and NDT 8DAP
SITE ................................ WEEKLY CHECK – 1000 μw/cm2 MINIMUM
LAMP SERIAL NO............ AT 15 inches DISTANCE CONTROL SHEET K
RECORD VALUE EACH WEEK
WEEK 1 WEEK 2 WEEK 3 WEEK 4 WEEK 5
WEEK 51 WEEK 52
NDT 8DAP
Page 17
60-00-00 May 31/09
ABC
F. Recording
(1) The background white light level shall be checked monthly in the viewing area using a
calibrated light meter and the value recorded on Control Sheet J.
(2) The output of the UV.A (black light) inspection lamps shall be checked daily using the black light
monitor to BS EN ISO 3059. The value shall be recorded on Control Sheet K weekly, and shall
exceed 1000μW/cm2 for acceptance.
(3) All other penetrant control checks are to be recorded on Control Sheet J. The periodic checks
are summarised on the Control Sheet.
(4) All testing equipment shall carry a ‘Calibration due’ sticker.
NDT 8DAP
Page 18
60-00-00 May 31/09

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Part of GE’s Aviation Business return to TOC

A. Final Clearance and Intermediate Inspections.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

B. Aluminium Alloy Forgings Class 1.

C. Components Undergoing Overhaul.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

BS M39 - Penetrant Inspection of Aerospace Materials and Components.

PS 5102 - Anodising of Aluminium and Aluminium Alloys.

PS 5202 - Temporary Protection of Parts.

PS 5203 - Degreasing with Trichloroethylene.

PS 5211 - Paint Stripping.

PS 51000 - The Use of Specifications in Manufacturing.

NDT 2DAP - Flaw Detection by the Wet Magnetic Particle Method.

NDT 10DAP - The Approval of Personnel for Non-Destructive Testing.

NAS410 - Certification of Penetrant and Magnetic Particle Inspection Personnel.

A-A-58050 - Fluorescent Penetrant Inspection Units.

ASTM E 1417 - Practice for Liquid Penetrant Examination.

AMS 2644 - Inspection Materials - Penetrant.

BS 3683 Part 1 - Terms used in Non-Destructive Testing (Penetrant Flaw Detection).

ISO 10012-1 - Quality Assurance Requirements for Measuring Test Equipment.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

4. Equipment and Materials

G. A supply of 9 PR12 Ardrox emulsifier made up to 10% mix by volume in water.

J. An automatic cycle dust storm developer cabinet.

M. Tank for de-watering oil.

N. A supply of de-watering oil: PS 5202 refers.

P. A supply of acids to make up the etch solutions.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

S. Calibrated timers: II No. 26 refers.

A. Pre-Penetrant Etch Treatment.

(3) Etch Process.

WARNING: IF HYDROFLUORIC ACID CONTACTS THE SKIN APPROPRIATE ANTIDOTE GEL

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

NOTE: Wash water effluent is to be neutralised by the addition of appropriate quantities of

(6) Dry the components in a re-circulating oven at 80°C.

(2) Treat in trichloroethylene vapour degreaser to PS 5203 or any other pre-cleaning/degreasing

(3) Cool to shop temperature.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

(8) Perform second water wash operation:

(a) Load parts - close and lock lid.

(b) Agitate dust with storm fans for approximately 15 seconds.

(c) Dwell time - approximately 4 minutes.

(d) Operate extraction for at least 30 seconds.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

(e) With extraction running, open lid and unload parts.

(11) Stand for 15 minutes minimum, 1 hour maximum.

(15) Processing Notes.

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

(1) The summary procedure shall be displayed in the test facility:

PENETRANT PROCEDURE SUMMARY

(d) Drain for 15 minutes.

(f) Emulsifier treatment - total contact time to be as shown:

Materials Surface Finish Emulsifier Contact

(h) Blow off and dry

(i) Developer application

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

C. Etch Solution for Aluminium Alloys

NOTE: Other alloys to be referred to the Materials Laboratory.

Hydrofluoric Acid, HF 40% 2,5 ml

DOWTY PROPELLERS STANDARD PRACTICES MANUAL

WARNING: ETCHING REAGENTS ARE DANGEROUS AND SHOULD NOT BE ALLOWED TO