Liquid Penetrant Inspection

A.K.A. Dye Penetrant Inspection (DPI)

Penetrant Flaw Detection (PFD)
Penetrant Testing (PT)
• Surface inspection method
• Applicable to all non-porous,
non-absorbing materials
 Penetrant Inspection

• Penetrating fluid applied to component and

drawn into defect by capillary action
 Principle : Capillary Action
• Interaction of adhesive and cohesive
forces
 Capillarity
• The ability of a material to enter a
discontinuity
• e = 2S Cos 
W
• e = Capillary pressure
• S = Surface tension
• W = Width of Crack
•  = Contact angle
 Contact angle
• Contact Wetting Droplet
angle ability shape
Less than 90º High
90º Moderate

More than 90º Low

 American terms

• Static Penetration • Kinetic Penetration

Parameter Parameter

• SPP =  Cos  • KPP =  Cos 



 = Surface tension  = Viscosity

 Penetrant Inspection

• Penetrating fluid applied to component and

drawn into defect by capillary action
• Developer applied to surface
 Penetrant Inspection

• 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
 Advantages of DPI
• Applicable to non-ferromagnetics
• Able to test large parts with a portable
kit
• Batch testing
• Applicable to small parts with complex
geometry
• Simple,cheap easy to interpret
• Sensitivity
 Disadvantages of DPI
• Will only detect defects open to the
surface
• Careful surface preparation required
• Not applicable to porous materials
• Temperature dependant
• Cannot retest indefinitely
• Compatibility of chemicals
 System Classification
• Type of penetrant
• Method of penetrant removal
• Type of developer
 System classification
• PENETRANT
• Colour
contrast
• Fluorescent
• Dual
 Fluorescence and the
Electromagnetic Spectrum
Absorbs Emits Dual

10 100 200 300 400 500 600 700

ULTRAVIOLET VISIBLE
LIGHT LIGHT
 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
 Electromagnetic Spectrum

A Damaged
UV-C UV-B UV-A
Black Light Emits

10 100 200 300 400 500 600 700

ULTRAVIOLET VISIBLE
LIGHT LIGHT
Fluorescent v Colour Contrast
• Fluorescent more sensitive
• Less operator fatigue with fluorescent
• More difficulty in monitoring fluorescent
penetrant removal
 System classification
• PENETRANT • REMOVAL
• Colour • Water
contrast washable
• Fluorescent • Solvent
• Dual • Post
emulsifiable
 Water Washable Penetrant
ADVANTAGES DISADVANTAGES
• Useable on rough • Susceptible to over
surfaces washing
• Suitable for batch • Least sensitive
testing method
• Cheaper than other • Requirement for a
methods water source
 Solvent Removeable
ADVANTAGES DISADVANTAGES
• Portability • Not suited to batch
• No water supply testing
needed • Requires hand wiping
so time consuming
• More expensive than
water washable
• Potentially hazardous
chemicals
 • 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
 Post emulsifiable
ADVANTAGES DISADVANTAGES
• Maximum • Not suited to rough
penetrating ability surfaces
• Greater control over • More expensive
penetrant removal • More time
consuming
 System classification
• PENETRANT • REMOVAL • DEVELOPERS
• Colour • Solvent • Dry powder
contrast • Water • Aqueous
• Fluorescent washable • Non-Aqueous
• Dual • Post
emulsifiable
 Dry powder developer
ADVANTAGES DISADVANTAGES
• Easy to handle • Difficult to see if
• No hazardous properly applied
vapours • Fine powders can be
• Easy to remove hazardous
• Do not offer a high
degree of colour
contrast
 Aqueous Developer

• Solutions • Suspensions
 Aqueous Developer
ADVANTAGES DISADVANTAGES
• No vapours or dust • Difficult to apply
• Cheaper than non- evenly
aqueous • Requires drying
after application
 Non-Aqueous Developer
ADVANTAGES DISADVANTAGES
• Most sensitive • Hazardous solvents
• Useable with • Higher cost
fluorescent or colour • Need to be correctly
contrast applied
 Developer Sensitivity
• Dry powder 100 - 140 %
• Aqueous solution 110 - 150 %
• Aqueous suspension 120 - 200%
• Non-Aqueous 120 - 240%
 Penetrant Systems
• PENETRANT • REMOVAL • DEVELOPERS

• Colour • Solvent • Dry powder

contrast
• Fluorescent • Water • Aqueous
washable

• Dual • Post • Non-Aqueous

emulsifiable
 BS EN 571
Penetrant Removal

• Type I Fluorescent • Method A Water

• Type II Colour • Method B Lipophilic
contrast Emulsifier
• Type III Dual • Method C Solvent
• Method D Hydrophilic
• Method E Water and
solvent
 BS EN 571
Developer Removal

• Form a Dry • Method A Water

• Form b Water • Method B Lipophilic
soluble Emulsifier
• Form c Water • Method C Solvent
suspendable • Method D Hydrophilic
• Form d Solvent • Method E Water and
based solvent
• Form e Peelable
 BS EN 571
• Fluorescent • Type I

• Solvent removable • Method C

• Solvent based • Form d

developer
 Mil-L-25135
• Group I Solvent removed,Visible
• Group II Post emulsified,Visible
• Group III Water washable,Visible
• Group IV Water washable,Fluorescent(L)
• Group V Post emulsified,Fluorescent(M)
• Group VI Post emulsified,Fluorescent(H)
• Group VII Solvent removed,Fluorescent
 Mil-L-6866

• Type I Fluorescent • Type II Visible

Method A Water Method A Water
Method B Post Method B Post
emulsifiable emulsifiable
Method C Solvent Method C Solvent
 Selection of System
• Nature of discontinuities (size and type)
• Geometry and intricacy
• Surface condition

• Component material
• Size and position
• Equipment and expertise available
• Cost
• Number of components to be tested
 Selection of System
• Inspection of a large number of threaded
components
• What method will you select and why ?

• Fluorescent water washable with dry

powder developer
• Fluorescent for mass inspections
• Water washable more suited than solvents
to batch inspections
• Post emulsifiable difficult to remove from
threads
 Selection of System
• Inspection of turbine blades for fatigue
cracks
• What method will you select and why ?

• Fluorescent post emulsifiable with non-

aqueous developer

• Fluorescent more sensitive than colour contrast

• Post emulsifiable more sensitive than water
washable
• Non-aqueous developer most sensitive