Penetrant Inspection Systems

Penetrant systems can be highly

portable or stationary.

Image courtesy of Nebraska Army National Guard

Portable Penetrant System

Stationary Penetrant System

Penetrant Test Equipment (Stationary)

Stationary equipment used in liquid penetrant testing varies in size and is
largely dependent upon the size of the test specimen. Depending on the
type and process used, a stationary system could include the following:
1. Pre-cleaning station (usually in remote area)
2. Penetrant station (tank)
3. Drain station
4. Emulsification station (tank)
5. Rinse station (tank)
6. Developing station (tank)
7. Drying station (usually oven)
8. inspection station (enclosed booth or table with proper lighting)
9. Post-cleaning station (usually in remote area)
SEE PICTURE
ON NEXT SLIDE

Penetrant Test Equipment (Portable)

Both visible and fluorescent dye penetrants are available in kits
which can be used at a remote location or when testing a small portion of
a large article.
A visible dye penetrant kit usually contains:
1. Pressurized spray cans of cleaning or removal fluid.
2. Pressurized spray cans of visible dye penetrant.
3. Pressurized spray cans of non-aqueous developer.
4. Wiping cloths and brushes.
A fluorescent dye penetrant kit usually contains:
5. A portable black light and transformer.
6. Pressurized spray cans of cleaning or removal fluid.
7. Pressurized spray cans of fluorescent dye penetrant.
8. Pressurized spray cans of non-aqueous developer.
9. Wiping cloths and brushes.

Black light equipment is required in fluorescent

penetrant testing since it supplies light of correct
wavelength to cause the penetrant to fluoresce.
A deep red-purple filter is used to pass only those
wavelengths of light that will activate the fluorescent
material.
At least a five-minute heat-up time is required to reach
the correct arc temperature when using mercury arc
lamps.
The black light emits a special light with wavelengths
that fall between visible and ultraviolet. Provided that
the filter is not broken or cracked, there is no danger of
injury to the human eye. It is suggested that the filter
be checked prior to each use.
Penetrant testing materials can be used in a

The flow chart below illustrates the different material

combinations. However, care should always be taken to
assure that manufacturers specifications or company
procedures are closely followed.

Penetrant Testing Materials

Penetrant materials are often restricted to specific groups.
The establishment groups of penetrant materials will use the
following in a variety of combinations to obtain the best
results:
1. Water-Washable penetrants Contain an emulsifying agent
which makes them easily removable by a water rinse or wash.
This penetrant material can be obtained with either a visible or
fluorescent dye.
2. Post-Emulsifiable penetrants Are highly penetrating, oily
visible or fluorescent penetrants which are not soluble in water.
These penetrants must be treated with an emulsifier before
they can be removed by a water rise or wash.
3. Solvent-Removable penetrants - Are oily penetrants that
do not contain an emulsifying agent and are removable only by
solvents specially designed for that purpose.
4. Emulsifiers When applied to a penetrant-coated specimen
make the resultant mixture removable by water rinse or wash.
Emulsifiers have low penetrant characteristics and do not

Choices of Penetrant Materials

Penetrant

Type

I Fluorescent
II Visible
Method

A Water Washable
B Postemulsifiable - Lipophilic
C Solvent Removable
D Postemulsifiable - Hydrophilic

Developer

Form

Dry Powder
Wet, Water Soluble
Wet, Water Suspendable
Wet, Non-Aqueous

Penetrant Materials
Penetrants are formulated to possess a
number of important characteristics. To
perform well, a penetrant must:
Spread easily over the surface being inspected.
Be drawn into surface breaking defects by
capillary action or other mechanisms.
Remain in the defect but remove easily from
the surface of the part.
Remain fluid through the drying and
developing steps so it can be drawn back to
the surface.
Be highly visible or fluoresce brightly to
produce easy to see indications.
Not be harmful to the inspector or to the
material being tested.

Sensitivity Levels

Penetrants are also formulated to produce

a variety of sensitivity levels. The higher
the sensitivity level, the smaller the defect
that the penetrant system is capable of
detecting.
The five sensitivity levels are:

Level
Level
Level
Level

4
3
2
1

Ultra-High Sensitivity
High Sensitivity
Medium Sensitivity
Low Sensitivity

As the sensitivity level increases, so does

the number of non relevant indications.
Therefore, a penetrant needs to be
selected that will find the defects of
interest but not produce too many non
relevant indications.

Visible Vs Fluorescent PT
Inspection can be performed

using visible (or red dye) or

fluorescent penetrant
materials.
Visible Pt is performed under
white light while fluorescent
PT must be performed using
an ultraviolet light in a
darkened area. All are all in
the level 1 sensitivity range.
Fluorescent PT is more
sensitive than visible PT
because the eye is more
sensitive to a bright
indication on a dark
background. Sensitivity
ranges from 1 to 4.

Photo Courtesy of
Contesco

Penetrant Removal Method

Penetrants are also classified by the
method of removing the excess penetrant.
Solvent Removable penetrants are removed
by wiping with a cloth dampened with
solvent. They are supplied in aerosol cans for
portability and are primarily used for spot
checks.
Water Washable penetrants are removed
with a course spray of water. They are the
easiest to employ and most cost effective
when inspecting large areas.
Post-Emulsifiable penetrants are waterwashable only after they have reacted with an
emulsifier solution. A post-emulsifiable
system is used when washing the penetrant
out of the defect is a concern. The emulsifier
is given time to reacts with the penetrant on
the surface but not the penetrant trapped in
the flaw.

5. Removers (Solvent) are designed to be used in conjunction

with specific penetrants. Typical removers are available in or
pressurized spray containers.
6. Dry developers Are a fluffy, absorbent white powder that is
used in both fluorescent and visible dye penetrant tests. It
functions to draw the penetrant indications to the surface thus
making them visible.
7. Wet developers Function similarly to dry developers except
that they are a mixture of a developing powder and water.
8. Non-aqueous Wet developers Differ from wet developers in
that the developer powder is mixed with a rapid-drying liquid
solvent.
9. Liquid Oxygen (LOX) Compatible Materials Must be used
when articles inspected are subjected to contact with either liquid
or gaseous oxygen. These materials are specifically designed to
be inert when in the presence of LOX.
10.Low Sulfur and Low Chlorine Penetrant materials must be
specifically designed to avoid the harmful effects caused on some
nickel and titanium alloys by the sulfur and chlorine content.

Developers
The role of the developer is to pull trapped

penetrant out of defects and to spread it

out on the surface so that it can be seen.
Also provides a light background to
increase contrast when visible penetrant is used.
Developer materials are available in several different
forms
Dry Powder is a mix of light fluffy powder that clumps
together where penetrant bleeds back to the surface to
produces very defined indications.
Wet, Water Suspendible is a powder that is suspended in
a water that covers the surface with a relatively uniform
layer of developer when the water is evaporated. The
solution is somewhat difficult to maintain as the powder
settles out over time.
Wet, Water Soluble is a crystalline powder that forms a
clear solution when mixed with water. The solution
recrystallizes on the surface when the water is driven off.
Indications sometimes lack definition and look milky. Not
recommended for use with water-washable penetrants.
Wet, Non-Aqueous - is supplied in a spray can and is the