Liquid Penetrant

Testing

24-Jun-24 PREPARED By Dinesh Kannan 1

 Liquid Penetrant Testing is a surface defect
detection method, that can be used on any
material (i.e., non-ferrous, conductive or non-
conductive, metals/non-metals). At its core,
LPI involves the application of penetrants,
An Overview which come in two primary forms, to surfaces
requiring inspection. These penetrants,
whether used in welding joint DP tests or
general liquid penetration testing, seep into
surface discontinuities, including cracks and
lack of fusion, enabling accurate defect
detection.
What is the Liquid Penetrant Examination
Procedure?
Liquid Penetrant Inspection is
not merely about detecting
flaws; it embodies a
commitment to quality, safety,
and reliability. Through
seamless integration into
manufacturing, maintenance,
and quality control processes,
LPI plays a pivotal role in
upholding industry standards
and ensuring the integrity of
critical components.

This step-by-step procedure

outlines the key stages involved
in conducting an LPE.

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CHOOSING PENETRANTS, REMOVERS, AND
DEVELOPERS
Penetrant Option: Developer Option:

Color contrast Dry Powder

Fluorescent Aqueous

Combination (both color contrast & fluorescent) Non-Aqueous developer

Remover Option:

Solvent

Post-emulsifiable remover

Water-soluble

Water-suspendable

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Surface Preparation
One of the most critical steps of a liquid
penetrant testing is the surface preparation.
the surface preparation should be free of
oil, grease, water, and other contamination.
That may prevent penetrant from entering
flaws.

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Penetrant Application:
Direct Spray
• Once the surface has been
thoroughly cleaned and dried,
the penetrant material is applied
by spraying, brushing, or
immersing the part in a penetrant
bath.

By Brush

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Penetrant Dwell:
The penetrant is left on the surface for a sufficient time to allow as
much penetrant as possible to be drawn from or to seep into a defect
Penetrant dwell time is the total time that the penetrant is in contact
with the part surface. Dwell times are usually recommended by
the penetrant producers or required by the specification being
followed. The times vary depending on the application, penetrant
materials used, the material, the form of the material being
inspected, and the type of defect being inspected or the radius of the
flaw or the distance between the flaw walls for Minimum dwell times
typically range from five to 5-60 minutes. Generally, there is no harm
in using a longer
The temperature of the specimen is an important factors usually at 10
to 45deg celcius
Penetrant dwell time if the penetrant is not allowed to dry. The
ideal dwell time is often determined by experimentation and may be
very specific to a particular application.

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Excess Penetrant
Removal:
This is the most delicate part of
the inspection procedure
because the excess penetrant
must be removed from the
surface of the sample while
removing as little penetrant as
possible from defects.

Depending on the penetrant

system used, this step may
involve cleaning with a solvent,
or smooth lint free cloths, or
direct rinsing with water, or first
treating the part with
an emulsifier and then rinsing
with water.

24-Jun-24 PREPARED By Dinesh Kannan 8

Developer
Application:
A thin layer of developer is then applied to the
sample to draw penetrant trapped in flaws back
to the surface where it will be visible. Developers
come in a variety of forms that may be applied
by dusting (dry powdered), dipping, or spraying
(wet developers).

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Indication Development:
• The developer is allowed to stand on the part surface for a period sufficient to
permit the extraction of the trapped penetrant out of any surface flaws. This
development time is usually a minimum of 10 minutes. Significantly longer times
may be necessary for tight cracks.
Indication Development

24-Jun-24 PREPARED By Dinesh Kannan 10

Inspection:
• The developer brings out the indications of defects on the surface, which can
now be inspected under appropriate lighting conditions. Adequate lighting, often
achieved through ultraviolet lamps, enhances the visibility of indications.
Trained NDT Inspectors carefully examine and interpret the indications,
considering their size, shape, and location, to assess the significance of the
detected defects. Light Intensity Checking
Equipment

UV Meter

24-Jun-24 PREPARED By Dinesh Kannan 11

 After completing the inspection and
recording the results, the test surface is
thoroughly post-cleaned. This step is
essential to remove any residual
penetrant and developer from the
surface, ensuring that subsequent
Post-cleaning inspections or other processes are not
affected.
 Advantage of Visible Dis-Advantage of Visible
Method Method
• High sensitivity (small discontinuities can • Only surface breaking defects can be detected
be detected
• Only materials with a relatively nonporous
• Few material limitation (metallic and surface can be inspected
nonmetallic, magnetic and nonmagnetic
and conductive and nonconductive • Pre cleaning is critical since contamination can
materials may be inspected masks the defects
• Rapid inspection of large areas and • Metal smearing from machining, grinding, and
volumes grit or vapor blasting must be removed
• Suitable for parts with complex shapes • Surface finish and roughness can affect
inspection sensitivity
• Indication are produced directly on the
surface of the parts and constitute a visual • Chemical handling and proper disposal is
representation of the flaw required

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 Penetrants are carefully formulated to process the
level of sensitivity desired by the inspector.

1. Spread easily over the surface of the material being

inspected to provide complete and even coverage
Penetrants 2. Be drawn into surface breaking defects by capillary
action
3. Remain in the defect but removed easily from the
surface of the part
4. Remain fluid so it can be drawn back to the surface
of the part through the drying and developing steps
5. Be highly visible or fluoresce brightly to produce
easy to see indications
6. Not be harmful to the material being tested or the
inspector.
 Penetrant Materials Types
Visible Penetrants: Florescent Penetrants

They contain a red dye that provides high They contain dye or several dyes that
contrast against the white developer fluoresce when exposed to ultraviolet
background radiation

However visible penetrant do not require a Florescent penetrant system are more
darkened area and an ultraviolet light to sensitive than visible penetrant system
inspect. because the eye is drawn to the glow of the
fluorescing indication.

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Penetrants are Classified by the method used to remove
excess penetrant from the part the four methods are:
❑ METHOD A - WATER WASHABLE:

• Penetrant can be removed from the part by rinsing with water alone these penetrant contain an
emulsifying agent (detergent) that makes it possible to wash the penetrant from the part surface with
water alone water washable penetrant ate sometimes referred to as self-emulsifying system

❑ METHOD B – POST EMULSIFYING LIPOPHILIC:

• The Penetrant is oil soluble and interacts with the oil-based emulsifier to make remover possible.

❑ METHOD C – SOVENT REMOVABLE:

• They require the use of solvent to remove the penetrant from the part by direct spray or manual
cleaning by using lint free cloths

❑ METHOD D – POST-EMULSIFIABLE HYDROPHILIC:.

• They use an emulsifier that is a water-soluble detergent which lifts the excess penetrant from the
surface of the part with a water wash.

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 Level ½ - Ultra low sensitivity
Penetrants are then classified based on
the strength or detectability of the Level 1 – Low sensitivity
indication that is produced for several
very small and tight fatigue cracks. The Level 2 – Medium sensitivity
five sensitivity levels are:
Level 3 – High sensitivity
Level 4 – Ultra-high sensitivity

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DEVELOPERS
The Role of developers is to pull the trapped penetrant material out of
defects and spread it out on the surface of the part so it can be seen by
an inspector. Developers used with visible penetrants create a white
background so there is a greater degree of contrast between the
indication and the surrounding background. On the other hand,
developers used with florescent penetrants with reflect and refract the
incident ultraviolet light, allowing more of it to interact with the
penetrant causing more efficient fluorescence.

According to standards developers are classified based on the

method that the developer is applied.

FORM A - DRY POWDER

FORM B - WATER SOLUBLE
FORM C - WATER SUSPENDABLE
FORM D - NONAQUEOUS TYPE 1: FLORESCENT
(SOLVENT BASED)
FORM E - NONAQUEOUS TYPE 2: VISIBLE DYE (SOLVENT
BASED)
FORM F - SPECIAL APPLICATION
DRY POWDER
Dry powder developers are generally considered to be
the least sensitive, but they are inexpensive to use and
easy to apply. Dry developers are white, fluffy
powders that can be applied to a thoroughly dry
surface in a numbers by dipping parts in a container of
developer, by using a puffer to dust parts with the
developer or placing parts in a dust cabinet where the
developers is blown around. Since the powder only
sticks to areas of indication since they are wet, powder
developers are seldom used for visible inspection.

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WATER SOLUBLE As the main implies, water soluble developers consist of a
group of chemicals that are dissolved in water and form a
developer layer when the water is evaporated away. The best
method for applying water soluble developers is by spraying
it on the part. The part can be wet or dry. Dipping, pouring, or
brushing the solution on the surface is sometimes used but
these methods are less desirable. Drying is achieved by
placing the wet but well drained part, will have an even light
white coating over the entire surface.

Advantages of water washable penetrants

Lower cost (no emulsifier needed)

Fewer processing steps

Process time reduced

Variables associated with emulsifier dwell time eliminated

Disadvantages of water washable penetrants

Over washing can occur in shallow defects

Water rinsing time is critical

Water contamination of the penetrant is possible

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WATER SUSPENDABLE
Water suspendable developers consist of insoluble developer
particles suspended in water. Water suspendable developers
require frequent stirring or agitation to keep the particles from
settings out of suspension. Water suspendable developers are
applied to parts in the same manner as water soluble developers
then the parts are dried using warm air.

24-Jun-24 PREPARED By Dinesh Kannan 21

 Nonaqueous
Nonaqueous developers suspend the developer in a
volatile solvent and are typically applied with a spray
gun. Nonaqueous developers are commonly distributed
in aerosol spray cans for portability. The solvent tends to
pull penetrant from the indication by solvent action.
Since the solvent is highly volatile, forced drying is not
required.

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Use & Selection Of a Developers

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 Advantages & Disadvantages

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Temperature Control Penetrant Quality
Control

The temperature of the penetrant materials

and the part being inspected can influence the The quality of penetrant inspection is highly
results. Temperature from 27 to 49 ° are dependent on the quality of the penetrant
reported in the literature to produce optimal materials used. Deterioration of new penetrants
results many specification allow testing in the primary results from aging and contamination.
range of 4 ° to 52° rising the temperature Virtually all organic dyes deteriorate over time,
beyond this level will significantly raise the results in a loss of color or florescent response,
speed of evaporation of penetrants causing keep materials always in a closed container and
them dry out quickly protection from freezing and exposure to high
heat.

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 Dwell Quality Control Emulsifier Bath Quality
Control

Dwell times are usually recommended by the

penetrant procedure or required by the
specification being followed. The only real
quality control required in the dwell step of
the process is to ensure that a minimum dwell
time is reached. There is no harm in allowing
a penetrant to dwell longer than the minimum
time if the penetrant is not allowed to dry the
part.

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Lipophilic Emulsifiers:
Lipophilic Emulsifiers mix with penetrants but when the concentration of penetrant contamination in the emulsifier
become too great the mixture will not function effectively as a remover. Standard require that lipophilic
emulsifiers be capable of 20% penetrant contamination without a reduction in performance. When the cleaning
action of the emulsifier become less than that of new material it should be replaced

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 Hydrophilic Emulsifiers

Hydrophilic emulsifiers have less tolerance

for penetrant contamination the penetrant
tolerance varies with emulsifier concentration
and the type of contaminating penetrant in
some cases, as little as 1% (by volume)
penetrant contamination can seriously affect
the performance of an emulsifier.

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 The optimal emulsifier contact
time is dependent on several
variables that include the
Emulsifier emulsifier used the emulsifier
concentration the surface
Concentration and roughness of the part being
inspected, and factor. Usually,
contact Time: some experimentation is
required to select the proper
emulsifier contact time.

24-Jun-24 PREPARED By Dinesh Kannan 29

 Wash Quality Control Drying Quality Quality
Control
• The wash temperature, pressure and time are three • The temperature used to dry parts after the
parameters that are typically controlled in penetrant application of an aqueous wet developer or prior to
inspection process specification. A coarse spray or the application of a dry powder or a nonaqueous wet
an immersion wash tank with air agitation is often developer, must be controlled to prevent drying in
used. When the spray method is used the water the penetrant in the flaw. To prevent harming the
pressure is usually limited to 276 Kpa. The penetrant material drying temperature should be
temperature range usually (10 to 38 ° c) kept to less than 71 °c also the dying time should be
limited to the minimum length necessary to
thoroughly dry the component being inspected

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• The function of the developer is very important in penetrant inspection. To accomplish its function a developer
must adhere to the part of the surface and result in a uniform, highly porous layer. With many paths for the
penetrant to be moved due to capillary action. Developer can either applied wet or dry

WET SOLUBLE/SUSPENDABLE
DEVELOPER
DRY POWDER DEVELOPER
Wet soluble developer must be completely
Should be checked daily to ensure that it is fluffy
and not caked. It should be like fresh powdered dissolved in the water and wet suspendable
sugar and not granulated powdered soap. method must be thoroughly mixed prior to
application. The concentration of powder in the
This check is performed by spreading a sample
of the developer out and examine it under the carrier solution must be controlled in these
light developers.
When using developer, a light coat is applied by The concentration must be checked at least
immersing the test components or dusting the weekly using a hydrometer to make sure it meets
surface after the development time the excess the specification.
powder can be removed by gentle blowing on the
surface.

Developer quality control

 SOLVENT SUSPENDABLE

in this method the developer is supplied in sealed

aerosol spray cans.

The spray developer should produce a fine even

coating on the part surface.

Make sure before applying the can is well shaken and

apply a thin coating to the test surface
in this method the developer coating must be thick
enough to provide a white contrast background. But
not heavy enough to mask the indication.

For florescent penetrant system, a very high coating

should be used the developer should be applied under
white light and should appear evenly transparent

DEVELOPMENT TIME:

parts should be allowed time for minimum 10 minutes

and not more than 2 hrs. before inspection.

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 LIGHTING FOR
FLORESCENT PENETRANT
INSPECTION
1. Standard procedure required verification of filter
condition and light intensity.

2. The black light filter should be clean, and the light

should be never used with a cracked filter.

3. The UV light should be warmed up prior to use and

should be on for at least 15 minutes prior to
inspection.

4. The accepted intensity is 1000 uw /cm2

5. Light level of less than 2-foot candles (22lux) are

required minimum.

6. For measurement, the instrument is mainly

radiometer some radiometer can measure both
black and white light intensity.

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 CHEMICAL SAFETY:

A. It is highly recommended that the material data

sheet (MSDS) be reviewed before using
chemicals.

B. Some of the penetrant materials are flammable

and therefore should be used and stored in small
quantities.

C. They should be only used in a well-ventilated

area and ignition sources avoided.

Chemical & UV light D. Eye protection should be always be worn to

prevent contact of the chemicals with the eyes

Safety E. Gloves and other protective clothing should be

worn to limit contact with the chemicals.

ULTRAVIOLET LIGHT SAFETY:

The UV light has wavelength ranging from 180 to 400

nanometer.

Too much exposure can be harmful to the skin and

eyes.

Skin and eye damage occurs wavelengths around

320nm and shorter, which is well below the 365 nm
wavelength
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 DPT Defects (Visible Method)
Pin Holes

Weld Crack Porosity

Pin Hole

Multiple Porosity

Branch
Crack

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 DPT Defects (Florescent Method)

Multiple
Crack
Weld Crack

Crater Type
Crack

Transverse Crack
Crack

Branch
Crack

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