PT - PROCESSING

Asosiasi Uji Tak Rusak Indonesia

Surface Method Training

Course

CONTENT

Surface Preparation
Penetrant Application
Removal of Excess Penetrant
Developer Application
Inspection
Post Cleaning

Surface Method Training

Course

1. SURFACE PREPARATION
PURPOSE
To have a clean and dry test surface
Clean no rust, no scale, no paint, no
corrosion product
Dry no oil, no grease, no water
Because if contaminants are present, it will
prevent the penetrant from entering the
discontinuities.
Example of contaminants:

Oil, grease, scale, rust, welding flux, acids,

water
Paint?
Plating?

Surface Method Training

Course

METHODS OF CLEANING

Mechanical Cleaning
Chemical Cleaning
MECHANICAL CLEANING
To remove rust, scale, paint, dust and etc.
Methods of cleaning

Wire brushing
Grinding
Polishing
Sand blasting
Ultrasonic cleaning

If we use sand blasting, be careful sand

blasting of low hardness material may close
discontinuity

Surface Method Training

Course

SAND BLASTING

BEFORE

AFTER

Soft part

It deforms and close

the discontinuity

Surface Method Training

Course

CHEMICAL CLEANING

To remove grease, oil, etc.

Methods of cleaning:

Detergent cleaning
Remove surface soil
Detergent may be alkaline or acid and shall
be non-corrosive
Thorough rinsing and drying required
Vapour degreasing
Remove organic contaminants such as oil,
grease
Use of solvent vapour
Chlorinated solvent can be harmful to Ni,
Stainless Steel, Ti
Steam cleaning
Suitable for large article
Removes inorganic or organic contaminants

Surface Method Training

Course

CHEMICAL CLEANING

Solvent cleaning

Remove grease and oil

Typical solvent: alcohol, acetone
Cleaner /remover normally supplied
penetrant manufacturer

by

De-scaling solution

Remove oxide film

After the cleaning the part should be dried so

that no water or solvent remains in or over the
discontinuities, as this will hinder entrance of
the penetrant
Drying can be done by using:

Infra-red lamps
Drying oven
Force air circulation
Normal evaporation

Surface Method Training

Course

2. PENETRANT APPLICATION

TYPES OF PENETRANT
Non-fluorescent/visible dye penetrant
Fluorescent penetrant

PENETRANT SYSTEMS
Water washable
Post-emulsified
Solvent removed

Surface Method Training

Course

PENETRANT SYSTEMS

Sometimes referred to water washable and

non water washable penetrants
The only different is emulsifier agents
Water washable
Emulsifier
agents

Dye

Solvent

Non-water washable
Dye
Solvent

Surface Method Training

Course

HOW THEY ARE APPLIED

Methods

Dipping (or immersing)

Spraying
Brushing
Pouring (flowing)
Compressed air spray gun

The way we applied is not very important

The temperature of the test part should be
between 160C 520C (600F 1250F) for
most of the standards
If out of this range, then the standards say
your procedure should be proved well apply

Surface Method Training

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PENETRATION TIME

Definition the period of time during which

the penetrant is permitted to remain on the
specimen. This is known as penetration time
or dwell time

Application
Technique

Soak
Time

Immersion

Period of
article is
in bath
-

Others

Dwell
Time

Penetration
Time

draining

Soak time
+
dwell time

Time
penetrant
remains
on article

Dwell time

Surface Method Training

Course

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FACTORS THAT AFFACTING PENETRATION

TIME

Types of penetrant used (related to surface

tension () and wetting ability (cos) less
time for non-water washable)
Specimen wetting ability
Material processes (forged parts required more
time than for casting parts)
Types of discontinuity that we are looking for
Temperature of the part

Surface Method Training

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TEMPERATURES OF THE PART

Normally in standard the penetration times

given are minimum recommended times

Example ASME the penetration times are

valid for temperature range 160C 520C

Parts with low or high temperature then the

penetration
time
indicated
in
manual
(manufactures recommendation) is not valid
any more
Lower temperature of the part penetration time and vise versa

Surface Method Training

Course

higher the

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THE GENERAL RECOMMENDED FOR

PENETRATION TIME*

1000C

<150C

Normal
160C-520C

1500C2000C

Nonwater
washable

8 minutes

15-25
minutes

10-15
minutes

2 minutes

Water
washable

20-30
minutes

15-20
minutes

*NOTE - use recommended values given by

manufacturer

If we use immersion method, then we do not

need 15 minutes to dip the part inside the

tank.
Surface Method Training
Course

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3. REMOVAL OF EXCESS
PENETRANT

It depends on the type of penetrant, namely;

Water washable
Non water washable

Solvent removed
Post emulsifiable process (hydrophilic remover,
lipophilic emulsifier)

Surface Method Training

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WATER WASHABLE PENETRANT

How to remove it from the surface of the test

part?
Two ways:
a) Simply apply water with certain pressure.
Normal standard the maximum pressure

of water jet is less or equal to 50psi.

Excellent result if P ~ 20psi and apply water

at an angle of 450 max.

Good for rough surface, water temperature

160C 430C.

900

wrong

450

OK
Surface Method Training
Course

much better

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WATER WASHABLE PENETRANT

b) For field application where we do not have

pressurised water/large amount of water then we
can use wet towel to remove excess penetrant, and
then use water applicator (no pressure) to remove
the residual penetrant
Water
Wet towel

Discontinuity

Surface Method Training

Course

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NON WATER WASHABLE PENETRANT

a) POST EMULSIFIED PROCESS

The penetrants employed in the post-emulsified

process do not contain an emulsifying agent
The penetrant is not soluble in water
Use emulsifier to render non water washable
penetrant to become water washable
Two types of emulsifier:
Lipophilic
hydrophilic

Surface Method Training

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NON WATER WASHABLE PENETRANT

LIPOPHILIC (OIL BASE)

is applied by dipping, spraying and NEVER by

brush
How it works?
Apply

P.E
penetrant)

penetrant

(non-water

washable

Non-water
washable
penetrant
Apply emulsifier before removing the penetrant

Non-water
washable
penetrant

Emulsifier

Apply emulsification dwell time

Water washable

Non-water washable
penetrant

Surface Method Training

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NON WATER WASHABLE PENETRANT

(LIPOPHILIC)

The emulsifier will completely mix with the

penetrant on the surface become water washable
Inside discontinuity it still non-water washable
For fluorescent penetrant washing should be
checked with black light
The amount of time that the emulsifier is permitted
to remain prior to the removal process is usually in
the range of 1 to 3 minutes, seldom exceeds 5
minutes
The exact emulsification dwell time must be
determined by experiment

Surface Method Training

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NON WATER WASHABLE PENETRANT

HYDROPHILIC
(WATER
REMOVER/EMULSIFIER

BASE)

Before dipping the part (after penetrant

application) into detergent tank rinse the part
with water sprayed is preferred
Immerse the part into detergent
Emulsification time or contact time may vary
from 30 sec. 15 min. depending on sample or
discontinuity to be inspected
Wash with water

Surface Method Training

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NON WATER WASHABLE PENETRANT

( Post Emulsified Process)

THE EMULSIFICATION TIME

Is the most important parameter in P.E process

To short emulsification time;

Emulsifier not completely mix with penetrant
During washing difficult to remove the penetrant from
the surface

emulsifier
Non water washable
penetrant

To long emulsification time;

Emulsifier will mix with penetrant inside the
discontinuities
During washing it is possible that the penetrant inside
the discontinuities will also be removed as well reduce
sensitivity

Water washable
penetrant

The best emulsification time can only be determined

on the part itself. The best time is the minimum time
that leaves no excess penetrant on the surface
Surface Method Training
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NON WATER WASHABLE PENETRANT

b)

REMOVED BY SOLVENT

Use cloth/paper tissue

Use solvent or penetrant removal from the
same penetrant manufacturer
Method

Remove as much excess penetrant as possible

with dry lint-free cloth
Remove the remaining excess with remover
dampened lint free cloth (clean) until no trace of
penetrant on cloth
When using visible dye penetrants, checked for
complete removal by nothing that the last
remover dampened wipe is `colour free
When removing fluorescent penetrants, check
progress with black light and stop when test
surface no longer fluoresces

Never apply (or spray) solvent directly to

specimen, because we also can clean some of
the penetrant inside the discontinuities
solvent

Less sensitivity

The less solvent we use the better is the result

Surface Method Training
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4. DEVELOPER APPLICATION
Sequence
1. Dry developer or non aqueous developer

The part should be dried first before apply

the developer

2. Water soluble or water suspendable

The parts have to be dried after applying the

developer

Surface Method Training

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WET AQUEOUS DEVELOPER

(WATER SOLUBLE)

How it applies?
By dipping the part into tank container
(contain developer)

Difficult to get uniform layer of developer

After developer application, the part has to be
dried in oven (80oC 100oC)

By pouring or flowing
By using compressed air spray gun

Surface Method Training

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DRY DEVELOPER

By dipping the part into the tank

By using powder applicator or rubber squeeze
bulb or low pressure spray gun

NON AQUEOUS DEVELOPER

Spray can or spray gun or electrostatic sprayer
Note never blow air to accelerate solvent
evaporation

Surface Method Training

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DEVELOPING TIME

Is the time from developer application to the

time part is inspected
Rule of thumb to use a developing time of
around half of the penetration time

Example: penetration time : 20 minutes

developing time : 10 minutes

10 minutes is 99.9% good because if the

indication is not seen after 10 minutes then
the part contain no discontinuities

Surface Method Training

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5. INSPECTION

LIGHTING REQUIREMENTS
Good illumination should according to
standard

White Light : visible penetrant

350 Lux or 32.5 ft/candles

Black light : fluorescent penetrant

ASME Code 1000watts/cm2 at 38cm from the

surface;
MIL-I-25135D - 1200watts/cm2

Surface Method Training

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GENERAL RECOMMENDATION
(BLACK LIGHT)

Allow a minimum of 5 minutes to warm the

lamps before starting inspection
Stay a minimum of 5 minutes in the darkened
area before starting inspection
DONT switch ON and OFF the lamp often it
will shortened the life of lamp
Keep the filter inside the lamp clean all the
time

Surface Method Training

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INSPECTION
(two Steps)

INITIAL INSPECTION
Is done as soon as possible after applying the
developer

Remember we have to write a report

Mainly good for porosity

To know better the type, nature and extend of
discontinuities
In-line
porosity

Need initial
inspection

Four
porosity

Big
porosity

Porosity

After 1
minute

Immediately
after applying
developer

After 3
minutes

Surface Method Training

Course

After 10
minutes

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INSPECTION
(two Steps)

FINAL INSPECTION
Is done when the developing time has elapsed
In-line porosity (looks like
linear discontinuity)

Final
inspection
Four porosity
(looks like big
porosity)

Big
porosity

Wrong interpretation it looks like a big defect

Therefore, initial inspection is required because
normally porosity has small opening but with
big volume inside
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6. POST CLEANING

After complete the inspection we have to

clean the part (as soon as possible especially
for standard sample)
Method (for standard sample)

Best vapour degreasing or ultrasonic cleaning

Apply developer if indication reappear then
the cleaning procedure should be repeated.

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