Documentos de Académico
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1. Surface Preparation
Physical Methods Chemical Methods
Scale
Slag
Corrosion products
Paints
Chemical Methods
Vapour Degreasing Hot Solvent Degreasing Cold solvent Degreasing Solvent materials with Emulsifiers Acid / Alkaline Cleaning Steam cleaning Paint Removal
2. Penetrant Application
Penetrating fluid applied to component and drawn into defect by capillary action
Penetrant Application
Critical factors
Penetrant Properties
Good Wetting Ability High Surface Tension Viscosity
Wetting Ability
Liquids having good wetting ability have a low contact angle. Liquids having a contact angle of 90 or less will act as penetrants. Contact angle is strongly affected by surface cleanliness.
Contact Angle
Contact Angle
Contact Angle
LOW
HIGH
Surface Tension
HIGH
LOW
Surface Tension
Viscosity
Viscosity is a measure of internal friction It affects the rate at which a liquid flows Viscosity has a strong effect on the time taken for capillary action to work A high viscosity penetrant will require a longer contact time and a longer development time A low viscosity penetrant may drain too quickly from vertical or overhead surfaces
Types of Penetrant
Colour Contrast Fluorescent All other factors being equal, fluorescent penetrants provide the best sensitivity Each of the above may be water washable, solvent removable or post-emulsifiable (in order of increasing sensitivity)
2. Penetrant Application
Preceded by a visual inspection
Spraying Methods
Brushing
Immersion
Penetrant application
Electrostatic spraying
Special Methods
Thixotropic penetrants
Penetrants are formulated for removal by one or sometimes more than one of the above.
Spray wash
Minimise mechanical action Pressure as low as possible Temperature less than 50C
Lipophilic
Contact time critical Determined by experimentation
Post emulsifiable
ADVANTAGES Maximum penetrating ability Greater control over penetrant removal DISADVANTAGES Not suited to rough surfaces More expensive More time consuming
Thou shalt not spray the cleaner directly onto the item under test.
Solvent Removable
ADVANTAGES Portability No water supply needed DISADVANTAGES Not suited to batch testing Requires hand wiping so time consuming More expensive than water washable Potentially hazardous chemicals
Drying
Hot air recirculating oven (max 80C)
Forced warm air Dry clean compressed air Component temperature shall not exceed 50C
4. Development
Penetrating fluid applied to component and drawn into defect by capillary action Developer applied to surface
Developer Properties
Absorptive Fine texture Able to mask out background colour Evenly and easily applicable Light and even coat Non-fluorescing Easily wetted Contrasting colour Easily removed Non-toxic and Nonirritant
Developer action
Penetrating fluid applied to component and drawn into defect by capillary action
Developer applied to surface
Developer action
Capillary Action - Increases the size of an indication far beyond the actual defect size; increases the thickness of an indication, thereby increasing its colour brilliance. Light scattering - Aids the conversion of UVA to visible light when using fluorescent systems; reduces background glare when using visible systems. Solvent Action - Solvent combines with penetrant, reducing penetrant viscosity, thereby inducing a more rapid, more efficient bleed-out.
Light Scattering
I0 If If
If If
No Developer
With Developer
No Developer
With Developer
Development
Dry powder Component must be dry Applied by Dipping Blowing Dust storm cabinet Aqueous liquid Dry after application Applied by Immersion Spraying Brushing
Aqueous Developer
Solutions
Aqueous Developer
Solutions
Suspensions
Aqueous Developer
ADVANTAGES No vapours or dust Cheaper than nonaqueous DISADVANTAGES Difficult to apply evenly Requires drying after application
Non-Aqueous Developer
ADVANTAGES Most sensitive Usable with fluorescent or colour contrast DISADVANTAGES Hazardous solvents Higher cost Need to be correctly applied
Developer Sensitivity
Dry powder Aqueous solution Aqueous suspension 120 Non-Aqueous 120 100 - 140 % 110 - 150 % - 200% - 240%
System Classification
Type of penetrant Method of penetrant removal Type of developer
System classification
PENETRANT Colour contrast Fluorescent Dual
DEVELOPERS REMOVAL Dry Water washable powder Aqueous Solvent Non-Aqueous Post emulsifiable
5. Inspection
Indications viewed as soon as practicable after developer application with final assessment taking place after a minimum development time has elapsed.
30 Seconds
1 Minute
15 Minutes
5. Inspection
Lighting levels critical Colour Contrast White light above 500 lux Fluorescent
5. Inspection
Fluorescent Allow 15 minutes lamp warm-up Allow 5 minutes dark adaptation Do not wear photo-chromatic spectacles
6. Post Cleaning
DPI residues are required to be removed because They may be harmful to the component or They may impair subsequent processing
Advantages of DPI
Applicable to all non-porous materials Able to test large parts with a portable kit Batch testing Applicable to small parts with complex geometry Simple,cheap, easy to interpret Good sensitivity Training requirements typically less than for other NDT methods.
Disadvantages of DPI
Will only detect defects open to the surface Careful surface preparation required Not applicable to porous materials Temperature dependent Cannot retest indefinitely Compatibility of chemicals
Penetrant Systems
PENETRANT
Colour contrast Fluorescent
REMOVAL
Solvent Water washable
DEVELOPERS
Dry powder Aqueous
Dual
Post emulsifiable
Non-Aqueous
Selection of System
Nature of discontinuities (size and type) Geometry and intricacy Surface condition Component material and application Size and position Equipment and expertise available Cost Number of components to be tested
Control Checks
Tank levels Overall system performance
Control Checks
Tank levels Overall system performance Rinse water temperature Oven temperature Equipment cleanliness Airline filters UV-A filters
Control Checks
UV-A / visible light levels Fluorescent / colour intensity Suppliers check Hydrophilic remover dilution Developer Meter / gauge calibrations
UV(A)
Electromagnetic Spectrum
X-rays & Gamma Microwaves Infra red TV Electric Waves
Ultra violet
Light
102
104
106 108
Electromagnetic Spectrum
UV-C UV-B UV-A
10
100
200 LIGHT
300
400
500
600 LIGHT
700
ULTRAVIOLET
VISIBLE
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
10
100
200 LIGHT
300
400
500
600 LIGHT
700
ULTRAVIOLET
VISIBLE