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
• Method C Solvent
• Type III Dual
• Method D Hydrophilic
• Method E Water and
solvent
BS EN 571
Developer Removal
• Form a Dry • Method A Water
• Form b Water soluble
• Form c Water
• Method B Lipophilic
suspendable Emulsifier
• Form d Solvent based • Method C Solvent
• Form e Peelable
• Method D Hydrophilic
• Method E Water and
solvent
BS EN 571
• Fluorescent • Type I
• Method C
• Solvent removable
• Form d
• Solvent based
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
