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H A P T E R
Introduction
Liquid penetrant testing is one of the
most widely applied methods of
nondestructive testing because of the low
cost of application, the perceived
simplicity of the process and its ability to
be applied to complex shapes with little
process adjustment. Liquid penetrant
testing is not, however, absolute and is
not capable of finding all cracks. The
end-to-end liquid penetrant process is
bounded by a lower limit for the
detection of small cracks (detection
threshold). In addition, the detection
threshold is not a constant value but
depends on multiple parameters inherent
to the test object and liquid penetrant
procedure applied or are a function of
rigid process control in application.
Although some confidence may be
provided by the ability of a liquid
penetrant procedure to reveal a known
crack in a test coupon, the brightness or
contrast intensity of the liquid penetrant
indication may be such that it would not
be detected under field conditions if its
presence and location were not known. It
is foolhardy to assume crack detection if
the indication is small or dim or both.
The inspection result of importance is not
the smallest discontinuity detected but the
largest discontinuity missed by application
of a given liquid penetrant procedure.
In many liquid penetrant testing
applications where requirements are for
the detection of large cracks, exceeding
25 mm (1 in.) long, demonstration of
Probability of Detection
(POD) As Measure of
Liquid Penetrant
Performance
The recognized metric for ascertaining the
detection capability for a liquid penetrant
procedure is the probability of detection
(POD). A characteristic POD curve is
generated by passing a large number of
cracks of varying size through a liquid
penetrant procedure and recording the
cracks that are detected. A standardized
data analysis procedure is then used to
produce a plot of probability of detection
as a function of crack size (typically crack
length). Figure 1 is an example of a POD
curve for a given liquid penetrant test
procedure.
By convention, the threshold detection
point is that point where the POD curve
crosses the 90 percent threshold and is
referred to as the 90/95 probability of
detection value (assuming the number and
distribution of crack sizes meet the criteria
for standardized analysis). In the example
shown, the single valued detection
capability is at the 3.5 mm (0.14 in.) crack
FIGURE 1. General form of probability of detection curve for liquid penetrant testing
procedure. Accepted 90 percent threshold detection point is noted.
100
90
80
70
Threshold
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
276
Multiparameter Process
Liquid penetrant testing is a
multiparameter process. Changes in one
or more of the process parameters can
significantly change the liquid penetrant
crack detection performance capability.
Liquid penetrant process performance
depends on the following: (1) test object,
(2) discontinuity type, (3) discontinuity
size, (4) discontinuity form and state,
(5) test materials, (6) test equipment,
(7) test process, (8) test environment,
(9) test procedure applied and (10) human
factors.
The test object material, shape
(configuration), surface texture (porosity
and surface finish), stress state, surface
condition and object size are parameters
that may affect liquid penetrant process
capability. For example, titanium alloys
wet differently than aluminum alloys
used in aircraft.
The discontinuity type may be a
significant factor; for example, a
condition for detection is that the
discontinuity must be open to the surface
and must have an opening such that
liquid penetrant can be retained using the
applied liquid penetrant procedure. It is
obvious that a crack that is covered by a
paint layer or smeared metal from a
machining or grinding process will not be
consistently detectable.
The discontinuity size i.e., length,
depth and opening greatly affect
detectability. The brightness of a liquid
penetrant indication for a small crack (less
than 0.75 mm [0.030 in.]) will be
significantly less than that for a larger
crack because of the reservoir size. The
ability of a human reader to discriminate
small indications is typically greater than
0.75 mm (0.030 in.) in length. Because
discontinuity size (length and depth) is a
basic material parameter used in static
design and life cycle analyses, it is the
277
FIGURE 2. Effect of ultraviolet radiation level for liquid penetrant testing procedure (water wash
process without developer, on tightly closed fatigue cracks in cobalt alloy; with 55 to 107 lx
[5 to 10 ftc] white light illumination): (a) 4 Wm2 (400 Wcm2) ultraviolet radiation;
(b) 12 Wm2 (1200 Wcm2) ultraviolet radiation.1
(a)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4 7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
(b)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4 7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
278
FIGURE 3. effect of developer for liquid penetrant testing procedure (water wash process on
tightly closed fatigue cracks in cobalt alloy): (a) without developer, (b) with developer.1
(a)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3 2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
(b)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3 2.5
3.8
5.1
6.4
7.6
8.9
10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
Process Performance
Assessment and
Proficiency Demonstration
Variation in end-to-end liquid penetrant
process performance is readily observed
by comparison of probability of detection
(POD) data as a function of varying liquid
penetrant process parameters. Table 1 and
Figs. 2 to 5 are examples of the assessment
of liquid penetrant process parameters
279
FIGURE 4. Effects of etching and proof test for liquid penetrant testing procedure (solvent
remover process; on tightly closed fatigue cracks in 6Al-4V titanium material): (a) as
machined condition; (b) after etch; (c) after proof load.1
(a)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
(b)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
(c)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4 7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
280
FIGURE 5. Effects of etching and proof test for liquid penetrant testing procedure (solvent
remover process; on tightly closed fatigue cracks in AISI 4340 steel material): (a) as machined
condition; (b) after etch; (c) after etch and proof load.1
(a)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3 2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45)(0.50)
(b)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3
2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7 14.0 15.2 16.5 17.8 19.1
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45) (0.50) (0.55) (0.60) (0.65) (0.70) (0.75)
(c)
Probability of detection (percent)
100
90
80
70
60
50
40
30
20
10
0
0
0
1.3 2.5
3.8
5.1
6.4
7.6
8.9 10.2 11.4 12.7
(0.05) (0.10) (0.15) (0.20) (0.25) (0.30) (0.35) (0.40) (0.45)(0.50)
281
282
(a)
Probability density distribution
(relative units)
Noise
Threshold
Decision
Level
Signal
Signal amplitude
(relative units)
(b)
Probability density distribution
(relative units)
Human Performance in
Liquid Penetrant Testing
Noise
Signal
False calls
Signal amplitude
(relative units)
(c)
Probability density distribution
(relative units)
Noise
Signal
Signal amplitude
(relative units)
Decision
reject (correct reject)
reject (false call)
accept (miss)
accept (correct accept)
Call
True positive
False positive
False negative
True negative
Positive (A)
Negative (N)
Positive (a)
Negative (n)
P(A,a)
True positive (hit)
No error
P(A,n)
False positive
Type II error
P(N,a)
False negative (miss)
Type I error
P(N,n)
True negative
No error
283
Summary
Liquid penetrant testing is an effective
and economical method of discontinuity
detection and is widely used in the
process of ensuring the safety and
structural integrity of engineering
materials, components, structures and
systems. Its wide use and superficially
simple application result in a wide range
of results that vary from consistent
detection of critical discontinuities to
parts washing exercises that do not add
value to the parts. Fortunately, it costs no
more to perform a valid inspection than it
does to conduct a parts washing exercise.
It is logical that a multiparameter testing
process requires attention to detail and
process control for successful application.
The tools and techniques for materials
and process control are readily available.
The end to end process performance may
also be quantified using the information
and techniques discussed herein. If the
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References
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