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H A P T E R
Interpretation of Liquid
Penetrant Indications
Definitions of Liquid
Penetrant Interpretation
and Evaluation
There is often a tendency on the part of
an inspector to confuse the terms
interpretation and evaluation and to fail to
recognize that there is a significant
distinction between them. Actually, the
terms refer to two entirely different steps
in the test process and require entirely
different categories of knowledge and
experience. To interpret an indication
means to give a decision as to what
material condition is causing the
indication. There may be many possible
conditions: cracks, porosity, lack of results
from the assembly of parts, such as a
forced fit. Evaluation then follows
interpretation. If it has been decided that
a crack of given size and direction exists,
the extent of its effect on the usefulness
of the part must be evaluated before the
part can be disposed of: either accepted as
is, reworked or scrapped.
126
Importance of the
Inspectors Evaluation
Because correct liquid penetrant
evaluation depends on accurate
interpretation, the inspector is the key
person in the test process. In some mass
inspection operations, the person who
operates the test equipment merely
segregates the parts that show indications.
Others decide their disposition. In most
cases, however, the inspector who first
sees the indication is also expected to
interpret it. Actually, if the inspector has
any of the qualifying background, he or
she is the one best able to do this, because
the inspector is most familiar with all
kinds of indications as they occur on the
parts the inspector handles. Also, the
inspector is best able, because he or she
performed the tests, to know that the
process has been properly carried out or
to know and assess any variations from
normal behavior during the test. The
inspector therefore must be thoroughly
honest and dependable. The inspector
must be fully alert to the importance of
the work he or she is doing.
Discontinuity detection with liquid
penetrants is more art than science. This
is necessarily true unless or until some
successful means is evolved that can
automatically see and accurately interpret
liquid penetrant indications. In the
meantime, the inspector must be relied
on to perform these functions. Skill and
proficiency in developing and then
interpreting indications must be acquired
by experience. A skilled and experienced
inspector can add greatly to the inherent
effectiveness of liquid penetrant testing.
Assuming that the inspector knows
how to operate the instruments and carry
out the techniques, it is almost self
evident that the inspector cannot do a
competent job unless he or she also
knows the materials under test. The
inspector must know what they are, how
they are made and how they have been
processed. This knowledge must include
an understanding of what discontinuities
may be introduced during manufacture
and processing. If the inspector knows
what discontinuities to look for and
where they are likely to occur, the
inspector can select the techniques
available for their detection much more
effectively.
General Classification of
Discontinuities by Their
Origination
Discontinuities are most commonly
classified on the basis of the progress of
127
MOVIE.
Fluorescent
bleedout
reveals
shrinkage.
128
Sources of Discontinuities in
Blooms and Billets
When cast into ingots, the metal is then
further worked down into usable forms by
forging, rolling or pressing. The steel
ingot, for example, is reheated to the
proper temperature and passed between
heavy rolls to form blooms or billets. The
size of ingots varies widely, depending on
the ultimate product to be made from
them. Ingots of alloy and tool steel may
be quite small, weighing perhaps 100 kg
(220 lbm), whereas ingots from which
large forgings or large thick plate are to be
made may weigh many tons. Blooms and
billets are formed in an intermediate step
between the ingot and the finished size or
product.
Sources of Discontinuities in
Forgings
If the ingot or billet is used for forging, a
variety of discontinuities can be produced,
usually because of improper handling of
the metal under the hammer or to
working at too low a temperature.
Common discontinuities are laps and
folds. Forging bursts, both external and
internal, can also occur. Figure 5 shows a
forging lap.
In the case of die or drop forging, laps
and surface tears and bursts may be
produced. In die forgings, excess metal is
forced out between the two halves of the
die forming the flash and this excess
metal is subsequently trimmed off. If not
properly done, flashline cracks or tears
may be formed. Another type of forging
discontinuity is the internal rupture
129
Sources of Discontinuities in
Rolled and Pierced Products
In the production of seamless tubing, the
billet is pierced. Discontinuities on the
inside surface of the pierced billet may
take the form of tears. Seams may occur
on the outside surface, especially if the
surface of the billet or blank had not been
properly cleaned.
Sources of Discontinuities in
Extrusions
Nonferrous seamless tubing is often made
by extrusion, starting with hollow or
pierced billets or from solid ingots.
Discontinuities that occur may be checks
and tears or imperfections may result
from uncovering or bringing to the
surface internal discontinuities of the
billets or ingots. In addition to tubing,
many shapes and products are made
today by various extrusion processes.
Because of flow of the metal of the
original ingot during extrusion, oxide and
surface skin sometimes becomes folded
into the interior. A form of pipe also
results from this action, which is most
objectionable when it appears in a
finished shape.
Sources of Discontinuities in
Fusion Weldments
Welding is a process that has its own
group of typical discontinuities that must
be guarded against. In fusion welding
processes, where liquid metal solidifies in
the weld, the same sort of discontinuities
may occur as in castings namely, slag
inclusions, gas porosity and thermal
cracks. In addition, cracking in the parent
metal may occur because of thermal
stresses or as a consequence of hydrogen
pressure. There are also discontinuities
due to lack of penetration of the weld and
failure to get proper fusion of the weld
metal to the parent metal.
Sources of Discontinuities in
Machined and Ground Surfaces
Sometimes machining operations, as for
instance too heavy a cut with improper
tools, may cause surface damage, leaving
discontinuities in the form of surface
tears. Grinding of surfaces for accurate
dimensions or for finish is a prolific
source of surface cracking, especially on
hardened steel surfaces. Parts that have
been hardened may have residual internal
130
MOVIE.
Quenching
cracks.
Significance of Surface
Discontinuities under Repeated
Loading or Vibration
Fatigue cracks almost invariably start at
the surface and are initiated by conditions
that bring about locally high stresses.
These stress concentrations involve
stresses above average for the part. The
stresses may, in their local area, be above
the fatigue strength of the metal. Surface
scratches, cracks or other discontinuities
may cause these local areas of high stress
(Fig. 7). Localized high stresses may also
be caused by design features of the part
for example, high stresses occur around
holes, fillets and stiffening members.
131
132
Appearance of Liquid
Penetrant Indications
If fluorescent liquid penetrant is used, the
examination is made under ultraviolet
radiation, sound areas appear as deep
violet-blue, whereas discontinuities glow
with a brilliant, generally yellow-green
light. The intensity of the fluorescence is
associated with the volume and
concentration of liquid penetrant retained
in the discontinuity. If visible dye liquid
penetrant is used, the examination is
made in ordinary white light. The
developer forms a white background and
discontinuities are made visible by a red
color indication, whose richness is closely
related to the volume of entrapped liquid
penetrant.
Several factors influence the exact
appearance of individual liquid penetrant
indications. However, there are certain
general trends that hold true for all sorts
and forms of materials.
MOVIE.
Linear
discontinuity.
(c)
(b)
(d)
MOVIE.
Open and
partially open
cracks.
MOVIE.
Pitting and
porosity.
133
134
Edges of Indications
The sharpness of liquid penetrant
indications is affected by the volume of
liquid retained in the discontinuity, the
test conditions such as temperature and
time allowed for indications to develop
and the type of liquid penetrant used.
Generally, clear cut indications come from
narrow linear discontinuities.
Persistence of Liquid
Penetrant Indications
One good way to estimate the size of
discontinuity is by the persistence of the
indication. If it reappears after the
developer has been removed and
reapplied, there must be a reservoir of
liquid penetrant present. In case of faint
or weak indications where there is some
doubt as to the type or even the existence
of a discontinuity, it is good practice to
repeat the entire liquid penetrant test. If
the indication reappears, it is probably
due to a small discontinuity rather than
to incomplete cleaning.
135
Effects of Metals
Manufacturing Processes
on Liquid Penetrant
Indications
Liquid penetrant indications can be
influenced seriously by previous
processing during manufacturing,
inspection or surface treatments of test
parts. Although the chemical composition
or form of material does not affect the
indications obtained from liquid
penetrant testing, it is true that the same
technique will produce varying
indications on rough castings, finish
Obscured Discontinuities
Irrelevant Indications
Casting
Polishing
metal flows over discontinuities
Heat treating
Anodizing
reduces fluorescence
porous oxide absorbs liquid penetrant
Chromate treatment
reduces fluorescence
136
Possible Result
no indications (openings closed) or false
fluorescence
no indications (openings closed)
no indications (openings closed)
weak indications (reduced fluorescence)
weak indications (reduced fluorescence)
weak indications (diluted penetrant)
no indications (openings closed) or false
indications
false indications
false indications
excellent
137
(b)
138
removal difficult
liquid penetrant removed from shallow defects
hide fine defects
139
Techniques
Specifications and standards may apply to
the following types of techniques:
1. broad procedural guidelines;
2. company procedural guidelines;
3. procedural guides for specific types of
products or for industries;
4. procedures for testing specific articles,
specified by a purchaser or by process
specifications internal to the
company;
5. procedures specified for overall
inspection of a companys products;
6. specifications for certification of
operators;
7. standards for acceptance or rejection,
set up by buyer or by company for
quality control;
8. repair station requirements;
9. equipment specifications; and
10. instructions for operating specific
types of equipment or individual
special units.
Materials
Specifications that apply to materials may
be of the following types:
1. specifications designed for use in
purchasing liquid penetrants and
other materials and
2. specifications designed for testing and
evaluating performance of liquid
penetrants and other materials.
140
(b)
Indications
__________________________________________________________________________
Weak Faint Line
Diffused
Many, Small
Heavy
Defect
Fabrication
Cleaning
Temperature
Washing
Lighting
Inspector
general porosity
embedded grease
oily or greasy
inadequate
poor sighta
porosity
rough surface
scale or rust
large flaws
a. Inadequate vision of inspector may be due to (1) inattention, (2) maladaption to darkness or (3) poor vision acuity,
which may be due to vitamin A deficiency.
Liquid Penetrant
Indications of Leaks
In any part such as a gas tank, tubing,
fitting, flange or cylinder that must
maintain pressure, a liquid penetrant
indication through the wall is considered
to be cause for rejection. It makes no
difference whether the discontinuity is a
crack, a hole, lack of penetration in a weld
or a porous area. The fact that a liquid
penetrant can pass through the wall
proves that the vessel cannot hold
pressurized fluids without leakage.
Indications of
Miscellaneous Parts
Many test laboratories handling a wide
variety of work do not have the advantage
of inspecting large quantities of any one
item. Most of these commercial
laboratories are performing tests to
government specifications and
consequently, the liquid penetrant
inspectors are trained and tested. There is
no substitute for experience, which is
gained only by seeing which
discontinuities caused which indications.
141
142
Forging Cracks
Forgings may have indications of cracks,
often at the juncture of light and heavy
sections or in thin fins. As in castings,
cracks are regarded as rejectable.
Indications similar to those from cracks
are produced by forging laps, discussed
elsewhere in this chapter.
(b)
Machining Marks
Machining practice may produce cracklike
indications from dull tools, chatter marks
and similar tool marks. Such indications
are ordinarily not intense and are not
considered sufficient cause for rejection.
Grinding Cracks
Grinding cracks are minute, often
invisible to the unaided eye and are cause
for rejection. The type of precision part
that must have a ground surface cannot
tolerate any surface cracks, however small.
While grinding cracks are extremely fine
and may be shallow, they usually occur in
a definite network that is easily identified.
Extensive grinding cracks are shown in
the two carbide tipped cutting tools
illustrated in Fig. 15. The photographs in
143
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Heat Checks
The third type of crack that may show up
on maintenance overhaul is the heat
check, occurring when surfaces are
overheated. Like grinding cracks (which
are initiated in the same way by local
overheating), heat checks are usually quite
shallow but occur in definite, recognizable
network. These indications may or may
not, be cause for rejection, depending on
the use of the part.
(b)
145
146
Forging Laps
Die Castings
In die castings, however, slight cold shuts
or skin folds, less than 0.1 mm (0.004 in.)
in depth, are common. Because die
castings are seldom used for applications
requiring very high strength, faint
indications of cold shuts or skin folds are
not causes for rejection. The usual practice
is to remove some of the worst looking
discontinuities and estimate how deep
they were, then make the decision of
acceptance or rejection.
Seams
FIGURE 21. Forging laps in aluminum forging.
147
Extrusion Discontinuities
Depending on the orientation of the
surface being examined, an extrusion
discontinuity may cause continuous or
dotted liquid penetrant indications. A
typical extrusion discontinuity is an internal
unsound area, longitudinally squeezed
during extrusion and sometimes
breaching the surface (Fig. 23). If the
extrusion is sectioned and a longitudinal
surface examined, the extrusion
discontinuity will show up as a line, like a
crack. If a cross section is inspected, liquid
penetrant indications will appear as short
lines or dots. An extrusion discontinuity
is usually considered a basis for rejection
in aircraft applications but may be
acceptable for other service where only
longitudinal strength is required.
148
Shrinkage Cavities
MOVIE.
Porosity in
casting.
(b)
149
Microshrinkage
Some materials, especially magnesium
castings, have shrinkage cavities so fine
that they are almost invisible. These
openings are so tiny that instead of
getting a speckled condition with a
number of small spots, the liquid
penetrant indication is more likely to be a
generally diffused condition. To confirm
the actual presence of microshrinkage, it
is best to clean and reprocess the part.
Microshrinkage is not always a rejectable
discontinuity; rejection depends on size
and severity of microshrinkage, its
location and the end use of the part.
Porosity in Ceramics
Liquid penetrant testing is a good way to
locate porosity in ceramics. The
appearance and interpretation of
indications are the same as in metals,
with the one extra caution that special
attention must be paid to cleaning
because most ceramics are somewhat
porous.
150
MOVIE.
False
indications.
Common Causes of
Nonrelevant Liquid
Penetrant and False
Indications
Nonrelevant indications may be due to
misapplied or improper testing procedures
or to actual discontinuities that do not
affect the usability of a part. False
indications, a subcategory of nonrelevant
indications, are best defined as indications
that distract from the quality of the
inspection but do not indicate a
discontinuity in a part. False indications
are due to several causes but the primary
cause is usually a deficiency in process
control.
MOVIE.
Nonrelevant
indications can
mask relevant
ones.
MOVIE.
Nonrelevant
indication from
part geometry.
151
Evaluation of Nonrelevant
Indications
One technique that an inspector can use
to help identify a nonrelevant indication
is wiping off the indication with a solvent
dampened lint free swab or cloth and
reapplying the developer. The original
developer dwell time must be repeated;
however, the inspector should monitor
the bleedout to help evaluate the
indication. If there is no bleedout, the
original indication can be considered
nonrelevant or false. This technique may
also reveal multiple relevant indications
that had previously merged into one or
had been hidden by excessive bleedout
from an adjacent nonrelevant indication
during the developer dwell.
152
Evaluating Indications to
Determine Causes of
Discontinuities
It is possible to examine an indication of
a discontinuity and to determine its cause
as well as its extent. Such an appraisal can
be made if something is known about the
manufacturing processes to which the
part has been subjected. The extent of the
indication or accumulation of liquid
penetrant, will show the extent of
discontinuity and the breadth and
brilliance will be a measure of its depth.
Deep cracks will hold more liquid
penetrant and therefore will be broader
and more brilliant. Very fine openings can
hold only small amounts of liquid
153
154
Examples of Interpretation
Guides Based on
Appearance of Liquid
Penetrant Indications
In some cases, specifications provide a
guide to parts evaluation based primarily
on the size, shape or location of liquid
penetrant indications. For such purposes,
a linear liquid penetrant indication is
defined as having a length greater than
three times the width. Rounded liquid
penetrant indications are those
indications that are circular or elliptical
with the length less than three times the
width. In some code applications,
unacceptable discontinuities are then
defined in terms such as (1) any crack or
linear indication; (2) rounded indications
greater than 5 mm (or 0.2 in.) in
dimension; (3) four or more rounded
indications in a line separated by 1.5 mm
(or 0.06 in.) or less, edge to edge; and
(4) ten or more rounded indications in
any 37.5 cm2 (6.0 in.2) of surface with the
major dimension of this area not to
exceed 150 mm (6.0 in.). The area must
be taken in the most unfavorable location
relative to the indications being
evaluated.
Representative Aerospace
Manufacturers Liquid
Penetrant Test
Interpretation Guide
A typical aerospace manufacturers process
specification requires that visual
inspection areas shall be illuminated with
essentially white light. The intensity of
white light at the visual test level shall be
equivalent to at least 750 lx (70 ftc).
Fluorescent liquid penetrant testing shall
be conducted in a suitable darkened area
(with an ultraviolet radiation intensity of
at least 10 Wm2 (1000 Wcm2) and
background illumination preferably not
exceeding 20 lx (2.0 ftc). The following
lists the criteria for parts acceptance or
rejection in accordance with the aerospace
companys quality requirements.
1. Propagating discontinuities, regardless
of location, are cause for rejection
unless completely removed within
drawing tolerances. Propagating
discontinuities are those
discontinuities that, because of their
nature or geometry, may enlarge in
any way during service life. Included
are linear porosity, laps, seams and
cracks.
Acceptance/Rejection
Criteria for Liquid
Penetrant Testing of Cast
Turbine Blades
An example of how one manufacturer
handles the liquid penetrant test
requirements for gas turbine engine
turbine blades and vanes is to issue a
specification that covers the
acceptance/rejection criteria for visual,
radiographic and liquid penetrant
indications. The specification indicates
that drawings shall designate zones on the
casting identified by letters A, B, C etc.
Each of these letters (or grades) as defined
in this specification establishes different
degrees of allowable discontinuities for
visual, fluorescent liquid penetrant and
radiographic testing. The zones for each
casting are established by the
manufacturers materials engineering and
stress analysis group.
The specification emphasizes the
importance of carefully controlled liquid
penetrant testing and the necessity to
record on the technique card or other
applicable document the exact techniques
used to process the parts. In a number of
specifications, porosity bleedout diameters
are specified as accept/reject criteria.
These maximum acceptable size limits for
liquid penetrant indications apply to the
bleedout indication, viewed immediately
after wiping the indication only one time
with a swab or cloth dampened with a
suitable solvent. The recurrence of the
fluorescent liquid penetrant indication
after once wiping clean is referred to as
bleedback.
Positive surface discontinuities (excess
metal), such as mold ridge, fins, bumps
etc., generally are not considered
potential stress raisers when not
associated with severe undercutting at
their bases. These discontinuities are
permissible on turbine blade and vane
castings provided they can be removed
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TABLE 5. Typical aerospace manufacturers liquid penetrant testing acceptance and rejection criteria.
Material and
Discontinuity
Bar Stock
cracks
seams
Castings
cold shuts
cracks
porosity
sand blisters
shrinkage
Extrusions
blisters
broken surface
deep scratches
die drag
die weld cracks
cracks
inclusions
metal pick up
pitting
Forgings
cracks
inclusions
laps
Formed Part
cracks
inclusions
metal pick up
orange peel
Heat Treated
cracks
scale
Machined parts
cracks
grinding cracks
tool marks
Plate
cracks
inclusions
laminations
pitting
scratches
Sheet
cracks
inclusions
laminations
pitting
scratches
Aluminum
Copper
Nickel
Iron
Alloy
High
Temperature
Titanium
Alloy
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
N
Q
N
A
A
Q
Q
N
A
A
Q
Q
N
Q
A
Q
Q
N
A
A
Q
Q
N
A
A
Q
Q
N
A
A
Q
Q
N
A
A
Q
Q
N
A
A
Q
N
N
Q
Q
N
N
Q
A
A
Q
Q
N
N
Q
A
Q
N
N
Q
Q
N
N
N
A
N
Q
Q
N
Q
A
Q
N
N
Q
Q
N
Q
A
Q
N
N
Q
Q
N
Q
A
A
N
N
Q
Q
N
N
A
N
N
N
Q
Q
N
Q
A
Q
N
Q
N
N
Q
N
N
N
N
N
Q
N
N
Q
N
N
Q
N
N
N
N
N
Q
N
N
Q
A
Q
N
Q
A
Q
N
N
A
Q
N
Q
A
Q
N
Q
A
Q
N
Q
A
Q
N
N
A
Q
N
Q
A
Q
N
A
N
A
N
A
N
N
Q
N
N
Q
N
N
N
N
N
Q
N
N
Q
N
N
Q
N
N
N
N
N
Q
N
Q
N
A
A
N
N
N
Q
A
N
N
N
N
N
N
Q
N
Q
A
N
Q
N
Q
A
N
Q
N
A
A
N
N
N
N
N
N
Q
N
Q
A
N
Q
N
A
A
N
Q
N
Q
A
N
N
N
N
N
N
Q
N
Q
A
N
Q
N
Q
A
N
Q
N
A
A
N
N
N
N
N
N
Q
N
Q
A
A = Acceptable.
N = Not acceptable.
Q = Questionable.
156
Magnesium
Stainless
Steel
TABLE 6. Example of acceptance standards for nondestructive testing of cast turbine blades and vanes.
Grade
Visual Testing
Radiographic Testing
Grade A
No defects allowed
No bleedback allowed
No defects allowed
Grade B
Bleedback of diameter
0.4 mm (0.016 in.)
Any number allowed if clearly
separated a distance 3 mm
(0.12 in.) apart
Grade D
Same as Grade C
Grade E
Stock surfaces,
all grades
Grade C
157
(b)
158
References
159