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IS 11732 (1995): Acceptance standards for dye penetrant

inspection of steel castings [MTD 14: Foundry]

! $ ' +-
Satyanarayan Gangaram Pitroda
Invent a New India Using Knowledge

! > 0 B


BharthariNtiatakam
Knowledge is such a treasure which cannot be stolen
 IS 11732: 1995
(Reaffirmed 2000)
srrTats W;r%

Indian Standard
ACCEPTANCESTANDARDSFORLIQUID
PENETRANTINSPECTIONOFSTEELCASTING
( First Revision )
First Reprint APRIL 1997

ICS 17*140*80 : 19.100

0 BIS 1995

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

December 1995 Price Group 3

Steel Castings Sectional Committee, MTD 17

FOREWORD

This Indian Standard ( First Revision ) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Steel Castings Sectional Committee had been approved by the Metallurgical Engineer-
ing Division Council.
Liquid penetrant inspection is a physico-chemical non-destructive inspection procedure, designed to
detect and expose surface discontinuities in engineering materials. The method can also reveal sub-
surface d&continuities that have an opening to the surface to which the liquid penetrant has been
applied. It has achieved recognition as a basic non-destructive test method owing to its advantages of
rapidity, simplicity, coverage and economy with which it cm be used on a variely of materials and
shapes with minimum capital investment. The objective is to detect cracks, porosity, laps, seams and
other surface defects, rapidly and economically and with a high degree of reliability. The method is
especially useful in case of steel castings made of non-magnetic material, to which the magnetic
particle ins.pection method cannot be applied.
To aid the process of evaluation and determining the limits of acceptance of surface discontinuities
detected by liquid penetrant inspection. it was considered necessary to evolve a specification for
acceptance standards for liquid penetrant inspection.
The committee decided to revise this standard in view of the experience gained. Main modifications
in this revision are as follows:
i) The title of the standard has been changed.
ii) Standard Reference Pictures for liquid penetrant indications applicable for various levels
of acceptance of quality have been modified.
iii) Details of procedure to follow for conducting the liquid penetrant test have been modified.
While preparing this standard, assistance has been derived from the following publications:
IS0 4987 : 1992 Steel castings - Penetrant inspection - International Standards Organization.
BS 4080 : Part 2 : 1989 Specification for seventy levels for discontinuities in steel castings. British
Standards institution.
 IS 11732 .: l!F93

Indian Standard
ACCEPTANCE STANDARDS FOR LIQUID
PENETRANT INSPECTION OF STEEL CASTING
/ First Revision )
1 SCOPE 4.3 The inspection shall be carried out before
This standard determines the limits of any surface treatment like scratching, hammer-
acceptance of surface discontinuities detected ing, peening, etc. which may damage or dull
by penetrant inspection for steel castings. The the surface of metal and prevent penetration of
procedure to be adopted for this examination is the dye into .the surface discontinuities.
as specified in IS 3658 : 1981. Liquid penetrant
inspection is generally applicable to castings in 5 PRINCIPLE
finished or nearly finished state. However, it is 5.1 Contrast Colour Liquid Penetrsnt with Nom-
applicable to in-process and maintenance Fluorescent Developers
inspection as well.
In this method, a coloured penetiant liquid,
2 REFERENCES usually red, is applted to the surface to be
inspected. Excess dye is removed by washing
The following Indian Standards are necessary
adjuncts to this standard: off the surface and the surface is then dried.
Interpretation follows application of a develo-
IS No. Title per, generally suspended in a volatile liquid.
3658 : 1981 Code of practice for liquid penet- NOTE - For certain applications, in order to
minimix the risk of corrosion, the percentageof
rant t-law detection (jirst revision ) halogens and sulphur in the dye and developer
8780 : 1978 Code of practice for non-destruc- material may be restricted by mutual agreement.
tive testing of steel castings
6 PROCEDURE
3 TERMINOLOGY
6.1 Cleaning .
For the purpose of this standard, the definitions
gtven in IS 3658 : 1981 shall apply. Cleaning may be done using a wire brush or by
grinding to remove dust, dirt, scales, etc. It is
4 SURFACE PREPARATION further essential to eliminate any trace of dust
or grease .on the surface to be inspected by
4.1 The surface to be exammed shall be free
wiping with a lint-free cloth soaked tn one of
from rust, dirt, welding spatter, lumps, grease,
oil contamination, water, dust, etc. Any the approved cleaning agents, such as
trichloroethylene, acetone, alcohol, or isopropyl
roughness which could mask, or interfere with
the effectiveness of the examination shall be alcohol.
eliminated either by machining or grinding. If 6.2 Drying
it is intended to also carry out magnetic
particle inspection using a liquid ink, then the It is essential that the surface to be examined
liquid penetrant inspection shall be carried out should be completely dry prior to the applica-
first. tion of the dye penetrant and there should not
remain either traces of water or the cleaning
4.2 The surface roughness for testing shall be agent left in the defects.
as follows:
6.3 Application of Dye
Acceptance Qua!ity Surface Roughness
Level in t.bm( micron ) The dye may be applied either by immersion or
(2) paint brush or using a spray gun. The dwell
(I)
time permissible for penetration is a critical
I 6.3 or less factor. The minimum time to be allowed is
7 minutes but a longer period may be required
12.5 or less for highly polished surfaces, very fine defects,
or where temperatures are below 15C and in
25 or less such cases the time to be aliowed for penetra-
tion shall be 10 to 20 minutes. The component

C
IS 11732 : 1995

temperatures outside the range of 10 to 7.1.4 Non-Linear Indication

50C are not acceptable for such inspection
unless mutually agreed to between the manu- An indication with a major dimension less than
facturer and the purchaser. The dye should not three times its minor dimension
get dried up during the specified dwell time. ( see Annex A )
NOTE - Care should be taken to see that the test
materials do not penetrate to inaccessible parts 7.1.5 Aligned Indications
( threaded holes, for example ) from which they
cannot be clean-d after completion of the test. Indications ( linear or non-linear ) at least
6.4 Removal of Excess Dye three in number, that are in a line and separa-
ted, one to the next, by a distance of less than
After the elapse of specified period of time 2 mm ( see Annex A ).
for the penetration, excess dye must be removed
from the surface in order to obtain an indica- 7.2 Evaluation of Indications
ting contrast. Care must be taken for the dye
lying in the defects not getting washed in 7.2.1 All indications in doubts must be treated
the process. The excess is thus removed by as potential defects and re-examined to check
using water or a suitable solvent which is at the presence or the absence of a real defect.
a temperature below 50C and a pressure less A prior re-dressing of the surface is envisaged.
than 3.5 kPa ( see 6.1 ). However, the surface
should not be flushed with the cleaning 7.2.2 Vague indications and areas of coloura-
medium The surface should be dried imme- tion which could mask defects shall be trealed
diate!y and the developer applied. as unacceptable.
6.5 Application of Developers 7.2.3 Indications having major dimension
It should be applied .preferably by a spray gun smaller than the limits given in Table I, under
having been mixed or shaken immediately prior the column hceading Major dimension of
smallest indication considered for each severity
to application in order to ensure a uniform
level, shall not be taken into consideration and
suspension in the solution. Other techniques of
shall not be treated as significant.
application are permissible if, by their use, one
can apply a light coating of uniform thickness
7.2.4 All significant indications shall be evalua-
without disturbing the dye lying in the defects.
ted as per the limits specified in Table 1.
The application of a thick layer needs to be
avoided in the process. The dwell time for the 7.2.5 It is to be considered that dye penetrant
developer should be at least 1.5 times the dwell inspection like all methods of non-destructive
time specified for applied dye. inspection, forms a part of an overall assess-
ment of quality of a casting and may not be
6.6 Examination
treated as the sole criterion of acceptance.
In view of the rapid diffusion of dye into the
developer, it is preferable to examine the sur- 8 ACCEPTANCE LIMITS
face twice, once immediately after the applica-
tion of the developer and a second time 11 to 8.1 Castings are classified into five quality
15 minutes later. The indicated areas of defects levels, 1, 2, 3, 4 and 5 as given in Table I
are assessed at the abovesaad second stage and according to the maximum permissible size and
the overall time for the examination should not, number of indications. Each inspected area
in any case, be delayed beyond 30 minutes from shall be judged and classified into different
the time of application of the developer. levels by direct visual comparison with the
acceptance standards detailed in Table 1 and
7 INTERPRETATION OF RESULTS shall be classified as levels I to 5, in descending
7.1 Definitions order of quality ( see Fig. I to 5 ).

7.1.1 Indication 8.1.1 a) A frame measuring 105 mm x 148 mm

Any dye stain revealed by the application of shall .be moved over the area under
the developer. inspection. The severi!y level shall
abe determined by assessment of the
7.1.2 Positive Indications discontinuity indications that appear at
Jndicutions that result from metal discontinui- any one time within the frame.
ties.
8 When calculating the cumulative
7.1.3 Linear Indications length of discontinuity indications,
An indication with a major dimension three or both aligned and non-aligned indica-
more times its minor dimension (see Annex A ). tions shall be taken into account.

2
 Table 1 Maximum Perrpissilale Extent of Indications
( CIauses 1.2.4, 8. I and 8.3 )

Nom-linear Indications Linear Inflicntiqs or Aljgqed

T-------_A_---- up---_-------- *-----__---___~
Obscrr- Major Number Maxi- Wall Thickness Wall Thickness Wall Thickness
ing.Indi- Dimen- of Indi- mum of Casting Less of Casting from of Casting Over
cations sion of cations Major than 16 mm$ 16 to 50 mm: 50 rnrnt
Smallest Dimen- p- .- -*- -_7 c--_*__-_Y - ._-_*__-_~
lndica- sions of Isola- Cumula- Isola- Cumula- Isola- Cumula-
tion Indivi- ted tive ted tive ted tive
Consi- dual indica- indica- indi- indi- ind i- indi-
dered Indi- tion tion cation cat ion cation cation
(mm) cationt
(3) (4) (5) (6) (7) (8) (9) (IO) (11) (12)
mm mm mm mm mm mm mm mm
15 8 3 2 4
20 6 1; IS ::
XI 30
50
100
* The criteria for severity levels 1 and 2 are extremely difficult to achieve except on precision castings and
should be specified with caution.
t Schematic illustrations concerning non-linear indications for each of these severity levels are given jn
Annex A for information, which is intended only as a guide.
$ For an area involving joining of more than one section thickness, the operative thickness shall be taken
as the thickness of the thinnest joining member.

c) The reference area for comparison 9 RECORD OF RESULTS

may be chosen so as to make it reflect
the lowest quality level attributable. If so specified at the time of enquiry and order,
the manufacturer shall furnish to the purchaser
8.2 The maximum permissible discontinuities the results of Liquid Penetrant Inspection
relate to the quality level as indicated in the carried out showing, for each casting or part
enquiry and order ( or drawing ). thereof, the following:
8.3 A set of reference pictures are given in a) the identity of the casting;
Annex A to illustrate different quality levels.
These reference pictures are for information b, details of the technique used;
only and the actual classification shall be in c) the manufacturing stage at which the
accordance with Table 1. inspection was carried-out;
NOTE - Provided that the frame of 105 mm x d) the identity and qualifications of the
148 mm does not contain discontinuities which exceed person carrying out the inspection; and
the severity level specified in the order, there is no
limit to the extent of discontinuities acceptable in c) all discontinuities in excess of the speci-
the total area under inspection. fied severity level.

-
IS 11732 : 1995

ANNEX A
( Clauses 7.1.3, 7.1.4, 7.1.5, 8.3 and Tublc 1 )

TYPICAL DISCONTINUITY DISTRIBUTION FIELDS FOR NON-LINEAR INDICATIONS

Table 1 should be consulted for exact details of allowable size and the number of indications.

Circular Linear Aligned

SR 1
8

l
6
I

. l l
0
0

.
.
. 4 l

SEVBRITYLEVELSR 1 EIGHT NON-LINEAR INDICATIONS,1.5 mm < D < 3 mm

-
 IS 11732 : 1995

SR 2

a
.
.
a

.
,

0 .

0
l .
0

--- .m.-

LEVELSR2 EIGHTNON-LINEARINDICATIONS.,
SEVERITY D>2 mm

SR 3
0 v
e 0
e

m .
.
0
0 . . .
$
. 0

SEVJZRITY SR3 TWELVENON-LINEAR~NDICATIOM,D > 3 mm

LEVI~L
5
 8 6

SWERITY LEVEL SR 4 TWENTY NON-LINEAR INDICATXOM, D> 5 mm

SR 5

l @

.
.
l
l
l

a
Qnb

0
l

. .
9
l

ulb
-- - _.-

SEVERITYLEVEL SR5 EIGHTY Two NON-LINEAR INDICATIONS, D > 10mm

6
Bureau of Indian Standards

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harmonious development of the activities of standardization, marking and quality certification of goods and
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Enquiries relating to copyright be addressed to the Director (Publication), BIS.
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Review of Indian Standards

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periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
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ofBIS Handbook and Standards Monthly Additions.
This Indian Standard has been developed from Dot: No. MTD 17 (3989).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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