PENETRANT TESTING (PT) – SKM Level 2 Direct Access – MC-112-2 – PTPK SCHEME

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PENETRANT TESTING (PT)

In Liquid Penetrant, the test object or material is coated with a visible or fluorescent dye solution. The excess dye is removed from the surface and a developer which acts like a blotter is applied drawing penetrant out of imperfections open to the surface. With visible dyes, the vivid color contrast between the penetrant and the developer is used. With fluorescent dyes an ultraviolet lamp is used to make the ‘bleed out’ fluoresce brightly allowing the imperfection to be seen readily.

TYPICAL APPLICATION
– Inspection of Castings
– Inspection of Forgings
– Inspection of Welds
– Inspection of Aerospace Components

INDUSTRIES THAT USE PENETRANT TESTING
– Service Inspection Companies
– Smelters & Foundries
– Rolling & Forging Mills
– Petro Chemical & Refineries
– Mining & Mineral Processing
– Aircraft Maintenance & Manufacturing
– Vehicle Maintenance & Manufacturing
– Government Bodies
– Engineering Firms
– Research & Development Facilities
– Education & Training
– Equipment Manufacture & Sales
– Maintenance, Service & Repair of Equipment

COURSE DESCRIPTION
The course provides a full appreciation in the techniques and methods of penetrant testing. A high theory and practical content is offered by the course. The course will suit a wide variety of NDT personnel including QC inspectors and technicians and relates to the inspection of forging, casting and welded structures.

WHO SHOULD ATTEND
This course is opened to all participants, in participant NDT personnel, supervisors, NDT trainers, contractors and researchers and those who are interested in Liquid Penetrant Testing technique.

SCOPE
This course covers the principles of Liquid Penetrant Testing and prepares a candidate to
• Select equipment to conduct test
• Setup test equipment
• Steps to conduct test
• Familiarize with codes and standards
• Interpret results with respect to applicable codes and standards
• Understand limitation of the test method
• Write test reports.

TRAINING
Training material is presented in modules that are followed by quizzes

PERSONNEL CERTIFICATION SCHEME
Sijil Kemahiran Malaysia (SKM) Level 2
Training, experience and examination requirements
Training Requirements
• Recommended Course Outline
• Training Hours
• Practical
• Quizzes and examinations

MODULE 1: MANUFACTURING DISCONTINUITIES
• Types of Discontinuities: Inherent, Processing and Service
• Casting Discontinuities: Hot Tear, Cold Shut, Porosity, Shrinkage
• Primary Processing Discontinuities including discontinuities in Rolling,Forging, Drawing, Extruding
• Secondary Processing Discontinuities including discontinuities in Grinding, Heat Treating, Machining, Welding, Plating
• Service Discontinuities:- Erosion, Wear, Fatigue, Corrosion, Creep

MODULE 2: PRINCIPLES
• Purpose of Liquid Penetrant Testing
• Physical Principles
• Wetting Characteristics and Contact Angle
• Wetting Ability
• Force of Cohesion and Surface Tension
• Capillary Action
• Viscosity
• Reversed Capillary Action
• Visibility of Indication
• Categories of Test Processes
• Types of Dye: Type I (Fluorescent) and Type II (Visible)
• Methods of Removal of excess Penetrant including Water Washable, Emulsifiers and Solvent Removable
• Sensitivity Levels – ½, 1, 2, 3, 4
• Selection of Process
• Limitations of Penetrant Testing

MODULE 3: BASIC STEPS
This module covers the basic steps involved in the following processes
• Method A – Water Washable
• Method B – Lipophilic Emulsifier
• Method C – Solvent Removable
• Method D – Hydrophilic Emulsifier

MODULE 4: PRE AND POST CLEANING
• Choice of Cleaning Method
• Different Cleaning Methods including Detergent, Solvent, Alkaline, Steam, Ultrasonic cleaning, Vapor Degreasing

MODULE 5: APPLICATION OF PENETRANTS AND DEVELOPERS
• Selection of Penetrant Materials

• Cleaner/Remover
• Penetrant
• Developer
• Selection based on family

• Application of Penetrant
• Standard Temperature Limits
• Dwell time
• Drying
• Drying Parameters
• Drying Time Limits
• Application of Developers

• Types of Developers

• Aqueous
• Non-Aqueous

• Developing Time

• Fluorescent Inspection

• Black Light Warm Up Time
• Minimum intensity and light meter
• Visual Adaptation

• Visible Inspection

• Minimum light intensity and light meter

• Post Cleaning

• Limitation of Penetrant Testing

MODULE 6: INTERPRETATION
• Interpretation of Test Results
• Flow Chart for Interpretation
• True, False, Relevant and Non Relevant indications
• Categories of Indications: – Rounded and Linear
• Evaluation of Indications
• ASTM E-433 Reference Photographs of Indications types

MODULE 7: CODES & STANDARDS (Specific Training)

Codes
• ASME Section V, Article 6
• ASME Section VIII, Appendix 8 (Accept/Reject Criteria)

Standards
• ASTM E-165 Standard Practice for Liquid Penetrant Examination
• ASTM E-1209 Fluoroscent Water Washable Liquid Penetrant Testing
Other codes and standards can be discussed at the request of the students.
Please make such requests at time of registration

PRACTICAL TRAINING
Test on component and weld samples

Visible
• Solvent Removable

Fluorescent
• Water Washable
• Solvent Removable
• Emulsifier both Hydrophilic and Lipophilic
• Tests on component and weld samples

EXAMINATIONS
• General
• Specific
• Practical Tests

Candidates must score a minimum of 70% in each examination

General Information

Recommended Pre Course Study
– Not Applicable