INSTRUCTION No. I.O. NP /I

Transcription

1 Appendix o. 6 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. ISTRUCTIO o. I.O. P /I For FPI testing of engine parts and aviation components Approval: Level 3 PT Position First and last name Date Signature Written by KDT Manager Piotr Wróbel Checked by Member of the Executive Board Krzysztof WAWRZYK Approved by President of the Board Managing Director Leszek WALCZAK

2 for FPI testing of engine parts (ame of documentation) ISTRUCTIO o. I.O. P /I (o. of document) Appendix. o. 4 to instruction Publishing of Internal ormative Acts Page o. 2 Of pages 49 Item o Modification Cards MODIFICATIO CARD REGISTRATIO SHEET Oper. o. Sheet no. Date of introduction In force from Introduced by (name) Signature and stamp Position ame Signature Date Revision Revision no. Date Signature

3 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. TABLE OF COTETS Page 1 OBJECTIVE OF THE ISTRUCTIO 4 2 SCOPE 4 3 APPLICABILITY 4 4 REQUIREMETS AD REFERECE DOCUMETS 6 5 TERMIOLOGY, DEFIITIOS AD ABBREVIATIOS 6 6 PERSOEL QUALIFICATIOS 9 7 CLASSIFICATIO OF PROCESSES 10 8 TYPE OF FLUORESCET TESTIG 12 9 EQUIPMET DESCRIPTIO OF THE PROCESS ITERPRETATIO OF IDICATIOS PERIODIC CHECKS SAFETY TECHIQUES REGULATORY PROVISIOS RELATED DOCUMETS LIST OF APPEDIXES 49

4 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 1 OBJECTIVE OF THE ISTRUCTIO The purpose of this process instruction is to determine the methodology and to compile the materials used in the penetrant method for detecting external defects (open to the surface, e.g. cracks, pits, etc.) and to ensure the quality of the process. 2 SCOPE This instruction contains the rules to be followed when testing using penetrant materials in Wojskowe Zakłady Lotnicze r 4 S.A. in Warsaw. 3 APPLICABILITY 3.1 This instruction is used by the on-destructive Testing Department for aviation parts and turbine components of the engine after their overhaul, for which WZL-4 S.A. is responsible. The instruction is limited to the detection of surface discontinuities through the use of capillary phenomena, in which penetrants with high wettability are used. 3.2 Advantages of penetrant testing - Liquid penetrant inspection is able to explore all external surfaces of the part. Geometrically complex parts can be dipped or sprayed with the penetrant to completely cover the surface. The entire area of the tested part must be covered with penetrant. - It applies to parts and fasteners of various shapes, for the entire surface or locally. It is used for the receipt, during production, final inspection, or in the testing of repair/overhaul parts. - Penetrant testing is able to detect very small surface discontinuities. It is one of the most sensitive non-destructive testing method for the detection of surface flaws - This method can be used to control various materials: ferrous and nonferrous metals, fired ceramics, glass and other types of non-porous materials. - Testing is carried out by means of relatively inexpensive, simple equipment. If there is a need for testing a small area, you can use portable equipment. - With the ability to "spill over" (creep), penetrant testing increases the size of the existing discontinuities causing that they are more visible to the operator. Also, the location, orientation and approximate length are visualized on the surface, making it possible to evaluate and measure. - Penetrant testing allows you to control 100 percent of the accessible surface. Small parts can be placed in baskets used in the immersion method. Larger parts can be covered with the penetrant by spraying.

5 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. - Sensitivity of the penetrant testing process can be adjusted by the selection of materials and techniques. This allows the suppression of the indication of small, non-significant discontinuities, indicating larger ones. 3.3 Disadvantages and limitations of penetrant testing - Penetrant testing depends on the ability of the medium to penetrate and fill the discontinuities with the penetrant. Penetrant testing reveals only discontinuities open to the surface. - Porous materials are not suitable for liquid penetrant testing because the penetrant trapped in the pores produces excessive fluorescence background and reduces the contrast which results in masking of potential discontinuities. It may also be possible to remove penetrant from the surface after penetrant testing. - The surfaces of tested parts must be clean and free of organic and inorganic contaminants, which will stop the penetrating properties of the penetrant. It is also important that the surface discontinuity is free from materials such as corrosion, combustion products or other impurities which reduce penetrant permeation. - Penetrants are generally oil-based materials with strong characteristics of solvents and highly concentrated dyes. Therefore, they can attack some non-metallic materials such as rubber and plastics. There is also the possibility of permanent dyeing of porous or coated materials. ATTETIO: - Due to the oil characteristics of most penetrants, the penetrant testing process cannot be used on elements such as assemblies, where the penetrant cannot be completely removed, then it may come into contact with gaseous or liquid oxygen. Oils, even in residual quantities, can explode and burn very quickly in the presence of oxygen. When it is not possible to completely remove residual penetrant materials, only materials specifically approved for this purpose can be used and applied if penetrant testing of such assemblies is required. Any use of these special oxygen compatible materials should be agreed with the authorized design department. - Some penetrant materials may contain sulfur and/or halogen compounds (chlorides, fluorides, bromides and iodides). These compounds, if not completely removed prior to heat treatment, can cause brittleness or cracking of austenitic stainless steels. Trapped halogen compounds, if not completely removed after the completion of testing, can corrode titanium alloys, if the element is subjected to elevated temperatures. The use of these materials should be agreed with the authorized design department. 3.4 If there is a contradiction between this instruction and specifications, design drawings, instruction sheets, instructions or other detailed document, a design drawing with specifications, client instructions or instruction sheets take precedence.

6 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 3.5 The information contained in this instruction l comply with the requirements specified in the ASTM E-1417 standard and classification according to SAE AMS-2644, QPL AMS However, ASTM-E1417 cannot be used as a substitute for this instruction. 4. REQUIREMETS AD REFERECE DOCUMETS ASTM E Standard procedure for penetrant testing E Aerospace. Qualification and approval of non-destructive testing personnel AS410 - Certification and qualification of personnel for non-destructive testing by AS 5. TERMIOLOGY, DEFIITIOS AD ABBREVIATIOS WZL-4 S.A Wojskowe Zakłady Lotnicze r 4 Spółka Akcyjna in Warsaw DT - on-destructive testing. Penetrant It is a liquid with high wettability and low surface tension, penetrating into all available openings (slots) based on a capillary phenomenon. Fluorescent penetrant It is a liquid with high wettability and low surface tension, penetrating into all available openings based on a capillary phenomenon. It contains a dye, usually yellow - green, which fluoresces in ultraviolet radiation, giving a sharp, clear indication. Fluorescent penetrant post emulsified that means washable with water after using the emulsifier (Method D) - does not wash off with water directly, but only after the application of an emulsifier and forming a water washable emulsification. Fluorescent penetrant solvent washable (Method C) Penetrant, the excess of which is easily removed from the surface of parts using an approved solvent. Emulsifier It is a chemical which, when combined with excess penetrant on the surface, forms a suspension washable with water. Hydrophilic emulsifier - type of detergent remover. Available as a concentrate for dilution with water (water spray force acts as abrasion, detergent detaches and removes the penetrant from the surface).

7 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Emulsification time The period of time between the application of the emulsifier and the start of the washing process. Penetration time (dwell time) This is the saturation time, -dwell time, -contact time of the penetrant with the part surface - it is the shortest time necessary to fill the discontinuity by the penetrant. Dwell time is counted from the moment of contact of the penetrant with the tested surface until its excess is removed. In the immersion method, penetration time consists of the time of immersion of the part in the penetrant and the dripping time. Dripping time The period of time between the end of applying the penetrant and the end of the run-off of excess penetrant from the surface Contact time A time period during which the parts are in contact with products used for testing Developer It is a substance highly absorbing the penetrant, applied to the test surface after the removal of the penetrant, it has a color contrasting with the color of the penetrant. Development Interaction of the developer with the penetrant, based on the capillarity phenomenon, causing the removal of the penetrant from open discontinuities and making it flow in the developer, the easier the rougher the tested surface. on-aqueous solvent-based wet developer (type "d") Developer mixed with a liquid which is a solvent or alcohol. The carrier liquid evaporates very quickly, allowing for rapid formation of a dry developer film on the surface. Dry developer (form "a") Dry, dusting powder, without the carrier, applied directly on the test surface after drying. It has strong hygroscopic properties. Development time Contact time of the developer with the part's surface, sufficient to remove the penetrant from the discontinuity and necessary to create the enlarged indications, i.e. defectograms. It is calculated from the time the application of the developer (immediately after drying the part) until observation. Fluorescence Emission of visible light by the penetrant, which appears only when it absorbs invisible UV light.

8 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. UV-A light Ultraviolet radiation, invisible to the human eye, with low wavelength ranging from 320 nm to 400 nm with a peak at 365 nm. Refers to both conventional lamps and LEDs. Electrostatic technique (method) It involves spraying the penetrant and the developer on the surface to be inspected. Parts to be inspected are negatively charged, while the products sprayed are positively charged. The force of attraction between the part and the materials provides an effective, uniform and thin layer covering the part's surface. Immersion technique (method) It consists of immersing the tested parts in a container/tub with penetrant materials. Application of penetrant materials occurs through direct contact. Indication Visible trace of a flowing penetrant. It can be classified as significant, insignificant or false. False indication An indication present on the surface but not due to the presence of a discontinuity. Insignificant indication (non relevant) An indication associated with a discontinuity in the material (acceptable) Significant indication (relevant) An indication associated with a discontinuity (not acceptable) Indication size The actual physical dimension of the defect; it may be its depth, length of the surface or diameter for rounded indications or a radius for half-round indications or angular indications having properties of passing through the wall. Interpretation The act of interpreting indications. Evaluation Comparing the received indications with the acceptance criteria in order to determine whether it is a defect or not. Linear indication Penetrant indication with the ratio of length to width of at least 3:1

9 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Rounded indication Penetrant indication with the ratio of length to width of less than 3:1. Mostly they are equal. Discontinuity Disruption of the continuity of the material's structure. Defect Discontinuity that impacts the performance parameters of the product. Calibration Setting the measurement characteristics of the device compared to the standard. Tam Panel PSM5 A plate consists of two areas, in which one is covered with electroless nickel plating with a thin layer of chromium, while the second area has been prepared to achieve an area of a certain roughness. The area coated with chromium has 5 artificial discontinuities in the shape of stars, which in their character are cracks of a certain size. 6. PERSOEL QUALIFICATIOS 6.1. Personnel performing non-destructive testing should be approved, qualified and comply with the requirements of P-E4179 / AS 410 and specific customer requirements. Qualifications relate to the tried and proven ability of the personnel to meet all the requirements of the relevant standards related to the training and approval of DT personnel. These qualifications relate to the physical abilities, professional experience, practice, knowledge and training, completed with the required examinations and obtaining a qualification level in the given method. A document confirming the qualifications must contain an authorization from the employer to allow the execution of tasks related to the activities corresponding to the requirements for the given qualification level in the company. Personnel preparing Instructions Sheets Fluorescent Testing (Work Instructions) must at least have the Level 2 certificate. Personnel preparing the instruction (methodologies, personnel approving the Instructions Sheets for Fluorescent Testing), and personnel supervising all the work related to PT must have the Level 3 certificate in the method. The decision to accept / reject a part is taken by the operators with at least Level 2 qualifications in the method. Supervision of DT personnel in regard to qualifications and the validity of approvals is exercised by the Responsible Level 3. The principles described in the procedure Written Practice o. I.O. J /I 6.2. Eye examination Applies to all operators once a year according to the requirements of P-E4179 / AS 410. The principles described in the procedure Written Practice o. I.O. J /I

10 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 7. CLASSIFICATIO OF PROCESSES CODUCTED WITH PEETRAT MATERIALS APLICATIO I WZL r 4 S.A. All new and incoming materials for penetrant testing should be inspected by the Level 2 operator in the given method. Inspection involves verification that products are identical in terms of batch number, checking for the presence of a Safety Data Sheet and Certificate of Conformity supplied by the given manufacturer / supplier for compliance with the requirements of SAE AMS2644. Expiration date of the material shown on the Certificate of Conformity shall also be verified. After verification, the Level 2 operator certificated for the given method marks the Certificate of Conformity with a personal stamp. Certificates of Conformity, like all other quality records, should be archived for a minimum period of 10 years. penetrant materials, excluding dry developers, must be kept away from the impact of sunlight in the temperature from 0 0 C to 55 0 C. Products not used during their period of validity should be scrapped. In each case, if new penetrant material from a new batch is added to the tanks, a test of the effectiveness of the penetrant system should be carried out. Based on AMS 2644, there is the concept of a "a family system" of penetrant materials. A "family system" does not allow for mixing penetrant materials together (penetrants, cleaners, emulsifiers or developers) of different types or from different manufacturers. Example: solvent remover from manufacturer "A" cannot be mixed with the solvent remover from manufacturer "B". The penetrant family system is defined as a system of penetrant and emulsifier together, originating from the same manufacturer. AMS 2644 requires that a penetrant/emulsifier combination was selected and used jointly for both materials. For methods using washing with water and using degreaser solvents, the system of a "family" contains the penetrant itself. Washes and solvent developers are classified separately and can be used with any qualified penetrant system. Therefore, a post-emulsified penetrant system from one manufacturer can be used with any developer; a solvent washable penetrant system can be used with any solvent and developer; a water washable penetrant system can be used with any developer (approved for a system washable with water). The materials, however, must be qualified and be on the QPL AMS 2644 list. It may happen that there are inconsistencies between the specialized penetrant systems and developers. In such a case, follow the instructions of the manufacturer and the provisions of AMS Penetrant materials made by Magnaflux used at WZL r 4 S.A. meet the requirements of SAE AMS 2644 and are on the list of qualified suppliers (QPL AMS 2644). Appendix 3 shows the classification of materials according to ASM 2644

11 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. There are the following types, methods and levels of sensitivity of penetrants used at WZL-4 S.A. TYPE: Penetrant type: TYPE I - fluorescent penetrant Method of removal: METHOD C - penetrant ZL27A from Magnaflux removable with SKC-S solvent METHOD D - penetrants: ZL27A, ZL37 from Magnaflux washable with water after application of a hydrophilic emulsifier ZR10B (or ZR10C). Sensitivity level: Sensitivity level 3 - high (using penetrant ZL27A) Sensitivity level 4 - very high (using penetrant ZL37) Developer: Form "a" - dry powder ZP-4B from Magnaflux Form "d" - ZP9F, from Magnaflux, non-aqueous, wet, solvent-based Removers: Class 2: SKC-S remover from Magnaflux. on-chlorinated. ATTETIO: Using penetrants type II (visible) is prohibited during the inspection of aircraft components if it is not specifically recommended and described in detail in a separate instruction approved by the Level 3 operator in the method method. When applying penetrants type II, the use of a developer in form "a" is prohibited. Using Method A (water washable penetrants) is prohibited during the inspection of critical aircraft components and engine components. Their use is allowed only after obtaining special written authorization from the engineering department. Using Method B (post-emulsified lipophilic penetrants) is prohibited for use during the examination of critical rotating engine parts. Unless otherwise specified in the client's technical documentation and the specific Inspection Instruction Cards, use sensitivity levels as shown in Table 1

12 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. PRODUCT FORM (all materials) Table 1. Choice of penetrant system Sensitivity level of the penetrant / system* Method Detection of cracks in overhaul parts. Components of aircraft engines. Sensitivity level 3 or sensitivity level 4 Critical consumables Sensitivity level 4 D Local testing Sensitivity level 3 C D *The choice of the test method for each client of WZL-4 may be different than shown in Table 1. The method used for each part is specified in the Fluorescent Inspection Instruction Card, consistent with the documentation / instructions for the manufacture of the given part. 8 TYPE OF FLUORESCET TESTIG. APPLICATIO METHOD OF PEETRAT MATERIALS Table 2. Methods of application of penetrant materials: Methods / techniques of application Penetrant by electrostatic spraying aerosol spray - for local applications Emulsifier by immersing the part using baskets Remover aerosol spray Developer by electrostatic spraying - form "a" using spray - for local applications - form "d" 8.1 General requirements A valid certificate of conformity issued by the manufacturer should be place on all tanks with penetrant materials. In addition, all tanks with penetrant materials must be labeled with information: - Kind of penetrant material - ame of the manufacturer, - Batch number. - Expiration date of penetrant materials All stations should always be kept clean. After completing work, all tubs and drip stations must be covered.

13 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Covering prevents dirt, dust, and other factors that may have a negative impact on the quality of materials used from getting into the tubs with penetrant materials and dripping stations. The tubs should be separated from each other, not to cause mixing of penetrant materials Compressed air should be filtered from the oil. Quantities of penetrant materials in the tanks must be kept at a constant level, necessary to completely submerge parts during penetrant testing. The minimum level of penetrant materials should be marked on each of the tubs used. In the case of lowering the level of materials, it is mandatory to replenish depleted materials with new ones. In the case of replenishing that exceeds 50% of the volume, penetrant material should be treated as new. Penetrant baths in tubs must not be mixed to avoid excitation of sediment at the bottom of the tank, 8.2 Method of electrostatic penetrant spraying This line includes: Electrostatic gun for spraying penetrant, Water gun (or air-water gun) to remove excess penetrant, Air gun to remove excess water Tub with emulator (application by immersion) Dryer for drying parts Electrostatic gun for spraying dry developer, Air gun to remove excess developer 8.3 Method of spraying using aerosol sprays. This method is used to control the part, where for technical reasons, the electrostatic spraying or immersion method is impossible in a traditional laboratory (e.g. the overall dimensions of the part are too large). It can be used also for local testing in cases where there is no capacity to perform fluorescent testing using stationary equipment. Penetrant materials used are in pre-packaged spray-type containers.

14 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 9 EQUIPMET The following equipment is used during the process of penetrant testing: Electrostatic system for applying penetrant / developer Tub with hydrophilic emulsifier (immersion) Stations for washing off excess penetrant from the surface of the part Water gun Water-air gun Air gun to remove excess water from depressions in the part UV lamp, hand-held or stationary: - Only lamps with a wavelength of nm, with max. peak at 365 nm are permitted. - Mercury vapor lamps with power of at least 100 watts equipped with appropriate filters limiting wavelengths - also long-wave visible light and LED lamps are acceptable for use in the inspection process. - Maximum power of the lamp at a distance of 15 inches (38 cm) may not exceed 10,000 µw/cm 2. Lamps with a higher power cannot be used in the inspection process. - Only lamps with an effective beam diameter of at least 3 inches with an intensity greater than or equal to 1000 µw / cm2 from a distance of 15 inches (38 cm) measured from the lamp filter may be used. Spotlights and lamps with a focused light beam are unacceptable. Water temperature sensor and indicator Part temperature sensor and indicator In addition: 1) Control samples type PSM-5 UV-A meter (radiometer), Lux meter to measure the intensity of white light, 2) TAM Crack Comparator (TAM ) for quick comparison of the size of indications received by penetrant, 3) White light lamp with intensity of at least 2000 lux. 4) Refractometer for measuring the concentration of hydrophilic emulsifier, 5) stopwatches to control the time parameter of individual operations, 6) Photofluorometer to measure the brightness of the penetrant (this measurement can be outsourced to other approved laboratories), 7) Manometers for water and air pressure. 8) Dryer temperature sensor, dryer temperature controller 9) Compressed air filter.

15 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 10. DESCRIPTIO OF THE PROCESS FLUORESCET ISPECTIO - general principles. Brief diagram of a typical penetrant process (method D). Before the following steps, it is necessary to effectively clean the surface of the part. 1. Application of the penetrant: 2. Removal of excess penetrant, prewash: 3. Application of the emulsifier 4. Effect of the emulsifier, and effect of detergent molecules on the penetrant Moving the solution or basket 5. Main wash 6. Clean surface:

16 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. 7. Drying 8. Development Testing with liquid penetrant is a non-destructive method for detection of surface discontinuities through the use of the capillarity phenomenon, which uses penetrants with high wettability. Fluorescent testing should be performed after all machining operations, which may cause or may reveal discontinuities coming to the surface. For some materials, such as steel parts made of corrosion-resistant steel and PH steels, the design drawing may require that the penetrant tests are performed with magnetic tests. In this case, fluorescent testing must precede magnetic testing and the results, if not indicated otherwise in the drawing, they should be regarded as complementary. 100% of the part's surface has to be inspected, unless the client's requirements indicate otherwise. 100% of the parts from the batch has to be inspected, unless the client's requirements indicate otherwise. Details are contained in the Fluorescent Testing Instruction Sheet. FLUORESCET TESTIG ISTRUCTIO SHEET / TECHIQUE / WORK ISTRUCTIO List of parts for inspection and requirements are included in the Documentation for the given product in electronic form in English, or constitute a separate Technical Documentation in Polish, containing the Fluorescent Testing Instruction Sheet for individual parts from the list. Fluorescent Testing Instruction Sheets are developed by the Level 2 operator in the method (if authorized to do so in the Employee Work Sheet). These sheets must be approved by the Level 3 operator.

17 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. As a minimum, it is required that the Instruction Sheets contain the following information: Identification of the process instructions, Identification of personnel with at least Level 2 qualifications, which drafted the Sheet and Level 3 qualifications, who approved the Sheet Identification of the minimum level of qualifications required to perform the test and carry out the qualification of defects, Identification of the part - part number, drawing number, material, product, Areas of the part that are subject to inspection (or designation of 100% of the part's surface) Preparation of the part's surface for fluorescent testing (surface cleaning). The relevant materials and parameters must be used specified. Type of materials used for testing and their classification according to AMS2644 Full process parameters: method of application of the penetrant, temperature of penetrant materials and parts, residence time in the penetrant, temperature and pressure of cleaning water, emulsifier concentration, drying temperature and time, development time, level of UV and white light radiation, Auxiliary materials, equipment used. Criteria for acceptance or rejection of parts or reference to other documents. Methods for marking/stamping parts - if they apply for the given part (location of the defect, if found, is subject to marking, stamping is not required for overhaul P&W parts) Cleaning parts after penetrant testing. Instruction Sheets should be prepared for each of the parts tested. If the testing method, test parameters, material group, part class, surface preparation, acceptance criteria for the parts have not changed - it is permitted to use a summary Instruction Sheet for larger groups of parts with different manufacturing numbers for the same product. 100% of the part's surface has to be inspected, unless the client's requirements indicate otherwise. 100% of the parts from the batch has to be inspected, unless the client's requirements indicate otherwise. Details are contained in the Fluorescent Testing Instruction Sheet. SEQUECE OF ISPECTIO The inspection process using liquid penetrants should be performed after each of the operations that can cause the occurrence of surface discontinuities (e.g. bending, forming, welding) and before each operation, which could mask potential discontinuities open to the surface (tumbling, grinding, etc.).

18 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o Preparation of the part's surface for PT inspection All surfaces to be tested should be clean, dry and free of soil, oil, fat, paint, chemical coatings, corrosion, scale, grease, flux, chemical residues or other material that could prevent the penetrant from penetrating discontinuities. Proper preparation of the part's surface for penetrant inspection is a critical activity. Effective detection of discontinuities during the penetrant inspection depends on the ability of the penetrating penetrant to enter and exit the discontinuity. The surface condition such as chemical coatings or contamination with dirt reduces the effectiveness of the inspection process by blocking the entry of the penetrant into the discontinuities. Penetrant inspection is effective only when the surface of the part is free from contamination. The DT operator performing the fluorescent testing is responsible for the preparation of the surface for PT testing in terms of alkaline degreasing and removal of contaminants such as dirt, oil, etc. (pre-cleaning). The process of preparing the surface boils down to: Carrying out the cleaning process in a correct manner, Checking the quality of the cleaned surface (there can be no traces of contaminants, such as dirt, oil, which could disrupt the correct process of penetrant inspection). For this purpose, use gloves so as not to contaminate the surface of the part). If the parts are not clean enough, repeat the cleaning process. IMPORTAT: Parts requiring more extensive cleaning should be transferred to the relevant department carrying out the cleaning and/or department responsible for corrosion control. DT personnel is not authorized and does not carry out operations like etching the part's surface, if they are not authorized and trained to carry out such operations. Cleaning methods appropriate to the type of parts and type of contamination used for each of the inspected parts are included in the Instruction Sheets. Examples of light impurities and dirt: - Hydraulic oil or lubricating oil - Coolant used during chemical treatment - Thin lubricants (e.g. vaseline) - Anti-corrosion coatings An effective method of removing these types of impurities is cleaning the surface with solvent or aqueous alkaline degreasing. Examples of heavy impurities and dirt: - Viscous oil - Thick layers of grease - Thick layer of a corrosion protective coating - Lubricant particles, such as graphite

19 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. An effective method of removing these impurities is the use of solvents or chemical cleaning combined with mechanical cleaning. Mechanical cleaning can be performed by instruction scrubbing or spraying cleaning fluid under pressure. Removal of heavy oil requires substantial mechanical cleaning. Excessive force can cause the phenomenon of smearing of the metal above narrow discontinuities - which is not preferred. Examples of contamination by coal, paint and other sealed contaminants: - Partially burned kerosene and other products of combustion - Remnants of vaporized fuel and oils - Dry lubricant coatings These impurities can be baked on the surface to form a glassy coating. An effective method of removing those hard to remove contamination is the use of special solvents and alkaline products for removing impurities baked on the surface. There are many products for removing paint, but they do not work on baked impurities. Strong mechanical cleaning may be required to remove such contaminants, such as scrubbing, spraying fluid under high pressure. However, be careful, because many cleaning compounds can attack metals and alloys. Contamination such as oxides, corrosion: Oxides are generally present as a result of high temperature. Inadequate cleaning method can cause destruction of the part's surface. Only trained personnel can select or use the given cleaning methods. This training must be documented in the training records. An effective method for removing those hard to remove impurities is aggressive cleaning, such as acid etching, abrasive blasting or other operations removing a layer of material. For P&W products, etching before PT testing is not recommended. Removing layers of cleaning materials: Chemicals used for cleaning solutions may contain strong acids and bases. If they are not completely removed from the surface prior to penetrant inspection, they may affect penetrant testing in several ways. Residues may hinder the wetting of the surface and prevent the penetrant from evenly coating the surface of the part. They also make it harder for penetrants to enter and exit discontinuities. Strong bases and acids can cause faint indications. Therefore, complete removal or neutralization of the remaining solution is always important and necessary. Usually, the residue removal process is achieved by washing in warm water and mixing, followed by repeated immersion of the part in fresh water. In some cases, residues of strong bases and acids is subjected to washing with a weak neutralization solution and rinsing with fresh water Alkaline cleaning method. Alkaline cleaners are aqueous solutions of chemicals that remove contamination chemically, e.g. by hydrolysis (conversion of chemicals into soap) or displacement instead of dissolving the contaminants. Cleaning materials of this type usually should help to raise the contamination from the part's surface. Alkaline cleaning is carried out in immersion tanks, where the solutions have the required temperature. The cleaning process is accelerated by stirring.

20 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. The four variables which affect the effectiveness of the alkaline cleaning process are immersion time, aggressive agitation, solution concentration and solution temperature. The cleaning process is more effective if each of these factors is increased. After alkaline cleaning, parts and components must be thoroughly rinsed to remove all traces of the cleaning process. Selection of materials used for P&W products are included in SPOP Degreasing during the use of Method C Only Class 2 non-chlorinated solvents are acceptable, which are qualified in QPL AMP Degreasing is carried out with SKC-S solvent. Apply the solvent to the tested surface by spraying. Then the part's surface should be wiped with a clean, lint-free cloth, towel or paper to remove the solvent residue along with impurities from the surface. Continue spraying / wiping until the removal of existing signs of contamination and stains. Because these solvents do not evaporate too quickly at room temperature, before applying the penetrant make sure that there are no solvent residues on the surface. This can be accomplished by thoroughly drying the surface with a lint-free cloth or paper, drying in an oven or, alternatively, using the more volatile solvents such as isopropyl alcohol, in order to remove less volatile solvents. To accelerate the drying process, use a dryer Smeared metal Mechanical operations such as shoot peening, smoothing with plastic fittings, polishing, abrasive blasting, sanding, brushing, grinding can blur (smear) the surface of metals, may close or reduce the opening area of any existing discontinuities. Any action that leads to smearing of metal surfaces should not precede a penetrant inspection, unless an effective chemical etching will be carried out before, or there is an express authorization issued by the Engineering Department. In the case of testing of consumables (directed back to maintenance), which experienced normal operational loads, it can be assumed that the aforementioned operations do not affect the closing of cracks, with the exception of shoot peening. Parts during their operation are subjected to normal loads, so it is assumed that they are re-exposed to the surface and penetrant inspection can be performed without etching. Such machining closes or reduces the opening of any other existing discontinuities to the surface. During the maintenance, remember and assume that smearing occurs when the parts are in contact with each other during operation and rub against each other. Penetrant inspection for such parts and in such case might not detect discontinuities in such places effectively.

21 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Chemical etching must be performed by highly qualified personnel, having the specialist approval of an engineering organization and having written instructions and a detailed description of the application process. Etching is not part of non-destructive testing. DT employees are is not qualified to carry out chemical etching, unless they have been individually trained and certified in this area. Etching is carried out using a mixture of suitable acids or bases and inhibitors. Types of etching solutions are selected depending on the material, part and its condition. Chemical etching requires very strict control of the composition of the etching solution, the process procedures and the contact time. Deviations in the etching process parameters cause a number of adverse effects such as: Excessive metal removal. Selective etching of critical surfaces. Increased susceptibility to environmental stress corrosion. Reduction of surface tension (bead blasted surfaces) and the corresponding reduction in fatigue life. After degreasing or etching, all parts must be dried. Drying time after degreasing is at least 15 minutes at a temperature of C. In case of local testing, the drying time is minutes at ambient temperature (10 o C to 40 o C, 50 o F to 104 o F) Verification of surface cleanliness Before applying the penetrant to the tested surface, visually verify the cleanliness of the surface of the tested part. The verification should be carried out by: Analyzing the correctness of the surface preparation, Checking the part's surface through its inspection using white light with a minimum illumination level of 1,000 lux (e.g. using a portable lamp), Analyzing using a UV lamp with illumination level of at least 100 µw/cm2, Using a white cotton cloth in order to verify the absence of contamination after the grinding process. In the case of finding traces of contaminants, dirt, or other factors capable of generating false positives during the inspection, the whole process of surface preparation should be repeated Application of penetrant Penetrant is applied by electrostatic spraying or using spray in accordance with the requirements of the Instruction Sheet for the given part. The choice of the method relates to the dimensions of the parts, configuration, status of the part in the manufacturing process, availability of surface, availability of equipment and contract requirements.

22 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Before applying penetrant, all surfaces having cavities and combined surfaces, or wherever penetrant could be difficult to remove, should be masked (as a precaution). However, masking cannot obscure the areas subject to penetrant inspection. Before applying penetrant, check whether the parts are completely dry (pay special attention to cavities). In the case of incomplete drying of the part, the drying process should be repeated. Small amounts of water can be removed with an air gun. Before applying penetrant, check the temperature of the part, the penetrant and the environment, which should be 4 o C to 52 o C (40 to F). Penetrant must cover evenly and thoroughly the entire inspected surface. Areas on the part with inaccurate coverage of the penetrant are unacceptable. It is ideal to perform this testing stage in the presence of ultraviolet radiation. Penetrant contact time with the part's surface, i.e. dwell time is the total amount of time the penetrant remains on the part's surface until the start of cleaning. Electrostatic spraying (method D): Using the electrostatic spraying method, high voltage power supply is connected to the gun. This creates a positive electric charge, which is passed to the penetrant's particles, when they leave the gun. The part is grounded and attracts charged penetrant particles. The attraction is strong enough to attract the particles to the surface, not only to the front surface of the part. This ability causes that electrostatic spraying is preferred in automatic lines, in which parts with a complex shape are tested. However, the reach of spraying inside cavities is limited. The advantages of electrostatic spraying are large savings resulting from the reduction of material requirements. Electrostatic spraying allows for applying thin layers and significantly reduces losses due to overspraying. The savings, compared to the immersion method, which can also be used, reach more than 80 percent The surface is covered with penetrant directly from the nozzle of the gun. Containers, where penetrant spray is prepared should be equipped with appropriate systems and nozzles, in order to apply the same amount of penetrant to the surface. Parts should be positioned to ensure complete coverage of the part's surface with the penetrant. Cover parts evenly with a uniform layer of penetrant. It is recommended to apply the penetrant in UV-A rays above µw/cm 2. This allows to check the accuracy of covering the part's surface with the penetrant. To prevent undesired drying out of the penetrant on the part's surface during the dwell time process, and if required by the large size of the part, 2 spraying cycles can be used. The second cycle is used halfway through the dwell time of the penetrant. Repeated spraying must be carried out using a penetrant of the same type as in the 1st spraying cycle.

23 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. Spraying (method C): Penetrant Magnaflux ZL27A must be applied by spraying. Spraying should be carried out using an aerosol container at a distance of 2 to 6 inches (76 to 152 mm) from the container to the surface. The tested surface must be thoroughly covered with the penetrant so as to obtain a thin, uniform (not dampened) penetrant layer on the surface. Excess penetrant is not desirable because it tends to move over the area, and may complicate removal of the excess. Keeping the part stationary or moving it too slowly during the spraying process may create an excessive penetrant layer. A short distance between the can's nozzle and the part reduces the size of the spray jet and produces a thick layer thickness of penetrant on a small area. A large distance between the nozzle and the part increases the spraying area and reduces the thickness of the penetrant layer. However, in this case there is an increase in losses of the penetrant during the spraying process and an increase of the risk of not covering areas of the part with the penetrant Minimal dwell time of the penetrant: Temperature 40 0 to 60 0 F (4 0 C to C): Detection of fatigue cracks during maintenance(service damage). Detection of cracks caused by intergranular stress corrosion Temperature 60 0 to F ( C to 52 0 C): Detection of fatigue cracks during maintenance(service damage). Detection of cracks caused by intergranular stress corrosion Minimum dwell time: 60 minutes 240 minutes Minimum dwell time: 30 minutes 240 minutes If it is suspected that the part does not have the required minimum dwell time, the part must be thoroughly cleaned and then the inspection process must be repeated from the beginning. Penetrant must be applied at 60-minute intervals when the dwell time exceeds 60 minutes, or when dry penetrant areas have been identified on the part's surface. Do not allow the penetrant to evaporate or dry on the part's surface. If for some reason, the penetrant becomes sticky after evaporation, the part MUST be subjected to the whole process again - including cleaning of the part's surface.

24 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o Removal of the penetrant This operation is required to remove excess penetrant only from the part's surface. Washing parameters must be checked before starting the washing process. Water temperature sensors, water pressure sensors and air pressure sensors must be within the sight of the operator. Pre-washing - only for the Type 1 Method D process. Following the required dwell time of the penetrant and before applying the emulsifier, pre-washing is carried out by spraying water on the test surface, free from contamination. Pre-washing using spraying removes about 80% of the excess penetrant from the surface of the part, leaving only a very thin, uniform layer of the penetrant on the part's surface. Pre-washing allows to optimize the main washing operation, minimizes contamination of the emulsifier with the penetrant. Gun nozzles should be able to emit a stream of large water droplets with the cross-section of a cone or fan. Where possible, the required distance of the gun nozzle from the part: 30 cm (12 inches) to the surface. Washing should be kept to a minimum (maximum 2 minutes on a given surface) to prevent excessive removal of the penetrant. If the part is subjected to excessive cleaning - the process must be repeated. Washing parameters: Use as short time as possible, depending on the geometry of the part, no longer than 2 minutes. The water temperature should be in the range of 10 o C to 38 o C (50 to F). Water pressure when using a water gun should be 275kPa / (40 psi) / (2.75 bar); Application of the emulsifier - only for Method D. Hydrophilic emulsifier is applied by immersion in a tub (working concentration of 8.0% to 10% volume in water, maximum concentration provided by the manufacturer is 33%). Application of the emulsifier with a brush is not allowed. In order to keep the emulsification process only on the part's surface, without the risk of emulsification in any discontinuities, emulsification time must be accurately determined for each part type and the type of their surface, and kept to an absolute minimum. The time required for immersion in a solution of emulsifier with water may be different for different surfaces, however, it cannot exceed 2 minutes. However, the time of 2 minutes is rarely required and needed. As a rule, it can be this long when testing raw, rough and unmachined surfaces. In case of exceeding this time, the inspection process must be repeated in whole. Emulsifier temperature: 4 o C to 52 o C (40 to F). During the emulsification process by immersion, the solution or parts must be gently moved. The gentle moving of the emulsifier or the parts in the tub is necessary to deliver fresh emulator to all surfaces of the parts during their immersion in the tub. On the other hand, excessive mixing can cause foaming.

25 Appendix o. 7 to instruction QP/4.2.3/J ISTRUCTIO o. I.O. P /I Rev / 49 Copy o. You should be sensitive to changes in the color of emulsifier solution. After some time of use, it may change its clean, pink color. The surface may also have a thin layer of the penetrant washed off the surface. Remnants of the penetrant might float (remain) on the surface of the part. In such cases, the emulsifier solution must be replaced. Main (final) rinsing - (only for Method D) It is performed after the step of immersion of the part in the emulsifier with a water gun, without the use of compressed air. Gun nozzles should be able to emit a stream of large water droplets with the cross-section of a cone or fan. Wherever possible, the distance between the nozzle and the part should be between 300 and 400 mm (minimum 12 inches) at an angle of 45 o to the surface of the tested part. To prevent excessive removal of the penetrant during instruction spraying, minimize the flushing with water for a specific area of the part to be less than: seconds. The water pressure using Method D (using a water gun) should be 275kPa / (40 psi) / (2.75 bar); Water temperature: 10 o C to 38 o C (50 to F). After washing, to prevent the accumulation of water in the recesses of parts, it is necessary to change the position or blow off with air at a pressure of <175 kpa / (25 psi) / (1.75 bar). If the part is subjected to excessive cleaning - the process must be repeated. Removal of excess penetrant should take place in an environment equipped with UV-A lamps in a semi-shaded area. Washing should be interrupted if a light background level is reached. It is recommended that the intensity of UV-A radiation was at a minimum level of 100 µw/cm 2. The size of the white light background should be 20 Lx (2fc). Water temperature sensors, water pressure sensors and air pressure sensors must be within the sight of the operator, to allow for ongoing monitoring. Method C - Removing excess penetrant from the surface of the tested part takes place in three stages: wiping with a clean dry cloth, then using a solvent remover, and finally again wiping with a dry, lint-free cloth according to the diagram: 1. First, the tested surface should be wiped with a clean, lint-free dry cloth or tissue paper. This is to roughly remove the penetrant. 2. Then, wipe the surface with a cloth moistened with solvent remover Magnaflux SKC-S. The amount of the remover used is critical. Soaking the fabric should be light, obtained by spraying the remover on the cloth. Do not use excessive spraying onto the fabric; do not fabrics immerse it directly in the remover.