In Use Penetrant Materials Process Controls

Transcription

1 In Use Penetrant Materials Process Controls Presented by Kevin Walker

2 Why? Aid in controlling your process A well monitored system will prevent costly and painful corrections

3 PENETRANT MATERIALS High quality Has the capacity to withstand abuse Not fail-safe

4 In Use Material Checks Inspectors must be aware of: Changes of performance Color Consistency Cost associated with this testing

5 Testing (In most cases) Simple tests Uses minimum equipment Can be run in inspection area Personnel should be familiar with inspection process Save a new standard sample at the time tanks are filled in a closed container

6 Storing Sample Materials Plastic containers should NOT be used for Long term storage Use metal or glass containers Should not be stored in high temperatures

7 Establish point of performance loss Determine exact point of material failure These limits apply mainly for critical applications Specifications

8 In Use Material Checks ASTM Material Checks (In Use) Does not apply to materials that are not recovered or reused, i.e. aerosols, some spray systems Records must be maintained at location for audit.

9 Each Shift Water wash pressure and temperature Inspection area Clean and free from excessive fluorescent contamination Free of white light background Not exceed 2 fc (21.5 lx)

10 Penetrant contamination Look for waxy deposits, white coloration, any separation, scum, or any other evidence Modify per manufacturers instructions Discard Daily Tests

11 Daily Tests - Continued System performance Processing a known defect standard through the system using in-use materials Comparative Penetrant Sensitivity Process with unused emulsifier and developer TAM Panel Not for determining sensitivity level of the penetrant NiCr Panels Or part known defect

12 Daily Tests Method A penetrant and Emulsifier Removability Test piece specified in AMS-2644 (Stainless steel test block with rough surface) Use normal wash parameters to process part

13 Daily Tests cont. Dry Developer condition For recycled material only Spread thin layer in 4 (10 cm) circle if TEN or more fluorescent specks discard 4

14 Daily Tests Cont. Developer contamination (aqueous - soluble and suspendable) Immerse 3 (7.6 cm)x10 (25.4 cm) aluminum panel, dry Look for fluorescence and uniform coverage

15 Daily Tests - Continued Black Light Intensity Minimum 1000 mw/cm 2 at 15 from front of filter to the face of the sensor

16 Daily Tests - Continued Black Light Intensity All types used to inspect parts (portable, hand-held, mounted or fixed)

17 Daily Tests - Continued Black Light Integrity (Weekly) Clean, repair or replaced as needed

18 Daily Tests - Continued Special UV Lighting Pencil lamps, borescopes or remote UV inspection equipment Measured at expected working distance at 1000 mw/cm 2 For borescopes & remote video equipment, the image must have enough resolution for proper inspection & evaluation

19 Weekly Tests Developer concentration (Aqueous: Soluble & Suspendible) Check with Hydrometer Concentration no higher than specified by supplier

20 Weekly Tests Emulsifier (hydrophilic) concentration Concentration checked with refractometer Concentration no higher than specified by supplier, for spray applications no higher than 5%

21 Weekly Tests Continued Water Content (Water-Based, Water- Washable penetrants only) Use refractometer Maintained according to manufacturer recommendation

22 Monthly Tests Water content 5% max. (Non-water-based, Method A only) Emulsifier water content (lipophilic only)

23 Quarterly Fluorescent brightness (ASTM E-1135-Test Method for Brightness of Penetrants) Measured with Fluorometer Brightness less than 90% of standard should be discarded or corrected

24 Quarterly Calibrate Drying Oven Calibrate temperature control and indicator

25 Calibrate light meter Black Light and White Light meters Calibrate water temperature indicator and pressure gages Semi-Annual

26 Contamination Penetrants can absorb large amounts of solvents or oils, but Usually will decrease fluorescence Some cleaning solvents, degreasers, acids, alkaline cleaners can destroy fluorescence Effect washability

27 Contamination Some aqueous cleaners contain metasilicates which may prevent penetrant from entering crack Incomplete cleaning of oil can also hinder penetrant from entering crack

28 CONTAMINATES Will cause loss of fluorescence in penetrant May enter a little at a time as residue on parts or All at once when foreign material is added accidentally

29 Types of Contaminates Water The most common contaminate Not harmful until water tolerance is met Small amounts of water may change viscosity and washability Contamination in PE penetrants causes separation

30 STANDARD ZL-60D - 16% water Contamination!

31 STANDARD ZL-60D 20% water tolerance

32 Types of Contaminates Dirt, soil, other insoluble solids Result of improper cleaning or matter falling into tank Organic material Organic solvents Acid Alkaline materials

33 Standard 10% conc. alkaline cleaner

34 Emulsifier Contamination Penetrant contamination Will slow emulsifying action Small amounts of contamination can be tolerated Emulsifier should be replaced based on performance rather than penetrant content

35 Heated Parts In some cases, used to speed up penetration Some fluorescent dyes decompose around F (71 0 C) Long term exposure to heated parts will effect fluorescence in tank

36 Standard Panel Heated to F(82 0 C)

37 Brightness Case Study LEVEL 3 POST EMULSIFIABLE - 90% minimum / 3/ / 3/ / 3/ / 3/ / 3/ / 3/ / 3/ 2002 DATE COMPANY ONE

38 Water Content Case Study Level 3 Water Wash - 5% maximum water content Water Content(%) /02 2/02 3/02 4/02 5/02 6/02 Date Company 2

39 THANK YOU