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AS 2062-1997 Non-destructive testing - Penetrant testing of products and components
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AS 2062—1997
Australian Standard
Non-destructive testing—Penetrant
testing of products and components
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This Australian Standard was prepared by Committee MT/7, Non-destructive
Testing of Metals and Materials. It was approved on behalf of the Council of
Standards Australia on 12 September 1997 and published on 5 December 1997.
The following interests are represented on Committee MT/7:
Australasian Railway Association
Australian Aerospace Non-Destructive Testing Committee
Australian Institute for Non-Destructive Testing
Australian Nuclear Science and Technology Organization
Australian Pipeline Industry Association
AUSTROADS
Bureau of Steel Manufacturers of Australia
Electricity Supply Association of Australia
Industrial Research Limited, New Zealand
Institution of Engineers, Australia
Metal Trades Industry Association of Australia
National Association of Testing Authorities, Australia
New Zealand Non-Destructive Testing Association
Society of Automotive Engineers — Australasia
Victorian WorkCover Authority
Welding Technology Institute of Australia
WorkCover New South Wales
Additional interests participating in preparation of Standard:
Aircraft maintenance laboratories
Review of Australian Standards. To keep abreast of progress in industry, Australi an Standards are
subject to periodic review and are kept up to date by the issue of amendments or new editions as
necessary. It is important therefore that Standards users ensure that they are in possession of the latest
editi on, and any amendments thereto.
Full details of all Australian Standards and related publications wil l be found in the Standards Australia
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Australian Standard’, which subscribing members receive, and which gives details of new publications,
new editions and amendments, and of withdrawn Standards.
Suggestions for improvements to Australian Standards, addressed to the head office of Standards
Australia, are welcomed. Notification of any inaccuracy or ambiguity found in an Australian Standard
should be made wit hout delay in order that the matter may be investigated and appropriate action taken.
This Standard was issued in draft form for comment as DR 93195 and DR 95405.
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AS 2062—1997
Australian Standard
Non-destructive testing—Penetrant
testing of products and components
Originated in part as AS B260.3A— 1968 (being endorsement of
BS 3889.3A:1965 with Amendment).
Previous editions AS 2062— 1977 and AS 2565— 1982.
AS 2062— 1977 and AS 2565— 1982 revised, amalgamated and
designated AS 2062— 1997.
PUBLISHED BY STANDARDS AUSTRALIA
(STANDARDS ASSOCIATION OF AUSTRALIA)
1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7337 1526 5
AS 2062 — 1997
2
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PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee MT/7, Non-destructive Testing of Metals and Materials, to supersede
AS 2062—1977, Methods for non-destructive penetrant testing of products and components.
This Standard is the result of a consensus among Australian and New Zealand representatives
on the Joint Committee to produce it as an Australian Standard.
The objective of this revision is to upgrade the requirements for penetrant testing of nonporous products and components for the detection of discontinuities that are open to the
surface. The Standard covers both site and factory testing.
This Standard now requires that all materials comply with MIL-I-25135E—1989, Inspection
materials, Penetrants . As a result, AS 2565— 1982, Non-destructive testing —Penetrant
testing media, is to be withdrawn.
During the preparation of this revision, cognizance was taken of the following International
and National Standards:
ISO
3452 (1984):
Non-destructive testing— Penetrant inspection— General principles
3453 (1984):
Non-destructive testing—Liquid penetrant inspection —Means of verification
ASTM
E 1417-95a
Practice for liquid penetrant examination
Members of the committee were in agreement that this Standard should align with
ASTM E 1417, which is more up-to-date than the two international Standards.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
 Copyright
STANDARDS AUSTRALIA
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3
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CONTENTS
AS 2062 — 1997
Page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 REFERENCED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 SPECIFICATION OF ACCEPTANCE CRITERIA . . . . . . . . . . . . . . . . . . .
1.5 CLASSIFICATION OF PENETRANT SYSTEM MATERIALS . . . . . . . . . .
1.6 WRITTEN PROCEDURE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . .
1.7 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 QUALIFICATION OF PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
6
6
7
7
SECTION 2
REQUIREMENTS FOR TESTING MATERIALS AND
PROCESS CONTROL
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TESTING MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
SECTION 3 METHODS OF TEST
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 PREPARATION OF THE TEST SURFACE . . . . . . . . . . . . . . . . . . . . . . .
3.3 APPLICATION OF THE PENETRANT . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 REMOVAL OF EXCESS PENETRANT . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 APPLICATION OF THE DEVELOPER . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 INSPECTION CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 EVALUATION OF INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10 CLEANING AFTER TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.11 RETESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.12 MARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
10
10
12
12
13
13
14
14
14
14
2.1
2.2
2.3
SECTION 4 TEST RECORDS AND REPORTS
4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 RECORD OF TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 TEST REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
APPENDICES
A PURCHASING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B EXAMPLES OF ACCEPTANCE CRITERIA FOR INDICATIONS OF
VARIOUS SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C PROCESS CONTROL PROCEDURES FOR PENETRANT TESTING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D REQUIREMENTS FOR STANDARD TEST PANELS FOR EVALUATING
THE PERFORMANCE OF PENETRANT TESTING MATERIALS . . . . . . . .
16
17
19
25
AS 2062 — 1997
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FOREWORD
Penetrant testing procedures are effective in revealing all types of discontinuities that are
open to the surface and into which the penetrant can enter, and may be used on a variety of
materials including ceramics, glass and plastics as well as metallic materials; however, they
may damage some non-metallic materials and are not suitable for use on porous materials.
Penetrant testing can be carried out at a number of sensitivity levels allowing the selection
of a system most suitable for the type of product being tested. As a general rule, castings,
particularly of light alloys that may contain some porosity, are tested using a low or medium
sensitivity penetrant system, whereas machined components, which may be highly stressed
under service conditions, are tested using a high or very high sensitivity penetrant system to
ensure that very small discontinuities are revealed. It is generally accepted that
water-washable penetrants are less reliable than post-emusifiable penetrants, and fluorescent
penetrants are more sensitive than colour contrast penetrants.
The effectiveness of the test relies on the competency and the efficiency of the tester to make
an assessment of indications revealed by the test.
It is a design or engineering responsibility to provide the penetrant tester with adequately
detailed acceptance criteria for the whole test surface including, if applicable, identification
of zones to which different acceptance criteria apply.
5
AS 2062 — 1997
STANDARDS AUSTRALIA
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Australian Standard
Non-destructive testing— Penetrant testing
of products and components
S E C T I O N
1
S CO P E
A N D
G E NE R A L
1.1 SCOPE This Standard specifies requirements for the penetrant testing of non-porous
products and components for the detection of discontinuities that are open to the surface. It
also specifies requirements for the materials used in penetrant testing, and requirements for
process control.
This Standard is intended for use in all situations where penetrant testing is used, including
on-site testing and permanent factory installations.
NOTES:
1 Penetrant testing is usually applied to non-magnetic metallic materials but can be used on any
material regardless of its physical properties, provided that its surface is non-absorbent and
compatible with the process.
2 Special requirements apply when penetrant-testing liquid oxygen system components.
3 Advice and recommendations on information to be supplied by the purchaser at the time of
enquiry and order are given in Appendix A.
1.2 REFERENCED DOCUMENTS The following documents are referred to in this
Standard:
AS
1449
1470
1627
1627.4
1929
2193
3669
3998
Wrought alloy steels—Stainless and heat-resisting steel plate, sheet and strip
Health and safety at work— Principles and practices
Metal finishing—Preparation and pretreatment of surfaces
Part 4: Abrasive blast cleaning
Non-destructive testing—Glossary of terms
Methods for calibration and grading of force-measuring systems of testing machines
Non-destructive testing— Qualification and registration of personnel— Aerospace
Non-destructive testing —Qualification and certification of personnel — General
engineering
JIS
Z 2343 Method for liquid penetrant testing and classification of the indication.
MIL
MIL-I-25135 Inspection materials, penetrants
1.3 DEFINITIONS For the purpose of this Standard, the definitions given in AS 1929
apply.
1.4 SPECIFICATION OF ACCEPTANCE CRITERIA When testing is required in
accordance with this Standard, documents such as product Standards, orders or contracts shall
indicate the acceptance criteria for the component(s) requiring testing.
NOTE: Examples of acceptance criteria are given in Tables B1 and B2 of Appendix B; they allow
the purchaser to nominate a Class or Classes appropriate to the requirements for the components.
However, other criteria may be utilized.
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AS 2062 — 1997
6
1.5 CLASSIFICATION OF PENETRANT SYSTEM MATERIALS This Standard
classifies penetrant systems in accordance with penetrant type, penetrant removal method,
sensitivity level, developer form and solvent remover class.
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1.5.1 Penetrants
(a)
Penetrants are classified as follows:
Penetrant types
The types of penetrant are as follows:
(i)
Type 1 — Fluorescent dye.
(ii)
Type 2 — Colour contrast (red dye).
(iii) Type 3 — Visible and fluorescent dye (dual mode).
(b)
Removal methods
The methods of penetrant removal are as follows:
(i)
Method A — Water washable.
(ii)
Method B — Post-emulsifiable, lipophilic.
(iii) Method C — Solvent removable.
(iv) Method D — Post-emulsifiable, hydrophilic.
(c)
Sensitivity
The penetrant sensitivity levels are described as follows:
(i)
Level 1 —Low.
(ii)
Level 2 —Medium.
(iii) Level 3 —High.
(iv) Level 4 —Ultra-high.
1.5.2
Developers
The forms of developer are as follows:
(a)
Form a— Dry powder.
(b)
Form b— Water soluble.
(c)
Form c— Water suspendable.
(d)
Form d— Solvent-based.
(e)
Form e— Specific application.
1.5.3
Solvent removers
The classes of solvent remover are as follows:
(a)
Class 1— Halogenated.
(b)
Class 2— Nonhalogenated.
(c)
Class 3— Specific application.
1.6 WRITTEN PROCEDURE REQUIREMENTS All liquid penetrant testing shall be
performed to a written procedure that implements the requirements of this Standard for the
components under test. A master written procedure may be utilized to cover the requirements
common to a variety of similar components. As a minimum, the following information is
required in individual procedures, a master procedure, or a combination thereof:
(a)
Identification of the components, or types of components to be tested.
(b)
Details of the precleaning process and the etching process (if required), including the
materials, the drying parameters and the processing times. If these processes are
performed by personnel other than those carrying out the inspection, the details may be
specified in other documents, provided the documents are referenced in the procedure.
(c)
Classification of the penetrant materials to be used (see Clause 1.5).
(d)
Complete processing requirements including requirements for concentrations of
solutions, methods of application and dwell, dwell times, drying times, temperatures and
pressures.
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AS 2062 — 1997
(e)
Complete inspection/evaluation requirements including light intensities (both inspection
and ambient), the acceptance criteria, and the method and location of marking of
acceptable components.
(f)
Complete postcleaning procedures. If postcleaning is performed by personnel other than
those carrying out the inspection, the details of this operation may be specified in other
documents, provided the documents are referenced in the procedure.
(g)
Minimum level of operator certification.
1.7 SAFETY As penetrant testing methods may require the use of toxic, flammable and
volatile materials, safety precautions shall be observed and testing shall be carried out in
well-ventilated rooms and in areas situated away from heat or naked flames.
CAUTION: PENETRANT TESTING MEDIA AND ANCILLARY EQUIPMENT
SHOULD BE USED WITH CAUTION AND ALWAYS IN ACCORDANCE WITH THE
MANUFACTURER’S RECOMMENDATIONS. BLACK LIGHT SHOULD NEVER BE
USED WHEN A FILTER GLASS IS CRACKED, BROKEN OR INCORRECTLY
FITTED, AS HARMFUL ULTRAVIOLET RADIATION MAY BE EMITTED.
Personnel who carry out penetrant testing shall be instructed in safe working methods
(see AS 1470). For requirements for the control of process materials, effluent disposal,
ventilation, protective clothing and safety equipment, reference shall be made to the relevant
regulatory authority.
1.8 QUALIFICATION OF PERSONNEL Personnel who perform penetrant testing to
this Standard shall have recognized qualifications in the specific area of test and shall meet
the visual acuity requirements of a relevant national Standard.
NOTE: The Australian Standards for qualification of personnel are AS 3669 and AS 3998.
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AS 2062 — 1997
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S E C T I O N 2
R E Q UI R E M E N T S F O R T E S T I N G
M A T E R I A L S A N D P R O C E S S C O N T R O L
2.1 SCOPE This Section specifies the requirements for penetrant testing materials, and
periodic tests to be carried out to maintain control of the testing system.
2.2 TESTING MATERIALS Penetrant testing materials shall satisfy the requirements of
the latest issue of MIL-I-25135, unless such materials are inadequate for the particular
application. The use of materials that do not conform to MIL-I-25135 shall require the
approval of the purchaser.
NOTE: Copies of MIL-I-25135 can be obtained from the following organizations:
ACEL, 66 Chapel Street, South Yarra, Vic. 3141.
HINTONS, Level 2, 10 East Parade, Eastwood, N.S.W. 2122.
(Locked Bag 7, Eastwood, N.S.W. 2122).
Penetrant testing materials shall be compatible with the product material being tested. When
a post-emulsifiable removal method is used, the penetrant and the emulsifier shall be from
the same manufacturer and shall be stated to be compatible by the manufacturer.
NOTE: It may be necessary to carry out special tests to check the compatibility of penetrant media
with the product material.
2.3 PROCESS CONTROL A penetrant system requires controlling and regular
monitoring to ensure that no harmful deterioration of materials or equipment occurs.
Procedures and tests to be conducted periodically for this purpose are specified in
Appendix C.
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S E C T I O N
3
M E T H O D S
AS 2062 — 1997
O F
T E S T
3.1
GENERAL The penetrant test includes the following operations:
(a)
Preparation of the test surface.
(b)
Application of the penetrant for the required dwell time.
(c)
Removal of excess penetrant.
(d)
Application of the developer for the required dwell time.
(e)
Inspection, interpretation and evaluation of the test surface in accordance with the
viewing conditions specified in Clause 3.7.
(f)
Cleaning after testing and, if required, the application of a corrosion inhibitor.
Penetrant inspection should be performed before carrying out any finishing or
corrosion-inhibiting process, such as the application of a coating or modification of the
component surface, that may bridge over discontinuities or reduce the effectiveness of the
inspection process. Such processes include electroplating, anodizing and dichromating.
Penetrant inspection should be performed both before and after any mechanical process that
can cause the formation of cracks and other discontinuities. Such processes include grinding
and all forms of abrasive cleaning.
Where a Type 3 penetrant is used, the requirements for Type 1 or Type 2 penetrant shall
apply according to the mode of use.
3.2 PREPARATION OF THE TEST SURFACE All surfaces shall be dry and free of
contaminants and foreign matter such as scale, dirt, grease, rust, weld spatter or paint that
may interfere with the test. Cleaning and preparation of the test surface shall not be
detrimental to the product, to its dimensions and surface finish, or to the testing materials.
Chemical methods for the removal of contaminants are preferred, and should be used
wherever possible. Physical methods, whilst satisfactory for the cleaning of contaminants
from the surface, are generally incapable of removing them from within surface
discontinuities. The presence of contaminants contained in surface discontinuities may
interfere with the entry of the penetrant, or otherwise degrade the test process. In addition,
abrasive methods of cleaning can smear metal over the surface opening of discontinuities and
so prevent their detection.
Deformation of the test surface produced by processes such as hammering, sand or shot
blasting, peening, grinding or machining, vapour blasting, deburring, applying abrasive paper,
buffing and lapping should be avoided before penetrant testing, because these processes often
close over or mask discontinuities. The use of a controlled etching procedure may be
specified in the relevant product specification to remove flowed metal from the surface of
components so treated, prior to penetrant inspection.
NOTES:
1
Penetrant residues from previous tests retained in discontinuities may prevent the entry of fresh
penetrant and may interfere with the interpretation of indications, especially when a different
penetrant system is used for the retesting.
2
Residues from a previous colour contrast penetrant test may react with a fluorescent penetrant
and result in the complete or partial quenching of its fluorescence.
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AS 2062 — 1997
10
3.3 APPLICATION OF THE PENETRANT After the surface has been prepared for
testing it shall be uniformly covered and wetted with penetrant applied by immersion,
flooding, swabbing, brushing or spraying.
The temperature of the test surface shall be within the range of 5°C to 50°C. Should testing
be carried out at a temperature of between 5°C and 15°C, the penetrant dwell time should be
increased in accordance with the recommendation of the penetrant manufacturer.
The penetrant dwell time shall be not less than that recommended by the manufacturer and
shall be a minimum of 10 min. For titanium, nickel alloys and stainless steels, the penetrant
dwell time shall be a minimum of 20 min. In general, the finer or tighter the discontinuity,
the longer the penetrant dwell time required.
When penetrant is applied by immersion, the drainage time shall be not less than half the
total penetrant dwell time.
Care is required to ensure that the penetrant does not dry out on the test surface. If this
occurs, the part shall be thoroughly cleaned and then retested.
NOTE: Longer penetrant dwell times may be required, depending on the nature of the
discontinuities being sought. Dwell times of up to 4 h may be necessary for the detection of
extremely fine discontinuities.
3.4 REMOVAL OF EXCESS PENETRANT
3.4.1 General After the appropriate penetrant dwell time has elapsed, excess penetrant
shall be removed from the test surface in accordance with the specified method for penetrant
removal. Removal shall be continued until a stage is reached when the residual surface
penetrant does not interfere with the detection and interpretation of subsequent penetrant
bleed-out from discontinuities. The removal of fluorescent penetrants shall be carried out in
subdued white light with the test surface irradiated with black light.
3.4.2 Method A process
3.4.2.1 General Water-washable penetrants shall be removed by a manual or an automated
water spray, or by a manual wipe in accordance with Clauses 3.4.2.2 and 3.4.2.3.
3.4.2.2 Manual and automated spray The requirements for the application of spray
washing are as follows:
(a) The maximum water pressure shall be 275 kPa.
(b) Water temperature shall be between 10°C and 38°C.
(c) A coarse spray shall be used; where possible the spray nozzle shall be a minimum of
30 cm from the component.
(d) Hydro-air nozzles are permitted only for Level 1 or Level 2 sensitivity processes, using
a maximum of 170 kPa added air pressure.
(e) Spraying shall be conducted under appropriate illumination to assure that over-washing
does not occur.
(f) Spraying times shall be held to a minimum to prevent over-washing. If over-washing
occurs, the components shall be thoroughly dried then cleaned and retested.
After rinsing, drain water from the component and utilize methods such as repositioning,
suction, blotting with clean absorbent materials or blowing with filtered shop air at a pressure
of less than 170 kPa, to prevent pooling. If over-removal is suspected, the component shall
be cleaned and retested.
3.4.2.3 Manual wipe Excess penetrant shall be removed by wiping with a clean, dry, lintfree cloth or absorbent towelling. The remainder of the surface penetrant shall then be
removed with a water-dampened cloth or towel. The surface shall not be flushed with water
and the cloth or towel shall not be saturated with water. The component shall be examined
under appropriate illumination to assure adequate removal of the surface penetrant. If overremoval of the surface penetrant occurs, the component shall be cleaned and retested. The
surface shall be dried by blotting with a clean, dry towel or cloth, or by evaporation.
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3.4.3 Method B process Penetrant shall be removed by the application of the lipophilic
emulsifier and then with a rinse, as follows:
(a)
Lipophilic emulsifier application and dwell Lipophilic emulsifiers shall be applied by
immersion or flowing over the part. When a lipophilic emulsifier is applied by
immersion, the part should be withdrawn from the tank immediately the test surface is
completely covered by the emulsifier and allowed to drain for the remainder of the
emulsifier dwell time. Lipophilic emulsifiers shall not be applied by spray or brush and
shall not be agitated while on the surface of the component. Maximum dwell times,
unless otherwise specified, shall be 3 min for Type 1 systems and 30 s for Type 2
systems. Actual dwell times shall be determined by trial and error and be the minimum
to produce an acceptable background on the component.
(b)
Rinsing After the appropriate emulsifier dwell time, emulsification shall be stopped
by immersion in water or by water spray. For spray removal of the penetrant/emulsifier
mixture, the requirements of Clause 3.4.2.2 shall apply.
Ensure that the emulsifier/penetrant is adequately removed by spraying to remove the
background penetrant but not the penetrant within any discontinuity.
When using an agitated immersion rinse, the dwell time shall be the minimum required
to remove the emulsified penetrant. The components shall be examined under
appropriate illumination after rinsing; components with excessive background shall be
cleaned and reprocessed. The water used for rinsing shall be free of any contaminant
that will leave a residue on the component when dried. After rinsing, drain water from
the component and utilize methods such as repositioning, suction, blotting with clean
absorbent materials or blowing with filtered shop air at a pressure of less than 170 kPa,
to prevent pooling. If over-removal is suspected, the component shall be cleaned and
retested.
3.4.4 Method C process Penetrant shall be removed by wiping the test surface with a
clean, lint-free, dry cloth or absorbent towelling, followed by wiping with a solventdampened lint-free cloth or towel. The surface of the component shall not be flushed with
solvent and the cloth or towel shall not be saturated with solvent. The component and cloth
or towelling shall be observed under appropriate illumination to assure adequate removal of
the surface penetrant. If over-removal of the surface penetrant occurs, the component shall
be cleaned and retested. The surface shall be dried by blotting with a lint-free dry cloth or
towel, or by evaporation.
3.4.5 Method D process Penetrant shall be removed with a water prerinse, the application
of hydrophilic remover and then a postrinse, as follows:
(a)
Prerinse The water prerinse shall be applied for the minimum amount of time
required to achieve removal of the bulk surface penetrant. The rinse requirements of
Clause 3.4.2.2 shall apply.
(b)
Hydrophilic remover application and dwell The hydrophilic remover shall be applied
by immersion, flowing, foaming, or spray. For immersion applications, the
concentration of the remover shall comply with that specified by the penetrant system
supplier. The remover or the part shall be mildly agitated. For spray applications, the
concentration of the emulsifier shall not exceed 5%. Dwell time shall be the minimum
required for adequate penetrant removal and shall be determined by trial and error, but
unless otherwise specified, shall not exceed 2 min.
(c)
Postrinse After the application and dwell of the hydrophilic remover, the component
under test shall be rinsed with water which is free of contaminants that could leave a
residue on the component after drying. The spray rinse requirements of Clause 3.4.2.2
shall apply. Evidence of over-removal of the penetrant shall require the part to be
cleaned and retested. Excessive background may be removed by an additional (touchup) application of the hydrophilic remover, provided that the maximum allowable dwell
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time is not exceeded for the remover. Additional rinsing of the touch-up area will be
required after application and dwell of the remover. If a careful touch-up application
of the hydrophilic remover does not produce an acceptable background, the part shall
be cleaned and retested. Manual systems shall require the use of appropriate
illumination to assure adequate penetrant removal.
After rinsing, drain water from the component and utilize methods such as
repositioning, suction, blotting with clean absorbent materials or blowing with filtered
shop air at a pressure of less than 170 kPa, to prevent pooling. If over-removal is
suspected, the component shall be cleaned and retested.
3.5 DRYING Parts shall be dried before the application of a dry or solvent-based
developer. When penetrant removal has been effected by water spray or immersion in water,
the bulk of the water shall be removed from the parts by draining, suction, blotting with clean
absorbent materials, or the use of filtered compressed air at a maximum pressure of 170 kPa.
Drying shall be completed either in a circulating-air oven at a temperature not exceeding
60°C, by the application of forced air at a temperature not exceeding 60°C, or in ambient air.
When air at a temperature above the ambient temperature is used to dry the part, the time
should be the minimum necessary and should normally not exceed 10 min. Excessive drying
times or temperatures should be avoided to prevent loss of penetrant contained in
discontinuities.
3.6
APPLICATION OF THE DEVELOPER
3.6.1 Dry developer Dry developer shall be applied to the test surface in such a manner
as to contact all surfaces to be inspected. Excess dry developer may be removed after the
development time by lightly tapping the parts. Dry developers shall not be used with Type 2
(colour-contrast) penetrants, unless otherwise specified in the product Standard.
If the part has been heated before the application of the dry developer, the developer should
be applied while the part is still hot.
3.6.2 Solvent-based developers Solvent-based developers shall be applied by spraying
only. For Type 1 penetrants, the developer shall be applied as a uniform thin coating over the
entire surface to be inspected. For Type 2 penetrants, the developer shall be applied over the
entire surface to form a uniform, white coating to provide suitable color contrast for the
penetrant indications. The uniformity and thickness of the developer coating is important for
both types of penetrant systems. The component shall be cleaned and retested if the developer
coating thickness is too heavy for Type 1 systems, causing the metallic surface to be
completely masked. The developer shall be sufficiently agitated before and during application
to ensure that a uniform concentration of suspension is obtained.
3.6.3 Water-based developers, soluble and suspendable Water-based developers may
be applied to the component after rinsing, or after the component is dry. Parts shall be at
ambient temperature before the application.
Water-based soluble developers shall not be used with Type 2 penetrants or Type I Method A
penetrants, unless otherwise specified. Water-based suspendable developers shall be
sufficiently agitated before and during application to ensure that a uniform concentration of
suspension is obtained. If the coating is streaky, the part shall be cleaned and retested.
Water-based developers shall be applied by immersion, by flow-on methods or by very coarse
spray. When application is by immersion, the components shall be withdrawn from the tank
as soon as all surfaces are wetted by the developer. The applied developer shall completely
cover all surfaces to be inspected and shall not be allowed to puddle. Components shall be
dried as soon as possible after application of the developer in a recirculating-air oven, at a
temperature not exceeding 60°C and for no longer than 10 min.
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3.6.4 Developer dwell time The developer dwell time shall be at least one-half of the
penetrant dwell time and shall be within the following ranges:
(a)
For solvent-based developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 min to 1 h.
(b)
For water-based developers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 min to 1 h.
(c)
For dry powder developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 min to 2 h.
NOTE: The developer dwell time is dependent on the testing materials used, the product examined,
and the nature of discontinuities present; however, for fine discontinuities, developer dwell time
is generally between one-half of the penetration time and the full penetration time. A very long
development time may cause excessive bleed out of penetrant from large deep discontinuities,
thereby causing a broad, smudgy or vague indication.
3.7
INSPECTION CONDITIONS
3.7.1 For colour contrast (Type 2) penetrants When colour contrast penetrants are used
the test surface shall be illuminated by daylight or artificial light to a level of not less than
1000 lx. The inspection conditions shall be controlled to prevent unnecessary glare.
As an exception, where it is deemed that the heat generated from the use of white lights
could become an ignition source in designated hazardous areas, the tester may use a lower
light intensity for the inspection, subject to the agreement of the purchaser. The use of a
lower light intensity shall be recorded both in the record of test and in the test report.
3.7.2 For fluorescent (Type 1) penetrants The requirements for the inspection of surfaces
when a fluorescent penetrant is used are as follows:
(a)
The inspection area shall be darkened to ensure that the illuminance, including that from
any black light sources, does not exceed 20 lx.
(b)
Inspection of the test surface shall be carried out using a black light source, which has
been checked with a calibrated black light meter, and which gives an irradiance of not
less than 10 W/m2 at a distance of 380 mm.
(c)
During inspection, the black light irradiance at the test surface shall be not less than
10 W/m2.
NOTES:
1 Goggles fitted with a filter to match the colour of fluorescence may be worn to increase
contrast during viewing.
2 Black light sources should be allowed to warm up to produce their maximum irradiance
before inspection commences, to ensure the irradiance is adequate.
3.8 INSPECTION Components shall be inspected when the developer dwell time has
elapsed. If the specified dwell time has been exceeded the components shall be cleaned and
retested.
All indications shall be interpreted. Components with no indications or nonrelevant
indications shall be accepted. Components with relevant indications shall be evaluated against
the appropriate acceptance criteria. Components with excessive background shall be cleaned
and retested.
Lights sources shall be positioned so that the inspection of the component is not impeded.
For Type 1 (fluorescent dye) processes, personnel shall allow an adequate adaptation time for
their eyes to become accustomed to the reduced ambient lighting prior to inspecting
components and shall not wear permanently darkened lenses or photochromic lenses, which
darken when exposed to black light.
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3.9
14
EVALUATION OF INDICATIONS
3.9.1 General Where doubt exists as to the presence of discontinuities, the test surface
shall be thoroughly recleaned and retested in accordance with procedures given in this
Section. Indications that exceed the specific acceptance criteria for the component shall be
cause for rejection.
3.9.2 Evaluation by wiping and redeveloping Indications may be evaluated by removing
them with a solvent-dampened brush or swab, allowing the area to dry, and redeveloping. The
redevelopment time shall be at least as long as the original development time.
3.9.3 Mechanical evaluation When permitted by the specific inspection procedure,
material may be removed by an approved procedure such as sanding (powered or manual) or
grinding, to determine the depth and extent of the discontinuity. After the mechanical
operation, the area shall be cleaned, etched, cleaned to remove the etchant, and re-tested. The
process used for re-inspection shall be at least as sensitive as the original process.
3.10 CLEANING AFTER TESTING Removal of penetrant and developer after testing
is good practice and shall be carried out where there is a possibility of interference with
subsequent processing and where residual penetrant testing materials might result in
corrosion. To facilitate the removal of water-based and solvent-based developers it is
recommended that cleaning be carried out as soon as possible after testing.
After removal of the developer and penetrant, the test surface shall be dried and, if required,
a corrosion inhibitor applied.
3.11 RETESTING If retesting is necessary for any reason, the complete procedure shall
be repeated from the initial cleaning operation, with special attention given to the removal
of residual penetrant from discontinuities before retesting.
Unless otherwise approved, the component shall be retested using the same materials and
procedure as were used for the original test.
3.12 MARKING When required, each component that has been penetrant tested to this
Standard and found to conform to the acceptance criteria shall be marked. Marking shall be
applied in a manner and at a location that is harmless to the component, or its intended
function.
NOTE: Manufacturers making a statement of compliance with this Australian Standard on a
product, packaging, or promotional material related to that product are advised to ensure that such
compliance is capable of being verified.
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S E C T I O N
4
T E S T
R E C O R D S
AS 2062 — 1997
A ND
R E P O R T S
4.1 GENERAL Details of tests carried out in accordance with this Standard shall be
recorded and, when required, included in a written test report.
4.2 RECORD OF TEST The record of test shall include at least the following
information, where applicable:
(a)
Name of laboratory or testing authority.
(b)
Identification of the component(s) and statement of the number tested.
(c)
Product specification.
(d)
Material specification or type.
(e)
Details of the areas of the component(s) that were tested.
(f)
Surface condition of the test areas and the surface cleaning procedure.
(g)
Number of this Australian Standard, i.e. AS 2062, identification of the test procedure
used and details of any departures from that procedure.
(h)
Identification of each of the test materials used (the name of the manufacturer, the
manufacturer’s identification of the test materials, and the batch numbers).
(i)
The test temperature if outside the range 15°C to 40°C.
(j)
Test results.
(k)
Any other relevant information required by the purchaser for the assessment of test
results.
(l)
Date and place of test.
(m)
Report number or other means of identifying the report.
(n)
Identification and signatures of testing personnel.
4.3
TEST REPORT
(a)
Name of laboratory or testing authority.
(b)
Report number and date of issue.
(c)
Identification of the component.
(d)
Product specification.
(e)
Material specification or type.
(f)
Areas of the component(s) tested.
(g)
Surface condition of the test areas.
(h)
Number of this Australian Standard, i.e. AS 2062, identification of the specific test
procedure, and details of any departures from that procedure.
(i)
Test results.
(j)
Any other relevant information required by the purchaser for the assessment of test
results.
(k)
Date and place of test.
(l)
Identification and signature of the person responsible for the test report.
The test report shall contain at least the following information:
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APPENDIX A
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PURCHASING GUIDELINES
(Informative)
A1 GENERAL Australian Standards are intended to include the technical requirements
for relevant products and processes, but do not purport to comprise all the necessary
provisions of a contract. This Appendix contains advice on the information to be supplied by
the purchaser at the time of enquiry or order.
A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER The purchaser of
penetrant testing services should supply the following information, when applicable, at the
time of enquiry or order:
(a)
Job reference number.
(b)
Description and identity of the component(s), including product specification reference
number, the material the component(s) are manufactured from, and area(s) to be tested.
NOTE: The supply of a sketch or a photograph of the area(s) to be tested may be helpful for
the correct setting up of any testing procedure.
(c)
Sampling procedures.
(d)
Manufacturing and service history.
NOTE: Written details of the manufacturing process would aid in the interpretation of
indications given by the test.
(e)
Surface condition (see Clause 3.2).
(f)
Whether any necessary surface preparation (apart from solvent precleaning) is to be
carried out by the supplier or the purchaser.
(g)
Penetrant type, method and sensitivity level required.
(h)
The form(s) of developer that are acceptable.
NOTE: If non-metallic materials are required to be tested, or if the penetrant test materials are
likely to come in contact with non-metallic materials, the possibility of damage to these
materials should be taken into account. In some cases, materials outside the scope of
MIL-I-25135 may be required. When the selection of materials is left to the testing agency, full
information concerning possible contact with non-metallic materials should be supplied so that
the appropriate test materials may be selected.
(i)
Acceptance criteria, if not specified in Item (b).
(j)
Any necessary departures from test methods described in this Standard.
(k)
Whether a permanent record of penetrant indications such as a photograph is required.
(l)
Whether the product is required to be cleaned after testing, and the type of corrosion
inhibitor treatment required.
(m)
Details of tests, other than process control tests, required to be carried out on penetrant
materials.
(n)
Reference to this Australian Standard, i.e. AS 2062.
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AS 2062 — 1997
APPENDIX B
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EXAMPLES OF ACCEPTANCE CRITERIA FOR INDICATIONS
OF VARIOUS SIZES
(Informative)
This Appendix is included to assist with the classification of maximum allowable indication
sizes. It comprises Table B1 and Table B2 which give examples of acceptance criteria that
may be used for the specification of maximum indication sizes, if no other acceptance
standards are available.
TABLE
B1
EXAMPLE OF A SPECIFICATION FOR MAXIMUM
PERMISSIBLE NUMBER OF ROUNDED INDICATIONS*
Maximum
dimension of
indication
mm
<1.0
≥1.0
≤1.8
>1.8
≤2.6
>2.6
≤3.9
>3.9
≤5.8
>5.8
≤8.6
>8.6
≤12.4
>12.4
1
Any length
0
0
0
0
0
0
0
0
2
≤0.4
0
0
1
2
2
3
3
4
3
≤0.4
>0.4 ≤0.8
0
0
1
0
2
0
2
1
3
2
4
3
4
3
5
4
4
≤0.4
>0.4 ≤0.8
>0.8 ≤1.2
1
0
0
2
0
0
2
1
0
3
2
1
3
2
1
4
3
2
5
4
3
6
5
4
5
≤0.4
>0.4 ≤0.8
>0.8 ≤1.2
>1.2 ≤1.6
2
1
0
0
3
2
1
0
3
2
1
0
4
3
2
1
4
3
3
1
5
4
3
2
6
5
4
3
7
6
5
4
Class
6
Material thickness range, mm
Specific acceptance limits subject to agreement
* The maximum number of permissible indications relates to 150 mm2 of surface area with the major
dimension of the containment area not to exceed 150 mm.
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TABLE
B2
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EXAMPLE OF A SPECIFICATION FOR MAXIMUM
PERMISSIBLE NUMBER OF LINEAR INDICATIONS
(see Notes 1 and 2)
Material thickness range, mm
Indication length
Class
mm
<1.0
≥1.0
≤1.8
>1.8
≤2.6
>2.6
≤3.9
>3.9
≤5.8
>5.8
≤8.6
>8.6
≤12.4
>12.4
1
Any length
0
0
0
0
0
0
0
0
2
≤0.8
0
0
0
0
1
2
2
3
3
≤0.8
>0.8 ≤1.6
0
0
0
0
1
0
2
1
3
2
4
3
4
4
5
4
4
≤0.8
>0.8 ≤1.6
>1.6 ≤3.2
0
0
0
1
0
0
2
0
0
3
1
0
4
2
0
4
3
0
5
4
1
5
4
2
5
≤0.8
>0.8 ≤1.6
>1.6 ≤3.2
>3.2 ≤6.4
1
0
0
0
2
1
0
0
2
2
0
0
4
2
1
0
4
4
2
0
5
4
3
1
6
5
4
2
6
5
4
3
6
Specific acceptance limits subject to agreement
NO TES:
1 The maximum number of permissible indications relates to 150 mm2 of surface area with the major
dimension of the containment area not to exceed 150 mm.
2 Any indication is required to be separated from any other indication (edge to edge) by a minimum
distance equal to the maximum length of the larger of the two indications.
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AS 2062 — 1997
APPENDIX C
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PROCESS CONTROL PROCEDURES FOR PENETRANT TESTING SYSTEMS
(Normative)
C1 SCOPE This Appendix states the procedures and tests required to assure that the
penetrant test materials and equipment provide an acceptable level of performance.
C2 GENERAL Prior to placing penetrant materials in use, it shall be verified that the
materials have been manufactured to the requirements of MIL-I-25135 (or otherwise as
approved by the purchaser) and that, if an emulsifier is to be used, it is from the same
manufacturer as the penetrant manufacturer, and is designated by the manufacturer as suitable
for use with that penetrant.
Penetrant testing personnel shall be alert to any change in performance, colour, odour,
consistency, or appearance of all penetrant test materials and shall conduct appropriate tests
if they have reason to believe that the quality may be unsatisfactory.
When penetrant testing materials are held in open containers, the containers shall be provided
with a lid which shall be closed when the system is not in use, in order to prevent
contamination and reduce evaporation.
All temperature and pressure indicators and controls shall be checked at the start of each shift
and adjustments made if the indicators show readings outside the nominated range. This
includes the temperature and pressure of the water used for washing, the pressure of any
compressed air used in the penetrant test process, and the temperature of the drying oven. The
indicators and controls used with water and compressed air shall be calibrated annually, or
more frequently if considered necessary, or required by contract. The drying oven indicator
shall be calibrated quarterly (see Paragraph C11).
C3
SYSTEM PERFORMANCE TEST
C3.1 System performance test Where the penetrant materials are subject to deterioration,
the system shall be tested daily for performance using one or more known-discontinuity
standards. This requirement does not apply when the penetrant is sprayed from aerosol
containers. The test shall be performed by processing each known-discontinuity standard
through the system using procedures and processing times appropriate for the standard and
comparing the indications obtained with those obtained from unused samples of the same
materials. This comparison shall be made with photographs or other such records of
indications previously obtained from the same known-discontinuity standard using the unused
materials.
When any deterioration in the indications is detected, the standard shall be thoroughly
cleaned, preferably using an ultrasonic cleaner, and the test repeated. If the second test also
shows a deterioration in the indications, or if there is any doubt that the quality of the
indications is equal to the quality of those previously obtained, a sensitivity comparison test
shall be performed (see Paragraph C4). If the sensitivity comparison test indicates no
deterioration in the penetrant system, the known-discontinuity standard shall be discarded and
replaced.
C3.2 Known-discontinuity standards The discontinuities in the standard shall be capable
of demonstrating unsatisfactory system performance. Star-cracked test panels, such as those
indicated in Appendix D, or similar commercially available test panels, are generally suitable.
Where more than one penetrant test system is in use, different known-discontinuity standards
shall be used for each system; the standards shall be labelled to ensure their identification.
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The known-discontinuity standards shall be thoroughly cleaned before and after use,
preferably using ultrasonic cleaning, and checked for residual penetrant using appropriate
illumination. When not in use they shall be stored in a closed container, preferably containing
volatile solvent.
C4
PENETRANT SENSITIVITY COMPARISON TEST
C4.1 General Penetrant sensitivity comparison tests, which compare the sensitivity of the
penetrant in use with unused penetrant of the same batch, shall be performed when penetrant
is subject to deterioration. A test shall be performed at least once a month and whenever
there is any doubt about the sensitivity of the in-use penetrant.
The test shall be performed using cracked nickel-chromium-plated panels with cracks in the
range 10 µm to 50 µm deep and approximately 1 µm to 2 µm wide. Either a single cracked
panel or two identical cracked panels may be used.
Cracks 10 µm to 20 µm deep shall be used when testing high and ultra-high sensitivity
penetrants. Cracks 30 µm to 50 µm deep shall be used for lower sensitivity and colour
contrast penetrants.
Where both colour contrast and fluorescent penetrants are in use, separate panels shall be
used for each penetrant type; the panels shall be labelled to ensure their identification.
C4.2 Test panel A suitable test panel is the type B comparative reference panel described
in JIS Z 2343.
C4.3 Test procedure The following test procedure shall be used:
(a)
Thoroughly clean the test panel(s) preferably using an ultrasonic cleaner, and check for
residual penetrant using appropriate illumination.
(b)
If a single panel is used, apply a small amount of the penetrant in use to one side of
the cracked surface by brushing or swabbing, and apply a similar amount of the unused
penetrant of the same batch to the other side of the cracked surface so that each crack
has in-use penetrant applied to one end and unused penetrant to the other.
If two identical panels are used, apply the penetrant in use to the cracked surface of
one panel by brushing or swabbing and similarly apply unused penetrant of the same
batch to the cracked surface of the other panel.
(c)
After the application of the penetrant, allow a dwell time of five minutes and during
which time tilt the panel(s) so that the penetrant drains to one end. When a single panel
is used this will minimize spreading of the two samples of penetrant into the middle.
(d)
At the end of the dwell time, process the panel(s) using unused emulsifier, if
applicable, and unused developer, following procedures and times determined to be
appropriate for the panel(s).
(e)
On completion of the developer dwell time, inspect the panel(s) using appropriate
lighting conforming to the requirements of Clause 3.7.1 or 3.7.2.
(f)
Thoroughly clean the test panel(s), preferably using ultrasonic cleaning, and check that
there is no evidence of remaining penetrant, using appropriate lighting. When not in
use store the panel(s) in a closed container, preferably containing volatile solvent.
If any reduction in the number, brightness, continuity, or clarity of the indications produced
by the in-use penetrant compared with the unused penetrant is detected, thoroughly clean the
panel, preferably using an ultrasonic cleaner, and repeat the test, but with the in-use penetrant
applied to the side or panel to which the unused penetrant was previously applied, and vice
versa. If any reduction in the quality of the indications formed using the in-use penetrant is
still evident, the penetrant shall be discarded and replaced. However, if the indications
formed using the unused penetrant show a reduction in quality compared with those formed
by the in-use penetrant, the test panel(s) shall be discarded and the test repeated using one
or two new panels.
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AS 2062 — 1997
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C5 PENETRANT REMOVABILITY TEST (applicable to water-washable penetrants)
C5.1 General Penetrant testing personnel shall be alert to any change in the removability
of water-washable penetrants which cannot be attributed to the condition of the test surface.
If there is any doubt concerning the removability of the water-washable penetrant, a
removability test shall be performed.
C5.2 Test procedure The following test procedure shall be used:
(a)
Apply the in-use penetrant to a test panel prepared in accordance with Paragraph D3
of Appendix D, or equivalent, and unused penetrant of the same batch to another
identical panel.
(b)
Allow a drain time of 10 min with the panels identically tilted to an angle of
approximately 60° with the abraded surface upward.
(c)
After completion of the drain time, wash the abraded side of the panels simultaneously
for 60 s with a spray that meets the requirements of Clause 3.4.2.2. When a fluorescent
penetrant has been used, washing is carried out under subdued ambient white light
conditions with the panels irradiated with black light of sufficient irradiance so that the
removal process can be observed. Take care that the spray is applied equally to both
panels, and the removal process is monitored for any differences between the two
panels.
(d)
On completion of the washing, inspect the abraded surface of the panels using
appropriate lighting conforming to the requirements of Clause 3.7.1 or 3.7.2.
If the two panels show any distinct difference during the removal process or in the
amount of residual penetrant, discard and replace the penetrant. Before discarding
penetrant, repetition of the test, but with the in-use penetrant applied to the panel to
which the unused penetrant was previously applied, and vice versa, is recommended
to ensure that any differences observed cannot be attributed to differences in the test
panels.
C6
CONTROL OF LIPOPHILIC EMULSIFIER
C6.1 General When lipophilic emulsifier is applied by immersion, the level of the
emulsifier in the tank shall be recorded and regular additions made to maintain the same
level. Because of relatively large drag-out losses and the regular additions of emulsifier,
penetrant contamination of emulsifier held in a tank for application by immersion usually
reaches a constant level. However, if the emulsifier becomes excessively contaminated,
indicated by inadequate removal after normal emulsifier dwell times, a schedule either for
regular removability testing in accordance with Paragraph C6.2 or for regular replacement
of the emulsifier shall be prepared and put into practice.
C6.2 Removability test Penetrant removability testing of systems using a lipophilic
emulsifier shall be performed as follows:
(a)
Apply the in-use penetrant by the immersion of two identical test panels prepared in
accordance with Paragraph D3 of Appendix D, or equivalent.
(b)
Allow a drain time of 10 min with the panels identically tilted to an angle of
approximately 60°.
(c)
After completion of the drain time, apply in-use emulsifier to the abraded face of one
panel and unused emulsifier of the same batch to the abraded face of the other panel.
Apply the emulsifier in the same manner to both panels, either by immersion or
flowing.
Allow an emulsifier dwell time of 2 min during which the panels are identically tilted
to an angle of approximately 60°.
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AS 2062 — 1997
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(d)
Wash for 60 s with a spray that meets the requirements of Clause 3.4.3. When a
fluorescent penetrant has been used, washing is carried out under subdued ambient
white light conditions with the panels irradiated with black light of sufficient irradiance
so that the removal process can be observed. Take care that the spray is applied equally
to both panels, and that the removal process is monitored for any differences between
the two panels.
(e)
On completion of the washing, inspect the surface of the panels using appropriate
lighting conforming to Clause 3.7.1 or 3.7.2.
If the two panels show any distinct difference in the removal process or in the amount
of residual penetrant, discard and replace the emulsifier. Alternatively, extract at least
25% of the emulsifier from the tank and replace it with unused emulsifier. However,
this procedure shall be carried out only once before replacing the entire volume in the
tank. Before discarding emulsifier, repetition of the test, but with the in-use emulsifier
applied to the panel to which the unused emulsifier was previously applied, and vice
versa, is recommended to ensure that any differences observed cannot be attributed to
differences in the test panels.
C7
CONTROL OF HYDROPHILIC EMULSIFIER
C7.1 General Penetrant floating on the surface of hydrophilic remover contained in an
immersion tank shall be removed at least daily. In addition, a schedule either for regular
removability testing in accordance with Paragraph C7.2, or for regular replacement of the
remover before it becomes excessively contaminated, indicated by inadequate removal after
normal remover dwell times, shall be prepared and put into practice.
C7.2 Removability test Penetrant removability testing of systems using a hydrophilic
remover shall be performed as follows:
(a)
Apply the in-use penetrant by immersion of two identical test panels prepared in
accordance with Paragraph D3 of Appendix D, or equivalent.
(b)
Drain for 10 min with the panels identically tilted to an angle of approximately
60° with the abraded surfaces upwards.
(c)
After completion of the drain time, process one panel through the removal system using
procedures and times which have previously been determined to be the minimum
required to produce a background-free surface when unused emulsifier of the
concentration in the test system is used.
(d)
Identically process the second panel through the removal system, except that the
immersion time in the hydrophilic remover is doubled.
NOTE: A typical procedure for the first panel would be a 10 s prewash, 10 s drain time, 20 s
immersion in remover with gentle agitation, 5 s drain and 10 s wash.
When a fluorescent penetrant has been used, washing is carried out under subdued
ambient white light conditions with the panels irradiated with black light of sufficient
irradiance so that the removal process can be observed. Monitor the removal process
for any differences between the two panels.
(e)
On completion of the washing, inspect the abraded surface of the panels using
appropriate lighting conforming to Clause 3.7.1 or 3.7.2.
If the two panels show only negligible differences in the amount of residual penetrant,
discard and replace the entire volume of remover in the tank.
NOTE: With use, the remover becomes contaminated with penetrant, and as a result, the test
panel with the short remover immersion time will show some residual penetrant. With further
contamination, the amount of penetrant on the test panel with the short remover immersion time
stabilizes, and the second panel begins to show some residual background.
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AS 2062 — 1997
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C8 CONTROL OF DRY DEVELOPER Dry developer shall be checked daily to ensure
that it is fluffy and not lumpy or caked. In addition, dry developer that is recycled shall be
checked daily for penetrant contamination by spreading a sample into a thin layer on a flat
surface. Dry developer that is lumpy, caked, or not fluffy, or, when spread, shows 10 or more
fluorescent specks in a 100 mm circle, shall be discarded.
C9 CONTROL OF WATER-BASED DEVELOPER Water-based developer applied by
immersion shall be checked daily for penetrant contamination and coverage, by immersing
a clean aluminium panel approximately 10 mm wide and 250 mm long in the developer,
drying, then examining the panel using lighting appropriate to the type of penetrant used.
Water-based developer that shows evidence of penetrant shall be discarded. Developer that
does not uniformly coat the panel shall either have additional wetting agent added and be
retested, or shall be discarded. In addition, the concentration of water-based developers shall
be checked weekly using a hydrometer and thermometer, and shall be maintained within the
range recommended by the developer supplier.
Water-based developers applied by spray or flowing shall be checked daily for coverage and
weekly for concentration.
C10 CONTROL OF SOLVENT-BASED DEVELOPER The following precautions shall
be taken when using a solvent-based developer, other than that applied from aerosol
containers:
(a)
Before transferring developer from one container to another, ensure that it is thoroughly
agitated to ensure that the concentration remains constant.
(b)
Keep the container of solvent-based developer closed except when transferring
developer, to ensure that evaporation of the liquid does not occur.
C11 DRYING OVEN CALIBRATION The temperature control and the temperature
indicator of the oven used for drying components during processing shall be calibrated at
least every three months. The allowable error in temperature measurement shall be no greater
than ±3°C.
C12
CONTROL OF LIGHTING CONDITIONS AND THE INSPECTION STATION
C12.1 Fluorescent penetrant systems The white light illuminance at the wash station and
the inspection station shall be checked using a white light meter when these stations are set
up, or are first used for testing to this Standard, and whenever any change to either station
which could affect the illuminance is made. The illuminance at the inspection station,
including that produced by any black light sources used, shall be a maximum of 20 lx at the
surface of parts being inspected.
Filters of mercury-arc black light sources used in the penetrant testing process shall be
checked daily for cleanliness, correct fitting, and integrity, as appropriate, before switching
on, and shall be cleaned, corrected or replaced when required for optimum output. In
addition, the irradiance of black light sources used for final inspection shall be checked
weekly, or at other intervals that ensure compliance with this Standard, at a distance of
380 mm from the front of the bulb or filter. The irradiance at 380 mm from black light
sources used for final inspection shall be not less than 10 W/m2.
NOTE: 1 W/m2 = 100 µW/cm2.
C12.2 Colour-contrast penetrant systems The illuminance at the inspection station shall
be checked at least monthly and shall be maintained at not less than 1000 lx at the surface
of parts being inspected (see Clause 3.7.1).
C12.3 Calibration of meters The black light and white light meters shall be calibrated
against a recognized national Standard at intervals recommended by the manufacturer or at
intervals not exceeding 12 months, whichever is the smaller.
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AS 2062 — 1997
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C12.4 Inspection station cleanliness The inspection station should be checked daily for
cleanliness. It shall be maintained in a clean condition, free from penetrant contamination and
clutter and, for fluorescent penetrant systems, free from fluorescing materials.
C13 DOCUMENTATION Detailed penetrant system process control procedures, which
implement the applicable requirements of this Standard, shall be prepared. Particular attention
shall be paid to the details of the system performance test, the penetrant sensitivity
comparison test and the removability test(s), and all procedures shall be documented in
sufficient detail to ensure that they achieve the intended control and that all tests are
repeatable.
C14 RECORDS OF TEST RESULTS A permanent record of the results of all tests,
measurements, and calibrations shall be maintained.
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AS 2062 — 1997
APPENDIX D
Licensed to MRS GABRIELLE COOPER on 10 May 2010. 1 user personal user licence only. Storage, distribution or use on network prohibited (10113017).
REQUIREMENTS FOR STANDARD TEST PANELS FOR EVALUATING
THE PERFORMANCE OF PENETRANT TESTING MATERIALS
(Normative)
D1 SCOPE This Appendix specifies the requirements for and the method of manufacture
of standard cracked test panels used for system performance testing, and of abrasive-blasted
test panels used for penetrant removability testing.
D2 STANDARD CRACKED TEST PANELS
prepared as follows:
Standard cracked test panels shall be
(a)
Material
Annealed 302 type stainless steel complying with AS 1449.
(b)
Nominal dimensions
(c)
Plating Hard chrome electroplate on one side to achieve a thickness of 100 µm to
150 µm (see Paragraph D4 for the plating method). Plating build-up at edges should
be blended smooth to maintain this thickness.
(d)
Force machine A uniaxial machine for force application complying with the
requirements for Grade A machines as specified in AS 2193.
(e)
Indentor
(f)
Anvil A 10 mm × 100 mm × 200 mm acrylic plate containing a centrally located
10 mm diameter hole.
(g)
Method of application of indentations to produce crack patterns Make five
indentations on the unplated side of the test panel, the first positioned 25 mm from one
end and the remainder at 25 mm spacings along the centre of the panel (see Figure D1),
with a force machine using the acrylic plate as the anvil between the test panel and the
bed of the force machine. The ball is positioned on the test panel and located over the
hole in the acrylic plate. Apply the force slowly and remove it as soon as the required
force value is achieved. Indentations shall be made with indicated forces of 2670 N,
2225 N, 1780 N, 1335 N and 1110 N.
2 mm × 50 mm × 150 mm.
A 10 mm hardened steel ball.
D3 ABRASIVE-BLASTED TEST PANELS
prepared as follows:
Abrasive-blasted test panels shall be
(a)
Manufacture panels having nominal dimensions 2 mm × 50 mm × 100 mm from
annealed type 301 or type 302 stainless steel complying with AS 1449.
(b)
Abrasive-blast one side with grit of nominal size 0.15 mm using an air pressure of
415 ±5 kPa, the gun being held at a distance of approximately 0.5 m from the test
panel (see AS 1627.4).
D4 METHOD OF ELECTROPLATING STANDARD CRACKED TEST PANELS The
method of preparing and electroplating of standard test panels shall be as follows:
(a)
Drill two holes of approximately 4 mm diameter along the centre-line and as close as
possible to the end of each test panel.
(b)
Bolt the test panel to a low carbon steel backing jig plate having nominal dimensions
of 1.25 mm × 150 mm × 300 mm.
NOTE: The backing jig is used to prevent chromium plating of the back of the test panel and
to prevent excessive chromium plating build-up on its edges.
(c)
Attach appropriate electrical plating connections.
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AS 2062 — 1997
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(d)
Degrease in trichloroethylene.
(e)
Scrub the test panel with a slurry of pumice and water until clean, and swill thoroughly
in water.
(f)
Anodically etch at 5 V for 1.5 min at ambient temperature in the following solution:
(i)
Sulfuric acid (ρ20 1840 kg/m 3) . . . . . . . . . . . . . . . . . . . 4 parts by volume.
(ii)
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 part by volume.
(g)
Swill thoroughly in water.
(h)
Electroplate the test panel in the chromium electroplating solution comprising Items (i)
and (ii), and under conditions given in Items (iii), (iv) and (v), as follows:
(i)
Chromic acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 g/L.
(ii)
Sulfuric acid (ρ20 1840 kg/m 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 g/L.
(iii)
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55°C.
(iv)
Plating time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 h.
(v)
Current density—raise slowly to . . . . . . . . . . . . . . . . . . . . . . . . 32 A/dm2.
NOTE: A plating time of 16 h under these conditions deposits approximately 150 µm of
chromium.
(i)
Remove the test panel from the plating bath and swill thoroughly in water.
(j)
Remove the test panel from the plating jig, swill thoroughly in hot water and dry.
DIMENSIONS IN MILLIMETRES
FIGURE D1
STANDARD CRACKED TEST PANEL
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