FLUORESCENT PENETRANT

Quick Start Guide to

Liquid Penetrant Testing

• Penetrants
• Emulsifiers
• Developers
• Removers

www.magnaflux.com

[email protected] +1 847-657-5300
 Technical Info

The Importance of Liquid Penetrant Inspection

Liquid penetrant inspection is a nondestructive test method which does not harm the parts being inspected. The testing
methods detect cracks, fractures, laps, seams and other flaws that are open to the surface that may have been caused
by fatigue, impact, quenching, machining, grinding, forging or overload. The process is used on machined parts, castings,
forgings and other items that will be placed into service or already in service requiring maintenance.

The process involves applying a penetrant chemical, visible or fluorescent, directly to the part that’s to be inspected. The
excess penetrant is removed and a developer is applied to draw the penetrant deep from the cracks to the surface of the
part. The penetrant contrasts with the surface of the part so the crack is identified more easily. Fluorescent penetrants are
used under an ultraviolet light that makes penetrant fluoresce. The chemical, equipment and NDT accessory choices have
grown but the fundamentals and benefits of liquid penetrant inspection have endured the test of time.

Versatile material uses and applications

Liquid penetrant inspection can be performed on most materials that are not extremely rough or porous,
including material composition that is metallic or nonmetallic, magnetic or nonmagnetic and conductive
or nonconductive.

Rapidly inspect large areas and high volumes of parts

Liquid penetrant inspection is a fast, easy and efficient means of surface inspection. Large quantities of
parts or materials can be inspected quickly. Parts of almost any shape, size and geometry can be inspected.

Identify small surface discontinuities with high sensitivity

Sensitivity levels are a classification system specifically for fluorescent liquid penetrants that are not applied
to visible penetrants. Higher sensitivity penetrants have the capability to detect smaller cracks and defects.

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Selecting the Correct Penetrant
Method Per AMS 2644

Penetrant Types
• Type 1: Fluorescent dye
• Type 2: Visible dye

Penetrant Methods
• Method A: Water washable
• Method B: Post emulsifiable, lipophilic
• Method C: Solvent removable
• Method D: Post emulsifiable, hydrophilic

Developer Forms
• Form a: Dry powder
• Form b: Water soluble
• Form c: Water suspendible
• Form d: Nonaqueous Type 1 fluorescent
• Form e: Nonaqueous Type 2 visible dye

This image compares penetrant with different sensitivity levels on NiCr panels.

Differences Between Sensitivity

AMS 2644 Penetrant Sensitivity Levels
Sensitivity levels are a classification system for fluorescent liquid penetrants which is outlined in AMS 2644 Inspection
Material, Penetrant specification. Sensitivity levels are not applied to visible penetrants.

• Level ½: Ultra low sensitivity

• Level 1: Low sensitivity
• Level 2: Medium sensitivity
• Level 3: High sensitivity
• Level 4: Ultra high sensitivity

How to Determine Which Sensitivity Level to Use

The primary consideration when deciding on which sensitivity level penetrant to use is the guidance provided by governing
specifications. The penetrant sensitivity level is stated in the working specifications for the process. This is particularly true
when penetrant inspection involves safety critical parts. The specifications and standard operating procedures will dictate
the penetrant sensitivity to be used.

If the penetrant sensitivity level is not already established by a specification or procedure, evaluation on actual parts with
a few penetrants is strongly recommended. A lower sensitivity penetrant works well on rough surfaces, while a higher
sensitivity penetrant is suitable for highly machined surfaces. Penetrant evaluation on actual parts is important to confirm
proper sensitivity with acceptable background fluorescence to detect the type of defects typically found on the parts.
Penetrant evaluation on actual test parts can also confirm proper processing parameters such as dwell time and rinse time.

It is possible that more than one penetrant sensitivity level will be used in a facility because of different parts, processes,
and customer specifications in use at a given location.

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 Technical Info

Common Applications Common Terms

Background – the surface of the test part

against which the indication is viewed. It may
be the natural surface of the test part or the
developer coating on the surface.

Bleedout – the action of an entrapped liquid

penetrant in surfacing from discontinuities to
form indications.

Developer – a material that is applied to the

test surface to accelerate bleedout and to
Aerospace processes commonly use Method D Level 4 enhance the contrast of indications.
penetrants for safety critical rotating parts
including turbine blades. Developing Time – the elapsed time
between the application of the developer and
the examination of the part.

Dwell Time – the total time that the penetrant

or emulsifier is in contact with the test surface,
including the time required for application and
the drain time.

Inspection – visual examination of the test

part after completion of the liquid penetrant
processing steps.

Liquid Penetrant Testing – a nondestructive

Automotive processes commonly use Method A Level 1 test that uses liquid penetrant materials
penetrants to inspect non ferrous components such to penetrate and detect various types of
as steering knuckles and subframes.
discontinuities open to the surface.

Liquid Penetrant – a solution of dye with

the ability to penetrate into fine openings.

Precleaning – the removal of surface

contaminants from the test part so that
they will not interfere with the examination
process.

Sensitivity Level – the descriptive term

for identifying the capability of a penetrant
system to indicate the presence of a surface-
connected discontinuity.
Power Generation commonly uses Method A Level 2
penetrants to inspect non ferrous parts such as large castings,
forgings, impeller blades, and more.

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 Fluorescent Liquid Penetrant Testing
Method A Method B/D Method C
Water Washable Post Emulsifiable Solvent Removable

Preclean with Preclean with Preclean

Aqueous Cleaner Aqueous Cleaner

Apply Penetrant
Dwell for 10−30 min.

Apply Penetrant
Dwell 10–30 min.
Apply Penetrant
Dwell 10–30 min.
Method B Method D

Apply Rinse
Emulsifier 50−100°F /
10−38°C at <40
psi / 2.75 bar

Rinse
50−100°F / 10−38°C at
<40 psi / 2.75 bar Apply
Emulsifier Remove Excess Penetrant
Apply cleaner on cloth and
then wipe the part

Form a Form b/c

Dry Apply Rinse

50−100°F / 10−38°C at <40 psi / 2.75 bar
140°F / 60°C Developer

Form a Form b/c Apply Developer

Dwell 10–60 min.
Dry Apply
140°F / 60°C Developer
Apply Dry
Developer 140°F / 60°C
Dwell 10 Dwell 10
min. – 4 hr. min. – 2 hr.

Apply Dry
Developer 140°F / 60°C
Dwell 10 min. – 4 hr. Dwell 10 min.– 2 hr.
Inspect

Inspect

Inspect

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 Product Selection

1 2 3 4 5
Select Select Select Select Select
Method Penetrant Emulsifier Developer Cleaner/Accessories

Foam Level
Description

Description
Removal

pH Level
Method

Method
Product Product Product

Level

Type

Form
Part Numbers Part Numbers Part Numbers
Name Name Name

Cleaner, Class 2
Heavy-Duty Solvent-based
5 gal pail..........01-3159-40

Dry Powder
Aerosol case.....01-5750-78
ZL-15B 1/2 20 gal drum.....01-3159-30
10 lb pail...................01-3328-69 1 gal.....................01-5750-35
55 gal drum.....01-3159-45 ZP-4D* a 20 lb pail..................01-3328-75 SKC-S 5 gal....................01-5750-40
55 gal.................01-5750-45

5 gal pail..........01-3263-40
ZL-19 1 55 gal drum....01-3263-45

Suspendible

High-Alkaline

Alkaline
Water
Water Washable

ZP-5B A C c Daraclean

Low
25 lb pail....................01-3341-81 55 gal.................01-6060-45
4 x 1 gal pail.....01-3272-35 283
5 gal pail..........01-3272-40
ZL-60D* AC 2 20 gal drum....01-3272-30
55 gal drum....01-3272-45

Nonaqueous

Moderate
Aerosol case...........01-3354-78

Neutral

Neutral
5 gal pail..........01-3274-40 ZP-9F* d Daraclean

C
5 gal pail..................01-3354-40 55 gal.................01-6040-45
ZL-67* 3 20 gal drum.....01-3274-30
236
55 gal drum.....01-3274-45

5 gal pail..........01-3267-40
ZL-56 4

Alkaline

Alkaline
55 gal drum....01-3267-45

Soluble
Daraclean

Water-
5 gal...................01-6000-40

Low
20 lb pail...................01-3381-75
ZP-14A C b 50 lb pail......................01-3381-8 282 55 gal.................01-6000-45

Emulsifier
Removal
Method

Method

Product
Level

Dry Powder
Type

Part Numbers Product

Name Part Numbers Product
Name 10 lb pail...................01-3328-69 Description Part Numbers
ZP-4D a 20 lb pail...................01-3328-75 Name

Nonaqueous
5 gal pail............01-3123-40
Lipophilic

ZL-2C 2 55 gal drum......01-3123-45 5 gal pail.........01-3550-40 UV technology

ZE-4E B 20 gal drum....01-3550-30
ZP-9F d
Aerosol case...........01-3354-78 developed
55 gal drum....01-3550-45 5 gal pail...................01-3354-40 ST700 Stationary......628243
UV Lamps exclusively for EV6000 Hand-Held.625784
nondestructive
Post Emulsifiable

B C D testing
4 x 1 gal pail..... 01-3187-35

Suspendible
5 gal pail...........01-3187-40
ZL-27A* B CD 3

Water
20 gal drum......01-3187-30
55 gal drum......01-3187-45 ZP-5B c 25 lb pail.....................01-3341-81

Sprayers for
Hydrophilic

penetrants,

D
5 gal pail.........01-3625-40 Portable Sprayer.......625773
4 x 1 gal pail......01-3188-35 ZR-10E* D 20 gal drum....01-3625-30 Applicators developers, Water Spray Gun......520090

Soluble
5 gal pail...........01-3188-40

Water-
ZL-37* 4 55 gal drum....01-3625-45 20 lb pail....................01-3381-75 cleaners, and
20 gal drum......01-3188-30 ZP-14A b 50 lb pail....................01-3381-89 water
55 gal drum......01-3188-45

*Commonly used product

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+1 847-657-5300
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