Dye Penetrant Test

Engineering
Materials
Module 7:Dye
Penetrant Test
Dye Penetrant Test

Module Objectives
After the completion of this module, the student will
be able to:
Explain the basic principles of the Dye Penetrant test.

Describe the main parts of the Dye Penetrant Kit used to
perform the Dye Penetrant test.
Identify the different types of penetrant used in the test.
Recommend the Dye penetrant test for a specific material.
Describe the most common flaws expected to be located
after the test.
Explain the Dye penetrant test procedure.
Carry out a Dye Penetrant test for different speciemen using a
certain procedure.
Use the product data sheet to identify relevant inforation.
Record and report the defects using standard report form.
A video
Dye Penetrant Test
http://www.youtube.com/watch?v=yvjfeZxu_Bw
Dye Penetrant Test

Introduction
Liquid penetrant is one of the most widely used NDT
methods.
It offers a fast, cheap and relatively simple means of
surface inspection, making it attractive to a large number
of industries.
It is used to detect surface flaws in almost all non-porous
materials, and this includes magnetic and non-magnetic
materials.
There are numerous non-destructive tests used to evaluate the

material, the most commonly used ones are:
1. Visual Test (VT)

2. Dye Penetrant Test (PT)
3. Magnetic Particles Test (MT)
4. Ultrasonic Test (UT)
5. Radiographic Test (RT)
* Dye penetrant is one of the most widely
Dye Penetrant Test

The portable spray cans test
kit consists of 3 main bottles
cleaner, penetrant, and
developer.
The cleaner is used for
cleaning the test piece
before and after the test.
The penetrant is the dye
used during the test, and
The developer is used to
show the indications and
make them visible.
Dye Penetrant Test
Water raises
more in the
small
diameter
tube
because of
the capillary
action
Principle of the test
The test is used to locate

surface breaking flaws by bleed
out of a colored or fluorescent
dye from the flaw.
The technique is based on the

ability of a liquid to be drawn
into a "clean" surface breaking
flaw by capillary action.
C ra c k
P e n e tra n t
d ra w n d u e to
c a p illa ry
a c tio n
Enlarged view
This effect can cause liquids to

flow against the force of
gravity. (Fig. 7.1).
Fig. 7.1:(a) Cappilary action in

tubes with different diameters. (b)
Cappilary action causes the
penetrant to be drawn into the
crack.
2. Types of penetrant
There are mainly two types
of penetrant used:
1) Visible penetrant: the dye
color used is usually red but
other colors can be
purchased for special
applications.
2) Fluorescent penetrant:
the dye used has a
Fluorescent material to show
the defects more clearly.
Fig. 7.2:(a) Visible penetrant

(b) Fluorescent penetrant.
Uses and limitations of the test.

Uses:
Penetrant test (PT) is used to detect welding,

casting and forging flaws such as cracks,
porosity, and other defects that break the
surface.
Limitations:
The material should have relatively smooth

and non-porous surface to provide true test
results.
3.1 What Cannot be inspected

using PT?
Components with rough surfaces, such as

sand castings, that traps and holds the
penetrant.
Porous ceramics.
Wood and other fibrous materials.
Plastic parts that absorb or react with the
penetrant materials.
Components with coatings (paints) that
prevent the penetrant from being drawn into
the defects.
Examples of surface flaws located using the

penetrant test
1. Cracks:
They are considered the most critical discontinuity as

they propagate very fast.
Cracks are most commonly initiated when the load or
stress applied to a member exceeds its tensile strength.
Cracks could be found in many parts that are
manufactured using operations such as welding,
casting and forging. (Fig. 6.3 (a-b)).
Crack
Crack
Fig. 6.3: (a) Welding crack.
(b) In service crack.

penetrant test:
Incomplete Fusion: It is a welding flaw in which

fusion doesnt occur between the base metal
and the weld metal. It is also called incomplete
fusion as the weld metal is less than required. (Fig.
7.3c). I n c o m p le te fu s io n
W e ld
Base metal
Fig. 7.3:
c) Incomplete fusion.

penetrant test
3. Porosity:
It is a cavity type flaw formed by the gas
entrapment during solidification.
Porosity could be found in casting, and welding
products. (Fig. 7.3d).
Porosity
Fig 7.3: (d) Welding porosity.
4. DYE penetrant test procedure

Surface
preparation
The surface must be free of dirt, scale, oil, grease,

water, and all the other contaminants that may
prevent the penetrant from entering flaws.

Penetrant application
The penetrant material is applied by

brushing, spraying or immersing the part in a
penetrant bath as shown in Fig. 7.5 (a-c).
Fig. 7.5: Applying the penetrant by (a) Brushing (b) Spraying. (c)
Immersing in a bath.

Penetrant Dwell
Penetrant dwell time is the total time that the
penetrant is in contact with the part surface.
Dwell times are usually recommended by the
penetrant producers.
Minimum dwell times typically range from 5 to 60
minutes.
Generally, there is no harm in using a longer
penetrant dwell time as long as the penetrant is
not allowed to dry.
4. DYe penetrant test procedure
Excess Penetrant Removal
The penetrant removal procedure

must effectively remove the penetrant
from the surface of the part without
removing the penetrant from the
defect.
The most commonly used methods for

excess penetrant removal are:
Water wash method: the test piece
Solvent wipe method: the test
is sprayed with water to remove the

excess penetrant as shown in Fig. 7.6a.
a) Water wash method
piece is wiped with a rag dampened

with the solvent cleaner as shown in
Fig. 7.6b.
Fig. 8.6: Excess penetrant removal
b)Solvent wipe method.

Application of developer
A thin layer of developer is
then applied to the sample.
The role of the developer is

to draw the penetrant
trapped in flaws back to
the surface to be visible.
Fig.7.7: Spraying the developer
Indication development
The developer is allowed to stay on the part

surface for a period of time sufficient to
permit the extraction of the trapped
penetrant out of any surface flaws.
This development time is usually around 10

minutes unless stated by the developer
manufacturers.
4. DYe penetrant test procedure
Inspection
Inspection is then performed

under appropriate lighting to
detect indications from any
flaws which may be present.
Crack
The crack if any will be

indicated with the red dye
absorbed
by
the white
absorbent as shown in Fig. 8.8.
A very important step of
evaluation is to document
findings on an inspection
report form.
Fig. 7.8: A crack indication that

appears after the test.

Clean the surface
The final step in the
process is to thoroughly
clean the part surface to
remove the developer
from the parts that were
found to be acceptable.
See Fig. 7.9.
Fig. 7.9: Cleaning the

acceptable parts.
NDT Lab Report
All 3 lab reports are posted on Weebly and

Plato.
Bring next class SAPET Saturday Nov 16th, 2013

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