Fluorescent Liquid

Penetrant Inspection

Penetrants, Emulsifiers,
Developers, & Removers
 Technical Info

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.

The Importance of Liquid Penetrant Inspection Differences Between Sensitivity

Liquid penetrant inspection is a nondestructive test method which does not harm the parts being inspected. The AMS 2644 Penetrant Sensitivity Levels
testing methods detect cracks, fractures, laps, seams and other flaws that are open to the surface that may have been Sensitivity levels are a classification system for fluorescent liquid penetrants which is outlined in AMS 2644 Inspection
caused by fatigue, impact, quenching, machining, grinding, forging or overload. The process is used on machined parts, Material, Penetrant specification. Sensitivity levels are not applied to visible penetrants.
castings, forgings and other items that will be placed into service or already in service requiring maintenance.
• Level ½: Ultra low sensitivity
The process involves applying a penetrant chemical, visible or fluorescent, directly to the part that’s to be inspected. • Level 1: Low sensitivity
The excess penetrant is removed and a developer is applied to draw the penetrant deep from the cracks to the surface • Level 2: Medium sensitivity
of the part. The penetrant contrasts with the surface of the part so the crack is identified more easily. Fluorescent • Level 3: High sensitivity
penetrants are used under an ultraviolet light that makes penetrant fluoresce. The chemical, equipment and NDT • Level 4: Ultra high sensitivity
accessory choices have grown but the fundamentals and benefits of liquid penetrant inspection have endured the test
of time.

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
Versatile material uses and applications governing specifications. The penetrant sensitivity level is stated in the working specifications for the process. This
Liquid penetrant inspection can be performed on most materials that are not extremely rough or porous, is particularly true when penetrant inspection involves safety critical parts. The specifications and standard operating
including material composition that is metallic or nonmetallic, magnetic or nonmagnetic and conductive procedures will dictate the penetrant sensitivity to be used.
or nonconductive.
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
Rapidly inspect large areas and high volumes of parts higher sensitivity penetrant is suitable for highly machined surfaces. Penetrant evaluation on actual parts is important to
Liquid penetrant inspection is a fast, easy and efficient means of surface inspection. Large quantities confirm proper sensitivity with acceptable background fluorescence to detect the type of defects typically found on the
of parts or materials can be inspected quickly. Parts of almost any shape, size and geometry can be parts. Penetrant evaluation on actual test parts can also confirm proper processing parameters such as dwell time and
inspected. 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.
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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 Technical Info

Common Applications Common Terms Fluorescent Liquid Penetrant Testing

Method A Method B/D Method C
Water Washable Post Emulsifiable Solvent Removable
Background – the surface of the test part
against which the indication is viewed. It may Preclean with Preclean with Preclean
be the natural surface of the test part or the Aqueous Cleaner Aqueous Cleaner
developer coating on the surface.

Bleedout – the action of an entrapped

liquid penetrant in surfacing from
discontinuities to form indications.
Apply Penetrant
Dwell for 10−30 min.
Developer – a material that is applied to
Apply Penetrant
the test surface to accelerate bleedout and Dwell 10–30 min.
Aerospace processes commonly use Method D Level 4 to enhance the contrast of indications. Apply Penetrant
penetrants for safety critical rotating parts Dwell 10–30 min.
including turbine blades. Method B Method D

Developing Time – the elapsed time

Apply Rinse
between the application of the developer
Emulsifier 10−38°C at
and the examination of the part. < 2.75 bar

Dwell Time – the total time that the

penetrant or emulsifier is in contact with the Rinse
10−38°C at < 2.75 bar
test surface, including the time required for Apply
application and the drain time.
Emulsifier Remove Excess
Inspection – visual examination of the test Penetrant
Apply cleaner on cloth and
part after completion of the liquid penetrant then wipe the part
processing steps.
Form a Form b/c

Liquid Penetrant Testing – a Dry Apply Rinse

10−38°C at < 2.75 bar
nondestructive test that uses liquid penetrant
60°C Developer
Automotive processes commonly use Method A Level 1
materials to penetrate and detect various
penetrants to inspect non ferrous components such
as steering knuckles and subframes. types of discontinuities open to the surface.
Form a Form b/c Apply Developer
Liquid Penetrant – a solution of dye with Dwell 10–60 min.
the ability to penetrate into fine openings. Dry Apply
60°C Developer
Precleaning – the removal of surface Apply Dry
contaminants from the test part so that
Developer 60°C
Dwell 10 Dwell 10
they will not interfere with the examination min. – 4 hr. min. – 2 hr.

process.
Apply Dry
Sensitivity Level – the descriptive term Developer 60°C
Dwell 10 min. – 4 hr. Dwell 10 min.– 2 hr.
for identifying the capability of a penetrant Inspect
system to indicate the presence of a
surface-connected discontinuity. Inspect

Inspect

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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 Product Selection

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

Description
Removal
Method

Method
Product Product

Level

Type

Form
Part Numbers Part Numbers
Name Name

Solvent-
25 litres ............ 056C061
ZL-15B ½

based
200 litres .......... 056C062 Aerosol case ............ 008A007
SKD-S2 d 5 litres x 4 ................. 055C014 Product
Description Part Numbers
Name
25 litres ............ 056C185
ZL-19 1

Dry Powder
200 litres .......... 056C186
1 Kg ............................ 055C022
ZP-4B* a 5 Kg ............................ 055C023 Aerosol case ....... 008A100
Aerosol case ... 008A008 Solvent-based
Water Washable

SKC-S 5 litres x 4 .......... 054C007

ZL-60C 2 25 litres ........... 056C205 Cleaner, Class 2 25 litres ............ 054C008
200 litres ......... 056C206

Suspendible
AC

Water
25 litres ............. 056C010
ZP-5B A C c 5 Kg ............................ 055C022
ZL-60D* 2 200 litres ........... 056C011

Solvent-
based
25 litres ........... 056C034
ZL-67B* 3 200 litres ......... 056C035 ZP-9F* d Aerosol case ............ 008A010

25 litres ............ 056C201

ZL-56 4 200 litres .......... 056C202

Soluble
Water-
ZP-14A† b 5 Kg ............................ 055C010

†Generally not used with Method A

Emulsifier
Removal
Method

Method

Product
Level

Product
Type

Solvent-
Part Numbers Part Numbers Product

based
Name Aerosol case ............ 008A007 Description Part Numbers
Name SKD-S2 d 5 litres x 4 ................. 055C014 Name

Powder
25 litres ............ 056C079 1 Kg ............................ 055C022

Dry
ZP-4B a
Lipophilic

ZL-2C 2 200 litres .......... 056C080 5 Kg ............................ 055C023 UV technology

ZE-4B B 25 litres ............ 065C025
developed ST700 Stationary: 628244
UV Lamps exclusively for
EV6000 Handheld: 628000
nondestructive

Solvent-
based
Post Emulsifiable

testing
ZP-9F B C D d Aerosol case ............ 008A010
Aerosol case ... 008A002
ZL-27A* B CD 3 25 litres ............ 066C017
200 litres .......... 066C016

Suspendible
Water
ZP-5B c 5 Kg ............................ 055C022
Sprayers for
Hydrophilic

penetrants,
Air-Wash Spray Gun: 04G003

D
25 litres ............ 065C002 Applicators developers,
ZR-10C* D 200 litres .......... 065C003 Water Spray Gun: 004G015
25 litres ............ 066C020 cleaners, and
ZL-37* 4 Soluble
Water-
200 litres .......... 066C019 water
ZP-14A b 5 Kg ............................ 055C010

*Commonly used product

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