in use materials - north star imaging, inc. use materials .pdf• system performance – 7.8.3 –...
TRANSCRIPT
Why?• Aid in controlling your process• A well monitored system will
prevent costly and painful corrections
In Use Material Checks
• Inspectors must be aware of:–Changes of performance–Color –Consistency
• Cost associated with this testing
Testing (In most cases)• Simple tests• Uses minimum equipment• Can be run in inspection area• Personnel should be familiar with
inspection process• Save a new standard sample at the
time tanks are filled in a closed container
Storing Sample Materials
• Plastic containers should NOT be used for Long term storage
• Use metal or glass containers
• Should not be stored in high temperatures
Specifications
• Establish point of performance loss
• Determine exact point of material failure
• These limits apply mainly for critical applications
In Use Material Checks
• ASTM 1417-05– 7.8.2 Material Checks (In Use)
• Does not apply to materials that are not recovered or reused, i.e. aerosols, some spray systems
• Records must be maintained at location for audit.
Each Shift
• Water wash pressure and temperature-7.8.4.6
• Inspection area – 7.8.4.5– Clean and free from excessive
fluorescent contamination – Free of white light background
• Not exceed 2 fc (21.5 lx)
Daily Tests• Penetrant contamination
– 7.8.2.1– Look for waxy deposits,
white coloration, any separation, scum, or any other evidence
– Modify per manufacturers instructions
– Discard
• System performance – 7.8.3– Processing a known defect standard
through the system using in-use materials
• Comparative Penetrant Sensitivity –7.8.3.4– Process with unused emulsifier and
developer– TAM Panel
• Not for determining sensitivity level of the penetrant
– NiCr Panels– Or part known defect
Daily Tests - Continued
Daily Tests• Method A penetrant 7.8.3.2 and
Emulsifier Removability 7.8.3.3– Test piece specified in AMS-2644
(Stainless steel test block with rough surface)
– Use normal wash parameters to process part
Daily Tests cont.
• Dry Developer condition – 7.8.2.7– For recycled
material only– Spread thin layer in
4” (10 cm) circle if TEN or more fluorescent specks discard
4”
• Developer contamination (aqueous -soluble and suspendable) – 7.8.2.8– Immerse 3” (7.6 cm)x10” (25.4 cm)
aluminum panel, dry– Look for fluorescence and uniform
coverage
Daily Tests – Cont.
• Black Light Intensity - 7.8.4.1– Minimum 1000 mW/cm2 at 15” from
front of filter to the face of the sensor
Daily Tests - Continued
• Black Light Intensity - 7.8.4.1– All types used to inspect parts
(portable, hand-held, mounted or fixed)
Daily Tests - Continued
• Black Light Integrity – 7.8.4.1 (Weekly)– Clean, repair or replaced as needed
Daily Tests - Continued
• Special UV Lighting –7.8.4.2– Pencil lamps, borescopes
or remote UV inspection equipment
– Measured at expected working distance at1000 mW/cm2
– For borescopes & remote video equipment, the image must have enough resolution for proper inspection & evaluation
Daily Tests - Continued
Weekly Tests
• Developer concentration (Aqueous: Soluble & Suspendible) – 7.8.2.9– Check with Hydrometer– Concentration no higher
than specified by supplier
Weekly Tests
• Emulsifier (hydrophilic) concentration –7.8.2.6– Concentration checked
with refractometer– Concentration no higher
than specified by supplier, for spray applications no higher than 5%
Weekly Tests – Continued
• Water Content – (Water-Based, Water-Washable penetrants only) - 7.8.2.3– Use refractometer– Maintained according to manufacturer
recommendation
Monthly Tests
• Water content – 5% max. (Non-water-based, Method A only) - 7.8.2.4
• Emulsifier water content (lipophilic only)-7.8.2.5
Quarterly• Fluorescent brightness (ASTM E-1135-Test Method for
Brightness of Penetrants)-7.8.2.2– Measured with Fluorometer– Brightness less than 90% of standard should be discarded or
corrected
Semi-Annual• Calibrate light
meter – 7.8.4.4– Black Light and
White Light meters
• Calibrate water temperature indicator and pressure gages –7.8.4.6
Contamination
• Penetrants can absorb large amounts of solvents or oils, but…
• Usually will decrease fluorescence• Some cleaning solvents, degreasers,
acids, alkaline cleaners can destroy fluorescence
• Effect washability
Contamination•Some aqueous cleaners contain
metasilicates which may prevent penetrant from entering crack
•Incomplete cleaning of oil can also hinder penetrant from entering crack
CONTAMINATES
•Will cause loss of fluorescence in penetrant
•May enter a little at a time as residue on parts or…
•All at once when foreign material is added accidentally
Types of Contaminates•Water
– The most common contaminate– Not harmful until water tolerance
is met– Small amounts of water may
change viscosity and washability– Contamination in PE penetrants
causes separation
Types of Contaminates
• Dirt, soil, other insoluble solids–Result of improper cleaning or
matter falling into tank• Organic material• Organic solvents• Acid • Alkaline materials
Emulsifier Contamination
• Penetrant contamination• Will slow emulsifying action• Small amounts of contamination
can be tolerated• Emulsifier should be replaced
based on performance rather than penetrant content
Heated Parts• In some cases, used to speed up
penetration• Some fluorescent dyes decompose
around 1600F (710C)• Long term exposure to heated parts
will effect fluorescence in tank
Brightness Case StudyLEVEL 3 POST EMULSIFIABLE - 90% minimum
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Water Content Case StudyLevel 3 Water Wash - 5% maximum water content
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