Penetrant Material Waste Reduction and Process Improvement

Conversion to water washable penetrants and use of dry powder developers shows promise to improve performance while significantly reducing waste streams by elimination of hydrophilic emulsifier and water based developer. These materials also will reduce equipment maintenance costs and costs associated with process control.  Texas Research Institute Austin, Inc. (TRI/Austin), in collaboration with Team Industrial Services, Inc. (TISI), proposes to conduct a POD study including obtaining brightness measurements and an over wash study in order to compare the performance of Method A and Method D penetrants as well as forms a, b, and c developers.  In addition, the TRI team will propose a method to apply and remove developers in an automated system.  In the Phase II work, TRI/Austin will manufacture crack specimens that will be inspected by TISI following guidelines from an experimental test program developed by TRI.  The TRI team will also obtain the necessary equipment for a water washable penetrant line and install at a location specified by the Air Force.  Tests requiring the use of Method A penetrant will be conducted at these facilities. The results of the Phase II tests will provide data to assess the performance of Method A penetrants and form a developers. BENEFITS: The proposed probability of detection and over wash studies will provide evidence that could possibly allow Method A penetrants and form a developers to be accepted for use in the United States Air Force.  This in turn may reduce material waste streams, decrease processing time, and minimize maintenance required for fluorescent penetrant inspection (FPI) processes. An improved FPI process could possibly extend the service life of aircraft components and minimize the possibility for catastrophic failure.