1.

0 TITLE
DYE FLOURESCENT PENETRATE
SEMESTER: 2
REPORT EXPERIMENT:
MECHANICAL ENGINEERING DEPARTMENT
DJL20012
LECTURER: ENCIK BURHAN
NAME MATRIX NO.

MEOR DANIAL HAIKAL BIN MEOR CHEK 10DJL22F1028

KAUSHALLYAA A/P NAVINDRAN 10DJL22F1016

2.0 EXPERIMENT OUTCOME
At the end of this experiment student should be able
1)to understand the condition monitoring using visual method
2)define condition monitoring using visual
3)conduct experiment on fluorescent penetrate

3.0 THEORY
1) Dye penetrant inspection (DP), also called liquid penetrate inspection (LPI) or
penetrant testing (PT), is a widely applied and low-cost inspection method used to
check surface-breaking defects in all non-porous materials (metals, plastics, or
ceramics). The penetrant may be applied to all non-ferrous materials and ferrous
materials, although for ferrous components magnetic-particle inspection is often
used instead for its subsurface detection capability. LPI is used to detect casting,
forging and welding surface defects such as hairline cracks, surface porosity, leaks
in new products, and fatigue cracks on in-service components.
2) The oil and whiting method used in the railroad industry in the early 1900s was the
first recognized use of the principles of penetrants to detect cracks. The oil and
whiting method used an oil solvent for cleaning followed by the application of a
whiting or chalk coating, which absorbed oil from the cracks revealing their locations.
Soon a dye was added to the liquid. By the 1940s, the fluorescent or visible dye was
added to the oil used to penetrate test objects.
3) Experience showed that temperature and soak time was important. This started
the practice of written instructions to provide standard, uniform results. The use of
written procedures has evolved, giving the ability for design engineers and
manufacturers to get the high standard results from any properly trained and certified
liquid penetrant testing technician.
4) DPI is based upon capillary action, where low surface tension fluid penetrates into
clean and dry surface-breaking discontinuities. The penetrant may be applied to the
test component by dipping, spraying, or brushing. After adequate penetration time
has been allowed, the excess penetrant is removed and a developer is applied. The
developer helps to draw penetrant out of the flaw so that an invisible indication
becomes visible to the inspector. Inspection is performed under ultraviolet or white
light, depending on the type of dye used - fluorescent or nonfluorescent (visible)
4.0 EQUIPMENT/MATERIAL
- Spot Check spray penetrant is a type of
dye penetrant that is used to detect surface
discontinuities in virtually any non-porous
material. It is the most reliable and widely
used penetrant inspection method that
reveals cracks and other surface
discontinuities. The formulation of Spot
Check using a high concentration of quality
dyes together with high-quality solvents
provides the best possible dye penetrants
for finding defects.

- Zyglo ZL-27A is a post-emulsifiable

fluorescent penetrant used for a wide range
of sensitivity applications. It is typically used
on castings, forgings, extrusions and rough
and machined surfaces to find cracks,
seams, laps, laminations and porosity². The
formulation has been designed to be
impervious to water to protect it from over
washing and permit more penetrant to
remain in discontinuities for improved
detection of small defects.
- Zyglo ZP-9F is a non-halogenated, ready-
to-use, solvent-based developer. White
developing particles suspended in fast-
drying solvent produce an opaque white
coating for a contrasting background
around penetrant indications, for both
fluores-cent and visible inspection
processes. It is typically used for a wide
variety of testing.

- A metal brush is a device consisting of

many small diameter pieces of metal
packed together very closely that is used to
clean a material's surface. The small metal
pieces are rubbed across a material's
surface either manually or by mechanical
means. Brushing removes undesirable
substances from the surface of the
material.

- The ZB-100F is a Portable Black Light

System that produces long wave ultraviolet
light at 365 nanometers. It is lightweight,
well balanced and has a cool running
temperature which provides superior
operator comfort. The unit also
incorporates multivoltage selection at 110
V, 220 V and 240 V. The typical black light
output is greater than 2500 W/c.
5.0 SAFETY PRECAUTION
1) Follow manufacturer's instructions when using black lights and filter.
2) Do not wear sunglasses or glasses with light-sensitive lenses during fluorescent
penetrant inspections. They cancontribute to improper interpretation of defects
3) Provide adequate ventilation when handling cleaner, emulsifier, penetrants, or
developers
4) Observe the following when handling cleaners, emulsifiers, penetrants, or
developers
i) Avoid contact with penetrant inspection materials by wearing neoprene gloves.
ii) Wash inside and outside of gloves
iii) Wash exposed areas of body with soap and water.
iv) Check for traces of fluorescent penetrant materials on skin, clothing, and
gloves using a black
light source.
6.0 PROCEDURE
1)The surface of the metal should be cleaned thoroughly using a wire brush.

2) For precleaning ,spray the part or section to be inspected with MAGNAFLUX

cleaner .Allow cleaner to remain on part long enough to dissolve dirt or film..Wipe dry
with a clean rag .A check with black light will show any oils remaining ,by their
fluorescene.Repeat if necessary.After final clean wiping allow time to dry before
using the penetrant.

3)After that ,take a clean cloth and wipe of the the excess cleaner before spraying
the penetrant .
4) Spray the part or section to be inspected so that the surface is covered with
penetrant .The penetrant remains at the same part for a period of time before it
which is correctly 10 minutes .

5) When the stopwatch reached 10 minutes using a new cloth the pentrant is wiped
of .This helps the penetrant to not affect the end result .

6) The procedure is repeated as it had additional residual surface penetrant that

need to be removed.
7)The defects will be marked when viewed with the portable black light .A glowing
line marks a crack ,lap ,forging burst , or cold shut .If wide and deep it would spread
.As for porosity,shrinkage,lack of bond and leaks appears as dots or bright areas
under the black light .During the observation through the black light we could see
how the developer sprayed has spread thoughout the metal.

7.0 RESULT /DATA

Throughout the observation during the observing under the portable balck light we
can see that it has a little bit leak and dots on the metal surface. Hence, we were
said to bring it back and clean it through nicely to avoid the spread from becoming
bigger. After the cleaning is done for the second time, when observed under the
bright light it looked perfectly fine as the metal piece was cleaned in the correct way
and it was how it should be without any leakage or crack bursting through it.
8.0 DISCUSSION
a) Discuss the defect when view with portable black light results that you obtain from
the experiment.
Process of MT is the following. Magnetic flux at test piece is occurred by
magnetization of test piece. Magnetic flux is leaked due to occurrence of N pole and
S pole, if there is any defect at the test piece. When ferrous particle is spread on the
test piece, leaked magnetic flux attracts ferrous particle at the area of defect, and
particles forms what is known indication. Indication can be judged according to
criteria.
It shall be selected proper method under the assumption of size of test piece,
expected defects, test condition and so on.

9.0 CONCLUSION
In conclusion we could conclude that ,we could explain the use of mechanical
components and basic concept of maintenance in plant ,we could also demonstrate
a good practice and write a good report based on the standard operating procedure
.Next we could understand the condition monitoring using visual method ,define the
condition monitoring and conduct an experiment on fluorescent dye .Based on the
experiment we have learned that the end result of the penetrant can only be
obtained by putting it under the black light.Hence ,we can conclude that the
experiment outcome was successfully done and we also learned the right way and
safety measurements to be used during the experiment .
10.0 REFERENCE
1) https://en.wikipedia.org/wiki/Dye_penetrant_inspection
2) http://aviationmiscmanuals.tpub.com/TM-1-1520-253-23/TM-1-1520-253-
230047.htm
3)
https://www.google.com.my/search?q=metal+brush+function&client=safari&hl
=en-
my&sxsrf=APwXEdcSZugIvZC5kIHiQ4eNpSyRkIiIew%3A1685415927007&ei=92
d1ZPQElNWx4w_EkZ64Cg&oq=metal+brush+function&gs_lcp=ChNtb2JpbGUt
Z3dzLXdpei1zZXJwEAMyCAghEKABEMMEMggIIRCgARDDBDoICAAQogQQsA
M6BwgjELACECc6BQgAEKIEOgQIIxAnOggIABCKBRCRAjoKCAAQigUQsQMQ
QzoGCAAQBxAeOggIABAHEB4QCjoICAAQBxAeEA86CAgAEAgQBxAeOggIA
BCKBRCGAzoKCCEQoAEQwwQQCkoECEEYAVDQEFiWkwFgipgBaABwAHgA
gAGYAYgB6BmSAQUxOC4xNZgBAKABAcABAcgBAg&sclient=mobile-gws-
wiz-serp
4) https://www.google.com.my/search?q=Zb-
100F++function&client=safari&hl=en-
my&sxsrf=APwXEdcSZugIvZC5kIHiQ4eNpSyRkIiIew%3A1685415927007&ei=92
d1ZPQElNWx4w_EkZ64Cg&oq=Zb-
100F++function&gs_lcp=ChNtb2JpbGUtZ3dzLXdpei1zZXJwEAMyCAghEKABE
MMEOggIABCiBBCwAzoHCCMQsAIQJzoFCAAQogQ6CgghEKABEMMEEAo6B
wgAEA0QgAQ6BggAEAcQHjoECCMQJzoICAAQigUQkQI6CggAEIoFELEDEEM
6CAgAEAcQHhAPOgoIABAHEB4QDxAKOggIABCJBRCiBEoECEEYAFCsEVi2n
wFgkqQBaBZwAHgAgAGBAYgB1weSAQMzLjaYAQCgAQHAAQHIAQI&sclient=
mobile-gws-wiz-serp