Preliminary Requirements

Procedure

1. SUBTASK 70-23-00-860-002 Introduction

   1. Fluorescent penetrant inspection (FPI) processes are non destructive methods of inspecting materials and parts for surface discontinuities and imperfections. FPI techniques use either water-washable fluorescent penetrants, or post-emulsifiable fluorescent penetrants that use separate emulsifiers. The Engine Manual will specify the parts that require FPI and the FPI procedure to be used.

   2. Aerospace Materials Specification AMS 2647 is an acceptable alternative document for the procedures used to prepare engine parts for fluorescent penetrant inspection and for procedure control instructions.

2. SUBTASK 70-23-00-230-001 General

   
   CAUTION
   THE USE OF VISIBLE DYE PENETRANTS ON ENGINE PARTS IS NOT PERMITTED. ABSORPTION OF VISIBLE DYE PENETRANT WILL MASK INDICATIONS AND DECREASE THE SENSITIVITY OF FPI.
   SURFACE TREATMENT (SUCH AS ABRASIVE BLASTING), IF NOT USED CORRECTLY, CAN CAUSE DAMAGE TO THE SURFACE LAYER. THIS WILL PREVENT AN ACCURATE NON-DESTRUCTIVE INSPECTION OF THE SURFACE DEFECTS. THE EFFECT WILL CHANGE, WITH THE DIFFERENT MATERIALS AND PROCEDURES USED. ALWAYS OBEY THE INSTRUCTIONS IN THE STANDARD PRACTICES AND ENGINE MANUALS. THEY WILL GIVE THE BEST NON-DESTRUCTIVE INSPECTION RESULTS.
   LIGHT-SENSITIVE SPECTACLES MUST NOT BE USED DURING THE FLUORESCENT PENETRANT INSPECTION PROCEDURES, BECAUSE EXPOSURE TO ULTRAVIOLET LIGHT CAN CAUSE A 50 PERCENT DECREASE IN THE LIGHT TRANSMITTED THROUGH SUCH SPECTACLES.
   PAINTED BULBS MUST NOT BE USED FOR INSPECTION OF PARTS.

   NOTE

   Fluorescent Penetrant Inspection must not replace visual inspection procedures, but must be used as an extension to visual inspection.

   1. Fluorescent Penetrant Inspection.

      1. General guidance on when Fluorescent Penetrant Inspection is necessary is given in the paragraphs that follow.

         1. FPI is necessary after:

            1. Broach procedure.

            2. Machining (includes boring), blending or routing to remove cracks or tears.

               NOTE

               Machining, blending or routing procedures to remove cracks or tears are permitted only if removal of cracks or tears is specified in the repair.

            3. Stop-drilling of cracks.

            4. Sizing, stretching or straightening.

            5. Welding or brazing.

            6. Machining or blending of weld repair areas.

            7. Heat treatment or stress-relief.

            8. Grinding to remove coating, plating or base material (but not after grinding of HPC platforms, LPT platforms or rotor blade tips in an assembly).

            9. Removal of base material, thermal spray coatings (such as plasma, HVOF, dual wire arc and D-Gun) or plating during dimensional or hardface restoration repairs on rotating parts (for example airseals, blades, disks, drums, shafts, tierods, retaining plates and spacers).

            10. Removal of chromium plate from rotating and non-rotating parts.

            11. Pressure testing of tube and manifold assemblies.

            12. Blending or smoothing of scratches, nicks, dents, pitting or galling on rotating parts.

         2. During repairs, FPI is not necessary after:

            1. Machine (includes bore) procedure for repairs other than crack removal.

            2. Riveting.

            3. Plasma, honeycomb or feltmetal repair.

            4. Blending or smoothing of scratches, nicks, dents, pitting or galling on non rotating parts.

            5. Honing or butterfly polish.

            6. Tack welding to temporarily hold components in position before a weld or braze repair. Only visual inspection is necessary for each tack welds.

         3. FPI is not necessary for:

            1. Honeycomb, feltmetal or composite details.

            2. Inspection after grinding of HPC platforms, LPT platforms or rotor blade tips in an assembly.

      2. For fluorescent penetrant procedures to be satisfactory, defects must be open to the surface to permit entry of the penetrant. It is important that all surfaces are fully clean of paint and other surface coatings, grease, oil, scale, or corrosion. Refer to the engine manual for the applicable cleaning procedure.

      3. The FPI penetrant and emulsifier, being used together, must be from the same manufacturer. However, the developer does not need to be from the same manufacturer as the penetrant and emulsifier.

      4. To maintain satisfactory results, periodic checks are necessary. The frequency of each necessary check is given in the table in Step.

      5. Do not use a lower sensitivity procedure than that specified in the Engine Manual for the part. Where a medium/normal sensitivity procedure is specified, it is permitted to use a high-sensitivity procedure as an alternative, but it is not recommended because it can cause parts to be rejected because of unrelated indications and/or it can result in too much background fluorescence which can cover related indications.

      6. Fluorescence.

         1. Constant background fluorescence is permitted on porous material parts.

            NOTE

            Diffused aluminide coatings on turbine hardware will cause some light constant background which is permitted.

         2. At no time is too much background fluorescence permitted on disk, hub or drum rotor bores or on fore and aft adjacent surfaces. On all other parts background fluorescence must be kept to a minimum.

      7. Background Fluorescence.

         1. Background fluorescence can be seen on:

            1. Castings.

            2. Mating surface contact areas, such as:

               1. Splines.

               2. Under bolt heads or spacer contact areas.

               3. Holes.

         2. Background fluorescence can be caused from:

            1. Manufacturing or refurbishment processes, such as:

               1. Diffused aluminide or thermal barrier (TBC) coatings.

               2. Edges of nickel plated areas.

               3. Chromium plating.

               4. Plasma spray.

               5. Anodizing.

            2. Oxidation/staining/coloration.

            3. Incorrect cleaning.

            4. Incorrect FPI procedure.

            5. The use of a penetrant with a sensitivity level greater than necessary.

   2. The FPI procedures used in the FPI of V2500 parts are listed in the table as follows:

      	TASK Number		Title
      	TASK 70-23-01-230-501		Medium Sensitivity Post-emulsified Fluorescent Penetrant Inspection
      	TASK 70-23-02-230-501		Medium Sensitivity Water-washable Fluorescent Penetrant Inspection
      	TASK 70-23-03-230-501		High Sensitivity Post-emulsified Fluorescent Penetrant Inspection
      	TASK 70-23-04-230-501		Ultra High Sensitivity Post-emulsified Fluorescent Penetrant Inspection
      	TASK 70-23-05-230-501		Local Application, Fluorescent Penetrant Inspection
      	TASK 70-23-08-230-501		High Sensitivity Water-washable Fluorescent Penetrant Inspection

   3. Inspection personnel.

      Fluorescent Penetrant Inspection inspectors must be fully approved to the applicable authority standards and in the use of these procedures. The inspectors must be able to identify and interpret the indications correctly to the engine manual inspection limits.

3. SUBTASK 70-23-00-860-001 Safety Precautions

   

   WARNING

   IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURER'S MATERIALS SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS. THESE CONTAIN INFORMATION SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL PRECAUTIONS INTO CONSIDERATION.

   

   WARNING

   THE ULTRA-VIOLET LAMPS MUST ALWAYS BE KEPT IN GOOD CONDITION. LAMPS WITH BROKEN OR DEFECTIVE FILTERS ARE DANGEROUS TO THE EYES. A REGULAR INSPECTION OF THE FILTERS IS NECESSARY. ALWAYS TURN OFF THE LAMP IMMEDIATELY IF THE ELEMENT BECOMES OPEN BECAUSE OF A BROKEN OR DAMAGED GLASS FILTER.

4. SUBTASK 70-23-00-230-002 General FPI Method to the Standard Practice Manual

   1. Examination of the Part.

      1. You must do an inspection of 100 percent of the part.

      2. Be sure to give special precaution to rotating disks, hubs, and drum rotors, especially:

         1. Bores and adjacent surfaces.

         2. Ends of holes and chamfer.

         3. Rim slots and cut-outs.

         4. Airfoils.

         5. High stressed areas.

      3. Other details of rotating and non-rotating parts which must have this precaution include:

         1. Splines and teeth.

         2. Lugs, bosses, and slots.

         3. Shoulders and flanges.

         4. Welds and brazes.

         5. Webs.

5. SUBTASK 70-23-00-230-003 Frequency of Control Tests

   1. To maintain satisfactory results constant checks are necessary, the necessary checks are given in the table as follows:

      Frequency of Check		Check to be done		Remarks
      Daily		Calibrated Pressure gages, Temperature gages or other Equipment		Step
      At the start of each shift		Make sure the equipment is clean. Make sure the tank levels and water temperature is correct
      At the start of each shift		Examine the ultra-violet lamps		Step
      At the start of each shift		Check indications can be detected		Step "Daily system capability test"
      At the start of each shift		Check condition of the dry developer.		Step
      Weekly		Check the fluorescent brightness		Step
      Weekly		Remover Check		Step
      Monthly		Measure UV Light-source output		Step
      Monthly		Measure water content of penetrant		Step
      Monthly		Inspection Area		Step
      Every Three Months		Check the fluorescent intensity		Step
      Every Six Months		Clean the tanks		Clean more frequently if necessary.
      To manufacturer's Instruction but at least every 12 Months		Light Meters and Refractometers		Step
      On Receipt		White Light Test on New Bulbs		Step

6. SUBTASK 70-23-00-230-004 FPI System Control Tests

   1. Initial Validation of System.

      1. Capability Test:

         1. Do an initial system validation test at each sensitivity level in use (refer to test panel calibration Step). The number of artificial discontinuities found must be the larger of (i) or (ii) as follows:

            1. Not less than the minimum permitted for calibration, or.

            2. One less than the number found at calibration.

         2. Record the number of discontinuities that you find, in the department record book. Be sure to keep this test result in the department for 30 days.

      2. If the process fails the initial system test, make sure the results are correct and confirm the process is set-up correctly.

         1. If the results of a second panel results are satisfactory, send the first panel to Gage Standards, or the supplier equivalent, to measure its value and quality.

         2. If the second panel results are not satisfactory, it is necessary to identify and correct the system malfunction and satisfactorily complete a system test.

   2. Daily System Capability Test.

      1. 

         CAUTION

         DO NOT PROCESS PARTS IF THE SYSTEM FAILS THIS TEST.

         Do this test at the start of each work shift.

      2. Be sure that the FPI test panel is clean, dry, and without any fluorescent material before use.

      3. Test parameter operating values are the same as those used when you do the parts.

      4. Measure the length of the indications produced or, alternatively, compare the indications to the replica or photograph of the initial system calibration test. For this test, the indications must be the same as the initial system calibration test.

         1. If the indications on the panel are not the same as at the initial system calibration (or are not comparable to the replica or photograph), the process shall not be used until the fault is located and rectified. All parts processed from the time of the last performance check shall be re-inspected.

      5. Write the results (that is, the number of artificial discontinuities found) in the record book of the department.

7. SUBTASK 70-23-00-230-005 FPI Materials and Their Control

   1. Introduction.

      1. Refer to the V2500 Consumable Material Index (CMI) for FPI consumables approved by IAE. The FPI penetrants, emulsifiers, developers and rust inhibitors must be tested before use to the manufacturer's instructions or by the method and at the frequency specified in the paragraphs that follow.

   2. Penetrants.

      NOTE

      These tests are not necessary for spray booths that do not apply used penetrant to parts.

      1. Test the contents of penetrant in immersion tanks and recirculation machines by the methods as follows:

         1. Fluorescence brightness test.

            NOTE

            This test is not necessary if you discard the penetrant in three months or less after you filled the tank with the penetrant.

            It is permitted to use ASTM E1135 standard test method for comparing the brightness of fluorescent penetrants as an alternative to this procedure.

            1. Compare the color intensity of the used fluorescent penetrant with that of the new or reference fluorescent penetrant under UV-light, by the method that follows:

               1. Soak a CoMat 02-012 FILTER PAPER (3.15 x 3.15 inches (80 x 80 mm)) in a sample of the used fluorescent penetrant. Soak a second filter paper in a sample of the new or reference fluorescent penetrant.

               2. Dry the two filter papers in an oven, at a maximum temperature of 185 deg F (85 deg C), for 5 minutes; if drying at a lower temperature the drying time will be longer.

               3. Compare the two filter papers in ultra-violet light. If there is a large visible difference in intensity do the "Fluorescent Intensity Test".

         2. Fluorescent intensity test:

            NOTE

            This test is not necessary if you discard the penetrant in three months or less after you filled the tank with the penetrant.

            It is permitted to use ASTM E1135 standard test method for comparing the brightness of fluorescent penetrants as an alternative to this procedure.

            1. Compare the fluorescent intensity of the used fluorescent penetrant with that of the new or reference fluorescent penetrant, as follows:

               1. Turn on the ultra-violet lamp and let it become stable (Approximately 20 minutes). Adjust the position of the ultra-violet monitor below the lamp until you get a meter indication of 1000 microwatts per sq cm minimum.

               2. Prepare a reference or standard solution of 1 percent of the new penetrant mixed with 99 percent of CoMat 01-060 ACETONE (CH3)2CO or CoMat 01-031 ACETONE (CH3)2CO. Also prepare a 1 percent test solution made up from the penetrant in use.

               3. Soak a CoMat 02-012 FILTER PAPER (3.15 x 3.15 inches (80 x 80 mm)) in the reference or standard solution and soak a second filter paper in the penetrant in use.

               4. Dry the two filter papers in an oven, at a maximum temperature of 185 deg F (85 deg C), for 5 minutes; if drying at a lower temperature the drying time will be longer.

               5. Position a white light meter directly under the UV-light and place the filter paper with the penetrant under test on the measuring lens such that it covers the light sensing area.

               6. Record the reading and repeat the operation with the filter paper of unused penetrant.

            2. If the measured intensity varies by more than 10 percent, the penetrant shall be discarded.

         3. Water content test.

            1. Test water-washable penetrants in immersion or recirculating tanks for water content each month after the tanks are initially filled.

               NOTE

               This test is not necessary if the penetrant is discarded in less than one month after the tanks are initially filled.

               1. Follow the last revision of ASTM D-95 for the water content test of the penetrant. Alternatively test the penetrant to B.S.4385 or to the manufacturer's instructions.

            2. The penetrant shall be discarded if the water content of penetrant is more than 5 percent water.

   3. Penetrant Removers/Emulsifier.

      1. Check the refractive index (concentration) of the penetrant remover every week with the refractometer or alternatively test to the latest revision of ASTM D-95 or to B.S.4385.

         NOTE

         A new calibration curve must be made whenever the make or type of remover is changed.

         1. The refractive index of the penetrant remover is compared against a prepared calibration curve of refractive index versus remover concentration. The remover concentration is calculated from the graph.

            NOTE

            This check is not necessary if the emulsifier is discarded within one week after the tanks are initially filled.

            Refer to Step for the manufacturer's recommended concentration.

            1. The calibration curve is produced by preparing 5 samples of remover at 90 percent, 95 percent, 100 percent, 105 percent and 110 percent of the proposed working concentration. The refractive index of these samples are measured and plotted onto a chart to produce a calibration curve of refractive index versus remover concentration.

   4. Dry Developers.

      1. At the start of each work shift, it is necessary to check all dry developer, that is used more than one time. Check as follows:

         1. Examine the CoMat 06-032 DRY DEVELOPER to make sure it is dry and light. If the powder has become solid, it must be discarded.

            1. Apply a thin layer of developer on a flat sample of an area of 4 inches diameter (10 cm) and examine under UV light. Examine the powder for penetrant contamination in ultra-violet light. If there are 10 specks or more of contamination, the powder must be discarded.

8. SUBTASK 70-23-00-230-006 FPI Equipment Controls

   
   CAUTION
   DO NOT USE EQUIPMENT IF IT DOES NOT OPERATE CORRECTLY. REPAIR AND CALIBRATE THE EQUIPMENT BEFORE YOU USE IT AGAIN. DO NOT USE ANY EQUIPMENT WITH AN EXPIRED DATE ON THE CALIBRATION STICKER.

   1. General.

      1. FPI equipment must be regularly calibrated, approved or controlled.

         1. Do all necessary calibrations of equipment initially, as scheduled, and after maintenance or repair. It is necessary for the operator to have a calibration schedule for the control of all equipment that must be calibrated, and a record of when it was completed and the next scheduled service or calibration.

            1. A calibration sticker will be applied to the equipment which passed calibration, showing calibration date and subsequent monitored date.

      2. Each FPI line must satisfactorily complete the "Daily System Capability Test" (Refer appropriate paragraph in Step).

      3. Make sure to report to the supervision all problems with equipment or instructions.

   2. UV Lights.

      1. It is necessary to do the UV light intensity check for all UV lights that you use to do part inspection.

      2. It is not necessary to do the UV light intensity check for the UV lights that you see only to monitor the fluorescent penetrant process (that is, the UV lights that you use to make sure that you correctly apply or remove the penetrant).

      3. Do an intensity check of the UV lights at the applicable interval.

         NOTE

         It is permitted to change the time interval between these checks if there is sufficient technical/reliability data to substantiate this change (that is, if there is sufficient test data to show that the new interval will also give the necessary quality) and the change is approved by the applicable engineering organization.

         1. For UV light units that operate on battery power, it is necessary to do a check of the UV light intensity at the start of the inspection and after battery change.

            1. If the UV light intensity is not satisfactory at the start of the inspection, do the subsequent procedure before you use the UV light unit to examine parts:

               1. Charge the battery, change the battery or get a different UV light unit.

               2. Do the check of the UV light intensity before you use the UV light unit to examine parts.

            2. For battery powered UV lights that operate continuously, do a check of the UV light intensity after each 2 hours of operation and at the end of each inspection.

            3. For battery powered LED UV flashlights that you use as evaluation aids intermittently during a shift, do a check of the UV light intensity at the start of the inspection and at the end of the shift.

         2. For all other UV light units, do a check of the UV light intensity one time each day.

         3. When you install a new light bulb or LED in a UV light unit, do a check of the UV light intensity of the unit before you use it to do an inspection.

      4. Use the subsequent procedure to do the intensity check:

         1. Make sure the light is at full intensity before you do the intensity check.

            1. For some types of light sources, the UV light must be on for 10 minutes minimum to let the light increase to full intensity. Refer to the manufacturer's instructions.

         2. Measure the intensity of the UV light with a UV-A light sensor and a calibrated light meter that measures UV-A light only or measures UV-A light and white light. The applicable intensity must be as specified in the subsequent table:

            NOTE

            It is permitted to move the light sensor around to find the peak meter reading.

            Table 4.

            Type Of Light Source	Minimum UV-A Intensity	Measurement Location
            Hand held UV Light	1000 microwatts per sq cm	15 in. (381 mm) from the front of the lamp
            UV Light Borescope	1000 microwatts per sq cm	1.5 in. (38.1 mm) from the front end of the borescope
            Fixed/Mounted UV Light	1000 microwatts per sq cm	At sufficient locations to make sure that the light has the necessary intensity at all intended working distances*
            Low Intensity UV Light Pencil Lamp	1000 microwatts per sq cm	0.50 in. (12.7 mm) from the lamp
            Light Emitting Diode (LED) UV Flashlight/Torch	1000 microwatts per sq cm	15 in. (381 mm) from the front end of the flashlight/torch
            Battery Powered UV Light	2000 microwatts per sq cm	15 in. (381 mm) from the front of the lamp

            *The intended working distances are the distances between the fixed/mounted UV lights and the inspection surfaces of all the different types of parts that you examine with these lights.

   3. UV Light Meter

      1. Calibrate the UV light meter every six months.

         NOTE

         It is permitted to extend the maximum time between calibrations if there is sufficient technical data to substantiate this change, and the change is approved by the inspection operation's quality organization.

   4. White Light Meter

      1. Calibrate the white light meter every six months.

         NOTE

         It is permitted to extend the maximum time between calibrations if there is sufficient technical data to substantiate this change, and the change is approved by the inspection operation's quality organization.

   5. Refractometer.

      1. Refractometers measure the amount that light is bent when it passes through a liquid. To calibrate refractometers, make a chart or graph that shows the relation of refractometer values to known emulsifier concentrations in the range of use.

      2. Calibration must apply to specific emulsifiers.

      3. Do a check of the refractometer before you do a check of the concentration of the emulsifier. Use water from the same source as the water used to makeup the emulsifier and make sure that the refractometer reads zero with this water before you do the check of the emulsifier.

   6. Facilities.

      1. Inspection Area.

         1. Do a check on the inspection area one time each month. Use a calibrated white light meter to make sure that the ambient white light intensity at the inspection surface of the part is no more than 20 Lux (2 foot candles) and the area is clean and free of unwanted, fluorescent contamination.

      2. Pressure and Temperature Indicators.

         1. Calibrate pressure and temperature indicators every year and be within plus or minus 10 percent. Do a check each day to make sure that parameters are within limits.

      3. Drying Oven.

         NOTE

         Fluorescent penetrants show a decrease in brilliance with a short exposure to high temperatures or with long exposure to moderately high temperatures. Loss of brilliance affects sensitivity because it decreases the number of indications found.

         1. The drying oven must have a temperature gage and a timer or clock. Do a check on the two regularly for accurate values.

9. SUBTASK 70-23-00-230-007 FPI Test Panel Initial Qualification and Annual Requalification

   1. It is necessary to do an initial qualification of all FPI test panels before you use them and to requalify each test panel annually. For suppliers of suitable test panels refer to Step.

   2. It is necessary to qualify test panels for each penetrant sensitivity level that the facility uses. It is necessary to use a separate test panel for each sensitivity level that the FPI system uses and to identify each test panel with the applicable sensitivity level.

   3. Do the subsequent procedure to do the initial qualification and the requalification of the test panels:

      1. Do the applicable FPI SPOP with new FPI materials and the maximum specified parameters.

      2. The test panel must show no cracks or damage that have a negative effect on the usefulness of the test panel and must show no singular cracks that radiate out from the typical pattern of a star burst (that is, a group of linear indications that radiate from a common center to make an approximately circular image) indications of the artificial discontinuities. If the panel has such cracks or damage, it is necessary to replace the panel.

      3. Examine the test panel for the artificial discontinuities that the selected sensitivity level must show. Each artificial discontinuity, other than the smallest artificial discontinuity (Artificial Discontinuity A), must show as a star burst. The smallest artificial discontinuity (Artificial Discontinuity A) can show as a pinpoint or a star burst.

         Table 5.

         Sensitivity Level	IAE Process No	Minimum No. of Artificial Discontinuities that Show Indications
         Medium/Normal (AMS 2644 Level 2)	SPM TASK 70-23-01-230-501 and SPM TASK 70-23-02-230-501	Three largest (Artificial Discontinuities C, D and E)
         High (AMS 2644 Level 3)	SPM TASK 70-23-03-230-501 and SPM TASK 70-23-08-230-501	Four largest (Artificial Discontinuities B, C, D and E)
         Ultra High (AMS 2644 Level 4)	SPM TASK 70-23-04-230-501	All five

      4. Measure each indication under UV light. The measurement must be of the actual indication size and not of the area that the penetrant has flowed to.

         1. For the initial qualification, the longest dimension of each indication area must agree with the specified sizes in the subsequent list. Record the longest dimension of each indication area as the baseline measurement of each indication area.

            Table 6.

            Artificial Discontinuity	Discontinuity Size
            A	0.015 - 0.032 in. (0.381 - 0.813 mm)
            B	0.046 - 0.062 in. (1.168 - 1.575 mm)
            C	0.075 - 0.093 in. (1.905 - 2.362 mm)
            D	0.125 - 0.171 in. (3.175 - 4.343 mm)
            E	0.180 - 0.250 in. (4.572 - 6.350 mm)

         2. For annual requalification, the longest dimension of each indication area must agree with the specified size relative to the baseline measurement:

            Table 7.

            Artificial Discontinuity	Longest Dimension of Indication
            A	Initial Qualification Baseline Measurement +/-30 percent
            B	Initial Qualification Baseline Measurement +/-30 percent
            C	Initial Qualification Baseline Measurement +/-30 percent
            D	Initial Qualification Baseline Measurement +/-30 percent
            E	Initial Qualification Baseline Measurement +/-30 percent

         3. It is permitted to see individual indications that are 0.015 in. (0.381 mm) or smaller in the discontinuity area(s).

      5. Record the initial qualification results and the annual requalification results in the test panel records and send the results to the inspection department that will use the test panel.

      6. Clean the test-piece.

         1. Fully clean the test-piece with water to remove the developer powder.

         2. Dry the test-piece with compressed air.

         3. Clean the test-piece as specified in the SPM TASK 70-11-03-300-503 (Ultrasonic may be used).

         4. Let the test-piece become cool, then examine it in ultra-violet light.

         5. If there are signs of remaining penetrant, clean the test-piece again.

         6. Store the test piece fully immersed in a sealed container of degreasing fluid, refer to the SPM TASK 70-11-26-300-503.

   4. After the initial qualification gives approval to a test panel, give the test panel a unique identification, such as a serial number, that identifies the test panel with the FPI method and sensitivity for which the test panel will be used.

10. SUBTASK 70-23-00-180-001 Preparation of Surface

    1. Abrasive blasting is not permitted before FPI, unless specified in the Engine Manual for cleaning or stripping.

    2. It is not permitted to clean or polish parts with vibratory mill procedures before FPI.

    3. It is necessary to strip/remove before FPI the items which follow :

       1. Antigallant, graphite varnish, paint, or similar surface coatings.

       2. RTV, adhesives, sealants, or similar applied coatings.

       3. Silver plate.

    4. It is not necessary to strip/remove before FPI the specific coatings which follow:

       1. Nickel, chromium, and electroless nickel plate.

       2. Anodise or conversion coat on gearboxes.

       3. Plasma coatings, diffused coatings and thermal barrier coatings.

11. SUBTASK 70-23-00-180-002 Vacuum Drying

    1. With vacuum assistance, you can use lower temperatures and reduced drying times as follows:

       Table 8.

       Minimum Surface Temperature		Maximum Pressure during Drying Cycle	Minimum Drying Time
       176 deg F (80 deg C)		25 mbar	10 minutes
       140 deg F (60 deg C)		15 mbar	10 minutes
       104 deg F (40 deg C)		10 mbar	10 minutes
       Less than 104 deg F (40 deg C)		Not Permitted	Not Permitted

       The minimum time may be used only if the surface temperature of the part is measured and has reached the temperature necessary. If the surface temperature of the part is not measured, the part must be dried for 60 minutes minimum.

       Always refer to the equipment manufacturer's instructions for correct operation of the vacuum drying system.

12. SUBTASK 70-23-00-290-001 Penetrant Remover Concentration

    1. For the emulsifier concentration limits for medium sensitivity post-emulsified fluorescent penetrant inspection, refer to TASK 70-23-01-230-501. For the emulsifier concentration limits for high sensitivity post-emulsified fluorescent penetrant inspection, refer to TASK 70-23-03-230-501. For the emulsifier concentration limits for ultra-high sensitivity post-emulsified fluorescent penetrant inspection, refer to TASK 70-23-04-230-501.

13. SUBTASK 70-23-00-290-002 Equipment and Equipment Suppliers

    1. General

       1. Refer to V2500 Vendor List in the V2500 Interactive Electronic Technical Publication for the suppliers that the specified Vendor Codes identify.

       2. For all purchases of UV light sources, the manufacturer must provide documentation that the supplied UV light sources agree with the requirements in the subsequent list:

          1. Peak wavelength must be 365 nm (3650 Angstroms) plus or minus 5 in ambient temperatures of 60 - 104 deg F (10 - 40 deg C).

          2. Visible light must not be more than 20 Lux (2 foot candles) at minimum working distance.

          3. The UV-A intensity at a working distance of 15 in. (381 mm) must not be more than 10,000 microwatts per sq cm.

    2. UV Light Meters

       1. The subsequent table contains approved UV light meters; but other UV light meters that agree with the specified requirements in SUBTASK 70-23-00-230-006 are permitted.

          Table 9.

          Manufacturer	Model	Vendor Code
          Gould-Bass Co	DLM-1000 Digital Radiometer	7Z769
          Labino AB	Labino Apollo 1.0 Radiometer And Photometer, Part Number M500	SWN96
          Magnaflux	Part Number 625024 UV-A Digital Light Meter	37676 K5549
          Marktec Corp.	UV-2500 II	S9502
          Megatron Ltd	DL3	*
          Megatron Ltd	DL3/C	*
          Megatron Ltd	DL5	*
          Spectronics Corp.	DM-365N	20772
          Spectronics Corp.	DM-365X	20772
          Spectronics Corp.	DM-365XA	20772
          Spectronics Corp.	Accumax XRP-3000	20772
          Spectronics Corp.	DSE-100X with DIX-365 sensor	20772
          Spectronics Corp.	DSE-100X with DIX-555A/L sensor	20772
          UVP LLC	UVX-36	4W3A0

          *This model is no longer manufactured, but it is permitted to continue to use this model.

    3. Test Panels

       1. The subsequent table contains approved test panels:

          Table 10.

          Manufacturer	Model	Vendor Code
          Magnaflux	Part Number 198055	37676*
          Sherwin Corp.	PSM-5	21405
          Hoffmann	PT-Guard	3DF34 EQ043

          *This model is no longer manufactured, but it is permitted to continue to use this model.

    4. LED UV-A flashlights/torches for local inspection of fir trees slots on Low Pressure Turbine (LPT) Disks and Hubs and on High Pressure Turbine (HPT) Disks and Hubs

       1. The subsequent table contains light emitting diode (LED) UV-A flashlights/torches that are approved for local inspection of fir-trees slots on Low-Pressure Turbine (LPT) Disks and Hubs and on High Pressure Turbine (HPT) Disks and Hubs:

          Table 11.

          Manufacturer	Model	Vendor Code
          Labino AB	Labino Torch Light Model UVG3 Spotlight	SWN96
          Spectronics Corp.	Spectroline Opti-Lux Model OLX-365B	20772

       2. It is permitted to use other LED UV-A flashlights/torches that meet with the following requirement:

          1. For each LED UV-A flashlight/torch unit, the manufacturer must provide a spectroradiometer certificate that identifies the unit by serial number or other unique identification and shows that the unit produces a wavelength of 365 - 370 nm (3650 - 3700 Angstroms)

    5. Hand held LED UV Lights for full-field inspection of parts

       1. The subsequent table contains hand held LED UV lights that are approved for full field inspection of parts:

          Table 12.

          Manufacturer	Model	Vendor Code
          Labino AB	Labino BigBeam Standard Version Floodlight	SWN96
          Labino AB	Labino BigBeam Standard Version Midlight	SWN96
          Labino AB	Labino BigBeam Helios Version Floodlight	SWN96
          Labino AB	Labino BigBeam Helios Version Midlight	SWN96
          Labino AB	Labino MidBeam Standard Version	SWN96
          Labino AB	Labino MidBeam Aerospace Version	SWN96
          Spectronics Corp.	Spectroline Tritan 365 Model TRI-365	20772
          Spectronics Corp.	Spectroline Tritan 365 Model TRI-365D	20772
          Spectronics Corp.	Spectroline Tritan 365 Model TRI-365DBB	20772
          Spectronics Corp.	Spectroline Tritan 365 Model TRI-365PWB	20772

       2. It is permitted to use other hand held LED UV lights that meet with the following requirement:

          1. For each hand held LED UV light unit, the manufacturer must supply a spectroradiometer certificate that identifies the unit by serial number or other unique identification and shows that the unit supplies a wavelength of 365 - 370 nm (3650 - .3700 Angstroms).

    6. High intensity UV light sources for hole inspection

       1. The subsequent list contains high intensity UV light sources that are approved for hole inspection. Use liquid light guides or equivalent equipment with these light sources.

          Table 13.

          Manufacturer	Model	Vendor Code
          Olympus Corp.	Model ALS-6250U	*
          Avanel Industries Inc.	Model ALS-UV3000	55060
          Intertest, Inc.	Lumatec Superlite UV/White Light Model SUV-DC-E (Part Number EM 10486)	0C800

          *This model is no longer manufactured, but it is permitted to continue to use this model.

    7. Low intensity UV pencil lamps for inspection of small diameter holes and tight cavities

       1. The subsequent table contains low intensity UV pencil lamps that are approved for inspection of small diameter holes and tight cavities:

          Table 14.

          Manufacturer	Model	Vendor Code
          UVP, LLC	Lumatec Superlite UV/White Light Model SUV-DC-E (Part Number EM 10486)	4W3A0

    8. UV borescopes for inspection of holes and internal surfaces

       1. The subsequent table contains UV borescopes that are approved for inspection of holes and internal surfaces.

          Table 15.

          Equipment	Manufacturer	Vendor Code
          UV Borescope	various	LOCAL

    9. UV liquid light guides to use with high intensity UV light sources for hole inspection

       1. The subsequent table contains UV liquid light guides to use with high intensity UV light sources that are approved for hole inspection:

          Table 16.

          Equipment	Manufacturer	Vendor Code
          UV Liquid Light Guide	various	LOCAL

    10. Fixed/mounted UV lights for general UV illumination of the inspection area

        1. The subsequent table contains fixed/mounted UV lights that give general UV illumination of the inspection area:

           Table 17.

           Equipment	Manufacturer	Vendor Code
           Fixed/Mounted UV Light	various	LOCAL

14. SUBTASK 70-23-00-290-003 Commonly used Terms

    1. List of Commonly used Terms for information and help in reporting indications.

       1. ALLIGATORING - cracks caused by splitting in a plane or parallel to the surface. Occurs on coated or plated surfaces. See Figure 1.

       2. BURST - cracks extending outwardly from a central point caused by a rupture.

       3. CHAIN POROSITY - porosity in linear alignment.

       4. CLUSTER - three or more discontinuities, clearly separated, which can be contained within a 0.185 inch (4.70 mm) diameter circle.

       5. COLD SHUT - intermittent or continuous lines in a closed loop caused by unfused material.

       6. CRACK - linear discontinuity in the form of a narrow break or fissure.

       7. CRAZING CRACK - series of narrow cracks occurring on coated or plated surfaces.

       8. DISCONTINUITY - interruption in the normal structure of a part configuration evaluated for acceptance to the assigned standard.

       9. DROSS - linear discontinuity within a cluster or discontinuities in the form of branching or sunburst or similar patterns caused by impurities or oxides in the cast material.

       10. HOT TEAR - linear discontinuity in the form of ragged, wavy lines of variable width caused by stresses in the material during solidification.

       11. INCLUSION - linear or nonlinear discontinuity caused by entrapped foreign material. Use white light to verify discontinuity is an inclusion.

       12. INCOMPLETE FUSION or LACK OF FUSION - linear discontinuity of varying width caused by failure of the weld material to fuse.

       13. INDICATION - fluorescence evaluated to determine presence of a discontinuity which may be non-relevant or false.

       14. LAMINATION - linear discontinuity of uniform or varying width caused by separation or weakness parallel to the worked surface.

       15. LAP - linear discontinuity of uniform or varying width and straightness caused by folding over hot metals and rolling or forging them into the surface.

       16. MECHANICAL IMPERFECTION - nonmetallurgical imperfection whose bottom is visible under white light.

       17. MISRUN - Inclusion resulting from the metal solidifying before the mold is filled. Use white light to verify discontinuity is a misrun.

       18. OXIDE SKIN - random pattern which forms on the surface of hot metal upon cooling.

       19. PIPE - linear discontinuity which may have several branches and is caused by contraction of metal during solidification in a central cavity.

       20. PIT - discontinuity that is round, irregular or elongated with a bottom visible under white light.

       21. POROSITY - discontinuity that is round, irregular or elongated caused by air or gas trapped in the mold.

       22. RELEVANT INDICATION - fault (discontinuity, void, etc.,) in any material or part which is rejectable to the assigned standard.

       23. SEAM - linear discontinuity caused by an unwelded fold or lap.

       24. SHRINKAGE - linear or nonlinear discontinuities of varying forms caused by stresses during solidification.

       25. SLAG - an inclusion caused by entrapped nonmetallic material. Use white light to verify discontinuity is slag.

       26. VOID - regular or irregular shape discontinuities resulting from lack or removal of metal. Use white light to verify discontinuity is a void.

Figure: Alligatoring on Turbine Blade Surface Coating

Alligatoring on Turbine Blade Surface Coating