Preliminary Requirements

Safety Requirements

WARNING

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

Procedure

1. SUBTASK 70-23-02-230-001 The Control of Equipment and Materials

   1. Refer to SPM TASK 70-23-00-230-501.

2. SUBTASK 70-23-02-230-002 Initial Preparation

   1. General.

      1. The surface to be inspected must be free of paint or other surface coating which will decrease the defect indications.

      2. The parts to be inspected must be fully cleaned. The cleaned surface must be free also from cleaning agents. Remove residue oil, grease, dirt and scale, unwanted material, or other surface contaminants by the cleaning method specified in the engine manual.

         1. To get the best results from the penetrant inspection procedure, the parts must always be fully cleaned.

         2. Surface contamination will cause the penetrant to stay on the surface, which will give incorrect indications.

            NOTE

            If degreasing is not carried out in the penetrant facility, or there is a delay between degreasing/aqueous processing and applying the penetrant, be sure to protect parts from airborne/handling contamination.

         3. Contamination in the defect will limit or stop the entry of the penetrant, which will decrease the defect detectability.

   2. Drying of parts after aqueous chemical procedures to prepare parts for FPI.

      1. If you use one or more aqueous chemical procedures to remove coatings from the part or to clean the part before FPI, it is necessary to use one of the procedures in the subsequent list to do the final dry in the last aqueous chemical procedure before FPI.

         1. Flash Dry Procedure:

            1. Put the part in clean hot water at 150 °F to 200 °F (66 °C to 93 °C) for the necessary time to increase the temperature of the part sufficiently to flash dry.

               NOTE

               The necessary time in the hot water is dependent on the number of parts in the water, and on the size and mass of the parts.

            2. Remove the part from the hot water. If the part has cavities and recesses, rotate the part as soon as possible to flash off the water, or use suction to remove the pooled water. Blow off remaining water from these areas.

               NOTE

               If the water on the part does not flash off when the part comes out of the hot water, then the time interval that the part stayed in the hot water was too short.

         2. Oven Dry Procedure:

            NOTE

            It is not permitted to use this procedure as an alternative to the hot water flush procedures or the flash dry procedures in SPM chemical cleaning tasks or SPM abrasive cleaning tasks.

            1. Do one of the subsequent procedures:

               1. Oven dry at 158 °F - 248 °F (70 °C - 120 °C) for one hour minimum.

               2. Oven dry at 257 °F - 275 °F (125 °C - 135 °C) for 30 minutes minimum.

         3. Vacuum-Assisted Oven Dry Procedure:

            NOTE

            The Vacuum-Assisted Oven Dry Procedure can use lower temperatures and shorter drying times than the Oven Dry Procedure.

            NOTE

            It is not permitted to use this procedure as an alternative to the hot water flush procedures or the flash dry procedures in SPM chemical cleaning tasks or SPM abrasive cleaning tasks.

         4. Dry the part in a vacuum-assisted oven. Refer to SPM TASK 70-23-00-230-501, SUBTASK 70-23-00-180-002.

3. SUBTASK 70-23-02-230-003 Inspection Procedure

   1. Apply the penetrant.

      1. The part surface temperature must be 40 °F - 125 °F (4 °C - 52 °C).

         NOTE

         It is permitted to do this step in ultra-violet light (UV light) to make sure that penetrant coverage is complete.

         NOTE

         It is not permitted to mix the selected CoMat letter suffix penetrant material with other CoMat letter suffix penetrant materials.

      2. Apply CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY) to the part by one of the procedures that follow:

         1. Put the part fully into the penetrant.

         2. NOTE

            Electrostatic spray is recommended where penetrant leakage can cause inspection problems (for example, with film cooled turbine blades, electostatic spray can stop the leakage).

            Apply the penetrant by the spray, flow-on, or brush procedures.

      3. Examine the part with ultra-violet light (UV light) for total coverage of the part with the penetrant.

   2. Drain the part.

      1. Let the part drain for 20 to 60 minutes. Draining can be done by suspending the part over the immersion tank. If the penetrant is drained into a separate drop tray, it must not be re-used unless it is re-checked to the manufacturer's instructions and found acceptable. However, it is generally best to discard the collected drained solution.

         1. Include the drain time in the total time that the penetrant touches the inspection surface. This total time must not be less than 20 minutes or more than 60 minutes.

      2. If the penetrant becomes dry, or the drain time is more than one hour, apply again the penetrant and allow to drain for five minutes maximum.

      3. If the drain time is more than two hours, the part must be fully cleaned of process chemicals. The penetrant must be apply again and the part drained as above.

   3. Final Wash Procedure.

      1. NOTE

         It is permitted to do this step in ultra-violet light (UV light) to monitor the removal of penetrant from the part surface.

         Rinse by one of the procedures that follow:

         1. Spray the part with water to remove excess penetrant . The water temperature must be 50 °F to 100 °F (10 °C to 38 °C).

            1. The maximum permitted spray time for each area of the part is 90 seconds.

            2. For manual FPI lines, keep the spray gun nozzle at a minimum distance of 12 in. (304.8 mm) from the part. Always be careful with closed areas, such as undercuts, blocked holes, and oilways.

            3. The spray gun nozzle must be adjusted to give a low velocity, moderately fine spray.

            4. The maximum permitted air pressure is 25 psi (172 kPa), and the maximum permitted water pressure is 25 psi (172 kPa).

         2. Put the part in a water bath for a time of 90 seconds maximum. The water temperature must be 50 °F to 100 °F (10 °C to 38 °C).

   4. Examine part for removal of surface penetrant.

      1. Examine the part with UV light for satisfactory removal of surface penetrant.

   5. Dry the part.

      1. Drying must start in less than 20 minutes of the Final Wash Procedure is completed.

         NOTE

         Areas such as undercuts, blocked holes, and oilways must be fully dry.

         Suction can be used to remove water from cavities.

      2. Air blast with filtered, dry, compressed air at a maximum pressure of 25 psi (175 kPa) to remove caught water.

      3. Fully dry the part in a hot air oven at a maximum temperature of 160 °F (70 °C) for not more than 30 minutes. If the part has closed areas, be sure to turn the part during this time.

   6. Apply CoMat 06-032 DRY DEVELOPER.

      1. When the part is fully dry, immediately apply CoMat 06-032 DRY DEVELOPER to the inspection area, and permit the developer to stay on the part for a minimum of 10 minutes.

         NOTE

         For aluminum castings and carbon liners, it is important to have a 10 to 30 minutes penetrant bleed-out time and then apply dry developer only to indications you are not sure of. Make an analysis immediately.

         1. The developer can be applied by an electrostatic spray gun or a powder storm cabinet.

         2. It is necessary to apply the developer in two hours or less after the Final Wash Procedure. If you do not apply the developer in two hours or less after the Final Wash Procedure is completed, it necessary to clean and dry the part, and then do this task again.

      2. To remove unwanted dry developer, shake the part or use dry compressed air at a maximum air pressure of 5 psi (35 kPa).

      3. Part must not be open to exposure of UV light between process steps and inspection.

      4. If you are not able to follow satisfactorily any process step, clean the part and do the procedure again.

   7. Inspection of Parts.

      1. General Requirements.

         1. The inspection area for fluorescent penetrant inspection must have protection from white light. White light must not be more than 20 Lux (2 foot candles) at the inspection area. For local inspection, you can darken the area with a black sheet.

         2. Install or adjust the UV lights to prevent glare during the inspection.

      2. Requirements on the Inspector.

         1. During inspection, it is not permitted to use eyeglasses that have lenses that darken in UV light.

         2. Do not start the inspection less than one minute after you enter the dark inspection area because the eyes need time to adjust to the change in light.

         3. Do not do continuous visual inspection for more than two hours at one time. Permit the eyes to rest for at least fifteen minutes. There must be no high visual concentration during this time. Inspectors must not face each other's UV lights during inspection.

         4. Use visual aids (such as, dental mirrors and boroscopes) during inspections of surfaces that are not easy to see by direct vision.

         5. Put the UV borescope probe ends at the correct distance from the inspection surface so that you get optimum light intensity as well as clarity of focus. Refer to manufacturer's instructions.

      3. Parts Requirements.

         1. If there are more than four hours between dry developer and inspection or more than one hour between non-aqueous developer and inspection, then clean the part and do the procedure again.

            NOTE

            Cracks are not permitted, unless specified differently by the Engine Manual.

      4. Inspection Requirements.

         1. Visually examine the part in UV light, in a darkened area, to the engine manual acceptance standards. Examine all unsatisfactory indications with low power magnification in UV light.

         2. Circle indications and areas you are not sure of, use one of the approved temporary marking procedures in SPM TASK 70-09-01-400-501. If it is not possible to make a mark around an indication or an area that you are not sure of, make a mark adjacent to the indication or the area that you are not sure of.

            1. For each indication or area that you are not sure of, use the penetrant 'wipe off' procedure given in Step.

               NOTE

               Some defects seen by penetrant with UV light cannot be seen with white light; if this occurs, it is necessary to get relevant help.

         3. If necessary to identify the type of defect, use binoculars at 3X to 10X magnification in white light to examine those areas that show fluorescent penetrant indications.

         4. Rejection of the parts that show fluorescent penetrant indications must be by persons with the relevant authority.

            NOTE

            This supplemental inspection with non-aqueous developer is optional.

         5. After you do the inspection of the part with dry developer, it is permitted to apply non-aqueous developer to local areas of the part to do supplemental inspection:

            1. Apply CoMat 06-030 NON AQUEOUS DEVELOPER by spray to each local area to get a developer layer of approximately equal thickness that is sufficient to see the developer layer on the part surface but is not sufficient to fully obscure the color of the part.

            2. Do the supplemental inspection in one hour or less after you apply the non-aqueous developer.

               NOTE

               Removal of developer is necessary only, if it interferes with subsequent processes or part function.

   8. Removal of developer.

      1. If the part has no areas in which dry developer can get caught, and will go to visual/dimensional inspection or engine assembly, remove the remaining developer powder with clean, dry, compressed air, but be very careful with internal holes.

      2. If the part has areas in which dry developer can get caught, flush with hot water to clean.

      3. If you use a non-aqueous developer, remove by SPM TASK 70-11-26-300-503.

   9. Temporary protection.

      1. If necessary to prevent rust or corrosion, apply corrosion inhibitor by SPM TASK 70-38-05-380-501.

4. SUBTASK 70-23-02-230-004 Penetrant 'Wipe-off' Procedure

   
   CAUTION
   IT IS NECESSARY TO BE CAREFUL DURING THE PENETRANT WIPE-OFF PROCEDURE BECAUSE IF THERE IS NO SECOND INDICATION, IT IS POSSIBLE THAT THE FIRST INDICATION SHOWED A CRACK THAT HAS A VOLUME THAT IS TOO SMALL TO HOLD SUFFICIENT PENETRANT FOR A SECOND INDICATION.

   NOTE

   You can use this procedure only one time for each indication.

   1. Use a cotton bud made moist with CoMat 01-031 ACETONE (CH3)2CO or CoMat 01-124 ISOPROPYL ALCOHOL or CoMat 01-499 CLEANER / REMOVER - FLUORESCENT PENETRANT to lightly clean the penetrant indication.

      NOTE

      The solvent will dry quickly.

   2. Let the surface of the part dry, then examine the area again in UV light.

      1. If the indication immediately shows again, then the indication is the result of a discontinuity. If you cannot easily see the initial mark around or adjacent to the indication, apply a new mark around or adjacent to the indication.

      2. If the indication does not immediately show again, do the subsequent procedure:

         1. Apply CoMat 06-030 NON AQUEOUS DEVELOPER by spray to get a developer layer of approximately equal thickness that is sufficient to see the developer layer on the part surface but is not sufficient to fully obscure the color of the part.

         2. Examine the indication area again in UV light.

            1. If the indication shows again in three minutes or less after you applied the non-aqueous developer, then a discontinuity is the cause of the indication. If you cannot easily see the initial mark around or adjacent to the indication, apply a new mark around or adjacent to the indication.

            2. If the indication does not show again in three minutes or less after you applied the non-aqueous developer, do an inspection of the area with 3X - 10X magnification in white light for the cause of the initial indication.

               1. If the inspection with 3X - 10X magnification in white light finds a discontinuity that caused the initial indication, and you cannot easily see the initial mark around or adjacent to the indication, apply a new mark around or adjacent to the indication.

               2. If the inspection with 3X - 10X magnification in white light does not find a cause for the initial indication, then it is permitted to ignore the initial indication, and to remove the mark around or adjacent to the indication by SPM TASK 70-11-26-300-503.

   3. Examine each marked indication with 3X - 10X magnification in white light to identify the type of discontinuity.