STATE STANDARD OF THE USSR
NON-DESTRUCTIVE TESTING
CAPILLARY METHODS GENERAL REQUIREMENTS
GOST 18442-80
USSR STATE COMMITTEE FOR STANDARDS
Moscow
STATE STANDARD OF THE USSR
NON-DESTRUCTIVE TESTING
Capillary methods GOST General requirements 18442-80* Instead of
GOST 18442-73
By Regulation № 2135 of USSR State Committee for Standards dated May 15, 1980 the present standard becomes effective
from 01.07.81 Reviewed in1986. By Regulation № 1031of Gosstandart dated 22.04.86 the period of validity was extended
till 01.07.91 Non-compliance with the standard is persecuted by law
The present standard covers capillary methods of nondestructive testing of materials, half-finished materials, articles (further – test specimens). The methods are intended for detection of invisible or weakly visible to unaided eye defects, such as discontinuity of material, that rise to the test surface.
The standard established the scope, general requirements for flaw-detection materials, apparatus, sensitivity levels, work flow, processing and presentation of results, and safety requirements.
1. BASIC PROVISIONS AND FIELD OF APPLICATION
1.1 Capillary methods are based on capillary penetration of indicator liquids into the cavities of surface and through discontinuities of the material of test specimens and recording of resulting indicator trails by visual method or with the help of a transducer.
1.2 Capillary methods are intended for detection of surface and through defects in test specimens, their location, extension (for crack-like extended defects) and surface orientation.
1.3 Capillary methods allow testing specimens of any size and form, manufactured from ferrous and non-ferrous metals and alloys, plastics, glass, ceramics, as well as from other hard non-ferromagnetic materials.
1.4 Capillary methods are used to test specimens manufactured from ferromagnetic materials if their magnetic properties, form, appearance and defect location does not allow
achieving the sensitivity required according to GOST 21105-87 using magnetic particle method and if specimen service conditions do not permit the use of magnetic particle inspection.
1.5 The necessary condition to detect discontinuity-like defects of materials by means of capillary methods is the presence of cavities, free from contaminations and other matter, rising to the surface of specimen and having the depth of extension considerably higher than their opening width.
1.6 Capillary methods are divided into basic methods, methods employing capillary effects, and combined methods based on the combination of two or more nondestructive testing methods with different physics, one of which is the capillary method. 1.7 Basic capillary methods are classified as follows: depending on the penetrant type: penetrating solutions, filterable suspensions:
depending on the way the primary information is obtained: luminance (achromatic), color (chromatic), luminescent,
luminescent-color.
1.8 Depending on the character of physical fields (radiations) and the characteristic of their interaction with the test specimen combined capillary testing methods are classified into: capillary- electrostatic; capillary- electroinduction; capillary- magnetic;
capillary- radiation of absorption; capillary- radiation of emanation.
2. FLAW-DETECTION MATERIALS
2.1 Flaw-detection materials are chosen depending on the requirements specified for the test specimen, its condition, and testing conditions. They are completed into specific-purpose sets (see reference appendix 1) that contain fully or partially interdependable compatible flaw-detection materials, listed below: И-indicator penetrant;
M- cleaner to clean the specimen from penetrant; Г-penetrant quencher; П-penetrant developer.
Cleaner, indicator penetrant, quencher and developer are characterized by the data, specified in prescription forms. Prescription forms are shown in reference appendix 2.
2.2 Compatibility of flaw-detection materials in sets or combinations is necessary.
Compositions of a set shall not make the performance of the test specimen material worse. 2.3 Depending on the nature of interaction with the indicator penetrant cleaners and
quenchers are divided into dissolving, self-emulsifying and emulsifying when under external influence.
2.4 Indicator penetrants are divided into the following:
depending on the physical condition and luminance-dyeing characteristics in accordance with Table 1.
Table 1
Physical condition Dyeing characteristic Dyeing characteristic of defect indicator trail of indicator of indicator penetrantpenetrant Solution Achromatic Black, grey, clear
Color Has a specific color tone when observing in
visible radiation
Luminescent Emits visible radiation under the influence of
long-wave ultraviolet radiation
Luminescent-color Has a specific color tone when observing in visible radiation and luminesces under the influence of long-wave ultraviolet radiation
Suspension Accumulation of luminescent or color particles of
suspension in the mouth of a defect.
depending on the physical properties: neutral, magnetic,
electro-conductive, ionizing,
absorbing ionizing radiation, combined;
depending on processing characteristics: removed by organic solvents, removed by water,
removed by water after using a cleaner or surface-active substances, neutralized by quenching of luminescence or color. 2.5 Developers are divided into:
depending on the condition in accordance with Table 2.
Table 2
Physical condition
Powder
Suspension
Paint (vanish)
Film
Principle of operationCharacteristic Dry, mainly white sorbent, absorbing the indicator
Sorption penetrant
Mainly white sorbent, absorbing the indicator
penetrant, dispersed in volatile solvents, water or quick-drying mixtures
Bonding pigmented or clear quick-drying solution,
Diffusion absorbing the indicator penetrant Clear or white attachment band with a developing
layer (for example, adhesive layer), absorbing the indicator penetrant, separated from the test surface by г indicator trail
depending on the interaction of the developer with the indicator penetrant:
chemically passive, not changing dyeing characteristics of the indicator penetrant;
chemically active (reactive), changing color, power to luminesce, or resulting in reaction products that initiate defects.
3. APPARATUS
3.1 While testing, apparatus according to GOST 23349-84 is used.
3.2 When necessary, different examination means (magnifiers, binocular stereoscopic microscopes, mirrors) to detect a defect trail and interpret test results are used under
conditions that ensure the illumination of the test specimen in compliance with the operating rules for such means.
4. TESTING PROCEDURE
4.1 The main stages of capillary nondestructive testing are: preparation of the specimen for testing;
treatment of the specimen with flaw-detection materials; development of defects
detection of defects and interpretation of test results; final cleaning of the test specimen.
4.2 The modes of testing operations (duration, temperature, pressure) are set depending on the sensitivity level required, flaw-detection materials used, features of the test specimen and types of defects sought, testing conditions and apparatus employed.
4.3 Preparation of the specimen for testing consists of cleaning of the test surface and defect cavities from various contaminations, lacquer coatings, detergent compositions and flaw-detection materials left from the previous testing, as well as of drying of the test surface and defect cavities. The methods of cleaning of the test surface are listed below:
mechanical- abrasive blasting (sand, shot, stone-grit) or machining of the surface; vapor- cleaning in organic solvent vapors;
dissolving- flushing, sponging using water, aqueous cleaning solutions or volatile solvents; chemical- cleaning by aqueous solutions of chemicals;
electrochemical - cleaning by aqueous solutions of chemicals with simultaneous exposure to electric current;
ultrasonic – cleaning by solvents, water, or aqueous solutions of chemicals in ultrasonic field using ultrasonic capillary effect;
anode- ultrasonic - cleaning by aqueous solutions of chemicals with simultaneous exposure to ultrasound and electric current;
thermal – cleaning by heating at temperature that does not cause inadmissible changes of the specimen material and oxidation of its surface;
sorbtion – cleaning by a mixture of sorbent and quick-drying organic solvent, applied on the surface to be cleaned, hold and removed after drying.
Notes:
1. The required methods of cleaning, their combination and cleanliness of the specimen surface is defined in
test specifications.
2. In case high sensitivity level of testing is specified, chemical and electrochemical methods, including
specimen exposure to ultrasound and electric current, are more preferable than the mechanical ones. The effectiveness of such methods is achieved due to the optimal choice of cleaning compositions, modes of cleaning, combination and consistency of the cleaning methods used, including drying.
4.4 While preparing the specimen for testing, when necessary, residual or working stresses in the specimen that squeeze the cavities of defects sought may be relieved or compensated.
While searching for through defects in walls of pipeline systems, balloons, devices and similar cavitary specimens filled with gas or liquid and under excessive pressure, liquid is removed from the cavities of such specimens, and gas pressure is brought to the atmospheric pressure.
4.5 Treatment of the specimen with flaw-detection materials consists of: filling defect cavities with indicator penetrant; removing of excess indicator penetrant; application of the developer.
4.5.1 The method of filling defects with indicator penetrant and their process characteristic is specified below:
capillary – spontaneous filling of defects cavities with indicator penetrant, applied on the test surface by wetting, submersion, jet, compressed air atomization, chladone or inert gas atomization;
vacuum – filling of defects cavities with indicator penetrant, with the pressure in the cavities being less than the atmospheric pressure;
compressive - filling of defects cavities with indicator penetrant under excessive pressure;
ultrasonic - filling of defects cavities with indicator penetrant in ultrasonic field using ultrasonic capillary effect;
deformation - filling of defects cavities with indicator penetrant when the specimen is under
elastic oscillation of acoustical frequency or static loading that increases the minimal defect size.
Note:
To detect through defects, it is allowed to apply penetrant on the surface opposite to the one being tested.
4.5.2 The temperature of the test specimen and indicator penetrant shall be within the limits specified in technical specifications for such flaw-detection material and specimen.
4.5.3 The duration of cavity filling is specified in technical specifications for specimens.
4.5.4 Excessive indicator penetrant is removed or quenched on the surface under test (depending on the processing characteristic per item 2.4) using the cleaner or without it, possibly within a short period of time from the moment the filling of defects cavities has been completed till development starts.
Indicator penetrant may be removed in the following ways:
wiping – removing of indicator penetrant using napkins with or without cleaning mixture or solvent;
flushing - removing of indicator penetrant using water, special cleaning mixture or the combination thereof (by submersion, jet, or atomized flow);
blasting - removing of indicator penetrant by sand blasting, shot or stone-grit blasting, or using saw dust;
quenching – removing of luminescence or color using a quencher.
4.5.5 When using indicator penetrants that can be removed by water-flushing (after exposure to the cleaner) and prior to the use of developers of any type (except for water-base suspensions) the wet surface being tested is climatic or air-blast dried. It is allowed to wipe the surface with clean hydroscopic cloth, cotton waste, saw dust.
It is allowed to remove indicator penetrant by blasting and quenching without cleaner or water pretreatment.
4.5.6 The developer is applied in the following ways:
atomization – application of a liquid developer by air-blast, chladone or inert gas jet, or by air-free method;
electro- atomization - application of a developer in the electrostatic field with air or air-free atomization;
suspension in air - application of a powder developer by generating its suspension in air in a chamber where the test specimen is located;
brush - application of a liquid developer using a brush or similar devices;
submersion - application of a liquid developer by short-time submersion of the test specimen into the developer;
flooding - application of a liquid developer by flooding;
electric precipitation - application of the developer by submersion of the test specimen into the developer and simultaneous exposure to electric current;
powdering - application of a powder developer by dusting or powdering of the test specimen; gluing - application of a film-developer band by pressing the adhesive layer to the specimen.
4.5.7 When using self-developing, filterable and other indicator penetrants not requiring the application of the developer, the latter is not applied.
4.6 The development of defects trails is a process of patterning in the areas of defects presence. The ways the defects indicator trails may be developed are listed below:
time – exposure of specimens to air till full and legible defects indicator trails appear; thermal – heating of specimens under normal atmospheric pressure;
vacuum – evacuation above the specimen surface with constant discharge or discharge changing according to a certain principle;
vibration - elastic deformation effect on the specimen by means of vibration, repeated or static loading.
4.7 Defect detection is a combination or individual use of indicator trail observation and recording methods, shown in Table 3.
4.7.1 Sensitivity level and illumination of test specimens.
Sensitivity level of testing is determined depending on the minimal size of defects detected in accordance with Table 4.
Sensitivity level, volume, frequency and quality assessment criteria are specified by the designer of the test specimen or of the material to be tested.
4.7.1.1 In case of achromatic and color methods of capillary flaw detection with visual detection of defects, combined illumination should be used (general lighting plus local lighting). Only general lighting is allowed when the use of local lighting is impossible due to process conditions. It is not allowed to use only local lighting in stationary working areas.
As light sources luminescent lamps, mainly of ЛБ or ЛХБ type, and incandescent lamps should be used. The use of high pressure gas-discharge lamps (ДРЛ, metal-halide lamps) is not allowed. To limit light fluctuation it is necessary to use two-tube, four-tube, etc. standard lighting fixtures with switching devices of УБИ and УБК type, or to provide for switching of the lighting fixtures (lamps) to different phases of electric main.
The use of one-tube fluorescent fixtures for local lighting is allowed provided high frequency converters are available.
Table 3
Method Technique of defect Designation Process characteristic
indicator trail of capillary detection methods
and techniques
Penetrating Luminance Я Defect detection by achromatic indicator solutions (achromatic), trail in visible radiation
Color Ц Defect detection by color indicator trail in (chromatic), visible radiation
Luminescent Л Defect detection in long-wave ultraviolet
radiation by indicator trail, luminescent in
visible radiation
Luminescent-colorЛЦ Defect detection by color or luminescent indicator trail in visible or long-wave ultraviolet radiation
Filterable Luminescent ФЛ Defect detection by accumulation of filtered suspensions particles (luminescent, color, luminescent-Color ФЦ
color) Luminescent-colorФЛЦ
Combined Capillary-КЭ Defect detection in non-metallic specimens
electrostatic by indicator trail, caused by electrified
powder or penetrant
Combined Capillary-КИ Defect detection in non electrically electroinduction conducting specimens using electro-induction method by changing specific
electric conductivity in the area of the defect, filled by penetrant
Capillary-КМ Defect detection (surface defects separately
magnetic-particle from subsurface defects) in magnetizable
ferromagnetic specimens by indicator trail, caused by the developer, containing ferromagnetic powder, and indicator penetrant
Capillary- radiation КР Defect detection by the presence of ionizing of emanation radiation in area of the defect, filled with
radioactive penetrant
Capillary- radiation of absorption
КП
Defect detection by the absorbtion of
ionizing radiation in the area of the defect, filled with radiation absorption penetrant
To prevent blindness, lighting fixtures with opaque reflectors, complying with SNiP II-4-79 and approved by USSR Gosstroy, should be used for local lighting.
Table 4
Sensitivity level Defect minimal size (opening width), mcm
I Less than 1 II From 1 to 10 III From 10 to 100 IV From 100 to 500 Process Not standardized
To limit reflected glare, measures specified in Appendix 7 of SNiP (construction regulations) II-4-79 shall be taken.
Illumination value is chosen in accordance with SNiP II-4-79 depending on the width of the extended indicator trail, formed during the detection of minimal defects for a given sensitivity level, and their contrast against the developer (or the specimen in case of the absence of the developer).
Table 5 shows illumination values to detect extended indicator trails of crack-like defects depending on the sensitivity level.
Table 5
Sensitivity Conditions of visual detection of defects extended indicator trails (trail width-level to-defect opening width ratio being 10:1)
Ultraviolet irradiance when Illumination, luxes, when using color and using luminescent methods luminance methods (Ц, Я, ФЦ) for lamps
(Л, ЛЦ, ФЛ, ФЛЦ)
luminescent incandescent relative unit microwatt/cm²combined general combined general300 -100 3000 I -1000 2500* 750 2000* 500 II
III 150±50 1500±500 2000 500 1500 400 IV 75±50 750±250 750 300 500 200 Process Up to 50 Up to 500
* When using color method with diffusion development it is allowed to take on values 4000 and 3000 luxes respectively.
Notes:
1. In normative-technical documentation it is allowed to subdivide sensitivity levels, designating sublevels
within, for example, level II - IIa, IIb, etc.
2. General illumination in a combined illumination system shall constitute 10% of the value specified for
combined illumination, but be not less than 150 luxes when using luminescent lamps.
4.7.1.2 When using luminescent method of capillary flaw detection with visual defect detection, ultraviolet radiation with waves 315-400 nm long should be used.
4.7.1.2.1 Ultraviolet irradiation of test specimens is measured integrally in energy units.
It is allowed to use an indirect system of integral estimate of ultraviolet irradiance by measuring the illumination caused by the luminescent screen, manufactured according to reference
appendix 3. The irradiance at which the luminescent screen emits luminous flux that produces illumination equal to1 lux is taken as the relative unit of integral irradiance. Calculation
technique to determine ultraviolet irradiation and its visible constituent from ultraviolet radiator is specified in reference appendix 4.
Table 5 shows ultraviolet irradiation values to detect extended indicator trails of single-crack type defects, with the depth considerably exceeding the opening width.
4.7.1.2.2 The area of visual inspection in ultraviolet radiation shall be equipped with indirect or diffusion light distribution fixtures ensuring illumination in the room equal to10 luxes. Direct accent lighting of the test area and operator’s eyes from visible light sources is not allowed. On the test surface it is permitted to have illumination from ultraviolet radiator not more than 30 luxes.
4.7.1.3 Sensitivity is determined using plant’s reference standards specified in GOST 23349-84. The size of defects in reference standards is determined by metallographic method or other methods of analysis.
4.7.1.4 The values of given ultraviolet irradiation may be less that the values for corresponding sensitivity levels shown in Table 5, when there is:
no stray light and illumination from ultraviolet radiator, measured in accordance with reference appendix 4, not more than 10 luxes;
adaptation of the operator (flaw detection inspector) to darkness with standardized duration; speed-fixed visual search for defects,
use of optical observation means (magnifiers, microscopes).
4.7.1.3, 4.7.1.4 (Modified Revision, Modification №2).
4.7.1.5 Specified sensitivity level is achieved when:
a set of certified flaw-detection materials with required sensitivity is used; specified workflow is adhered to;
atmospheric conditions (temperature, humidity, air velocity) comply with those required for proper use of flaw-detection materials and apparatus;
surface roughness of test specimens comply with the requirements of flaw-detection materials set; contaminants are removed from the test specimens surface and access of penetrants to defects cavities is ensured;
defects of a certain type are detected;
the operator (flaw detection inspector) has received training on the testing method and got permission to perform capillary testing operations.
4.8 Final cleaning of specimens represents one operation of removing the developer, and, when
required, removing indicator penetrant residuals, or a combination of several such operations. The developer may be removed in the following ways:
wiping – removing the developer using napkins with or without water or organic solvents; flushing - removing the developer by flushing in water or organic solvents using necessary additions and supporting equipment (brushes, cotton waste, sponges);
ultrasonic machining - removing the developer by solvent or cleaning solution when exposed to ultrasound;
anodic treatment – electrochemical treatment by aqueous solutions of chemicals with simultaneous exposure to electric current;
blasting – the specimen covered with the developer is abrasive blasted using sand, granulated material or hydroabrasive mixture;
peeling off – separation of film-developer band with indicator trail from the test surface; burning-off - removing the developer by heating of the specimen to developer burnout temperature;
delamination – separation of the developer in the form of a film in liquids that do not dissolve the developer.
4.9 Capillary tested specimens should be corrosion protected in accordance with the requirements of GOST 9.028-74.
5. RECORDING OF TEST RESULTS
5.1 Type and amount of test result recording is specified in standards or specifications for test specimens.
5.2 Test results are logged, reported or entered into a punchedcard, indicating the following: name and type of the test specimen; size and location of the test areas;
testing method characteristics (method, set of flaw-detection materials, sensitivity level); main characteristics of defects detected; name and type of apparatus used;
normative-technical documentation in accordance with which the testing is performed; date and time of testing;
position, surname of the person who performed the testing.
5.3 When recording test results it is allowed to use conventions of defects detected and abbreviated notation of the testing method in accordance with reference appendix 5.
It is permitted to make a reference to operation sheet number (see reference appendix 6) instead of giving the information about the specimen and method of testing.
6. SAFETY REQUIREMENTS
6.1 During handling, storing, transportation and use of flaw-detection and auxiliary materials, waste products and specimens tested, the requirements for fire and explosion protection according to GOST 12.1.004-85 and GOST 12.1.010-76 should be followed.
6.2 Work site location and arrangement, the equipping of the site with devices required for safe performance of operations, shall comply with production facility safety requirements in accordance with GOST 12.2.003-74.
6.2.1 Apparatus safety requirements – according to GOST 23349-84.
6.2.2 Production processes safety requirements – according to GOST 12.3.002-75.
6.2.3 Safety requirements for detrimental substance content, temperature, humidity and air mobility in the working area – according to GOST 12.1.005-76 and GOST 12.1.007-76; requirements for ventilation systems – according to GOST 12.4.021-75.
6.4 Electrical safety requirements – according to GOST 12.2.007.0-75 - GOST 12.2.007.6-75, GOST 12.2.007.7-83, GOST 12.2.007.8-75, GOST 12.2.007.9-88, GOST 12.2.007.10-87, GOST
12.2.007.11-75, GOST 12.2.007.12-88, GOST 12.2.007.13-75, GOST 12.2.007.14-75, GOST 12.1.019-79, “Regulations for electrical installation arrangement”, “Operational regulations for consumers’ electrical installations” and “Safety regulations for operating consumers’ electrical installations”, approved by Gosenergonadzor.
6.2.5 Static charge protection requirements should contain specific information about charge values, earthing, methods and means of protection from increased levels of static electrization and electrostatic field strength, availability of electric charge neutralizer, - availability of individual and shared anti-electrostatic protective means and methods to evaluate their effectiveness.
6.2.6 Acoustic protection requirements – according to GOST 12.1.003-83.
6.2.7 Daylight factor requirements (DFR) and requirements for work area illumination,
luminance, contrast, direct and reflected glare, luminous flux fluctuation, - according to SNiP II-4-79, approved by USSR Gosstry.
6.3 Waste products in the form of used flaw-detection materials shall be utilized, recovered, removed to collectors or destroyed (for organic materials- incineration).
6.4 Use of workers’ individual and shared protective means requirements – according to GOST 12.4.011-87.
6.5 Requirements for overalls - according to GOST 12.4.016-83. (Modified Revision, Modification №1).
6.6 Requirements for hands protection - according to GOST 12.4.020-82.
6.7 Ultraviolet protection requirements - according to “Hygienic regulations for designing and operating the units with man-made UV-radiation sources for luminescent examination of manufactured articles quality”, approved by Central sanitary-epidemic authority of USSR Ministry of Health.
While inspecting the test surface in ultraviolet radiation, it is necessary to use protective goggles according to GOST 12.4.013-85 with glasses ЖС4, 2 - 2,5 mm thick, according to GOST 9411-81.
(Modified Revision, Modification №1).
APPENDIX 1
Reference
Flaw-detection material set form
Name of flaw-detection material set Range and conditions of Test material and test
application specimen
Surface roughness parameter per GOST 2789-73
Temperature range
Flaw-detection material
Unified designation per Penetrant Cleaner Developer GOST 18442-80
Field designation
Form of packing (aerosol package or other)
Supplier or manufacturer Material standard
APPENDIX 2
Reference
Prescription form
Flaw-detection material
Designation of the developer
Constituents: 1. _____________________________
designation according to item 2.1 of the present standard
GOST Quantity (% by mass
(TU (technical or % by volume) specifications))
___________ 2. _____________________________GOST
(TU) 3. _____________________________GOST (TU)
Preparation and storage rules _____________________________________________________
Usage rules
____________________________________________________________________________________________________________________________________________________
APPENDIX 3
Reference
MANUFACTURE OF LUMINESCENT SCREEN
1. Screen technical requirements
Luminescent screen shall have even, smooth surface without streaks, buildups, cracks or foreign matter. Screen thickness without the substrate – from 0,5 to 1,0 mm. Screen size – not less than 55 x 55 mm.
2. Manufacture process
Manufacture process includes the following operations: substrate machining;
preparation of screen substrate surface prior to the application of the luminescent solution; preparation of the luminescent solution;
application of the solution on screen substrate.
Screen substrate is manufactured from duralumin alloy plate Д16 ЛМ-1 according to GOST 4784-74. The manufactured plate is straightened. Prior to anodic oxidation the surface of the screen substrate is prepared in the following sequence:
the workpiece is degreased in petrol, then in acetone, using a harsh hair brush; dry workpiece is treated in 50% NaOH solution at 25-30ºC for 15 minutes; the workpiece is flushed in warm water first, then in cold running water;
the workpiece is clarified in HNO3 solution (density 1,2-1,4 g/cm3) for 15-30 s. the workpiece is flushed in cold running water.
Oxidation of the workpiece is performed in sulfuric electrolyte, containing 200 g/l H2SO4 (density 1,84 g/cm3). The process is carried out at the temperature of electrolyte being 15-25ºC, anode current density 1,0-1,3 A/dm2, and with cathodic-lead plate. The duration of the process is 1 h. Then the workpiece is flushed in cold running water and dried.
The mixture applied on the screen substrate after drying is a suspension of phosphor Б-ЗЖ in acetone solution of acetyl cellulose, plasticized by dibutyl phthalate to avoid cracking. Mixing ratio, % by mass: phosphor Б-ЗЖ – 12,0; acetone – 80,5; acetyl cellulose – 6,0; dibutyl phthalate – 1,5.
The preparation of the luminescent mixture is carried out in the following sequence: acetyl cellulose is dissolved in acetone; dibutyl phthalate is added;
phosphor is loaded and mixed thoroughly.
The ready luminescent mixture is poured on the substrate surface in the amount sufficient for full spreading. The mixture is applied in 4-5 layers and dried at 20-125ºC for 40-60 minutes. While applying the mixture the substrate is placed in a vessel with high walls (10-12 cm) ensuring slowed-down drying due to the solvent vapors above the coating surface. Slowed-down drying prevents the formation of irreversible internal stresses in the coating that cause blisters and tightening to rise to the screen surface. The appearance of the screen is checked visually.
3. Safety requirements
Screen manufacture safety requirements:
the work is carried out in exhaust hood when there is draft;
measures shall be taken to avoid inflammation of organic materials; acids and alkali safe handling provisions shall be adhered to. When manufacturing the screen the following materials are used:
acetyl cellulose - according to specification, acetone – according to GOST 2603-79, aviation petrol – according to GOST 1012-72, dibutyl phthalate - according to specification, nitric acid - according to GOST 4461-77, sulfuric acid - according to GOST 4204-77, sodium hydroxide - according to GOST 4328-77, phosphor Б-ЗЖ - according to specification, sheet lead - according to GOST 9559-75, harsh brush - according to GOST 10597-87. (Modified Revision, Modification №1).
APPENDIX 4 Reference
METHOD FOR DETERMINATION OF ULTRAVIOLET IRRADIATION AND ITS
VISIBLE CONSTITUENT FROM ULTRAVIOLET RADIATOR
1. Ultraviolet irradiation should be determined in accordance with the scheme shown in Drawing 1 using the following method.
1- ultraviolet radiator; 2- sensor; 3- light filter; 4- luminescent screen
Drawing 1
1- ultraviolet radiator; 2- sensor; 3- light filter
Drawing 2
In the darkened room under the test ultraviolet radiator a luminescent screen is mounted at the distance D, equal to the distance from the radiator to the test specimen.
The screen is positioned at the angle of 45º to the axis of ultraviolet radiation flux. At the
distance of 70 mm from the screen a general purpose photoelectric luxmeter sensor, type Ю-16 or Ю-116 per GOST 14841-80, and ultraviolet radiation absorbing filter, made of ЖC4-grade glass per GOST 9411-81, thickness 5 mm, is mounted. Filter size is chosen depending on the size of the input window of the luxmeter used. The planes of the sensor and the screen shall be parallel. Illuminated (luminescent) size of the screen shall be 55 x 55 mm. While storage the screen shall be protected from visible and ultraviolet radiations. Irradiation is determined by luxmeter readings.
2. Visible light illumination from UV-radiator should be determined according to the scheme shown in Drawing 2, using the following method.
In the darkened room, without any stray lighting, under the ultraviolet radiator a luxmeter sensor is mounted at the distance D, equal to the distance from the radiator to the test specimen. The sensor is preliminary covered with glass filter, used according to item1. If ultraviolet radiation
sensor has not passed through the light filter, its ingress on the photocell is not allowed. The plane of the sensor shall be perpendicular to the axis of radiant flux. Illumination is determined by luxmeter readings.
3. To check the luminescent screen as per item 1, luxmeter readings are compared when UV-radiation is constant and when using working screen and reference screen by turn. Reference screen should be manufactured together with the working one, and stored at room temperature in a lighttight case and plastic sachet, preventing from extraneous gas, vapors, etc. If there is a more than 10% difference (decrease) in working screen readings the working screen shall be replaced.
APPENDIX 5
Reference
CONVENTIONS OF DEFECTS DETECTED AND TESTING PROCEDURE RECORD
WHEN RECORDING CAPILLARY TEST RESULTS
1. The defects found may be characterized according to the following features: Location: A- single,
B- clustered, located in limited areas of the test surface; C- located ubiquitously;
Orientation with respect to the principal axes of the test specimen:
- parallel;
- perpendicular;
- located at an angle;
without any mark – defects without dominant orientation;
Admissibility:
- allowable (minor or repairable in accordance with GOST 15467-79),
without any mark – not allowable (critical, major, not repairable in accordance with GOST 15467-79).
Note: Above-mentioned defects refer to surface defects. When there is a “through defect” symbol “*” is added. For example, a single through defect has the marking A*.
1. Example of specific defects marking:
- single allowable defects, located in parallel with the principal axis of the specimen;
- clustered allowable defects, located perpendicular at the angle to the axis of the specimen;
- ubiquitously distributed allowable defects, located at the angle to the axis of the specimen;
- ubiquitously distributed allowable defects without any dominant orientation;
A- single unallowable defects without any dominant orientation.
1. Example of testing procedure record:
X -X -(X) Conventions for flaw-detection materials (see item 2.1)
Sensitivity level (see Table 4 of the present standard)
Visualization method and technique (see Table 3 of the present standard)
4. Example of testing procedure record:
Capillary method using penetrating solutions with luminescent detection, having the first sensitivity level, using penetrant № 1, developer № 1 and penetrant cleaner № 7:
Л=I-(И1П1M7).
Capillary method using filterable suspensions with color detection, having the third sensitivity level, using penetrant № 38:
ФЦ-III-(И38).
Note: The numbering of flaw-detection materials is established in standards or specifications for a certain material.
APPENDIX 6
Reference
Form of capillary nondestructive testing operation sheet
Shop On ____ pages №______________ Operation Page № 1 Site № sheet № ____________ Code _____ _________________ of capillary nondestructive testing Operation № _______________ per flow chart
№ _______________
Article ___________ Name and Quantity per article __ Standard man-hours __ number of the ________ ________
component ________ ______ Assembly unit Material of the Category of work Price ____________
component
Areas to be tested Testing operations and results Means of testing (sketch) and rejection interpretation specification 1. Preparatory operations To specify apparatus, 1.1 ___________________ fixings, accessories, 1.2 ___________________ reference standards,
consumables 2. Testing procedure (techniques,
testing modes, component location, operations) 2.1 ____________________ 2.2 ____________________ 3. Estimation of test results 3.1 ____________________ 4. Final operations
Further pages of capillary nondestructive testing operation sheet
Areas to be tested OPERATION On ____ pages (sketch) and rejection SHEET № ____________ Page № specification
Means of testing
Testing operations and results interpretation
Last page of capillary nondestructive testing operation sheet
Areas to be tested (sketch) and OPERATION On ____ pages
SHEET № ____________ Page № rejection specification
Testing operations and results
interpretation
Doc.№
Means of testing Reason _____ Prepared by ____ Mod. Page Doc.№
Sign. Date Mod. Page Sign. Date
Head of Quality Control Department ________ Head of Technical Department _______ Head
of Central Plant Laboratory _______
(Modified Revision, Modification №2).
CONTENT
1. Basic provisions and field of application 2. Flaw-detection materials 3. Apparatus 4. Procedure
5. Recording of test results 6. Safety requirements
Appendix 1 Flaw-detection material set form Appendix 2 Prescription form
Appendix 3 Manufacture of luminescent screen
Appendix 4 Method for determination of ultraviolet irradiation and its visible constituent from ultraviolet radiator
Appendix 5 Conventions of defects detected and testing procedure record when recording capillary test results
Appendix 6 Form of capillary nondestructive testing operation sheet
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