NON-DESTRUCTIVE TESTING FPI
FLUORESCENT PENETRANT INSPECTION
WORK INSTRUCTION
BA/FPI-02
(WATER WASHABLE)
Ensure all relevant and appropriate Health and Safety Instructions are adhered to during this procedure.
1.1 Component: Outer Half Wheel Assembly & Inner Half Wheel Assembly
1.2 Part Number: OTBD: 5006868, 5006868-1, -2, -3 &
INBD : 5006865, 5006865-1, -2, -3, -4
1.3 Material: Aluminum Alloy
1.4 Area of Examination: Complete surface area of Hub-Sub Assembly.
1.5 Purpose of Examination: To detect surface breaking fatigue cracks
1.6 Type/ Method of Inspection: Fluorescent Water Washable Penetrant
1.6 Standards / Reference:
ASTM-E1417 standard practice for liquid penetrant testing, I.A.W Buddha Air (P) Ltd. NDT Quality
Procedure Manual. MABS Standard Practice Manual 32-46-35 (AP-842), MABS NDT Manual with
Procedures 32-42-07 (AP-763) and MABS CMM with IPL Chapter 32-40-74 (AP-615).
1.7 Equipment & Materials Required:
1.7.1 Penetrant- Type I, Method A, Level 2 or 3. Form a Developer,
Specifications SAE AMS 2644 and QPL-2644.
1.7.2 Wash Station/ Working Area
1.7.3 Any suitable Air circulating drying oven
1.7.4 Any suitable Black light source capable of producing 365 nm wavelengths
1.7.5 Calibrated Light Meter (Radiometer) White & UV.
1.7.6 Dust cabinet/ Manual Spray
1.7.7 Tam Panel, digital thermometer, 10X Magnification Glass
1.7.8 UV Goggles, Gloves, Cotton buds, Soft Tissue, Measuring Device, Marking pen.
1.8 Preparation/Safety:
Ensure component is free from paint, corrosion etc. Before carrying out this instruction, the
examination candidate shall comply with the relevant safety instructions.
1.9 Procedure
1.9.1 Surface Preparation.
All surfaces to be examined shall be clean, dry, and free of soils, oil, grease, paint and other
coatings (except anodizing)
1.9.2 Pre-Cleaning:
Pre clean the component/ part by etching or vapour degreasing or ultrasonic cleaning bath.
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Dated 30th Jan’2025 Page 1 of 4
NON-DESTRUCTIVE TESTING FPI
FLUORESCENT PENETRANT INSPECTION
WORK INSTRUCTION
BA/FPI-02
(WATER WASHABLE)
1.9.3 Component Temperature.
All Component, Penetrant, and Ambient temperatures must be between minimum 40°F
(4°C) to maximum 125 °F (52°C).
1.9.4 Apply Penetrant:
Apply the penetrant on all surfaces of the component(s) by spraying, dipping, brushing to
provide coverage to all surface area.
1.9.5 Penetrant Dwell Time:
Contact (dwell) time of penetrant shall be minimum of 10 minutes.
It is recommended to rotate or otherwise move components as necessary during dwell to
prevent pooling of the penetrant.
For dwell times greater than 2 hrs. the penetrant shall be reapplied as required.
1.9.6 Remove Excess Penetrant.
Note: All pre- rinse and excess penetrant removal to be carried out under UV-Light
conditions.
Use coarse water spray with water temperature Between 50°F to 100°F (10°C to 38 °C).
Pressure of water should not exceed 40 PSI with distance of component approx. 12 inches
from water spray nozzle.
Washing shall be conducted under appropriate (fill-in light) fluorescent illumination. Caution
shall be exercised to ensure that over-washing does not occur.
After rinsing, drain water from the component and utilize repositioning, suction, blotting with
clean absorbent materials, or filtered shop air at less than 25 psi [172 kPa] to prevent
pooling in cavities, recesses, and pockets.
If over-washing occurs, the component(s) shall be thoroughly dried and reprocessed.
1.9.7 Dry
Dry component(s) in air circulating oven. Oven temperature not to exceed 160 °F (71 °C).
Time in oven should be the minimum as necessary time required to allow component to dry.
Note: Components shall not be placed in the oven with pooled water or pooled
aqueous solutions/suspensions.
1.9.8 Apply Developer.
Apply dry developer to the component(s) to cover all surfaces be examined. Remove excess
dry developer shall be removed by light tapping or light air blow-off after the developing time.
Minimum developer dwell times shall be 10 min.
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NON-DESTRUCTIVE TESTING FPI
FLUORESCENT PENETRANT INSPECTION
WORK INSTRUCTION
BA/FPI-02
(WATER WASHABLE)
1.9.9 Viewing Conditions.
Inspector’s eye adaptation time of minimum 1 minute is required before inspection. Ambient
white light should not exceed 2 fc (20 lx) and Black light (UV-A) of 1200µw/cm² minimum at
38cm (15 in).
Note:
i. For all UV-A sources except LED UV-A Sources allow source to warm up for a min.
of 10 minutes prior to its use.
ii. Inspector should not wear photochromic or permanently darkened lenses while
processing or reviewing parts under UV-A irradiance
1.9.10 Inspection.
View immediately and after 20 minutes. All area of fluorescence must be interpreted and
evaluated.
Examine all surfaces of component and report all Indications of fatigue cracking.
Indication Verification by wiping the indication with a solvent-damped swab, brush or lint free
cloth avoiding flooding the area with solvent, allowing the area to dry, and redeveloping the
area. Redevelopment time shall be a minimum of 10 min.
If the indication does not reappear, the original indication may be considered false.
Note: Indication verification may be performed up to two times for any indications.
Any parts that have either excessive background, false or non-relevant indications, which
interfere with the detection of relevant indications, must be processed again from beginning.
Use magnification of 10X to interpret and evaluate indication if required.
Record all relevant discontinuities by size measurement and location.
1.9.11 Post- cleaning.
After examination, clean component(s) by any suitable Vapour Degreaser or Ultrasonic
Cleaning Bath to remove developers and other examination material.
1.9.12 Protection.
Re-apply protection coating including painting.
1.10 Evaluation/Examination standard:
Examine all surfaces of component and report all Indications of fatigue cracking. All indications
must be interpreted, evaluated and sentenced by comparison to appropriate criteria and when
required, using an appropriate measuring device that is calibrated and traceable. If indications
cannot be interpreted or remain questionable, Report to level III.
1.11 Additional information:
Ensure all pre use PT Checks to be carried out IAW NDT Procedure Manual, Form No NDT-06.
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Dated 30th Jan’2025 Page 3 of 4
NON-DESTRUCTIVE TESTING FPI
FLUORESCENT PENETRANT INSPECTION
WORK INSTRUCTION
BA/FPI-02
(WATER WASHABLE)
1.12 Manpower: 1.5 MHrs.
1.13 Nonconformance statement:
If any part of this procedure cannot be carried out, the head of NDT and QAD has to be informed
and work ceased until further information is received.
Note: Refer Fig 1 for Typical Fault Location
Typical Crack location
I/B HUB SUB ASSY. O/B HUB SUB ASSY.
Main Wheel Hub Sub-Assemblies
Figure 1: P/No: OTBD: 5006868 Series & INBD: 5006865 Series
Technique Compiled by: Technique Approved by
…………………………… ……………………………
Megh Pd. Upadhaya Mangesh Thapa
(NDT Level II) (NDT Level III)
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Dated 30th Jan’2025 Page 4 of 4
