process controll verification

1. 1
MONITORING CAPABILITY OF
THE TAM PANELL FOR SYSTEM
PERFORMANCE VERIFICATION

2. 2
• ASTM E1417-11ε1
• PRIME SPECIFICATION THAT FORESEEN THE SYSTEM PERFORMANCE
VERIFICATION THROUGH TAM PANEL PSM-5, AS:
• GE Aviation:P3TF2/P3TF47 – Rolls Royce: RPS702/EIS1169 –
Pratt&Whitney:FPM MASTER - SNECMA/SAFRAN: DMC0010 – MTU: MTV
1030 – Honeywell: 52309 - Aviogroup: 9300F – Agusta
Westland:AWPS006X
REFERENCE SPECIFICATION
Premises

3. 3
• In the “Top 5 Checklist Findings for 2011 “- AC7114/1 the first 4
places include topics relevant to the System Performance
Verification or to the control of the TAM Panel
• TAMs, became “reference standard”, especially in the aerospace,
but nevertheless few test have been performed to document their
capability to realize actually what the specification expect by them.
• The purpose has always been to establish the "BASELINE"
conditions of the know defect standard casting - that is the initial
condition of the Performance of the Penetrant System , to be
compared daily in monitoring the System.
RELEVANT ISSUES
Premises

4. 4
(Penetrant System Monitoring – 5 indications)
“STARBUST”
TAM (Testing And Monitoring)
A B C D E
TAM PSM-5
Manufactured on the basis of the original P&W drawing

5. 5
Identification of the Starbust A B C D E
Dimensional range (mm.) 0.38 ÷ 0.79 1.17 ÷ 1.57 1.91 ÷ 2.36 3.18 ÷ 4.34 4.57 ÷ 6.35
Drawing & Dimensions from Pratt&Whitney
146040
TAM PSM-5

6. 6
TYPE OF TAM PANEL
• TAM 146040-1: It shows chrome-plated
surfaces and mirror polished in the area where
the artificial defects are placed.
• TAM 146040-2: It shows everywhere
sandblasted surfaces
TAM PSM-5

7. 7
Sensitivity level
of the Penetrant
Minimum number of
surface indications
Classification
of the defects
to be found
2 3 C,D,E
3 4 B,C,D,E
4 5 A,B,C,D,E
BASELINE PROCESS
• Minimum number of TAM panel defects visible
during PT
TAM PSM-5

8. 8
BASELINE PROCESS
TAM PSM-5
8
S/N28220
970P
25E
S/N33995
S/N31334
RC 77
S/N31335

9. 9
• Document the "real" capability of these tools
in 'carrying out the daily System Performance
Verification for which they are employed.
• Determine the effectiveness of these known
defect standards by checking if they are able
to discriminate deviations exceeding the
limits of the specification, even very slight,
connected to the control of the penetrant
process.
TARGET of the TEST

10. 10
a) Chemical contamination of the
penetrant and of the emulsifier
Performed tests
b) Temperature variations of the
penetrant
c)Variation of penetrant and developer
dwell time
Check influences on the process control
through:

11. 11
POLLUTANTS
TEST PARAMETERS
Pressure Time Temperature
Performed Tests

12. 12
Sherwin Hydrofilic
Emulsifier ER83A
Ardrox WW Penetrant
970P25E
Type 1 Method A Level 3
Sherwin PE Penetrant
RC 77
Type 1 Method D Level
4
Sodium
Hydroxyde (2-5-7-
10 % v/v)
Nitric Acid
(2-5-7-10 % v/v)
Water
(5-10-15-20 % v/v)
Ardrox WW
Penetrant HM430
Type 1 Method A Level 3
Turco 4215
NC-LT
(30 % v/v)
Pollutants

13. 13
Test identification
S/N28220
Details
of test
parameters
S/N33995
Green square highlights a
substantial invariance of
the performance of the
TAM respect to the
BASELINE
S/N28220
Details
of test
parameters
S/N33995 Red square highlights a
substantial variance of
the performance of the
TAM respect to the
BASELINE
Name Product – Test Parameters

14. 14
Pollutants
S/N28220
5%
S/N33995
S/N28220
10%
S/N33995
ARDROX 970P25 – H2O (5-10 %v/v)

15. 15
Pollutants
S/N28220
15%
S/N33995
S/N28220
20%
S/N33995
ARDROX 970P25 – H2O (15-20 %v/v)

16. 16
Pollutants
S/N31334
5%
S/N31335
S/N31334
10%
S/N31335
SHERWIN RC77 – H2O (5-10 %v/v)

17. 17
Pollutants
S/N31334
15%
S/N31335
S/N31334
20%
S/N31335
SHERWIN RC77 – H2O (15-20 %v/v)

18. 18
S/N28220
2%
S/N33995
S/N28220
5%
S/N33995
ARDROX 970P25 – HNO3 (2-5 %v/v)
Pollutants

19. 19
Pollutants
S/N28220
7%
S/N33995
S/N28220
10%
S/N33995
ARDROX 970P25 – HNO3 (7-10 %v/v)

20. 20
Pollutants
S/N31334
2%
S/N31335
S/N31334
5%
S/N31335
SHERWIN RC77 – HNO3 (2-5 %v/v)

21. 21
Pollutants
S/N31334
2%
S/N31335
S/N31334
5%
S/N31335
SHERWIN RC77 – NaOH (2-5 %v/v)

22. 22
Pollutants
S/N31334
7%
S/N31335
S/N31334
10%
S/N31335
SHERWIN RC77 – NaOH (7-10 %v/v)

23. 23
Pollutants
S/N28220
2%
S/N33995
S/N28220
5%
S/N33995
ARDROX 970P25 – NaOH (2-5 %v/v)

24. 24
Pollutants
S/N28220
7%
S/N33995
S/N28220
10%
S/N33995
ARDROX 970P25 – NaOH (7-10 %v/v)

25. 25
Pollutants
S/N31334
2%
S/N31335
S/N31334
5%
S/N31335
SHERWIN ER83A – NaOH (2-5 %v/v)

26. 26
Pollutants
S/N31334
7%
S/N31335
S/N31334
10%
S/N31335
SHERWIN ER83A – NaOH (7-10 %v/v)

27. 27
Pollutants
S/N31334
10%
S/N31335
SHERWIN ER83A – HNO3 ( 10%v/v)

28. 28
Pollutants
S/N31334
20%
S/N31335
SHERWIN ER83A – H2O ( 20%v/v)

29. 29
SHERWIN HM430 – TURCO 4215 NC-LT (30 %v/v)
Pollutants
S/N28971
30%
S/N28218

30. 30
Water pressure
Ardrox WW Penetrant
970P25E
Type 1 Method A Lev 3
Sherwin PE Penetrant
RC 77
Type 1 Method D Lev 4
Washing
pressure
50-300 kPa

31. ARDROX 970P25 50-300 kPa
TEST PARAMETERS :
WATER PRESSURE
31
S/N31334
50
kPa
S/N31335
S/N31334
300
kPa
S/N31335

32. 32
S/N31334
50
kPa
S/N31335
S/N31334
300
kPa
S/N31335
SHERWIN RC77 50-300 kPa
TEST PARAMETERS :
WATER PRESSURE

33. 33
Time
Ardrox WW
Penetrant HM430
Type 1 Method A Level 3
Dwell time with liquid
penetrant
Developping time
(4-10-30-60 min.)
Immersion
(min.)
Draining
(min.)
0 0
2 2
5 5
1 15
60 60

34. 34
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430
Immersion 1 sec. – Draining 1 sec.
TEST PARAMETERS:
PENETRANT DWELL
TIME

35. 35
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430
Immersion 2 min. – Draining 2 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

36. 36
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430
Immersion 5 min. – Draining 5 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

37. 37
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430
Immersion 1 min. – Draining 15 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

38. 38
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430
Immersion 60 min. – Draining 60 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

39. 39
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 4 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

40. 40
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 10 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

41. 41
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 30 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

42. 42
S/N 28971 S/N 28217 S/N 28218
SHERWIN HM430 – 60 min.
TEST PARAMETERS:
PENETRANT DWELL
TIME

43. 43
Temperature
Ardrox WW
Penetrant HM430
Type 1 Method A Level 3
Penetrant
Temperature
(5°-50°-80 °C)
Ardrox WW Penetrant
970P25E
Type 1 Method A Level 3
Sherwin PE Penetrant
RC 77
Type 1 Method D Level
4
Drying
Temperature
(100-120 °C)
Washing
Temperature
(5°-50°-80 °C)

44. 44
SHERWIN HM430 5 °C
TEST PARAMETERS:
PENETRANT
TEMPERATURE
S/N28971
5°C
S/N28218

45. 45
SHERWIN HM430 50 °C
S/N28971
50°C
S/N28218
TEST PARAMETERS:
PENETRANT
TEMPERATURE

46. 46
SHERWIN HM430 80 °C
S/N28971
80°C
S/N28218
TEST PARAMETERS:
PENETRANT
TEMPERATURE

47. 47
S/N28220
5 °C
S/N33995
S/N31334
S/N31335
ARDROX 970P25 - SHERWIN RC77 5 °C
TEST PARAMETER:
WASHING
REMPERATURE

48. 48
S/N28220
50 °C
S/N33995
S/N31334
S/N31335
ARDROX 970P25 - SHERWIN RC77 50 °C
TEST PARAMETER:
WASHING
REMPERATURE

49. 49
S/N28220
80 °C
S/N33995
S/N31334
S/N31335
ARDROX 970P25 - SHERWIN RC77 80 °C
TEST PARAMETER:
WASHING
REMPERATURE

50. 50
S/N28220
100°
C
S/N33995
S/N28220
120°
C
S/N33995
ARDROX 970P25 100-120 °C
TEST PARAMETERS:
DRYING TEMPERATURE

51. 51
S/N31334
100
°C
S/N31335
S/N31334
120
°C
S/N31335
SHERWIN RC77 100-120 °C
TEST PARAMETERS:
DRYING TEMPERATURE

52. 52
Temperature &
Time
Drying
Temperature
(25°-80 °C)
Ardrox WW Penetrant
970P25E
Type 1 Method A Level 3
Sherwin PE Penetrant
RC 77
Type 1 Method D Level
4
Drying Time
(30-60 min.)

53. 53
S/N28220
25 °C
S/N33995
S/N28220
80 °C
S/N33995
ARDROX 970P25 25°- 80 °C 15 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI
OF DRYING

54. 54
S/N31334
25 °C
S/N31335
S/N31334
80 °C
S/N31335
SHERWIN RC77 25°- 80 °C 15 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI
OF DRYING

55. 55
S/N31334
30
min.
S/N31335
S/N31334
60
min.
S/N31335
SHERWIN RC77 65 °C 30-60 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI
OF DRYING

56. 56
S/N28220
30
min.
S/N33995
S/N28220
60
min.
S/N33995
ARDROX 970P25 65 °C 30-60 min.
TEST PARAMETERS:
TEMPERATURE / TIME DI
OF DRYING

57. 57
Conclusions (1)
 The addition of sodium hydroxide does not show significant effects
about the process monitoring at all tested concentrations
 The presence of water, causes a progressive attenuation of the
intensity of the indications and a degradation of their size - At
levels of 15 -20% only parts of the two discontinuities of greater
dimensions (D – E) are still visible
 Alkaline degreasers in aqueous solution such as the TURCO 4215
NC-LT not seem to have impact on the effectiveness of the
Penetrant System
 Pollutants in the emulsifier, used for high sensitivity penetrant
cause no tangible effects - only nitric acid causes valuable
changes!
 The presence of nitric acid , progressively eliminates the brightness
of the penetrant, which remains almost unchanged up to a
concentration of 2% (v / v)

58. 58
Conclusions (2)
 Increasing the temperature in the oven drying occurs a progressive
deterioration of the sharpness of the indications accompanied by the
deposition of fluorescent pigment from the temperature of 100 ° C. The
dwell time of greatest impact on water washable reducing penetrant
brightness and sharpness of starbusts
 The obtained results appear to be insensitive to changes in penetrant
dwell time (immersion and draining), ranging from a few seconds up to
one hour and to variations in the application temperature from 5 ° C to
80 ° C!
 Increasing the pressure of the water washing a small attenuation of the
brightness of the individual indications has been observed, but no dramatic
evidence appear even up to 300 kPa
 The variation of washing temperatures (operation, typically performed in
the range 10 ° to 38 ° C) is not detected during System Performance
effectiveness. After a washing at 80 ° C It is still valuable the starbust A

59. Conclusions (3)
 WHAT IS APPEARING FROM THE OBTAINED RESULTS:
 1) The TAM PANEL 146040 showed some limits relevant to the
possible drift of the penetrant process.
 2) Therefore, there is the possibility to have working conditions do not
conform to the applicable requirements ….
BUT…………….
 3) What can happen instead on the actual defects in the inspected
components?
 4) And 'the magic halo attributed to this instrument which is delegated
to the effective Performance Effectiveness Verification of the system is
justified?
 The evidence of the monitoring do not seem to be affected by the
percentage of dwell time - immersion respect to that of drainage
 The tests reveal no variations due to different development time used, at
least in the range tested.

60. Conclusions (4)
 After all these consideration about the TAM146040 effectiveness,what do
we have to consider about the its supply condition?
 For a good daily practice, it is mandatory the initial fulfillment of 146040
drawing requirements , about the 5 starbusts size ?

61. 61
Special Thanks / Credits
Thanks to the article of George Hopman published on
“Material Evaluation” - February 2009 …It has given
us an opportunity to deepening the concept
concerning an subject that raised so many issues
during the audit
A special thanks to a couple of colleagues:
A.Martignetti and G. Petronella – Alenia Aermacchi
who have shared and contributed to the development
of these subjects.

62. 62
Question time
?
? ?