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Inspecting motorsport components by penetrant flaw detection techniques

URN: SEMAUT3078
Business Sectors (Suites): Automotive Engineering Suite 3
Developed by: Enginuity
Approved on: 30 Mar 2020

Overview

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This standard identifies the competences you need to carry out penetrant flaw detection tests on ferrous or non-ferrous motorsport components, materials or structures, in accordance with approved procedures. You will be required to prepare the components for the penetrant flaw detection activities, and to check that the equipment complies with the specification requirements is safe to use and fit for purpose. You must ensure that the ambient conditions are satisfactory for the tests to proceed, and you will carry out the specified tests using the correct procedures (according to the non-destructive testing (NDT) instructions and requirements) and observe and record the test indications. You will complete the tests by preparing/completing a NDT test report containing the required test information and data, along with your interpretation of the test indications. You will be expected to mark up the components to show where there are indications of flaws. The completed inspection report will be passed to the appropriate person, in accordance with procedures.

Your responsibilities will require you to comply with organisational policy and procedures for the penetrant flaw detection testing activities undertaken, and to report any problems with the activities or equipment in use, that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will show a good understanding of your work, and will provide an informed approach to the inspection of motorsport components using penetrant flaw detection testing techniques. You will have a working knowledge of the principles of penetrant flaw detection techniques, and will understand the role of penetrant fluids, developers and ultraviolet light imaging. You will have a detailed knowledge of testing practice, and will understand why this method has significant limitations in its flaw detecting capabilities. Your knowledge will include an appreciation of hazards and safe working practice, and you will understand the risks posed by material defects and the consequences of failure. The importance of compiling accurate and legible reports will also be a key issue in completing this standard.

You will understand the safety precautions required when carrying out the penetrant flaw detection activities, and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace.

Performance criteria

You must be able to:

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  1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
  2. follow the correct specification for the product or equipment being inspected

  3. identify and confirm the inspection checks to be made and acceptance criteria to be used

  4. carry out all required inspections as specified, using appropriate equipment, methods and techniques

  5. identify any defects or variations from the specification
  6. deal promptly and effectively with problems within your control and report those that cannot be solved
  7. ensure that work records are completed, stored securely and available to others, as per organisational requirements
  8. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements

Knowledge and Understanding

You need to know and understand:

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  1. the specific safety precautions to be taken whilst carrying out the  activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
  2. the health and safety requirements of the work area  and the activities, and the responsibility these requirements place on you
  3. the hazards associated with  the activities, and how to minimise them and reduce risks

  4. the personal protective equipment and clothing (PPE) to be worn during the activities

  5. how to obtain the necessary job instructions, testing specifications, and how to interpret their information

  6. the reasons why some components, materials or structures need to be tested using non-destructive testing methods
  7. why it is sometimes necessary to use a range of different non-destructive testing methods (magnetic particle, penetrant flaw detection, ultrasonic and radiography)
  8. the various types of penetrant flaw detection equipment used (such as portable kits and fixed installations; containers and dispensers for penetrants, removers and developers)
  9. the basic concepts of penetrant flaw detection testing (the type and characteristics of penetrant liquids; how the liquids are absorbed by capillary flow into the surface of the product, breaking any discontinuities/flaws in the products)
  10. how to develop indications of the discontinuities/flaws so that they show up clearly
  11. the different types of penetrants that are used (colour and fluorescent intensity, methods of applying them and contact time required to be effective)
  12. the various types of penetrant removers (such as solvents, water-soluble and oil-soluble emulsifiers)
  13. the various types of developers that are used (dry powder, powder in aqueous and non-aqueous carriers, developers in solution), and the contact times required for effective development
  14. the type of lighting that is required for the defects to show up clearly
  15. the preparations to be carried out on the test area (degreasing); the effect of finish, contaminants and testing temperature on the test results achieved
  16. how to carry out the testing activities (the application of the penetrant, removal of excess penetrant, contact time, drying of products, application of developer, conditions for viewing developed indications (ambient light or ultraviolet (UV) light) and cleaning of the products on completion of the testing activities
  17. the types of defect that are detectable using penetrant flaw detection methods
  18. how to recognise the defects from the developed indications, and how to identify false indication of effects and their cause
  19. the level of defects that are acceptable in the components, materials or structures; influence of the defects on the service/performance of the components, materials or structures
  20. why it is critical that records of penetrant flaw detection on the products, materials or structures are accurate, comprehensive and maintained legibly
  21. the problems that can occur with the NDT activities and how they can be avoided
  22. the extent of your own responsibility, and to whom you should report if you have problems that you cannot resolve
  23. how to access, use and maintain information to comply with organisational requirements and legislation

Scope/range

Scope Performance

  1. Carry out all of the following during the penetrant flaw detection activities:

    1. obtain and use the appropriate documentation (such as job instructions, NDT testing inspection specifications, drawings, welding specifications, quality control documentation)
    2. adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
    3. obtain the required penetrant flaw detection equipment and materials, and check that they are in a safe and usable condition
    4. use appropriate personal protective equipment
    5. check that penetrant flaw detection dispensers are fully operational
    6. follow the defined NDT testing procedures, and apply safe working practices and procedures at all times
    7. dispose of waste materials in accordance with approved procedures
    8. leave the work area in a safe and appropriate condition on completion of the activities

  2. Check and confirm that all of the following ambient testing conditions are satisfactory:

    1. temperature                 
    2. humidity                       
    3. freedom from pollutants

  3. Prepare the components, materials or structures for testing, to include carrying out all of the following:

    1. identifying and marking the test areas
    2. removing any contaminants from the test area (such as degreasing)
    3. preparing the surface of the test area to the specified finish (such as grinding or polishing)

  4. Use both of the following penetrant flaw detection dispensers:

    1. penetrant                                 
    2. developer

  5. Carry out all of the following, in accordance with instructions and procedures:

    1. washing and drying the test area
    2. applying penetrant to the area under inspection
    3. applying a developer (where appropriate)
    4. observing defect indications under correct lighting conditions (ambient light or ultraviolet (UV) light)
    5. recording conclusions of observations
    6. restoring and cleaning the component on completion of the test

  6. Carry out penetrant flaw detection on one of the following:

    1. welded joints
    2. motorsport mechanical components (such as brake discs, cylinder heads, drive shafts)
    3. motorsport/vehicle structures (such as chassis members)
    4. other specific components or materials

  7. Identify all of the following:

    1. defect type
    2. location of the defect
    3. dimensional size of the defect

  8. Follow the correct procedure to deal with components, materials or structures which fall into three of the following categories:

    1. components, materials or structures which meet the specification
    2. components, materials or structures with identified defects
    3. components, materials or structures requiring further investigation
    4. components, materials or structures requiring other inspection methods

  9. Complete a NDT report, to include recording all of the following:

    1. product identification

    2. material of construction

    3. geometry, thickness and surface condition where defect indications were found

    4. ambient testing conditions

    5. defects identified
    6. comparison of flaw data with acceptance criteria
    7. conclusions and recommendations
    8. test personnel information

  10. Complete the inspection activities, to include carrying out all of the following:

    1. marking up defective components, materials or structures with all relevant information
    2. recording all the required details of the inspection in the appropriate format
    3. handing over the inspection details to the appropriate people

  11. Check completed inspections comply with one of the following:

    1. approved construction drawings
    2. client specifications
    3. current industry standards, codes of practice and legislation
    4. welding procedure specification

Scope Knowledge

Values

Behaviours

Skills

Glossary

Links To Other NOS

External Links

Version Number

2

Indicative Review Date

31 Mar 2023

Validity

Current

Status

Original

Originating Organisation

Semta

Original URN

SEMAUT3078

Relevant Occupations

Engineering, Engineering and Manufacturing Technologies, Science and Engineering Technicians, Vehicle Trades

SOC Code

5231

Keywords

Engineering; automotive; manufacturing; inspecting; motorsport; components; penetrant flaw detection; techniques; ferrous; non-ferrous materials; non-destructive testing; NDT