Characterization of metal smear in consideration of prepenetrant etch requirements

Julie Henkener; Charles Salkowski

doi:10.1117/12.213559

7 July 1995 Characterization of metal smear in consideration of prepenetrant etch requirements

Julie Henkener, Charles Salkowski

Proceedings Volume 2455, Nondestructive Evaluation of Aging Aircraft, Airports, Aerospace Hardware, and Materials; (1995) https://doi.org/10.1117/12.213559
Event: Nondestructive Evaluation of Aging Infrastructure, 1995, Oakland, CA, United States

Abstract

A controversy exists within the aerospace community as to whether etching of components before dye penetrant testing to remove metal smear is always necessary. A test program was initiated to detect the degree of metal smear present in aluminum alloy 2024-T851 after machining by various techniques. Use of the scanning electron microscope confirmed the presence of metal smear. In addition, dye penetrant tests were performed before and after a chemical etching process that removed approximately 0.0005 in. It was determined that etching always improves flaw detectability, even for cracks that have not been smeared.

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Julie Henkener and Charles Salkowski "Characterization of metal smear in consideration of prepenetrant etch requirements", Proc. SPIE 2455, Nondestructive Evaluation of Aging Aircraft, Airports, Aerospace Hardware, and Materials, (7 July 1995); https://doi.org/10.1117/12.213559

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KEYWORDS

Metals

Etching

Inspection

Polishing

Aluminum

Scanning electron microscopy

Wet etching

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