Magnetic Particle Inspection

Classification of Materials based

on Magnetic Property
Ferromagnetic Materials

 Ferromagnetic materials include most of the iron, nickel, and cobalt alloys.
 Many of the precipitation-hardening steels, such as 17-4 PH, 17-7 PH, and 15-4 PH stainless steels, are magnetic after
aging.
 These materials lose their ferromagnetic properties above a characteristic temperature called the Curie point.
 Although this temperature varies for different materials, the Curie point for most ferromagnetic materials is
approximately 768 °C
MAGNETIC PARTICLE INSPECTION
• MPI is a method of locating surface and subsurface discontinuities in ferromagnetic materials.
• Magnetic discontinuities that lie in a direction generally transverse to the direction of the magnetic
field will cause a leakage field to be formed at and above the surface of the part.
• The presence of this leakage field is detected by the use of finely divided ferromagnetic particles
applied over the surface, with some of the particles being gathered and held by the leakage field.
• This magnetically held collection of particles forms an outline of the discontinuity and generally
indicates its location, size, shape, and extent.
• Magnetic particles are applied over a surface as dry particles, or as wet particles in a liquid carrier
such as water or oil.
• The direction of the magnetic field in an electromagnetic circuit is controlled by the direction of the flow of
magnetizing current through the part to be magnetized.
• The magnetic lines of force are always at right angles to the direction of current flow.
Leakage Field
History
• 1868- Cannon barrels were checked for defects by magnetizing the barrel
then sliding a magnetic compass along the barrel's length. These early
inspectors were able to locate flaws in the barrels by monitoring the
needle of the compass.
• 1920’s- William Hoke realized that magnetic particles (colored metal
shavings) could be used with magnetism as a means of locating defects.
Hoke discovered that a surface or subsurface flaw in a magnetized
material caused the magnetic field to distort and extend beyond the
part. This discovery was brought to his attention in the machine shop
• In the early 1930’s, magnetic particle inspection was quickly replacing
the oil-and-whiting method (an early form of the
liquid penetrant inspection) as the method of choice by the railroad
industry to inspect steam engine boilers, wheels, axles, and tracks.
Application Areas
 Variety of product forms including castings, forgings etc.
 Inspection of welds in pipelines, tank cars, shipbuilding, pressure vessels, and general structural
steel construction
 Field inspection of used drill pipe and tubing
 Overhaul and routine field maintenance on aircraft, trucks, buses, and railroad equipment
 General industrial maintenance inspection of structural parts and equipment components-
automotive, petrochemical, power generation, and aerospace industries, underwater pipelines.
Advantages

• The magnetic particle method is a sensitive means of locating small and shallow surface cracks in
ferromagnetic materials.
• Indications may be produced at cracks that are large enough to be seen with the naked eye
• Discontinuities that do not actually break through the surface are also indicated in many cases by this method
• If a discontinuity is fine, sharp, and close to the surface, such as a long stringer of nonmetallic inclusions, a
clear indication can be produced.
• Magnetic particle indications are produced directly on the surface of the part and constitute magnetic pictures
of actual discontinuities.
• Skilled operators can sometimes make a reasonable estimate of crack depth with suitable powders and proper
technique.
• Occasional monitoring of field intensity in the part is needed to ensure adequate field strength.
• There is little or no limitation on the size or shape of the part being inspected.
• Ordinarily, no elaborate precleaning is necessary, and cracks filled with foreign material can be detected.
Limitations
• Thin coatings of paint and other nonmagnetic coverings, such as plating, adversely affect the sensitivity of
magnetic particle inspection.
• The method can be used only on ferromagnetic materials
• For best results, the magnetic field must be in a direction that will intercept the principal plane of the
discontinuity; this sometimes requires two or more sequential inspections with different magnetizations
• Demagnetization following inspection is often necessary
• Post-cleaning to remove remnants of the magnetic particles clinging to the surface may sometimes be required
after testing and demagnetization
• Exceedingly large currents are sometimes needed for very large parts
• Care is necessary to avoid local heating and burning of finished parts or surfaces at the points of electrical
contact
• Although magnetic particle indications are easily seen, experience and skill are sometimes needed to judge
their significance
 Method

1. Part Preparation

2. Introduction of Magnetic Field

3. Application of magnetic particles

4. Examination of component surface

5. Demagnetization
Part Preparation

• Clean and dry

• Thin non-conducting films-paints>0.05mm should be removed
• Demagetization=
• Remanent magnetic fields can:
a) affect machining by causing cuttings to cling to a component.
b) interfere with electronic equipment such as a compass.
c) create a condition known as "arc blow" in the welding process- to be
repelled from the weld.
d) cause abrasive particles to cling to bearing or faying surfaces and
increase wear
• It is often inconvenient to heat a material above its curie temperature to
demagnetize it
• Subjecting the component to a reversing and decreasing magnetic
field will return the dipoles to a nearly random orientation throughout
the material.
• A field meter is often used to verify that the residual flux has been
removed from a component
Magnetic Field Introduction
• DC is very desirable when inspecting for subsurface defects because
DC generates a magnetic field that penetrates deeper into the
material.
• AC- the magnetic field will be limited to narrow region at the surface
of the component.
• This phenomenon is known as the "skin effect”….Why?
 -Prods
Direct
-Head Shot
Magnetization
-Yokes-
Electromagnets/Permanent
Indirect Magnet
-Coils

Contact and Non contact

Prods

• Are handheld electrodes that are pressed

against the surface of the component being
inspected to make contact for
passing electrical current through the metal
• The current passing between the two contacts
creates a field suitable for finding defects with
magnetic particles.
• Prods are typically made from copper and
have an insulated handle to help protect the
operator.
• The use of prods is not allowed when
inspecting aerospace and other critical
components.
• Portable
• Circular Magnetic field
 Portable Coils and Conductive Cables
• Coils and conductive cables are
used to establish
longitudinal magnetic field within
a component.
• When a preformed coil is used,
the component is placed against
the inside surface on the coil
• Coils typically have three or five
turns of a copper cable within the
molded frame.
• Conductive cables are wrapped
around the component.
•An electromagnetic yoke is a very
common piece of equipment that is
used to establish a magnetic field
•Used in Industries
• It is basically made by wrapping an
electrical coil around a piece of
soft ferromagnetic steel
•This type of magnet generates a very
strong magnetic field in a local area
where the poles of the magnet touch
the part being inspected Electromagnet
yoke

Permanent -Lack of control of field strength

and difficulty in placement but for under
water applications
Head Shot
• Stationary Unit
• For small parts having no
openings through the
interior, circular magnetic
fields are produced by direct
contact to the part.
• This is done by clamping the
parts between contact heads Circular Magnetic field
(head shot), generally on a
bench unit that incorporates
the source of the current.
Magnetic Particles

• Magnetic particles are classified according to the medium used to

carry the particles to the part.
• Air (dry-particle method) or a liquid (wet-particle method)
• Magnetic particles -ferromagnetic material that is finely subdivided.
Magnetic properties
• High magnetic permeability so that they can be readily magnetized by the
low-level leakage fields that occur around discontinuities and can be drawn
by these fields to the discontinuities themselves to form readable
indications
• Low-retentivity
• If high in coercive force, wet particles become strongly magnetized and
form an objectionable background.
• Highly retentive wet particles tend to clump together quickly in large
aggregates on the test surface-Mobility
• Dry particles having coercive force and high retentivity would become
magnetized during manufacture or in first use and would therefore become
small, strong permanent magnets.
Particle Size
• Large, heavy particles are not likely to be arrested and held by weak
fields
• Extremely fine particles may also adhere to surface areas where there
are no discontinuities (especially if the surface is rough) and form
confusing backgrounds.
• Coarse dry particles fall too fast and are likely to bounce off the part
surface without being attracted by the weak leakage fields at
imperfections.
Other properties
• Wet particles, because they are suspended in a liquid, move more
slowly than do dry particles to accumulate in leakage fields.
• Long, slender particles develop stronger polarity than globular
particles but mobility is less
• The greatest sensitivity for the formation of strong indications is
provided by a blend of elongated and globular shapes.
• Visibility and contrast are promoted by choosing particles with colors
that are easy to see against the color of the surface of the part being
inspected
Dry Magnetic Particles
• Available with yellow, red, black, and gray pigmented coloring and
with fluorescent coatings.
• Dry particles are most sensitive for use on very rough surfaces and for
detecting flaws beneath the surface.
• They are ordinarily used with portable equipment. The reclamation
and reuse of dry particles is not recommended.
• Dry powders can be applied with small rubber spray bulbs or specially
designed mechanical powder blowers
 Wet Particles
• Wet particles are commonly used in stationary equipment where the
bath can remain in use until contaminated.
• They are also used in field operations with portable equipment, but
care must be taken to agitate the bath constantly.
• Oil Suspending Liquid- The oil used as a suspending liquid for
magnetic particles should be an odorless, well-refined light
petroleum distillate of low viscosity
• Water Suspending Liquid- The use of water instead of oil for
magnetic particle wet-method baths reduces costs and eliminates
bath flammability
 Inspection Using Magnetic Rubber
• The magnetic rubber technique was developed for detecting very fine cracks and is capable of revealing
finer cracks than other magnetic techniques.
• The techniques uses a liquid (uncured) rubber containing suspended magnetic particles.
• The rubber compound is applied to the area to be inspected on a magnetized component. Inspections
can be performed using either an applied magnetic field, which is maintained while the rubber sets
(active field), or the residual field from magnetization of the component prior to pouring the
compound.
• The magnetic particles migrate to the leakage field caused by a discontinuity
• As the rubber cures, discontinuity indications remain in place on the rubber.
• The rubber is allowed to completely set, which takes from 10 to 30 minutes.
• The rubber cast is removed from the part. The rubber conforms to the surface contours and provides a
reverse replica of the surface. The rubber cast is examined for evidence of discontinuities, which appear
as dark lines on the surface of the molding. The molding can be retained as a permanent record of the
inspection.
• Magnetic rubber methods requires similar magnetizing systems used for dry method magnetic particle
tests. The system may include yokes, prods, clamps, coils or central conductors
• Alternating, direct current, or permanent magnets may be used to draw the particles to the leakage
fields. The direct current yoke is the most common magnetization source for magnetic rubber
inspection.
Selection of Particles
• Dry particles, when used with direct current for magnetization, are
superior for detecting discontinuities lying wholly below the surface
• Wet particles are better than dry particles for detecting very fine
surface discontinuities regardless of which form of magnetizing
current is used-Fatigue Cracks
Nomenclature Used in Magnetic Particle Inspection
• An indication is an accumulation of magnetic particles on the surface of the
part that forms during inspection.
• Relevant indications are the result of errors made during or after metal
processing. They may or may not be considered defects.
• A non relevant indication is one that is caused by flux leakage. This type of
indication is usually weak and has no relation to a discontinuity that is
considered to be a defect
• False indications are those in which the particle patterns are held by gravity
or surface roughness. No magnetic attraction is involved.
• A discontinuity is any interruption in the normal physical configuration or
composition of a part. It may not be a defect.
• A defect is any discontinuity that interferes with the utility or service of a
part.
• Interpretation consists of determining the probable cause of an indication,
and assigning it a discontinuity name or label.
Assignment Questions

• 1. Why is pre-rinsing before emulsification required in Method D LPT?

• 2. Magnetic printing in MPT