Automotive Engineering

Phd Eng. Marcin Korzeniowski

Non Destructive Evaluation in Contemporary
Manufacturing Systems
Lecture 3
Magnetic Particle Testing
Magnetic Testing (MT)
MAGNETIC PARTICLE INSPECTION

Method of locating surface and subsurface discontinuities in
ferromagnetic materials.
When the material or part under test is magnetized,
magnetic discontinuities that lie in a direction generally
transverse to the direction of the magnetic field cause a
leakage field to be formed at and above the surface of the
part.
The discontinuity, 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.
Limitation for Magnetic Particle Testing:
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.
Magnetic Testing (MT)
Magnetic Testing (MT)
FERROMAGNETIC MATERIALS
Metals which conduct magnetic field:
elements:
iron,
nickel,
cobalt,
alloys:
cast iron
carbon steel
Ferromagnetic Materials
A material is considered ferromagnetic if it can be
magnetized. Materials with a significant Iron, nickel or cobalt
content are generally ferromagnetic.
Ferromagnetic materials are made up of many regions in
which the magnetic fields of atoms are aligned. These
regions are call magnetic domains.
Magnetic domains point randomly in demagnetized material,
but can be aligned using electrical current or an external
magnetic field to magnetize the material.
Demagnetized
Magnetized
S
N
Magnetic Testing (MT)
The physical
background
Magnetic Testing (MT)
Directions of the discontinuities
Magnetic Testing (MT)
Magnetic Testing (MT)
The ways of magnetization
circular
Producing a Longitudinal Magnetic Field Using a Coil
A longitudinal magnetic field is
usually established by placing the
part near the inside or a coils
annulus. This produces magnetic
lines of force that are parallel to
the long axis of the test part.
Coil on Wet Horizontal Inspection Unit
Portable Coil
Magnetic Testing (MT)
Magnetized ring
When a magnetic material is
placed across the poles of a
horseshoe magnet having
square ends, forming a closed or
ringlike assembly, the lines of
force flow from the north pole
through the magnetic material to
the south pole
Magnetic Testing (MT)
Magnetizing current
Both direct current (dc) and alternating current (ac) are suitable for
magnetizing parts for magnetic particle inspection.

The strength, direction, and distribution of magnetic fields are
greatly affected by the type of current used for magnetization.

The important difference with regard to magnetic particle inspection
is that the fields produced by direct current generally penetrate
the cross section of the part, while the fields produced by
alternating current are confined to the metal at or near the
surface of the part, a phenomenon known as the skin effect.
Therefore, alternating current should not be used in searching for
subsurface discontinuities.
Magnetic Testing (MT)
Magnetizing current
alternate current
rectified
three phase AC
rectified
one phase AC
Magnetic Testing (MT)
Yokes
Two basic types of yokes that
are commonly used for
magnetizing purposes:

permanent-magnet,
electromagnetic yokes.

Both are hand held and
therefore quite mobile.
Permanent-magnet yokes
are used for applications where a source of electric power is
not available or where arcing is not permissible (as in an
explosive atmosphere). The limitations of permanent-magnet
yokes include the following:
Large areas or masses cannot be magnetized with enough
strength to produce satisfactory crack indications,
Flux density cannot be varied at will,
If the magnet is very strong, it may be difficult to separate
from a part,
Particles may cling to the magnet, possibly obscuring
indications.

Magnetic Testing (MT)
Yokes
Electromagnetic yokes
Consist of a coil wound around a U-shaped core of soft iron.
The legs of the yoke can be either fixed or adjustable.
Adjustable legs permit changing the contact spacing and the
relative angle of contact to accommodate irregularly-shaped
parts.
Unlike a permanent-magnet yoke, an electromagnetic yoke
can readily be switched on or off.
This feature makes it convenient to apply and remove the
yoke from the testpiece.

Magnetic Testing (MT)
Yokes
Electromagnetic yokes
Magnetic Testing (MT)
Application of Magnetic
Media (Wet Versus Dry)
MPI can be performed using either dry
particles, or particles suspended in a
liquid. With the dry method, the particles are
lightly dusted on to the surface. With the wet
method, the part is flooded with a solution
carrying the particles.

The dry method is more portable. The wet
method is generally more sensitive since
the liquid carrier gives the magnetic particles
additional mobility.
Dry Magnetic Particles
Magnetic particles come in a variety of colors. A color that
produces a high level of contrast against the background
should be used.



Wet Magnetic Particles
Wet particles are typically supplied as visible or
fluorescent. Visible particles are viewed under
normal white light and fluorescent particles are
viewed under ultraviolet light.
Crane Hook with Service Induced Crack

Fluorescent, Wet Particle Method
Gear with Service Induced Crack

Fluorescent, Wet Particle Method
Drive Shaft with
Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method
Splined Shaft with
Service Induced Cracks
Fluorescent, Wet Particle Method

Threaded Shaft with
Service Induced Crack
Fluorescent, Wet Particle Method
Large Bolt with
Service Induced Crack
Fluorescent, Wet Particle Method
Crank Shaft with Service Induced Crack Near
Lube Hole
Fluorescent, Wet Particle Method
Lack of Fusion in SMAW Weld
Visible, Dry Powder Method
Indication
Toe Crack in SMAW Weld
Visible, Dry Powder Method
Advantages of Magnetic Particle Inspection
Can detect both surface and near sub-surface defects.
Can inspect parts with irregular shapes easily.
Precleaning of components is not as critical as it is for
some other inspection methods. Most contaminants
within a flaw will not hinder flaw detectability.
Fast method of inspection and indications are visible
directly on the specimen surface.
Considered low cost compared to many other NDT
methods.
Is a very portable inspection method especially when
used with battery powered equipment.
Limitations of Magnetic Particle Inspection
Cannot inspect non-ferrous materials such as aluminum, magnesium
or most stainless steels.
Inspection of large parts may require use of equipment with special
power requirements.
Some parts may require removal of coating or plating to achieve
desired inspection sensitivity.
Limited subsurface discontinuity detection capabilities. Maximum
depth sensitivity is approximately 0.6 (under ideal conditions).
Post cleaning, and post demagnetization is often necessary.
Alignment between magnetic flux and defect is important