TWI Knowledge Summary

Magnetic Particle Inspection

How does it work?
Magnetic particle inspection (MPI) is used for the detection of surface and nearsurface flaws in ferromagnetic materials. A magnetic field is applied to the specimen, either locally or overall, using a permanent magnet, electromagnet, flexi le ca les or hand-held prods. If the material is sound, most of the magnetic flux is concentrated elow the material!s surface. "owever, if a flaw is present, such that it interacts with the magnetic field, the flux is distorted locally and !lea#s! from the surface of the specimen in the region of the flaw. $ine magnetic particles, applied to the surface of the specimen, are attracted to the area of flux lea#age, creating a visi le indication of the flaw. %he materials commonly used for this purpose are lac# iron particles and red or yellow iron oxides. In some cases, the iron particles are coated with a fluorescent material ena ling them to e viewed under a &' lamp in dar#ened conditions. Magnetic particles are usually applied as a suspension in water or paraffin. %his ena les the particles to flow over the surface and to migrate to any flaws. (n hot surfaces, or where contamination is a concern, dry powders may e used as an alternative to wet in#s. (n dar# surfaces, a thin layer of white paint is usually applied, to increase the contrast etween the ac#ground and the lac# magnetic particles. %he most sensitive techni)ue, however, is to use fluorescent particles viewed under &' ( lac#) light. MPI is particularly sensitive to surface- rea#ing or near-surface crac#s, even if the crac# opening is very narrow. "owever, if the crac# runs parallel to the magnetic field, there is little distur ance to the magnetic field and it is unli#ely that the crac# will e detected. $or this reason it is recommended that the inspection surface is magnetised in two directions at *+, to each other. Alternatively, techni)ues using swinging or rotating magnetic fields can e used to ensure that all orientations of crac# are detecta le. %he method of magnetisation depends on the geometry of the component and whether or not all or only part of the specimen is to e magnetised. Permanent magnets are attractive for on-site inspection, as they do not need a power supply. "owever, they tend only to e used to examine relatively small areas and have to e pulled from the test surface. -espite needing their own power supply, electromagnets (yo#es) find widespread application. %heir main attraction is that they are easy to remove (once the current has een switched off) and that the strength of the magnetic field can e varied. $or example, an A. electromagnet can e used to concentrate the field at the surface where it is needed. "and-held electrical prods are useful in confined spaces. "owever, they suffer two ma/or disadvantages that can rule out their use altogether.

$irstly, arc stri#es can occur at the prod contact points and these can damage the specimen surface. 0econdly, ecause the particles must e applied when the current is on, the inspection ecomes a two-man operation. 1ench units are fixed installations used to test large num ers of manufactured specimens of various si2es. %he electrical components of a mo ile unit (as descri ed a ove) are incorporated in the ench unit ma#ing testing more rapid, convenient and efficient. In some cases, MPI can leave residual fields which su se)uently interfere with welding repairs. %hese can e removed y slowly wiping the surface with an energised A. yo#e.

What will it find?

MPI is used to detect surface- rea#ing and near-surface flaws in ferromagnetic materials. It cannot, however, e used to detect deeply em edded flaws, nor can it e used on non-ferromagnetic materials, such as aluminium, copper or austenitic stainless steel.

Where is it used?
MPI is often used to loo# for crac#ing at welded /oints and in areas identified as eing suscepti le to environmental crac#ing (e.g. stress corrosion crac#ing or hydrogen induced crac#ing), fatigue crac#ing or creep crac#ing. 3et fluorescent MPI finds widespread use in loo#ing for environmental damage on the inside of vessels. $urther information on each of these crac#ing mechanisms and their significance in piping systems is given in API 45+. .opyright 67++8 %3I 9td