NDT-Magnetic Particle Inspection

Ref: ASM HAND BOOK, VOL :17

Dr. B.N.Sarada
BMSCE
 Magnetic Particle Inspection
• Magnetic Particle Inspection:
• Introduction
• Principle
• Procedure
• Methods of generating magnetic field,
• Types of magnetic particles and suspension
liquids
• application and limitations.
 MAGNETIC PARTICLE INSPECTION
INTRODUCTION:
• MAGNETIC PARTICLE INSPECTION is a method of
locating surface and subsurface discontinuities in
ferromagnetic materials.
• Ferromagnetic materials include most of the iron,
nickel, and cobalt alloys.
• Precipitation-hardening steels, such as stainless
steels, are magnetic after aging.
• It can be considered as a combination of two
nondestructive testing methods: magnetic flux
leakage testing and visual testing.
 Magnetic Particle Inspection
Working principle:
• When the material or part under test is magnetized,
magnetic discontinuities that lie in a direction
transverse to the direction of the magnetic field will
cause a leakage field.
• The presence of this leakage field, and therefore the
presence of 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.
• Magnetic particles are applied over a surface as dry
particles, or as wet particles in a liquid carrier such as
water or oil.
 MAGNETIC PARTICLE INSPECTION
Basic Principles:
• Consider the case of a bar magnet. It has a magnetic field
in and around the magnet.
• Any place that a magnetic line of force exits or enters
the magnet is called a pole.
• From north pole a magnetic line of force exits and from
south a line of force enters the magnet.
• When a bar magnet is broken in the center of its length,
two complete bar magnets with magnetic poles on each
end of each piece will result.
MAGNETIC PARTICLE INSPECTION
• If the magnet is just cracked but not broken completely in two, a
north and south pole will form at each edge of the crack.
• The magnetic field exits the north pole and reenters at the south
pole.
• If iron particles are sprinkled on a cracked magnet, the particles
will be attracted and cluster not only at the poles at the ends of
the magnet, but also at the poles at the edges of the crack.
 Introduction to Magnetism

• Magnetism is the ability of matter to attract other

matter to itself.
• Objects that possess the property of magnetism are
said to be magnetic.
• Magnetic lines of force can be found in and around
the objects.

Magnetic lines of force Opposite poles attracting Similar poles repelling

around a bar magnet
 Procedure
General Procedures for Magnetic Particle Inspection
Variations in the procedure depend upon
• Magnetic characteristics of the material ,size, shape,
location, and direction of the expected discontinuity.
The following parameters must be considered in
establishing a set of procedures
• Type and Magnitude of applied current
• Type of magnetic particles
• Method of magnetization
• Direction of magnetization
• Equipment
 Procedure contd….
A ferromagnetic test specimen is magnetized with a strong
magnetic field created by a magnet or special equipment.
If the specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the specimen
and a leakage field will occur.
 Procedure cond…
Steps Involved
1.Component pre-cleaning
2.Demagnetization
3.Introduction of magnetic field
4.Application of magnetic media
5.Interpretation of magnetic particle indications
6. Demagnetization
 Procedure
1]Pre-cleaning
• The part’s surface should be clean and dry before
inspection.
• Contaminants such as oil, grease, or scale may not only
prevent particles from being attracted to leakage
fields, they may also interfere with interpretation of
indications.
2]Demagnetization:
• Components which have been machined on magnetic
chucks or handled in magnetic field should be de
magnetized to remove residual magnetism to avoid false
indication.

Demagnetized
 Procedure contd…..

3]Introduction of magnetic field

• The required magnetic field can be introduced into a
component in a number of different ways.
1. Using a permanent magnet or an electromagnet that
contacts the test piece
2. Flowing an electrical current through the specimen
3. Flowing an electrical current through a coil of wire around
the part or through a central conductor running near the
part.
 Procedure contd….
4.Application of Magnetic Media (Wet or Dry)
• MPI can be performed using either dry particles, or wet
particles suspended in a liquid.
• With the dry method, the particles are lightly dusted on
to the surface.
• The dry method is more portable.
• Dry magnetic particles come in a variety of colors. A
color that produces a high level of contrast against the
background should be used.
 Procedure
• With the wet method, the part is flooded with a solution
carrying the particles.
• The wet method is generally more sensitive since the liquid
carrier gives the magnetic particles additional mobility.
• Wet particles are typically supplied as visible or fluorescent.
• Visible particles are viewed under normal white light and
fluorescent particles are viewed under black light.
 Procedure contd…
5.Interpretation of Indications
• After applying the magnetic field, indications that form must
interpreted.
• This process requires that the inspector distinguish between
relevant and non-relevant indications.
6. Demagnetization
• Parts inspected by the magnetic particle method may sometimes have an
objectionable residual magnetic field that may interfere with subsequent
manufacturing operations or service of the component.
• Possible reasons for demagnetization include:
–May interfere with welding and/or machining operations
–Can effect gauges that are sensitive to magnetic fields if placed in close
proximity.
–Abrasive particles may adhere to components surface and cause and
increase in wear to engines components, gears, bearings etc.
 Procedure contd….

• Demagnetization requires that the residual magnetic field

is reversed and reduced by the inspector.
• This process will scramble the magnetic domains and
reduce the strength of the residual field to an acceptable
level.

Magnetized Demagnetized
 Generation of magnetic field
introduction
• Both direct current (dc) and alternating
current (ac) are suitable for magnetizing parts
for magnetic particle inspection.
• The fields produced by direct current generally
penetrate the cross section of the part.
• The fields produced by alternating current are
confined to the metal at or near the surface of
the part(skin effect)
 Direction of the Magnetic Field
Two general types of magnetic fields (longitudinal and
circular) may be established within the specimen. The type of
magnetic field established is determined by the method used
to magnetize the specimen.

• A longitudinal magnetic field has

magnetic lines of force that run parallel
to the long axis of the part.
• A circular magnetic field has magnetic
lines of force that run circumferentially
around the perimeter of a part.
 Importance of Magnetic Field Direction

Being able to magnetize the part in two directions is important

because the best detection of defects occurs when the lines of
magnetic force are established at right angles to the longest
dimension of the defect.
This orientation creates the largest disruption of the magnetic
field within the part and the greatest flux leakage at the
surface of the part.
An orientation of 45 to 90 degrees between the magnetic field
and the defect is necessary to form an indication.
 Importance of Magnetic Field
Direction
Since defects may occur in various and unknown directions, each
part is normally magnetized in two directions at right angles
to each other.
Methods of generating magnetic field

Using Yokes , Using a Coil, Induced using Current

• 1]Yokes :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).
• Inspection of large surface areas for surface discontinuities.
• Highly portable.
• Can locate discontinuities in any direction, with proper yoke
orientation
• But, Yoke must be properly positioned relative to
orientation of discontinuity and Time consuming.
• Also often used to produce a longitudinal magnetic field.
• 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
 Methods of generating magnetic field
• Electromagnetic yoke consists of a coil 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.
• Yoke can readily be switched on or off. This feature makes it
convenient to apply and remove the yoke from the test piece.
• The magnetic lines of force run from one pole to the other, and the
poles are positioned such that any flaws present run normal to these
lines of force.

Permanent magnets and electromagnetic

yokes are also often used to produce a
longitudinal magnetic field.
 Producing a Longitudinal Magnetic
Field Using a Coil

Single-loop and multiple-loop coils are used for the longitudinal magnetization
of components.
A longitudinal magnetic field is usually established by placing the part near the
inside or a coil.
This produces magnetic lines of force that are parallel to the long axis of the
test part.
• The flux density passing through the interior of the coil is proportional to
the product of the current, I, in amperes, and the number of turns in the
coil, N.
• Therefore, the magnetizing force of such a coil can be varied by changing
either the current or the number of turns in the coil.
Adv: No thermal damage since there is no direct electrical contact
 Methods of generating magnetic field
Induced Current
• Induced current provides a
convenient method of
generating circumferential
magnetizing current in ring-
shaped parts without
making electrical contact.
• This is accomplished by
properly orienting the ring
within a magnetizing coil
such that it links or encloses
lines of magnetic flux (flux
linkage), as shown in Fig.
13(a).
 Methods of generating magnetic field
• To enhance the total flux linkages, laminated soft iron pole
pieces are usually inserted through the hole in the part as
shown in Fig. 13(a).

• The magnitude of this current depends on the total flux

linkages, rate of flux linkage changes, and the electrical
impedance.

• The circular field associated with this current takes the form
of a toroidal magnetic field that encompasses all surface areas
on the ring which discloses the circumferential types of
discontinuities.

• This is shown schematically in Fig. 13(b).

• Direct Versus Alternating Current. The choice of
magnetizing current for the induced-current method
depends on the magnetic properties of the part to be
inspected.
• In cases in which the residual method is applicable, such as
for most bearing races or similar parts having high
magnetic retentivity, direct current is used for magnetizing.
• The rapid interruption of this current, by quick-break
circuitry, results in a rapid collapse of the magnetic flux and
the generation of a high-amperage, circumferentially
directed single pulse of current in the part. Therefore, the
part is residually magnetized with a toroidal field, and the
subsequent application of magnetic particles will produce
indications of circumferentially oriented discontinuities.
• Passing an alternating current through a
conductor will set up a fluctuating magnetic field
as the level of magnetic flux rapidly changes from
a maximum value in one direction to an equal
value in the opposite direction.
• This is similar to the current that would flow in a
single-shorted-turn secondary of a transformer.
The alternating induced current, in conjunction
with the continuous method, renders the method
applicable for processing magnetically soft, or
less retentive, parts.
 Types of magnetic particles and suspension
liquids

Types of magnetic particles

• Magnetic particles are classified according to the medium used to

carry the particles to the part.
• The medium can be air (dry-particle method) or a liquid (wet-
particle method).
• Magnetic particles can be made of any low-retentivity
ferromagnetic material that is finely subdivided.
• The characteristics of this material, such as magnetic properties,
size, shape, density, mobility, and degree of visibility and contrast,
vary over wide ranges for different applications.
 Characteristics of magnetic particles and
suspension liquids
• Magnetic Properties. The particles used for magnetic
particle inspection should have high magnetic
permeability so that they can be readily magnetized by
the low-level leakage fields that occur around
discontinuities.
• They should be drawn by these fields to the
discontinuities to form readable indications.
• Low coercive force and low retentivity are desirable for
magnetic particles.
• With high in coercive forces particles become magnetic
and may stick to the test specimen. High retentivity
reduces the particle mobility of particles.
 Characteristics of magnetic particles
• Particle Size. Particle Size should be as small as possible.
• Large, heavy particles cannot be held by weak fields when such
particles are moving over a part surface, but fine particles will be
held by very weak fields.
• However, extremely fine particles may also adhere to surface areas
where there are no discontinuities (especially if the surface is
rough) and form confusing backgrounds.
• Magnetic particles for the wet method are applied as a suspension
in some liquid medium, and particles much smaller than those for
the dry method can be used.
• Coarse particles would quickly become stranded and immobilized.
• The stranding of finer particles as a result of the draining away of
the liquid occurs much later, giving these particles mobility for a
sufficient period of time to be attracted by leakage fields and to
accumulate and thus form true indications.
• Particle Shape. Long, slender particles develop
stronger polarity than globular particles.
• Because of the attraction exhibited by opposite poles,
these tiny, slender particles, which have pronounced
north and south poles, arrange themselves into strings
more readily than globular particles.
• But elongated particles tend to mat in the container,
but globular particles flow freely and smoothly under
similar conditions.
• 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.
• The natural color of the metallic powders used in the dry method is
silver-gray, but pigments are used to color the particles.
• The colors of particles for the wet method are limited to the black
and red of the iron oxides.
• For increased visibility, particles are coated with fluorescent
pigment.
• The search for indications is conducted in total or partial darkness,
using ultraviolet light to activate the fluorescent dyes.
• Fluorescent magnetic particles are available for both the wet and
dry methods, but fluorescent particles are more commonly used
with the wet method.
 Suspending liquids
• Dry particles, when used with direct current for
magnetization, are superior for detecting discontinuities
lying wholly below the surface.
• The use of alternating current with dry particles is excellent
for revealing surface cracks that are not exceedingly fine,
but is of little value for discontinuities even slightly beneath
the surface.
• Wet particles are better than dry particles for detecting
very fine surface discontinuities regardless of which form of
magnetizing current is used.
• The surface of a part can easily be covered with a wet bath
because the bath flows over and around surface contours.
Suspending liquids
• Wet particles are available in red and black colors or as fluorescent
particles that fluoresce a blue-green or a bright yellow-green color.
• The particles are supplied in the form of a paste or other type of
concentrate that is suspended in a liquid to produce the coating bath.
• The liquid bath may be either water or a light petroleum distillate having
specific properties.
• Both require conditioners to maintain proper dispersion of the particles
and to allow the particles the freedom of movement to form indications
on the surfaces of parts.
• 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 having a low sulfur content and a high flash point.
• Water Suspending Liquid. The use of water instead of oil for magnetic
particle wet-method baths reduces costs and eliminates bath
flammability.
• Because water is a conductor of electricity, units in which water is to be
used must be designed to isolate all high-voltage circuits so as to avoid all
possibility of operator shock, and the equipment must be thoroughly and
positively grounded.
• Permeability of Magnetic Materials
• Magnetic Hysteresis
 Equipment

Selection of equipment for magnetic particle inspection depends

on the size, shape, number, and variety of parts to be tested.

Bench Units. For the production inspection of numerous

parts that are relatively small but not necessarily identical in
shape, a bench unit with contact heads for circular magnetization,
as well as a built-in coil for longitudinal magnetization,
is commonly used .
 using yokes, or hand-wrapped
• Portable units
coils may be most convenient for large parts.
• Dry particles are often used with portable
equipment.
• Wet particles can be used with portable
equipment, but the bath is usually not
recovered.
• Mass Production Machinery.For large lots of
identical or closely similar parts, single-
purpose magnetization-and inspection units or
fixtures on multiple-purpose units can be used.
Joining Process
Application
 Detectable Discontinuities
Surface Discontinuities. The largest and most important
category of discontinuity consists of those that are
exposed to the surface.
• Surface cracks or discontinuities are effectively located
with magnetic particles.
• Magnetic particle inspection is capable of locating
seams, laps, quenching and grinding cracks, and
surface ruptures in castings, forgings, and weldments.
Subsurface discontinuities those lying just beneath the
surface of the part and Deep-lying discontinuities
 Forging defects

1045 steel crane hook showing Magnetic particle indications of a

indications of forging laps of the type seam (at arrow) in the shank of a
revealed by magnetic particle forged crane hook
inspection. Dimensions given in
inches
 Inspection of Hollow Cylindrical Parts

central conductor

Encircling-coil technique used to magnetize the

upset ends in the longitudinal direction
Welds in Carbon Steel Pipe
Inspection of Weldments
Inspection of Castings and Forgings

Fig. 41 Methods of
using cable for applying
magnetizing circuits to
large forgings and
castings. For the
forging
in (a), circuits 1 and 3
are head shots and
circuit 2 is a cable
wrap. For the casting in
(b), circuits 1 and 3 are
central conductors and
circuit 2 is a cable
wrap.
Inspection of Billets

Discontinuities on the
surfaces of steel
billets that can be
detected by magnetic
particle inspection.
(a)Arrowhead cracks.
(b) Longitudinal
cracks.
(c) Normal seams.
(d) Brush seams.
(e) Laps.
(f) Scabs.
Crane Hooks.

Forged crane hook showing stress

areas subject to inspection
Advantages
Limitations