Magnetic Particle Inspection (MPI) is a
non-destructive testing technique used to
detect surface and slightly subsurface
discontinuities in ferromagnetic materials.
The technique is based on the principle of
magnetism and the behavior of magnetic
fields around ferromagnetic materials.
Principles:
The basic principle of MPI is to induce a
magnetic field in the test object and then
introduce magnetic particles into the field.
The magnetic particles will be attracted to
areas of flux leakage caused by surface
and subsurface discontinuities. The
particles will then accumulate at the
discontinuity, forming a visible indication
of the defect.MPI can be performed using either an AC
or DC magnetic field. AC magnetic fields
are used for surface defects, while DC
magnetic fields are used for subsurface
defects.
MPI can also be performed using either
dry or wet magnetic particles. Dry particles
are used for surface defects, while wet
particles are used for subsurface defects.
Techniques:
MPI can be performed using several
different techniques, including:
1. Yoke method: This method uses a
magnetic yoke that is placed on the
surface of the test object. The yoke
induces a magnetic field in the test object,
and magnetic particles are then introducedinto the field.
2. Prods method: This method uses a pair
of magnetic prods that are placed on the
surface of the test object. The prods
induce a magnetic field in the test object,
and magnetic particles are then introduced
into the field.
3. Central conductor method: This method
uses a central conductor that is placed
inside the test object. An AC or DC current
is passed through the conductor, inducing
a magnetic field in the test object.
Magnetic particles are then introduced
into the field.
MPI is a widely used NDT technique due to
its ability to detect surface and subsurface
discontinuities in ferromagnetic materials.
The technique is relatively simple and cost-effective, making it a popular choice for
many industries. However, MPI does have
limitations, including its inability to detect
non-ferromagnetic materials and its
reliance on trained personnel to interpret
the test results.
Magnetic Particle Inspection (MPI) is a
non-destructive testing method used to
detect surface and slightly subsurface
discontinuities in ferromagnetic materials.
It works on the principle of magnetism,
where a magnetic field is applied to the
material being inspected, and magnetic
particles are introduced to the surface.
The magnetic particles align themselves
along the magnetic field lines and form
visible indications at the locations of the
discontinuities.
The behavior of magnetic fields in MPI iscritical to the success of the inspection
process. The magnetic field must be
strong enough to magnetize the material
and align the magnetic particles, but not
so strong that it causes saturation or
damage to the material. The direction and
strength of the magnetic field also affect
the orientation and visibility of the
indications.
There are two types of magnetic fields
used in MPI: longitudinal and transverse.
Longitudinal fields are applied parallel to
the surface being inspected and are used
to detect surface-breaking discontinuities.
Transverse fields are applied
perpendicular to the surface and are used
to detect slightly subsurface
discontinuities.
The strength of the magnetic field ismeasured in units of Gauss or Tesla. The
strength required for MPI depends on the
type of material being inspected and the
size and depth of the discontinuities being
detected. The strength of the magnetic
field decreases with distance from the
source, so the distance between the
source and the surface being inspected
must be carefully controlled.
In conclusion, understanding the behavior
of magnetic fields in MPI is essential to
ensure accurate and reliable inspection
results. The strength, direction, and
distance of the magnetic field must be
carefully controlled to detect surface and
subsurface discontinuities in
ferromagnetic materials.
3. Magnetic particle inspection is a non-
destructive testing method that utilizes themagnetic properties of iron and steel
components to detect surface and
subsurface defects. In this method,
magnetic particles are applied to the
surface of the component under
inspection, and a magnetic field is applied
to the component. The magnetic particles
are attracted to the areas of the
component where the magnetic flux is
concentrated, revealing any surface or
subsurface defects.
There are several types of magnetic
particles used in magnetic particle
inspection, including:
1. Dry magnetic particles: These are fine
iron particles that are coated with a dry
powder. They are used for inspecting non-
porous materials, such as steel and iron.2. Wet magnetic particles: These are iron
particles that are suspended in a liquid
carrier. They are used for inspecting
porous materials, such as cast iron and
aluminum.
3. Fluorescent magnetic particles: These
are magnetic particles that are coated with
a fluorescent dye. They are used for
inspecting components in low light
conditions, as they emit a bright glow
under ultraviolet light.
4. Colored magnetic particles: These are
magnetic particles that are coated with a
colored dye. They are used for inspecting
components that have a dark background,
as they contrast well with the surface.
The properties of magnetic particles that
are important in magnetic particleinspection include:
1. Magnetic properties: Magnetic particles
should have high magnetic permeability
and saturation, which allows them to be
easily attracted to areas of magnetic flux
concentration.
2. Particle size: Magnetic particles should
be small enough to penetrate into any
surface cracks or defects, but not so small
that they are easily washed away by the
liquid carrier.
3. Coating: Magnetic particles should be
coated with a material that prevents them
from clumping together, which can affect
their ability to detect defects.
4. Fluorescence: Fluorescent magnetic
particles should emit a bright glow underultraviolet light, which makes them easier
to detect in low light conditions.
In summary, the type of magnetic particle
used in magnetic particle inspection
depends on the material being inspected
and the type of defect being detected. The
properties of magnetic particles, such as
their magnetic properties, particle size,
coating, and fluorescence, are important
factors to consider when selecting the
appropriate magnetic particle for a
specific inspection application.
1. Yoke Magnetization: This technique
involves using a yoke, which is a U-shaped
magnetic device that creates a magnetic
field around the test piece. The yoke is
placed on the surface of the test piece,
and a current is passed through it to create
a magnetic field. This technique iscommonly used for inspecting large, flat
test pieces.
2. Prod Magnetization: In this technique, a
prod is used to create a magnetic field in
the test piece. The prod is a handheld
device that is placed on the surface of the
test piece, and a current is passed through
it to create a magnetic field. This
technique is commonly used for
inspecting small or irregularly shaped test
pieces.
3. Coil Magnetization: This technique
involves using a coil to create a magnetic
field in the test piece. The coil is wrapped
around the test piece, and a current is
passed through it to create a magnetic
field. This technique is commonly used for
inspecting long, cylindrical test pieces.A. Central Conductor Magnetization: This
technique involves using a central
conductor to create a magnetic field in the
test piece. The central conductor is a rod
or wire that is inserted into the test piece,
and a current is passed through it to create
a magnetic field. This technique is
commonly used for inspecting small, thin
test pieces.
5. Head Shot Magnetization: This
technique involves using a special
magnetizing fixture called a head shot.
The head shot is placed on the surface of
the test piece, and a current is passed
through it to create a magnetic field. This
technique is commonly used for
inspecting welds and other areas where
access is limited.
6. Residual Field Magnetization: Thistechnique involves using the residual
magnetic field left in the test piece after it
has been magnetized. This technique is
commonly used for inspecting
ferromagnetic materials that have already
been magnetized, such as those used in
magnetic storage devices.
Advanced magnetization techniques are
used in Magnetic Particle Inspection (MPI)
to detect surface and subsurface defects
in ferromagnetic materials. These
techniques involve the use of specialized
equipment and components such as
yokes, prods, coils, central conductors,
head shots, and residual field magnets.
1. Yoke Magnetization:
Yoke magnetization is a common methodused in MPI to magnetize ferromagnetic
materials. It involves using a yoke, which is
a horseshoe-shaped magnet, to create a
magnetic field in the material being
inspected. The yoke is placed on the
surface of the material, and a current is
passed through it to create a magnetic
field.
Components needed: Yoke magnet, power
source, and cables.
Applications: Yoke magnetization is
commonly used in the inspection of welds,
castings, and forgings.
2. Prod Magnetization:
Prod magnetization is another method
used in MPI to magnetize ferromagnetic
materials. It involves using a prod, which isa handheld magnet, to create a magnetic
field in the material being inspected. The
prod is placed on the surface of the
material, and a current is passed through it
to create a magnetic field.
Components needed: Handheld prod
magnet, power source, and cables.
Applications: Prod magnetization is
commonly used in the inspection of small
parts and hard-to-reach areas.
3. Coil Magnetization:
Coil magnetization is a method used in
MPI to create a magnetic field in
ferromagnetic materials. It involves using
a coil, which is a cylindrical magnet, to
create a magnetic field in the material
being inspected. The coil is placed aroundthe material, and a current is passed
through it to create a magnetic field.
Components needed: Coil magnet, power
source, and cables.
Applications: Coil magnetization is
commonly used in the inspection of large
parts and complex shapes.
4. Central Conductor Magnetization:
Central conductor magnetization is a
method used in MPI to create a magnetic
field in ferromagnetic materials. It involves
using a central conductor, which is a metal
rod, to create a magnetic field in the
material being inspected. The central
conductor is placed in the center of the
material, and a current is passed through it
to create a magnetic field.Components needed: Central conductor,
power source, and cables.
Applications: Central conductor
magnetization is commonly used in the
inspection of round parts such as pipes
and tubes.
5. Head Shot Magnetization:
Head shot magnetization is a method
used in MPI to create a magnetic field in
ferromagnetic materials. It involves using
a head shot, which is a small magnet, to
create a magnetic field in the material
being inspected. The head shot is placed
on the surface of the material, and a
current is passed through it to create a
magnetic field.Components needed: Head shot magnet,
power source, and cables.
Applications: Head shot magnetization is
commonly used in the inspection of small
parts and hard-to-reach areas.
6. Residual Field Magnetization:
Residual field magnetization is a method
used in MPI to detect residual magnetic
fields in ferromagnetic materials. It
involves using a residual field magnet,
which is a small magnet, to detect
changes in the magnetic field in the
material being inspected.
Components needed: Residual field
magnet, power source, and cables.
Applications: Residual field magnetizationis commonly used in the inspection of
parts that have been previously
magnetized.
In conclusion, the components needed for
advanced magnetization techniques in
MPI include yokes, prods, coils, central
conductors, head shots, and residual field
magnets. These techniques are used to
detect surface and subsurface defects in
ferromagnetic materials and are
commonly used in the inspection of welds,
castings, forgings, small parts, hard-to-
reach areas, large parts, complex shapes,
round parts, and parts that have been
previously magnetized.