MPI Level II Notes for Mastering

1.0. Principles

1.1 Theory

1.1.1 Flux patterns

1.1.2 Frequency and voltage factors

1.1.3 Current calculations

1.1.4 Surface flux strength

1.1.5 Subsurface effects

1.2 Magnets and magnetism

1.2.1 Distance factors versus strength of flux

1.2.2 Internal and external flux patterns

1.2.3 Phenomenon action at the discontinuity

1.2.4 Heat effects on magnetism

1.2.5 Materials hardness versus magnetic retention

1.0 Principles of Magnetic Particle Testing:

Magnetic Particle Testing (MPT) is a non-destructive testing method used to detect surface and
subsurface defects in ferromagnetic materials. It works on the principle of magnetism and relies on the
ability of magnetic fields to penetrate the material and detect any discontinuities or defects.

1.1 Theory:

1.1.1 Flux patterns: The magnetic field is directed through the material using an externally applied
magnetic field or an electromagnet. The magnetic field will follow a specific flux pattern based on the
orientation of the magnetic field and the shape of the material. Discontinuities perpendicular to the flux
lines will produce the strongest indications.
1.1.2 Frequency and voltage factors: The frequency and voltage of the applied magnetic field will affect
the depth of penetration and the sensitivity of the test. Higher frequencies and voltages will provide
greater sensitivity but lower depth of penetration.

1.1.3 Current calculations: The amount of current applied will depend on the size and shape of the
material being tested and the strength of the applied magnetic field.

1.1.4 Surface flux strength: The strength of the magnetic field on the surface of the material will depend
on the distance between the magnet and the material, as well as the orientation of the magnet.

1.1.5 Subsurface effects: Magnetic particle testing can detect subsurface defects as well as surface
defects, depending on the strength of the magnetic field and the depth of penetration.

1.2 Magnets and magnetism:

1.2.1 Distance factors versus strength of flux: The strength of the magnetic field decreases with distance
from the magnet. Therefore, the closer the magnet is to the surface of the material, the stronger the
magnetic field and the greater the sensitivity of the test.

1.2.2 Internal and external flux patterns: The magnetic field can be directed either externally or
internally through the material, depending on the type of magnet used.

1.2.3 Phenomenon action at the discontinuity: When the magnetic field encounters a discontinuity, such
as a crack or void, the magnetic flux will be disrupted and magnetic particles will be attracted to the
area, producing an indication.

1.2.4 Heat effects on magnetism: High temperatures can affect the magnetic properties of the material
being tested and may reduce the sensitivity of the test.
1.2.5 Materials hardness versus magnetic retention: The hardness of the material can affect the
retention of the magnetic particles on the surface of the material, and may require a higher magnetic
field strength or longer dwell time to produce a clear indication.

1.1 Theory:

1.1.1 Flux patterns: The flux pattern of the magnetic field will depend on the orientation of the magnetic
field and the shape of the material. For example, if a magnetic particle test is being conducted on a
cylindrical component, the orientation of the magnetic field will be circumferential and the flux lines will
be parallel to the axis of the cylinder. Discontinuities perpendicular to the flux lines, such as a crack
oriented transverse to the axis of the cylinder, will produce the strongest indications.

1.1.2 Frequency and voltage factors: The frequency and voltage of the applied magnetic field will affect
the depth of penetration and the sensitivity of the test. For example, when testing a thin-walled
component, a high-frequency AC magnetic field may be used to provide good sensitivity to surface-
breaking defects. On the other hand, when testing a thick-walled component, a lower-frequency AC
magnetic field or a DC magnetic field may be used to provide greater depth of penetration.

1.1.3 Current calculations: The amount of current applied will depend on the size and shape of the
material being tested and the strength of the applied magnetic field. For example, when testing a large
component with a high magnetic permeability, a higher current may be required to provide sufficient
magnetization.

1.1.4 Surface flux strength: The strength of the magnetic field on the surface of the material will depend
on the distance between the magnet and the material, as well as the orientation of the magnet. For
example, if the magnetic particle test is being conducted on a curved surface, the magnet may need to
be placed at a specific distance and orientation to ensure that the magnetic field is directed
perpendicular to the surface and that the flux lines are evenly distributed.

1.1.5 Subsurface effects: Magnetic particle testing can detect subsurface defects as well as surface
defects, depending on the strength of the magnetic field and the depth of penetration. For example,
when testing a component with a high magnetic permeability, the magnetic field may penetrate deeper
into the material and detect subsurface defects.
1.2 Magnets and magnetism:

1.2.1 Distance factors versus strength of flux: The strength of the magnetic field decreases with distance
from the magnet. Therefore, the closer the magnet is to the surface of the material, the stronger the
magnetic field and the greater the sensitivity of the test. For example, when testing a component with a
curved surface, the magnet may need to be placed as close as possible to the surface to ensure
sufficient magnetization and sensitivity.

1.2.2 Internal and external flux patterns: The magnetic field can be directed either externally or
internally through the material, depending on the type of magnet used. For example, when testing a
weld, a yoke magnet may be used to direct the magnetic field through the weld from the outside, or a
prod magnet may be used to direct the magnetic field through the weld from the inside.

1.2.3 Phenomenon action at the discontinuity: When the magnetic field encounters a discontinuity, such
as a crack or void, the magnetic flux will be disrupted and magnetic particles will be attracted to the
area, producing an indication. For example, when testing a component with a surface crack, the
magnetic particles will be attracted to the area of the crack and produce a visible indication.

1.2.4 Heat effects on magnetism: High temperatures can affect the magnetic properties of the material
being tested and may reduce the sensitivity of the test. For example, when testing a component that has
been subjected to high temperatures, the magnetization may need to be increased to compensate for
the reduced magnetic properties of the material.

1.2.5 Materials hardness versus magnetic retention: The hardness of the material can affect the
retention of the magnetic particles on the surface of the material and may require a higher magnetic
field strength or longer dwell time to produce a clear indication. For example, when testing a hardened
steel component, a higher magnetic field strength may be required to ensure that the magnetic particles
adhere to the surface of the material and produce a clear indication.

Standards and acceptance criteria have been established to ensure that the MPT results are reliable and
repeatable. For example, ASTM E1444 outlines the appropriate magnetization methods, sequence of
operations, and acceptance criteria for specific alloys and parts. The acceptance criteria specify the
allowable sizes and types of indications that are acceptable, as well as the procedures for evaluating and
reporting the results of the test. The standards also provide guidelines for the qualification and
certification of personnel who perform magnetic particle testing.

2.0.Flux Fields

2.1 Direct current

2.1.1 Depth of penetration factors

2.1.2 Source of current

2.2 Direct pulsating current

2.2.1 Similarity to direct current

2.2.2 Advantages

2.2.3 Typical fields

2.3 Alternating currents

2.3.1 Cyclic effects

2.3.2 Surface strength characteristics

2.3.3 Safety precautions

2.3.4 Voltage and current factors

2.3.5 Source of current

2.0 Flux Fields in Magnetic Particle Testing:

In magnetic particle testing, the magnetic field is used to detect surface and subsurface defects in
ferromagnetic materials. The type of flux field used can affect the sensitivity and accuracy of the test.

2.1 Direct Current:

Direct current is used to magnetize the material being tested. It is typically applied using a magnetic
yoke or a portable electromagnetic unit. Here are some additional details about direct current:
2.1.1 Depth of penetration factors: The depth of penetration for direct current is limited, typically to a
few millimeters, which makes it suitable for detecting surface defects.

2.1.2 Source of current: The source of current can be a battery or a rectifier, which converts alternating
current to direct current.

2.2 Direct Pulsating Current:

Direct pulsating current is similar to direct current, but it is applied in pulses instead of a continuous
current. Here are some additional details about direct pulsating current:

2.2.1 Similarity to direct current: Direct pulsating current has similar characteristics to direct current, but
it can produce stronger magnetic fields and deeper penetration.

2.2.2 Advantages: Direct pulsating current can provide greater sensitivity and accuracy than direct
current, especially for detecting subsurface defects.

2.2.3 Typical fields: Direct pulsating current is typically used with portable electromagnetic units or
stationary magnetic benches.

2.3 Alternating Currents:

Alternating currents are used to produce an alternating magnetic field that can detect subsurface
defects in ferromagnetic materials. Here are some additional details about alternating currents:

2.3.1 Cyclic effects: Alternating current produces a cyclic magnetic field that can penetrate deeper into
the material than direct current.
2.3.2 Surface strength characteristics: The strength of the magnetic field on the surface of the material is
weaker than with direct current, but the alternating field can detect subsurface defects.

2.3.3 Safety precautions: Alternating current can be dangerous and should be used with caution. Safety
precautions include using insulated gloves and avoiding contact with the material being tested.

2.3.4 Voltage and current factors: The voltage and current used for alternating current can affect the
sensitivity and accuracy of the test.

2.3.5 Source of current: The source of current for alternating current can be a generator or a rectifier,
which converts alternating current to direct current. Alternating current can also be produced by an
electromagnetic yoke or a stationary magnetic bench.

3.0 Effects of Discontinuities on Materials

3.1 Design factors

3.1.1 Mechanical properties

3.1.2 Part use

3.2 Relationship to load – carrying ability

4.0 Magnetization by means of electric current

4.1 Circular technique

4.1.1 Current calculations

4.1.2 Depth – factor considerations

4.1.3 Precautions – safety and overheating

4.1.4 Contact prods and yokes

4.1.4.1 Requirements for prods and yokes

4.1.4.2 Current – carrying capabilities

4.1.5 Discontinuities commonly detected

4.2 Longitudinal technique

4.2.1 Principles of induced flux fields

4.2.2 Geometry of parts to be inspected

4.2.3 Shapes and sizes of coil

4.2.4 Use of coils and cables

4.2.4.1 Strength of field

4.2.4.2 Current directional flow versus flux field

4.2.4.3 Shapes, sizes, and current capacities

4.2.5 Current calculations

4.2.5.1 Formulas

4.2.5.2 Types of current required

4.2.5.3 Current demand

4.2.6 Discontinuities commonly detected

3.0 Effects of Discontinuities on Materials in Magnetic Particle Testing:

Discontinuities in ferromagnetic materials can affect their magnetic properties and therefore their
detectability using magnetic particle testing. Here are some details about the effects of discontinuities:

3.1 Design factors:

3.1.1 Mechanical properties: The mechanical properties of the material, such as its hardness and
ductility, can affect the retention of the magnetic particles on the surface of the material.

3.1.2 Part use: The function of the part being tested can affect the sensitivity of the test, as parts that
are subject to stress or load may be more likely to produce indications.
3.2 Relationship to load-carrying ability: Discontinuities that affect the load-carrying ability of a part,
such as cracks or voids, are of particular concern in magnetic particle testing, as they may indicate a
potential failure point.

4.0 Magnetization by means of electric current:

Electric current is used to magnetize the material being tested in magnetic particle testing. There are
two common techniques for magnetization: circular and longitudinal.

4.1 Circular technique:

The circular technique involves passing an electric current through the material in a circular pattern.
Here are some additional details about the circular technique:

4.1.1 Current calculations: The amount of current used will depend on the size and shape of the material
being tested and the desired depth of penetration.

4.1.2 Depth-factor considerations: The depth of penetration for the circular technique is limited,
typically to a few millimeters, which makes it suitable for detecting surface defects.

4.1.3 Precautions - safety and overheating: Safety precautions should be taken when using the circular
technique, as overheating can damage the material or cause a fire.

4.1.4 Contact prods and yokes:

4.1.4.1 Requirements for prods and yokes: The prods or yokes used to apply the electric current should
be made of a non-magnetic material to prevent interference with the magnetic field.
4.1.4.2 Current-carrying capabilities: The prods or yokes should also be able to carry the necessary
amount of current without overheating or breaking.

4.1.5 Discontinuities commonly detected: The circular technique is suitable for detecting surface defects
such as cracks, laps, and seams.

4.2 Longitudinal technique:

The longitudinal technique involves passing an electric current through the material in a longitudinal
pattern. Here are some additional details about the longitudinal technique:

4.2.1 Principles of induced flux fields: The longitudinal technique induces a magnetic field in the material
being tested along its length.

4.2.2 Geometry of parts to be inspected: The geometry of the part being tested should be suitable for
the longitudinal technique, as it requires a lengthwise current flow.

4.2.3 Shapes and sizes of coil: The shape and size of the coil used to apply the current will depend on the
size and shape of the material being tested.

4.2.4 Use of coils and cables:

4.2.4.1 Strength of field: The strength of the magnetic field produced by the coil will depend on the
amount of current used and the shape and size of the coil.

4.2.4.2 Current directional flow versus flux field: The direction of the current flow will affect the
direction of the magnetic field, which can be used to detect different types of defects.
4.2.4.3 Shapes, sizes, and current capacities: The coils and cables used should be suitable for the size
and shape of the material being tested and should be able to carry the necessary amount of current.

4.2.5 Current calculations:

4.2.5.1 Formulas: The amount of current required can be calculated using formulas based on the size
and shape of the material being tested.

4.2.5.2 Types of current required: The type of current used can affect the depth of penetration and the
sensitivity of the test.

4.2.5.3 Current demand: The amount of current required can be high, which may require specialized
equipment.

4.2.6 Discontinuities commonly detected: The longitudinal technique is suitable for detecting subsurface
defects such as cracks, inclusions, and voids.

5.0 Selecting the Proper Method of Magnetization

5.1 Alloy, shape, and condition of part

5.2 Type of magnetizing current

5.3 Direction of magnetic field

5.4 Sequence of operations

5.5 Value of flux density

5.0 Selecting the Proper Method of Magnetization in Magnetic Particle Testing:

The proper method of magnetization should be selected based on a variety of factors, including the
alloy, shape, and condition of the part being tested, as well as the type of magnetizing current, the
direction of the magnetic field, the sequence of operations, and the value of flux density.
5.1 Alloy, shape, and condition of part:

The alloy, shape, and condition of the part being tested can affect the sensitivity and accuracy of the
test. For example, parts with complex shapes or those made from certain alloys may require a specific
magnetization method to detect defects.

5.2 Type of magnetizing current:

The type of magnetizing current used can affect the sensitivity and accuracy of the test. For example,
direct current is typically used for detecting surface defects, while alternating current is better for
detecting subsurface defects.

5.3 Direction of magnetic field:

The direction of the magnetic field should be selected based on the type of defect being detected and
the orientation of the part being tested. For example, longitudinal magnetization is better for detecting
subsurface defects in parts with a lengthwise orientation, while circular magnetization is better for
detecting surface defects in parts with a circular or irregular shape.

5.4 Sequence of operations:

The sequence of operations should be selected to ensure that the part is properly magnetized and that
any defects are detected. This may involve multiple passes or changes in the direction of the magnetic
field.

5.5 Value of flux density:

The value of flux density used can affect the sensitivity and accuracy of the test. Higher flux densities can
provide greater sensitivity but may also increase the risk of false positives or damage to the part being
tested. The appropriate flux density will depend on the type of defect being detected and the properties
of the material being tested.

5.0 Selecting the Proper Method of Magnetization in Magnetic Particle Testing:

Magnetic particle testing requires proper magnetization of the part being inspected to detect surface
and near-surface defects. The selection of the proper method of magnetization is critical to the
effectiveness and accuracy of the test.

5.1 Alloy, shape, and condition of part:

The alloy, shape, and condition of the part being tested can affect the sensitivity and accuracy of the
test. For example, parts with complex shapes or those made from certain alloys may require a specific
magnetization method to detect defects. The industry and government regulations specify the
appropriate magnetization methods for specific alloys and parts.

5.2 Type of magnetizing current:

The type of magnetizing current used can affect the sensitivity and accuracy of the test. Direct current is
typically used for detecting surface defects, while alternating current is better for detecting subsurface
defects. The selection of the appropriate magnetizing current depends on the type of defect being
detected and the properties of the material being tested.

5.3 Direction of magnetic field:

The direction of the magnetic field should be selected based on the type of defect being detected and
the orientation of the part being tested. For example, longitudinal magnetization is better for detecting
subsurface defects in parts with a lengthwise orientation, while circular magnetization is better for
detecting surface defects in parts with a circular or irregular shape.
5.4 Sequence of operations:

The sequence of operations should be selected to ensure that the part is properly magnetized and that
any defects are detected. This may involve multiple passes or changes in the direction of the magnetic
field. The industry and government regulations specify the appropriate sequence of operations for
specific alloys and parts.

5.5 Value of flux density:

The value of flux density used can affect the sensitivity and accuracy of the test. Higher flux densities can
provide greater sensitivity but may also increase the risk of false positives or damage to the part being
tested. The appropriate flux density will depend on the type of defect being detected and the properties
of the material being tested. The industry and government regulations specify the acceptable range of
flux density for specific alloys and parts.

Standards and acceptance criteria for magnetic particle testing are specified in industry standards such
as ASTM E1444 and ASME BPVC Section V. These standards provide guidelines for the selection and use
of magnetization methods, as well as the inspection and acceptance criteria for indications of defects.
The selection of the proper magnetization method is critical to the effectiveness and accuracy of the
magnetic particle testing process.

Tell me more about sequence of.

The sequence of operations in magnetic particle testing refers to the order in which the part is
magnetized and inspected to detect surface and near-surface defects. The sequence of operations may
involve multiple passes or changes in the direction of the magnetic field to ensure that the part is
properly magnetized and that any defects are detected.

The sequence of operations may vary depending on the type of part being tested and the magnetization
method being used. For example, in the case of circular magnetization, the sequence of operations may
involve placing the part in a circular coil and passing an alternating current through the coil to create a
magnetic field. The part is then rotated to inspect all areas for indications of defects. This sequence may
be repeated multiple times with changes in the direction of the magnetic field to ensure that all areas of
the part are properly magnetized and inspected.

In the case of longitudinal magnetization, the sequence of operations may involve placing the part
between two poles of a magnet and passing a direct current through the part to create a magnetic field.
The part is then inspected for indications of defects. This sequence may be repeated multiple times with
changes in the direction of the magnetic field to ensure that all areas of the part are properly
magnetized and inspected.

The sequence of operations is critical to the effectiveness and accuracy of the magnetic particle testing
process. The sequence of operations must be carefully controlled and documented to ensure that all
areas of the part are properly inspected and that any defects are detected. Standards and acceptance
criteria for magnetic particle testing specify the appropriate sequence of operations for specific alloys
and parts to ensure the reliability and repeatability of the inspection results.

Can you provide examples of specific alloys and parts with their appropriate sequence of operations?

Sure, here are a few examples of specific alloys and parts with their appropriate sequence of operations
for magnetic particle testing:

Alloy: Steel forgings

Part: Round bars

Magnetization method: Circular magnetization

Sequence of operations: Place the part in a circular coil and pass an alternating current through the coil
to create a magnetic field. Rotate the part and inspect all areas for indications of defects. Repeat the
sequence in different directions to ensure that all areas of the part are inspected.

Alloy: Aluminum alloys

Part: Castings

Magnetization method: Longitudinal magnetization

Sequence of operations: Place the part between two poles of a magnet and pass a direct current
through the part to create a magnetic field. Inspect the part for indications of defects. Repeat the
sequence with the part rotated in different directions to ensure that all areas of the part are inspected.

Alloy: Nickel alloys

Part: Welds

Magnetization method: Yoke magnetization

Sequence of operations: Place the yoke around the weld and pass a direct current through the yoke to
create a magnetic field. Inspect the weld for indications of defects. Repeat the sequence with the yoke
positioned in different directions to ensure that all areas of the weld are inspected.

Alloy: Titanium alloys

Part: Plates

Magnetization method: Coil magnetization

Sequence of operations: Place the part in a coil and pass a direct current through the part to create a
magnetic field. Inspect the part for indications of defects. Repeat the sequence with the part rotated in
different directions and with changes in the direction of the magnetic field to ensure that all areas of the
part are inspected.

These are just a few examples, and the appropriate magnetization method and sequence of operations
will depend on the specific alloy and part being tested. In general, it is important to follow the guidelines
and standards set forth by industry and government regulations to ensure the reliability and
repeatability of the inspection results.

Can you provide more examples of alloys and parts with different magnetization methods?

Sure, here are a few more examples of alloys and parts with different magnetization methods used in
magnetic particle testing:

Alloy: Stainless steel alloys

Part: Welds

Magnetization method: Prod magnetization

Sequence of operations: Place the prod on the surface of the weld and pass a direct current through the
prod to create a magnetic field. Inspect the weld for indications of defects. Repeat the sequence with
the prod positioned in different directions to ensure that all areas of the weld are inspected.

Alloy: Copper alloys

Part: Castings

Magnetization method: Coil magnetization

Sequence of operations: Place the part in a coil and pass an alternating current through the part to
create a magnetic field. Inspect the part for indications of defects. Repeat the sequence with the part
rotated in different directions and with changes in the direction of the magnetic field to ensure that all
areas of the part are inspected.

Alloy: Magnesium alloys

Part: Forgings

Magnetization method: Head shot magnetization

Sequence of operations: Use a head shot coil to create a magnetic field in the part by placing the coil on
the surface of the part and passing a direct current through the coil. Inspect the part for indications of
defects. Repeat the sequence with the head shot coil positioned in different directions to ensure that all
areas of the part are inspected.

Alloy: Carbon steel alloys

Part: Bars

Magnetization method: Longitudinal magnetization

Sequence of operations: Place the part between two poles of a magnet and pass a direct current
through the part to create a magnetic field. Inspect the part for indications of defects. Repeat the
sequence with the part rotated in different directions to ensure that all areas of the part are inspected.
These examples demonstrate that the appropriate magnetization method and sequence of operations
will depend on the specific alloy and part being tested. It is important to follow the guidelines and
standards set forth by industry and government regulations to ensure the reliability and repeatability of
the inspection results.

Can you explain the guidelines and standards for magnetic particle testing?

Sure, the guidelines and standards for magnetic particle testing are established by industry
organizations, government agencies, and standards-setting bodies. These guidelines and standards
provide a framework for conducting magnetic particle testing and ensure that the results are reliable,
repeatable, and consistent.

Here are some examples of guidelines and standards for magnetic particle testing:

ASTM E1444 - Standard Practice for Magnetic Particle Testing: This standard provides general guidelines
for magnetic particle testing and covers the equipment, materials, and procedures used for conducting
the test. It also includes acceptance criteria for detecting surface and subsurface discontinuities.

ASME BPVC Section V - Nondestructive Examination: This code section provides guidelines for
nondestructive examination methods, including magnetic particle testing. It outlines the requirements
for personnel qualification, equipment, and procedures used for conducting the test.

ISO 9934-1 - Non-destructive testing: Magnetic particle testing: Part 1: General principles: This
international standard provides general principles and requirements for magnetic particle testing. It
covers the equipment, materials, and procedures used for conducting the test and provides acceptance
criteria for detecting surface and subsurface discontinuities.

MIL-STD-1949 - Nondestructive Testing Acceptance Criteria for Magnetic Particle Inspection: This
military standard provides acceptance criteria for detecting surface and subsurface discontinuities using
magnetic particle testing. It covers the inspection of ferromagnetic materials and provides guidelines for
conducting the test.
These guidelines and standards provide a common language and framework for magnetic particle
testing. They define the requirements for personnel qualification, equipment, and procedures used for
conducting the test. They also provide acceptance criteria for detecting surface and subsurface
discontinuities, which ensure that the results are reliable, repeatable, and consistent.

It is important to follow these guidelines and standards when conducting magnetic particle testing to
ensure that the results are accurate and reliable. This helps to ensure the safety and integrity of the
parts being inspected and helps to prevent failures that could result in injury or damage.

Can you recommend any resources for learning more about magnetic particle testing?

Yes, there are many resources available for learning more about magnetic particle testing. Here are a
few resources that you may find helpful:

Standards and Codes: The industry and government regulations specify the appropriate magnetization
methods, sequence of operations, and acceptance criteria for specific alloys and parts. Standards such
as ASTM E1444 and ASME BPVC Section V provide guidelines for the selection and use of magnetization
methods, as well as the inspection and acceptance criteria for indications of defects.

Training Courses: Many companies and organizations offer training courses in magnetic particle testing.
These courses cover the equipment, materials, and procedures used for conducting the test, as well as
the interpretation of the results. The American Society for Nondestructive Testing (ASNT) offers courses
and certification programs in magnetic particle testing.

Books and Publications: There are many books and publications available on magnetic particle testing.
Some recommended books include "Nondestructive Testing Handbook: Magnetic Particle Testing" by
ASNT, "Magnetic Particle Inspection: A Practical Guide" by David Lovejoy, and "Magnetic Particle
Testing: Level I and II Training Manual" by M. R. Bandyopadhyay.

Online Resources: There are many online resources available for learning more about magnetic particle
testing. The ASNT website provides information on certification programs, training courses, and
publications related to magnetic particle testing. The NDT Resource Center website provides information
on nondestructive testing methods, including magnetic particle testing.
These are just a few examples of resources available for learning more about magnetic particle testing. It
is important to ensure that any resource you use is up-to-date and reliable, and that you follow the
guidelines and standards set forth by industry and government regulations when conducting magnetic
particle testing.

6.0 Demagnetization Procedures

6.1 Need for demagnetization of parts

6.2 Current, frequency, and field orientation

6.3 Heat factors and precautions

6.4 Need for collapsing flux fields

6.0 Demagnetization Procedures in Magnetic Particle Testing:

After magnetization and inspection, it is important to properly demagnetize the part to avoid any
residual magnetism that may affect its performance or future inspections. Here are some details about
demagnetization procedures:

6.1 Need for demagnetization of parts:

Parts may become magnetized during magnetic particle testing, which can affect their performance and
future inspections. Demagnetization is necessary to remove any residual magnetism.

6.2 Current, frequency, and field orientation:

The current, frequency, and field orientation used for demagnetization will depend on the type and size
of the part being demagnetized. Typically, alternating current with a decreasing frequency and a rotating
field orientation is used.

6.3 Heat factors and precautions:

Demagnetization can generate heat, which can damage or deform the part being demagnetized.
Precautions should be taken to avoid overheating, such as using a demagnetization unit with a cooling
system.

6.4 Need for collapsing flux fields:

Demagnetization is achieved by collapsing the magnetic field in the part being demagnetized. This is
typically accomplished by using an alternating current that gradually decreases in frequency and rotates
the field orientation.

7.0 Equipment

7.0 Equipment in Magnetic Particle Testing:

Magnetic particle testing requires equipment that can generate a magnetic field and detect the
presence of magnetic particles. There are different types of equipment used in this testing, each with its
own capabilities and characteristics.

7.1 Portable type

Portable equipment is designed for use in the field or in areas where access to stationary equipment is
limited.

7.1.1 Reason for portable equipment

7.1.2 Capabilities of portable equipment

7.1.3 Similarity to stationary equipment

7.1.1 Reason for portable equipment:

Portable equipment is used for its convenience and mobility, as it can be easily transported to different
locations where the testing is needed.

7.1.2 Capabilities of portable equipment:

Portable equipment is capable of producing magnetic fields for magnetization and detecting indications
of defects on parts.

7.1.3 Similarity to stationary equipment:

Portable equipment is similar to stationary equipment in terms of its basic operation, but it may have
limitations in terms of its power and capacity.

7.2 Stationary type

7.2.1 Capability of handling large and heavy parts

7.2.2 Flexibility in use

7.2.3 Need for stationary equipment

7.2.4 Use of accessories and attachments

7.2 Stationary type:

Stationary equipment is typically used in manufacturing or inspection facilities where parts can be
brought to the equipment.

7.2.1 Capability of handling large and heavy parts:

Stationary equipment is capable of handling larger and heavier parts than portable equipment.

7.2.2 Flexibility in use:

Stationary equipment is more flexible in terms of its power and capacity, allowing for a wider range of
applications.

7.2.3 Need for stationary equipment:

Stationary equipment is necessary for large-scale production or inspection facilities that require a
consistent and reliable source of magnetization and detection.

7.2.4 Use of accessories and attachments:

Stationary equipment may have a variety of accessories and attachments available to customize it for
specific applications.

7.3 Automatic type

7.3.1 Requirements for automation

7.3.2 Sequential operations

7.3.3 Control and operation factors

7.3.4 Alarm and rejection mechanism

7.3 Automatic type:

Automatic equipment is used for high-volume production or inspection facilities that require a high
degree of automation.

7.3.1 Requirements for automation:

Automatic equipment requires a high level of control and automation to ensure consistent and reliable
operation.

7.3.2 Sequential operations:

Automatic equipment typically performs sequential operations, such as magnetization, inspection, and
demagnetization, with minimal human intervention.

7.3.3 Control and operation factors:

Automatic equipment requires sophisticated control systems and operator training to ensure proper
operation and maintenance.

7.3.4 Alarm and rejection mechanism:

Automatic equipment may have an alarm and rejection mechanism to automatically reject parts with
defects.

7.4 Multidirectional units

7.4.1 Capability

7.4.2 Control and operation factors

7.4.3 Applications

7.4 Multidirectional units:

Multidirectional units are designed to produce magnetic fields in multiple directions, making them
useful for inspecting parts with complex shapes.

7.4.1 Capability:

Multidirectional units are capable of producing magnetic fields in multiple directions, allowing for a
more thorough inspection of complex parts.

7.4.2 Control and operation factors:

Multidirectional units require sophisticated control systems and operator training to ensure proper
operation and maintenance.

7.4.3 Applications:

Multidirectional units are useful for inspecting parts with complex shapes, such as turbine blades and
engine components.

7.5 Liquids and powders

7.5.1 Liquid requirements as a particle vehicle

7.5.2 Safety precautions

7.5.3 Temperature needs

7.5.4 Powder and paste contents

7.5.5 Mixing procedures

7.5.6 Need for accurate proportions

7.5 Liquids and powders:

Liquid and powder media are used to carry magnetic particles to the surface of the part being inspected.

7.5.1 Liquid requirements as a particle vehicle:

Liquid media must be able to suspend magnetic particles and be able to be easily cleaned from the
surface of the part.

7.5.2 Safety precautions:

Safety precautions must be taken when using liquid and powder media, as they can be flammable or
toxic.

7.5.3 Temperature needs:

Liquid media must be maintained at a specific temperature range to ensure proper particle suspension
and flow.

7.5.4 Powder and paste contents:

Powder and paste media may contain a variety of materials, such as iron oxide, which is the most
commonly used magnetic particle.

7.5.5 Mixing procedures:

Liquid and powder media must be mixed thoroughly to ensure proper particle suspension and
distribution.

7.5.6 Need for accurate proportions:

Accurate proportions of magnetic particles to media must be maintained to ensure proper particle
concentration and detection.

7.6 Ultraviolet radiation type

7.6.1 Ultraviolet radiation and fluorescence

7.6.2 Visible light and black light comparisons

7.6.3 Requirements in the testing cycle

7.6.4 Techniques in use

7.6 Ultraviolet radiation type:

Ultraviolet radiation is used in fluorescent magnetic particle testing to enhance the visibility of
indications.

7.6.1 Ultraviolet radiation and fluorescence:

Ultraviolet radiation causes magnetic particles to fluoresce, making indications more visible in low light
conditions.

7.6.2 Visible light and black light comparisons:

Visible light and black light are used to compare the indications visible under ultraviolet radiation.

7.6.3 Requirements in the testing cycle:

Ultraviolet radiation is used in the inspection phase of magnetic particle testing to enhance the visibility
of indications.

7.6.4 Techniques in use:

Techniques such as wet, dry, and continuous methods may be used in fluorescent magnetic particle
testing.

7.6 Ultraviolet radiation type:

In magnetic particle testing, ultraviolet radiation is used in fluorescent magnetic particle testing to
enhance the visibility of indications of defects in the part being inspected.

7.6.1 Ultraviolet radiation and fluorescence:

During fluorescent magnetic particle testing, ultraviolet radiation is used to cause the fluorescent
coating on the magnetic particles to emit visible light, making indications of defects more visible in low
light conditions. When the ultraviolet radiation is applied to the part being inspected, the magnetic
particles present in any defects on the surface of the part will fluoresce, making the defects more visible.

The use of ultraviolet radiation and fluorescent magnetic particles allows for the detection of smaller
defects that may not be visible with the naked eye. The intensity and wavelength of the light emitted by
the fluorescent magnetic particles can be measured using light-sensitive instruments, providing
quantitative data on the size and location of any defects.

7.6.2 Visible light and black light comparisons:

Visible light and black light can be used to compare the indications visible under ultraviolet radiation.
Visible light is used as a reference to compare the brightness of the fluorescent indications, while black
light is used to enhance the contrast between the indications and the background.

By comparing the indications visible under visible light and black light, the operator can determine the
relative brightness of the indications and the effectiveness of the magnetic particle testing procedure.

7.6.3 Requirements in the testing cycle:

Ultraviolet radiation is used in the inspection phase of magnetic particle testing to enhance the visibility
of indications of defects. The testing cycle typically involves the following steps:

Magnetization: The part being inspected is magnetized, causing the magnetic particles to align with the
magnetic field.

Application of fluorescent magnetic particles: The fluorescent magnetic particles are applied to the
surface of the part, either in a dry or wet form.
Inspection under ultraviolet radiation: The part is inspected under ultraviolet radiation, causing the
fluorescent magnetic particles to emit visible light and making indications of defects more visible.

Comparison under visible light and black light: The indications visible under ultraviolet radiation are
compared to those visible under visible light and black light to determine the relative brightness of the
indications.

Demagnetization and cleaning: The part is demagnetized and cleaned to remove any residual magnetic
particles.

7.6.4 Techniques in use:

Various techniques can be used in fluorescent magnetic particle testing, including wet, dry, and
continuous methods. Wet methods involve the application of a liquid suspension of fluorescent
magnetic particles to the surface of the part, while dry methods involve the application of a dry powder
or aerosol.

Continuous methods involve the use of equipment that applies the magnetic field, fluorescent magnetic
particles, and ultraviolet radiation in a continuous process. These methods are typically used in high-
volume production facilities where speed and efficiency are important.

Standards and acceptance criteria for fluorescent magnetic particle testing are specified in industry
standards such as ASTM E1444 and ASME BPVC Section V, which provide guidelines for the selection and
use of fluorescent magnetic particles, as well as the inspection and acceptance criteria for indications of
defects.

7.7 Light – sensitive instruments

7.7.1 Need for instrumentation

7.7.2 Light characteristics

7.7 Light-sensitive instruments:

Light-sensitive instruments are used to detect and measure the light emitted by fluorescent magnetic
particles.

7.7.1 Need for instrumentation:

Light-sensitive instruments are necessary for accurate detection and measurement of indications.

7.7.2 Light characteristics:

Light-sensitive instruments are designed to detect and measure the intensity and wavelength of light
emitted by the fluorescent magnetic particles.

7.7 Light-sensitive instruments:

In magnetic particle testing, light-sensitive instruments play a crucial role in detecting and measuring the
light emitted by fluorescent magnetic particles. This is particularly important in fluorescent magnetic
particle testing, where the magnetic particles used are coated with a fluorescent material that emits
light when excited by ultraviolet radiation.

7.7.1 Need for instrumentation:

The need for light-sensitive instrumentation in magnetic particle testing arises from the fact that
indications of defects can be very subtle and difficult to detect with the naked eye. Light-sensitive
instruments are necessary for accurate detection and measurement of these indications.

The instruments are designed to convert the light emitted by the fluorescent magnetic particles into an
electrical signal, which can then be displayed on a digital readout. This allows the operator to accurately
determine the size and location of any defects present in the part being inspected.

Standards and acceptance criteria are important in determining the level of accuracy required for the
light-sensitive instruments used in magnetic particle testing. The most commonly used standards for
magnetic particle testing include ASTM E1444 and ASME BPVC Section V, which provide guidelines for
the selection and use of light-sensitive instruments.

7.7.2 Light characteristics:

The light emitted by fluorescent magnetic particles has specific characteristics that can be measured by
light-sensitive instruments. The intensity of the light is directly proportional to the number of magnetic
particles present in the area being inspected. The wavelength of the light is dependent on the type of
fluorescent material used and can be used to differentiate between background fluorescence and
indications of defects.

The light-sensitive instruments used in magnetic particle testing are designed to detect and measure
these characteristics. They typically have a photodetector that converts the light into an electrical signal,
which can then be displayed on a digital readout. The readout provides information about the intensity
and wavelength of the light, which can be used to determine the presence and location of any defects in
the part being inspected.

Acceptance criteria for the intensity and wavelength of the light emitted by fluorescent magnetic
particles are specified in industry standards such as ASTM E1444 and ASME BPVC Section V. These
standards provide guidelines for acceptable levels of background fluorescence and minimum levels of
indication brightness required for accurate detection and measurement of defects.

8.0 Types of discontinuities

8.1 In castings

8.2 In ingots

8.3 In wrought sections and parts

8.4 In welds

8.0 Types of Discontinuities:

8.1 In Castings:
In castings, magnetic particle testing can detect various types of discontinuities such as cracks, porosity,
and inclusions that can occur due to improper casting techniques or material defects. For example, in a
casting for an aircraft engine, MPT can detect surface and subsurface cracks caused by thermal stresses
during the solidification process.

8.2 In Ingots:

In ingots, magnetic particle testing can detect discontinuities such as cracks, shrinkage cavities, and
inclusions that can occur during the solidification process. For example, in an ingot for a nuclear reactor
pressure vessel, MPT can detect subsurface cracks caused by thermal stresses during the cooling
process.

8.3 In Wrought Sections and Parts:

In wrought sections and parts, magnetic particle testing can detect discontinuities such as surface
cracks, subsurface cracks, and inclusions that can occur during the manufacturing process or due to
material defects. For example, in a steel pipe for oil and gas transportation, MPT can detect surface
cracks caused by improper manufacturing techniques or inclusions caused by impurities in the material.

8.4 In Welds:

In welds, magnetic particle testing can detect discontinuities such as cracks, lack of fusion, and porosity
that can occur due to improper welding techniques or material defects. For example, in a welded joint
for a high-pressure vessel, MPT can detect subsurface cracks caused by improper welding techniques or
porosity caused by improper cleaning of the weld surface.

9.0 Evaluation technique

9.1 Use of standards – e.g., ASTM E 1444, E709

9.1.1 Need for standards and references

9.1.2 Comparison of known with unknown

9.1.3 Specifications and certifications

9.1.4 Comparison techniques

9.1 Use of Standards:

Standards such as ASTM E1444 and E709 provide guidelines for equipment selection, materials,
procedures, and acceptance criteria for magnetic particle testing. The use of standards is important to
ensure that testing is performed consistently and accurately, and that results can be compared between
different operators, facilities, and applications. For example, in the aerospace industry, ASTM E1444 is
commonly used to ensure the quality of magnetic particle testing for critical components such as engine
parts and landing gear.

9.1.1 Need for Standards and References:

Standards and references are essential for ensuring that magnetic particle testing is performed correctly
and consistently, and that results can be compared and interpreted accurately. For example, reference
standards such as AMS 2641 and MIL-STD-6866 provide specific requirements for the inspection of
aerospace components using magnetic particle testing.

9.1.2 Comparison of Known with Unknown:

Magnetic particle testing results are compared with known defects or reference standards to determine
the severity and location of any detected discontinuities. For example, a known defect reference
standard can be used to calibrate the magnetic particle testing equipment and to verify the sensitivity
and accuracy of the inspection process.

9.1.3 Specifications and Certifications:

Specifications and certifications are used to establish acceptance criteria for magnetic particle testing
results, based on the intended application and performance requirements of the component or
structure being inspected. For example, in the energy industry, the American Petroleum Institute (API)
specifies the acceptance criteria for magnetic particle testing for oil and gas pipeline components.

9.1.4 Comparison Techniques:

Comparison techniques such as visual comparison, magnetic field strength comparison, and magnetic
particle distribution comparison are used to evaluate magnetic particle testing results and determine
the severity and location of any detected discontinuities. For example, visual comparison can be used to
confirm the location and shape of any detected cracks, while magnetic field strength comparison can be
used to compare the strength of the magnetic field at the defect location with the background magnetic
field.
9.2 Defect appraisal

9.2.1 History of part

9.2.2 Manufacturing process

9.2.3 Possible causes of defect

9.2.4 Use of part

9.2.5 Acceptance and rejection criteria

9.2.6 Use of tolerances

9.2 Defect Appraisal:

9.2.1 History of Part:

The history of the part, including its previous use, maintenance, and repair, can provide important
information on the potential causes and significance of any detected discontinuities. For example, the
history of a pressure vessel used in a chemical plant can provide information on the types of chemicals
and environments it has been exposed to, which can affect the severity and potential impact of any
detected defects.

9.2.2 Manufacturing Process:

The manufacturing process, including casting, forging, rolling, welding, and heat treatment, can affect
the occurrence and severity of discontinuities in the material or component being inspected. For
example, the manufacturing process for a turbine blade can affect the presence and type of defects that
may occur, such as surface cracks or inclusions.

9.2.3 Possible Causes of Defect:

Possible causes of defects, such as improper material selection, welding techniques, or heat treatment,
must be considered to determine the significance and potential impact of any detected discontinuities.
For example, improper welding techniques or heat treatment can cause subsurface cracks in a welded
joint, which can affect the structural integrity of the component.
9.2.4 Use of Part:

The intended use of the part, including theexpected loads, stresses, and environmental conditions, can
affect the significance and potential impact of any detected discontinuities. For example, a pressure
vessel used in a corrosive environment may have more stringent acceptance criteria for magnetic
particle testing results than a pressure vessel used in a non-corrosive environment.

9.2.5 Acceptance and Rejection Criteria:

Acceptance and rejection criteria are established based on the intended application and performance
requirements of the component or structure being inspected, and are used to determine the
acceptability of any detected discontinuities. For example, in the aviation industry, the acceptance
criteria for magnetic particle testing results for critical components such as engine parts and landing
gear are very strict, while the acceptance criteria for non-critical components may be less stringent.

9.2.6 Use of Tolerances:

Tolerances are established based on the intended application and performance requirements of the
component or structure being inspected, and are used to determine the acceptable level of deviation
from the specified dimensions or performance criteria. For example, in the automotive industry, the
tolerance for the size and location of any detected cracks in a suspension component may be more
lenient than the tolerance for the size and location of any detected cracks in a steering component.

In summary, Magnetic Particle Testing is a non-destructive testing method that can detect various types
of discontinuities in different materials and components. The evaluation technique involves the use of
standards and acceptance criteria, as well as defect appraisal techniques such as analyzing the history of
the part, the manufacturing process, and possible causes of defects to determine the significance and
potential impact of any detected discontinuities.

10.0 Quality Control of Equipment and Processes

10.1 Malfunctioning of equipment

10.2 Proper magnetic particles and bath liquid

10.3 Bath concentration

10.3.1 Settling test

10.3.2 Other bath – strength tests

10.4 Tests for ultraviolet radiation intensity

Magnetic Particle Testing (MPT) is a non-destructive testing method used to detect surface and near-
surface defects in ferromagnetic materials. MPT can be used in a variety of industries, such as
aerospace, automotive, and manufacturing, to inspect components such as gears, welds, and castings.

To ensure accurate and reliable results in MPT, quality control measures must be in place. The following
are the key aspects of quality control in MPT:

10.1 Malfunctioning of Equipment:

Equipment used in MPT, such as magnetizing equipment, demagnetizing equipment, and UV lamps,
must be regularly maintained and calibrated to ensure proper functioning. Malfunctioning equipment
can lead to missed defects or false positives.

Example: If the magnetizing equipment is not calibrated correctly, it may cause the magnetic field
strength to be too weak or too strong, resulting in missed defects or false positives.

10.2 Proper Magnetic Particles and Bath Liquid:

Proper magnetic particles and bath liquid are essential for accurate and reliable MPT results. The
magnetic particles must be of the correct size, shape, and magnetic properties to be attracted to any
defects. The bath liquid must be compatible with the magnetic particles and not interfere with the test.

Example: If the wrong type of magnetic particles or bath liquid is used, it may result in false positives or
missed defects.

10.3 Bath Concentration:

The concentration of magnetic particles in the bath liquid must be sufficient to ensure that the particles
are attracted to any defects but not so high that they clump together and form false positives.
10.3.1 Settling Test:

The settling test involves measuring the time it takes for the magnetic particles to settle in the bath
liquid. If the settling time is too short or too long, it can indicate that the concentration of magnetic
particles is too high or too low.

10.3.2 Other Bath Strength Tests:

Other tests, such as the shot test or the coil shot test, can also be used to ensure the correct
concentration of magnetic particles. These tests involve measuring the amount of magnetic particles
attracted to a metal shot or coil, which is then weighed to determine the concentration.

10.4 Tests for Ultraviolet Radiation Intensity:

UV radiation is used to illuminate the magnetic particles and make any defects visible. The intensity of
the UV radiation must be sufficient to ensure that the particles are visible but not so high that it can
damage the eyes or skin of the operator.

Example: Regular testing of the UV intensity is important to ensure that it is within safe and effective
levels. If the UV intensity is too low, it may result in missed defects, while if it is too high, it may cause
eye or skin damage to the operator.

Standards and Acceptance Criteria:

Standards, such as ASTM E1444 and E709, provide guidelines for equipment selection, materials,
procedures, and acceptance criteria for MPT. The use of standards is important to ensure that testing is
performed consistently and accurately, and that results can be compared between different operators,
facilities, and applications.

Acceptance criteria are established based on the intended application and performance requirements of
the component or structure being inspected. For critical components, such as engine parts and landing
gear in the aerospace industry, the acceptance criteria for MPT results are very strict, while for non-
critical components, the acceptance criteria may be less stringent. The acceptance criteria may include
the size, location, and quantity of any detected defects, as well as the required level of safety and
reliability.

In summary, quality control measures are critical for accurate and reliable MPT results. Regular
maintenance and calibration of equipment, proper magnetic particles and bath liquid, correct bath
concentration, and regular testing of UV intensity are key aspects of quality control. Standards and
acceptance criteria, such as ASTM E1444 and E709, provide guidelines for equipment selection,
materials, procedures, and acceptance criteria for MPT.