Unit-4 Magnetic Particle Test 4.

Unit magnetic particle

4
test

PART-A
SHORT QUESTIONS with solutions
Q1. Write short notes on magnetic materials.
Answer : [April/May-17, Set-4, Q1(d) | Model Paper-I, Q1(d)]

S.No Parameter Diamagnetic Paramagnetic Ferromagnetic

1. Definition The materials that get The substance that get The materials that are strongly
feebly repelled by feebly attracted by magnetic attracted to magnetic field
magnetic fields field
2. Magnetic Small and negative Small and positive Positive and large
Susceptibility
3. Magnetic Less than one Slightly greater than one Far greater than one
Permeability
4. Examples Glass and wood Aluminium and magnesium Iron, nickel and cobalt
Q2. What are the conditions, under which demagnetization of material is not required?
Answer :
Demagnetization of Materials is not Required under Following Conditions
1. When the ability of the materials to retain magnetism is very low.
2. When the objects are to be heat treated above curie temperature.
3. Structures made of high-strength alloys such as boilers, welded components etc., and large size castings. Residual magnetism
has no effect on service performance of these components.
4. When the components are needed to be re-magnetized in various directions.
5. If work holding device which is used to perform next operation on the component is a magnetic chuck.
Q3. State the principle of Magnetic particle test.
Answer : [April-18, Set-1, Q1(d) | Model Paper-II, Q1(d)]

Principle of Magnetic Particle Test

Principle of magnetic particle test involves magnetization of a homogeneous component of ferromagnetic type by positioning
the component in a magnetic field. And this leads to the formation of a continuous circuit of the magnetic field from one pole to
the other in the material. The magnetic lines of force gets deflected, if any discontinuity exists in the surface or subsurface in the
component, the deflected magnetic field forms a leakage field.
The length, shape, size and location of the discontinuity in the test component can be detected by sprinkling magnetic
particles on the surface of the test component. These magnetic particles forms an outline around the discontinuity due to the
attraction of leakage field towards it. And this gives the indication of discontinuities on the test component. This methods provides
very quick results for the defects present in the surface and subsurface of the test component.

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4.2 Non-destructive evaluation [JNTU-kakinada]
Leakage field Defect indications

Magnetic field lines

Defect

N S
Component

Figure
Q4. What are the various components of magnetic non destructive test?
Answer : April/May-19, Set-1, Q1(d)

Components of Magnetic Non Destrucitve Test

Operation Component
Magnetization Using Movable or Portable equipment Permenent magent yokes, cables, coils, prods, etc.
Using fixed or stable equipment Transformer providing electricity.
Applcation of Magnetic Particles A device consisting of a hose with a lever operated noz-
zle and a tank carrying a liquid with suspended magnetic
particles is employed.
Demagnetization AC coils, AC yoke, reversing DC yoke and special demag-
netizers for special testing units.
Q5. What is demagnetization of materials?
Answer : [April-18, Set-4, Q1(d) | Model Paper-III, Q1(d)]

Demagnetization
Demagnetization is carried out to decrease the residual magnetism that is present in a specimen. Although this process is
is not compulsory, it can be preferred based on the usage. AC coil method, AC yoke, AC through current etc., are the methods
that are used to demagnetize a specimen.
Q6. Define magnetic flux and draw diagram of different types of magnetic fields used in magnetic particle test.
Answer : April/May-19, Set-2, Q1(d)

Magnetic Flux
The total number of lines of induction cutting through a surface is called magnetic flux through that surface. The unit of
magnetic flux is weber.
Types of Magnetic Fields Used in Magnetic Particle Test
1. Circular Magnetic Field
Magnetic field

Figure(1): Circular Magnetic Field

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Unit-4 Magnetic Particle Test 4.3
Q9. What are the inspection aids employed in
Contact prob magnetic particle inspection?
Answer :

Inspection Aids

Inspection aids are described to avoid failures caused due

to continual detection of flaw using magnetic particle inspection
(MPI). Ways to avoid failures are as follows,
Magnetic field (i) Prevention of non-relevant indications
Figure (2): Circular Magnetic Field Using Contact Probs (ii) Control of system parameters and magnetization.
2. Longitudinal Mangetic Field
Magnetic field (iii) Control of suspension of particles.
Q10. Write a note on types of indications of magnetic
particle testing.
Answer :
Figure (3): Longitudinal Mangetic Field
3. Magnetic Field in Yoke Magnetization Indications of magnetic particle test are classified as,
either they are relevant, non relevant or false. This classification
is done before evaluation.
Yoke
Relevant Indications
Magnetic field Relevant indications are produced as a result of
discontinuities in the component by flux leakages. Acception
or rejection of these discontinuities depends on their agreement
with acceptance criteria.

Figure (4): Magnetic Field in Yoke Magnetization Non-Relevant Indications

Q7. What is the concept of magnetography?
Answer : April-18, Set-4, Q1(c)
Magnetography
It is one of the methods of measuring leakage fields
of magnetic flux. Such measurement is carried out by using
magnetic tape of special type which is able to detect and store
magnetic flux leakage fields. Prior to the test, magnetic tape is
applied or masked over the surface of component undergoing
test. During the test,magnetic flux is applied to the component.
Any leakage of flux field due to discontinuities is detected
and stored on the tape. After particular period of time, tape is
removed for processing and thus obtained signals are analysed.
Q8. Define the terms standardization and calibration.
Answer :
Standardization
Standardization refers to the process of producing
diversified products by using minimum variety of materials,
parts, tools and processes. Standardization is a process where
standards or the units of measures can be compared or measured
in terms of quantity, quality, value, extent performance etc.
Non-relevant indications are produced by flux leakages
because of factors such as geometrical changes, excessive
magnetization or variation in permeability. These indications
may disappear when demagnetized and component is
remagnetized to a slightly lesser level of magnetic strength.
False Indications
False indications are produced as a result of mishandling
of the component and has no regard about the condition of the
component.
Q11. Name the materials which can be tested by
magnetic particle testing.
Answer : [April/May-17, Set-2, Q1(d) | Model Paper-IV, Q1(d)]
Ferromagnetic materials can be effectively tested by
magnetic particle testing method. Few of the ferromagnetic
materials are,
1. Iron

Calibration 2. Nickel
Calibration can be stated as a process of making a set
of operations to establish a relationship between the values 3. Cobalt
indicated by the measuring system and the corresponding known
value of the physical quantity (or measurand). 4. Some of alloys of above materials.

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Q12. List out the industries which utilize magnetic particle testing.
Answer :
Few of the industries in which magnetic particle test is used are,
1. Petroleum
2. Nuclear
3. Railways
4. Aerospace and aircraft
5. Shipping
6. Chemical
7. Paper
8. Defence
9. Food
10. Construction.
Q13. Give the limitations of magnetic particle test.
Answer : April/May-19, Set-4, Q1(d)

For answer refer Unit-IV, Q31, Topic: Disadvantages of Magnetic Particle Test (Only first four points).
Q14. Enumerate the applications of magnetic NDT
Answer : April/May-17, Set-1, Q1(d)

For answer refer Unit-IV, Q32, Topic: Applications.

Q15. List the sequence of steps in magnetic particle testing procedure.
Answer : April-18, Set-3, Q1(d)

For answer refer Unit-IV, Q22, Topic: Steps Involved in Magnetic Particle Test.
Q16. State the reasons for demagnetization of materials after completion of magnetic partic test.
Answer : April/May-19, Set-3, Q1(d)

For answer refer Unit-IV, Q21, Topic: Need for Demegnetization.

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Unit-4 Magnetic Particle Test 4.5

Part-B
essay Questions with Solutions
4.1 Magnetic materials, Magnetization of materials, demagnetization of
materials, principle of magnetic particle test, magnetic particle test
equipment, magnetic particle test procedure, standardization and
calibration, interpretation and evaluation, effective applications and
limitations of the magnetic particle test
Q17. Give the classification of magnetic materials and also list their corresponding properties.
Answer :
Classification of Magnetic Materials
Depending on the atomic dipoles and interaction between them, the magnetic materials are classified as,
1. Diamagnetic materials
2. Paramagnetic materials
3. Ferromagnetic materials.
1. Diamagnetic Materials
The materials that get feebly repelled by magnetic fields are called diamagnetic materials and the phenomenon is known
as, diamagnetism. The repulsion is due to the fact that these materials are magnetized weakly in the direction opposite to the
applied field. Hence the value of susceptibility, χ is small and negative.
Magnetization of these materials is due to the magnetic dipoles that are induced temporarily by the applied field. When
the external field is removed, the induced dipoles disappear. That means there are no permanent dipole magnetic materials. Also
diamagnetism does not depend upon temperature.
Examples: Glass, wood, etc.
Properties
Properties of diamagnetic materials are as follows,
(i) Diamagnetic materials are repelled by the applied magnetic field.
(ii) The induced magnetic moment of diamagnetic materials is opposite to the direction of external magnetic field.
(iii) Diamagnetic materials don not have permanent magnetic dipoles. As a result, magnetic effects are very small.
(iv) The susceptibility of these materials is small and negative.
(v) The susceptibility of these materials is independent of temperature and magnetic field strength.
Examples: Bismuth, niobium, alkali earths etc.
2. Paramagnetic Materials
The substances that get feebly attracted by magnetic field are called ‘paramagnetic materials’ and the phenomenon is known
as, ‘paramagnetism’. Internally, these materials are weakly magnetized in the direction of the applied magnetic field. That means
susceptibility, χ of these materials is small and positive.
Examples: Aluminium, magnesium etc.
Properties
The following are the properties of paramagnetic materials,
(i) Paramagnetic materials are feebly (weakly) attracted by magnetic fields.
(ii) When paramagnetic materials are placed in magnetic field, they move from weak magnetic field area to strong magnetic
field area.
(iii) Paramagnetic materials obey curie law.
(iv) The susceptibility of paramagnetic materials is very small.
(v) Paramagnetism depends on temperature.
(vi) The net dipole moment of paramagnetic atoms is due to their orbital and spin magnetic moments.
(vii) The permeability of paramagnetic materials is 1.
(viii) In absence of a magnetic field, the magnetic dipoles of paramagnetic materials align in random directions.

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3. Ferromagnetic Materials Magnetic Field by an Electric Current
The materials that are strongly attracted to magnet fields The components that are to be subjected to magnetic
and magnets, and get permanently magnetized after the removal particle test can be magnetized by using both alternating and
of external magnetic field are called ferromagnetic materials. direct currents. The factors such as direction, distribution and
Examples of ferromagnetic materials are iron and nickel. strength of magnetic field are considered for selection of type
Properties of current to be used.
(i) Ferromagnetic materials possess enormous permanent When an alternating current is used, resulting magnetic
dipole moment or magnetic moment in each atom the field is unable to penetrate across the component cross-section
induced magnetic moment produced by the external but confined only to component surface because of skin effect.
magnetic field is very large and it increases the magnetic When direct current is employed, obtained magnetic field is able
induction present in the metal. to pass through the component cross section. Magnetic particle
test essentially used direct current obtained by the rectification of
(ii) Susceptibility is always positive and large and it depends
alternating current. A half wave rectified direct current is obtained
upon temperature in a complex manner. This behaviour
by the rectification of single phase alternating current. In order to
is as shown in figure (a).
obtain full wave rectified direct current, single phase alternating
χ= C current is rectified in such a way that current flow through the circuit
(Only in paramagnetic region, i.e., T > θ)
T –θ is same in reverse half of the cycle also. For magnetic particle test,
direct current of range 50 to 6000 amperes is employed.
Q19. Explain the methods of magnetization of
Ferro Para region
materials with aid of magnetic field generated
χ region
by an electric current.
Answer : Model Paper-I, Q5(a)

Methods of magnetization of materials with aid of

θ Temperature magnetic field generated by an electric current are induction,
solenoid coil, surge and alternating current methods.
Figure (a) Induction Method
(iii) All spins or magnetic moments are orderly oriented as
Magnetization of objects in the shape of ring is obtained
shown in figure (b).
by induction method. Circumferential defects in such objects
are effectively detected by using this method.
In this method, test object is positioned on transformers
main core primary winding, so that it forms secondary winding
of one turn. Desired current, either direct or alternating current
Figure (b) is supplied to primary winding. Then current induced in the
(iv) When the temperature of the material is greater object leads to generation of magnetic field around the object
than its curie temperature then it gets converted into as shown in the figure. Thus, the object gets magnetized.
paramagnetic material. Half wave rectified current or alternating current is
(v) Examples used for materials possessing small values of retentivity and
direct current is employed for materials with high values of
Fe, Ni, Co, Fe2O3, MnO, Zn-ferrite, Ni-ferrite etc.
retentivity. Damage of object because of arcing does not occur
Q18. What the methods for magnetization of in this method.
materials? Discus about magnetic field Current
generated by an electric current.
Answer :
Methods for Magnetization of Materials Main
Core
Magnetization of materials is obtained either by using Primary
permanent magnet or with aid of magnetic field generated by Winding
an electric current. The later method of magnetization is further
classified as, Magnetic
field
1. Induction method Defect

2. Solenoid coil method Ring

shaped
3. Surge method Induced Current
part

4. Alternating current method Figure : Magnetization of Ring Shaped Components

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Unit-4 Magnetic Particle Test 4.7
Solenoid Coil Method
Solenoid coil method is mostly used for generating
longitudinal fields in materials of ferromagnetic type. In this
method, a solenoid coil is wound around a object to be tested. Flux lines
Coils wound around the frames of movable type are employed
for small objects and for large objects, coil is directly wound
on the objects.
Crack
When an electric current is allowed to pass through the Plate
solenoid coil, generation of magnetic field along the solenoid
axis occurs. Number of solenoid coil turns and magnitude of
current supplied are the variables, which effects the strength of Weld bead
the magnetic field produced. And field strength varies in direct Figure : Circular Magnetization Using Contact Probs
proportion with the product of number of turns and current
supplied. (b) Longitudinal Magnetization
Coil Current

Magnetic field Defect

Defect Current
Magnetic field
Figure : Magnetization with a Solenoid Coil Figure : Longitudinal Magnetization
Surge Method (c) Longitudinal Magnetization Using Wandering Cable
This method is employed to magnetize objects made
of ferromagnetic material to their saturation level. High Direction of Cable
magnitude of current is suddenly allowed to pass through the Cracks
test object for stort time period, then current is decreased to a defected
lower steady value. Thus, object gets magnetized. Component
Alternating Current Method
In this method, the component is magnetized by using
single phase alternating current of 50 to 60 cycle frequency.
It makes use of step up voltage type of transformer, which is
directly connected to commercial supply lines. This process
require very high current of about few thousands of amperes Figure : Longitudinal Magnetization Using Wandering Cable
and low voltage. AC power supply produces skin effect, which (d) Yoke Magnetization
is used to detect discontinuities at the surface.
Current
Q20. Illustrate different arrangements of magnetiza-
tion with neat sketches.
Answer :
The following arrangements are made according to the
requirements of magnetization. They are,
(a) Circular Magnetization
Magnetic field
Current Defect Plate

Weld bead
Crack
Flux lines

Figure : Circular Magnetization Figure : Yoke Magnetization

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Q21. Why and how demagnetization is carried out? Flow chart
April/May-17, Set-3, Q1(d)
The following is the flow chart describing the process
OR of magnetic particle test.
Why it is essential to demagnetize the Surface
materials? Enlist the techniques employed for cleaning

demagnetization, mentioning their application.

Answer : Model Paper-II, Q5(a)
Demagnetization
Demagnetization of component is necessary, as some
part of magnetism may be left with in the component after
completion of the test. Following factors influence the amount Circular
of magnetism remained in the component. magnetization

(i) Magnetic properties of the component

(ii) Direction of magnetization
Inspection
(iii) Magnetic field strength
(iv) Components geometry
Need for Demagnetization Longitudinal
magnetization
Presence of magnetism in the component is undesirable
due to following reasons.
(i) When the component reasons with residual magnetism Inspection
undergoes machining, the formed chips during the
process sticks to the component surface or to the
machining tool.
Demagnetization
(ii) When the component is subjected to arc welding, problem
in performing the welding is encountered because of a Accepted parts
phenomenon called arc blow, to residual magnetism. Inspection and
Evaluation of No Yes Paraffin
(iii) Residual magnetism affects proper function of rejected parts acceptance decision wash
navigational instruments, as they are very sensitive to
magnetic field.
Temporary
(iv) In machine components like ball bearing - races, gear protection
assemblies etc., presence of magnetized chips on them
affects its function during their operation.
Figure: Flow Chart for Magnetic Particle Test
(v) Finishing operations such as painting and plating are
also affected by residual magnetism. Q23. Write a note on methods of magnetic particle test.
Techniques Employed for Demagnetization Answer :
1. AC coil method : Employed for large components Methods of Magnetic Particle Test
possessing high hardness value. There are five methods used in magnetic particle test.
2. Reversing DC yoke and AC yoke : Employed for small 1. Dry Method
or big components involving localized demagnetization.
Dry method is usually adopted in rough surface
3. DC through current and AC through current : Employed examination. Examination of the surface is carried out by
for small components possessing medium hardness value. sprinkling fine particles of ferromagnetic materials after the
Q22. Write the sequence of steps to perform magnetic surface has been magnetized. The particles are sprinkled
particle test and illustrate magnetic particle test uniformly over the surface with the help of a spray gun or an
with the help of flow chart. atomizer. The particles are in the form of dry powder, with
Answer : different colours such as red, black or gray which are mainly
used to show variation in the indication. It is a very convenient
Steps Involved in Magnetic Particle Test
method for fieldwork.
1. Surface cleaning and demagnetizing the component.
2. Wet Method
2. Magnetizing the component
3. Sprinkling of magnetic particles on components surface. Wet method involves sprinkling (or spraying) of
suspended magnetic particles in kerosene or any liquid tank, on
4. Examining the surface of the component in order to
the magnetized test surface. When comapred with dry method,
detect the discontinuities.
magnetic particles of this method are fine i.e., are of small size.
5. Demagnetizing the component. This method is highly sensitive to defect detection, as the size
6. Temporary protection of the component. of magnetic particles used lies in between 10 and 50 μm.

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Unit-4 Magnetic Particle Test
3. Continuous Method
Continuous method involves application of magnetic
powder on the surface of the component in the presence of
magnetic field. The component should be magnetized to a level
such that, it should be able to generate the field of leakage with
high strength to enable both attracting and holding magnetic
particles in order to obtain meaningful indications.
4. Fluorescent Method
Fluorescent method is employed to detect the flaws (or
discontinuities) that are likely to be present in key ways, corners,
deep holes etc. In this method, fluorescent dye coated magnetic
particles are sprinkled on finely surface finished component.
And these component undergo inspection in the presence of
UV light of 3650 Aº wavelength.
5. Residual Method
Residual method is employed for testing the components
with high retentivity. The value of retentivity should be high
enough such that, the residual magnetism can cause a leakage
field at the flaws. This method involves, application of magnetic
field only until the component gets magnetized. Then after,
sprinkling of magnetic particles is carried out in the absence of
magnetic field. Thus, sensitivity of this method to detect surface
discontinuities, completely depends upon residual magnetism
in component.
Q24. Describe the equipment of magnetic particle
test.
Answer :
A magnetic particle test equipment is classified into two
types, based on the requirement.
They are,
(i) Movable or portable equipment
(ii) Fixed or stable equipment
This magnetic particle test (MPT) equipment mainly
consists of three mechanism or devices. They are as follows.
1. A device to magnetize a specimen
2. A device to apply particles that are magnetic in
nature
3. A device to demagnetize the specimen.
1. Magnetizing Device
Magnetizing device of fixed or stable type equipment is
attached to a table. This equipment makes use of transformer
as a source of electricity which produces 2000 to 20,000 amp
of electric current and 6-27 V of low voltage.
The devices like permanent magnet yokes, cables, coils,
prods,etc., are used as magnetizing devices in the movable
equipment. These are used to carryout the magnetic particle
test,at the places with hazardous detonatives and no source of
electricity. These movable equipments can be easily carried to
desired location to perform the test.
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4.9
But, the fixed or stable equipments cannot be used for
heavy, big and complex specimens. Thus, a multidirectional
magnetizing system of heavy duty DC type is used to generate
series of multiple magnetic fields, at a faster rate. By this system
the flaws present in various directions can be detected easily.
2. Application of Magnetic Particles
For the application of magnetic particles, a device which
comprises a hose with a nozzle which is operated by a lever and
a tank carrying a liquid with suspended magnetic particles is
employed. Hose with nozzle is connected to the tank and upon
activating the nozzle, magnetic particle application is obtained.
To stop the settling of these magnetic particles, the fluid is
disturbed either by pump or by hand operation.
3. Demagnetizing Device
The demagnetizing device is implemented with
switches that produce current in reverse direction to obtain
demagnetization of a component.
Q25. Explain demagnetization in Magnetic particle
testing? How do you ensure it? What are
portable Equipments used in MPT?
Answer : [April/May-17, Set-3, Q5 | Model Paper-III, Q5(a)]
Demagnetization in Magnetic Particle Testing
There are two requirements of demagnetization. They are,
1. Successive reversal of polarity.
2. Reduction in field strength or flux density.
Demagnetization of Components is obtained by
following methods
1. AC Coil Method
This method makes use of coil through which AC is
passing. During the process, component is pulled out and away
from AC coil. This method is employed for large components
possessing high hardness value.
2. Direct or Alternating Through Current Method
In this method DC field is applied in reverse direction
and field is decreased in stages to zero or AC is applied and is
reduced gradually to zero. Among DC and AC methods, AC is
preferred as it possess inherent reversing nature. This method
is used for components possessing medium hardness value.
3. Reversing DC Yoke or AC Yoke Method
Demagnetization can be obtained by employing
either reversing DC yoke or AC yoke. During the process.
Yoke contacts are placed on the surface of component to be
demagnetized and yoke is moved so that it contacts makes
circular patterns around area to be demagnetized. Then,
yoke is pulled away slowly while current being applied. This
method is used for small or big components involving localized
demagnetization.
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4.10 Non-destructive evaluation [JNTU-kakinada]
4. Heating Above Curie Temperature Method
Temperature at which materials lose their permanent
magnetic properties is called. Curie temperature. This method
involves components are heated above their curie temperature
followed cooling to room temperature. Due to this, complete
removal of residual field occurs as magnetic domains of each
grain gets oriented in a random way. This is the only method
by which complete demagnetization is obtained. But there
exists is difficulty in heating the components above their curie
temperature. Therefore, above mentioned methods are used by
which removal of residual field to considerable level is obtained.
Ensuring Demagnetization
Level of residual field in the component is measured by
using field meter. After demagnetization, magnetic field in the
component is checked by field meter. As per industrial standards
magnetic field in the component should be less than 0.0003 Tesla
or 3 Gauss.
Portable Equipments Used in MPT
For answer refer Unit-IV, Q24.
Q26. Explain the procedure of magnetic particle test.
OR
Explain the magnetic particle inspection test in
detail.
Answer : April-18, Set-2, Q5(a)
The main purpose of a magnetic particle test is to evaluate
the surface and subsurface defects of specimens that are obtained
from manufacturing processes and by service limits. Cracks,
laps, folds, inclusions, pores, shrinkages, seams etc are the
surface and subsurface faults that are required to be detected
by a magnetic particle test.
Procedure
In order to obtain the above objective, following are the
basic steps involved in a magnetic particle test.
They are
1. Surface cleaning
2. Demagnetization
3. Magnetization
4. Magnetic particle application
5. Inspection or Evaluation
1. Surface Preparation
Surface preparation involves both scale removal and
degreasing
(a) Scale Removal
The surface of a test specimen should be prepared well
for necessary operations in a magnetic particle test. At
first, the test specimen with scaled and rough surfaces
is allowed to under go surface treatment by using
compound solution containing chemical like sulphuric
acid (10%), Hydrogen fluoride (5%) or Hydro Chloric
acid (10%) and stanic solution (2gm/lit) . By this
mixtures reaction the surface scales may get removed
or loosened. Then the surface are washed by using cool
water. To obtain complete removal of the scales, the
water washed surfaces should be hot blasted.
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In addition to scale, loose rust present on the surface
should be removed. In case of component with painted
surface, localised removal of the painting should be
performed in order to obtain sufficient area of contact
for flow of the current.
(b) Degreasing
Scale removal process is followed by degreasing
process, in which corrosion residue, dirt and the organic
contaninants like grease, oil etc., are removed. But on
the machined surfaces, surface treatment by acid solution
and shot blasting are not imposed.
2. Initial Demagnetization
Demagnetization is carried out to decrease the residual
magnetism that is present in a specimen. Although this
process is is not compulsory, it can be preferred based
on the usage. AC coil method, AC yoke, AC through
current etc., are the methods that are used to demagnetize
a specimen.
3. Magnetization
Then the specimen can be magnetized with the help of a
permanent magnet or by other methods in which electric
current used to produced magnetic field.
4. Application of Magnetic Particles
Particles of suitable magnetic material either in the form
of fine dry particulates or particles suspended in a liquid
are sprinkled on magnetized surface. Particle application
is carried out with help of spray guns or atomizers.
5. Inspection or Evaluation
After completion of magnetization and magnetic particle
application the inspection of the specimen must be done
under the light. The obtained markings or indications
are to be examined and evaluated based on certain
acceptance standards. The rejected parts are evaluated
again and the accepted specimen should be cleaned well,
demagnetized and protected temporarily.
Q27. What are the pre-requisties for a material to be
tested through magnetic particle NDT?
Answer : [April/May-19, Set-1, Q5(a) | Model Paper-IV, Q5(a)]
Prerequisites for a Material to be Tested Through Magnetic
Particle Test
1. Prior to the test, components are required to be
checked for material type. Only components made of
ferromagnetic material should be choosen for the test.
2. Component material in which flaws likely to be occur
at the surface should be selected for the test.
3. Component material shape is required to be considered
before the test. Since, for large and irregular shapes, the
flow of the flux is non uniform and insufficient.
4. Prerequisites prior to the actual magentization of the
component includes,
(i) Surface Preparation:
For answer refer Unit-IV, Q26, Topic: Surface
Preparation.
(ii) Initial Demagentization:
For answer refer Unit-IV, Q26, Topic: Initial
Demagnetization.
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Unit-4 Magnetic Particle Test 4.11
Q28. What is the purpose of standardization of Answer : [April-18, Set-1, Q5(b) | Model Paper-I, Q5(b)]
magnetic particle test system and explain how Calibration of Magnetic Particle Test Procedure
it is calibrated.
April/May-19, Set-2, Q5(b)
Test procedure is calibrated to ensure standardization of
test system.
OR
Discuss in detail about the standardization and For answer refer Unit-IV, Q28.
calibration of Magnetic particle test. Diameter and heights of holes on calibration block and
Answer : April-18, Set-3, Q5(b) frequency of magnetic field applied to each hole is as follows,

Standardization of Magnetic Particle Test Frequency in Height in inch Diameter in inch

Hetz
Standardization of the system for magnetic particle
test is carried out in order to make sure that the equipment 1 0.07 0.07
and its accessories operate under proper conditions which are 2 0.14 0.07
acceptable and with consistent sensitivity. Hence, Calibration 3 0.21 0.07
of the system is done to detect even the smallest discontinuity 4 0.28 0.07
with more confidence. During experimentation (or usage), a
5 0.35 0.07
test piece with artificial defects is considered and the variables
involved in the system are enhanced, to clearly indicate these 6 0.42 0.07
discontinuities during practical examination. Usually, standard 7 0.49 0.07
test blocks with artificial defects are used in magnetic particle 8 0.56 0.07
test system. Blocks are of ring shaped and manufactured with
9 0.63 0.07
tool steel. Each block is provided with 12 similar diameter holes,
drilled at different heights. 10 0.7 0.07
11 0.77 0.07
The test blocks are cleaned, demagnetized and checked
for any presence of residual magnetism after completion of an 12 0.84 0.07
individual shift of work. Current is supplied and corresponding Basic Properties of Specimen for MPI
indications at each hole are observed . The maximum value of
magnetizing current at which acceptable indications are shown 1. Specimen should possess ferromagnetism.
is noted for an appropriate magnetic unit. Then the obtained 2. Should readily demagnetized.
values are employed at regular intervals for proper functioning
Q30. How can you interpret and evaluate the defects
of the test system.
in magnetic particle testing?
The following are the reasons for obtaining unsatisfactory April/May-19, Set-3, Q5(b)
indications.
OR
1. Amount of magnetic particles usage is less than below Interpretation and evaluations procedure for
optimum value magnetic particle test.
2. Error in ammeter readings [April-18, Set-2, Q5(b) | Model Paper-II, Q5(b)]

3. Improper functioning of the system. OR

D
How the component is examined in magnetic
particle test. Write few defects and their
observed indications.
1''
14φ 5'' f Answer :
1. Examination or Evaluation in Magnetic Particle Test
A component or a specimen surface is examined after
magnetizing the component and applying the magnetic
7/8''
particles or substances on test surface. Usually examina-
Figure tion is carried out under a light source. The type of light
used, depends on type of magnetic particles applied i.e.,
Calibration of Magnetic Particle Test non-fluorescent type and fluorescent type particles.
For answer refer Unit-IV, Q29. (i) For Non-Fluorescent Particles
Q29. How the magnetic particle test procedure is If the magetic particles that are on a surface are non-
calibrated? What are the basic properties fluorescent, then their evaluation and inspection can be
specimen to qualify for magnetic particle test? done either under daylight or artificial light.

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4.12 Non-destructive evaluation [JNTU-kakinada]
In daylight, with 500 lux intensity level, a glass that en-
ables the magnified view of a surface is used to examine
the test surface.
If the component is examined under an artificial light, a
fluorescent tube of 80 W or a lamp with tungsten filament
having 100 W are used to obtain desired illumination.
(ii) For Fluorescent Particles
The fluorescent magnetic particles are examined under
the black light. Because these particles are coated with
dyes which glow only when they are subjected to black
light exposure.
2. Defects
The flaws present on the surface of the specimen should
be evaluated in a proper manner. The examiners should
be able to differentiate between the false indications
and flaw indications. Few defects and their respective
observed indications are explained below.
(i) Non metallic Inclusions
Cause: At the time of melting of a metal, if the metal is
improperly cleaned, it will cause non metallic inclusion.
Indication: The appearance of the faults are in the
form of stringers that are either passing along the fibers
(in forging) and along the component axis. Based on the
severity of flaws, sharpness of indication varies.
(ii) Seams
Cause: If a component with defects such as surface
tears, laps etc., undergoes rolling, elongation of these
discontinuities occurs and results in seams.
Indication: A definite indication is shown when there
is only a single seam which is deep in the surface. Pres-
ence of a group of small seams leads to an inaccurate
indication.
(iii) Forging Laps
Cause: These flaws are caused during forging, when
the metals folds are compressed together. These laps
are contours of irregular shapes and are observed only
at direction normal to the metal flow.
Indication: There are no definite indications for this
type of flaws as the leakage of flux is weak.
(iv) Hot Tears and Thermal Cracking
Cause: These types of flaws are occured at the casting
level or while heat treatment of the specimen. These tears
in the surface are caused due to the non-uniform cooling
of the surface.
Indication: The formation of surface cracks shows a
sharp indication.
(v) Flakes
Cause: When the dissolved gases are released, flakes
are formed on the surfaces that are usually machined.
Indication: Flakes provides a clear indication.
(vi) Weld Cracks and Defects
Cause: These faults are due to improper selection of
process or corresponding process parameters.
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Indication: Large metal cracks and cracks in longitudinal
or transverse direction are discovered easily as they give
clear indications. Undercuts, porosity, slag inclusions,
lack of fusion etc., are the weld defects which shows
frizzy indications.
(vii) Grinding Cracks
Cause: This cracks are found on a surface which has
undergone very fine finishing and causes due to improper
choice of grinding parameters.
Indication: The cracks are formed as a group and they
shows definite indications.
(viii) Fatigue Defects
Cause: The fatigue defects are in the form of cracks,
which are formed on a component that has been in
work or utility. Fatigue crack is a brittle fracture that is
produced on a component under the cyclic loads.
Indication: These defects provides definite indications.
Sharp indications are exposed on surface cracks that are
in transverse direction with respect to the direction of
local stress.
(ix) Laminations
Cause: If there is a separation of layers or any non-
metallic film present in the plates, then laminations are
formed, which are parallel to surface of the specimen.
Indication: The sides and cut portions of the plate are
the places where indications will appear.
(x) Piping
Cause: The magnetic particle test, in piping only dis-
plays the internal defects that are present at the end of
a component.
Indication: The cross-section of piping is shown at the
end of the component as an indication.
(xi) Heat Treatment Cracks
Cause: The presence of sharp corners, fillets, holes, slots
and seams in a component, behave as stress boosters at
the time of quenching and leads to heat treatment cracks.
Indication: Strong indications are displayed as the
cracks are deep and sharp.
Q31. What are the advantages and disadvantages of
magnetic particle test.
Answer : Model Paper-III, Q5(b)
Advantages of Magnetic Particle test
The advantages of magnetic particle test (MPT) when
compared to other NDT methods of choice are given
below
1. The Magnetic particle test is a suitable and a reliable
method to detect the cracks present on a surface which
are very thin and less deep.
2. This testing method is simple and very easy to perform.
3. The markings or indications obtained on the surface of
the specimen closely resembles the flaw shape. Thus,
the indications can be interpreted easily.
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Unit-4 Magnetic Particle Test 4.13
4. Specimens of any shape (or) size can be tested.
5. After the application of magnetic particles, indications that are formed on the surface are very quick i.e., less than two
seconds.
6. The cost of it’s equipment is very less.
7. The surfaces with thin paint coats and platings can be tested by this method.
8. Sensitivity of MPT wont be affected by the presence of foreign particles in the flaws.
9. The operators only need a small amount of training, because the process is simpler than other NDT methods.
10. This test method can also be automated.
11. The testing can be done at any level of production.
12. These tests can be carried out easily in field work with the usage of portable magnetic particle equipment
13. Processing or developing time is eliminated.
Disadvantages of Magnetic Particle test
Disadvantages of Magnetic particle test are compared with other NDT methods and are given below.
1. This test can only be performed on components made of ferromagnetic material.
2. The flaws which are nearer and present at the surface are only detected.
3. The process of demagnetization should be carried out after almost every inspection. This is a time taking process.
4. For large and irregular shapes, the flow of the flux is non uniform and insufficient.
5. During the test, the specimens may get burnt due to arching and localized heating.
6. Each and every part or specimen is to be handled individually during magnetization.
7. For large and heavy components huge amount of electricity is required.
Q32. What are the applications, effective application and limit of detection of magnetic particle inspection?
Answer :
Applications
Magnetic particle inspection (MPI) is widely utilised for detection and evaluation of the discontinuities that are likely to be
present at surface and sub-surface of the components made of ferromagnetic materials, at the time of manufacturing, processing
and service of components.
MPI is utilised in industries such as shipping, railways, nuclear, aeronautical, food, paper etc.
The two factors of MPI which has a serious effect on effectiveness and limitations in detection of defects are accuracy of
testing method and surface finish of test component.
Effective Application
Effective application of MPI is to inspect products like castings, weldments, ground and machined components. And to
inspect processes such as forging, assemblies and all ferromagnetic materials.
The following defects are detected in above given products and processes. The respective defects are, surface and sub-
surface cracks, heat treatment cracks, grinding cracks, porosity, fatigue cracks, laps and folds and stringer type non metallic
inclusions.
Limit of Detection
The values for limitation of detection of above mentioned defects in corresponding product or process is given as follows,
1. At laboratory level, it is limited to detect the flaws of 0.5 mm
2. At production level, detection is limited to the range of 2 mm
3. At service level, defect detection is limited to the range of 2 mm
But it is possible to enhance the limits of detection, by using improved techniques and facilities.

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4.14 Non-destructive evaluation [JNTU-kakinada]
Q33. Compare the magnetic particle and liquid penetrant inspection methods.
Answer : April-18, Set-4, Q4(a)
Differences between magnetic particle and liquid penetrant inspection methods are,
Parameter Magnetic Particle Test Liquid Penetrant Test
Principle Test principle involves magnetization of a In this testing method, a liquid penetrant is applied on the
homogeneous component of ferromagnetic parts to be tested, to identify surface defect such as cracks,
type by positioning the component in a porosity, folds, slag inclusions etc., present in the non-po-
magnetic field from one pole to the other rous materials. The liquid penetrant has the ability to fill
in the material. The magnetic lines of force the defects open to the surface. During the test, penetrant
gets deflected, if any discontinuity exists in enters the flaws, then the excess liquid is washed and a
the surface or subsurface of the component, developer is applied on the surface. Upon the application,
the deflected magnetic field forms a leakage the flaws are shown on the surface of the developer. By
field. this, the flaws on various materials such as stainless steel,
brass, aluminium, magnesium and other non-ferrous metal
can be detected.
Defects detected Surface and subsurface defects like cracks, Defects which are open to the surface such as cracks, po-
seams, inclusions etc. rosity, through wall leaks etc.
Detection basis Ultrasonic waves Liquid penetrant
Merits i. Surfaces with thin paint coats and platings i. No need of power source.
can be tested by this method. ii. Specimen surface can be completely inspected.
ii. Better portability.
Demerits i. Suitable only for ferromagnetic materials. i. Requires clean test surface.
ii. Component is needed to be demagnetized ii. Not suitable for internal defects.
after the test.
Q34. Distinguish ultrasonic and magnetic particle tests.
Answer : [April-18, Set-1, Q5(a) | Model Paper-IV, Q5(b)
Differences between ultrasonic test and magnetic particle test are,
Parameter Ultrasonic Test Magnetic Particle Test
Principle Test principle involves allowing the high Test principle involves magnetization of a homogene-
frequency sound waves that is ultrasonic ous component of ferromagnetic type by positioning the
waves to pass through the test component. If component in a magnetic field from one pole to the other
the waves encounters with any discontinuity in the material. The magnetic lines of force gets deflect-
in their way, they gets reflected back. Reflec- ed, if any discontinuity exists in the surface or subsurface
tion of waves is observed on the cathode of the component, the deflected magnetic field forms a
ray oscilloscope screen so as to identify the leakage field.
discontinuity.
Defects detected Internal cracks, porosity, inclusions, shrink- Surface and subsurface defects like cracks, seams, inclu-
age cavities etc. sions etc.
Detection basis Magnetic effect Ultrasonic waves
Merits i. Reliable i. Surfaces with thin paint coats and platings can be
ii. Low cost tested by this method.
iii. High operation speed ii. Better portability.
Demerits i. Test surface should be smooth. i. Suitable only for ferromagnetic materials.
ii. Results of complex components are messy. ii. Component is needed to be demagnetized after the
test.
Q35. Explain the principle of magnetic particle testing (MPT). What are its advantages and limitations?
Answer : April/May-17, Set-1, Q5(a)
Principle of Magnetic Particle Testing
For answer refer Unit-IV, Q3.
Advantages and Limitations
For answer refer Unit-IV, Q31.

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Unit-4 Magnetic Particle Test 4.15

Q36. What are the defects that are faced after magnetic particle testing?
Answer : April/May-17, Set-1, Q5(b)

For answer refer Unit-IV, Q30, Topic: Defects.

Q37. Which materials are subjected to magnetic particle testing? Discuss them briefly.
Answer : April/May-17, Set-2, Q5(a)

Materials For Magnetic Particle Testing

For answer refer Unit-IV, Q11.
Ferromagnetic Materials
For answer refer Unit-IV, Q17, Topic: Ferromagnetic Materials
Q38. Name different methods of magnetization. Discuss briefly any one.
Answer : April/May-17, Set-2, Q5(b)

Methods of Magnetization
For answer refer Unit-IV, Q18, Topic: Methods for Magnetization of Materials.
Induction Method
For answer refer Unit-IV, Q19, Topic: Induction Method.
Q39. Discuss magnetic particle testing with reference to
(i) Principle
(ii) Method of Magnetization
(iii) Limitations.
Answer : April/May-17, Set-4, Q5

(i) Principle
For answer refer Unit-IV, Q3.
(ii) Method of Magnetization
For answer refer Unit-IV, Q18.
(iii) Limitations
For answer refer Unit-IV, Q31, Disadvantages of Magnetic Particle Test.
Q40. Draw the schematic diagram of Magnetic particle test equipment with a sketch? Explain.
Answer : April-18, Set-3, Q5(a)

Magnetic Particle Test Equipment

For answer refer Unit-IV, Q24.
1. Magnetizing Device
For answer refer Unit-IV, Q19 and Q20, Only figure.
2. Application of Magnetic Particles
For answer refer Unit-IV, Q3, Only figure.
Q41. Explain various methods of magnetization and demagnetization commonly practiced in non destructive
testing procedure.
Answer : April/May-19, Set-1, Q5(b)

Methods of Magnetization
For answer refer Unit-IV, Q19.
Methods of Demagnetization
For answer refer Unit-IV, Q25, Topic: Demagnetization in Magnetic Particle Test.

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4.16 Non-destructive evaluation [JNTU-kakinada]
Q42. Explain the procedure of magnetic particle testing and state its limitations.
Answer : April/May-19, Set-2, Q5(a)

Procedure of Magnetic Particle Testing

For answer refer Unit-IV, Q26.
Limitations of Magnetic Particle Testing
For answer refer Unit-IV, Q31, Topic: Disadvantages of Magnetic Particle Test.
Q43. Explain the procedure of magnetic particle testing and state its limitations.
Answer : April/May-19, Set-3, Q5(a)

Principle of Magnetic Particle Testing

For answer refer Unit-IV, Q3.
Applications
For answer refer Unit-IV, Q32, Topic: Applications.
Limitations
For answer refer Unit-IV, Q31, Topic: Disadvantages of Magnetic Particle Test.
Q44. Briefly explain the principle and flow chart of magnetic particle test.
Answer : April/May-19, Set-4, Q5(a)

Principle of Magnetic Particle Test

For answer refer Unit-IV, Q3.
Flow Chart of Magnetic Particle Test
For answer refer Unit-IV, Q22, Topic: Flow Chart.
Q45. Name different methods of magnetization. Why and how demagnetization is carried out?
Answer : April/May-19, Set-4, Q5(b)

Methods of Magnetization
For answer refer Unit-IV, Q19.
Need for Demagnetization
For answer refer Unit-IV, Q21, Topic: Need for Demagnetization.
Methods of Demagnetization
For answer refer Unit-IV, Q25, TOpic: Demognetization in Magnetic Particle Testing.

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