Magnetic particle testing This method is applicable to ferromagnetic materials, which can be easily magnetised.

This method involves disturbance of magnetic flux lines (leakage flux) and detection of the same. If the method, employs finely divided ferromagnetic particles for the detection of leakage flux, then the method is known as magnetic particle testing. If Hall probes or other sensors s are employed, then the method is known Magnetic Flux Leakage method. (MFL) Surface preparation is not very rigorous as in the case of PT. Painted surfaces do not pose much problems (upto 40 micrometer). Platings also do

Magnetic and ferromagnetic materials

Magnetic materials have poles due to which the material possesses magntism. The origin of poles or magnetism is attributed to the material having large number of magnetic domains (tiny magnets) inside the material and all the domains are aligned leading to definite poles. In the case of ferromagnetic materials (without induction) there is no net magnetism, even though they also possess large number of magnetic domains. The difference is that the domains are randomly oriented here, with the result there is no net magnetism.

Principle of Magnetic particle testing

(MT)
When a material (ferromagnetic material) is magnetised, magnetic lines of force are set up in the material. In presence of defects that are oriented suitably, the lines of force inside the material are disturbed due to permeability variations, thereby setting up of local leakage flux. This local leakage flux can be easily detected by sprinkling ferromagnetic particles on the surface which crowd near the leakage, thereby providing an indication of the discontinuity. ( leakage flux can also be detected by compass needle and Hall probes which are not normally used. MFL method) The method is applicable only to ferromagnetic materials. Unlike PT subsurface defects also can be detected. The material is brought back to the original condition by a simple method namely demagnetisation.

Comparison of AC and DC current

AC has the limitation of skin effect, meaning the currrent and hence magnetisation is confined to the surface. DC is cappable penetration to some extent.

CURRENT
AC
TH

D E P T H

HWDC

TYPE OF CURRENT * STRENGTH OF CURRENT * PERMEABILITY ( )

AC is still used for detecting surface defects because the sensitivity of the technique is better. The higher sensitivity can be explained in the following way. MT depends upon 1. Setting up of leakage flux and 2. Detection of leakage flux by crowding up of ferromagnetic material While it can be assumed the factor 1 is nearly same in both the cases, detection

Methods of magnetisation : Circular and longitudinal

Method Circular Methods of introduction 1. Head-shot 2. Central conductor 3. Prods 1.Permanent Yokes 2. Electromagnetic yokes 3.a. Coils or solenoids b. wire raps

Longitudinal

Entire weld testing is carried out by prod and yoke methods of magnetisation as these are most convenient for weld inspection

Longitudinal crack can be detected

Crack at 45 can be detected

Current Transverse cracks cannot be detected

Current

Magnetic Field

Circular magnetisation
Magnetizing Current Magnetic Lines Of Force 45 Crack can be Detected

Longitudinal crack Cannot be detected

Transverse crack Can be detected

Longitudinal and circular magnetisation magnetisation

Longitudinal and circular magnetisation

Longitudinal and circular magnetisation methods

Application of ferromagnetic particles

Inspection materials The properties required of the ferromagnetic particles 1. Magnetic properties 2. Size and shape 3. Visibility- (contrast factor) - Visible -Fluorescent 4. Others (nontaxic)

1.Magnetic properties- High permeability and

low retentivity are the two required properties of the dry and wet powder particles High permeability - to get attracted be very weak leakage field Low retentivity - to decrease tendency to adhere to the surface so that they can move easily towards field - to reduce objectionable background 2. Shape Spherical shaped good for mobility and not good for getting magnetised Long slender jagged - good for magnetisation and not good for mobility

3. Size large heavy particles - may not be able to move under the magnetic field extremely fine - may adhere to the surface even withoutfield Very fine particles - is capable of attracted by weak fields ( wet method finer particles 40 to 50 microns finer particles also to keep the powder in Suspension dry method 5 - 100 microns- all sizes: reason ) 4. Visibility and Contrast: Visibility is better when contrast factor is high. Contrast factor is ratio of the light emitted by the surface of the object and the magnetic indication C.F- for visible dye around 1:10

Inspection and evaluation

Colour and fluorescence colours
Visible light spectrum - 380 nm to 700 nm or(Vto R ) 3800 Ao to 7000 Ao Ultravioletspectrum- 200-380nm or 2000 -3800 Ao Black light spectrum - 3200 - 3800 Ao or320 -400 nm

(with peak at 365 nm) Black light from UV : by use of filters. The filters that are used, filters out visible light above 380 nm and UV below 320 nm. The filters that are used, give black light with maximum peak intensity at 365 nm. Sometimes, not very correctly, black light is taken to give 365 nm light. Fluorescent inspection: Darkended area and black light Dark room adaptation time 5mts 1 mt

INDICATING MEDIUM: FEERROMAGNETIC POWDER. WET METHOD:

FINELY DIVIDED FERROMAGNETIC POWDER SUSPENDED IN LIQUID VEHICLE. POWDERS MAY FLUORESCE UNDER BLACK LIGHT - - FLUORESCENT METHOD.

* NON-FLUORESCENT POWDER. * VEHICLES ARE WATER OR KEROSENE.

ADVANTAGES:

1. COVERS ENTIRE SURFACE 2. HIGHLY SUITABLE FOR FINE SHALLOW DISCONTINUITIES. DISADVANTAGES:1. NOT SUITABLE FOR SUBSURFACE DISCONTINITIES.
POWDER SIZE FOR WET MAGNETIC PARTICLE TESTING. UPTO 15 MICRONS - FOR FLUORESCENT 15 TO 30 MICRONS - FOR NON FLUORESCENT CONCENTRATION: 0.1 TO 0.5 ml / 100 ml FLUORESCENT 0.75 TO 1.25 ml / 100 ml NON-FLUORESCENT

DRY METHOD
POWDER REQUIREMENTS SIZE : 30 TO 60 MICRONS SHAPE : BOTH SPHERICAL AND ELONGATED COLOUR: GRAY, YELLOW,RED,BLACK SHALL BE CONTARSTING COLOUR WITH THE BACKGROUND. PERMEABILITY() : HIGH() BEST FOR SUBSURFACE DISCONTINUITIES.

Demagnetisation: All ferromagnetic materials will retain a residual field to some degree, after having magnetised. Reasons for demagnetisation 1. The part will be used in an area where a residual magnetic field will interfere with the operation of instruments that are sensitive to magnetic fields. 2. During subsequent machining, chips may adhere to the surface being machined and adversely affect surface finish, dimensions and tool life. 3. During cleaning operations, chips may adhere to the surface and interfere with subsequent operations such as painting or plating. 4. Abrasive particles may be attracted to magnetized parts such as bearing surfaces, bearing raceways, or gear teeth, resulting in abrasion or galling, or may obstruct oil holes and grooves. 5. During some electric arc-welding operations,

Methods of demagnetisation Remnant magnetism need be brought to very low level 1.Heating to above Curie temperature 2.Mechanical vibrations 3.Applying reverse current equal coercive force Practically not possible or difficult
Demagnetisation method Subjecting the part to current continually reversing its direction and at the same time gradually decreasing its strength to zero. The magnetising force is to be high enough at the start to overcome the coercive force and to reverse the residual magnetic field initially in the part. Also the decrements between the sucessive reductions in the current must be small enough so that the reverse magnetising force will be able on each cycle to reverse the field remaining in the part

DEMAGNETIZATION
THE PROCESS OF REMOVING THE RESIDUAL FIELD, THERE BY BRINGING BACK THE JOB TO UNMAGNETIZED CONDITION.

KEEP THE OBJECTS LONG AXIS IN EAST-WEST DIRECTION.

MT of welds
To cover all orientations of discontinuities, magnetisation is introduced in two directions (longitudinal and circular or longitudinal in two mutually perpendicular directions (Yoke) circular in two mutually perpendicaular direction (prods) In the case of welds, prod method of magnetisation and yoke method of magnetisation are employed. Angle is changed to cover all oriented discontinuities Highly suited to test thin welds for surface and subsurface cracks, lack of penetration and incomplete fusion. Undercut can also be detected. Less sensitive to porosity While surface preparation with respect to scales and paint coatings is not as stringent as in penetrant testing, rough surfaces may lead to false indications. .
AC for surface and DC for subsurface discontinuities Better than UT to detect surface tight cracks

Magnetic particle testing of welds

Prods and yokes are generally used in entire magntic particle testing because of convenience. Prod method of magnetisation:

Features of prod and current requirements

Prod contacts: (ASM Handbook) Large and massive parts too bulky to be put into units having clamping contacts or solenoids/coils Advantages Portability and convenient for field use Sensitivity for subsurface defects especially in conjunction with HWRC, Dry powder and continuous method. Limitations Suitable fields exist only between and near the prod contacts. Normally 12 (8) Local heating and burning of the parts Interference effects at the prod contact points

Current requirements
Optimum current high excessive background-/banding low not enough field strength-no indication

90-115 A/in-for thickness and less 100-125 A/in for and above Width of magnetising field 1/4th the prod spacing on each side

Prod placement ( angle) and type of defects that can be detected

Parallel to the weld axislongitudinal defects Perpendicular to the weld- transverse This is different from the placing of yoke

Some more points on prod magnetisation

Detection of subsurface discontinuities like such as slag inclusion,voids,and inadequate joint penetration at the root is best accomplished by prods using HWRC and dry powder. For applications in which the holding of prods is difficult or tiring, magnetic clamps, or leeches, that magnetically hold the prods to the work are Nonrelevant indication in T Joints for which complete penetration is not specified AC can indicate whether it is open root or not

Yoke magnetisation
Yokes are often used for weld inspection using AC or DC or HWRC for surface Discontinuities.

The positioning of yoke with respect to discontinuity is different from corresponding positioning of prod

Parallel to weld axis-Transverse flaw Perpendicular to weld axis longitudinal flaw

Subsurface discontinuities in butt welds using yoke

In thin plates, the detectability of subsurface defects can be improved by positioning the dc yoke opposite to the weld bead Magnetic particles are applied along the weld bead. Improvement due to extraneous leakage flux that emanates from the yoke pole pieces