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
not that much interfere with the testing. Another
advantage of the method is that the method can
be used for detection of subsurface
discontinuities unlike PT which is confined to
surface discontinuites.
 
 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.
Ferromagnetic materials become magnetised
by the alignment of magnetic domains which
can be accomplished by passage of electric
current or by interacting with permanent
magnetic material.
 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 ferro-
magnetic materials. Unlike PT subsurface
defects also can be detected. The material is
brought back to the original condition by a
simple method namely demagnetisation.
 Flux distribution in presence and absence of
defect

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
not that much interfere with the testing.
 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
 
HWDC
 
 
E
P
T
H
 

 
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 Methods of introduction

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

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 Crack at 45 can
detected be detected

Current
Current
Transverse cracks cannot be
detected
Magnetic Field

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

Longitudinal crack Transverse crack

Cannot be detected 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
multifaceted rugged type or mixture of long
Slender particles and globular particles
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
fluorescent dye around 1:100
Dry powder - silvery grey and pigments are used
to colour them red and black and yellow
Fluorescent dye
Wet powder – black or red powder
 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:
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.
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,
strong residual magnetic fields may deflect arc
away from the point at which it should be applied. 
6. A residual magnetic field in a part may interfere
with remagnetization of the part at a field intensity
too low to overcome the remanent field in the part.
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
from the last reversal previous reversal.
Applicability of demagnetising methods:
Applicability of demagnetizing methods, are based on part
size, metal hardness, and production rate, is given in
Table 2
 
 DEMAGNETIZATION
THE PROCESS OF REMOVING THE RESIDUAL FIELD,
THERE BY BRINGING BACK THE JOB TO UNMAGNETIZED
CONDITION.

KEEP THE OBJECT’S

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 Limitations
Portability and Suitable fields exist only
convenient for field use between and near the prod
Sensitivity for subsurface contacts. Normally 12 ”
defects especially in (8”)
conjunction with HWRC, Local heating and burning
Dry powder and of the parts
continuous method. 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 ¾” and less
100-125 A/in for ¾” 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 axis–longitudinal 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