Exam 4 Rev.00 Magnetic Particle Testing Nov.

2010

Name: ………………………………………………………. Date: ……………………………..

Each question has only one correct answer!

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

1. In the continuous method, ink should ideally be applied:

(a) Before magnetisation

(b) During magnetisation
(c) After magnetisation
(d) Immediately before and during magnetisation

2. Magnetic flux indicators will not give a reliable indication of flux density if used:

(a) With magnetic ink

(b) With dry powder
(c) With magnetic flow techniques (especially DC)
(d) With current flow techniques

3. Which of the following is a current flow inspection technique?

(a) Prods
(b) Rigid coil
(c) Alternating current yoke
(d) Flexible cable

4. Which of the following is not a stage of a magnetic particle inspection?

(a) Demagnetisation
(b) Application of detecting medium
(c) Protection against corrosion
(d) All of the above are required

5. Compared with the magnetic particles used in magnetic inks those used in dry
powder detection media are:

(a) The same size

(b) Smaller
(c) Larger
(d) Lower density

6. According to BS EN 9934-1, painted surfaces can be tested if:

(a) Never
(b) The paint is below 50 m thick, non-ferromagnetic, continuous and tightly
adhered
(c) The paint is electrically conducting
(d) (b) but the sensitivity must be verified

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

7. In accordance with BS EN 9934-2 the distribution of particle sizes in a magnetic ink

would typically be in the range:

(a) 200 to 750 m

(b) 100 to 500 m
(c) 1 to 50 m
(d) 0.1 to 200 m

8. MPI will reveal and classify indications as

(a) Crack like

(b) Non-relevant
(c) Rounded
(d) All of the above

9. Viewing conditions for non-fluorescent techniques in accordance with BS EN 9934-

1 shall be:

(a) A minimum of 200 lux of monochromatic light

(b) A minimum of 200 lux of white light
(c) A minimum of 500 lux of monochromatic light
(d) A minimum of 500 lux of white light

10. Viewing conditions for fluorescent techniques in accordance with

BS EN 9934-1 shall be:

(a) Maximum ambient white light 20 lux, minimum black light at the test
surface 800 W/cm2, photochromatic spectacles shall be worn.
(b) Maximum ambient white light 20 lux, minimum black light at the test
surface 1000 W/cm2, photochromatic spectacles shall not be worn
(c) Maximum ambient white light 20 lux, minimum black light at the test
surface 800 W/cm2, photochromatic spectacles shall not be worn
(d) Maximum ambient white light 10 lux, minimum black light at the test
surface 1000 mW/cm2, photochromatic spectacles shall not be worn

11. In accordance with BS EN 9934-1 the maximum prod spacing used in the prod
technique should normally be:

(a) 300 mm
(b) 100 mm
(c) 150 mm
(d) 200 mm

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

12. In accordance with BS EN 9934-1 which type of prods is not acceptable?

(a) Steel prods

(b) Galvanised prods
(c) Aluminium prods
(d) None of the above

13. Portable flux indicators:

(a) Give an accurate measurement of field and flux

(b) Should only be used for confirmation of flux and field levels
(c) Give only a rough guide to flux and field levels
(d) Both (b) and (c) are correct

14. The axial current flow method is not recommended for detecting:

(a) Linear flaws lying parallel to the direction of current flow

(b) Linear flaws lying perpendicular to the direction of current flow
(c) Forging seams
(d) None of the above

15. The British standard for magnetic inks is

(a) BS 6072
(b) BS EN 9934-2
(c) BS 4069
(d) BS EN 9934-3

16. In accordance with BS EN 9934-1 the minimum flux density at the component
surface shall be:

(a) 0.72 Tesla

(b) 1.0 Tesla
(c) 2000 amps/metre
(d) 2 amps /metre

17. With reference to MPI the abbreviation RMS stands for:

(a) Root mean square

(b) Real mean standard
(c) Root mid square
(d) Registered magnetic standard

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

18. BS EN 9934-2 is the standard for:

(a) Equipment
(b) Detection media
(c) General principles
(d) Viewing conditions

19. Improved sensitivity to surface indications is achieved with which of the following
current forms

(a) DC
(b) HWRAC
(c) AC
(d) FWRAC

20. A cylindrical component has a length of 500 mm (L = 500) and a diameter of

20 mm (D = 20). When calculating the current required for a coil of N turns
in accordance with BS EN 9934-1 the L/D ratio shall be taken to be:

(a) 25
(b) 5
(c) 20
(d) L/D is not used in calculations for the rigid coil method

21. "Current obtained from an external source passed between 2 contact areas
established on the surface of the component " describes which method of
magnetisation

(a) Magnetic flow

(b) Y6 electromagnet
(c) Current flow
(d) Coil

22. Which method is least suitable for use on a forging in the final machined condition?

(a) Adjacent conductor

(b) Rigid coil
(c) Induced current flow
(d) Prods

23. A 'K' value of 11,000 when utilising the rigid coil method corresponds to what form
of current?

(a) AC
(b) DC
(c) HWRAC
(d) FWRAC

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

24. I = 4dH is the formula used to calculate magnetising current when using:

(a) The adjacent cable method

(b) The induced current method
(c) The rigid coil method
(d) The axial current flow method

25. The contamination of a flaw with foreign matter will have what effect upon the
sensitivity of a magnetic particle inspection?

(a) Severely reduce

(b) Greatly improve
(c) Very little provided the contaminant is non-magnetic
(d) The effect will vary according to the current used

26. Maximum sensitivity in MPI is achieved when:

(a) The flaw is at right angles to the direction of the current

(b) The flaw is parallel to the magnetic flux
(c) The flaw is at right angles to the magnetic flux
(d) The current is at right angles to the magnetic flux

27. The solid content of fluorescent inks is usually:

(a) around 10% of that for non-fluorescent inks

(b) around 200% of that for non-fluorescent inks
(c) around 70% of that for non-fluorescent inks
(d) about the same as that for non-fluorescent inks

28. Complete coverage of an item during a MPI will involve:

(a) Testing twice at varying current values

(b) Testing with 2 different circular magnetisation methods
(c) Utilising 2 methods with fields at 90 to one another
(d) Testing with at least 2 different techniques

29. When utilising the threading bar method of magnetisation the bar shall be:

(a) Highly permeable

(b) Highly retentive
(c) Insulated from the work piece
(d) Made of high carbon steel or nickel

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

30. Irradiance of a UV-A source is measured using a:

(a) Light meter

(b) Irradiance monitor
(c) Radiometer
(d) Photometer

31. A multi-turn coil of wire around a ferromagnetic former is called a:

(a) Resistor
(b) Amplifier
(c) Solenoid
(d) Conductor

32. Fluorescent inks offer a higher level of sensitivity than black because:

(a) They create a larger flux leakage field

(b) They create larger indications
(c) The human eye is more sensitive to fluorescent indications
(d) All of the above are correct

33. In the prod method the prod spacing is doubled from 100 to 200 mm. What effect
does this, in accordance with BS EN 9934-1, have on the required current?

(a) No effect, the required current does not change

(b) The required current is doubled
(c) BS EN 9934-1 does not permit the use of the prod method with a prod
spacing that exceeds 150 mm
(d) The required current depends not only on the prod spacing, but on the
thickness of the component too

34. The magnetisation method that would probably provide the best sensitivity for sub-
surface flaws is:

(a) permanent magnet or DC electromagnetic yoke

(b) AC prods
(c) induced current flow
(d) flexible cable wrap (AC)

35. In MMA welding lack of root penetration may result if:

(a) the electrode diameter is too large

(b) the root gap is too small
(c) the root face is too large
(d) all of the above could cause lack of root penetration

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

36. The first stage in the production of a rolled product from a cast bloom or billet is
called:

(a) cogging
(b) roughing
(c) finishing
(d) fettling

37. Banding is an imperfection that may affect a rolled steel product. Which is the best
description of banding?

(a) it is caused by segregation and is only visible after the steel has been
polished & suitably etched
(b) it is caused by slag inclusions & is easily detected by UT or MPI
(c) it is a surface defect that manifests as slight corrugations transverse to the
rolling direction
(d) it is a type of surface lap sometimes revealed by MPI in the edge of a
rolled steel plate

38. Piping is a defect that affects steel ingots. Piping is caused by:

(a) dissolved gas

(b) shrinkage
(c) slag inclusion
(d) segregation

39. The particle concentration of a visible magnetic ink is typically in what range?

(a) 0.1 to 0.3% by volume

(b) 0.1 to 0.3% by weight
(c) 1.25 to 3.5% by volume
(d) 1.25 to 3.5% by weight

40. The particle concentration of a fluorescent magnetic ink is typically in what range?

(a) 0.1 to 0.3% by volume

(b) 0.1 to 0.3% by weight
(c) 1.25 to 3.5% by volume
(d) 1.25 to 3.5% by weight

41. Which specification describes a 4.5 kg lift test for an electromagnetic yoke?

(a) BS EN 3059
(b) BS EN 1330-2
(c) BS EN 9934-1
(d) BS EN 9934-3

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Exam 4 Rev.00 Magnetic Particle Testing Nov. 2010

42. The correct action to take if recirculating magnetic ink is found to be discoloured or
contaminated is to:

(a) pass the ink through a 50 m filter and recheck, replace if still
contaminated or discoloured
(b) drain out the ink, clean the reservoir & replace with new ink
(c) drain out 50% of the old ink, top up the reservoir with new ink
(d) after allowing 24 hours for settlement siphon off the carrier fluid for re-use
then thoroughly clean the reservoir of contaminated particles

43. In accordance with BS EN 9934-3 a current generator for use in MPI must have a
duty cycle of equal to or better than:

(a) 2%
(b) 5%
(c) 10%
(d) 90%

44. The preferred magnetising current for dry powder methods is:

(a) AC
(b) FWRAC
(c) HWRAC
(d) DC

45. The magnetising current least suitable for dry powder methods is:

(a) AC
(b) pulsed DC
(c) HWRAC
(d) DC

46. Magnetic particles for use in magnetic ink are generally made from:

(a) iron oxide

(b) ferrous sulphate
(c) kryptonite
(d) a special high nickel alloy

47. In order to aid good electrical contact the contact heads of a bench unit are typically
fitted with:

(a) copper gauze or braid

(b) lead pads
(c) aluminium pads
(d) none of the above