Siemens Ltd, Aurangabad.

MAGNETIC PARTICLE TESTING

SL, Aurangabad.

Introduction

• This module is intended to present

information on the widely used method of
magnetic particle inspection.
• Magnetic particle inspection can detect
both production discontinuities (seams,
laps, grinding cracks and quenching
cracks) and in-service damage (fatigue
and overload cracks).
SL, Aurangabad.

Outline

• Magnetism and Ferromagnetic Materials

• Introduction of Magnetic Particle
Inspection
• Basic Procedure and Important
Considerations
1. Component pre-cleaning
2. Introduction of magnetic field
3. Application of magnetic media
4. Interpretation of magnetic particle
indications
• Examples of MPI Indications
SL, Aurangabad.

Introduction to Magnetism

Magnetism is the ability of matter to Magnetic field lines:

attract other matter to itself. Objects • Form complete loops.
that possess the property of • Do not cross.
magnetism are said to be magnetic or • Follow the path of least
magnetized and magnetic lines of resistance.
force can be found in and around the • All have the same strength.
objects. A magnetic pole is a point • Have a direction such that
where the a magnetic line of force they cause poles to attract
exits or enters a material. or repel.

Magnetic lines of force Opposite poles attracting Similar poles repelling

around a bar magnet
SL, Aurangabad.
How Does Magnetic Particle
Inspection Work?
A ferromagnetic test specimen is magnetized with
a strong magnetic field created by a magnet or
special equipment. If the specimen has a
discontinuity, the discontinuity will interrupt the
magnetic field flowing through the specimen and a
leakage field will occur.
SL, Aurangabad.
How Does Magnetic Particle
Inspection Work? (Cont.)
Finely milled iron particles coated with a dye pigment
are applied to the test specimen. These particles are
attracted to leakage fields and will cluster to form an
indication directly over the discontinuity. This
indication can be visually detected under proper
lighting conditions.
SL, Aurangabad.

Basic Procedure

Basic steps involved:

1. Component pre-cleaning

2. Introduction of magnetic field

3. Application of magnetic media

4. Interpretation of magnetic particle indications

SL, Aurangabad.

Pre-cleaning

When inspecting a test part with the magnetic

particle method it is essential for the particles to
have an unimpeded path for migration to both
strong and weak leakage fields alike. The part’s
surface should be clean and dry before
inspection.
Contaminants such as oil,
grease, or scale may not
only prevent particles from
being attracted to leakage
fields, they may also
interfere with interpretation
of indications.
SL, Aurangabad.

Introduction of the Magnetic Field

The required magnetic field can be introduced into a
component in a number of different ways.
1. Using a permanent magnet or an electromagnet that
contacts the test piece
2. Flowing an electrical current through the specimen
3. Flowing an electrical current through a coil of wire
around the part or through a central conductor running
near the part.
SL, Aurangabad.

Direction of the Magnetic Field

Two general types of magnetic fields (longitudinal

and circular) may be established within the
specimen. The type of magnetic field established is
determined by the method used to magnetize the
specimen.

• A longitudinal magnetic field has

magnetic lines of force that run
parallel to the long axis of the
part.
• A circular magnetic field has
magnetic lines of force that run
circumferentially around the
perimeter of a part.
SL, Aurangabad.

Importance of Magnetic Field Direction

Being able to magnetize the part in two Flux Leakage
directions is important because the best
detection of defects occurs when the lines of
magnetic force are established at right angles to
the longest dimension of the defect. This
orientation creates the largest disruption of the
magnetic field within the part and the greatest
flux leakage at the surface of the part. An
orientation of 45 to 90 degrees between the
magnetic field and the defect is necessary to
form an indication. No Flux Leakage

Since defects may

occur in various and
unknown directions,
each part is normally
magnetized in two
directions at right
angles to each other.
SL, Aurangabad.

Question

? From the previous slide regarding the optimum

test sensitivity, which kinds of defect are easily
found in the images below?

Longitudinal (along the axis) Transverse (perpendicular the axis)

SL, Aurangabad.
Producing a Longitudinal Magnetic
Field Using a Coil

A longitudinal magnetic field Coil on Wet Horizontal Inspection Unit

is usually established by
placing the part near the
inside or a coil’s annulus.
This produces magnetic
lines of force that are
parallel to the long axis of
the test part.

Portable Coil
SL, Aurangabad.
Producing a Longitudinal Field Using
Permanent or Electromagnetic Magnets

Permanent magnets and

electromagnetic yokes
are also often used to
produce a longitudinal
magnetic field. The
magnetic lines of force
run from one pole to the
other, and the poles are
positioned such that any
flaws present run normal
to these lines of force.
SL, Aurangabad.

Circular Magnetic Fields

Magnetic Field

Electric
Current

Circular magnetic fields are produced by

passing current through the part or by
placing the part in a strong circular
magnet field.
A headshot on a wet horizontal test unit
and the use of prods are several common
methods of injecting current in a part to
produce a circular magnetic field.
Placing parts on a central conductors
carrying high current is another way to
produce the field.
SL, Aurangabad.

Application of Magnetic
Media (Wet Versus Dry)
MPI can be performed using either
dry particles, or particles
suspended in a liquid. With the
dry method, the particles are
lightly dusted on to the surface.
With the wet method, the part is
flooded with a solution carrying
the particles.
The dry method is more portable.
The wet method is generally more
sensitive since the liquid carrier
gives the magnetic particles
additional mobility.
SL, Aurangabad.

Dry Magnetic Particles

Magnetic particles come in a variety of colors. A

color that produces a high level of contrast
against the background should be used.
SL, Aurangabad.

Wet Magnetic Particles

Wet particles are typically supplied

as visible or fluorescent. Visible
particles are viewed under normal
white light and fluorescent particles
are viewed under black light.
SL, Aurangabad.

Interpretation of Indications

After applying the magnetic field, indications that

form must interpreted. This process requires that
the inspector distinguish between relevant and
non-relevant indications.

The following series of images depict

relevant indications produced from a
variety of components inspected
with the magnetic particle method.
SL, Aurangabad.
Crane Hook with
Service Induced Crack

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.
Gear with
Service Induced Crack

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.
Drive Shaft with
Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

SRSPL,
SL, Aurangabad.
Aurangabad.
Splined Shaft with
Service Induced Cracks

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.
Threaded Shaft with
Service Induced Crack

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.
Large Bolt with
Service Induced Crack

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.
Crank Shaft with
Service Induced Crack Near Lube Hole

Fluorescent, Wet Particle Method

 SL, Aurangabad.
SRSPL, Aurangabad.

Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

SRSPL, Aurangabad.
SL, Aurangabad.

Toe Crack in SMAW Weld

Visible, Dry Powder Method

SRSPL,
SL, Aurangabad.
Aurangabad.
Throat and Toe Cracks in
Partially Ground Weld

Visible, Dry Powder Method

 SL, Aurangabad.
SRSPL, Aurangabad.

Demagnetization

• Parts inspected by the magnetic particle method

may sometimes have an objectionable residual
magnetic field that may interfere with subsequent
manufacturing operations or service of the
component.
• Possible reasons for demagnetization include:
– May interfere with welding and/or machining
operations
– Can effect gauges that are sensitive to
magnetic fields if placed in close proximity.
– Abrasive particles may adhere to components
surface and cause and increase in wear to
engines components, gears, bearings etc.
 SL, Aurangabad.
SRSPL, Aurangabad.

Demagnetization (Cont.)

• Demagnetization requires that the residual

magnetic field is reversed and reduced by the
inspector.
• This process will scramble the magnetic domains
and reduce the strength of the residual field to an
acceptable level.

Magnetized Demagnetized
SL, Aurangabad.
Advantages of
Magnetic Particle Inspection
• Can detect both surface and near sub-surface
defects.
• Can inspect parts with irregular shapes easily.
• Precleaning of components is not as critical as it
is for some other inspection methods. Most
contaminants within a flaw will not hinder flaw
detectability.
• Fast method of inspection and indications are
visible directly on the specimen surface.
• Considered low cost compared to many other
NDT methods.
• Is a very portable inspection method especially
when used with battery powered equipment.
SL, Aurangabad.
Limitations of
Magnetic Particle Inspection
• Cannot inspect non-ferrous materials such as
aluminum, magnesium or most stainless steels.
• Inspection of large parts may require use of
equipment with special power requirements.
• Some parts may require removal of coating or
plating to achieve desired inspection sensitivity.
• Limited subsurface discontinuity detection
capabilities. Maximum depth sensitivity is approximately
0.6” (under ideal conditions).
• Post cleaning, and post demagnetization is often
necessary.
• Alignment between magnetic flux and defect is
important
SL, Aurangabad.

Glossary of Terms

• Black Light: ultraviolet light which is filtered to

produce a wavelength of approximately 365
nanometers. Black light will cause certain materials to
fluoresce.
• Central conductor: an electrically conductive bar
usually made of copper used to introduce a circular
magnetic field in to a test specimen.
• Coil: an electrical conductor such a copper wire or
cable that is wrapped in several or many loops that
are brought close to one another to form a strong
longitudinal magnetic field.
SL, Aurangabad.

Glossary of Terms

• Discontinuity: an interruption in the structure of the

material such as a crack.
• Ferromagnetic: a material such as iron, nickel and
cobalt or one of it’s alloys that is strongly attracted to
a magnetic field.
• Heads: electrical contact pads on a wet horizontal
magnetic particle inspection machine. The part to be
inspected is clamped and held in place between the
heads and shot of current is sent through the part
from the heads to create a circular magnetic field in
the part.
• Leakage field: a disruption in the magnetic field.
This disruption must extend to the surface of the part
for particles to be attracted.
SL, Aurangabad.

Glossary of Terms
• Non-relevant indications: indications produced due
to some intended design feature of a specimen such
a keyways, splines or press fits.
• Prods: two electrodes usually made of copper or
aluminum that are used to introduce current in to a
test part. This current in turn creates a circular
magnetic field where each prod touches the part.
(Similar in principal to a welding electrode and
ground clamp).
• Relevant indications: indications produced from
something other than a design feature of a test
specimen. Cracks, stringers, or laps are examples of
relevant indications.
SL, Aurangabad.

Glossary of Terms
• Suspension: a bath created by mixing particles with
either oil or water.
• Yoke: a horseshoe magnet used to create a
longitudinal magnetic field. Yokes may be made from
permanent magnets or electromagnets.