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6 Magnetic - Intro Final 03092013 OK PDF

1. Magnetic particle testing uses magnetic fields to detect discontinuities in ferromagnetic materials. 2. A ferromagnetic part is magnetized, then magnetic particles are applied to reveal defects that interrupt magnetic field lines. 3. Indications form where particles cluster at defects, making flaws visible on the part surface.

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92 views27 pages

6 Magnetic - Intro Final 03092013 OK PDF

1. Magnetic particle testing uses magnetic fields to detect discontinuities in ferromagnetic materials. 2. A ferromagnetic part is magnetized, then magnetic particles are applied to reveal defects that interrupt magnetic field lines. 3. Indications form where particles cluster at defects, making flaws visible on the part surface.

Uploaded by

ankit7588
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© © All Rights Reserved
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MAGNETIC PARTICLE TESTING

Introduction to Magnetism
-Magnetism is the ability of matter to
attract other matter to itself.
Objects that possess the property of
magnetism are said to be magnetic and
-magnetic lines of force can be found in
and around the objects.
A -magnetic pole is a point where the a Magnetic lines of force
magnetic line of force exits or enters a around a bar magnet
material.

Magnetic field lines-:


• Form complete loops.
• Do not cross.
• Follow the path of least
resistance.
Opposite poles attracting Similar poles repelling
Ferromagnetic Materials

• What is a ferromagnetic material ? -


• if it can be magnetized.
• Contents of ferromagnetic material ? -
• Materials with a significant Iron, nickel or cobalt content
are generally ferromagnetic.
• Ferromagnetic materials are made up of many regions in
which the magnetic fields of atoms are aligned. What
these regions are called -
• magnetic domains. Demagnetized
• Magnetic domains lie randomly in
demagnetized material, but can be
S N
aligned using electrical current or
an external magnetic field to Magnetized
magnetize the material.
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.
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.
- 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


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. Using electrical current through the specimen-

Direction of the Magnetic Field


Two types of magnetic fields may be established
within the specimen.
(i) Longitudinal Magnetic Field and
(ii) Circular Magnetic Field
--
Longitudinal Magnetic field & Circular Magnetic Field

• A longitudinal magnetic field has


magnetic lines of force that run
parallel to the long axis of the -
part. –

• In circular magnetic field, -


magnetic lines of force run
circumferentially around the
perimeter of a part.
What we can measure by longitudinal magnetic
field and by circular magnetic field?

Flux Leakage
- --

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.
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)


Producing Magnetic Field in the component
(i) Long. Magnetic Field -
• Using a Coil
• Using Permanent magnets or Electromagnets

(ii) Circular Magnetic Field - -


• Passing current through the part.
• Central Conductor
• Prod Technique ---
Producing a Longitudinal Magnetic Field
Using a Coil

A longitudinal magnetic field is


usually established by placing Portable Coil
the part inside a coil’s
annulus. This produces
magnetic lines of force are
parallel to the long axis of the
test part.
-Longitudinal magnetic field
being produced in a crankshaft
using coil Coil on Wet Horizontal Inspection Unit
Producing a Longitudinal Field Using
Permanent magnets or Electromagnets-

Using Permanent magnets:


use is limited due to lack of
control of the field strength
and the difficulty of placing
and removing magnets from
the component. -

Electromagnets - in the form


of an adjustable horse shoe
magnet (called a -yoke) are
used extensively.
Producing a Circular Magnetic Field

Circular magnetic fields are produced by passing current


through the part. - -
-

Central Conductor - -
Producing a Circular Magnetic Field
Prod Technique -
This technique involves using clamps or
prods, which are placed in contact with
the component. Electrical current flows
through the component from contact to
contact. The current sets up a circular
magnetic field around the path of the
current.
- -

Prod magnetization
Magnetic Particles -
Types of Magnetic Particles: Dry & Wet

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.
Size: Fine particles 50µm & Coarse particles 150µm

Properties:
High magnetic permeability and low retentivity - -
Magnetic Particles
Wet Magnetic Particles - -
Wet particles are typically supplied
as visible or fluorescent.
Visible particles are viewed under
normal white light and fluorescent
particles under black light.
Application of Magnetic Media
(Wet Versus Dry)
In 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. - fig.-

The dry method is more portable.


The wet method is generally more sensitive? - -
Capabilities

• Magnetic particle inspection can detect both


production discontinuities such as seams, laps,
grinding cracks and quenching cracks and in-
service damage such as fatigue and overload
cracks. -

Some Photographs of MPT


Throat and Toe Cracks in Partially Ground Weld:

Visible, Dry Powder Method


Crane Hook with Service Induced Crack

Fluorescent, Wet Particle Method


Gear with Service Induced Crack

Fluorescent, Wet Particle Method


Drive Shaft with Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

Crank Shaft with Service Induced Crack

Fluorescent, Wet Particle Method


Demagnetization-

• Parts inspected by the magnetic particle method


may sometimes have an objectionable residual
magnetic field, may interfere with, subsequent
manufacturing operations, or during service of
the component.
• Possible reasons for demagnetization include:
– Magnetic field may interfere with welding and
machining operations
– Abrasive particles, may adhere to components
surface, and cause wear to engines
components, gears, bearings etc.
How to demagnetize

• Demagnetization is done by reversing the magnetic


field.

Magnetized Demagnetized
Advantages of
Magnetic Particle Inspection
• Can detect both surface and near sub-surface
defects.
• Can inspect parts with irregular shapes easily.
• Precleaning is not very critical. Most Contaminants
within a flaw will not hinder flaw detectability.
• Fast method of inspection and indications are
visible directly on the specimen surface.
Limitations of
Magnetic Particle Inspection
• Cannot inspect non-ferrous materials such as
aluminum, magnesium or many stainless steels.
• Inspection of large parts require equipment with
special power requirements.
• Limited subsurface discontinuity detection
capabilities. Maximum depth sensitivity is approximately
0.6” .
• Post demagnetization is often necessary.
• Alignment between magnetic flux and defect is
important
Magnetic Particle Practice Test
1) Magnetic particle testing can be used on all the following with the
exception of
a) Cobalt b) Nickel c) Iron d) Copper
d) Copper
2) True or False - MT can not detect discontinuities running perpendicular to
the test object's axis.
a) True b) False
b) False
3) What is a head shot?
a) Indirect magnetization by passing current through a conductor surrounded by test
object
b) Direct Magnetization by passing current directly through the test object
c) Both Answers "A" and "B“ d) Neither "A" or "B"
c) Both Answers "A" and "B“
4) What is skin effect?
a) Field that remains in magnetizible material after magnetic force has been removed
b) Current is transmitted on the surface of the object
c) Build up of magnetic particles caused by excessive magnetization
d) When a specific material has a high decree of magnetization and can not become
any more magnetized.
b) Current is transmitted on the surface of the object
5) Which wave is used to detect subsurface discontinuities?
a) Alternating Current b) Full Wave Direct Current
c) Half Wave Direct Current d) Both "b" and "c"
e) Both "a" and "c" d) Both "b" and "c"
7) How do you induce longitudinal magnetism in material?
a) Probes b) Yoke
c) Coil d) both "b" and "c"
d) both "b" and "c"
8) How do you achieve the greatest amount of demagnetization in a part?
a) demagnetization coil should be located east-west
b) demagnetization coil should be located north-south
c) demagnetization coil should be located north-east
d) demagnetization coil should be located south-west
a) demagnetization coil should be located east-west
9) When a ferromagnetic material is in a unmagnetized state, the domains are:
a) Aligned in a north and south direction
b) Aligned in a east and west direction
c) Randomly organized
d) Balanced to produce a gauss rating of 2
c) Randomly organized
 10) A hysteresis loop shows the relationship between the:
a) Induced magnetic flux density and the magnetizing force
b) Induced magnetic flux density and the electron force
c) Electron flow and magnetic field strength
d) Flux density and number of coil turns

a) Induced magnetic flux density and the magnetizing force

********

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