INTRODUCTION... Basic principles . MAGNETIC PROPERTIES «.. “Magnetism ines of force.. Material characteristics Permeability (1). Retentivity Magnetic flux (0) and magnetic flux density (B). ¢Magnetic field strength (H) Coercive force Magnetic hysteresis Penetration of magnetic flux Flux leakage. #lectromagnetism CONSIDERATIONS WHEN USING MPI Limitations of MPI General considerations .. Surface conditions... MAGNETIZING METHODS & APPARATUS ... Continuous magnetisation method . Residual magnetisation method. Permanent magnets .. THE DETECTING MEDIUM Dry powders Tn nen 7 Health and safety considerations.. VIEWING CONDITIONS... ‘Non-fluorescent inks and powders. Fluorescent inks and powders Safety. Electromagnetic spectrum DEMAGNETIZATION... MAGNETIC FIELD INDICATORS. Portable magnetic field strength meters (magnetometers) ‘Shim type/foil strips (trade name Castrol Strips/Ely Strips).. ‘The ASME field indicator. The Berthold penetrameter. Hall effect meters... Performance checks Alternative test block(s).... 7REPORTING. Interpretation definitions Preservation of indications. CURRENT TYPES, Altemating current Direct current. Responsibilities . Occupational Exposure Limits (EH40 — January 2002). LIST OF APPLICABLE STANDARDS ..Ferromagnetic mtrilre thse cha be imtoo cob? eke onnony fee Sie 20 ‘The area boing tested is Jnowm asthe ‘est area’ 50 ODUCTIO! ‘Magnetic particle inspection (MPI) is an NDT method which may only be used on ferromagnetic materials to detect surface breaking discontinuities and also, in certain cases, slight sub-surface discontinuities up to 2 mm or 3 mm below the material's surface, BASIC PRINCIPLES ‘A magnetic field is introduced into a specimen to be tested, then fine particles of ferromagnetic powder, or ferromagnetic particles in a liquid suspension, are applied to the area being tested. ‘Any discontinuity in the test area which cuts across the magnetic fld creates a Jeakage field. A leakage field has a north and south pole on either side of it, and therefore will attract the ferromagnetic particles in great numbers. It is common on site work to use flack inks as the detecting medium; these are usually contrasted against a white paint background which has been pre-applied. In workshops and similar, it is more common to use fluorescent inks which are usually greeniyellow. Fluorescent inks or powders are automatically contrasted against a deep violet background created by the use of an ultraviolet (UV-A) light, this is essential 10 cause fluorescence of the particles, although the use of a darkened inspection area is required. A contrast paint is not required with fluorescent inks. Fluorescent inks or powders are more sensitive at detecting defects compared to non Aluorescent inks or powders, because of the greater contrast achieved between the detecting medium and the background. ‘There are many ways to apply a magnetic field, e.g, by the use of permanent magnets, clectromagnetic-yokes, cols, prods, cables and other devices. ‘A basig sequence of operations for the examination of a weld using MPI with a ‘permanent magnet and black ink is shown below: 1. Clean area using a wire brush if required. 2. Apply a thin layer of white contrast paint 3. When the pain is dry, straddle the magnet over the weld at 90° to the weld axis. 4. Apply ink (typically 1.25% to 3.5% ferromagnetic particles to a paraffin bas). 5. Interpret the area. Look for indications with their length lying along the same axis as the weld. Evaluate in accordance with the relevant specification. 6. To look for transverse weld defects, tun magnet approximately 90° and re-apply the ink. 7. Interpret the area. Look for indication with their length perpendicular to the weld axis. Evaluate in accordance with the relevant specification. et 288 MTLTTT MAGNETISM [All materials consist of atoms and molecules which may or may not have a permanent to | _ magnetic influence depending on the electron configuration within the material ‘Atoms in magnetic materials group together in regions called magnetic domains; each domain has its own north and south pole. When these domains are randomly positioned, the material is unmagnetized. If the domains are aligned in a commen tangential field strength Whreas BS 6072 nated d= M30 Where MI = ampere turns 30 = conson (peak value) 30 » 0 10d. Fig. 4.10 Adjacent cable technique (alternative names include parallel conductors ‘and the kettle element technique). ‘When testing radiused comers on cylindrical components or branch joints, e.g. stub to hheader welds, the cable may be wrapped round the surface of the component or the branch, and several turns may be bunched up in the form of a closely-wrapped coil. In this case, the surface inspected shall be within a distance, dof the winding? Advantages of flexible cable techniques include: + Ac.orde. fields. + A.c. energised equipment may be used for demagnetisation operations. ‘+ Large areas inspected with each set-up. ‘No poles to attract magnetic particles. Field strength can be altered. ‘Predictable field strengths. Disadvantages include: ©. Cumbersome long heavy cables required. © Longer setting up times. ‘+ Heavy transformers required for large amperages. ‘© Expensive equipment. tee DNB MTSBuane & TPO’ NOTES 0 » 0 0 7 [BS EN ISO 9934-1 quotesd ‘0 half the inspection area, whereas BS 6072 sated dos the widh ofthe inspection 100 LAGNETIZING METHOD: ‘When using any of the current flow or threader bar methods, the field strength is largely determined by the current (amperes) flowing in the circuit. When using any form of coil the field strength is determined by the current flowing in the circuit and by the number of tums in that coil, thercby obtaining ampere/tums. ‘The number of ampere/tums can be applied to the specimen length in metres to give the field strength unit for coils as ampere turns/metre (AT/m). Flexible cables (FC) ‘When a single conductor is used, the magnetic field reduces rapidly at increasing distance from the conductor; this restricts the production of an adequate test area with ‘a sufficiently constant magnetic field. If the current is made to flow in the same direction through conductors spaced some distance apart, a relatively constant field is produced. Flexible cable techniques can be used on a considerable variety of component shapes. ‘Configurations used are normally obtained with a heavy insulated flexible cable which is placed through, on, or around the specimen. A current passed through the cable will then induce a magnetic field into the test piece. Fig. 4.9 Threader cable technique Defects lying parallel to the cable will be the most readily detected. On complex shapes the position and method in which the cable is wound may have to be found by experimentation to ensure an adequate field in all areas, ‘One method of test utilising flexible cables is the adjacent cable technique. This method of magnetization requires the material being tested to be in close proximity to current flowing in one direction. ‘The retum cable for the electric current must be arranged to be as far removed from the inspection zone as possible and, in all cases, this distance should be greater than ues 20 MT48FBR BS ENIS0 9936-2: 2002 49 Jforink sates bowen 13 and 40 pm. whereas ponders are generely Baoan BS 4069 stated a marie {100 pm fer inks and 200 pn for powders. 20 30 40 +A maximum of 315°C (600°), however, a these lemperatres convection currents from the test piece 50 make application dificult, ‘BS EW 180 9934.2: 2002 no longer specifies solid ‘content range and sates the apple will ie thie myformation ng. To 10 heck the overall Appendix of his lndord. BS 4069 stated the sod contents for inks as 125.33% for non Buorescentinks and (.1-0.396 for fturescent ‘nk The carter fad shall make the vole pt 100%. 90 100 TET The detecting media should normally be in accordance with BS EN ISO 9934-2 : 2002 Detection Media, When inks are used for MPI the test may be referred to as a wer ‘method; when powders are used the test may be referred to as a dry method. ‘The basic requirements for magnetic particles areas follows: ional effect. However, ifthe grains are too fine, a, Fine grains to reduce the gra this could coagulate the particles. 'b. Blongated shape for easier polarization. Spherical particles are also needed to ensure dispersal over the surface, c. High permeability for magnetization in weak flux leakage fields Low retentvity if particles are to be removed from the test surface after the test. High contrast against the background of the test surface, DRY POWDERS Dry powders consist of finely divided ferromagnetic particles available in a variety of colours, e.g. black, grey, red, orange or yellow, some dry powders’ may also be fluorescent. Dry powders are usually applied to a surface by means of a puffer device (insuffulator), they should be floated, not blasted, onto the area under test. Dry powders should ideally be used with ac. or half-wave rectified current (h.w.r.) because ofthe extra mobility that these current types impart onto the powder. Dry powders must be used when MPI is being carried out on hot surfuces*, a situation ‘where inks would obviously not be suitable. Dry powders are also encountered for use ‘on rough surfaces and for better indications for slight sub-surface discontinuities. INKS Ferromagnetic particles suspended in a suitable carrier fluid should have the same basic properties as the dry powders, There are two distinet divisions when dealing with MPL inks, these being fluorescent inks and non-fluorescent inks. Non-fiuorescent inks are usually black and referred to as black inks. IE water is used as a carrier fluid for the ferrous oxide particles, it should contain additives to prevent corrosion of the surface or particles, and improve the wetting, action. Paraffin based products have good wetting action, are odourless, have a relative tolerance to oil or grease on the surface and are not corrosive. Atypical method of test for assessing the solid content of magnetic inks: 1, Maximum volume of magnetic ink for test should not exceed 5 litres. 2, Agitate container for not less than 5 minutes. 3. Pour sample of ink into 100 ml settlement flask (centrifuge type or Sutherland flask). 4, Allow to settle for 60 minutes. ‘5. Read off the solid content to nearest 0.1 ml. ‘The solid content range is very important as too high 2 concentration will cause excessive background and too low a concentration will cause weak indications to be missed. wet 2088 é MTS-1UNIT MTS Ruane & TPO! HE DETECTING MEDIUM ‘Sutherland Flask Centrifuge Tube or Crow Receiver 10 Fa Fig, 5.1 -Settiement flasks used to determine the solid content of MPI inks ‘An additional test for fluorescent inks after settling is to check the suspension fluid with UV-A light, if a yellow-green fluorescence is observed, the ink should be discarded and replaced with a fresh solution. In general itis stated forall inks that: so | % They shall form a uniform suspension when agitated. b. They shall not contain any other ingredients that are likely to cause injury to the perio iter during or afer use asevosst2qorse |e The inks shall not corrode or otherwise adversely afect the surfaces of the mu eran eee . sateen cme 4. They may contain small quantities of other ingredients at the manufacturers 2o0ppm Of gq | dseretion providing the solid content remains within the speifed proportion. Setotoen commas HEALTH AND SAFETY CONSIDERATIONS. ‘The supplier of MPI consumables is obliged to make availabe tothe purchase, al relevant health and safety data applicable to the supplied goods. The user also has an 10 | obligation to comply with te heath and sully requirements. See also the COSHAL Regulations in Unk MTII. sev iom2uiny | Specific heat and safety considerations ae: sh fash pot re ee : Tese go | Pemmho: Reemner i rh ee 0 | Asthmatic: ‘Do not use in confined spaces without masks or adequate ventilation. eee ‘Skin hazard: Use protective clothing, Inksto be assed na closed cup test and should not Be les than 63°C. 0 100 fee 208 . MTS2 t#éedweeoewwssRuane & TPO! ‘The darker the ambient lighting condition, he 10 higher the operator exe strain Becomes, warranting ‘more regular Breaks to reduce operator fatigue. 20 BS EN 180 9934.1 refers ‘BS EN ISO 3059 for UV-A condions which quotes a ‘minimum UF irradiance 2f 1000 pWiem? anda ‘maximum 20 lax ambit background lighting. 39 Whereas BS 6072 stated (2 mininan UPA lnradiance of 800 pon? onda marina 10 ba ‘anbient backgroud lighting. 40 ‘The temperature aliers the _presure ise the quarts ‘xsl capsule which in 50 tom aes the spectram of emited wavelengths. Only high pressure mercary vapour lamps are used for irradiating the uorescent hes. Low presswe gy ‘discharge lamps are only sed fr ambient lighting conditions, -BS BN 180 3059: 2001, (guotes a minimum warm up Period ef 10 miraes. n BS EN 9934-3 quotesa UV-A inns of 10000 mf 400m 0 The old Brush Standard for checking UV-A lamp was BS $489: Method Jor Assessing UV-A Light ‘we in NDT 100 UNIT MT6 + VIEWING CONDITION: All areas under test using non-fluorescent inks should be adequately illuminated using artifical light if necessary. For fluorescent inks, a UV-A light with subdued background lighting should be used, the darker the better, to increase the overall contrast ratio, NON-FLUORESCENT INKS AND POWDERS The area under inspection should be evenly illuminated. Most commonly used standards quote @ minimum illumination level of $00 lux in daylight or under artificial Tight. FLUORESCENT INKS AND POWDERS. ‘The area under inspection should be irradiated with UV-A light. The levels of UV-A. irradiation are quoted in the relevant standards (see side note), together with the ‘maximum permitted background illumination. Fluorescence degrades with exposure to ordinary light over a period of several hours, moreover, it can be arrested entirely at high temperatures. As the intensity of the ultraviolet light is increased, the amount of fluorescence increases. UV-A light Mtraviolet light is generated by a 100/12SW ‘amp (NB. 400W flood lights are also available). The mercury is vaporised inside a ‘Giarts capsule by a small low current are from an auxiliary electrode. After about 5 minutes there is sufficient mercury vapour in the capsule to initiate an arc between the tain electrodes. The lamp should not be used for approximately 15 minutes to allow sufficient time frit o attain ull working intensity Medium screw base ‘Auaary starting wetrode Fig. 6. - Ultraviolet (UV-A) lamp Assessment of UV-A intensity ‘The efficiency of the mercury vapour lamp can deteriorate quickly without any obvious effect, therefore the lamp's intensity should be checked regularly with an ultraviolet light monitor, such as that specified in BS EN ISO 3059 : 2001 Non-Desiructive Testing — Penetrant Testing and Magnetic Particle Testing ~ Viewing Conditions BS EN ISO 3059 : 2001 gives information and recommendations for the testing of UV- A light sources, in particular the assessment of emission from new lamps and the regular testing of any lamps in service which may produce a drop in output after approximately three months use, The testis carried out using a radiometer. MT6-1Buane. & UNIT MT6 * VIEWING CONDITIONS 0 Iuorescent sereon lack Box ‘wth black frame 30 Fig, 6.2 Analogue style radiometer ” 0 « Fig, 6.3~ Digital sole combined radiometer and photometer 70 SAFETY LUV-A lights operate with wavelengths between 315-400 nm (3150-4000 A), shorter ‘wavelengths than this can cause injuries to the eyes. To prevent injury, a filter should bbe used which cuts out wavelengths below 315 nm. | Looking into a UV-A light will cause temporary clouding of vision due to the fuid in the eyeball luoreseing, it will nomalse with no permanent effects after afew seconds, although itis important to note that prolonged exposure may cause cataracts. * 100 ee Ha . MT62ee FeO Kal i i ~ 3s z & Pe UVC UV-B 3 & B3 2» i t ; t > > a 4h 100-200} 300! | 400 600700 280-315 : aes . Sun 30-50 re -wey"artaeh || Thay fers eet coeur | | Tatras ‘anacare’ || miuanbowrete rs ferme |) eto ouice | “traeesps ° cotohnan staan peter mre ° e . ‘ t nerd 208 MT63Auane [UUM ewe LEN TPO! ETIZATION Demagnetization of a specimen may be required before testing, between successive shots/magnetizing positions, and/or after testing in order to remove any residual ‘magnetism in the specimen. 10 | Demagnetization may be carried out forthe following reasons: 1. To remove any residual magnetism which may remain from previous MPI procedures or other sources, which may interfere with the subsequent test. 2, To remove any residual magnetism between successive MPI shots in the test procedure. 20 3, To remove any residual fields after MPI has been carried out so as not to interfere with other work processes, ga residual magnetic field may attract cutting swarf during machining operations and may also interfere with subsequent welding ‘operations causing are-blow. 20 0 50 a Fig. 7.1. Hysteresis loop showing demagnetization ‘There are several methods of demagnetization: Aperture coil with a.c. ‘This isa coil of several hundred tums which is connected to the mains. The object to be demagnetized is placed inside the coil and slowly withdrawn to a distance of 70 at least 1.5 metres away from the coil, or the object is left stationary in the coil and ‘the current gradually turned down to zero. This is generally accepted as the most commonly used method for demagnetisation. Aperture coil with reversing dc. » This method is similar to the ac. coil but the demagnetizing field penetrates farther in the test piece. The curent direction is reversed periodically, but at dlereasing amplitude until the residual magnetism is removed. Using a. reversing and decreasing, power supply will achieve the most effective method for demagnesistion 99 | © As. electromagnetic yokes. (wiper brush) ‘These can be used to demagnetize large arcas in stu. ‘The yoke is stroked over the surface, lifting is well clear (450 mm to BS 6072) between strokes. 4. Ac. current flow ‘When using a current flow crack detector, demagnetization can be carried ot by 100 using ac. current and slowly reducing the current lowing to zero. A variation on ‘this method is the peak and drop technique where the eurent is initially introduced noe 2umve8 MTL+ These temperanees are quoted in BS 3683: Part 2 owever the erie temperate of iron is more ‘fen quoted around 730°C. 0 20 30 50 0 80 0 ‘current is then re-introduced at successively decreased values whilst returning to ‘zero current after each peak current. ¢. Flexible cable (induction system). If a portable induction type crack detector is available, demagnetization can be ‘carried out by wrapping 2 or 3 tums of the cable around the object 10 be demagnetized and gradually reducing the a.c. current to zero, If magnetization is ‘carried out using the induction coil, the object under test is automatically demagnetized if the current is reduced to zero before the unit is switched off £ Heat treatment. Itis not necessary to demagnetize ifa heat treatment process isto follow magnetic particle inspection and the specimen isto be heated beyond its curie point, which is approximately two thirds of the material's melting point, e.g. 358°C: for nickel, 870°C for iron® and 1127°C for cobalt. Above this level ferromagnetic materials. lose their magnetism, Le. the magnetic domains become randomly orientated. ‘When a material isto be demagnetized, by methods other than heat treatment, the inital demagnetizing field stength must be stronger than the residual field, ‘Demagnetisation may be easy or hard, deper ‘material soft or hard? Circular magnetism is generally considered to be harder to demagnetise than Tongitudinal magnetism because theoretically the field is contained within the test piece ‘with no poles and itis therefore difficult to measure the field strength. ‘on the test piece material, ie. is the To fully demagnetise a test piece it should be carried out in an east-west direction so that the earth's magnetic field will not interfere. By laying a test piece north-south, the earth's magnetic field will weakly magnetise it ‘The level to which a specimen must be demagnetized may be laid down in an MPI test procedure or specification. ‘The amount of residual magnetism remaining may be checked with a calibrated field strength meter ot existence may be confirmed with other types of field indicator. MI7220 30 BS 6072 quoted wo ‘techniques forthe presence ‘efaresidual feld which 2. msing a compass 1 popercipona thread, 0 UNIT MTS TORT IO MERCURY Magnetic field indicators, eg. flux indicators and field strength meters are used 0 assess the presence, intensity and/or direction of a magnetic flux either before, during, or after testing, Specific uses ofthese instruments are as follows: ‘© To ensure MPI test machines are functioning correctly. ‘© To ensure that the specified field strength and field direction are apparent. ‘© To check for the presence of residual magnetism before testing. To check for the presence of residual magnetism after testing. Magnetic field strength meters and portable flux indicators should not be used in conjunction with permanent magnets or with dc. electromagnets for determining adequate flux density. A flux indicator may be used with these magnets but only to verify the suitability or correct application of an ink or powder. Circular fields may be contained completely within a specimen, if this is the case, the field will not be detected, Many terminologies are encountered when referring to types of magnetic field indicators, which can be confusing. There are also altemative methods other than those listed below to check for residual fields. PORTABLE MAGNETIC FIELD STRENGTH METERS (MAGNETOMETERS) To measure residual magnetism, calibrated magnetic field strength meters of the type ‘which contains a soft iron vane are commonly used. The vane aligns itself with the ‘magnetic field, the strength and direction of the field is measured by the meter calibrated in gauss or tesla’; similar non-calibrated instruments also exist. Neither of ‘these instruments should be brought into close contact with any strong magnetic fields as this may cause damage tothe instrument. Fig. 8.1 - Field strength meter ‘SHIM TYPE/FOIL STRIPS (TRADE NAME CASTROL STRIPS/ELY STRIPS) ‘These are small brass or silver finish strips containing artificial defects (3 slots) in Mu ‘etal; Mu metal is a highly permeable material containing nickel, manganese and iron. ‘The brass finish strips are commonly used in general engineering applications and indicate low field strengths. The silver finish strips will show higher feld strengths and are used in aerospace industries or areas that require a more critical examination. fect sam _ MTBAn alternative collective ‘erm for penetrameters, eg. ASME, Berthold, Castrol Type 3s pie 40 % Ii either case, if the field is strong enough, three linear indications will show ou the stcip; they should be rotated on the specimen surface to define field direction. Fig. 8.2 - Castrol strip With reference tothe brass finish strip (type 1), ifno indications are apparent the field is too weak for inspection and it is below 3 amps ac. r.m.s/mm (240 Oc). Three indications show that the field strength is greater than 5 amps a.c. rm.s./mm (400 Oe). With reference tothe silver finish strip (type 2), ifno indications are apparent the field is below 5 amps ac. r.m.s/mm (400 Oc). Three indications show that the field strength is greater than 15 amps a.c. r2m./mm (1200 Oe) and the field is suitable for critical inspection Note: The above figures are based on a mild steel bar and only meet the BS 6072 requirements, ‘THE ASME FIELD INDICATOR ‘This consists of eight sections of mild steel brazed together, the separating lines between the sections forming artificial defects. One side also has a chromium coating applied, this has a greater sensitivity than the opposite side which shows surface breaking defects. When the indicator is placed on a magnetized component the magnetic field passes through the indicator. ‘The separating lines between the sections become visible when the detecting media is applied. To determine the direction of the magnetic field the indicator should be rotated until one of the lines is perfectly visible, a this point the direction of the field is at 90° to the line. ‘THE BERTHOLD PENETRAMETER ‘This field indicator contains two artificial defects at 90° to one another. There is a sensitivity adjustment consisting of a cover plate which can be tuned to one of four setting which vary the distance of the cover plate and detecting media from the artificial defects; the greater the gap the higher the field strength necessary to render the lines visible. They are used in a manner similar to the ASME indicator. Fig. 84 - Berthold penetrameter Ie res MT8-210 20 0 40 100 [UTP MER ER UENCE Cob AICO U RO) HALL EFFECT METERS ‘These instruments are usually used in laboratory type environments to. measure tangential, normal, or axial fields depending on the probe design, Hall effect meters use, as their name suggests, the Hall effect principle. ‘An electric current is passed through a small semi-conducting crystal contained within a probe. A voltage is generated across the crystal, when the probe is placed in a magnetic field, the magnitude of this voltage is directly proportional to the magnetic flux density ‘within the probe. The relative permeability of the semi-conducting crystal is very close to one, so the voltage generated is proportional to the magnetic field strength at the point where the probe is placed. The voltage generated by the probe is measured by an electronic circuit and indicated on a meter marked in units of field strength. ‘The Hall effect meter is calibrated with a series of standard magnets which provide Known values of field strength within the working range of the instrument Manufacturers supply a zero-field chamber which is required to set the zero. If the peak value of a time varying field is required, the meter reading is multiplied by a conversion factor, the value of which depends upon the shape of the waveform and upon the measuring principle employed by the instrument. PERFORMANCE CHECKS Performance checks are used to ensure an MPI test system is functioning correctly, ‘a magnetic field is capable of being produced and reproduced so that test results cean be maintained at a consistent level. Typical reference blocks are given below. Current flow (headshots) ‘When current flow techniques are used on bench units, the following test should be carried out for each wave form available for use: a. Ensure the test piece is thoroughly demagnetized and pre-cleaned satisfactorily. b. Position the test piece (sce diagram below) between the head and tailstock of the bbench equipment. ¢. Slowly introduce a current and apply ink until the fist hole (closest to the external surface )is visible. 4. Note the applied amperage and continue to apply the current progressively until ‘the second and third holes are noted. ‘es 1 am il tg ogat 5.20825 mn low Fe (fet 25 dee chatter) Filg, 8.5 - Test piece for current flow technique oe 2a _ MT83[ann TVR TERI CRU ROT) frond ‘Magnetic flow 10 | If magnetic flow is being used, a similar procedure to the above would stil apply, ‘except that the dial readings/switch settings would be taken instead of amperage values ‘and the following test piece would be used. 1.5mm Diameter 2» Fig, 8.6 - Test piece for magnetic flow and rigid coil techniques Rigid coil If a rigid coil is being used, the procedure in the section above for Current flow (headshots) would still apply, except that the test piece used would be as shown in 50 | previous section for Magnetic Flow. ALTERNATIVE TEST BLOCK(S) [As to BS EN ISO 9934 : Part 2 for type testing, batch testing and in-service testing of 0 | Mluorescent inks, reference block no.1 should be used. % ‘Atdeenions mm 0 100 wet 200008 Mrs42» 30 100 INTERPRETATION DEFINITIONS Discontinuity ~ an interruption in the normal physical structure or configuration of a part, Non-relevant ~ indications from something on the test piece which is expected, i.e. brazed joints, internal splines or drilled holes. Indication ~ particles accumulated and held ata site by a leakage field ‘Adequate reporting is essential for the transmission of relevant and correct information aftr the test. Any test report should include the information required by the relevant specification forthe work being performed. A typical report would require the following: name of the company; ‘work location; description and identity ofthe part tested; stage of test e.g. before or after heat treatment, before or after final machining); reference to the writen test procedure and the technique sheets used; description of equipment used; magnetising technique, including (as appropriate) indicated current values, tangential field strengths, waveform, contact or pole spacing, coil dimensions ete; detecting media used and contrast paint if used; surface preparation; ‘viewing conditions; ‘method of recording or marking of indications; date of test; m. name, qual wre pe ee ication and signature of the person performing the test. ‘The test report shall then contain the test results, including a detailed description of the indications and a statement as to whether they meet the acceptance criteria ‘A common method of recording indications is to reproduce indications on a scaled diagram. Indications should be drawn with references to a datum on the test piece. The iagram(s) should not be overloaded with too much information; use two diagrams if necessary, A separate diagram showing magnetizing techniques should ideally be included where itis not obvious which technique has been applied. PRESERVATION OF INDICATIONS Prior to the recording of indications, itis essential to ensure thatthe test conditions, and in particular the magnetizing levels, are as near as possible to the level recommended for the technique. fdry powder is used, no preparation is necessary. If any oil based carrer fhuid is used, the surface should be drained and adequately dried. Another possibility is to retest the ‘workpiece using a magnetic ink made with a volatile carrier fluid. Itis essential that a common datum be established on both the workpiece and the record and that care be taken not to disturb the indications. ‘Other methods of recording indications are: 1. Photographs When a photographie record is made, the resulting photograph of the tested surface should, if possible, be actual size. If the surface of the workpiece is highly polished, care should be taken to avoid highlights. The use of a matt-contrast medium applied prior to testing may be desirable. 2. Clear sticky tape Ie Ta MT9-1RON) Piege ay NIT MT9 POF This is used to peel the dred magnetic particle indication from the test piece. Cover the indications with a transparent adhesive fl. Carefully peel off the film and the adhering indications and reapply to either paper or card of contrasting 10 colour, b. Degrease the test surface, cover with a white matt adhesive film and retest. After drying, if necessary, cover the indications with a clear film in the munner described in (a) and transfer together the pair of films to the record card. 3. Proprietary coatings sprayed on wet; when dry, the resultant film is then peeled a away with the indication. a. Spray the tested area with a quick-drying, stippable coating. Strip off this coating and view the face previously in contact with the workpiece, to which the indications will be transferred, . Heat the workpiece to an approved temperature and, without delay, slowly no | immerse in a powdered plastic material and slowly withdraw. Allow io drain 2 51290: 1998 alto and eure tin aocordance with the manufecurersinstuctons. trp off the coating ists: complete with indications from the workpiece and view the face previously in Tomar oth contact with it So ecg . Degrease the test surface and coat with a proprietary, srippable, magnetic axide = paint, Magnetic the part to saturation and peel off te coating. Itt is dipped in 1 Ticorcoring. go} aitated magnetic ink, it will reveal th flaw indications on the oxide fim. © Hpomerchomeat “|g. Degrese the tet area and coat wih a proprietary self euing, magnetic slcone- magnetic particle rubber compound. Magnetise to saturation and allow the compound to cure. The =. cxide in the compound will migrate to the position ofan flaw and, when removed fol ecromencneee’ from the workpiece, the rubber previously in contact with the surface will show the flaw. decvotlaprearsion 50| 4. Magnetic sachets with light sensitive paper backings. tenes bata” | 5 Magneto graph, mde fe Limitations of preservation methods Linear ~ the length is more Methods 1 and 2 above are generally restricted to surfaces of simple geometric form ‘hon ree tines the width «| because of the difficulties involved in removing the films. Method 3b does not Rounded be nh generally produce satisfactory results from fluorescent magnetic inks as compared with qual wort thn ree | ack magnetic inks. . te ei » 90 100 wet 248 MT9.2The following waveform! ‘power supplies are shown 19 1. swinging fields are also ‘now possible, Le. the bench equipment is ‘aviomaticaly changing rom CF to MF and vice versa, allowing he ‘perator view in all 30 ‘directions inane ‘operation. 1NB. Also refered to as sequential field of mal directional esting fonger duty cycles on the 4p ‘equipment (NB. BS.EN 180 9936 Part 3 now quotes current ‘generators io havea nim dy jee of ime 0 » 100 Magnetic particle inspection using electrical apparatus can use several types of current, each form has advantages and disadvantages, ALTERNATING CURRENT For all practical purposes altemating current (ac. is used to detect surface defects. A.c. does not penetrate deeply into the metal but produces a high density field near the surface of a ferromagnetic conductor, this characteristic is called the skin effect and will ‘emphasise surface breaking discontinuities, e.g. fatigue or stress induced cracks. The skin effect is caused by the concentration of eddy currents near the surface of the specimen; eddy currents are only produced by an alternating current. Fig, 10.1 Alternating current (single phase) Ifsurface breaking defects are the prime consideration for detection, then an additional advantage of ac. is that less relevant indications from sub-surface discontinuities are not created by the low penetration capabilities of this type of current, wh ‘otherwise distract the inspector. ‘Other advantages of ac. include: © Current at required values can normally be obtained directly from the mains supply, or via simple transformers. ‘© Ac. machines are relatively inexpensive, are easy to maintain and have basic ‘operating characteristics. ‘© Due to the current form fluctuation (negative to positive), magnetic particles will vibrate and readily align themselves to flux leakages; this enhances the definition of defect indications. ‘© Ifafter magnetization the current is reduced to zero via a rheostat or step down device the component is automatically demagnetized Disadvantages: © The main disadvantage of ac. is that it will only detect surface defects with any degree of reliability DIRECT CURRENT ‘A major advantage of dc. for magnetization is its deeper penetration into the metal thus enabling sub-surface discontinuities to be revealed. D.c. also leaves residual magnetism which will hold an indication and allow more time for evaluation of the indication, however residual magnetism is not always an advantage and may present problems if complete demagnetization of the component is required. ove HH . MTAoe Peon The technique bnown as de. suge enplsade. 49 ‘xrren which nally ars with avery High vale and rapidly reduces oa lower vale for the majority ofthe shot duration. The advantage ofthis t 4. less chance of damaging 20 the object from a continuous high current ‘it Improved particle ‘Leal fer detection of hep big daconiatles 0 Co 0 100 De. current may be obtained in various forms, either from batteries or rectified a.c., ‘each having their own advantages and disadvantages. Direct current from battery packs ab Fig. 10.2 Direct current from battery ‘Advantages include: ‘© Does not require mains electrical supply. ‘© Sub-surface defects may be detected. Disadvantages include: + Weight of batteries. + Limited battery life (high current draw). * Continuous current flow does not produce particle vibration and will not therefore enhance defect detection. Because of this, continuous d.c. should not be used with dry powders which require a pulsating magnetic field to provide mobility to the powder when it lands on the test surface. Half-wave rectified current H.w.r. is achieved by removing all the negative current values from a.c. allowing the positive half cycles to remain, this current may be considered to be a form of dc. with all the associated characteristics of this current form with the added advantage of a pulsating wave, — Peak Fig. 10.3 Half-wave rectified current (single phase) owe 2806 MT102Fd 0 50 » ” 100 io TPO ONT Se Since h.wsc. will eave a component partially magnetized itis usualy packaged as an a.c/h.wse. unit so that the ac. is available for demagnetization. Advantages include: © Will detect sub-surface defects © Will detect fine surface breaking defects. ‘© Simple, effective and inexpensive current form to achieve. ‘© Due to pulsating current the magnetic particles will vibrate and provide greater attraction to flux leakages. Disadvantages: © May leave the part partially magnetized. Full-wave rectified current Revere. provides the most efficient conversion of ac. power to d.c... With this current form the negative half cycle of an a.c. waveform is removed from below the zero Tine ‘and reversed to make all values positive (or vice versa). YA. Fig, 10.4 Full-wave rectified current (single phase) ‘Advantages include: © Detection of sub-surface defects ‘© Simple and efficient means of providing direct current. Disadvantages include: + More expensive than haw. + Particle vibration and mobility reduced. ‘© Higher current requirements than a.c. or haw.r. ‘© Can produce demagnetization problems. Three phase full wave rectified current k Fig. 10.5 Three phase full wave rectified current ‘we #220988 MTI0310 20 40 50 ‘The ocepational exposure limit forsylene san $0 ‘ccapationlexponure standard (OES), herefore the hort term OEL is 100 ppm over a15 minute reference period. The long term OEL i $0 ppm over 8 how tine weighed ‘erage reference period. °° 100 eB OnE) Ceo a Score ‘The Control of Substances Hazardous to Health Regulations, referred to as ‘The COSHH Regulations, define a substance hazardous to health as: a substance listed in part 1A of the approved list as dangerous for supply, see Hazard Information & Packaging for Supply Regulations 1994 (CHIP2) - nature of risk classified as very toxic, toxic, harmful, corrosive or isitant. 'b. one which has an MEL in Schedule 1 of COSHH or if the H & S Commission has approved an OES. ©. amioro-organism which creates a hazard to health 4. dust in air (when substantia). ©. substance comparable with the above. ‘The COSHH regulations are not applicable to the contro} of lead, radioactivity, explosive or flammable properties of materials, high or low temperatures, high pressures, medical treatment or below ground work (mining). RESPONSIBILITIES ‘The exposure of an employee to substances hazardous to health is under the control of the employer. A training organisation is responsible for exposure by trainees. Employers must prevent exposure to substances hazardous to health, or control exposure when total prevention is not reasonably practicable. Personal protective ‘equipment, e.g, masks, ate a second choice for control. Employees have a duty to report any problems in exposure control procedures or any defects found in protective equipment. Employers must keep records of examinations/monitoring tests carried out. These are kept for 5 years; 30 years for identifiable employees. OCCUPATIONAL Exposure Limits (EH40—2005) ‘The Guidance Note EH40, entitled Occupational Exposure Limits, is « document published by the Health and Safety Executive which gives occupational exposure limits for substances hazardous to heath ‘A solvent, which is a substance hazardous to health, has its own occupational exposure limit as given in B40. ‘The toxicity value of a solvent is expressed in parts per million (ppm), e.g. the short ‘erm occupational exposure limit for xylene is 100 ppm, this means to say that ifthe air ‘contained xylene exceeding 100 ppm, the air would be considered to be a significant hazard to health. ‘There are two types of occupational exposure limit: 1. Maximum exposure limit (MEL): "is the maximum concentration of an airbome substance, averaged over a reference period, to which employees may be exposed bby inhalation under any circumstances and is specified, together with the appropriate reference period, in Schedule | of COSHH" 2 Occupational exposure standard (OES): "is the concentration of an airbome substance, averaged over a reference period, at which, according to current knowledge, there is no evidence that it is likely to be injurious to employees if they are exposed to inhalation, day after day to that concentration, and’ which is specified ina list approved by HSE". doves nase MTLuane & TPO! Sos 0 2» 0 0 30 © ian When a MEL is specified, exposures must be kept as low as is reasonably practicable, but always below the specified value. ‘As OES should not be exceeded, but, an exposure over the limit is acceptable, providing the reason for exceeding the OES has been identified and measures are taken ‘to reduce the exposure below the OES as soon as is reasonably practicable. MTin210 20 30 40 so 7” %0 90 100 BS EN 1290 : 1998 BS EN 1291 : 1998 BS EN 1330-1 : 1998 BS EN 1330-2: 1998 BS EN 1369:1997 BS EN ISO 12707 cP 3012, BS EN ISO 3059 : 2001 BS 3683 : Part 2: 1985 BS 4069 : 1982 BS 4489 : 1984 BS 5044: 1973, BS 6072: 1981 PD 6513: 1985, Sir: 95 BS EN 12062 : 1998 BS EN ISO 9934-1 : 2001 LOSERS ATO De ROT UTS Non-Destructive Examination of Welds Magnetic Particle Examination of Welds Non-Destructive Examination of Welds Magnetic Particle Testing of Welds — Acceptance Levels ‘Non-Destructive Testing ~ Terminology art 1: List of General Terms Non-Destructive Testing ~ Terminology Part 2: Terms common to Non-Destructive Testing Methods Founding: Magnetic Particle Inspection ‘Non-Destructive Testing ~ Terminology ‘Terns used in Magnetic Particle Testing Code of Practice for Cleaning and Preparation of Metal ‘Surfaces (SUPERSEDED] ‘Non-Destructive Testing Penetrant Testing and Magnetic Particle Testing ‘Viewing Conditions British Standard Glossary of Terms used in Non- Destructive Testing Part 2: Magnetic Particle Flaw Detection British Standard for Magnetic Flaw Detection Inks and Powders [SUPERSEDED] ‘ British Standard method for Measurement of UV-A Radiation (Black Light) used in Non-Destructive ‘Testing [SUPERSEDED] Specification for Contrast and Paints used in Magnetic Particle Flaw Detection /SUPERSEDED] Method for Magnetic Particle Flaw Detection [SUPERSEDED] Magnetic Particle Flaw Detection ‘A Guide to the Principles and Practice of applying ‘Magnetic Particle Flaw Detection in accordance with BS 6072 Code of Practice for Cleaning and Preparation of Metal Surfaces Non-Destructive Examination of Welds General rules for Metallic Materials Non-Destructive Testing ~ Magnetic Particle Testing Part 1 : General Principles MTI2-1Ruane & TPONeI 0 20 30 40 50 0 0 0 _PSEN ISO 9934-2 : 2001 | As EN1S0 9934-3 : 2001 ISO 17638:2003, ‘BS EN 10228:1999 CPE RO on ONLY ‘Non-Destructive Testing ~ Magnetic Particle Testing, Part2 : Characterisation of Products ‘Non-Destructive Testing ~ Magnetic Particle Testing Part 3: Equipment NDT of Welds ~ MPI MPI of Steel Forgings MTI22