MAGNETIC PARTICLE

TESTING(MPI)
 Introduction
 A nondestructive testing method used for defect detection. Fast
and relatively easy to apply and part surface preparation is not
as critical as for some other NDT methods.

 MPI one of the most widely utilized nondestructive testing

methods.

 MPI uses magnetic fields and small magnetic particles, such as

iron particles to detect flaws in components.

 The only requirement is that the component being inspected

must be made of a ferromagnetic material such as iron, nickel,
cobalt, or some of their alloys.
Sample Video
 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 or
magnetized and magnetic lines of force
can be found in and around the objects.
A magnetic pole is a point where a Magnetic lines of force
magnetic line of force exits or enters a around a bar magnet
material.
 Introduction to Magnetism

Magnetic field lines:

• Form complete loops.
• Do not cross.
• Follow the path of least resistance.
• All have the same strength.
• Have a direction such that they cause poles to attract or repel.

Opposite poles attracting Similar poles repelling

 Theory of Magnetization

• An Object is magnetized when Part or all of it’s magnetic

domains have their North and South poles oriented .
• magnetic domains is the magnetic fields of atoms .
• The Force that attract other magnetizable materials to the
magnetic poles is known as Magnetic Flux.
• The Magnetic flux is made up of all of the magnetic lines “line of
force”.
• Flux Density : Flux per unit Area at right angles to the direction
of flux .

S N

Demagnetized Magnetized
magnetic domains

 Sample Video for magnetic domains

 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.
Leakage Field (Flux Leakage ) : Actually Magnetic lines of
force that leave the part and pass through air from one
pole to the other of opposite polarity .
Right Hand Rule

 To find the direction of an electrically induced

magnetic field , place your thumb on the conductor in
the direction of current and your fingers will thin point
in the direction of the line of force .
 This rule suppose the
Current flow form + to - (current flow).
Left Hand Rule

 If More commonly accepted “Electron flow “ theory

which consider that the electricity flow from – to+
(Electron flow) , it would be necessary to use Left
Hand Rule
Magnetic Materials
 The Magnetic Material are divided into 3 divisions
according to their susceptibility to be magnetized & it will
be discussed as below ,

 Diamagnetic Metals : have a small & negative

susceptibility to magnetization ( slightly repelled )
Copper – gold – silver

 Paramagnetic Metals : have a small & positive

susceptibility to magnetization ( slightly attracted )
Magnesium – Molybdenum - Lithium
Magnetic Materials

 Ferromagnetic Metals : have a large & positive

susceptibility to magnetization . They have a strong
attraction & they are able to retain their magnetization
after the magnetic field has been removed .
Iron – Cobalt – Nickel

 Ferromagnetic Metals are only metals commonly

inspected with Magnetic particle method .
Important Magnetic properties

 Permeability : Refers to the Ease which a magnetic flux is

established in the article being inspected .

 Reluctance : The opposition of a magnetic material to the

Establishment of a magnetic flux .

 Residual Magnetism : Refers to the amount of Magnetism

retained after the magnetizing force is removed .
Important Magnetic properties

 Retentivity : Refers to the ability of material to retain a

certain amount of residual magnetism .

 Coercive Force : Refers to the reverse magnetizing force

necessary to remove the residual magnetism .
High carbon steel Magnetic properties :

 If a piece of high carbon steel were placed into a

magnetizing flux , it would have exhibit the following :
 Low permeability .
 Highly Reluctant .
 High residual Magnetism .
 High Retentivity.
 High Coercive Force
Question

 …………….. Is the opposition of a

magnetic material to the establishment
of a magnetic flux .
 ………………Magnetic line of force that
leave the part and pass through the air
Question

 Reluctance Is the opposition of a

magnetic material to the establishment
of a magnetic flux .
 Flux leakage Magnetic line of force that
leave the part and pass through the air
 Types 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
around the perimeter of a part.
 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.
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 a Longitudinal Magnetic
Field Using a Coil
When a current carrying conductor is formed into a
loop or several loops to form a coil, a magnetic field
develops that flows through the center of the loop or
coil along its longitudinal axis and circles back around
the outside of the loop or coil.
 Producing a Longitudinal magnetic
Field Using Yoke
Electromagnetic yokes
are 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.
 Producing a 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 and 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.
Direct induction using Head Shot
Direct induction using Prods
Indirect induction using central conductor
Indirect induction using central conductor

 In Nonmagnetic materials , the line of force will not stay in

the material .
for example when a copper bar is used the magnetic field is
established around the bar .
Important Note

 The Iron Particles will not be attracted to

a magnetized part except where a flux
leakage exists
Question ??

 Which of the Following defects could be detected if

the part contained circular magnetization & which of
them could be detected if the part contained
longitudinal magnetization ??
Question ??

 Which of the Following defects could be detected if

the part contained circular magnetization & which of
them could be detected if the part contained
longitudinal magnetization ??
 Circular will detect B & C
 Longitudinal will detect A & B
Alternating Current

 AC has a little penetration power and provide the best detection

of Surface Discontinuities .
 The Reversing direction of the AC gives iron particles more
agitation & mobility .
 AC can be rectified to produce Half wave alternating current
(HWAC) , Commonly called Have wave Direct Current (HWDC).
AC & DC & HWDC

Current Type Used for

AC Surface defects

DC Subsurface defects

HWDC Surface & subsurface defects

Hysteresis Loop
Wide Hysteresis Loop

The materials which

have a wide hysteresis
loop will have the
following properties ,
Low permeability.
High Retentivity .
High Coercive force .
High Reluctance.
High Residual
magnetism.
Thin Hysteresis Loop
The materials which
have a thin hysteresis
loop will have the
following properties ,
High permeability.
Low Retentivity .
Low Coercive force .
Low Reluctance.
Low Residual
magnetism.
Question

 Indentify the parts indicates by numbers 1 ,2 and 3 ..

Question

 Indentify the parts indicates by numbers 1 ,2 and 3 ..

 1 Residual Magnetism
 2 Saturation point
 3 coercive force
Magnetic Fields
Distribution and Intensity

 The field strength varies from zero at the center of the

conductor to a maximum at the surface.
 The field strength outside the conductor decreases with
distance from the conductor.
 The field strength outside the conductor is directly
proportional to the current strength Inside the conductor,
the field strength is dependent on the current strength,
magnetic permeability of the material.
Magnetic Field Distribution in solid Magnetic &
nonmagnetic conductors (DC Current).

 When the conductor is a magnetic material, the field strength

within the conductor is much greater than it is in the
nonmagnetic conductor. This is due to the permeability of the
magnetic material. The external field is exactly the same for the
two materials provided the current level and conductor radius
are the same.
Magnetic Field
Distribution in hollow Magnetic & Nonmagnetic
conductor (DC Current).

 In a hollow circular conductor there is no magnetic field in

the void area. The magnetic field is zero at the inside wall
surface and rises until it reaches a maximum at the
outside wall surface. As with a solid conductor, when the
conductor is a magnetic or non magnetic material,
Magnetic Field
Distribution through Nonmagnetic Central Conductor &
Tube (DC Current).

 when current is passed through a nonmagnetic central

conductor (copper bar), the magnetic field produced on the
inside diameter surface of a magnetic tube is much greater and
the field is still strong enough for defect detection on the OD
surface.
Alternating Current field distribution

 When the conductor is carrying alternating current, the

field is concentrated in a thin layer near the surface of the
conductor. This is known as the "skin effect“ so that the
AC provides a good detection for the surface
discontinuities .
Current Requirements

 The amount of current will vary with the shape and

permeability of the specimen being inspected.
 Too much current may burn the part or may cause heavy
accumulations of particles .
 Too little current may not provide sufficient flux leakage to
attract the iron particles .
Current Requirements

 Circular Magnetization ;
 The Used Rule :
 800 – 1000 Amperes per Inch Thickness or diameter .
Current Requirements

 Circular Magnetization ;
 The Used Rule :
 800 – 1000 Amperes per Inch Thickness of diameter .
Current Requirements
Current Requirements

 Longitudinal Magnetization via coil :

 The amount of Current needed will be controlled by the
formula :
 N I = 45000/(L/D) ratio where ,
 I : Current in amperes
 N: No of turns in the coil
 L : Length of the article
 D: Diameter or thickness of article
Current Requirements

 Longitudinal Magnetization :
Current requirements

 The a/m formula used only when the following assumptions are
made :

 1. an article greater than 18 inches requires more than one coil

shot .
 2. The cross section of the article is not greater than one-tenth
the area of the coil .
 3. The article has an L/D ratio of between 2 and 15 .
 4. The Article is placed against the inside wall of the coil .
Current requirements

 Prod Magnetization ;
 The amperage required to be as mentioned below ;
 Demagnetization

• Demagnetization is defined as :
• The removal of residual magnetism by reducing
the strength and reversing the direction of a
magnetic field.
• 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.
– Residual Fields in rotating parts will attract
metal particles ,causing excessive wear.
 Demagnetization (Cont.)

• Demagnetization requires that the residual magnetic

field is reversed and reduced by the inspector.
• Reversing the Magnetic field :
• 1. Reversing the part in magnetic field .
• 2. Reversing the current through the coil .
• 3. Reversing the coil ( turn it 180 deg )
• Reducing the Magnetic field :
• 1. Reduce the magnetizing current .
• 2. move the part away from coil .
• 3. Move the coil away from the part.
Circular & Longitudinal demagnetization :

 AS the flux lines do not normally leave the part in a circular

magnetization , it is difficult to tell if the demagnetization process
done as required .

 On the other hand it’s easy to tell if a longitudinally magnetized

bar is still magnetized or demagnetized .

 Therefore , it is often recommended that a circularly

magnetized part be longitudinally magnetized and then go
through the magnetization process .
Demagnetization Procedures :

 Alternating Current coil method :

 As the coil using an alternating
current , it’s verify one of the two
requirements of the demagnetization
process ( reversing direction ) .

 To complete the demagnetization

process , the part is placed In the
reversing current magnetic field and
the current is slowly reduced .
Demagnetization Procedures :

 Demagnetization using direct current :

 DC is not reversing automatically so it is necessary to have
some mechanical means to reverse the current .
 The maximum degree of demagnetization can be obtained
when we reverse the current once per second .
 In the DC demagnetization the current should be reduced first
then reversed .
 When demagnetize large parts the earth’s field will leave a
small amount of residual magnetism , so where complete
magnetization is required , the demagnetizing field must be
placed in East – West direction .
Field Indicator

 Note : There must be a leakage field in

order to determine whether the part is
magnetized .
 Field Indicator :
 Used to :
 Locate flux leakage .
 Measure field strength .
 Show when the part is demagnetized .
 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.
 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.
Wet magnetic particles Concentration .

 For 100 CC of magnetic particles liquid

 The following concentration should be achieved :
 1.5 to 2 CC in visible type .
 0.2 to 0.4 CC in fluorescent type .
 The a/m concentrations to be verified through the settling
test.
 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.
Magnetic particles Medium & their
preparation

 Particles of testing medium should have two important

properties ,
1. high permeability.
 2. low Retentively .

 Size of particles usually pass 100 mesh screen .

 It’s also should have round size
 Good mobility .
 Good visibility .
Magnetic particles Medium & their
preparation

 Particles of testing medium should have two important

properties ,
1. high permeability.
 2. low Retentively .

 Size of particles usually pass 100 mesh screen .

 It’s also should have round size
 Good mobility
 Good visibility .
Safety Precautions ,

 Electric Arcing is Hazard .

 Excessive amount of Magnetic particles inhalation
should be avoided .
 Open flam should not be near from testing area
 The black light may damage the skin or eyes so be
sure that the filter in good condition
 Burns can be caused due to the resistance heating ,
caution is required in handling parts immediately after
the test
Residual Method Continuous method

 The medium is applied  The magnetic operation is

after the specimen has conducted simultaneously
been magnetized and the with the application of the
magnetizing force test medium .
removed .  Uses dry & wet particles
 Uses wet particles only
 Pre-cleaning
When inspecting a test part with the magnetic particle method
it is essential for the particles to have a suitable path for
traveling 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.
Also the cleaning process should be involved in the
removal of slag , rust and heavy build up paints as it is may
interfere with the results .
The smoother the surface and the more uniform color ,the
more favorable are the conditions for formation of magnetic
particle indication
Application of Magnetic Particle Testing
procedure

 Magnetizing of A solid cylindrical specimen

Magnetizing of A solid cylindrical specimen
Magnetization of large Gear
Magnetization of large Gear
Magnetizing of hollow cylindrical
Specimens
Magnetizing of hollow cylindrical
Specimens
Magnetization of large weldments or
casting using prods
 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.
 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

 Splined Shaft with
Service Induced Cracks

Fluorescent, Wet Particle Method

 Threaded Shaft with
Service Induced Crack

Fluorescent, Wet Particle Method

 Large Bolt with
Service Induced Crack

Fluorescent, Wet Particle Method

 Crank Shaft with
Service Induced Crack Near Lube Hole

Fluorescent, Wet Particle Method

Indication of cracks
Indication of cracks
Indication of cracks
Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

Toe Crack in SMAW Weld

Visible, Dry Powder Method

Throat and Toe Cracks in
Partially Ground Weld

Visible, Dry Powder Method

Relevant and non relevant indications

 Non Relevant indication :

 A group of non relevant magnetic
disturbance not caused by a
discontinuity .
 Non relevant indication could caused by
,
 1. Excessive magnetizing current .
 2. Structural design of the part .
 3. variances of permeability within the
part .
Relevant and non relevant indications

 Typical forms of non relevant indications ,

Relevant and non relevant indications
Relevant and non relevant indications

 Non relevant indication could be avoided in the interpretation if

we remember that ,
 1 . They can be identified by fuzzy more than sharp .
 2. they are usually to be associated with some features of
construction .
 3. They are usually uniform in direction & size .
 False indication ,
 False indication are caused when particles are accumulated by
gravity or if the surface was rough .
Relevant and non relevant indications

 Relevant indication :
 Typically true indication caused by material discontinuity
and it will appear as follows ,
 Surface indication ,
 Sharp , distinct , clean cut
 Subsurface indication ,
 Less distinct , fuzzy or defused patterns .
 Advantages of
Magnetic Particle Inspection
• Can detect both surface and near sub-surface defects.
• Can inspect parts with irregular shapes easily.
• Pre-cleaning 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.
 Limitations of
Magnetic Particle Inspection
• Cannot inspect non-ferrous materials such as
aluminum, magnesium .
• 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 ¼ inch (under ideal conditions).
• Post cleaning, and post demagnetization is often
necessary.
• Alignment between magnetic flux and defect is
important
Discontinuities ,

 Materials discontinuities are divided into

two section ,
 Inherent Discontinuities .
 Processing Discontinuities .
Inherent Discontinuities .
Inherent Discontinuities .
Inherent Discontinuities .
Processing discontinuities ,
Processing discontinuities ,
Welding discontinuities ,
Welding discontinuities ,
Forging discontinuities
Forging discontinuities
Grinding cracks
  The End
Let’s go to the practical part
after our break


 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.
 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.
 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.
 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.
For More Information

The Collaboration for

NDT Education

www.ndt-ed.org

The American Society

for Nondestructive
Testing

www.asnt.org