NON DESTRUCTIVE TESTING – MAGNETIC PARTICLE INSPECTION

1.0 Introduction

Magnetic Particle Inspection (MPI) is used to detect surface and near surface flaws in
ferromagnetic materials such as iron, nickel, cobalt and some of their alloys. The
indications provided by this type of test occur at the surface of the part, directly above
the location of the flaws, and the general size, shape, and orientation of the flaws can
usually be directly inferred. Magnetic particle testing is used in receiving inspections, in
in-process or final inspections, and in in-service inspections. MPI is one of the best
established non destructive testing methods used on ferromagnetic materials.

The presence of a surface or subsurface discontinuity in the material allows the

magnetic flux to leak, since air cannot support as much magnetic field per unit volume
as metals. Ferrous iron particles are then applied to the part. The particles may be dry
or in a wet suspension. If an area of flux leakage is present, the particles will build up at
the area of leakage and form what is known as an indication (refer Figure 2). The
indication can then be evaluated to determine what it is, what may have caused it, and
what action should be taken, if any. When ferromagnetic material (typically iron or steel)
is defect-free, it will transfer lines of magnetic flux (field) through the material without
any interruption (refer Figure 1).

Figure 1: A defect-free ferromagnetic material

But when a crack or other discontinuity is present, the magnetic flux leaks out of the
material. As it leaks, magnetic flux (magnetic field) will collect ferromagnetic particles
(iron powder), making the size and shape of the discontinuity easily visible.

Figure 2: A ferromagnetic material with a crack.

However, the magnetic flux will only leak out of the material if the discontinuity is
generally perpendicular to its flow. If the discontinuity, such as a crack, is parallel to the
lines of magnetic flux, there will be no leakage and therefore no indication observed. To
resolve this issue, each area needs to be examined twice. The second examination
needs to be perpendicular to the first so discontinuities in any direction are detected.
The examiner must ensure that enough overlap of areas of magnetic flux is maintained
throughout the examination process so discontinuities are not missed.

2.0 Equipment

2.1 Electromagnetic Yoke: Used to establish a magnetic field. A switch is included in

the electrical circuit so that the current and, therefore the magnetic field can be
turned on and off. It can be powered with AC from a wall socket or by DC from a
battery pack. This equipment can generate a very strong magnetic field in a local
area where the poles of the magnet touch the part being inspected.
2.2 Portable Coils: The coils allow for the use of either dry powder or wet fluorescent
inspection and can be used for demagnetizing as well.
2.3 Magnetic Particle Powder: A common particle used to detect cracks, for both dry
and wet systems

3.0 Procedure

Depending on the application, there is different magnetization technique used in

magnetic particle testing. These techniques can be grouped into the following two
categories:

3.1 Direct current techniques: These are the technique in which the current flows
through the test specimen and the magnetic field produced by this flow current is
used for the detection of defects.
3.2 Magnetic flux flow techniques: In these techniques magnetic flux is induced into
the specimen either by the use of a permanent magnet or by flowing current
through a coil or conductor.

Step 1: Surface Preparation.

Prior to the test the area to be in inspected and at least one inch either side shall be free
from any features that may inhibit the test or mask unacceptable discontinuities. These
include but are not limited to, slag, spatter, oil, scale, rough surface and protective
coatings. Surface preparation by grinding, machining or other methods may be
necessary where surface irregularities could mask indications of unacceptable
discontinuities.
Step 2: Equipment and Consumable Control.

The magnetic force of yokes shall be checked at least once a year or after any damage
and/or repair. The yoke shall be able to lift a weight of at least 10 pounds at the
maximum pole spacing that will be used. Magnetic powders shall be used once only,
expendable basis. Care shall be taken to avoid possible contamination and the
magnetic powders range in size from 5 to 170 micrometers, are designed to be seen in
white light conditions. For wet systems, magnetic inks shall be used once, and care
shall be taken to thoroughly agitate the ink before use. Particles used in wet systems
have pigments applied that fluoresce at 365nm (ultraviolet) requiring 1000 µW/cm 2(10
W/m2) at the surface of the part for proper inspection.

Step 3: Direction of Magnetizing Field.

The magnetizing field shall be applied in two directions approximately perpendicular to

one another. Determination of field direction shall be carried out for each weld to be
inspected.

Step 4: Sequence of Operations:

i. The surface to be inspected shall be prepared and cleaned of contaminants.

ii. The continuous magnetization technique is to be employed by the aid of an
electromagnetic yoke. Ensure in all operations that the pole faces remain in
maximum contact with the surface.
iii. For the wet magnetic particle method, apply the ink onto the area under test and
allow to flow over the surface such as allowing maximum exposure of the
magnetic particles to any flux leakage present, excess material may be gently
blown across the surface to aid interpretation.
iv. Dry magnetic powders should be applied in such manner that a light, uniform,
dust like coating settles on the surface of the area under inspection. Excess
powder may be gently blown across the surface to aid interpretation and increase
exposure of magnetic particles to any flux leakage present.
v. Maintain the magnetizing field for at least two seconds after step iii or iv and
inspect immediately. The sequence is repeated at approximately 90° to the
above. Inspection can be time consuming to carefully look for indications that are
only 45° to 90° from the magnetic field.
vi. The area to be inspected shall be limited to maximum distance of one fourth of
the poles spacing (25%). Pole spacing shall be limited to a maximum value equal
to or less than that used when conducing the lift test of the standard weight but
shall be not less than 3 inches.
Step 5: Evaluation of Indications.

An indication may be the evidence of a surface imperfection. All indications need not be
relevant. Relevant indications are those caused by leakage flux. Relevant indications
due to unacceptable mechanical discontinuities are to be noted, located and sized. Non
relevant indication shall be re-examined again.

4.0 Advantages

4.1 A superior method for detection of surface cracks.

4.2 The method is fast and simple to carry out.
4.3 It does not need very stringent pre-cleaning operation.
4.4 Best method for the detection of fine, shallow surface cracks in ferromagnetic
material.
4.5 Fast and relatively simple NDT method.
4.6 Generally inexpensive.
4.7 Will work through thin coating.
4.8 Few limitations regarding the size/shape of the test specimens.
4.9 Highly portable NDT method.
5.0 Limitations

5.1 Material must be ferromagnetic.

5.2 Orientation and strength of magnetic field is critical.
5.3 Detects surface and near-to-surface discontinuities only.
5.4 Large currents sometimes required.
5.5 “Burning” of test parts a possibility.
5.6 Misinterpretations may occur depending on the test object surface, differences in
chemical composition of welds and base materials and object geometry.
5.7 Parts must often be demagnetized, which may be difficult.

6.0 Standards

6.1 International Organization for Standardization (ISO)

 ISO 3059, Non-destructive testing - Penetrant testing and magnetic particle

testing - Viewing conditions
 ISO 9934-1, Non-destructive testing - Magnetic particle testing - Part 1: General
principles
 ISO 9934-2, Non-destructive testing - Magnetic particle testing - Part 2: Detection
media
 ISO 9934-3, Non-destructive testing - Magnetic particle testing - Part 3:
Equipment
 ISO 10893-5, Non-destructive testing of steel tubes. Magnetic particle inspection
of seamless and welded ferromagnetic steel tubes for the detection of surface
imperfections
 ISO 17638, Non-destructive testing of welds - Magnetic particle testing
 ISO 23279, Non-destructive testing of welds - Magnetic particle testing of welds -
Acceptance levels

6.2 European Committee for Standardization (CEN)

 EN 1330-7, Non-destructive testing - Terminology - Part 7: Terms used in

magnetic particle testing
 EN 1369, Founding - Magnetic particle inspection
 EN 10228-1, Non-destructive testing of steel forgings - Part 1: Magnetic particle
inspection

6.3 Canadian Standards Association (CSA)

 CSA W59
6.4 American Society of Testing and Materials (ASTM)

 ASTM E1444/E1444M Standard Practice for Magnetic Particle Testing

 ASTM A 275/A 275M Test Method for Magnetic Particle Examination of Steel
Forgings
 ASTM A456 Specification for Magnetic Particle Inspection of Large
Crankshaft Forgings
 ASTM E543 Practice Standard Specification for Evaluating Agencies that
Performing Nondestructive Testing
 ASTM E 709 Guide for Magnetic Particle Testing Examination
 ASTM E 1316 Terminology for Nondestructive Examinations
 ASTM E 2297 Standard Guide for Use of UV-A and Visible Light Sources and
Meters used in the Liquid Penetrant and Magnetic Particle Methods

6.5 Society of Automotive Engineers (SAE)

 AMS 2641 Magnetic Particle Inspection Vehicle

 AMS 3040 Magnetic Particles, Nonfluorescent, Dry Method
 AMS 3041 Magnetic Particles, Nonfluorescent, Wet Method, Oil Vehicle, Ready-
To-Use
 AMS 3042 Magnetic Particles, Nonfluorescent, Wet Method, Dry Powder
 AMS 3043 Magnetic Particles, Nonfluorescent, Wet Method, Oil Vehicle, Aerosol
Packaged
 AMS 044 Magnetic Particles, Fluorescent, Wet Method, Dry Powder
 AMS 3045 Magnetic Particles, Fluorescent, Wet Method, Oil Vehicle, Ready-To-
Use
  AMS 3046 Magnetic Particles, Fluorescent, Wet Method, Oil Vehicle, Aerosol
Packaged5
 AMS 5062 Steel, Low Carbon Bars, Forgings, Tubing, Sheet, Strip, and Plate
0.25 Carbon, Maximum
 AMS 5355 Investment Castings
 AMS I-83387 Inspection Process, Magnetic Rubber
 AMS-STD-2175 Castings, Classification and Inspection of AS 4792 Water
Conditioning Agents for Aqueous Magnetic Particle Inspection AS 5282 Tool
Steel Ring Standard for Magnetic Particle Inspection AS5371 Reference
Standards Notched Shims for Magnetic Particle Inspection

6.6 United States Military Standard

 A-A-59230 Fluid, Magnetic Particle Inspection, Suspension

7.0 References

7.1 http://www.inspection-for-industry.com/magnetic-particle-inspection.html
7.2 http://en.wikipedia.org/wiki/Magnetic_particle_inspection
7.3 http://www.aero.ing.unlp.edu.ar/catedras/archivos/ASTME%20709%20%2008.p
df
7.4 http://gaussbusters.com/resources/articles/principles-of-magnetism/