UNIVERSITY OF ENGINEERING & TECHNOLOGY PESHAWAR

DEPARTMENT OF MECHANICAL ENGINEERING

CRACK DETECTION BY MAGNETIC

PARTICAL INSPECTION (MPI)
ME-207L ENGINEERING METALLURGY LAB

1
 OBJECTIVE
1. To explain the term ‘Non – Destructive Testing’.

2. To list and define the Basic Elements of Non – Destructive Testing.

3. To briefly discuss Magnetism and state the properties of Magnetic Field Lines.

4. To understand the nature of Ferro – magnetic materials.

5. To tabulate different Inspection Methods and their respective characteristics.

6. To understand the Basic Principle of MPI Test.

7. To state and define the types of MPI Testing.

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 What is NDT?
NDT stands for ‘Non – Destructive Testing’.
NDT is a wide group of analysis techniques used in science and technology industry to
evaluate the properties of a material, component or system without causing damage.
NDT is necessary whenever we need to assure ourselves of the integrity of our
infrastructure. Aircraft, trains, pipelines, oil rigs, bridges and pressure vessels are
examples of everyday things that are regularly examined.
In addition to the need to ensure safety, non-destructive testing can be used to improve
output and profitability.
Furthermore, a component or an entire structure or machine can be tested many times
using several types of tests through the complete life cycle to ensure its continued
integrity.

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 BASIC ELEMENTS OF NDT
There are five basic elements of Non – Destructive Testing:
1. Source: To produce a probing path or investigation unit.
2. Modification: If there is any flaw or defect in source, it must modify the probing
medium.
3. Detection: Device that records the change in probing medium.
4. Indication: Special pattern formed due to flaw in specimen.
5. Interpretation: Histograms, Graphs, Charts, Scatter Plots etc.

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 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 line of force exits or enters a material.
Magnetic field lines:
i. Form complete loops.
ii. Do not cross.
iii. Follow the path of least resistance.
iv. All have the same strength.
v. Have a direction such that they cause poles to attract or repel.

Magnetic lines of force around a Opposite Poles Attracting Similar Poles Repelling
bar magnet DEPARTMENT OF MECHANICAL ENGINEERING 5
 FERRO MAGNETIC MATERIALS
A material is considered ferromagnetic if it can be magnetized. 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. These regions are call magnetic domains.
Magnetic domains point randomly in demagnetized material, but can be aligned using electrical
current or an external magnetic field to magnetize the material.

Demagnetized Magnetized

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 NDT METHODS
S.No. Inspection When to Use? Where to Use? Advantages?
Method

1. Eddy Current Variation in Size Uniform Geometry High Speed

2. X – Ray Surface Cracks Casting, Welded Vessels Permanent Films

(Deep Crack)

3. MPI Sub-surface Cracks Ferro-magnetic Material Economic and Easy

4. Penetrant Porosity All Metals, glass, ceramics Fast and Portable

etc

Inspection Methods and their Characteristic

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 MAGNETIC PARTICLE INSPECTION (MPI)
Magnetic Particle testing is one of the most widely used NDT methods since it is fast
and relatively easy to apply and part surface penetration is not as critical as it is for some
other methods.

This method uses magnetic fields and small magnet particles (i.e. iron fillings) to detect
flaws in components.

The method is used to inspect a variety of products including castings, forgings and
weldings.

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 MAGNETIC PARTICLE INSPECTION (MPI)
Basic Principle of MPI Testing:
Any place that a magnetic line of force exits or enters the magnet is called a “pole” (magnetic
lines of force exit the magnet from north pole and enter from the south pole).

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 MAGNETIC PARTICLE INSPECTION (MPI)
i. When a bar magnet is broken in the center of its length, two complete bar magnets with
magnetic poles on each end of each piece will result.
ii. If the magnet is just cracked but not broken completely in two, a north and south pole will form
at each edge of the crack.
iii. The magnetic field exits the north pole and reenters at the south pole.
iv. The magnetic field spreads out when it encounters the small air gap created by the crack
because the air cannot support as much magnetic field per unit volume as the magnet can.
v. When the field spreads out, it appears to leak out of the material and, thus is called a flux
leakage field.

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 MAGNETIC PARTICLE INSPECTION (MPI)
‘If iron particles are sprinkled on a cracked magnet, the particles will be attracted to and cluster not
only at the poles at the ends of the magnet, but also at the poles at the edges of the crack. This
cluster of particles is much easier to see than the actual crack and this is the basis for magnetic
particle inspection.’

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 TYPES OF MPI
There are two types of MPI:

Residual Method:
◦ Dry and wet Method. (Iron Fillings are dipped in Kerosene Oil)
◦ Specimen is magnetized and then iron fillings poured for inspection.

Continuous Method:
◦ Dry and wet Method. (Iron Fillings are dipped in Kerosene Oil)
◦ Specimen is magnetized and iron fillings are poured simultaneously.

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 RESULTS AND CONCLUSIONS
The following results were concluded at the end of this experiment:

1. SOURCE Current (Electricity)

2. PROBING MEDIUM Magnetic Field

3. MODIFICATION Small Localized Magnet (N and S Pole)

4. DETECTION Iron Fillings

5. INDICATION Different Pattern around the Crack

6. INTERPRETOR Student/Operator/Observer

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 AIM OF THE EXPERIMENT
To Perform Magnetic Particle Test

Dry Magnetic powder

APPARATUS REQUIRED:
Specimen/Sheet, Dry magnetic powder, Yokes, Magnetic
Particle Testing Machine

AC Electromagnetic Yok
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 PRINCIPLE OF MPI
This method involves the magnetization of an area to be examined and the application of
ferromagnetic particles to the surface.

The particles gather at areas of magnetic flux leakage and form indications characteristic
of the type of discontinuity detected.

It can be considered as a combination of two nondestructive testing methods: magnetic

flux leakage testing and visual testing.

 Consider the case of a bar magnet. It has a magnetic field in and around the magnet. Any
place that a magnetic line of force exits or enters the magnet is called a pole. A pole where
a magnetic line of force exits the magnet is called a north pole and a pole where a line of
force enters the magnet is called a south pole.

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 How Magnetic Particle
Examination Works
When ferromagnetic material is defect-free, it will transfer lines of magnetic flux through
the material without any interruption.

But when a crack or other discontinuity is present, the magnetic flux leaks out of the
material. As it leaks, magnetic flux will collect ferromagnetic particles

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.

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 EXPERIMENTAL PROCEDURE
1. Clean the surface to be examined.
2. Magnetize the component that is to be inspected.
3. If any defects on or near the surface are present, the defects will create a leakage
field.
4. After the component has been magnetized, iron particles, either in a dry or wet
suspended form, are applied to the surface of the magnetized part.
5. The particles will be attracted and cluster at the flux leakage fields, thus forming a
visible indication that the inspector can detect.
6. Repeat the same process to get accurate value

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BASIC STEPS OF MPI

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 BASIC STEPS
OF MPI

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PRECAUTION FOR USING MPI

Dry magnetic particles should be Specimen should be clean

distributed all over the surface. before experiment.

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 ADVANTAGES OF USING MPI
Can detect both surface and near-surface indications.

Surface preparation is not as critical compared to other NDE methods.

A relatively fast method of examination.

Indications are visible directly on the surface.

Low-cost compared to many other NDE methods.

Post-cleaning generally not necessary.

A relatively safe technique; materials generally not combustible or hazardous.

Indications can show relative size and shape of the discontinuity.

Easy to use and requires minimal amount of training.

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 DISADVANTAGES OF USING MPI
Non-ferrous materials, such as aluminum, magnesium, or most stainless steels, cannot be inspected.

Examination of large parts may require use of equipment with special power requirements.

May require removal of coating or plating to achieve desired sensitivity.

Limited subsurface discontinuity detection capabilities.

Post-demagnetization is often necessary.

Alignment between magnetic flux and indications is important.

Each part needs to be examined in two different directions.

Only small sections or small parts can be examined at one time.
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 References
1. http://www.nationalboard.org/index.aspx?pageID=164&ID=377
2. http://www.inspection-for-industry.com/magnetic-particle-inspection.html
3. http://mech.vub.ac.be/teaching/info/Damage_testing_prevention_and_detection_in_aeronautics/PDF/magn
etic.pdf
MPI DEMONSTRATION VIDEO.
1. https://www.youtube.com/watch?v=m7ABg--BVv8
2. https://www.youtube.com/watch?v=qZC_uGt6B_8
3. https://www.youtube.com/watch?v=93sRATwdHo4
DYE PENETRANT TESTING.
1. https://www.youtube.com/watch?v=UtJTkrgvt2c
2. https://www.youtube.com/watch?v=xEK-c1pkTUI&t=110s

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