Magnetic Particle Inspection Module 3 Department of MechanicalIntroduction Magnetic Particle inspection is governed by the laws of magnetism and is therefore restricted to the inspection of materials that can support Magnetic flux lines. Materials are generally classified as Ferromagnetic: are those that are strongly attracted to a magnet and can become easily magnetized eg: Fe,Ni,Co Paramagnetic: Materials are those that are weekly attracted by magnetic force of attraction. eg: Austenitic Stainless steel Diamagnetic: Materials are slightly repelled by a magnet and cannot be magnetized.eg: Bi,Au,Sb Hareesh k,AP,DOME,VAST 2* Magnetic particle inspection (MPI) is a non-destructive testing method used for defect detection. MPI is fast and relatively easy to apply, and part surface preparation is not as critical as it is for some other NDT methods. These characteristics make MPI one of the most widely utilized non-destructive testing methods. * The method is used to inspect a variety of product forms including castings, forgings, and weldments. Many different industries use magnetic particle inspection for determining a component's fitness-for-use. Some examples of industries that use magnetic particle inspection are the structural steel, automotive, petrochemical, power generation, and aerospace industries. * Underwater inspection is another area where magnetic particle inspection may be used to test items such as offshore structures and underwater pipelines. Hareesh k,AP,DOME,VAST 3Principles of MPI * In theory, magnetic particle inspection (MPI) is a relatively simple concept. It can be considered as a combination of two non-destructive testing methods: magnetic flux leakage testing and visual testing. Hareesh k,AP,DOME,VAST 4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. 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. The magnetic field exits the north pole and re enters at the south pole. When the field spreads out, it appears to leak out of the material and, thus is called a flux leakage field. 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. FLUX LEAKAGE N Hareesh k,AP,DOME,VAST 5Basic Physics of Magnetism |. Polarity: Polarity refers to the orientation of north and south poles space 2.Magnetic force: It is a force of attraction or repulsion that one body has upon another 3. Magnetic field: It is the area around a magnet which the magnetic forces are Observable 4, Permeability: Permeability is the case with which a material can be magnetised .Exp---=B/H (henry per meter H/M) 5. Flux Density: Flux density is defined as the number of lines of force per unit area. Measured in Gauss (B) 6.Magnetizing Force: The total number of line of force making up a magnetic field determines the strength of the force of attraction or repulsion that can be exerted by magnet. Exp—(H) Hareesh k,AP,DOME,VAST 67. Coercive Force: Is a measure of Ability of a ferromagnetic material to withstand an external magnetic field without becoming demagnetised. 8. Retentivity: The ability of a coil to retain some of its magnetism within the core after ihe magnetism process has stopped is known as retentivity. 9. Hysteresis Loop: By exposing an magnetised piece to magnetic current. We can plot the flux density B of the field induced by the applied magnetizing force H and the resultant curve is called the hysteresis loop. 10.Residual Magnetism: \t is defined as the amount of magnetism left behind after removing the eternal magnetic field from the cireuit. 7 Hareesh k,AP,DOME,VASTMethods of Magnetisation The Basie principles of magnetisation is to produce magnetic lines of force across the expected direction of cracks. If the likely crack direction is unknown , then test must be performed in two directions at right angles. The basic magnetisation metheds are. Magnetic Flow: To make the component of a magnetic circuit by effectively using it as the bridge of a permanent or electromagnet. Cols to gnerate magnetic field Magnetic eld liaueed Veitage gage by magneve Held Hareesh k,AP,DOME,VAST 8Current flow: To pass an electric current through the specimen, broadly along the direction and through the region in which cracks are to be expected. «Direction of flow of electrons. +@<+@<@-+ @<+@«@<+8 +@<+@<« @<« @-+-@ «0+ 8 Direction of flow of electric current——» + I Ci ell Hareesh k,AP,DOME,VAST 9Induced current flow: Used for ring specimens, by effectively making them the secondary of a main transformer. This method has no application to weld inspection. AC Generator fle Load Hareesh k,AP,DOME,VAST 40Electromagnetic Induction: To pass an electric current through a conductor which is threaded through a hollow specimen or placed adjacent to or wrapped around it. Hareesh k,AP,DOME,VAST WMagnetization Techniques 1. Head Shot Technique: MAGNETIC FIELD ELECTRIC CURRENT Hareesh k,AP,DOME,VAST2.Coil Shot Technique “ale Coit __\ Longitudinal Field Figure 4 Hareesh k,AP,DOME,VAST 433. Central Conductor Technique Stationary Head Flux Lines” Current Flow Movable’ Head Central Conductor Figure 6 Hareesh k,AP,DOME,VAST 444 Magnetisation Using yoke: Hareesh k,AP,DOME,VAST 45Direct Method of Magnetization The direct method of magnetization is also called as current flow method, the magnetizing current flows through the part, thereby, completing the electric circuit. The magnetic field formed during this method as at right angles to the direction of current flow. Thus we can locate the defect at right angles to the applied magnetic field direction Eg: Head Shot technique. Limitations: In direct method, the head can cause a burn in the a part if the high current is passing through a small contact area. To avoid this, the contact faces on the heads should be flexible and the tips of the prods should have a low melting point in order to spread the thermal load. Hareesh k,AP,DOME,VAST 46Magnetic field Workpiece Hareesh k,AP,DOME,VASTIndirect Method of Magnetization The indirect method of magnetization is also called as magnetic flow method. In this method the test part becomes a part of the magnetic circuit, thus bridging the part between the poles of a permanent magnet. The main advantages of the indirect techniques is that the risk of are burning of critical components does not exits. Also, the use of permanent magnet or electromagnet can be vary convenient for inspections in continuous locations Hareesh k,AP,DOME,VAST 48CURRENT __ MA {____FIELD Hareesh k,AP,DOME,VAST 49Continuous Testing of MPI Continuous testing of MPI can be broadly classifieds in to two types, They are 1Dry Continuous 2.Wet Continuous 1.Dry Continuous The term dry’ means that the MP are applied in fine particle form. The term continuous means that the magnetic particles are applied while the current is till flowing onto it. In this technique, the dry particles are applied when the magnetic forces is on. The particle application must cease before the current flow cease. The use of dry particle is for detecting slightly sub surfaces discontinuities, since the particles have higher permeability compared to the particle in wet inspection Only Advantages of using dry particles is that their mobility which relatively poor when used with DC Current. Hareesh k,AP,DOME,VAST 20Hareesh k,AP,DOME,VAST2.Wet continuous The term wet means that the particles applied are suspended in a liquid carrier. The Liquid carrier such as Kerosene, other petroleum distillates or water containing specially formulated additives can be used during wet suspension Compared to the dry particles, the suspended particles are generally lower permeability which makes this technique lass favourable for the direction of slightly subsurface discontinuities. Advantages are i) The improved mobility of the particles makes the technique very suitable ii) The suspension will adhere to the complex shapes better than dry particles. Hareesh k,AP,DOME,VAST 23Hareesh k,AP,DOME,VAST 24Hareesh k,AP,DOME,VAST.Advantages and Limitations of Different Liquid carriers 1. Kerosene and Petroleum distillates Advantages: *Help to lubricate parts *Do not constitute the corrosion source Limitations: *They are more expensive *Produce health problems 2. Water Advantages: *They are inexpensive “No health Issues Limitations Constitute Corrosion Hareesh k,AP,DOME,VAST 26Residual Techniques of MPI Similar to continuous testing methods, the residual techniques of MPI also be classified in to two types |.Dry residual The term “residual means that, the material has sufficient retentivity to allow applications of the magnetic particles afier the current has ceased. Advantages Suitable for low sensitivity materials Multiple parts can be magnetized simultaneously Limitations Subsurface discontinuities are difficult to detect 2. Wet Residual In this techniques uses the suspended particles where the suspension is applied after the magnetizing force has been stopped Hareesh k,AP,DOME,VAST arSystem Sensitivity Many fine cracks of size less than .02mm deep can be located using the sensitivity of MPI. It not only involves crack detection, but also allow us to locate wide range of defects like *Detecting segregations, Macro inclusions *Marks generated using stamping operations *Laps in the threaded section Sensitivity depends on the type of current used AC Magnetization suitable for Surface defects, but not for subsurface “DC magnetization is good for subsurface defects *Half wave DC give superior penetration than straight DC Hareesh k,AP,DOME,VAST 28Checking Devices in MPI In order to maintain consistency and control during MPI, checking devices have to use. Commonly used are i)Settling test: Is also called as suspension concentration test. The purpose is to assure that the proper concentration of particles is being maintained in the liquid carrier (video) ii)Ketos ring: The ketos ring is a device made of tool steel and is designed to show the effectiveness of the MPI and the relative penetration based on the number of holes that display indications (video) iii) Field indicator: Field indicator is used to check the presence of residual magnetism on the system (video) Hareesh k,AP,DOME,VAST 29Indications Indications may be classify as i) False Indications False indications can be produced due to improper handling, use of excessively high magnetizing currents, inadequate precleaning of the parts to remove oil , Grease, corrosion products and other surface contaminants. ti) Non Relevant Indications Non-relevant indications are the result of flux leakage due to the geometrical changes of the test object Eg;- Thread roots , Gear teeth etc. iii) Relevant Indications Relevant indications are produced by flux leakages due to discontinuities in the part 30Advantages of Magnetic Particle Inspection (MPI) Advantages of the Magnetic Particle method of Non-Destructive Examination are: *It is quick and relatively uncomplicated *It gives immediate indications of defects *It shows surface and near surface defects, and these are the most serious ones as they concentrate stresses *The method can be adapted for site or workshop use *It is inexpensive compared to radiography *Large or small objects can be examined *Elaborate pre-cleaning is not necessary Hareesh k,AP,DOME,VAST 34Disadvantages of Magnetic Particle Inspection (MPI) It is restricted to ferromagnetic materials - usually iron and steel, and cannot be used on austenitic stainless steel It is messy Most methods need a supply of electricity It is sometimes unclear whether the magnetic field is sufficiently strong to give good indications The method cannot be used if a thick paint coating is present Spurious, or non-relevant indications, are probable, and thus interpretation is a skilled task Some of the paints and particle suspension fluids can give a fume or fire problem, particularly in a confined space Hareesh k,AP,DOME,VAST 32GAretL{ Ct [kamsahamnidal]