Inspection and Quality Control in Manufacturing

Prof. Kaushik Pal

Department of Mechanical and Industrial Engineering

Indian institute of Technology Roorkee

Lecture – 08
Magnetic Particle Inspection
Hello my friends, so now today we are going to discuss about our new lecture on magnetic particle
inspection. So before going to start, just let us know what is magnetic particle inspection?
Generally, it is a non-destructive testing, that mean we are not going to hamper our materials just
from outside we are going to check that whether there is any cracks or pores are present inside the
materials or not, so it’s a one kind of testing process for detecting the surface and shallow
subsurface discontinuities in the ferromagnetic materials. So this is the vital point over there, so
the ferromagnetic materials such as the iron, nickel, cobalt and some of their alloys can only be
inspected using this technique.

(Refer Slide Time: 00:57)

Now, let us know about the history. In the earliest known use of magnetism to inspect an object
took place as early as 1868. Cannon barrels were checked for defects by the magnetizing the barrel
then sliding a magnetic compass along the barrel’s length. So, when there will be any crack, so
simple it will generate some kind of signals, that signals we have to catch and we have to know
that where the crack is it.
In the early 1930s, magnetic particle inspection was quickly replacing the oil and whiting method
as the method of choice by the railroad industry to inspect steam engine boilers, wheels, axles and
tracks. For the railways we are continuously monitoring the kind of cracks at the railway wheels
or railway tracks because when there is a certain change in the temperature then these tracks or
wheels can get certain kind of damage over there due to that this kind of defects may occur.

In short form magnetic particle inspection is also known as MPI. It is very fast and relatively easy
to apply and part surface preparation is not as critical as it is for some other NDT testing. It uses
magnetic fields and small magnetic particles to detect flaws in components. The method is used to
inspect a variety of products from including castings, forgings and weldments or may be any other
type of materials, so we can see the surface integrity of that particular materials. Many different
industries use magnetic particle inspection for determining a components fitness for use.

(Refer Slide Time: 03:13)

Now what are the principle behind this method? The working principle of this techniques is the
magnetic flux leakage due to surface/subsurface discontinuities. So magnetic moments in a
ferromagnetic material have the tendency to become aligned parallel to each other under the
influence of a magnetic field. So here, you can see the magnetic flux line, these all are the parallel
to each other, so here this is the magnetized metal without the crack. However, unlike the moments
in a paramagnet, these moments will then remain parallel when a magnetic field is not applied at
all to the particular material. This phenomenon is observed below a critical temperature generally
we are calling it as a curie temperature; above which the material behaves like a paramagnetic
material. When a homogenous ferromagnetic material is placed in a magnetic field, it gets
magnetized and forms a continuous circuit from pole to pole through the material. So that means
from north pole to south pole, it will create a particular circuit.

If any surface or sub-surface discontinuity is present, the magnetic flux leaks out of the material
since air cannot support as much magnetic field per unit volume as metals. So, in this particular
case, as I told already you can see that at all the magnetic flux lines are the parallel one but when
there is certain cracks over there. So that in that particular flux the air has been entered into the
system, so that time the magnetic field will be disturbed. As it leaks magnetic flux will collect
ferromagnetic particles generally the iron powder, making the size and shape of the discontinuity
easily visible.

(Refer Slide Time: 04:50)

Basic steps. So, there are total five steps are available. So, first one is the part preparation:
component pre-cleaning/degreasing and the demagnetizing, say suppose we are using that
particular materials for sometimes in some applications, so maybe there is we are using certain
kind of oil or may be the grease or maybe we are dipping materials for any kind of lubrication
purpose. So, first we have clean all those things, then suppose we are using that materials in a may
be the pump or may be some motors, so if already any pre-magnetizations has been done that thing
we have to remove.

And then second one is the introduction of the magnetic field, third one is the application of the
fine magnetic particles on the test surfaces, fourth is the examination of the component surface for
defect, fifth is the, because we are creating the magnetic field or may be the magnetic flux inside
the materials so after examining again we have to demagnetizing the component.

(Refer Slide Time: 05:50)

So first, we will elaborately discuss about all these five points so about the part preparation when
inspecting a test part with the magnetic particle method, it is essential for the particles to have an
unimpeded path for migration to both strong and weak leakage fields alike. The part’s surface
should be clean and dry before starting the inspection as I told already.
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, yes of course because if
there is any cracks or may be the pores are present onto the surface, so if there is any oil or grease
are present, so what will happen, that cavity will be filled up by those material, so first initially,
we have to clean the surface, so that whatever the cracks and pores that will be without any oil free
or may be grease free or may be the any kind of contaminant free, then only we can perform the
test and we can achieve the 100% result from that.

Thin nonconductive coatings, such as paint in the order of 0.02 to 0.05 mm so this is the vital one,
will not normally interfere with the formation of indications, because when we are talking about
any parts, sometimes we need to paint it to restore or may be to save its working life, so that if the
thickness is from 0.02 to 0.05 mm, then no need to remove otherwise we have to remove, but they
must be removed at all points where electrical contacts is to be made for direct magnetizations,
yes of course, because here the paint will act as an insulator.

If the part/piece holds a residual magnetic field from a previous magnetization that will interfere
with the examination, the part must be demagnetized.

(Refer Slide Time: 07:58)

Next come to the second point, now we have to do the introductions of the magnetic field, so there
are a variety of methods, which can used to introduce a magnetic field in component for evaluation
using the magnetic particle inspection. These magnetizing methods are classified as direct
magnetization and second one is called the indirect magnetization.

If we talk about the direct magnetization, sometimes it is called as a magnetization using direct
inductions. It is also called as current flow method, the magnetizing current flows through the part
thereby completing the electric circuit. Magnetic field formed during this method is at right angle
to the direction of current flow. Thus, we can locate the defect at the right angles to the applied
magnetic field directions. So, this is the important one, so if we flow the current in this directions,
the magnetic field will be generated in this directions, so both will be the exactly at the 90° to the
each other.

Now we have to take certain precautions, what are those? First is that when using the direct
magnetization method, care must be taken to ensure that good electrical contact is established and
maintained between the test equipment and the test component. Second, improper contact can
result in arcing that may damage the component. Yes of course, because, we are touching the
positive and the negative terminal over there, so if it will not properly touch or maybe there will
be gap, so sparks will take place, that can change the shape of the particular material, it is also
possible to varied components of areas of high resistance such as the contact points and in areas
of small cross-sectional area.

(Refer Slide Time: 09:38)

Now what are the types of the direct magnetization techniques? So, there are two main methods
through which the direct magnetization is accomplished. First one is called the Head shot technique
and second one is called as the prods or clamps technique.

First one is called the head shot technique. So here, magnetizing current is passed through the
component directly by clamping the component between two electrical contacts. If you carefully
see the right-hand side image, so you can see that this is our main work piece over there right. So
now we are giving two contact points over there, so directly these contact points are attached with
the our specimen and now we are creating the magnetic field, so this is called the head shot
technique, so both the head, just we are giving one positive terminal and another one is the negative
terminal. Magnetizing current produces circular magnetic field in and around the component that
creates poles on either side of any crack or discontinuity which runs parallel to the length of the
part.
Say suppose, so now the current we are giving in this direction so magnetic flux, so here suppose
there is certain crack over there, so it is not there, so there is crack, either it will generate the north
pole or south pole or may be the vice versa. The pole attracts magnetic particles, which form an
indication of the discontinuity. When magnetizing current is stopped, a residual magnetic field will
remain within the component, now again after that we have to do the demagnetization. The strength
of the induced magnetic field is proportional to the amount of current passed through the
component.

(Refer Slide Time: 11:15)

Now, come to the second one, using prods or clamps technique. Prods are handheld electrodes that
are pressed against the surface of the component being inspected to make contact for passing
electrical current though the metal. So, in this particular case you can see, that is the handheld
instrument, so you can easily carry it and whenever or wherever you need it, simple you can put it
over there and you can do the test. So these all are the prods, so now you can see that we are testing
it with the weld samples. So, we are having two parts, then we have joined it and this is the welding
zone and then we are testing it.
The passing current between the prods create a circular magnetic field around the prods that can
be used in magnetic particle inspection. Prods are made from copper and have an insulated handle
to help protect the operator, so easily we can hold it. One of the prods has a trigger switch so that
the current can be easily and quickly turned on or may be the off. So, in this particular case either
any of that it is having the switch. Sometimes two prods are connected by an insulator to facilitate
one hand operation. In this case you can see, that it is both these two prods are segregated, but
sometimes it may happen that it can join with a particular metals or may be the insulating materials
so that, we can do it by only single hand.

(Refer Slide Time: 12:45)

Next come to the indirect magnetization. Generally, it is knowns as the magnetization using
indirect induction. It is accomplished by using a strong external magnetic field to establish a
magnetic field within the component. So in this case we are not directly using the current to the
particular material to magnetize, so in this case, we are creating the magnetic field just outside the
component and then same vice versa we are producing inside the specimen and we are doing the
testing.
There are several ways that indirect magnetization can be accomplished. Some of the common and
useful methods are: using permanent magnets, using electromagnet yoke, using central conductor,
using coils or may be the solenoids.

First using the permanent magnets. Permanent magnets use is a low-cost method of establishing a
magnetic field in a part. Their use is limited due to lack of control of field strength and the difficulty
of placing and removing strong permanent magnets from the components. So just what we are
doing, we are keeping a permanent magnet just beside our sample, which will affect our sample
and then after that we can do the testing. These magnets are used to make inspection under water
and explosive environments where electromagnets cannot be used.

They can also be used in those congested areas where electromagnet cannot be used or where a
source of electric power is not available, so any remote conditions, in remote area, we can do this
testing. Two types of permanent magnets most commonly are bar magnets or may be the yoke
magnets. So, this is the example of a permanent magnet yoke.

(Refer Slide Time: 14:43)

Now, second is by using electromagnet yoke. Electromagnet yoke uses electric current to produce
magnetic field for magnetic particle inspection. They eliminate the problems associated with
permanent magnets and are used extensively in industry. This is widely used. This yoke is basically
made by wrapping an electrical coil around a piece of soft iron core.

You can see from the figure, this is known as the soft iron core, and if you cut it, that inside you
can see, that it is having the current carrying coil. Electromagnets only exhibit a magnetic flux
when the electric current is flowing around the soft iron core. So when we are passing the electric
current over there, then that time only the electromagnetic force or may be the magnetic flux is
generating at that particular point through this soft core or may be sometime we are calling it as a
leak.

The design of an electromagnetic yoke can be based on the use of either direct or alternating current
or may be the both. When the magnet is placed on the component, a magnetic field is established
between the north and south poles of the magnet. The legs of the yoke can be either fixed or may
be the adjustable. Nowadays, we are using the adjustable one, because it is very widely used and
widely acceptable for any shape and size, we can easily do this kind of test. Adjustable legs permit
changing the contact spacing and relative angle of contact to accommodate irregularly – shaped
parts.

(Refer Slide Time: 16:23)

Now come to the positioning of the electromagnetic yoke on the test surface. In general,
discontinuities to be disclosed should be centrally located in the area between the pole and the
pieces and oriented perpendicular to an imaginary line connecting them. Here are some examples
of how we can use magnetization yoke to perform better magnetic particle inspection.

You can see the examples, that how we can fix this electromagnetic yoke to get the better results,
so whatever the green in color are the good practices or the right positions and whichever are red
in color in the cross mark are the bad practices or we cannot get the proper result.

(Refer Slide Time: 17:04)

Next using the central conductor. So another way of indirectly inducing a magnetic field in a
material is by using the magnetic field of a current carrying conductor, so that is another interesting
thing. A circular magnetic field can be established in cylindrical components by using a central
conductor itself. Say suppose I am having one cylindrical component so now I want to test it, so
how I can generate the magnetic field over there or may be magnetic flux over there.

So simple, I am taking a cylindrical component over there and then inside it, I am putting my
central conductor. In this technique a conductor carrying high amperage current are passed through
the cylindrical components which induces a circular magnetic field in the component to reveal
radial and the longitudinal defects. The effective region of examination when using an offset
central conductor is equal to four times the diameter of the conductor as indicated.

Next one is called the using coils or the solenoids. When the length of a component is several times
larger than its diameter then we can produce longitudinal magnetic field using the coil. Say in this
case this is our test specimen or may be the work piece, so now suppose you are having a long
pipe, whether it is may be the solid one or may be the hallow one, now you are going to test it. So
in that case, generally we are using this kind of things. In this method the component is placed
longitudinal in the concentrated magnetic field that fills the centre of a coil.
(Refer Slide Time: 18:48)

Next direction of the magnetic field. The basic principle of magnetization is to produce magnetic
lines of force across the expected direction of cracks. Two general types of magnetic fields may
be established within the specimen. Number one is called the longitudinal magnetization and the
second one is called the circular magnetization. These are the examples of longitudinal magnetic
field and longitudinal magnetization of crankshaft using the solenoid method.

First we are going to discuss about the longitudinal magnetization, it has magnetic lines of force
that run parallel to the long axis of the part. You can see here this arrow. Longitudinal
magnetization of a component can be accomplished using the longitudinal field set up by a coil or
maybe the solenoid. Flexible coil method is useful for large or irregularly shaped parts for which
standard solenoids are not available. It can also be accomplished using permanent magnets or may
be the electromagnets.

(Refer Slide Time: 19:56)

Next come to the circular magnetization. It has magnetic lines of force that run circumferentially
around the perimeter of a part. In the last cases we have seen that the magnetic flux was generating
in this direction, now the magnetic field was generating into the circular direction along the
periphery. A circular magnetic field is induced in an article by either passing current through the
component or by-passing current through a conductor surrounded by the component itself.

This type of magnetization will locate defects running approximately parallel to the axis of the
part. So this is the circular magnetic field and here the circular magnetization of camshaft using
the head shot technique.

(Refer Slide Time: 20:38)

Now come to the magnetic field orientation and the flaw delectability: Orientation of the crack
relative to the magnetic lines of force determines if the crack can or cannot be detected. So how
you are going to generate the magnetic flux. Whether it will be longitudinal or may be whether it
will be into the circumferential, that depends upon the which type of crack is generally you are
expecting, so based on that you have to choose the right method.

An orientation of 45° to 90° between the magnetic field and the defect is necessary to form an
indication. Since defects may occur in various and unknown directions each part is normally
magnetized in two directions at right angles to each other. In this particular case you can see that
we are generating the magnetic field, so current is passing in this case, so cracks at the 45° will
show, irregular cracks may show or may not show, longitudinal crack will show, so these are the
conditions.

So example: with circular magnetization discontinuity that have a significant dimension in the
direction of the current are detectable, while transverse-type defects will not be detectable, so this
is the drawback.

(Refer Slide Time: 22:05)

Now, magnetizing current. Electric current used to establish the magnetic field in components
during magnetic particle inspection is known as the magnetizing current. Current flow is often
modified to provide the appropriate field within the part itself. There are three types of currents
generally we are using: direct current (DC), alternating current (AC), and the rectified alternating
current.

So, what is direct current? So direct current flows continuously in one direction at a constant
voltage. So, you see, that current so it’s a totally constant, it is not changing over time. DC is very
desirable when inspecting for subsurface defects because DC generates a magnetic field that
penetrates deeper into the material. That is the result here. In ferromagnetic materials, the magnetic
field produced by the DC generally penetrates the entire cross-section of the component itself.
Conversely, the field produced using alternating current is concentrated in a thin layer at the
surface of the component.

(Refer Slide Time: 23:20)

Now come to the alternating current. So alternating current reverses in direction at a rate of 50 or
60 cycles per second. So you can see that it is going into the positive side and then again it is
coming to negative side, so it is varying nature is sinusoidal, so this is known as the alternating
current.

Since AC is readily available in most facilities, it is convenient to make use of it for magnetic
particle inspection. Because nowadays everywhere we are using the AC current, in our home,
office, industry everywhere. When AC is used to induce a magnetic field in ferromagnetic
materials, the magnetic field will be limited to narrow region at the surface of the component itself.
This phenomenon is known as the skin effect and occurs because the changing magnetic field
generates eddy currents in the test object. The eddy currents produce a magnetic field that opposes
the primary field, thus reducing the net magnetic flux below the surface, therefore, it is
recommended that AC be used only when the inspection is limited to surface defects.

(Refer Slide Time: 24:40)

Now come to the third one that is the rectified alternating current. With the use of rectifiers, the
reversing AC can be converted to a one directional current, which is known as the rectified
alternating current. So in that case what will happen, you can get a constant current over there, but
still you are using the AC current.

The three commonly used types of rectified alternating currents are, half wave rectified alternating
current (HWAC), full wave rectified alternating current generally (FWAC) single phase, and three-
phase full wave rectified alternating current.

(Refer Slide Time: 25:14)

What is half wave rectified alternating current (HWAC)? When a single-phase alternating current
is passed through a rectifier, current is allowed to flow in only one direction. The reverse half of
each cycle is blocked out so that a one directional, pulsating current is produced. In this particular
case, normally input AC is that, as I told already it is having the plus and it is having the minus, so
when you are using the rectifier over there. So, the thing is that it will show you only the first part
or may be positive part and the negative part it will be blocked. The HWAC repeats at same rate
as the unrectified current. Since half of the current is blocked out, the amperage is half of the
unaltered AC. This type of current is often referred to as half wave DC or may be the pulsating
DC.

The pulsation of the HWAC helps magnetic particle indications form by vibrating the particles
and giving them added mobility. This added mobility is especially important when using dry
particle. The pulsation is reported to significantly improve inspection sensitivity. HWAC is most
often used to power electromagnetic yokes. If you use a rectified and filtered AC, you cannot get
any signal.

(Refer Slide Time: 26:45)

Next come to the full wave rectified alternating current (FWAC-Single phase). Full wave
rectification inverts the negative current to positive current rather than blocking it out, so you can
see now we are getting a constant one. But first from the positive highest peak it will come to the
zero then again it will reach the highest peak, like this way, so whatever is the negative just it will
become into the opposite direction.

This produces a pulsating DC with no interval between the pulses. Filtering is usually performed
to soften the sharp polarity switching in the rectified current. While particle mobility is not as good
as half wave AC due to the reduction in pulsation, the depth of the subsurface magnetic field is
improved.

Now come to the three-phase full wave rectified alternating current. Three phase current is often
used to power industrial equipment because it has more favorable power transmission and line
loading characteristics. This type of electrical current is also highly desirable for magnetic particle
testing because when it is rectified and filtered the resulting current very closely resembles the
direct current. So, you can see when you are using the filtering and already used the rectifier so
almost, we are getting same like the DC current.
(Refer Slide Time: 27:58)

Next application of the magnetic particles. So magnetic particle characteristics. Particles used in
MPI are made of finely divided ferromagnetic materials have the following characteristics. What
are those? Number one it should have high magnetic permeability. It is important because it makes
the particles attract easily to small magnetic leakage fields from the discontinuities. Now you have
created the magnetic field, suppose you are having the cracks and top of that, you are putting some
kind of ferromagnetic particles, so what will happen from the cracks itself the magnetic flux it will
attract the magnetic particles, then after that when you clean out, so you can easily see the cracks
over there, because that has been taken care by the ferromagnetic materials and if you put some
kind of colors in the ferromagnetic materials so you can easily detect that where the crack or may
be any kind of pores are present onto the surface of your workpiece.

Next is low retentivity: it is important because the particles themselves never become strongly
magnetized so they do not stick to each other or the surface of the part. So it should not repel.

Others: other properties of importance that affect the sensitivity of the MPI are the size, shape,
density, mobility and visibility or contrast of the particles. There are two basic forms of magnetic
particles used in magnetic particle inspection, what are those? One is called the dry magnetic
particles and another one is called the wet magnetic particles.
(Refer Slide Time: 29:42)

So, what is dry magnetic particles? So generally the dry particles are primarily used for the
examination of welds and castings where the detection of discontinuities lying slightly below the
surface is considered important. They are provided in powder form and available in red black,
yellow and grey colors. Magnetic properties, particle size and shape and coating method are similar
in all colors making the particles equally efficient. Choice of powder is then determined primarily
by which powder will give the best contrast and visibility on the parts being examined and the
degree of sensitivity desired. So it depends upon the work piece color you have to choose the
different color magnetic particles.

What are the advantages? Excellent for locating discontinuities which are slightly below the
surface. Easy to use for large objects and for field examinations with portable equipment. Good
mobility when used with alternating current or may be the HWDC. Not as many as the wet particles
and equipment usually less expensive. But of course, there are certain limitations, what are those?
Not as sensitive as the wet method for very fine and shallow cracks. Not easy to cover all surfaces
properly especially of irregularly shaped or large parts. Slower than the wet particles for large
number of small parts. Difficult to adapt to an automated test system.

(Refer Slide Time: 31:15)

Next come to the wet magnetic particles. Magnetic particles are also supplied in a wet suspension
such as water or may be the oil. These particles are available in two forms. One is called the visible
and another one is called fluorescent magnetic particles. When exposed to near ultraviolet light or
may be the black light fluorescent dye coated magnetic particles glow with a highly visible yellow
green color. Fluorescent particles are particularly useful for corners, key ways and the deep holes
type discontinuities.

What are the advantages? This method is more sensitive than dry because the suspension provides
the particles with more mobility and makes it possible for smaller particles to be used since dust
and adherence to surface contamination is reduced or may be eliminated. It quickly and thoroughly
covers all surfaces of irregularly shaped parts, large or small, with magnetic particles. It is the
fastest and most thorough method for the examination of large numbers of small parts. It is easy
to measure and control the concentration of particles in the suspension, which makes for uniformity
and accurate reproducibility of results. It is readily adaptable to any kind of automated
examinations.

(Refer Slide Time: 32:41)

Now what are the limitations? Usually wet particles are as reliable of finding discontinuities lying
below the surface as dry particles. So it can detect more precisely. It is messy to work with
especially when used in the field testing. A recirculation system is required to keep the particles in
suspension. It sometimes presents a post-examination cleaning problem. For dry particles means
after doing the experiment, simple you can make it opposite and the particle will come out, but
wet particles means it can adhere to the system either you have to clean it or wash out or some
other help you may require.

Application of the fine magnetic particles on the test surface. Dry particles application: fine
magnetic particle in dry powder form are dusted over the test surface. Wet particles application.
Fine magnetic particles suspended in kerosene or any other liquid are sprayed over the test surface
after magnetization.

(Refer Slide Time: 33:41)

Now come to the examination of the surface: when fine particles of magnetic material are applied
on the surface of test material, the leakage field attracts particles which forms an outline of the
discontinuity and indicate the location, size extent and shape of the discontinuity. Visible particles
clusters formed at specimen surface are viewed under white light, whereas fluorescent particles
are viewed under black the light.

So, you can see, as I told already so when we are generating the magnetic lines inside if there is
any cracks or pores and on top of that when we are putting the magnetic particles over there, so
only through this crack the leakage magnetic field will come and it will attract. So easily you can
understand from the outside where the cracks or may be the pores are present.

Now, come to the visible wet/dry particle method: so here are some examples: surface defects in
gas pipe weld, so you can easily see. Cracks in seal weld of boiler tube to steam drum, this red in
color. Lack of fusion in SMAW weldments. Throat and toe cracks in partially ground weld. So,
you can see by this particular color.

(Refer Slide Time: 34:55)

Fluorescent wet particle methods. So here, crane hook with service induced crack, so it is showing
some yellow green color. Drive shaft with heat treatment induced cracks, so before testing and
after testing we can see some kind of cracks over there. Gear with the service induced crack, a fine
crack you can see over there, or may be the large bolt with service induced crack. These all are
cracks which can easily detectable by this MPI technique.

Now come to the last one that is the demagnetization. As I told already, because first initially we
have created the magnetic flux and after that you have to destroy the magnetic flux so that you can
use that particular material.

(Refer Slide Time: 35:44)

Parts inspected by the magnetic particle method may sometimes have an objectionable residual
magnetic field that may interfere with subsequent manufacturing operations or service of the
component. Retained magnetic field depends upon, magnetic characteristics of the component,
geometry of the component, direction of the magnetization, strength of the magnetic field.

Effects of the residual magnetization or may be the magnetism: it affect machining by causing
cuttings to cling to a component; interfere with navigational instruments that are sensitive to
magnetic fields if placed in close proximity; create a condition known as “Arc Blow” in the
welding process, Arc blow may cause the weld arc to wonder to filler metal to be repelled from
the weld, cause abrasive particles to cling to bearing or faying surface and increase wear.

(Refer Slide Time: 36:41)

Now what are the methods of demagnetization? There are two methods of demagnetization. One
is the simple one heating method and another is called the electrical method. So when you are
talking about heating method: this random orientation of magnetic domains can be achieved most
effectively by heating the material above its curie temperature. When part is heated above its curie
temperature, it loses its magnetic properties and when it is cooled back down it will go through a
reverse transformation and will contain no residual magnetic field.

The material should also be placed with its long axis in an east west orientation to avoid any
influence of earth’s magnetic field. So we have to keep it into the east and west direction. If we
talk about the electrical method, so it is subjecting the component to a reversing and decreasing
magnetic field will return the dipoles to a nearly random orientation throughout the material. So
now we have to do the opposite thing. To demagnetize a part, the current or magnetic field is
needed which has to be equal to or greater than the current or magnetic field used to magnetize the
part.

Either it should be equal or may be it should be more than that. The current or magnetic field is
then slowly reduced to zero, leaving the part demagnetized.

(Refer Slide Time: 38:09)

Now what are the advantages, limitations and application of magnetic particle inspection? So first
is the advantages. Rapid and economical compared to other NDT methods. Staff can be trained
quite rapidly to operate a procedure. It can detect both surface and near sub-surface discontinuity.
It can inspect parts with irregular shapes easily. Pre-cleaning of components is not as critical as it
is for some other inspection methods.

Inspection and indications are fast and visible directly on the specimen surface. Very portable
method especially when used with battery powered equipment.

(Refer Slide Time: 38:41)

Now limitations: it can only be used on ferromagnetic materials that is a vital one, so your material
should have that property, unable to inspect non-ferrous materials such as aluminum, magnesium
or most stainless steels. It is only effective for seeking surface breaking or near-surface defects.
Components or materials must be magnetized in at least two directions for complete coverage.
Components or materials often must be demagnetized after magnetic particle testing. Weldments
with different magnetic characteristics of base metal and weld metal are difficult to inspect. Post
cleaning and post demagnetization is often necessary. Yes, because if you are joining two different
dissimilar metals then that time it is a big problem.

Applications: Industries that use MPI are structural steel, automotive, petrochemical, power
generation and the aerospace industries. Underwater inspection is another area where MPI may be
used to test items such as offshore structures and any underwater pipelines.

(Refer Slide Time: 39:57)

Now we have come to the last slide of this particular lecture. So now we have to summarize the
whole thing. So generally, in this particular lecture we have discussed about the magnetic particle
inspection is a fast and relatively easy NDT method for surface/subsurface flaw inspection in
ferromagnetic materials. It is based on the magnetic flux leakage caused by material discontinuities
which collects magnetic particles either maybe the dry or may be in a wet suspension to form the
indications.

Different types of direct or may be the indirect methods are used to magnetize the component to
perform the inspection. After conducting a magnetic particle inspection, it is usually necessary to
demagnetize as it may interfere with manufacturing processes or service, so that it can again be
used for the next operations or other things. Thank you.