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Introduction
MAGNETISM
Concept of dipole and
magnetic field
Source of magnetism
Magnetic domains
Ferro magnetic materials are made up of small
regions called domains.
In each domain the atomic dipole are oriented in
one direction.
domains form during the solidification of the
material from the liquid state.
Theory of magnetism
Magnetic field
It is the area surrounding a magnetic
material around which its magnetic effect is
felt.
It is imaginary lines of force passing from
north pole to south pole.
It is the force with which a unit north pole is
attracted towards south pole
The
magnetic
field
surrounding a bar magnet can
be seen in the magnetograph .
The particles align
themselves with the lines of
magnetic force produced by
the magnet.
The magnetic lines of force
show where the magnetic field
exits the material at one pole
and reenters the material at
another pole along the length
of the magnet.
Flux Leakage
A flux leakage is a
break or a
discontinuity in a
magnetic circuit.
Any abrupt change
of permeability
within a magnetic
specimen will
change the
number of flux
lines.
Accumulation of
magnetic particles
at the field leakage
point that leads to
clear indication of
the presence of
defect
Electromagnetic fields
Retentivity
Residual MagnetismorResidual Flux
Coercive Force
Permeability
Reluctance
Definitions
Flux Density:
The number of
magnetic flux lines per Magnetizing force/
unit area of cross
Field Strength:
section
The total force tending to
Symbol= B
set up a magnetic flux in
SI Unit = Tesla = T
a magnetic circuit.
Previous unit is Gauss
Symbol = H
1 Tesla = 10000
SI unit = ampere per
Gauss
meter = A /meter
Definitions
Permeability:
The ease with which
a magnetic field or
flux can be set up in
a magnetic circuit.
Symbol= (mu)
= B/H
Where,
is the absolute magnetic
permeability in Henry/meter
B is the flux density
H is the magnetizing force.
Reluctance:
A measure of the
degree of difficulty
with which a
component can be
magnetized that is
similar to resistance in
a electric circuit. It is
reciprocal of
permeability.
High Permeability Low
Reluctance
Low Permeability- High
Reluctance
Definitions
Saturation:
The stage at which
any increase in the
Coercive force:
magnetizing force
The
H applied to a
reverse/negative
specimen,
magnetizing force
produces no
required to remove
significant gain in
residual
flux
density B
Retentivity:
magnetism from a
The property to retain material.
residual magnetic
field in a material
Definitions
Remanence:
The magnetic flux
density remaining
in a material after
the magnetizing
force has been
reduced.
Residual Magnetic
field:
The magnetic field
remaining in a
material after the
magnetizing force
has been reduced to
zero.
Methods of Magnetization
Longitudinal
magnetization
Circular
magnetization
Magnetization technique by
induction
Magnetizing Current
Rectified currents
Half Wave Rectified
Alternating Current
(HWAC)
This removes the negative
cycle from the alternating
current
The HWDC does not
produce skin effect
Its main advantage is it can
locate deeper lying
discontinuities than AC
generated fields.
HWDC also experiences as
a pulsating effect that
agitates the magnetic
Work Methods
Remnant field
Continuous field
used to hard magnetic
Used for soft
materials
magnetic materials
Inspection is done
Inspection is done
after the magnetic
while the material is
material is being
being magnetized.
magnetized.
The residual method employed for highly retentive
materials is not as sensitive as continuous method
EQUIPMENTS
PORTABLE
EQUIPMENT
STATIONARY
EQUIPMENT
M o b ile
S t a t io n a r y
P e rm a n e n t m a g n e t
F ix e d B e n c h U n it s
E le c t o M a g n e t
T h r e a d in g b a r
P ro d s
M a g n e t ic flo w
C o ils
R ig id c o il
F le x ib le c a b le &
C lo s e d lo o p
In d u c e d c u rre n t
C u r r e n t flo w
PORTABLE EQUIPMENT
Permanent magnets
Prods
Permanent magnets
Electromagnets
Unlike permanent
magnets
electromagnets can
vary the magnetic
fields.
removal of magnet
from the material is
easy.
prods
Stationary equipment
Fixed bench units
Producing a Longitudinal
Magnetic Field Using a Coil
A longitudinal magnetic
field is usually established
by placing the part near
the inside or a coils
annulus. This produces
magnetic lines of force
that are parallel to the
long axis of the test part.
Portable Coil
Current Requirement
Longitudinal Magnetic Field
Using a Coil
NI = 45000 / (L/D)
N Number of Turns of the Coil
I Current in Amperes
L-Length of the Part
D-Diameter of the part
Flexible coil
In this technique
the current
carrying cable is
wound tightly
around the
component.
It is a longitudinal
magnetization and
find defects lying
parallel to the
cable
Electro Magnets
Electromagnets are
made from soft
iron laminates to
reduce eddy
current losses, if
powered by AC
fields.
The legs of the
equipment are
articulated.
Electric
Current
Prods
Prods induce a circular magnetic
field by sending a high amperage
current through test piece
The high Amps can cause arcing
on the test piece surface
Up to 19mm thickness-100A/inch
of Prod Spacing
Greater than 19mm- 125 A/inch of
Prod Spacing.
Minimum 2 Max -8
General- 4-6
Prod Set Up
Current flow
The component is
fixed firmly between
contact heads which
have a soft conductive
surface, such as
copper braiding. A low
voltage high current is
passed through the
component and create
circular magnetic field.
Current = 800 to 1000 A
per inch dia of cross
section.
Threading Bar/Offset
Method
Magnetization by
the threading bar
technique is
induced by passing
current through an
insulated nonmagnetic
conductor (Al, Cu
or Brass)
Mobile Equipment
As the name implies, mobile equipment is
too bulky and heavy to carry and yet
needs to be moved to the work. Some
mobile units are capable of supplying
output currents up to 20,000A, although
5000A is a more normal figure.
In addition to the normal portable unit, the
mobile is likely to have better current
control and a step control to allowing
demagnetizing.
Bench Units
Magnetic Flow
Energized solenoids in
the bench heads
create a longitudinal
magnetic field in a
component, which is
clamped between the
heads, completing the
magnetic circle.
Defect where the
major axis lie
transverse to a line
joining the heads, are
found best.
Rigid Coil
The component is
placed in a current
carrying rigid coil with
its longitudinal axis at
90 to the direction of
the windings on the
coil. 4 to 8 turns are
usual the specimen is
placed in the bottom
of the coil wherever
possible.
Flux Indicators
Field strength meters are the best way of
ascertaining adequate field strength at the
surface of the test component. However
they are expensive and the probes used
tend to be fragile.
Portable flux indicators are an acceptable
alternative, They are simple to use
a. segment type -Berthold flux indicator
/Pie Gauge
b. foil type - Burma Castrol flux indicator
Pie gau
ge
Foil Type
Slotted strips, also known as Burmah-Castrol Strips, are pieces of
highly permeable ferromagnetic material with slots of different
widths.
Advantages
They are relatively easily applied to
the component,
they can be used successfully with
either the wet or dry method when
using the continuous magnetization,
they are repeatable as long as
orientation to the magnetic field is
maintained
they can be used repetitively.
Disadvantages
they cannot be bent to complex
configuration
they are not suitable for
multidirectional field applications
since they indicate defects in only
one direction.
Quality Indicators
KETOS/BETZ RING
LIFTING BAR
Quality Indicators
MTU Block
The MTU Test Block is used
to check the sensitivity of
magnetic particle materials.
This two sided block has a
variety of indications ranging
in size from small to large.
Advantages
QQI
it can be quantified and related to other parameters,
it can accommodate virtually any configuration with suitable
selection
It can be reused with careful application and removal practices.
Disadvantages
the application process is somewhat slow
the parts must be clean and dry, shims cannot be used as a residua
magnetism
they can be easily damaged with improper handling
they will corrode if not cleaned and properly stored.
Quality Indicators
Particles
Dry powders
Dry powders are dispersed on to the test
component either through a puffer or a
dry spray can. The chosen color is the one
which gives the best contrast against the
specimen background.
Powders are usually applicable to site work
such as welds and castings, often as an
initial check on a weld root pass, where
wet materials would cause contamination
Morphology of particles
Magnetic properties
High permeability and low retenvity
Visibility properties
Colour contrast and good lightning
Mobility properties
Geometric properties
Grain size, shape
Dry Powders
Magnetic Inks
Magnetic Inks are subdivided into
1. Contrast and fluorescent
2. Kerosene and water based
Important
Demagnetization
Affect machining
Interfere electronic equipment
During welding
Abrasive particles can cling to the
bearing materials
Methods of demagnetization
by heating the specimen
by hammering the material.
by subjecting the component to
reversing and decreasing magnetic
field
Inspection Requirements
Visible:
Minimum Light 1000 lux
Fluoroscent:
Black Light- 1000 microwatt/cm2
Warm up time-black light-5 minutes
Dark adoption time-5 minutes
Background light- 20 lux
Evaluation
The Evaluation of an MPI testing is purely
based on Operators skill such as vision,
experience etc.
Basically the Indications are classified into
False Indications
Non relevant Indications
Relevant Indications
Evaluation
False
Indication:
a. Powders stick due to gravity/Roughness
b. Magnetic Writing:
This phenomenon occurs due to accidental
pole formation where two magnetized parts
gets in contact with each other
Evaluation
Non Relevant Indication:
Excessive Magnetization
Variations of Permeability
Part Design
e.g: Keyways,heat treated chisel, bent nail,
rectangular part magnetized completely by
circular magnetization
Evaluation
Relevant
Indication
The Indications which are seen due to the
leakage flux from a artificial flaw or
discontinuities.
Relevant Indication are discontinuities which
you as an Inspector looking for!
Relevant Indication
1.Linear indication
Length greater than 3 times Width (L3W)
2.Rounded Indication
Length less than 3 times Width (L<3W)
Area to be examined.
Type of magnetic particle
Magnetic particle equipment.
Part surface preparation requirements.
magnetizing process.
Magnetizing current.
Means of establishing part magnetization.
Direction of magnetic field.
Magnetic field strength
Application of examination media.
Interpretation and evaluation of indications.
Type of records.
Demagnetizing techniques, if required, and
Post-examination cleaning, if required.
Evaluation of Weldments
Gear with
Service Induced Crack
Test Procedure
Generally the Test procedure is based on a
Published standard such as
BS 6072:1981
BSEN 1290:1998
Calibration-British
Standards
Yokes using Lifting block ( Before use)
Light Meters- Monthly/Ref-Yearly
Inspection Tools, rulers, Magnifiers
Ink Bath Concentration ( representative
sample from a batch)
Sensitivity of Ink Using Standard block
Lifting Blocks 2years
Calibration-American Standards
Yokes:
Lifting Capacity at least a year
AC Yoke 4.5 Kg (10 lbs)
DC Yoke-18.1 Kg(40 lbs)
Permanent magnet 18.1 kg ( 40lbs)
Equipments with Ammeter:
Ammeter calibrated every year
Acceptance Standards
BS 5135:1984
BSEN25817 (BS EN1291:1998)
ASME B 31.3
AWS D 1.1
Linear Indications , Rounded Indication.
Demagnetization
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.
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.
Abrasive particles may adhere to
components surface and cause and increase
in wear to engines components, gears,
bearings etc.
Demagnetization (Cont.)
Demagnetization requires that the residual
magnetic field is reversed and reduced by the
inspector.
This process will scramble the magnetic domains
and reduce the strength of the residual field to
an acceptable level.
Magnetized
Demagnetized
Demagnetization (Cont.)
Types Of Demagnetization
General Procedure:
Reversing the field and reducing the current.
Use a current slightly higher than the one used for magnetization
AC Coil Demagnetization:
Because of the automatic current reversal either the part can
be moved away from an energizing coil or the part can be
stationary and the coil moved over the part. Even a AC Yoke
could be utilized for demagnetization.
DC Demagnetization:
Reverse switch the DC (which is slightly difficult) and reducing
the current.
Heating to Curie Point
Curie Point of a magnetic material is the temperature at which a
material loses its magnetic property. So heating the object to
the curie point temperature demagnetizes the part.
Demagnetization
Measuring Residual magnetism by Gauss
Meter
Advantages of
Magnetic Particle Inspection
Can detect both surface and near sub-surface
defects.
Can inspect parts with irregular shapes easily.
Precleaning 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
Glossary of Terms
Black Light:
Glossary of Terms
Discontinuity:
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: