Magnetic Particle Testing

This NDT method is accomplished by inducing a

magnetic field in a ferromagnetic material and then
dusting the surface with iron particles (either dry or
suspended in liquid). Surface and near-surface flaws
produce magnetic poles or distort the magnetic field
in such a way that the iron particles are attracted and
concentrated. This produces a visible indication of
defect on the surface of the material.

Magnetization
There are basically two types of magnetic field:
1.

Longitudinal Magnetic field.

2.

Circular Magnetic Field.

Magnetization
1.

Longitudinal Magnetization : When the length of a

component is several time larger than its diameter, a
longitudinal magnetic field can be established in the
component. The component is often placed
longitudinally in the concentrated magnetic field that
fills the center of a coil or solenoid. This
magnetization technique is often referred to as a "coil
shot."

Yoke for Longitudinal Magnetization

Magnetization
2. Circular

Magnetization : when current is passed

through a solid conductor, a magnetic field forms in
and around the conductor. The following statements
can be made about the distribution and intensity of
the magnetic field.

The field strength varies from zero at the center of

the component to a maximum at the surface.

The field strength at the surface of the conductor

decreases as the radius of the conductor increases
when the current strength is held constant.
(However, a larger conductor is capable of carrying
more current.)

Magnetization

The field strength outside the conductor is directly

proportional to the current strength. Inside the
conductor the field strength is dependent on the
current strength, magnetic permeability of the
material.

The field strength outside the conductor decreases

with distance from the conductor.

Magnetic Fields
Circular Magnetic Field for
Longitudinal Defects.

Longitudinal
Magnetic field for
Circular Defects.

Prods for Circular Magnetization

Examples of Magnetic Particle Indication

Indications of Cracks

Examples of Magnetic Particle Indication

Before and after inspection pictures of cracks

emanating from a hole

Examples of Magnetic Particle Indication

Indication of a crack in a saw blade

Examples of Magnetic Particle Indication

Indication

of cracks running between

attachment holes in a hinge

Examples of Magnetic Particle Indication

Indication

of cracks originating at a
fastener hole

Examples of Magnetic Particle Indication

Magnetic

particle wet fluorescent indication

of a cracks in a drive shaft

Examples of Magnetic Particle Indication

Magnetic

particle wet fluorescent indication of

a crack in a bearing

Main uses of MT
Used to inspect ferromagnetic materials (those that
can be magnetized) for defects that result in a
transition in the magnetic permeability of a material.
Magnetic particle inspection can detect surface and
near surface defects.

Advantages of MT
Large

surface areas of complex parts can be

inspected rapidly.
Can

detect surface and subsurface flaws.

Surface

preparation is less critical than it is in

penetrant inspection.
Magnetic

particle indications are produced

directly on the surface of the part and form an

image of the discontinuity.
Equipment

costs are relatively low.

Disadvantages of MT

Only ferromagnetic materials can be inspected.

Proper alignment of magnetic field and defect is critical.

Large currents are needed for very large parts.

Requires relatively smooth surface.

Paint or other nonmagnetic coverings adversely affect

sensitivity.

Demagnetization and post cleaning is usually

necessary.

Penetrant Testing
Penetrant solution is applied to
the surface of a precleaned
component. The liquid is pulled
into surface-breaking defects by
capillary action. Excess
penetrant material is carefully
cleaned from the surface. A
developer is applied to pull the
trapped penetrant back to the
surface where it is spread out
and forms an indication. The
indication is much easier to see
than the actual defect.

Steps of Penetrant Testing

1. Surface Preparation: One of the most critical
steps of a liquid penetrant inspection is the
surface preparation. The surface must be free of
oil, grease, water, or other contaminants that may
prevent penetrant from entering flaws. The
sample may also require etching if mechanical
operations such as machining, sanding, or grit
blasting have been performed. These and other
mechanical operations can smear the surface of
the sample, thus closing the defects.

Steps of Penetrant Testing

2. Penetrant Application: Once the surface has been thoroughly

cleaned and dried, the penetrant material is applied by

spraying, brushing, or immersing the parts in a penetrant
bath.

Steps of Penetrant Testing

3. Penetrant Dwell: The penetrant is left on the surface for a

sufficient time to allow as much penetrant as possible to be

drawn from or to seep into a defect. Penetrant dwell time is the
total time that the penetrant is in contact with the part surface.
Dwell times are usually recommended by the penetrant
producers or required by the specification being followed. The
times vary depending on the application, penetrant materials
used, the material, the form of the material being inspected, and
the type of defect being inspected. Minimum dwell times
typically range from 5 to 60 minutes. Generally, there is no
harm in using a longer penetrant dwell time as long as the
penetrant is not allowed to dry. The ideal dwell time is often
determined by experimentation and is often very specific to a
particular application.

Steps of Penetrant Testing

4. Excess Penetrant Removal: This is a most delicate
part of the inspection procedure because the excess
penetrant must be removed from the surface of the
sample while removing as little penetrant as
possible from defects. Depending on the penetrant
system used, this step may involve cleaning with a
solvent, direct rinsing with water, or first treated with
an emulsifier and then rinsing with water .

Steps of Penetrant Testing

Steps of Penetrant Testing

5. Developer Application: A thin layer of developer is
then applied to the sample to draw penetrant
trapped in flaws back to the surface where it will be
visible. Developers come in a variety of forms that
may be applied by dusting (dry powdered), dipping,
or spraying (wet developers).

Steps of Penetrant Testing

6. Indication Development: The developer is allowed to

stand on the part surface for a period of time sufficient

to permit the extraction of the trapped penetrant out of
any surface flaws. This development time is usually a
minimum of 10 minutes and significantly longer times
may be necessary for tight cracks.

Steps of Penetrant Testing

7. Inspection: Inspection is then performed under
appropriate lighting to detect indications from any
flaws which may be present.

8. Clean Surface: The final step in the process is to

thoroughly clean the part surface to remove the
developer from the parts that were found to be
acceptable.

Main uses of Penetrant Testing

Used to locate cracks, porosity, and other defects
that break the surface of a material and have
enough volume to trap and hold the penetrant
material. Liquid penetrant testing is used to inspect
large areas very efficiently and will work on most
nonporous materials.

Advantages of Penetrant Testing

Large surface areas or large volumes of

parts/materials can be inspected rapidly and at low
cost.

Parts with complex geometry are routinely

inspected.

Indications are produced directly on surface of the

part providing a visual image of the discontinuity.

Equipment investment is minimal.

Disadvantages of Penetrant Testing

Detects only surface breaking defects.

Surface preparation is critical as contaminants can

mask defects.

Requires a relatively smooth and nonporous surface.

Post cleaning is necessary to remove chemicals.

Requires multiple operations under controlled

conditions.

Chemical handling precautions are necessary (toxicity,

fire, waste).

Radiography Testing
The radiation used in radiography testing is a higher
energy (shorter wavelength) version of the
electromagnetic waves that we
see as visible light. The radiation can come from an
X-ray generator or a radioactive source.

Radiography Testing
High Electrical Potential

Electrons
+

X-ray Generator or Radioactive Source Creates

Radiation

Radiation
Penetrate
the
Sample
Exposure Recording Device

Radiography Testing
RT involves the use of penetrating gamma- or Xradiation to examine material's and product's defects
and internal features. An X-ray machine or
radioactive isotope is used as a source of radiation.
Radiation is directed through a part and onto film or
other media. The resulting shadowgraph shows the
internal features and soundness of the part. Material
thickness and density changes are indicated as
lighter or darker areas on the film.

Radiography Testing

X-ray film

Top view of developed film

X-rays are used to produce

images of objects using film or
other detector that is sensitive
to radiation. The test object is
placed between the radiation
source and detector. The
thickness and the density of
the material that X-rays must
penetrate affects the amount
of radiation reaching the
detector.

Radiography Testing
This variation in radiation produces an image on the
detector that often shows internal features of the test
object.The part is placed between the radiation
source and a piece of film. The part will stop some
of the radiation. Thicker and more dense area will
stop more of the radiation.

Main Uses of RT
Used to inspect almost any material for surface and
subsurface defects. X-rays can also be used to
locates and measures internal features, confirm the
location of hidden parts in an assembly.

Advantages of RT

Can be used to inspect virtually all materials.

Detects surface and subsurface defects.

Ability to inspect complex shapes and multi-layered

structures without disassembly.

Minimum part preparation is required.

Disadvantages of RT

Extensive operator training and skill required.

Access to both sides of the structure is usually required.

Orientation of the radiation beam to non-volumetric

defects is critical.

Field inspection of thick section can be time consuming.

Relatively expensive equipment investment is required.

Possible radiation hazard for personnel.

Eddy Current Testing

Alternating electrical current is passed through a coil
producing a magnetic field. When the coil is placed
near a conductive material, the changing magnetic
field induces current flow in the material. These
currents travel in closed loops and are called eddy
currents. Eddy currents produce their own magnetic
field that can be measured and used to find flaws
and characterize conductivity, permeability, and
dimensional features.

Eddy Current Testing

Coil

Coil's
magnetic field

Eddy current's
magnetic field
Eddy
currents
Conductive
material

Main Uses of Eddy Current Testing

Used to detect surface and near-surface flaws in
conductive materials, such as the metals. Eddy
current inspection is also used to sort materials
based on electrical conductivity and magnetic
permeability, and measures the thickness of thin
sheets of metal and nonconductive coatings such
as paint.

Advantages of Eddy Current Testing

Detects surface and near surface defects.

Test probe does not need to contact the part.

Method can be used for more than flaw detection.

Minimum part preparation is required.

Disadvantages of Eddy Current Testing

Only conductive materials can be inspected.

Ferromagnetic materials require special treatment to

address magnetic permeability.

Depth of penetration is limited.

Flaws that lie parallel to the inspection probe coil winding

direction can go undetected.

Skill and training required is more extensive than other

techniques.

Surface finish and roughness may interfere.

Reference standards are needed for setup.

Preparations before NDT

Preparations before NDT

ASPECT
Cleaning of dirt, rust, oil, slag etc. from the job
IMPACT
Dirt, rust, scale, spatters, oil & flux may fill the openings of
defects and prevent the Penetrant to enter. Obstruct the free
movement of iron particles in case of MT. Cause unwanted
or irrelevant indications in case of UT and RT.

Preparations before NDT

ASPECT
Grinding and smoothening (wire rolling) of job
IMPACT
Uneven bead, crevice or sharp contour may give irrelevant
indications in the radiograph and creates confusion of
defects. Similarly sound beam may be reflected and
diffracted in other directions than those anticipated due to
sharp edges of uneven bead, & crevices, and give
unwanted indications in UT which may lead to wrong
interpretation and evaluation. Smooth surface is also very
necessary for good interpretation of indications revealed in
PT & MT.

Preparations before NDT

ASPECT
Easy accessibility to the job.
IMPACT
In case of RT both sides of the job should be accessible to
facilitate the placement of film on one side and the source
on the other side. In case of UT enough access should be
there for movement of the probes from different sides and
angles.

Preparations before NDT

ASPECT
Visibility.
IMPACT
Proper lighting should be there on the job (1000 lx) for
proper interpretation of indications in PT & MT. Although RT
radiographs are viewed on illuminator and UT indications
are seen on the CRT which do not require additional light
source, however proper lighting is still needed to perform
the RT & UT.

Preparations before NDT

ASPECT
Correct Parameters related to the job.
IMPACT
Parameters of the job like thickness, diameter, seam length,
material, etc. should be entered properly and correctly in the
BaaN system, as these parameters are essential to perform
the NDT and to record the results properly.

NDT Facility at L&T Hazira

1. Ultrasonic Testing
Sr.no.

Model

Make

Key Features

USM 25 S

Krautkramer

Recording and printing facility upto

200 nos of A-Scan displays

USD 15X

Krautkramer

Output for permanent recording

SS-130/230

Sonatest

Multiple DAC and echo dynamics

determinations

ISONIC
UDS 3.3

Sonotron

Recording and printing of B & C scan,

end view, TOFD and probe
characteristic determination .

EX 10/100

EEC

Printing of freeze wave form

USK 6/7

Krautkramer

More gain reserve and more

resolving power

NDT Facility at L&T Hazira

2. Radiography Testing.
S.No

M/c
Description

Capacity

Quantity

Key Features

1.

LINAC/Mtsubi
shi

12.5MeV

Radiation thickness up to 500mm

with micro seconds

2.

X-Ray :
Seifert
India Ltd.

450KeV

High sensitivity. Using in control

rods (cd sandwich), for lower thick
and nuclear jobs.

3.
4.
5.

6.

Gamma ray/
Tech ops

AGFA
GEVERT

200KeV
Co.60
Ir.192
Auto
Processor

1
2NO.

Radiation thickness
thickness.

2NO.

Radiation thickness up to 3
thickness
Reduce cycle time, optimum
quality, easy to service, low
chemical consumption

2NO.

up

to

NDT Facility at L&T Hazira

3. Penetrant Testing.
Pre-Cleaner

Penetrant

Excess Penetrant
Remover

AcetoneCommercial
Grade

PP-15

PC-21

PP-110

PC-120

Thane

AcetoneCommercial
Grade

FLAWGUIDE
Penetrant-NP

FLAWGUIDE
Cleaner-NP

FLAWGUIDE
Developer-NP

Magnaflux

AcetoneCommercial
Grade

SPOTCHECK
SKL-I

SKC-I

SPOTCHECK
SKD-S2

Manufacturer

P-Met,
Vadodra

Pradeep,

Developer

PD-31&31A
PD-130&
PD-130 A

Questions & Answers

Thank You