Magnetic Particle Testing

Compiled for ASNT by

Duane Badger
NDT Assistance
 Level I

Magnetic Particle
Testing
 Lesson 1

Principles of
Magnetic Particle Testing
 Introduction
Magnetic particle testing is:
1. Cost effective.
2. Simple.
3. Fast.
4. The most reliable nondestructive
testing method for detecting
surface and near surface
discontinuities.
 Introduction

5. Able to detect discontinuities in

ferromagnetic materials that are
not open to the surface.
6. An easier method in terms of
cleaning than liquid penetrant
testing.
Capabilities of Magnetic
Particle Testing
1. Will detect discontinuities
through smeared metal.
2. The discontinuity does not have
to be completely dry.
3. Discontinuities disrupt the
magnetic flux field and small
magnetic particles will form a
visual indication of the
discontinuity.
Personnel Qualifications
1. Recommended Practice No.
SNT-TC-1A.
2. ANSI/ASNT CP-189.
3. NAS 410.
4. Each company performing
nondestructive testing must have
its own written practice
describing technician training
and certification requirements.
Magnets and Magnetic Fields

1. Permanent magnets.
2. Directly induced by current flow.
a. Head shot.
b. Prods.
Magnets and Magnetic Fields

3. Indirectly induced with no

electrical contact.
a. Central conductor.
b. Coil.
c. Yoke.
d. Wrapped cables.
 Magnetic Fields

1. Permanent magnets and

longitudinally magnetized test
objects have a north and south
pole.
2. Opposite poles attract each
other.
3. Like poles repel each other.
 Magnetic Fields

4. Direct electrical contact creates a

circular field.
5. A central conductor creates a
circular field with no electrical
contact.
 Magnetic Fields
6. A coil, yoke or wrapped cables
create a longitudinal field with no
electrical contact.
7. A discontinuity will interfere with
the magnetic field and form north
and south poles which will attract
small magnetic particles applied.
 Law of Magnetism

1. Magnetic particle testing will not

work on paramagnetic or
diamagnetic materials.
2. Magnetic particle testing only
works on ferromagnetic materials
that are strongly attracted to a
magnet.
Materials Influenced by
Magnetic Fields
1. Ferromagnetic materials are
strongly attracted. (Commonly
tested with magnetic particle
testing.)
2. Paramagnetic are weakly
attracted materials. (Not tested
with magnetic particle testing.)
Materials Influenced by
Magnetic Fields
3. Diamagnetic materials are
weakly repelled. (Not tested with
magnetic particle testing.)
4. Nonferromagnetic materials are
not attracted or repelled. (Not
tested with magnetic particle
testing.)
Characteristics of Magnetic Fields

1. Magnetic lines of force are

strongest and most dense at the
poles.
2. Magnetic lines of force always seek
the shortest path of least
resistance which is through metal.
3. Magnetic lines of force never cross
each other.
Characteristics of Magnetic Fields
4. Magnetic lines of force are called
magnetic flux.
5. Magnetic lines of force only enter
or leave the poles of a magnet.
6. A circular magnet with no
irregularities has no poles.
7. Magnetic poles will attract
magnetic particles.
 Lesson 2

Effects of Discontinuities
on Materials
Surface Discontinuities

1. If linear and 90˚ from the

magnetic field direction,
discontinuities will form poles
and a leakage field that will
attract magnetic particles and
form a visible indication.
Surface Discontinuities

2. Surface discontinuity indications

are sharp and well defined.
 Scratches

Scratches sometimes attract

particles in a very strong field, and
the field strength may have to be
reduced to verify there is no deeper
discontinuity present.
Subsurface Discontinuities

1. Subsurface discontinuities are

broad and fuzzy and more easily
blown or rinsed away than a
deep surface indication.
Subsurface Discontinuities

2. Subsurface discontinuities are

more difficult to detect unless
larger than 0.15 cm (0.06 in.)
and especially if more than
0.15 cm (0.06 in.) deep when
direct current must be used.
Leakage Field from Surface and
Subsurface Discontinuities
Lesson 3

Magnetization
 Circular Fields

1. Through direct magnetization,

circular fields are created when
current is passed through a test
object (head shot or prods), but
these techniques can cause arc
burns.
 Circular Fields

2. Through indirect magnetization,

circular fields are created when a
central conductor or other indirect
induction is used (no damage
possible from arc burns).
 Circular Fields

3. The magnetic field direction is

always 90˚ from the current flow
unless distorted due to the test
object shape or the interaction from
the two fields created.
 Contact Plates

Stationary unit direct contact

copper pads for contact head shot
must be clean, with no fraying and
a firm contact maintained to prevent
burning or arcing.
Contact Plates
 Prods

1. Prods must have clean and firm

contact.
2. Daily maintenance of contacts
should be done.
3. Prods are not used much
because of the danger of arc
burns.
 Prods

4. Heavy bulky equipment with few

advantages over the yoke method
for surface discontinuities.
Discontinuity Detection

A discontinuity that is 45˚ to 90˚

from the magnetic field direction will
disrupt the magnetic field and will
create new poles. These poles will
attract small particles and form an
indication if an adequate magnetic
field is used for testing.
 Longitudinal Field

1. Formed with a coil or solenoid,

usually five turns.
2. Wrapped cables using three to
seven wraps.
3. Yoke.
4. Transverse discontinuities will be
detected if the proper
magnetizing force is used and
verified.
 Longitudinal Field

5. The magnetic field strength is

increased with increased
amperage.
6. The magnetic field strength
increases with the number of
turns in the coil or number of
wraps around the test object.
 Field Direction
1. The field direction is 90˚ from
current flow for direct current
flow through the test object.
2. The field direction is 90˚ from the
current flow through wrapped
cables of a solenoid.
3. Odd-shaped test objects will
have distorted field direction and
require verification of proper field
strength and direction in certain
locations.
Magnetization Methods
The following determines the test
parameters to be followed by the
technique supplied to the Level I or
Level II technician:
1. The service intended for the test
object and what discontinuities
are acceptable for that service.
2. The sequence of operations
including field strength, direction
verification and demagnetization
requirements.
Magnetization Methods

3. The method to be used,

including current type, direction,
and required field strength and
direction.
4. Alloy and shape.
5. Type of current required.
Test Materials: Wet Particles

Suspended in an oil or water carrier

controlled for wettability, corrosion
and anti-foaming.
Test Materials: Dry Particles

1. Come in various colors for

contrast and different sizes and
shapes to form better indications.
2. The method, type of particles and
application will be in the work
instruction.
Longitudinal Magnetization

1. Longitudinal fields are created

with wrapped cables or a coil.
2. Field direction will always be 90˚
to current flow, except for
distorted fields in odd-shaped
test objects.
Longitudinal Magnetization
 Circular Magnetization

Central conductor or contact plates.

 Field Strength

1. Field strength will always be

maximum at the surface of test
objects, and also maximum at
the surface closest to the
conductor that induced the field.
2. Discontinuities formed by
longitudinal fields will be
transverse to the test object
length.
 Lesson 4

Principles of
Demagnetization
 Introduction

1. Ferrous materials usually retain

some residual magnetic field
after the magnetizing current is
removed.
2. Hard, alloy or high carbon steels
usually have a higher residual
field.
Alternating Current Demagnetization

1. A simple and fast process is by

using an alternating coil to
reduce residual magnetism to
ideally zero but less than 2 or
3 G (0.0002 or 0.0003 T) by
remagnetizing a test object.
Alternating Current Demagnetization

2. Then the technician reduces the

field strength to zero by
increasing the distance from the
energized alternating current in
the coil, which is usually a
10 s process.
Direct Current Demagnetization

1. Some stationary bench units

have a reversing step-down
demagnetizing coil which,
theoretically, will demagnetize
deeper fields induced with direct
current better than the
alternating current coils.
Direct Current Demagnetization
2. With either alternating current or
direct current, the initial magnetic
field strength in the coil must first
initially be stronger than the
residual field present.
3. The demagnetizing force must
reverse which is normal for
alternating current coils and
controlled by circuits for direct
current coils.
Direct Current Demagnetization

4. The demagnetizing force must be

reduced, usually by distance from
the alternating current coil and an
amperage step-down circuit for
direct current.
5. Demagnetization may be aided by
vibrations or by striking with a
hammer during current reversal
and step down.
Direct Current Demagnetization

6. Residual field strength is measured

with a pocket-size field indicator
that measures low field strength (0
to 10 G [0 to 0.001 T]).
Efficiency of Demagnetization

1. Demagnetization can only be

measured accurately if the last
field induced was a longitudinal
field.
2. It is very difficult to measure or
detect if a round test object has a
residual circular field.
Efficiency of Demagnetization

3. The requirements for

demagnetization will be specified
in the specification, technique
sheet, procedure or work order.
Reasons to Demagnetize

1. Difficulty in postcleaning.
2. Interference with welding due to
arc blow.
3. Causes chips to cling to the test
object during machining.
4. Particles attracted to the field can
cause wear.
Reasons to Demagnetize

5. Interference with nearby

instruments that work on magnetic
principles.
6. The test object needs to be
magnetized in a different direction
at a lower magnetization force.
Reasons Not to Demagnetize

Demagnetization is usually not

required for assemblies of low
carbon steel with low retentivity, if
the material is heat treated above
its curie temperature or magnetized
in another direction at the same or
higher amperage.
Lesson 5

Equipment
Equipment Selection

Considerations include the cost

versus the purpose of the test.
Technical and Specification
Requirements
1. Wet or dry method.
2. Automation or manual.
3. Demagnetization requirements.
4. Solution capacity for wet methods.
5. Electricity, air, and water supply
requirements.
6. Accessories required.
Technical and Specification
Requirements
7. Indication, recording, and
reporting requirement.
8. Technician training and
certification requirements.
9. Mobile or stationary equipment.
 Purpose of Test
1. Verify construction and service
expectations were correct.
2. The equipment used will be
specified in the work instruction for
a Level I or II.
3. If the test is required by a national
standard, a specification,
procedure or technique, approval
by a Level III may be required for
the technician to follow.
 Area Tested
1. The area tested will be in
accordance with customer and
contract requirements, and a
Level III approved written
instruction will normally be
provided for the Level I or II
technician.
2. Level I technicians may operate
equipment with direct
supervision of a Level II or III
technician.
Mobile Equipment
 Mobile Equipment
1. Mobile equipment can be moved
around a shop and usually
moved in a truck.
2. Provides about 3000 to 4000 A,
and can be a power supply for
prods or wrapped cables.
3. The power supply is usually 220
or 440 V and may provide either
alternating or direct magnetizing
current.
Stationary Equipment
Stationary Equipment

1. Stationary horizontal wet units

have two adjustable contact
heads that can be used for direct
magnetization (head shots), or
central conductor indirect
magnetization and a coil (which
is normally five turns of cable).
Stationary Equipment

2. The unit has a tank, pump and

agitation and circulation system
for the wet solution used for
testing, and a nozzle for wetting
the test object.
Stationary Equipment

3. The unit has amperage controls,

current timers, an air or hydraulic
cylinder for clamping test objects,
and is usually supplied with three
phase 220 or 440 V. It may provide
either low voltage alternating or
direct current at high current for
magnetization.
 Particles Used

1. The particles must have high

permeability to be strongly
attracted to magnetic leakage
fields, have a low residual field
and must be tested for standard
performance prior to use.
 Particles Used

2. Dry powder or suspended in a

liquid.
3. Visible or fluorescent.
4. Visible comes in various colors
for contrast.
 Lesson 6

Discontinuities
Inherent Discontinuities

Inherent discontinuities are formed

during the initial melting and
solidification process.
1. Ingot pipe is caused by
shrinkage at the top of the ingot.
2. Ingot crack can form anytime
during solidification or cooling of
metal.
Inherent Discontinuities

3. Nonmetallic inclusions are slag

pickets, alloy, segregation or foreign
material.
4. Blowholes are caused by gas
pockets escaping the molten metal.
Blowholes in casting may be caused
when moisture in the mold flashing
to steam and blowing into the
molten metal occurs.
Processing Discontinuities

Additional processing can cause

discontinuities or change the shape
of inherent discontinuities.
1. Seams are in rolled bar.
2. Laminations are in rolled plate.
3. Cupping is in cold drawn
material.
4. Cooling cracks are caused during
cooling.
Processing Discontinuities

5. Forging flakes are caused by

cooling and hydrogen
embrittlement.
6. Forging bursts are caused by
improper forging temperatures.
7. Forging laps are caused by
metal folded over during forging.
Processing Discontinuities

8. Forging flash line tears are

caused by improper trimming or
stress build-up.
9. Casting cold shuts are caused by
molten metal flowing together but
not fusing together.
10. Casting hot tears and shrinkage
are caused by unequal cooling
and stress build-up.
Processing Discontinuities

11. Weld lack of fusion and lack of

penetration are caused by
improper weld joint preparation or
welder technique.
12. Weld heat affected zone cracks
can be caused by improper
preheat, heat input during
welding, post weld cooling or
incorrect filler material.
Processing Discontinuities

13. Weld crater cracks are caused

by improper technique for
stopping the weld.
14. Machine grinding cracks are
caused by overheating.
15. Machine tears are caused by
dull tools or excessive depth of
cut.
Processing Discontinuities

16. Cracks can be caused by a

multitude of reasons at any
stage during manufacturing
including residual stress,
improper heating and cooling,
or improper hydrogen control.
Inservice Discontinuities

1. The most common inservice

discontinuities are fatigue cracks
and corrosion.
2. Cracks are usually at or near the
surface and propagate longer
and deeper. They may also start
as internal cracks and propagate
longer and toward the surface.
Inservice Discontinuities

3. Cracks can happen as a single

cycle fatigue crack or from
multiple cycles.
 Summary
1. Magnetic particle testing is used
to detect surface and some
slightly subsurface discontinuities
as early in the manufacturing
process as possible.
2. Some specifications require half
wave or full wave rectified current
for manufacturing tests.
Alternating current may be used
for inservice tests.