Digital Research and Development

Testing Procedure for Magnetic Particle Testing

TABLE OF CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. 9. PURPOSE SCOPE REFERENCE DOCUMENTS PERSONNEL WRITTEN PROCEDURE MATERIALS EQUIPMENT EQUIPMENT CALIBRATION LIGHTING 9. 9. 9. 9. 10. 1 2 3 4 Visible light Ambient visible light Black light Special lighting. Novell 5 5 5 6 6 7 7 7 7 7 7 8 8 8 8 9 9 10 10 11 11 11 11 12 12 12 12 12

QUALITY CONTROL REQUIREMENTS 10. 1 Systems performance verification 10. 2 Concentration tests 10. 3 Contamination test 10. 4 Water break test 10. 5 Keytos ring test 10. 6 Black light intensity 10. 7 Visible light intensity 10. 8 Background ambient light 10. 9 Current magnitude test 10. 10 Ammeter accuracy 10.11 Timer control check 10.12 Magnetic field quick break check 10.13 Internal shortening check 10.14 Yokes

TABLE of CONTENTS (continued) 11. GENERAL REQUIREMENTS 11.1 Dark adaptation 11.2 Testing sequence 11.3 Pre-testing demagnetization 11.4 Surface cleanliness 11.5 Pre-cleaning 11.6 Plugging or masking 11.7 Coatings MAGNETIC FIELD DIRECTIONS MAGNETIC FIELD STRENGTH CIRCULAR MAGNETIZATION 14.1 Direct current levels 14.2 Centrally located conductor 14.3 Offset Central conductor LONGITUDINAL MAGNETIZATION 15.1 Effective field coverage 15.2 Low fill factor coils 15.3 Cable wrap and higher fill factor coils 15.4 Intermediate fill factor coils 15.5 Determination of cross-sectional area 15.6 Calculating the L/D ratio for hollow or cylindrical parts 15.7 L/D ratio MAGNETIC PARTICLE APPLICATION 16.4 Dry magnetic particle testing method 16.5 Wet magnetic particle testing method 16.6 Residual testing method DEMAGNETIZATION 13 13 13 13 13 13 14 14 14 14 15 15 15 15 16 16 16 17 17 18 18 18 19 19 20 20 20

12. 13. 14.

15.

16.

17.

TABLE OF CONTENTS (continued) 18. 19. 20. POST TESTING/CLEANING ACCEPT/REJECT CRITERIA REPORT 21 21 22 22 23 24

RECORDS TABLE 1 required verification intervals TABLE 2 required indications

PURPOSE 1.1 This procedure establishes the requirements when magnetic particle testing is used for the detection of discontinuities at or immediately below the surface of ferromagnetic materials.

SCOPE 2.1 This procedure shall be used whenever Mil-Standard-1949 or ASTM -1444 is referenced works instructions, unless otherwise specified by the customer. This procedure meets or exceeds the minimum requirements of Mil-Std1949 or ASTM-1444.

2.2 3

REFERENCE DOCUMENTS 3.1

The following documents form a part of this procedure to the extent specified herein, unless specifically noted or specified by the customer, the latest revision shall apply. 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 ASTM E-1444 Mil-Std-1949 QAM-101 SNT-TC-1A Mil-Std.410 CP-1 Standard Practice for Magnetic Particle Examination Magnetic Particle Inspection Nondestructive Testing Personnel, Qualification and Certification Recommended Practice, Personnel Qualification and Certification in Nondestructive Testing Nondestructive Testing Personnel, Qualification and Certification Calibration Systems Requirements

PERSONNEL 4.1 All personnel performing magnetic particle testing to this procedure shall be qualified and certified in accordance with the requirements of SNT-TC1A and Mil-Std-410.

4.2

Only certified Level II or Level III personnel shall make accept/reject determinations. 4.2.1 A certified Level I or personnel under the direct supervision of a Level II or III may act as an assistant technician in the performance of magnetic particle testing.

WRITTEN PROCEDURE 5.1 Magnetic particle testing shall be performed in accordance with a written procedure or technique applicable to the parts or groups of parts being tested. The procedure or technique shall be capable of detecting the smallest rejectable discontinuities specified in the acceptance criteria. All written procedures or techniques shall be reviewed and signed by a qualified and certified Level III magnetic particle inspector. Procedures shall be submitted to the customer upon request.

5.2 5.3 5.4 6

MATERIALS 6.1 6.2 All materials used for testing to this procedure shall meet the minimum requirements of ASTM E-1444. Material certifications shall be kept on file and made available for review upon request.

EQUIPMENT 7.1 All equipment used to perform testing to this procedure shall be capable of adequately magnetizing and demagnetizing the component(s) under test using one or more of the following currents. 7.1.1 7.1.2 7.1.3 7.1.4 Direct Current (DC) Alternating Current (AC) Half-Wave Rectified Current (HWDC) Full-Wave Rectified Single or Three Phase Current (FWDC)

EQUIPMENT CALIBRATION 8.1 All equipment requiring calibration shall be calibrated in accordance with the requirements of CP-1 8.1.1 8.2 8.3 Intervals for calibration shall be as noted on Table 1 of this procedure.

All calibrated equipment shall have a current calibration sticker affixed to it. Records of all calibrations shall be kept on file and made available for review upon request.

LIGHTING 9.1 Visible Light 9.1.1 When performing testing using non-fluorescent particles, the intensity of the white light at the testing surface shall be a minimum of 1,000 lx (100 foot candles).

9.2

Ambient visible light 9.2.1 Unless otherwise specified, testing using fluorescent particles shall be performed in a darkened area with A maximum ambient background light intensity of 20 lx (2 foot candles).

9.2.1.1 Intensity shall be checked at the interval noted on Table 1. 9.3 Black light
9.3.1

When performing testing using fluorescent particles, testing shall be performed in a darkened area using a black light with a minimum intensity 1,000 uW/cm2 at the part surface.

9.4

Special Lighting 9.4.1 For hard to access areas that are to be tested, such as small holes or internal diameter's, special ocular devices, such as mirrors and black light borescopes shall be used.

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QUALITY CONTROL REQUIREMENTS 10.1 Systems performance verification 10.1.1 The overall effectiveness of the magnetic particle testing system, including the equipment, materials and environment used, shall be verified initially periodic intervals. (see Table 1) The frequency of calibration of current and voltage measuring devices, ammeter shunts, timers and gaussmeters used in the systems verification shall comply with the requirements of MIL-STD-45662 and CP-1. If the results of any system performance test fail to meet the minimum requirements of this procedure, then no part shall be processed until appropriate corrective action has been taken. All results of the performance tests shall be recorded, filed and made available for review upon request

lighting and at 10.1.2

10.1.3

10.1.4

10.2 Concentration tests 10.2.1 10.2.2 Particle concentration tests shall be performed at the beginning of each shift or every eight hours, as applicable. To perform test 10.2.2.1 Agitate the particle suspension for at least 30 minutes to ensure uniform dispersal throughout the bath. Fill a centrifuge tube to the 100-ml mark, demagnetize and let settle undisturbed for a minimum of 60 minutes if using a petroleum distillate suspension, or 30 minutes if using a conditioned water suspension. After the applicable settling time, read the volume of particles. For fluorescent particles, the concentration shall be 1.2 to 2.4 ml. For nonfluorescent particles, the concentration shall be 1.2 to 2.4 ml.

10.2.2.2

10.2.2.3

10.2.2.3.1 10.2.2.3.2 10.2.2.4

Should the concentration be out of these limits or the particles appear to be loose agglomerates rather than an even layer, then appropriate corrective action shall be taken prior to any parts being processed.

10.3 10.3.1

Contamination test In addition to determining the particle concentration when performing the settling test outlined in paragraph 10.2, fluorescent baths shall be examined for contamination. This shall be accomplished by examining the liquid above the precipitate under a black light.

10.3.2

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10.3.3 10.3.4

The liquid shall be comparable to the fresh, unused sample taken when the bath was last changed. The graduated portion of the tube shall be examined under both black light and white light for striations, banding or a difference in color. If the total volume of contaminates, including bands or striations, is greater than 30%, or if the solution is noticeably fluorescent, the bath shall be changed prior to any part being processed. Water break test

10.3.5

10.4 10.4.1

Using an approximately 3 x 5 panel with a surface finish comparable to the type of parts tested, flow the solution over the panel and observe the results. The panel should show and even coating with no bare spots. If bare spots are present, then appropriate corrective action shall be taken prior to any part being processed. The pH shall be maintained between 6.0 and 10.0. Ketos ring test

10.4.2 10.4.3 10.4.4 10.5 10.5.1 10.5.2

A ketos ring test shall be performed to ensure the overall system is functioning properly. To perform this test, place a copper central conductor 1 to 1-1/4 in diameter and a minimum of 16 in length through the ketos ring, centering the ring on the conductor. Using the continuous method, apply the dry or wet particles, as applicable, over the ketos ring.

10.5.3

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10.5.4

The amperages to be used in the minimum number of indications that should be detected shall be in accordance with requirements noted in Table 2. Black light intensity

10.6
10.6.1

Black light intensity shall be a minimum of 1200 uw/cm2 when measured at a distance of 15 inches from the face of the UV lens. The intensity shall be measured with an Ardrox DLM-1000 radiometer or equivalent. Visible light intensity

10.6.2 10.7 10.7.1

Visible light intensity shall be measured from the source to the parts surface or testing area and shall be a minimum of 1,000 lx (100 foot candles) when measured with an Ardrox DLM-1000 radiometer or equivalent. Background ambient light

10.8 10.8.1

When using fluorescent particles, testing shall be performed in a darkened area with a maximum of 20 lx (2 foot candles) of background ambient light. The intensity shall be measured using an Ardrox DLM1000 radiometer or equivalent. Current magnitude test

10.8.2 10.9 10.9.1 10.9.2 10.9.3

Place the central conductor between the head and tail stock. Set amperage control to maximum rated output and energize three (3) times. The amperage should meet maximum rated output, 10%.

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10.9.4

If amperage does not meet maximum rated output, the machine shall be placarded to show the actual maximum output. Ammeter accuracy

10.10 10.10.1 10.10.2 10.10.3

A calibrated ammeter shall be connected in series with the output circuit to check the equipment ammeter. Comparative readings shall be taken at three (3) output levels encompassing the usable range of the equipment. The equipment ammeter reading shall not deviate more than 10% of full scale from the current value shown on the calibrated ammeter. Timer control check

10.11 10.11.1

On equipment using a timer to control the current duration, the timer should be checked to within 0.1 second using a suitable electronic timer. Internal shorting check

10.12 10.12.1 10.12.2 10.13 10.13.1 10.13.2 10.13.3

Magnetic particle machines shall be checked for internal shorting. With a machine set for maximum amperage through the contacts, there shall be no deflection of the ammeter. Yokes AC and DC yokes shall be tested using the dead weight method. AC yokes shall be capable of lifting a minimum of 10 pounds with a 2 to 4 spacing. DC yokes shall be capable of lifting a minimum of 50 pounds with a 4 to 6 spacing.

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11 11.1

GENERAL REQUIREMENTS Dark Adaptation 11.1.1 Technicians shall not wear photochromatic or permanently darkened lenses while performing magnetic particle testing. 11.1.2 When performing testing using the fluorescent method, the technician shall wait at least one (1) minutes for dark adaptation prior to beginning testing. 11.2 Testing sequence 11.2.1 Magnetic particle testing shall be performed after operations that could cause surface or near-surface defects. 11.3 Pre-testing demagnetization 11.3.1 The part shall be demagnetized before testing if prior operations have produced a residual magnetic field that may interfere with testing. 11.4 Surface cleanliness 11.4.1 All surfaces to be magnetic particle tested shall be essentially smooth, clean, dry and free of oil, grease, scale and other contaminants that may interfere with the efficiency of the testing. 11.5 Precleaning 11.5.1 The cleaning method used shall be consistent with the type of contaminate (s) to be removed. 11.5.1.1 Such cleaning methods are, but not limited to, detergents, solvents, vapor degreasing, wire brushing and blasting.

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11.6

Plugging or Masking 11.6.1 Unless otherwise specified by the customer, small openings such as blind holes leading to internal cores or passages shall be plugged or masked to prevent entrapment or contamination from the testing media.

11.7

Coatings 11.7.1 Testing shall not be performed on parts with coatings in places that could prevent the detection of surface defects in ferromagnetic substrate. 11.7.1.1 Examples of such coatings are, but not limited to, nonferromagnetic coatings such as chrome plate or paint greater than 0.003 inch thickness and ferromagnetic coatings such as nickel greater than 0.001 inch in thickness.

11.7.2 When such coatings are non-conductive, such as paint or black oxide, then the coating shall be removed where electrical contact is to be made. 12 MAGNETIC FIELD DIRECTION 12.1 Discontinuities are often hard to detect when they are oriented at an angle of less than 45 degrees to the direction of the magnetic field. 12.1.1 To ensure detection of all discontinuities, all parts shall be magnetized in at least two (2) directions. 12.2 13 A pie-field indicator may be used to verify field directions.

MAGNETIC FIELD STRENGTH 13.1 The magnetic field strength shall be sufficient enough to detect all indications, but not so strong that it may mask small surface indications due to excessive background fluorescence.

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13.2

One or a combination of these methods may determine adequate field strength. 13.2.1 Use of parts with known or artificial defects of the type, size and location as specified in the acceptance criteria. 13.2.2 By use of a Hall-Effect probe gaussmeter. 13.2.3 By use of the formulas provided in this procedure.

13.3 14

When using a gauss meter, the measured field strength shall be maintained between 30 and 60 gauss in the area(s) of the component under testing.

CIRCULAR MAGNETIZATION 14.1 Direct current levels 14.1.1 When magnetizing a component by passing the current directly through the part (head shot), the current shall be 300 to 800 amps per inch of part diameter. 14.1.2 The part diameter shall be considered the greatest distance between any two (2) points on the outside circumference. 14.1.3 Currents will normally be 500 amps per inch of diameter or lower, with the higher currents, up to 800 amps per inch of diameter being used to detect for inclusions or to test low-permeability alloys such as precipitation-hardened steels. 14.1.4 For testing of inclusions in precipitation steels, higher currents may be used, up to 1000 amps per inch of diameter. 14.2 Centrally located conductor 14.2.1 When the axis of the central conductor is located in or near the central axis of the component being tested, then the amperages provided in paragraph 14.1 shall apply.

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14.3

Offset central conductor 14.3.1 When the conductor is placed against an inside wall of a part, then the current levels given in paragraph 14.1 shall apply, except the diameter shall be considered the sum of the diameter of the conductor and twice the wall thickness. 14.3.2 The distance along the parts circumference (ID) that can be effectively magnetized shall be taken as four times the diameter of the conductor. 14.3.3 Rotating the part, allowing for a 10% field overlap shall test the entire circumference of the part.

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LONGITUDINAL MAGNETIZATION 15.1 Effective field coverage 15.1.1 For low fill-factor coils, the effective field extends a distance on either side of the coil approximately the same distance at the coils radius. 15.1.2 For cable wrap or high fill-factor coils, the effective field extends 9 inches on either side of the coil center. 15.1.3 For parts longer than these effective distances, the part must be repositioned to allow 100% testing, allowing for a 10% magnetic field overlap. 15.2 Low fill-factor coils 15.2.1 When the cross-sectional area of the coil is 10 or more times the cross-sectional area o the part, the following formulas for amperage determination shall be use.

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15.2.1.1

For parts positioned at the side of the coil NI = L/D Where: K ( 10%) K = 45,000 ampere turns L = Length of part D = Diameter of part )measured in same units as length)

15.2.1.2

For parts positioned at the center of the coil NI = _ KR (6L/D)-5 Where ( 10%) R = Radius of coil K = 43,000 ampere turns per inch L = Length of part D = Diameter of part (measured in same units as length)

15.3

Cable wrap and high fill-factor coils. 15.3.1 When the cross-sectional area of the coil is 2 times or less than the cross-sectional area of the part, the following formula shall be used. NI = _ K L/D+2 Where: ( 10%) K = 45,000 ampere turns L = Length of part D = Diameter of part )measured in same units as length)

15.4

Intermediate fill-factor coils 15.4.1 When cross-sectional area of the coil is between 2 and 10 times the cross-sectional area of the part, then the following formula shall be used. NI = (NI) h (10-t) / 8 + (NI)1 (t-2) / 8

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Where:

(NI) l = value of NI calculated for low fill-factor coils (NI) h = value of NI calculated for high fill-factor coils t = ratio of the cross-sectional area of the part

equals 15.5

For example: If the coil is 10 inches in diameter and the part is 5 inches in diameter, then t = (3.14 x 52) / (3.14 x 2.52) which 4. Determination of cross-sectional area 15.5.1 To determine the cross-sectional area of a coil or part, the following formula shall be used. A = 3.14 (R2) Where: A = cross-sectional area R = radius of the coil or part 15.6 Calculating the L/D ratio for hollow or cylindrical parts 15.6.1 For cylindrical or hollow parts, the actual part diameter shall be replaced with an effective diameter, Deff, using the following formula. Deff = [(OD)2 (ID)2] 1/2 Where: OD = outside diameter ID = inside diameter 15.7 L/D ratio 15.7.1 The longitudinal formulas provided in this procedure only holds true if the L/D ratio is greater than 2 and less than 15.

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15.7.2 If the L/D ratio of 2 or greater cannot be achieved, then pole pieces (pieces of ferromagnetic material with the same diameter as the part being tested) shall be used to increase the L/D ratio. 15.7.3 If the part geometry is such that the use of pole pieces is impractical, then artificial shims of the type noted in Figure 6 shall be used to verify adequate field strength and direction. 15.7.4 If the length is greater than 15, then 15 shall be used as the length when calculating the L/D ratio. 16 MAGNETIC PARTICLE APPLICATION 16.1 16.2 The type of equipment, method and magnetic particles used shall be determined by customer requirements. If customer requirements do not specify what method of magnetic particle testing is to be used, then it shall be the technicians determination as to what method will be best suited to provide accurate 100% testing of the part. In all cases, only the fluorescent, wet continuous method shall be used for the testing of aerospace components (flight hardware). Dry magnetic particle testing method 16.4.1 The current flow shall be initiated prior to and during the application of particles. 16.4.2 The particles shall be applied by squeeze bulbs, shakers or other suitable means in a manner that will result in a uniform, dust-like coating. 16.4.3 The duration of the magnetization shall be at least second.

16.3 16.4

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16.5

Wet magnetic particle testing method 16.5.1 Fluorescent or nonfluorescent particles suspended in a liquid vehicle shall be applied and then diverted either simultaneously with or slightly before the current is applied. 16.5.2 A minimum of two(2) current applications of at least second each shall be used.

16.6

Residual testing method 16.6.1 When using this method, the magnetic particles are applied immediately after the current has been removed. 16.6.2 This method shall not be used unless specifically requested by the customer

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DEMAGNETIZATION 17.1 All parts shall be demagnetized after testing when using AC current. 17.1.1 With a fixed coil, hold the part approximately 1 foot in front of the coil and slowly pass the part through the coil, positioning it as closely as possible to the side of the coil, to the point approximately 3 feet beyond the coil. 17.2 When using DC demagnetization, the initial field shall be higher than, an in nearly the same direction as, the field reached during testing. 17.2.1 The field shall then re reversed, decreased in magnitude, and the process repeated (cycled) until an acceptably low value of residual field is reached. 17.3 17.4 Whenever possible, parts that have been circular magnetized shall be magnetized longitudinally prior to demagnetization. After demagnetization, the residual magnetic field shall not exceed three (3) gauss anywhere on the part when measured with a field indicator or equivalent.

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PST TESTING CLEANING 18.1 18.2 18.3 Cleaning shall be accomplished in accordance with the requirements specified in paragraph 11.5. Care shall be taken to remove all plugs or masking, as applicable. Parts shall be protected from possible corrosion by a suitable means.

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ACCEPT/REJECT CRITERIA 19.1 19.2 It shall be the customers responsibility to provide the accept/reject criteria for the part to be tested. If no criteria is provided, the following defects, such as, but not limited to, cracks, laps, seams, cold shuts, bursts, laminations and arc burns, shall be rejected. Acceptable parts 19.3.1 All parts that have been accepted using magnetic particle testing shall be marked in accordance with the applicable drawing, purchase order, contract or as specified herein. 19.3.2 the applicable marking shall appear on the Certification of Test Report, see Exhibits 3 and 4. 19.3.3 Ink stamping 19.3.3.1 When specified, acceptable parts shall be rubber ink stamped by the technician who performed the test in an area where subsequent operations will not remove it.

19.3

19.3.4 Dying 19.3.4.1 19.3.4.2 When the size or part configuration does not facilitate ink stamping, dying may be used. Dying shall be accomplished by using a predominately blue color.

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19.3.5 Other methods 19.3.5.1 For small parts such as bearings, pins, rollers or bushings, bagging and attaching a tag with ink stamp may be used.

19.4

Rejected parts 19.4.1 Parts, which do not conform to the customers accept/reject criteria, shall have the defect marked and the part red tagged noting the reason for rejection. 19.4.1.1 All rejectable parts shall be recorded on the job assignment sheet and the customers testing report.

19.5 20

When possible, the part(s) shall be identified by a serial number.

REPORTS 20.1 This report shall contain the name and stamp of the certified technician who performed the test and the signature of an authorized company representative. This report shall be signed by the certified technician who performed the test and will include his/her level of certification.

20.2 21

RECORDS 21.1 21.2 The results of all magnetic particle testing shall be documented and provide traceability to the specific part or lot tested. All records of magnetic particle testing shall be kept on file for a minimum of seven (7) years.

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TABLE 1
Required verification intervals
ITEM Lighting: Black light intensity Ambient light intensity Visible light intensity System performance using the test Piece or ring specimen of Figure 1 Wet particle concentration Water break test Wet particle contamination Equipment calibration/check: Ammeter accuracy Timer control Dead weight check NOTE: MAXIMUM TIME BETWEEN VERIFICATIONS 1 Day 1 Day 1 Day 1 Day Every 8 hours or Every shift change 1 Day 1 Week 6 months 6 months 6 months

The maximum time between verifications may be extended when substantiated by actual technical stability/reliability data.

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TABLE 2
Required indications when using the ring specimen with artificial sub-surface defects.
PARTICLES USED Wet suspension, Fluorescent or Non-fluorescent Dry Powder CENTRAL CONDUCTOR FWDC AMPERAGE 1,400 2,500 3,400 1,400 2,500 3,400 MINIMUM NUMBER OF HOLES INDICATED 3 5 6 4 6 7