CIRCULAR MAGNETIZATION:

( Manfred Gunz )

A circular magnetic field is generated around a conductor or a specimen, when a current flows through the conductor/specimen. The generated magnetic field is perpendicular to the current flow direction. The generated magnetic field is called circular. This is due to the magnetic field lines around the conductor/specimen which are distributed around the conductor/specimen in circular shape. See also image below:

Magnetic Field Lines Flaws perpendicular to the magnetic field direction can be detected best. Flaws which are in same direction to the magnetic field can hardly be detected. This caused by the flux leakage, which is greatest when perpendicular to the magnetic lines of force. Like shown in above left image, flaws which crossing the lines of magnetic force between 45 and 90 can be easily detected by any type of magnetic field. In case the angle is less than 45, it is more likely that flaws can not be detect. A circular field can be direct / indirect induced by the following equipment: 1) Head Shot 2) Prods 3) Central Conductor Head Shot: The sketch below is illustrating a typical head shot application for industrial use. To avoid contact surface damages at the ends, the magnetization time should be between 0.5 sec and 1.5 sec. Left images shows a bench, where Specimen Magnetic Field the specimen is fixed by force at the ends of the specimen surface ( red arrow ). The current flows through the specimen and induced a circular shaped magnetic field, represented by green magnetic lines of force. Current I

Current Requirements: The amount of current will vary with the shape and permeability of the material being tested. A test specimen with a good indication is a good method to ensure that only sufficient current is used to show the indication. Too much current will burn the part or may cause heavy accumulations of iron particles Too less current may not provide the required field strength to attract the iron particles The ensure, sufficient current will be use, the following rule of thumb is used to determine the needed current. ( 800A 1000A per inch) or ( 300 A- 400 A per cm ) of article thickness in diameter. If a specimens cross section is not round, e.g.: a square, than the diagonal width needs to be considered for computing like mentioned in below sketch. For square cross sections the following equation needs to be used to determine required current: I = 2000 ( a + B ) / ( a & b in inches ) ( According SE-709 ) I = 800 ( a + b ) / ( a & b in cm ) If the specimen is having different cross sections, than for each cross section one shot is required. While inspection a specimen with different cross sections, it is recommend that the inspector starts from the smallest cross section to the next bigger cross section. Other bigger cross sections will be treated accordingly. Example: Given is a specimen with the following dimensions.
100 mm 140 x 100 mm 5 80 mm 100 x 100 mm 50 mm

4 1 200 mm 600 mm

3 800 mm 300 mm

2 1000 mm

Inspection sequence of the specimen. Compute first the diameter / diagonals of all cross sections and then start inspection with the smallest cross section. Continue with the next bigger cross section and son on. Start with diameter 50 mm, which is equal to two inches. Amperage for a shot should be between 1,600 A and 2,000 A.

Continuing with diameter 80mm, which is a bit more than 3 inches. Amperage for each shot should be between 2,400 A and 3,000 A. Continuing with diameter 100 mm, which is equal to 4 inches. Amperage for each shot should be between 3,200 A and 4,000 A. Continuing with the cross section 100 x 100 mm, which is equal to 4 inch x 4 inch. Amperage for each shot should be approx. 5,100 A. Finishing with the cross section 140 x 100 mm, which is equal to 5.5 inch x 4 inch. Amperage for each shot should be approx. 6050 A.

Another often used application for the head shot, is to use the heat shot machine as a central conductor on which some other components can be inspected. The sketch below will explain the above mentioned situation.

Inner Bar

Article 1

Article 2

Article 3

Current Flow

OD = 50 mm OD = 75 mm OD = 100 mm

As shown on previous page, the inner bar is having actually two functions. One function is, the bar provides the circular field while current flows to the material like a central

conductor. The other function is, the bar is a kind of holder on which other articles can be inspected. Also under this condition, the current rule of thumb needs to be applied. For computing the required current, the outside diameter needs to be considered. The actual required current for above mentioned examples would be like follow: Article 1: Magnetization current is 1,600 A 2,000 A Article 2: Magnetization current is 2,400 A 3,000 A Article 3: Magnetization current is 3,200 A 4,000 A Prods : The image below shows a typical prods application for industrial use. Prod magnetization is used, where the size or location of an article does not permit the use of a head shot or a central conductor. The current flow and the circular field distribution are shown in above sketch. Prods are current carrying conductors ( usually copper ) which are used to magnetize localized areas.

Please consider: Prods are producing sparks while inspection the specimen. Due to this fact, prods are not allowed to use in some industrial fields like: Chemical Plants Petrochemical Plants All industrial plants with strong fire/spark restrictions.

The prods should be placed on a part so that the resultant circular field is at 90 Degree to the suspected discontinuity. While inspecting welds, it is recommend to place the prods like shown in below sketch, whereas the recommend prod distance is approximately 8 inches ( 200 mm ).

6 - 8 inches ( 150 200 mm )

A guideline to determine how much current is required by varying prod spacing is mentioned in below table.

Prod Spacing ( inches / mm ) 2 4 inches ( 50 100 mm ) 4 6 inches ( 100 150 mm ) 6 8 inches ( 150 200 mm )

Section Thickness ( inches / mm ) Under 3/4 inch / 19 mm 200 300 Amperes 300 400 Amperes 400 600 Amperes 3/4 inch / 19 mm and over 300 400 Amperes 400 600 Amperes 600 800 Amperes

When half wave direct current ( HWDC ) is used, the field strength per ampere is about the same as with direct current ( DC ) at typical prod spacing ( 6 8 inches ). However, since HWDC consumes less power and produces lower heating effect at the prod contact points, it is often recommend. In addition HWDC produces better Powder mobility compared prod inspection performed with DC. Prods are handheld electrodes that are pressed against the surface of the component being inspected to make contact for passing electrical current through the metal. The current passing between the prods creates a circular magnetic field around the prods that can be used in magnetic particle inspection. Prods are typically made from copper and have an insulated handle to help protect the operator. One of the prods has a trigger switch so that the current can be quickly and easily turned on and off. Sometimes the two prods are connected by any insulator (as shown in the image) to facilitate one hand operation. This is referred to as a dual prod and is commonly used for weld inspections. In addition prods are also widely used for big castings and forgings. The left image is showing a relative small portable prods inspection unit. Due to fact that arcs are product while performing inspection with prods, the prod inspection method is also not recommend on final machined components.

If proper contact is not maintained between the prods and the component surface, electrical arcing can occur and cause damage to the component. For this reason, the use of prods are not allowed when inspecting aerospace and other critical components. To help prevent arcing, the prod tips should be inspected frequently to ensure that they are not oxidized, covered with scale or other contaminant, or damaged. The user is encouraged to manipulate the prods to orient the magnetic field to "cut across" suspected defects.

Central Conductor: Image below shows a typical application of a central conductor.

Multi Cable Technique Effective Length

OD

Wall-Thickness = WT Applied Current

This method is also called indirect induction of a magnetic field into a specimen. This can be realized by passing a current through the central conductor as shown above. The required current can be computed according the following rule of thumb according SE709. Required current = ( 300 A 800 A per inch OD ) or ( 120 A 320 A per cm OD ) ( If conductor is central to the OD ) Actual current = Required Current / Number of conductors inside For the central conductor technique, a central conductor is used to examine the internal surfaces of cylindrical and o-ring shaped parts. This technique may also be used to check the outer surface for possible indications, if the wall thickness is not too thick and the remaining magnetic field strength at the outside diameter is still strong enough for examinations. Where large diameter cylinders needs to be examined, the conductor shall be positioned close to the internal surface of the cylinder. If the conductor is not centered, the circumference of the cylinder shall be examined in increments. Bars as well as cable may be used to induce a circular magnetization. The computed required current shall be for a single turn central conductor. While using a cable, it can be wrapped in loops many times around the outside wall, so that the required current will be divided by the number of loops. The magnetic field will increase in proportion to the number of loops the central conductor cable passes through the hollow part. Example: If 2000 Amperes are required to examine a part using a single central conductor, then 1000 Amperes are required when two turns of the through cable are used.