CAAP 42V-3(0): Magnetic Particle Inspection

Coil: The coil provides a means of longitudinally magnetising a component. The coil is generally a four or five turn coil. Some new generation coils contain numerous turns of smaller diameter lower current carrying coils and are rated as an effective four or five turn coil. Control Panel: The control panel generally contains: An ammeter for displaying the applied magnetising current. Current selector for dialling the required amperage AC/DC selector switch (optional) Head/coil selector switch Demagnetisation button (optional) Magnetisation button

Sump: The sump contains the magnetic particle fluid. Sumps will vary in size from 20 litres (newer generation) to 200 litres for the older style of benches. The sump contains a pump and applicator nozzle. Note: The use of AVTUR as a magnetic particle carrier fluid is not permitted due to the high risk of fire. Black light: The black light is usually mounted on the bench via an arm to allow hands-free operation of the bench. Note: Black light should not be operated with cracked, chipped or missing filters. Failure to comply may result in injury. 4.3 POST CLEANING

Usually a solvent bath is provided near the MPI bench for rinsing of the part to remove residual magnetic particles. After the rinse, the parts are cleaned and inhibited (if required) in a similar manner to the pre-cleaning process.

5. Magnetic Particle Inspection (MPI) Portable Hand-held Yokes

5.1

EQUIPMENT REQUIREMENTS

To carry out MPI on an aircraft in-situ, the following equipment is required: Black light (capable of 1000W/cm2 @ 15 inches); Light protective cloak approx 1 metre square; Approved marking media, mirror and rule; Lint free cloth and cleaning solvent; Hand held AC/DC magnetic yoke; Castrol Type II strips (or equivalent); Ardrox 8561 MPI fluid in aerosol can (or equivalent); and Field indicator or gauss meter.
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CAAP 42V-3(0): Magnetic Particle Inspection

6. Quality Control Equipment Magnetic Particle

6.1 THE FOLLOWING IS A LIST OF EQUIPMENT REQUIRED: Black and white light meter; 100 ml pear-shaped centrifuge; Tool steel ring (Ketos ring) is optional Flexible laminated strips (Castrol strips); Field indicator; Shunt meter for bench verification; Dead weight 4.5 kg for permanent and AC yokes; and Dead weight 13.5 kg for DC yokes. APPROVED DATA

7. Use of the Procedures attached to this CAAP

7.1

Attached as Appendixes to this CAAP are two Magnetic Particle Procedures. These procedures have CAR 2A (4) approval and should be used in the absence of approved OEM data or where approved data refers an inspection to be carried out in accordance with ASTM-E-1444 (or a European equivalent). 7.2 QUALIFICATIONS

A Level 2 MPI Technician should select the most suitable MPI Method Procedure based on the information contained at paragraph 3.3 of this CAAP. If a Level 1 MPI Technician is to perform the inspection, a person qualified to Level 2 or 3 MPI is to nominate which procedure is appropriate.

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CAAP 42V-3(0): Magnetic Particle Inspection

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APPENDIX A TO CAAP 42V-3(0)

CASA/MPI/1 ISSUE 1

PROCEDURE FOR MAGNETIC PARTICLE INSPECTION UTILISING A FIXED LINE BENCH

INTRODUCTION 1 ASTM-E-1444 establishes a requirement to use a dedicated procedure for the inspection of parts. In the absence of an approved procedure, this procedure has CAR 2A (4) approval and is an acceptable means of compliance for the completion of Magnetic Particle Inspections utilising a fixed line magnetic particle bench as detailed in CAAP 42V-3.

Note: This procedure does not supersede or replace procedures supplied by an Original Equipment Manufacturer (OEM).
PROCEDURE NOMINATION 2 This procedure must be accepted by a Level 2 or 3 MPI Technician prior to use on a particular component. OPERATOR LEVEL 3 Personnel carrying out this procedure must posses a current CASA NDT Airworthiness Authority or an authorisation under CAR 42ZC (6). In addition, personnel must be qualified to a minimum of AS 3669 NDT Level 1. Note: When approved data (usually the OEM) requires a Technician to be qualified to Level 2

MPI to carry out an inspection in accordance with ASTM-E-1444, this takes precedence over the Operator Level stated in this procedure.
APPLICABILITY 4 This procedure must be used in conjunction with CAAP 42V-3 and is applicable to all component types as listed at Selection of a Magnetic Particle Inspection Method in CAAP 42V-3(0). LIMITATIONS 5 This procedure should detect surface breaking defects of 2 mm (0.080") in length or greater and may detect some near surface defects (less than 3 mm into the parent material) of 5 mm in length. This procedure may detect smaller defects than stated and technicians should not ignore these indications if located. PRE-INSPECTION REQUIREMENTS 6 Ensure the parts are removed from the aircraft, disassembled and cleaned utilising an appropriate cleaning method or methods. Note: Paint in good condition does not have to be removed unless the risk of arcing exists.

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CAAP 42V-3(0): Magnetic Particle Inspection

EQUIPMENT REQUIREMENTS 7 The equipment applicable to this procedure is: a Fixed wet Magnetic Particle Inspection Bench; WARNING: DO NOT USE BLACK LIGHTS WITH CRACKED OR MISSING FILTERS. HARMFUL ULTRA VIOLET RADIATION EMITTED CAN DAMAGE EYES. b c d e Black light with a minimum intensity of 1,000W/cm2 @ 40 cm (15"); Castrol flux indicator strips (or equivalent); Permanent marking pen and field indicator; Lint free cloth and approved cleaning solvent.

INSPECTION PROCEDURE 8 After a minimum of one minute dark adaptation, carry out the inspection as follows:

Circular Magnetism (when required) a Place the part between the heads, preferably on a central conductor (geometry permitting) to reduce the risk of arcing. b Utilising a Type II Castrol Strip (or equivalent) in accordance with the manufacturers instructions, magnetise the part utilising 800-1,000 amps per 25 mm of cross-section utilising AC or DC wet continuous method. Ensure correct flux density is evident on the Castrol strip. Adjust the magnetising current if necessary. Three distinct lines should be evident on the flux indicator strip.

Note: Calculate and obtain the correct current requirements for the thinner sections first, working to the larger diameters (higher amperages) as the inspection progresses, utilising the Castrol strips each time there is a significant change in part geometry.
c Once adequate flux density has been obtained, carry out the wet continuous method utilising AC or DC. Inspect the part for defect indications. Defect indications will appear as sharp, well-defined lines. Conversely, non-relevant indications will generally appear broad and fuzzy and generally follow part geometry. d Mark any suspect defect indications for further visual/optical evaluation.

Longitudinal Magnetism e Place the part in the coil. Effective magnetising length is approximately 150 mm either side of the coil, hence several shots may be required on longer parts such as crankshafts, etc. f Establish the approximate current requirement utilising the following formula: I = K (constant 45,000) L x N D Where: L is the length-to-diameter ratio D and N refers to the number of effective number of turns in the coil.

Note: The formula stated provides a guide and is based on the part cross-section being less than 10% of the coil opening and having a length to diameter ratio of less than 15.

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