Complete Magnetic Particle Inspection Workbook ‘A clear, concise overview of principles, applications, techniques Skill-building exercises and quizzes for each key area A comprehensive glossary Basic criteria for selection of types and methods HSB, Global StandardsHSB Y Global Standards Code Services COMPLETE MAGNETIC PARTICLE INSPECTION WORKBOOK Copyright © 1991, 2004 by The Hartford Steam Boiler Inspection and Insurance Company of Connecticut, Hartford, CT 06103. Printed in the United States of America. ‘The material presented in this guidebook is based on information contained in available literature, developed by The Hartford Steam Boiler Inspection and Insurance Company of Connecticut, or provided by other parties and is believed to be correct. While every precaution has been taken in the preparation of this guidebook, the publisher assumes no responsibility for errors or omission. Neither is any liability assumed for damages resulting from the use of the material contained herein.TABLE OF CONTENTS INDEX OF ILLUSTRATIONS... INSTRUCTION BOOK..... Vii GLOSSARY . . eee ete ix LESSON 1 - INTRODUCTION TO MAGNETIC PARTICLE INSPECTION... 2 QUIZ... 6 QUIZKEY.. 8 LESSON 2 ~ SECTION I, PRINCIPLES OF MAGNETS AND MAGNETIC FIELDS ...0cnneore 10 LESSON 3 - TYPES OF CURRENT.. QUIZ... QUIZ KEY. LESSON 4 TYPES OF PARTICLES AND METHODS OF APPLICATION..... QUIZ. QUIZ KEY... LESSON 5 ~ METHODS OF MAGNETIZATION. Quiz. QUIZ KEY. LESSON 6 ~ MAGNETIC FIELD DISTRIBUTION ......cces QUIZ. QUIZ KEY. LESSON 7 - CALCULATING CURRENT VALUES, QUIZ. QUIZKEY LESSON 8 - INSPECTION \ EQUIPMENT Quiz. QUIZKEY. LESSON 9 ~ SECTION I, STEPS IN PERFORMING MAGNETIC PARTICLE INSPECTION. QUIZ. QUIZ KEY... LESSON 9 - SECTION Il, DEMAGNETIZATION Quiz. QUIZ KEY.Table of Contents LES.N 10 - SECTION I, CLASSIFICATION & INTERPRETATION OF INDICATIONS ......00..004.82 QUIZ... seeesnanenenon sesunnnegeeeenanencenesenee “ QUIZ KLY.. vs vs hese 86 LESSON 10- SECTION II, EVALUATION OF INDICATIONS 87 QUIZ. 95 QUIZ KEY.. 96 LESSON 10 - SECTION Ill, RECORDING OF INDICATIONS. quiz... QUIZKEY LESSON I - SAMPLE MAGNETIC PARTICLE PROCEDURE. QUIZ. 120 QUIZKEY.. 122INDEX OF ILLUSTRATIONS Figure | ~ Principle of Flux Leakage. Figure 2 ~ Domains, Figure 3 - Lines of Force. Figure 4 — Left Hand Rule... Figure 5 ~ Narrow Hysteresis Loop... Figure 6 ~ Wide Hysteresis Loop Figure 7 — Mid-Range Hysteresis Loop. Figure 8-1 —Horse Shoe Magnet... Figure 8-2 — Circular Magnetism. Figure 9 — Flux Leakage at a Crack Figure 10-1 — Current Flow vs. Magnetic Field. Figure 10-2 — AC Voltage vs. Time...... Figure 10-3 - DC Voltage vs. Time. Figure 10-4 ~ Half-Wave DC... Figure 11-1 — Black Light... Figure 11-2 ~ Stationary Unit..... Figure 12-1 - Head Shot... Figure 12-2 ~ Central Conductor. Figure 12-3 - Prod: Figure 12-4 — Coil Figure 12-5 - Yoke Figure 13 — Stationary Unit. Figure 14 — Centrifuge Tube. Figure 15 — Rounded Indications. Figure 16 ~ Three Typical Six-Square-Inch Rectangles.. Figure 17 - Ten Rounded Indications in a Six-Square-Inch Are 116 7 us. ‘Attachment Attachment IL. Attachment IILINSTRUCTION BOOK OVERVIEW WORKBOOK MATERIAL NOTE This workbook is intended for individuals who have little or no prior experience in magnetic particle inspection as well as for those who are experienced, but desire to increase their knowledge or upgrade their skills in this important method of non-destructive testing. This workbook presents major variables and provides a broad base from which you may expand your knowledge. We recommend that you use this workbook as follows: Review the terms in the Lesson Glossary, Read the workbook section, Complete the Quiz at the end of each Lesson, Compare your answers to those in the Quiz Key. The definitions found in the general Glossary, and the individual Glossary for the various lessons are not identical to those found in ASME Section V. These definitions are simplified somewhat to help the reader reach a basic understanding of the presented concepts. To determine the ASME Code recognized definitions for the terms used, please refer to ASME Section V, Articles 7 and 30. Article 30 contains SE-1316, “Standard Terminology for Nondestructive Examinations,” which lists the ASTM and ASNT recognized definitions for terms used throughout the NDE industry.GLOSSARY ACOUSTIC EMISSION TESTING - A nondestructive method which can detect ultrasonic frequencies emitted when materials undergoing deformation release energy creating transient elastic waves. ALLOY ~ A metallic substance composed of two or more elements, which has properties different from those of its constituent elements. ALTERNATING CURRENT (AC) ~ An electrical current that periodically reverses its direction of flow and its potential value (voltage). AMPERE - The unit of electrical current. One ampere is the current that flows through a conductor having a resistance of one ohm, at a potential of one volt. ANGSTROM - A unit of length used to express wavelength. One angstrom equals 10° centimeters or 10" meters. ARC BLOW - When molten metal during welding is drawn away from the center of deposition. Can be caused by the attraction from a magnetic field, ASME CODE — Contains rules for manufacturing boilers and pressure vessels. Published by the ‘American Society of Mechanical Engineers to facilitate safe construction of fossil and nuclear power components. BLACK LIGHT ~ Light energy just below the visible range of violet light, often predominately of about 3,650 angstrom units (365 nanometers). This wavelength reacts strongly on certain dyes that make them fluoresce in a range visible to the eye. BLOWHOLE — A hole in a casting or a weld caused by gas entrapped during solidification, BURST ~ Fissures or ruptures caused by rolling or forging improperly or at improper temperatures. CASTING — A product created by melting metal or plastics and pouring them into a mold to create a specific shape. CASTING HOUSE - An establishment (foundry) where articles are cast, usually from metal. CENTRAL CONDUCTOR ~ A solid or hollow electrical conductor that is passed through the opening of a ring, tube, or any hole of a part for the purpose of creating a circular magnetic field in or around the ring, tube or hole. CIRCULAR FIELD — A magnetic field without poles where the magnetic lines of force are contained within the part in a circular direction. CIRCULAR MAGNETIZATION - Circular magnetization involves the production of a magnetic field in a part such that the magnetic lines of force are mostly contained within the part and normally run substantially perpendicular to the long axis of the part. COIL SHOT - A short pulse of magnetizing current passed through a coil surrounding a part; for the purpose of longitudinal magnetization, called a “coil shot.” Duration of the passage of the current is usually only a fraction of a second.Glossary CORROSION ~ The deterioration of a metal by chemical or electro-chemical reaction with its envisosrvent CRATER CRACK ~ In welding, a depression at the termination of a bead or in the weld pool beneath the electrode from which a star, longitudinal, or transverse crack may develop. CURIE POINT — The temperature at which a material’s positive and negative charges (domains) will be influenced. Heating a polarized material above its curie temperature will cause it to lose polarization. DATA SHEET — A form used to record the results of an inspection activity along with other pertinent operational information DEFECT — A discontinuity the size, shape, orientation, or location of which exceeds the acceptance criteria, DEMAGNETIZATION ~ The act of removing a magnetic field, DIRECT CURRENT (DC) ~ An clecirical current flowing in one direction continuously, with minimal changes in its potential value. DISCONTINUITY ~ Any interruption in the normal physical structure or configuration of a part or weld, such as cracks, laps, seams, inclusions, or porosity. A discontinuity may or may not affect the usefulness of a part POMAIN ~ A substructure in magnetic material within which the electronic spins are held aligned in one direction by interatomic forces. The domains are randomly situated when a part is not magnetized. EDDY CURRENT TESTING — Nondestructive testing method in which eddy current flow is induced in the test object. Changes in the flow caused by variations in the object are reflected into a nearby coil or coils for subsequent analysis by suitable instrumentation and techniques. EXAMINATION TEST REPORT — A report that details the technique and/or procedure parameters used to perform the examination and to record the results. (Date Sheet) FATIGUE CRACKS and unloading of a part. Progressive cracks that develop in the surface caused by the repeated loading FERROMAGNETIC ~ A class of metals that can be highly magnetized and that contain a high percentage of iron. Iron, steel, cobalt, and nickel can be strongly magnetized, FLASII POINT ~ The lowest temperature at which the vapors of combustible liquids will give a slight explosion on exposure to flame. FLUORESCENCE ~ The ability to give off visible light when exposed to shortwave radiation, such as ultraviolet light. FORGING — Working metal into a desired shape by hammer; upsetting; pressing, either hot or cold; or by a combination of these processes. MALF-WAVE DIRECT CURRENT (HWDC) ~ Alternating current, which is changed into direct current by utilizing a rectifier to delete the reverse (negative) portions of the altemate pulses, thus creating pulsed unidirectional flow of current.Glossary HEAD SHOT — A short pulse of magnetizing current passed through a part while clamped between the head contacts of a stationary magnetizing unit for the purpose of circular magnetization of the part. Duration of the passage of the current is usually less than one second. HEAT TREATMENT - Heating and subsequent cooling of ¢ material in a controlled manner to obtain desired metallurgical conditions or properties. HOT TEAR — A fracture formed in a metal during solidification because of restricted contraction. HYSTERESIS LOOP ~ A curve that defines important characteristics of magnetic material by plotting flux density as a function of magnetizing force. INCLUSION ~ Particles or impurities, usually oxides, sulfides, silicates, and such that are retained in the metal during solidification. INDICATION — Response from an NDE technique indicating the presence of a discontinuity. INTERPASS MAGNETIC PARTICLE INSPECTION - Performing inspection after each successive weld bead or weld layer. Used as a way of examining the entire volume of a weldment. LACK OF FUSION ~ Two-dimensional defect due to lack of union between weld metal and parent metal. LAMINATION — Discontinuity in plate, sheet, or strip caused by pipe, inclusions, or blowholes in the original ingot; after rolling, they are usually flat and parallel to the outside surface. LAP ~ A surface defect caused by the folding of metal in a thin but separated and conforming layer on the surface. LEAKAGE FIELD - When a magnetic field is interrupted by a discontinuity, some of the field is forced ‘out into the air above the discontinuity creating an attraction to applied magnetic particles. LINEAR INDICATION ~ In most specifications, an indication that the length is more than three times the width, LIQUID PENETRANT TESTING - The use of liquids, with good penetrating ability, to locate discontinuities open to the material surface. LONGITUDINAL FIELD ~ A magnetic field that extends within a part from one or more poles to another or other poles and which is completely through a path external to the part. LONGITUDINAL MAGNETIZATION — Magnetization of a material in such a way that the lines of ‘magnetic flux are substantially parallel to the ong axis of the part, with the flux path completing itself through the air outside the material. It is sometimes called bipolar magnetization, because at least two extemal poles exist in longitudinal magnetization. MACHINING TEARS — Sometimes called machining cracks; they are caused by too heavy a cut, a dull tool, or chatter. MAGNETIC CONDUCTOR - A central conductor made of ferromagnetic material. MAGNETIC FIELD ~ Magnetic lines of force within which ferromagnetic materials are attracted.Glossary MAGNETIC PARTICLE FIELD INDICATOR — A simple sectioned device that when placed on a part gives an approximate indication of the direction of a magnetic field and the approximate adequacy of the magnetic ficld strength used. Sometimes referred to as a “pic gage.” MAGNETIC PARTICLE INSPECTION (often referred to as MT as an abbreviation for Magnetic Particle Testing) ~ A nondestructive method of inspection for determining the existence and extent of possible defects in ferromagnetic materials. Fincly divided magnetic particles applied to the magnetized part are attracted to and outline the pattern of any magnetic leakage fields created by discontinuities. MAGNETIC PARTICLES — Finely divided ferromagnetic particles applied over a leakage field to indlicate the size, shape, and location of a discontinuity. MAGNETISM - The ability of matter to attract other matter to itself due to magnetic field interactions, MAGNETIZING FORCE — The force that establishes a magnetic flux in a magnetic circuit. It is measured in ocrsteds, which is a unit of ficld strength that produces magnetic induction, The force may be the resultant magnetic field produced in an electrical circuit or via another magnet, MOBILE EQUIPMENT - Magnetic suitable line voltage is available. particle equipment that can be moved to an inspection site where NANOMETER ~ One-tenth of an angstrom unit, NONDESTRUCTIVE TESTING (NDT) ~ A means of evaluating a part, assembly, or system without rendering the item untit for or incapable of subsequent normal use or operation. NONMAGNETIC CONDUCTOR ~ A central conductor made from nonferromagnetic material, such as copper OVERLAP — Protrusion of weld metal beyond the toe of the weld, lapping over the base metal, PITTING ~ Small, sharp-edged cavities in a metal surface created by a nonuniform electro-deposition or by corrosion. POROSITY — Void caused by gases entrapped ot liberated in the metal as it solidifies. PORTABLE EQUIPMENT - Small magnetic particle units that can be hand carried, thereby providing the most flexibility at remote sites PRIMARY PROC! ING ~The various forming process used to manufacture parts QUENCH CRACKS — Ruptures produced in the tempering of metal due to more rapid cooling and contraction of one portion of a part than occurs in adjacent portions, RADIOGRAPHY ~ The use of radiant energy in the form of X-rays or gamma rays for nondestructive examinations of opaque objects, in order to produce graphic records on sensitized films that indicate the comparative soundness of the object being tested, ROLE ING — Forming of stcel billets or ingots into bars, plate, or strip by passing it between suitableGlossary ROUNDED INDICATION ~ In most specifications, an indication that is circular or elliptical in shape, with the length equal to or less than three times the width. SAPONIFYING 1) The result of making a soapy substance, 2) A decomposition in which an ester is changed into an acid and an alcohol. ‘SEAM — Longitudinal surface discontinuity on stock originated in a surface crack or blowhole near the surface of the ingot; generally follows the direction of flow lines. SECONDARY PROCESSING ~ Metal removal processes applied to a material that has already been formed, or material joining processes such as welding or brazing, and other operations such as heat treating or plating, SHRINK ~ Internal rupture occurring in castings due to contraction during cooling. Also applied to surface shrinkage cracks. SNT-TC-1A ~ A recommended practice used as a guideline by employers to establish their written practice for qualification and certification of NDT personnel. Published by the American Society for Nondestructive Testing. STATIONARY UNIT — A magnetic particle inspection machine that is located at a fixed site. STRESS CORROSION CRACKING (SCC) — Failure by cracking under combined action of corrosion and stress, either external (applied) or internal (residual). Cracking may be either intergranular or transgranular, depending on metal and corrosive medium, ULTRASONIC CLEANING — The use of high-frequency sound waves in combination with a cleaner to break up or dislodge contaminants such as oxides, carbon, and magnetic particles. ULTRASONIC TESTING - A nondestructive method of testing materials by transmitting high frequency sound waves through them. UNDERCUT — A depression or groove adjacent tothe toe of a weld in @ metal object, caused by excessive heat input. VAPOR DEGREASING — Vapor degreasing is one of the most common methods of precleaning parts prior to a magnetic particle test. It is effective at removing oil, grease, water, and other soluble organic contaminants, Vapor degreasers use the hot vapors of a chlorinated solvent to remove soils.Lesson 1 Introduction to Magnetic Particle Inspection <fete Magnetic Particle Inspection Workbook Lesson 1 — Introduction to Magnetic Particle Inspection GLOSSARY DISCONTINUITY ~ Any interruption in the normal physical structure or configuration of a part or weld, such as eracks, laps, seams, inclusions, or porosity. A discontinuity may or may not affect the usefulness of a part. FERROMAGNETIC — A class of metals that can be highly magnetized and that contain high percentage of iron, Iron, stcel, cobalt, and nickel can be strongly magnetized, MAGNETIC PARTICLE INSPECTION (often referred to as MT as an abbreviation for Magnetic Particle Testing) — A nondestructive method of inspection for determining the existence and extent of possible defeets in ferromagnetic materials. Finely divided magnetic particles applied to the magnetized part are attracted to and outline the pattern of any magnetic leakage fields created by discontinuities. MAGNETIC PARTICLES ~ Finely divided ferromagnetic particles applied over a leakage field to indicate the size, shape, and location of a discontinuity. NONDESTRUCTIVE TESTING (NDT) — A means of evaluating a part, assembly, or system without rendering the item unfit for or incapable of subsequent normal use or operation. HSBY Global Standards ** Goile Services:Lesson 1 ~ Introduction to Magnetic Particle Inspection INTRODUCTION TO MAGNETIC PARTICLE INSPECTION Magnetic particle inspection is one of several major methods of nondestructive testing (NDT) employed to inspect materials. Other commonly used methods are: ‘* Visual Inspection (VT) + Radiographic Testing (RT) ‘* Ultrasonic Testing (UT) «Eddy Current Testing (ET) ‘* Acoustic Emission Testing (AE) «Liquid Penetrant Testing (LP) THE CONCEPT The concept, first patented by William Hoke in the early 1920s, utilizes the basic theory that a surface or near-surface discontinuity will distort a magnetic field. When this magnetic field is distorted, itis called a leakage field, which extends beyond the surface of the material. When fine magnetic particles are applied to the leakage field, the particles are magnetized and are held in place (Figure 1). ferromagnetic material magnetic particles Figure I ~ Principle of Flux Leakage HSB YY Global Standards F Cone ServicesComplete Magnetic Particle Inspection Workbook MAT ERIALS PROCESSING ‘Magnetic particle inspection is used to locate discontinuities at various stages of material production and subsequent processing. During the primary processing of formed or fabricated parts, magnetic particle inspection is capable of locating discontinuities in forgings, castings, rolled products, and welds, to name justa few. During subsequent secondary processing, discontinuities are revealed that are caused by heat trcating, grinding, machining, or repairing. Additionally, discontinuities that are deep in one stage of production or processing may be revealed at a later stage, because subsequent operations open the discontinuity to the surface or slightly below. In-service parts are magnetic particle inspected periodically for corrosion and fatigue cracking, pitting, thermal cracks, and weld imperfections. An internal flaw (an inclusion, shrinkage area, burst, ec.) undetected during manufacturing may become a stress concentration point in a part or material. A crack could develop and propagate until the part fails. The following are examples of discontinuities revealed by magnetic particle inspection. Primary Processing Casting Rolled Products = cold shuts ~ laminations (if close to the surface) = hot tears, = seams - shrinkage ~ cracks = porosity - blowholes Welding (During Part Fabrication) = porosity Forgings = undereut external burst - overlap = lack of fusion = lack of penetration = stress cracks ~ crater crack | Secondary Processing = machining tears = quench eracks ~ grinding cracks = welding repair discontinuities (same as = heat treat listed under Primary) Inservice ~ fatigue cracking - stress corrosion cracking = corrosion eracking , SB Global Standards Code ServicesLesson 1 ~ Introduction to Magnetic Particle Inspection If discontinuities can be detected in the early stages of fabrication, they can be removed or repaired and prevent rejection or the cause of failure at a later date. A substantial savings in labor and materials can be realized by detecting discontinuities early in material processing. ‘The “Cradle-to-Grave” concept should be followed in utilizing NDT during: ‘+ Initial design — assure the product can be tested. + Drawing preparation ~ assure NDT requirements are specified. ‘+ Fabrication ~ for process control. + Final inspection — assure part meets drawing quality requirements, + in-service ~ assure part functions as designed and to close the loop by supplying information back to design. Advantages of magnetic particle tests are: © Complex shapes can be effectively tested. * There is generally no precleaning required as in liquid penetrant inspection. © One can test a large number of parts of similar components at one time, ‘+ Very small, very fine cracks can be detected. ‘* Subsurface discontinuities can also be located. However, it should be noted that the correct, terminology would be “near-surface,” as magnetic particle inspection cannot detect discontinuities generally in the entire volume of a part. * One may detect discontinuities located undemeath thin coatings of paint. ‘© Magnetic particle inspection is generally considered to be a relatively low-cost operation. © Personnel performing magnetic particle inspection can learn to do this method of nondestructive testing without too much difficulty. Some of the disadvantages of magnetic particle inspection are: ‘© Only ferromagnetic materials can be tested, ‘+ Very high electric currents may be required to magnetize parts, especially large components. ‘+ Depending on the ultimate service of the component, the added step of demagnetization is required. Demagnetization is sometimes required because a magnetized component can affect electronic components such as instrumentation on aircraft. Also, ifa subsequent machining operation is to be performed, then the part must be demagnetized or the magnetized component will collect the machined particles and may cause the tool to break. * Due to the high currents, the part may be pitted or burned. + Itis sometimes difficult to detect finite defects located below the surface. * There is an added extra step or post-test cleaning to remove the magnetic particles, ‘+ Attimes, wide, shallow cracks are difficult to detect. HSB ¥ Global Standards Code Services eeComplcte Magnetic Particle Inspection Workbook Lesson 1 — Introduction to Magnetic Particle Inspection Quiz 1. Magnetic particle inspection is used for surface and examination of materia Bo can be credited with the carly application of magnetic particle inspection. 3. State three stages of a component's history where magnetic particle inspection may be used. 4, Magnetic particle inspection can be used on most materials. ofrue a False 5. Generally, substantial emphasis must be placed on precleaning a test specimen prior to magnetic, particle inspection, are a False 6 Due to high electrical eurrents, the part may be 7. Magnetic particle inspection can be used to detect discontinuities undemeath coatings of paint. & AL __ may or may not affect the usefulness of @ part, 9, When a magnetic field is distorted, it is called a 10. Cold shuts, laps, seams, and crater cracks are considered processing, discontinuities, 6 — SB 8 Global Standards ~~ Code ServicesLesson | ~ Introduction to Magnetic Particle Inspection (This page intentionally left blank) HsBY Global Standards Code Services,Complete Magnetic Particle Inspection Workbook Lesson 1 — Introduction to Magnetic Particle Inspection QUIZ KEY L near surface William Hoke 3 primary processing, secondary processing, in-service 4. False (Ferromagnetic only) 5. False ‘ pitted or burned 7 thin 8, discontinuity 9. leakage field 10. primary | | | { } | i | i | , HSB ¥ Global Standards Code ServicesLesson 2 Section I, Principles of Magnets and Magnetic Fields <¢ Section I, Characteristics of Magnetic Fields <4Complete Magnetic Partiele Inspeetion Workbook Lesson 2 ~ Scction I, Principles of Magnets and Magnetic Fields GLOSSARY DOMAIN ~ A substructure in magnetic material within which the electronic spins are held aligned in one direction by interatomic forces. The domains are randomly situated when a part is not magnetized, JLYSTERESIS LOOP — A curve which defines important characteristics of magnetic material by plotting flux density as a function of magnetizing force. MAGNETISM ~ The ability of matter to attract other matter to itself duc to magnetic field interactions, MAGNETIZING FORCE — The force that establishes a magnetic flux in a magnetic circuit. It is measured in oersteds, which is a unit of field strength that produces magnetic induction. ‘The force may be the resultant magnetic ficld produced in an electrical circuit or via another magnet. 10 ———____________ HISB'¥Global Standards Code ServicesLesson 2~ Section I, Principles of Magnets and Magnetic Fields PRINCIPLES OF MAGNETS AND MAGNETIC FIELDS HISTORY OF MAGNETISM ‘The first knowledge of magnetism came from the mineral Magnetite (FeO:) in Asia Minor and was known to the Greeks. The Greeks referenced in their writings that the mineral magnetite had the property of attracting and holding bits of iron and could impart this power to the bits. Later on, experiments by Brugmanns, Becquerel, and Faraday revealed that all matter, including liquids and gases, were affected to some extent by magnetism. However, it was Faraday who discovered that all materials were susceptible to magnetism, but only a few responded to a great extent. CLASSIFICATION OF MATERIALS WITH RESPECT TO MAGNETISM All magnetic materials are classified under one of three headings. The first is diamagnetic, which is material repelled by a magnetic field such as copper. Paramagnetic material is slightly attracted to a magnetic field. Another classification is ferromagnetic, which comes from the Latin work ferum, meaning iron. Ferromagnetic material, such as iron and steel, is highly attracted to a magnet. In magnetic, particle inspection this is the classification that we are concerned with, For our purposes, magnetic particle inspection is used on materials made of iron, steel, cobalt, some nickel, and some stainless steels, Ferritic and martensitic steels may be magnetic particle inspected; however, the 400 series of Austenitic steels are not magnetizable due to their heat treatment. CLASSIFICATION OF MAGNETS ‘There are two classifications of magnets — natural magnets and man-made or artificial magnets. Both natural and man-made magnets can be the permanent type; this is how they retain their magnetism; however, man-made magnets may also be of the temporary type. Most magnetic particle inspections are conducted using the stronger temporary magnets. These magnets retain only a very small field after the external magnetization is removed. In other words, they are ‘magnets only as long as some external field is applied to them. This external field may be an electrical field or another magnet. Soft steel and pure iron are considered the best materials for temporary magnets because they are good magnets as long as they are in contact, but lose their power quickly. Electromagnets are temporary magnets made by winding an electrical conductor around a soft steel or iron core and applying direct current. When the current is off, they lose their magnetism. THEORY OF MAGNETIC PARTICLE INSPECTION ‘Now that we have some of the basics of magnetism, let us look closer into the theory. An object is magnetized when the parts or all of its magnetic domains have their north and south poles oriented (Figure 2). When these domains align, you obtain lines of force or flux lines. A phenomenon occurs ‘when two north poles meet each other in that they tend to repel each other. The same occurs when two south poles are placed adjacent to each other on two magnets. The only time attraction occurs is when a north and a south pole are placed in close proximity. Whenever a leakage field is forced out of the part by a discontinuity, applied iron particles attract each other and when these iron particles are of a different color than the background, the naked eye can see an indication, As stated in Lesson 1, even some slight subsurface discontinuities may be detected if the leakage field is strong enough. As a general rule, ‘magnetic pa spection is not considered to be effective more than 1/4 inch below the surface; however, this is a general rule, When performing inspection, if an indication appears to be diffused or is HSBY Global Standards Code Services uComplete Magnetic Particle Inspec not clear, then gencrally it would most likely be a subsurface indication, The best way to determine the depth is through actual experimentation with known defects at certain depths. Unmagnetized, no orientation of domains ts4422- 3235323222222: BZSSSSSSSSSSS2= n | #3333 3232323233322 | N | S3S223 2232323233552 3333533323525 52= SS sssss2SesSSs= Figure 2— Domains FLUX & GAUSS. The total number of magnetic lines of force existing in a magnctic circuit is called a magnetic flux. Flux density, another term, or induction is usually designated in Gauss units and refers to the flux per unit area at a right angle to the direction of the flux (Figure 3). eae StS 2972 TE ogni Pet ouside of SOON rr, object vv S Magnetic Field inside of ae ‘object Figure 3 ss of Force 12 ——_____ HSB ¥Global Standards Code Services:Lesson 2 ~ Section 1, Principles of Magnets and Magnetic Fields LEFT HAND RULE To find the direction of an electrically induced magnetic field, place the thumb of your left hand on the conductor in the direction of current flow and your fingers will then point to the direction of the lines of force. This is known as the left-hand rule. The thumb is always positive, and since electricity flows from positive to negative in alternating current, itis called the left-hand rule (Figure 4). Figure 4 — Left Hand Rule MAGNETIC PROPERTIES It is important to know the following properties of metal in order to determine how effective the magnetic particle method for inspection will be in evaluating a part. The first term is permeability. This refers to the ease with which magnetic flux is established in the article being inspected. Reluctance is the opposite of permeability. This is the opposition of a magnetic material to the establishment of a magnetic flux. In other words, a material with high permeability will have low reluctance and a material with low permeability will have high reluctance. Another term is residual magnetism. This refers to the amount of magnetism that is retained after the magnetizing force is removed. We stated previously that there are two ways to have a magnetizing force: (1) through electricity, and (2) through another magnet. Retentivity is the ability of the material to retain a certain amount of residual magnetism after the extemal magnetic force has been removed. The fifth term we need to be familiar with is coercive force. This refers to the reverse magnetizing force necessary to remove the residual magnetism, EXAMPLE ‘The following should help you understand the aforementioned five terms more clearly. High carbon steel thas low permeability, high reluctance, and high retentivity. A high coercive foree is tequired to demagnetize it, and it would have high residual magnetism. HYSTERESIS CURVE OR LOOP Since permanent magnets are not generally used in magnetic particle inspection, we will concentrate on ‘temporary magnets using electrical current to produce the magnetization. A curve depicting the ‘magnetization of ferromagnetic material can be developed by plotting flux density versus the magnetizing force. As we said, flux density increases when the magnetizing force is first applied. However, as the HSB'¥ Global Standards , B Code Services eeMagnetic Particle Inspection Workbook force is further increased, it has less and less effect on the flux density until the material is at the point of saturation, This means that any more force that is applied will have no effect on the flux density since all the domains in the material are aligned with the magnetic field. If one was to reverse the magnetic force and carry to the saturation point in the negative direction, a characteristic S-shaped loop called a hysteresis loop is developed. The width of this loop depicts magnetic characteristics of the material. As stated previously, a narrow loop would exhibit low retentivity, low coercive force, low residual magnetism, low reluctance, and high permeability. A wide loop, as with high carbon steel, would indicate low permeability, high reluctance, high residual magnetism, high retentivity, and high cocreive force (Figures 5 and 6). In Figure 7, which is a detailed example of a hysteresis loop, the areas “0” to “a” depict the initial or virgin curve. The virgin curve is theoretical as it assumes there is no lag time or opposition to current flow, which impedes the formation of flux density. “a,” by itself, is the saturation point. “BY” is the flux density (how much magnetism is developed). ““H” is the magnetizing force or electric current and “0” to “p” is the retentivity, which reflects how much magnetic flux is left after the electric current has been removed. Points “0” to “e” depict the coercive force. Points “c”, “a”, *e,” and “P” represent the hysteresis loop in the opposite polarity. Figure 5 — Narrow Hysteresis Loop SB Global Standards Code ServicesLesson 2~ Section I, Principles of Magnets and Magnetic Fields rT Figure 6 - Wide Hysteresis Loop Figure 7 — Mid-Range Hysteresis Loop The horizontal line represents the applied “magnetizing force”. ‘The vertical line represents the “flux density” measured Gauss. HsBY Global Standards —________ 5 Code Services| iComplete Magnetic Particle Inspeetion Workbook (This page intentionally teh blank) 6 CS BY Global Standards Code Services10, Lesson 2 Section 1, Principles of Magnets and Magnetic Fields Lesson 2 ~ Section I, Principles of Magnets and Magnetic Fields Quiz Material which is repelled by a magnetic field is said to be Iron, steel, cobalt, and nickel are considered ferromagnetic material. oTrue ao False The two classifications of magnets are and A near-surface discontinuity would most likely appear as a sharp and distinct indication. oTre 0 False Flux density is usually measured in The left-hand rule is used to find the direction of an electrically induced A materi with high permeability will have reluctance. A narrow hysteresis loop would indicate high retentivity oTrue o False The: is theoretical as it assumes there is no lag time between current flow and the formation of flux density. ‘A wide hysteresis loop would indicate permeability. HSBY Global Standards 7 Gode Services| ee -Complete Magnetic Particle Inspection Workbook Lesson 2 ~ Section I, Principles of Magnets and Magnetic Fields QUIZ KEY 1 diamagnetic 2. True 3, natural and artificial (man-made) 4. Talse 5. Gauss units: 6. magnetic field 7. low 8. False 9. virgin curve 10. low, iy SBF G Hoda! Standards Code Services eeLesson 2~ Section Il, Characteristics of Magnetic Fields Lesson 2 — Section II, Characteristics of Magnetic Fields GLOSSARY CIRCULAR FIELD — A magnetic field without poles where the magnetic lines of force are contained within the part in a circular direction. LONGITUDINAL FIELD - A magnetic field that extends within a part from one or more poles to another or other poles and which is completely through a path extemal to the part. HSB Y Global Standards Code Services _——_ eeplete Magnetic Particle Inspection Workbook CHARACTERISTICS OF MAGNETIC FIELDS MORSESHOE MAGNET The horseshoe maguct is the more familiar type of magnet to most of us. We can remember in our earlier years of schooling using the horseshoe magnet to attract particles placed over a piece of paper. The ends to the horseshoe magnet are called the north and south poles. ‘The magnetic flux lines or lines of force flow from north to south, always form a complete circuit, never cross each other, and when entering inside the magnet, the lines of force flow from south to north (Figure 8-1). Figure 8-1 — Horse Shoe Magnet CIRCULAR MAGNETISM If one were to take a horseshoe magnet and completely bend the magnet into a circle, where the poles are fused together, their magnetic ficld would remain; however, there is no north or south pole in such a magnet and itis said to have a circular ficld or to be circularly magnetized because the magnetic lines of fotce are circular. In this ease, any crack in the fused magnet or circularly magnetized part that crosses the magnetic flux lines will ereate a north and south pole on either side of the crack. The magnetic materials or particles will be attracted by the poles created by the crack, thereby forming an indication of the discontinuity in the material. (Figure 8-2). Figure 8-2 ~ Circular Magnetism 90 SB Global Standards Code ServicesLesson 2 Section Il, Characteristics of Magnetic Fields FLUX LEAKAGE Ifa horseshoe magnet is straightened, then we have a bar magnet, The bar magnet also has poles, as in a horseshoe magnet. But the magnetic particles will be attracted only to the poles. In this case, we are said to have a longitudinal field or to be longitudinally magnetized. A discontinuity in a bar magnet that crosses magnetic flux lines will create north and south poles on cither side of the discontinuity. These poles will attract magnetic particles. In a similar manner, if the discontinuity is a crack, even though it may bea very small crack, it will still create magnetic poles as indicated in Figure 9. Bear in mind that the greater the flux strength (number of flux lines), the greater the pole strength and the greater the leakage field. ‘This means that if a strong magnetic field exists, then the leakage field will also be strong. N oN S Figure 9 ~ Flux Leakage at a Crack HSB'Y Global Standards Code Services a eeComplete Magnetic Particle Inspection Workbook (This page intentionally left blank) 2 ISB Global Standards Code ServicesLesson 2 ~ Section Il, Characteristics of Magnetic Fields Lesson 2 — Section II, Characteristics of Magnetic Fields QUIZ ‘The ends of a horseshoe or a bar magnet are called the and poles. ‘Magnetic flux lines flow from to ‘When entering a magnet, magnet flux lines flow from to Ifa crack interrupts the lines of force of a magnetic field, these lines will then cross each other. oTme a False Ifa horseshoe magnet is completely bent and fused into a circle, it will no longer have north and south poles and is said to have a field. A bar magnet is said to have a field. HB Y Global Standards ode Services 23Complete Magnetic Particle Inspection Workbook Lesson 2 ~ Section II, Characteristics of Magnetic Fields QUIZ KEY 1. north and south 2. north to south 3. south to south 4. False 5. circular 6. longitudinal 2 UsB'Y Global Standards Code Services a oyLesson 3 Types of Current <4Complete Magnetic Particle Inspection Workbook Lesson 3 — Types of Current GLOSSARY ALTERNATING CURRENT (AC) ~ An elcettical current that periodically reverses its direction of flow and its potential value (voltage). DIRECT CURRENT (DC) ~ An elccitical current flowing in one direction continuously, with minimal clianges in its potential value. HALF-WAVE DIRECT CURRENT (HWDC) ~ Alternating current, which is changed into direct current by utilizing a rectifier to delete the reverse (negative) portions of the alternate pulses, thus creating pulsed unidirectional flow of current. HSB '¥ Global Standards 6 — Code ServicesLesson 3~ Types of Current TYPES OF CURRENT CREATING MAGNETIC FIELDS. Both alternating current (AC) and direct current (DC) can be used to create magnetic fields and to induce magnetic fields in parts made of magnetic material. We must remember the magnetic lines of foree are always aligned at right angles or 90° to the direction of electric current flow. Therefore, itis important to understand the relationship between the current flow and the induced magnetism. In order that a proper inspection be accomplished using magnetic particle inspection, the magnetic lines of force must always ‘cross a discontinuity or a defect as near as possible at right angles to the defect (Figure 10-1). In other words, the electric current runs 90° to the magnetic lines of force and the discontinuity must be in the same direction as the electric current. When the flux lines are oriented in a direction that isin line or parallel to a discontinuity, the indication will be weak or may not even show up. In order to obtain a readable magnetic particle indication, the discontinuity must intercept the flux lines of force at some angle. For this reason, it is always best to obtain two inspections with the second inspection performed so the magnetic lines of flux are 90° to the first inspection. ALTERNATING CURRENT Alternating current is the most widely used power source for conducting magnetic particle inspection (Figure 10-2). It has low penetrating power. It is good for locating surface defects, because the magnetic field is concentrated on the surface and the constantly reversing flow of current gives the magnetic particles greater mobility DIRECT CURRENT Direct current is generally used when the inspection requires deeper penetration (Figure 10-3). The actual penetrating ability of any power source for magnetic particle inspection can only be judged through testing. The direct current application does not give the particles the mobility as in AC inspection. ‘Therefore, a variation of this can be used, which is called half-wave direct current (HWDC).. HALF-WAVE DC Half-wave direct current means that the reverse polarity or negative portion of the AC sine wave is eliminated. With HWDC there are intervals of individual pulses of direct current and also intervals when no current is flowing, thus giving the particles mobility and also the penetrating ability of direct current (Figure 10-4). Ifa discontinuity is found during inspection using DC or HWDC, itis recommended another inspection be performed using AC current to determine if the discontinuity is surface oriented. RECTIFIED AC Direct current from rectified altemating current is the most satisfactory source of direct current since it is difficult to obtain direct current using other methods such as battery power. The disadvantages of true Girect current are that you obviously need the battery power, the partis difficult to demagnetize, and it has a fixed voltage, which does not allow one to control the strength of the current. HSB'Y Global Standards ‘Code Services 27Particle Inspeetion Workbook Figure 10-1 ~ Current Flow vs. Magnetic Field Figure 10-2— AC Voltage vs. Time Figure 10-3 - DC Voltage vs. Time re 10-4 — Half-Wave DC 290 SBF Global Standards __ Code ServicesLesson 3~ Types of Current Lesson 3 - Types of Current Quiz ‘When a discontinuity is found using DC current, what is the next sequence that should be taken to determine if itis a surface or subsurface condition? Magnetic lines of force are always aligned to the direction of electric current flow. For obtaining best results, the magnetic lines of force should cross a discontinuity as near as possible at right angles (90°) to the defect. oTme o False For best results, a second inspection should be performed with the lines of flux being 90° to the first inspection. aTme o False Direct current may be used for surface inspection requirements but is generally used when the inspection requires penetration. One disadvantage of a true direct current is that battery power does not allow one to control the strength of the current. oTme o False Battery power is the most widely used source of direct current used in magnetic particle inspection. oTrue 0 False HSB 'Y Global Standards Code Services 29Complete Magnetic Particle Inspection Workhook 30 Lesson 3 — Types of Current QUIZ KEY perform another inspection using AC current right angles or 90° ‘True “True deeper True False H1SB¥ Global Standards Code ServicesLesson 4 Types of Particles and Methods of Application <4Complete Masuetic Particte Inspection Workbook Lesson 4 — Types of Particles and Methods of Applicat GLOSSARY ANGSTROM ~ A unit of length used to express wavelength, One angstrom equals 10° centimeters or 10" meters. BLACK LIGHT ~ Light energy just below the visible range of violet light, often predominately of about 3,650 angstrom units (365 nanometers). This wavelength reacts strongly on certain dyes that make them fluoresce in a range visible to the eye. FLASH POINT - The lowest temperature at which the vapors of combustible liquids will give a slight explosion on exposure to flame. FLUORESCENC ultraviolet light. The ability to give off visible light when exposed to short wave radiation, such as NANOMETER -- One-tenth of an angstrom unit, 0 —____________ 8B ¥ Global Standards Code Servici Code Services Lesson 4~ Types of Particles and Methods of Application TYPES OF PARTICLES AND METHODS OF APPLICATION MAGNETIC PARTICLE CHARACTERISTICS ‘The particles used in magnetic particle tests are made of ferromagnetic materials, usually a combination of iron and iron oxides. They normally have high permeability and low retentivity. Particles are required that are easily magnetized and are attracted to low-level leakage fields. This is to prevent the particles from being permanently magnetized and allowing reuse of the particles. Particles that have strong retentivity properties tend to cling together and to the surface which can result in reduced particle mobility and false indications. Particle sizes generally range from .002 inch to around .006 inch and each batch of magnetic particle ‘material contains a range of these sizes and various shapes to produce maximum results, Normally the smallest particles will be attracted to and held by the low-level leakage fields and very fine discontinuities while larger particles can more easily bridge course discontinuities where leakage fields are usually stronger. In al instances, magnetic particles must not be toxic. They must have high permeability, low retentivity, and a mixture of various-sized particles, including a mixture of shapes. Particle mobility and uniform dispersion of particles on the surface is also a must. The ferromagnetic particles can be applied as a dry powder or wet, using either water or high flash point petroleum distillate as a liquid vehicle carrier for wet applications. Both wet and dry particles are available in various colors in order to have the best contrast on the surface that is to be inspected. Both ‘wet or dry particles are supplied either in color contrast form or in fluorescent form. The color contrasting particles are used in normal light situations and typical colors are red, gray, black, and yellow. The red and black colored particles are the most commonly used for ordinary visible light inspection, For fluorescent particles, the color ranges between the yellow to green spectrum and a black light is used to activate the fluorescents, usually in a darkened environment for maximum contrast. BLACK LIGHTS ‘The most commonly used black light units consist of a mercury vapor arc bulb, a deep-purple glass filter, a housing, and a transformer. The bulb produces light in the ultraviolet range from 2,000 to 4,000 angstroms (200-400 nanometers) and the filter screens out the unwanted light waves as the optimum inspection wavelength is 3,650 angstroms (Figure 11-1). Filter Housing () Transformer Figure 11-1 ~Black HSB'Y Global StandardsComplete Magnetic Particle Inspection Workbook DRY APPLICATION OF PARTICLES When the dry particles are used, they should be observed as they are applied and the application should be a light and even flow of distribution so the inspector can sce the formation of the indication. Heavy coatings tend to impede particle movement and make it difficult to discern leakage fields. WET ATPLICATION CONSIDERATION Magnetic particles designed for use in the wet method are normally supplied by the manufacturer in a paste form that is mixed with the liquid vehicle. When the vehicle is the water-type wet bath, then normally a wetting agent to reduce surface tension and possible rust inhibitors are added. It is good to note that if the parts have high surface tension, more wetting agents should be added so that the part surface will be completely wetted and covered with the bath. Generally, with petroleum-type wet baths, no additives are used WET APPLICATION OF PARTICLES ‘The most common method for applying wet patticle inspection is through a stream via a hand-held nozzle and recirculating pump on a stationary unit (Figure 11-2). Occasionally for field-type inspections, hand-held lever operated wet containers are used, or aerosol-type containers similar to those used to spray paint are available, When using the acrosol-type spray container, the area should be well ventilated to prevent the buildup of flammable vapors PARTICLE CONCENTRATION IN WET METHOD In ail cases, whether the wet particles are applied via stream, spray, or immersion, the bath concentration {be maintained within the recommended limits to assure a uniform concentration, A weak particle concentration will produce weak indications and a too heavy concentration may produce heavy background accumulations, which reduces contrast. yo HSB YF Giobal Standards Code Servic ——<—< <<les and Methods of Application Lesson 4 ~ Types of Particles. vices HSB 'Y Global Standards Code Ser36 etic Particle Inspection Workbook (This page intentionally left blank) HSB '¥ Global Standards Code ServicesLesson 4 - Types of Particles and Methods of Application Lesson 4 — Types of Particles and Methods of Application Quiz 1. Magnetic particles normally have high permeability and low retentivity. aTrue 0 False 2. Each batch of magnetic particles must contain the same size and shape to produce maximum results, True o False 3. Magnetic particles can be app! o True 0 False as a dry powder or wet. 4, Both wet or dry particles are supplied either in color contrast or form. 5. The fluorescent particles usually range from the yellow to color spectrum, 6 A light is used to activate particles in a darkened environment. 7. The dry particles should be forcefully applied to the part. OTe 0 False 8. A wetting agent may be used to reduce 9. Wet particles may be applied by using a stream, spray or immersion method. aTrue 0 False 10. A strong particle concentration will produce a weak indication. a True 0 False 11. The petroleum-based vehicle used for wet particles must have a low flash point. oTrue False Hs! lobal Standards 37 ‘ode ServicesComplese Magnetic Particle Inspection Workbook Lesson 4 — Types of Particles and Methods of Application QUIZ KEY Truc I 2 False | 3. Tne 4, fluoresce 5. geen 6. black, fluorescent 7. False 8. surface tension 9. True 19. False LL False 39 ISB Goda Standards ote Services FELesson 5 Methods of Magnetization <Complete Magnetic Particle Inspection Workbook Lesson 5 — Methods of Magnetization GLOSSARY AMPERE ~ The unit of electrical current. Onc ampere is the current that flows through a conductor having a resistance of one ohm, at a potential of one volt. CENTRAL CONDUCTOR - A solid or hollow electrical conductor that is passed through the opening ofa ring, tube, or any hole of a part for the purpose of ereating a circular magnetic field in or around the ring, tube or hole. CIRCULAR MAGNETIZATION ~ Circular magnetization involves the production of a magnetic field in a part such that the magnetic lines of force are mostly contained within the part and normally run substantially perpendicular to the long axis of the part. COIL SHOT ~ A short pulse of magnetizing current passed through a coil surrounding a part; for the purpose of longitudinal magnetization, called a “coil shot.” Duration of the passage of the current is usually only a fraction of a second. HEAD SHOT — A short pulse of magnetizing current passed through a part while clamped between the head contacts of a stationary magnetizing unit for the purpose of circular magnetization of the part. Duration of the passage of the current is usually Iess than one second. LONGITUDINAL MAGNETIZATION ~ Magnetization of'a material in such a way that the lines of nia.gaictie flux are substantially parallel to the long axis of the part, with the flux path completing itself tough the air outside the material. It is sometimes called bipolar magnetization, because at least two external poles exist in longitudinal magnetization, HiSB’Y Global Standards Code Services 00 ——Lesson 5 ~ Methods of Magnetization METHODS OF MAGNETIZATION DIRECT AND INDIRECT MAGNETIZATION ‘Magnetic fields can be induced either directly or indirectly into a part. Using direct magnetization, electric current is passed directly through the ferromagnetic part to be inspected. With indirect magnetization, a magnetic field is induced into the part by placing it in a magnetic field generated by an adjacent electric current conductor, a permanent magnet, or a coil carrying electric current, As stated previously, there are two basic types of common methods used to provide magnetic particle inspections: the circular field and the longitudinal field. CIRCULAR FIELDS HEAD SHOT ‘There are three common techniques for inducing a circular magnetic field. The first is the head shot. With the head shot, the current is passed directly through the solid or hollow part. The part is magnetized between two heads, and we look for indications situated in the same direction as the electric current and the opposite direction of the magnetic field (Figure 12-1). Generally, on hollow parts, only the external surface is inspected. CENTRAL CONDUCTOR ‘The second magnetizing technique is the central conductor. With this shot, the current is sent directly into a bar and the part is located around the bar, which is a form of indirect magnetization (Figure 12-2), Normally, the inside surface is inspected when using this technique. In most cases, a nonmagnetic central conductor is used, since nonmagnetic material tends to force magnetic flux lines to its surface, which results in a stronger magnetic field being induced on the inside surface of the part being inspected. Additionally, a nonmagnetic conductor, such as copper, has better heat conductivity characteristics, which can be a problem at higher amperage settings. MAGNETIZING PRODS ‘Where it is not practical to use either a head shot or a central conductor, prod magnetization is used. This is the third magnetizing technique. The magnetic field induced is variable and distorted and is used in the field and/or manufacturing environments where either the product is too large or the magnetic particle equipment or part cannot be moved (Figure 12-3). When prods are used, the inspector must be very careful as it is a direct magnetization using electric current, which can cause arc strikes thus burning the part. Good contact prior to turing on the current is essential with all direct magnetization because arc strikes can form localized hardened areas, which are stress risers and may propagate to the point of part failure during subsequent cyclic loading HSB 'Y Global Standards * Goge Services alCompote Magnetic Particle Inspection Workbook Figure [2-1 — Head Shot Figure 12-2 — Central Conductor | Figure 12-3 ~ Prods HSB" Global Standards Cove Services ESLesson 5 ~ Methods of Magnetization LONGITUDINAL FIELDS Longitudinal magnetization is generally used for the detecting of circumferential discontinuities, which lie in a direction opposite (right angles) to the magnetic field. Circumferential discontinuities around a cylinder, for example, are detected by magnetizing the cylinder longitudinally and in a direction parallel with its axes. Longitudinal magnetization is accomplished in a number of ways. The two common ways are ‘magnetizing with a coil, which is the most widely used method, or by using a yoke. COs A coil is produced by winding one or more tums of an electrical conductor (Figure 12-4). The collective circular fields around the electrical conductor produce a longitudinal field that induces a magnetic flux in and around the part. The part is normally laid on the bottom inside of the coil where the field is stronger. When using a stationary unit, the part can be supported in the coil by the conduct heads, Because the effective field does not extend far beyond a coil, most specifications require multiple shots on long parts, usually at increments of 9 inches on either side of the coil. ‘A variation of the typical coil isto inspect a heavy part by simply wrapping a cable, such as the one used ‘on welding machines, around the part. The cable-wrapped coil, usually 2/0 and 4/0 American wire gage, ‘can be connected to a mobile magnetic particle machine or portable power pack, or it can be connected to the contact heads of a stationary inspection unit. When using this method, cable lengths must be kept as short as practical to minimize electrical resistance losses, thus aiding in obtaining higher amperes. coil Figure 12-4 ~ Coil HSB Y Global Standards “Code Services: 3Complete Magnetic Particle Inspection Workbook YORE Yokes can be of two types: permanent magnet or electromagnetic, which is essentially cores of soft iron with a current carrying coil wound around the core. They are not normally used for deep-seated discontinuities duc to their limited power, which normally cannot be adjusted. The permanent magnet yoke is used for applications where portability is a requirement and where no source of electrical power exists (Figure 12-5). Electromagnetic yokes also offer some portability and are more versatile because they normally have jovable legs and may be purchased to provide cither AC or DC magnetization or both. The articulating Jegs can be moved to provide the best spacing for inspection and for optimum concentration of the magnetic flux, since actual field strength at any point depends upon the distance between the legs. ‘The inspector should exercise care by not placing the leg spacing too close as magnetic particles will tend to band around the poles legs) which can mask discontinuities, Figure 12-5— Yoke ‘Two separate magnetic fields having different directions cannot exist in a part at the same time. But two ‘or more ficlds in different directions can be imposed on a part sequentially in rapid succession. This, in effect, does constitute the formation of two or more fields in different directions at the same time, thus enabling the detection of defects oriented in any direction in one operation, This multidirectional magnetization method, although uncommon, is sometimes referred to as a “swinging field” or “vector ic.” 4 ———__________ HSB ¥ Global Standards Code Services10. LL Lesson 5 ~ Methods of Magnetization Lesson 5 — Methods of Magnetization QUIZ In magnetization, current is passed directly into the part to be inspected The three common ways to circularly magnetize a part are: a) ) 2 When using prods, the magnetic field is considered to be a distorted circular field. oTrue 0 False Good contact is essential with all because are strikes can occur. Longitudinal magnetization is generally used for the detection of discontinuities A is produced by winding one or more tums of an electrical conductor into a coi When using a coil, its recommended that inspection be limited to 18 inches in either side of the coil, a True 0 False ‘The two types of yoke are: rectional magnetization, two or more magnetic fields can be imposed on a part sequentially and in succession, One reason leg spacing of a yoke is important is because when the legs are too close particles tend to _ around the poles. Indirect magnetization can be generated via: a) ») °°) HSB 'Y Global Standards Code Services 4s46 fagnetic Particle Inspeetion Workbook Lesson 5 ~ Methods of Magnetization QUIZ KE direct head shot, central conductor, prods True direct magnetization circumferential magnetizing coil False (9 inches on either side) permanent and electromagnetic ropid band afjavent electrical conductor, permanent magnet and coil HSB'¥ Global Standards Cove ServicesLesson 6 Magnetic Field Distribution <¢Complete Magnetic Particle Inspection Workbook Lesson 6 — Magnetic Field Distribution GLOSSARY CENTRAL CONDUCTOR — A solid or hollow electrical conductor that is passed through the opening of a ring, tube or any hole of a part for the purpose of creating a circular magnetic field in or around the ring, tube or hte, MAGNETIC CONDUCTOR - A central conductor made of ferromagnetic material, NONMA > CONDUCTOR ~ A central conductor made from nonferromagnetic material, such as copper. HSB ¥ Global Standards Gode ServicesLesson 6 ~ Magnetic Field Distribution MAGNETIC FIELD DISTRIBUTION DIRECT CURRENT FIELD DISTRIBUTION When direct current is passed directly through a solid magnetic conductor, the following occurs. ‘A. The magnetic field strength outside the conductor decreases as distance is increased from the central conductor's center. B. The magnetic flux density increases evenly from zero at the center until it reaches peak strength at the surface, C. Because of the permeability of steel, the field strength is greater inside a solid magnetic conductor as compared to a nonmagnetic conductor, and the flux density drops rapidly just outside the surface of the steel conductor. D. The field strength outside a solid conductor is the same with either a magnetic or nonmagnetic conductor. In both magnetic and nonmagnetic hollow conductors, the field strength is zero at the inside surface and increases to its greatest at the outside surfaces. As with both solid and hollow and both magnetic and nonmagnetic, the field strength outside the conductor decreases with the distance from the central conductor center. However, the difference between the permeability of a magnetic and nonmagnetic conductor affects the field strength distribution within the conductor since a nonmagnetic conductor concentrates the flux at the surface. On a hollow magnetic conductor, permeability is again a factor in determining field strength in the inside. If the outer diameter and current flow are identical when comparing a solid versus 2 hollow conductor, the total field strength will be the same. ALTERNATING CURRENT Altemating current tends to flow near the surface of a conductor. This is commonly referred to as the “skin effect,” which provides for good detection of surface discontinuities. The field strength outside the conductors is comparable for both AC and DC. As with DC, both conductivity and permeability affect the field strength and distribution of AC current similarly inside the conductor. It should be obvious that either a magnetic or nonmagnetic material could be used for a central conductor. However, a material such as copper is normally used as a central conductor because there is less heat buildup due to better heat conductivity and because itis a good conductor of electricity HSB Y Global Standards Code Services 49 me -Complete Magnetic Particle Inspection Workbook (This page intentionally left blank) 59 HSB 9 Global Standards Cove ServicesLesson 6 ~ Magnetic Field Distribution Lesson 6 — Magnetic Field Distribution QUIZ When electric current is passed through an electrical conductor, such as steel or copper, a magnetic field is produced. True 0 False ‘When using direct current, the flux density increases evenly from 0 at the center to peak strength at the surface of a solid magnetic control conductor. oTme o False ‘The field strength outside a solid conductor is with either magnetic or nonmagnetic conductor. With hollow conductors, the field strength is greatest at the surfaces. ‘A nonmagnetic conductor concentrates the flux density at the surface. oTrue 0 False ‘A nonmagnetic material, such as copper, is normally used as a central conductor because it is @ good conductor of electricity and it possesses better conductivity. The term “skin effect” is associated with current, ‘As with DC, conductivity and permeability affect the field strength and distribution of AC current similarly outside the conductor. oTrue 1 False HSB 'Y Global Standards 31 ‘ode ServicesComplete Magnetic Particle Inspection Workbook | Lesson 6 ~ Magnetic Field Distribution QUIZ KEY True | 2 Tre 3. greatest 4, outside 5. True 6. heat 7. AC 8. False ' | 3 ISB Giobal Standards * Code Services neLesson 7 Calculating Current Values <4Complete Magnetic Particle Inspection Workbook Lesson 7 — Calculating Current Values GLOSSARY MAGNETIC PARTICLE FIELD INDICATOR ~ A simple sectioned device that when placed on a | part gives an approximate indication of the direction of a magnetic field and the approximate adequacy of the magnetic field strength used. Sometimes referred to as a “pic gage.” 4 HSB Global Standards i Coute Services iLesson 7 ~ Calculating Current Values MAGNETIC PARTICLE FIELD INDICATOR DETERMINING AMPERAGE USE. Rules have been developed for use in determining amperages to be used for magnetization. For proper values, a specification or procedure should be followed, but if there are no predetermined values through code or specification, then the best way to assure a sound inspection is by trial with known defects or by special equipment that is available in the industry, such as a magnetic particle field indicator. The following are general values given for training purposes. 1. Forcircular magnetization, generally 800 to 1,000 amps per inch of part diameter is used. This is the outer diameter or cross-sectional thickness. 2, For longitudinal magnetization, use the formula Ni = 45,000 + the L/D ratio (“L” being the length and “D” the diameter of the part) and then dividing the answer by the number of tums in the coil, For prods, itis generally recommended to use 90 to 125 amps per inch of prod spacing, 4, The power of the yoke is normally determined through its lifting power. Examples: 1. Circular Magnetization What amperage would be used to magnetize a stee! bar which is 10 inches long and 2 inches thick? ‘The answer is 1,600 to 2,000 amps based on our values above. When performing inspection on a part with two thicknesses, one must always start out with performing an inspection on the thinner portion as the second “shot” must have a greater value of flux density than the first in order to overcome the residual field of the first. 2. Longitudinal Magnetization (coil method) When performing longitudinal inspection using a coil, the following parameters are given. The part is 18 inches long by 2 inches thick. Using a horizontal unit with a 5-turn coil, what would be the amp setting? To calculate this problem you would use the formula Ni = 45,000 « the L/D ratio which calculates to 5,000 amp turns. Then take the 5,000 amp turns and divide them by the number of turns in the coil. In this case, we're using a coil which has 5 turns; therefore, to set the amperage on the machine to perform inspection of a part that is 18 inches long and 2 inches thick, one would set the amperage at 1,000 amps. It is important to remember that when calculating, you must go one step further with the answer by dividing it by the number of turns in the coil. = 45,000 = the L/D ratio, the following considerations should be adhered to: When using the formula Ni * Anarticle greater than 18 inches normally requires more than one coil shot * The cross section of the articles should not be greater than 1/10th the area of the coil oper © The article should have an L/D ratio between 2 and 5. ‘© The article should be placed against the inside wall of the coil and notin the center where the flux density is 0. HSB Global Standards Code Services 35Complete Magnetic Particle Inspection Workbook Lesson 7 — Calculating Current Values QUIZ 1. Given: Part length is 12 inches ‘Thickness is 3 inches Coil has 3 turns Using the formula NI= 4 , the proper amperage value to be used on a magnetic particle “ID machine is 2. Given: Part length is 12 inches Cross-sectional thickness is 3.5 inches For circular n:agnetization the amp setting would be 3. Using a prod spacing of 6 inches, what would the amperage setting be placed at? 4, Apart requiring circular magnetization is 15 inches long. One end is 3 inches thick with the other being 5 inches thick. Describe a logical sequence for inspecting the part. When using the formula NI am ‘an article 20 inches long would normally require more than. shot. 6. ISB ¥ Global Standards Code Services eeLesson 7 ~ Calculating Current Values (This page intentionally left blank) HSB Global Standards gy Code ServicesComplete Magnetic Particte Insp cction Workbook Lesson 7 — Calculating Current Values QUIZ KEY 3,750 amps 2,800 to 3,500 amps 540 to 750 amps Start with inspecting the thinner portion and take a second shot for the thick portion. One _ usb Y Global Standards. Coule ServicesLesson 8 Inspection Equipment <4Complete Mag etic Particle Inspection Workbook Lesson 8 — Inspection Equipment GLOSSARY MOBILE EQUIPMENT - Magnetic particle equipment that can be moved to an inspection site where suitable line voltage is available. PORTABLE EQUIPMENT - Small magnetic particle units that can be hand carried, thereby providing the most flexibility at remote sites. STATIONARY UNIT - A magnetic particle inspection machine that is located at a fixed site. HsBY Global Standards Cove ServicesLesson 8 ~ Testing Equipment INSPECTION EQUIPMENT STATIONARY UNITS ‘There are many general types of equipment used in magnetic particle inspection and various custom-built systems that are highly specialized depending on applications. With the wet horizontal stationary unit depicted (Figure 22), an article or central conductor is clamped between the head and the tail stock for circular magnetization. Large soft contact areas, such as lead or copper braid, are used for the head surfaces to increase the contact area and to reduce the possibility of buming the part. For longitudinal magnetization, a coil, movable on rails on one end with one contact head fixed, is, positioned so that the area to be tested is encircled by the coil while the article is held in place by means of a contact pneumatic cylinder. ‘The unit has a self-contained AC or DC power supply, depending on usage requirements, with all the necessary electrical controls, including a switch for demagnetizing. A tank with pump agitation and circulating system for wet inspection is located beneath the head and coil mounting rails. A hand hose with a nozzle is provided for applying the bath and on special units, automatic bath application facilities are provided. HSB'Y Global Standards Code Services I asespsemmon pe mgeceoneers E i Lesson 8 - Testing Equipment ‘MOBILE EQUIPMENT In addition to the wet horizontal stationary unit, mobile inspection equipment is also available, These units have remote current output and demagnetization controls that permit operation atthe site of inspection. The units are used with either rigid or cable-wrapped coils for longitudinal magnetization or demagnetization and cables may be connected or passed through a part for circular magnetization. The advantage of mobile equipment is it can be readily used at any inspection site where suitable line input voltages and current capacities are available. PORTABLE EQUIPMENT Additional to stationary and mobile equipment, there is also portable equipment that is normally used where only normal voltage 115 AC power is accessible or where no power is available at all. In the case of no power, the permanent magnet type yoke is the most commonly used equipment. For field inspections, the most commonly used equipment is either yokes or prods. YOKES ‘Yokes are small, easily portable and they are very easy to use in testing small components to induce a strong magnetic field into that portion of the part between the poles or legs of the yoke. However, yokes should not be used for the detection of deep-seated discontinuities because of the limited penetrating power due to the fixed field strength. PRODS. ‘When partial magnetization of large articles is required, prods can provide adequate penetrating power with good sensitivity. Care must be used when using prods in order to prevent arcing or burning of the surface, particularly on high carbon materials where localized hard spots can occur. EQUIPMENT SELECTION For adequate and reliable inspections, the following should be considered when selecting equipment for magnetic particle inspection 1. Is the equipment available for the wet or dry method? ‘What are the magnetization requirements, AC or DC or both? 2. 3. What are the demagnetization requirements? Are they incorporated in the same unit or separate? 4. The amperages required? 5 Line voltage requirements and accessories needed or required. HSB Global Standards Code Services 6Complete Magnetic Particle Inspection Workbook (This page intentionally left blank) of ISB Global Standards Code ServicesLesson 8 ~ Testing Equipment Lesson 8 — Inspection Equipment Quiz State the three general classifications of equipment used in magnetic particle inspection. a) db). ©) Portable equipment is normally used where the voltage availability is at least 155 AC. True 0 False For field inspections, the most commonly used equipment is either yokes or Mobile equipment can be used when no line voltage is available. oTme 0 False For deep-seated discontinuities, yokes should be used because of the variable field strength they produce, aTme a False Some portable equipment does not require a source of electric current. oTrme o False HSBY Global Standards “Code Services 65 - SSComplete Mognetic Particle Inspection Workbook 06 Lesson 8 — Inspection Equipment QUIZ KEY stationary, mobile, portable False Prods 11SB¥ Global Standards Code ServicesLesson 9 Section I, Steps in Performing Magnetic Particle Inspection < Section II, Demagnetizing <Complete Magnetic Particle Inspection Workbook Lesson 9 — Scetion I, Steps in Performing Magnetic Particle Inspection PRECLEANING Before performing magnetic particle inspection, the specimen should be dry and thoroughly precleaned. Teaning can involve removal of slag, heavy buildup of paint, rust, grease, or other organic material that may interfere with the test results, No single cleaning method can assure removal of all types of contaminants. Most methods are limited to the removal of only a few types of contaminants, Further, some methods require equipment that may not be adaptable to the job at hand; i.e., the part may be too big to fit, or must be cleaned in place on the asscinbly. Finally, not all processes are adaptable to the alloy being inspected; they may corrode it. The cleaning process must then be chosen with knowledge of the contaminant, the alloy, and the accessibility of the part to be inspected. ‘The following lists typical cleaning methods: Alkaline cleaners ~ are nonflammable water solutions containing alkaline detergents that can remove certain types of oils by saponitying and emulsifying them. They can be used hot or cold, as a dip, or as a spray. Vapor degreasing — is the preferred method for the removal of almost any kind of oil, wax, or grease contaminant. Tt will not remove dirt or corrosion products, mineral deposits, plastic, varnish, or paint coatings. Solvent cleaners — remove the same type of contaminants as vapor degreasing does and are applicable for cleaning surfaces that cannot be immersed in a vapor degreaser because of size or inaccessibility. They can be applied by spraying, wiping, or dipping. Mechanical methods — such as wire brushing or abrasive blasting can be used to remove rust or other corrosion deposits. These methods can damage parts and conceal fine discontinuities and should be used as directed Paint removers — are compounds developed only to loosen and strip paints, where presence of a paint coating will letract from the inspection operation. Although discontinuities may extend through the paint, the presence of the paint coating may interfere with the magnetic particle inspection process and reliable significant results may not be obtained. Steam cleaning ~ the spraying of steam or very hot cleaning solutions can remove loosely bound inorganic contamination and many organic contaminants from the test surfaces. Ultrasonic cleaning ~ combines solvent or detergent cleaning with very vigorous mechanical action to shake contaminants loose, It should be used with water and detergent if the material to be removed is inorganic (rust, ditt salts, corrosion products, ete.) and with an organic solvent if the material to be remioved is organic (oils, paint residues, varnish, lubricants, ete.) RESIDUES ART, CONTAMINANTS Residues from cleaning processes can remain on the part surface and become contaminants. Paint remew-rrs can leave sticky residues that cither trap particles or contaminate recirculating baths. Alkaline cleaner residues ean loosen the binder holding fluorescent dye to the magnetic particles. Alll cleaning residues nutst be removed before inspecting parts or components. Moisture from cleaning processes and liquids from vapor degreasers or solvent cleaners are also contaminants. All parts must be clean and dry before the inspection process takes place. IS BF Global Standards Corte ServicesLesson 9 ~ Section I, Steps in Performing Magnetic Particle Inspection ‘The smoother the surface and the more uniform the color, the more favorable the conditions for performing a magnetic particle inspection. Inspection — Wet Method Since the wet horizontal equipment is the most commonly used equipment, we will start with this to sequence the steps in performing inspection. To obtain circular magnetization, clamp the article between the head and the tail stock. For longitudinal magnetization, the article is positioned so that the area to be tested is encircled by the coil. The wet continuous field method has three basic steps that are the same for either the head shot or coil shot. 1. Flow the bath through the nozzle and over the entire surface of the part. 2. Stop the bath flow. 3. Apply current at the instant bath flow is stopped. 4 Inspect. Settling Test ‘When performing the wet method in a horizontal unit, it is important to check the strength of the bath. ‘The way to check the strength of the bath is via a settling test that is accomplished by the gravity method using a graduated pear-shaped centrifuge tube as shown below (Figure 14). The steps are as follows: 1, Agitate the suspension thoroughly to assure particle distribution. This is normally done through a pump system. There should be a manufacturer's or internal procedure that is used in the facility that details how long to agitate the suspension, 2. Fill the 100 ce centrifuge tube from the delivery hose. Demagnetize when clumping occurs. The demagnetizing will reduce the amount of clumping. 4, Normally, allow the particles to settle out of the vehicle to the bottom of the centrifuge for a minimum of 30 minutes. Take a reading and record it. 6. Adjust the bath either by adding particles or adding the wet vehicle as necessary. The reading is normally recommended to be between 1.5 and 2.0 cc of particles for a nonfluorescent bath and between .2 and .4 cc for a fluorescent bath. However, these are only guidelines and they will vary from manufacturer to manufacturer as well as from the types of components being checked. HSB Y Global Standards Code Services °Complete Magnetic Particle Inspection Workbook Centrifuge Tube Figure 14~ Centrifuge Tube Dry Continuous Doring the dry continuous method, which is typically used with mobile and portable equipment, the powder is usually applied from a shaker bulb with the following steps 1. Apply magnetizing current. 2. Blow the powder particles over the magnetized area. 3. Blow excessive powder off gently. 4. Shut off the magnetizing current 5. Inspect It is important to note that the powder should always flow to the magnetized area so that the particles will (tracted to any flux leakage. They should not be forced onto the part surface. Dry Residual tic particles are applied after the magnetizing current is shut off, this is known as the residual hod. In the residual dry method, the powder is applied by sprinkling or dusting the specimen after the magnetizing curtent has been shut off, 1iSB'Y Global Standards Code ServicesLesson 9 ~ Section I, Steps in Performing Magnetic Particle Inspection Wet Residual With the wet residual method, the particles are mixed with a liquid, either water base or kerosene base, to make a bath that is then applied to the surface of the specimen after the magnetizing current has been shut off. Demagnetizing ‘After inspecting the component, the next step is to demagnetize if the residual magnetism can affect subsequent manufacturing operations or the use of the component. This step of the magnetic particle inspection process is addressed in depth in Section II of this lesson. Postcleaning ‘After demagnetizing the article, the next step is to clean the part again (postcleaning) in order to remove ‘any magnetic particles and wet medium if the wet method is used. If the residue can be tolerated because itmakes no difference to the usefulness of the part or to subsequent operations, postinspection cleaning can be eliminated. When postinspection cleaning is necessary, the following methods are most ‘commonly used: Vehicle Removal A) Oil base, remove by vapor degrease or solvent B) Water base, rinse or spray with plain water. Dry Particles Wiping, vapor degreasing, ultrasonic cleaning, detergent cleaning, solvent cleaning, HSB Y Global Standards Code Services nComplete Magnetic Particle Inspection Workbook (This page intentionally left blank) 2 ISB Global Standards i Code Servlets eeLesson 9 - Section I, Steps in Performing Magnetic Particle Inspection Lesson 9 — Section I, Steps in Performing Magnetic Particle Inspection QUIZ 1. State the steps for performing magnetic particle inspection using the wet continuous method, 2. State the steps for performing magnetic particle inspection using the dry residual method. 3. Alkaline cleaners can affect the fluorescent ability of magnetic particles. OTe 0 False 4, When using the settling test to check the fluorescent bath strength, the reading should normally be between and : 3. Inthe dry continuous method, the particles are applied after the magnetizing current has been shut | off. oTme 0 False 6. Magnetic particles should always flow on the magnetized area rather than being forcefully applied. oTmue a False 7. The vehicle used to mix particles in the wet method can be either base or base. 8. tis always necessary to postclean a part. oTrue 0 False 9, Prior to performing inspection, all parts must be clean and dry. oTnue 0 False 10. Wire brushing or abrasive blasting are excellent methods for opening fine discontinuities because of the pening effect. oTne 0 False HSB'Y Global Standards, —_______ 3 Code Services peComplete Magnetic Particle Inspection Workbook Lesson 9 — Section I, Steps in Performing Magnetic Particle Inspection QUIZ KEY 1. precleans dry; flow the bath over the surface; stop the bath flow, and at the same instant, apply current; inspect; perform shot at 90° to first; inspect; demagnetize (if required); postclean; fill out data report, 2, preclean; dry; apply current; shut off current; gently apply particles; gently blow off excessive powder; inspect; perform second test at 90° to first shot; inspect; demagnetize (if required); postclean; fill out data report. 3. True 4. Qand tee False 6. Tne 1. water or kerosene (oil) base 8. False 9. True 10. False 4 _____ HSB'¥ Global Standards ** ode ServicesLesson 9~ Section Il, Demagnetization Lesson 9 — Section II, Demagnetization GLOSSARY ARC BLOW - When molten metal during welding is drawn away from the center of deposition. Can be caused by the attraction from a magnetic field. CURIE POINT - The temperature at which a material’s positive and negative charges (domains) will be influenced, Heating a polarized material above its curie temperature will cause it to lose polarization. DEMAGNETIZATION - The act of removing a magnetic field. INTERPASS MAGNETIC PARTICLE INSPECTION — Performing inspection after each successive weld bead or weld layer. Used as a way of examining the entire volume of a weldment. HSBYY Global Standards _____— 75 Code Services reComplete Magnetic Particle Inspection Workbook DEMAGNETIZING Ri Ferromagnetic materials retain some magnetism after the magnetizing force has been removed. Tt can be a serious problem for metals having high retentivity. High residual magnetic fields will interfere with the operation of many types of instruments and with certain manufacturing processes as well as with the remagnetization of the part. As an example, residual fields will affect magnetic compasses or create problems with dlicate instruments, Residual fields on rotating parts will attract particles causing fe wearing or binding. A very important consideration when performing interpass magnetic, | particle inspection is the presence of residual magnetic fields between welding passes. During subsequent welding layers, the residual fields can cause arc blow; therefore, itis important that the component be demagnetized so the metal will not be affected. DUAL MAGNETISM CONSIDERATIONS. UNNECESSARY TO DEMAGNETIZE At times, it is not necessary to demagnetize if it is judged the magnetic field will not adversely affect the operation of the item or the performance of instruments, or if the component is to be heated above the curie point which will automatically demagnetize the part. Cobalt 1130 Tron 770 Iron, 5% Silicon 720 Tron, 19% Chromium: 740 Nickel 358 DEMAGNETIZATION PROCESS. ‘The demagnetization process involves subjecting the parts to a magnetic field of continually reversing direction and diminishing magnitude. ‘The initial demagnetizing force must be high enough to overcome the residual coercive forces. Either AC or DC can be used to demagnetize parts. Normally a switching atrangement is required for the DC. An casy method of demagnetizing small parts is to pass them through a stationary coil energized with AC current, This provides the alternating and diminishing field that is required. With large parts, it is recommended that a DC current be used for more penetration, Reduce the first ficld and then reverse polarity. Usually, one reversal per second is required for about 10 0 30 seconds. When planning your magnetic particle inspection process, consider that it is easier to demagnetize a Jongitudinal ficld because of the north and south poles that are created on the component. As stated in previous lesson, there are no north and south poles for a circularly magnetized component. It is easier to doa circular shot first and do the second one at a higher amperage, performing a longitudinal inspection that will allow casier demagnetization. Yor very large components, it is generally casier to demagnetize the part completely by shifting it to a line in the eas¥west direction if it has been originally in the north/south position. The reason for this is the influence of the carth's magnetic field. 60 8B YX Global Standards = | Code Services — << — —Lesson 9 ~ Section II, Demagnetization SUMMARY Again, one needs to be concerned with two areas when demagnetizing. One must reverse the magnetic field and have a constantly reducing magnetic field. Three ways to reverse the field are: 1. Reversing the part in the magnetic field. 2. Reversing the current. 3. Reversing the magnetic field; in other words, turing the coil or equipment 180°. ‘When you want to reduce the magnetic field, these three options may be used. 1. Reduce the magnetizing current. 2. Slowly move the part away from the magnetic field. 3. Move the magnetic field away from the part. Any method of demagnetization must combine one of the three options of reducing the magnetic field with one of the three options to reverse the magnetic field, There is no practical method to assess a residual field in circular magnetization since no external poles exist. However, with longitudinal magnetization, one may use a leakage field indicator. The point isthat there must be an external leakage field in order to determine whether the article is magnetized. The leakage field indicator (Gaussmeter) compares the strength of the field of the article inspected with a fixed field inside the indicator. It is generally used more to locate rough flux leakage (than to measure field strength) and to show when the part is demagnetized. HSB'Y Global Standards __—————— 7 Code ServicesComplete Magnetic Particle Inspection Workbook (This page intentionally left blank) HsB’¥ Global Standards Code ServicesLesson 9 ~ Section ll, Demagnetization Lesson 9 — Section II, Demagnetization Quiz High residual magnetic fields can interfere with: a) ») 9 How can residual magnetic fields interfere with rotating parts? The curie point of a material is the point where material becomes ‘The demagnetization process involves subjecting the part to a magnetic field of continually direction and magnitude. ‘The demagnetizing force must be set as high or higher than the residual field, aTrue oFalse State three ways to reverse the magnetic field. a) b) ° State three ways to reduce (diminish) the magnetic field. a) ») °) ‘You are instructed to perform circular and longitudinal inspections on a component that will be demagnetized after the inspection process. Describe the sequence of operations you would perform to assure accurate results HSB'Y Global Standards ~~ Code Services: 980 mplete Magnetic Particle Inspection Workbook Lesson 9, Section If - Demagnetization QUIZ KEY instrument operation; manufacturing processes; remagnetizing a part. By attracting particles which cause excessive wearing or binding, nonmagnetic reversing; diminishing True reversing the part; reversing the current; reversing the magnetic field reduce the current; move the part away from the field; move the field from the part, a) magnetize circularly b) inspect ©) set magnetizing force higher than the force used for circular magnetization and perform a longitudinal inspection inspect ©) demagnetize H1SBY Global Standards Code ServicesLesson 10 Section I, Classification & Interpretation of Indications <4 Section IT, Evaluation of Indications < Section II, Recording of Indications <Complete Magnetic Particle Inspection Workbook Lesson 10 — Section I, Classification & Interpretation of Indications GLOSSARY “FECT ~ A discontinuity the size, shape, orientation, or location of which exceeds the acceptance criter INDICATION — Response from an NDE technique indicating the presence of a discontinuity. @ —_____ HSB¥ Global Standards Code ServicesLesson 10 Section 1, Classification & Interpretation of Indications CLASSIFICATION AND INTERPRETATION OF INDICATIONS There are two major classes of indications. The first is a relevant indication, which is a result of a mechanical discontinuity that attracts particles to a leakage field. This isa true discontinuity, which requires further examination to a predefined standard in order to determine whether it is acceptable or rejectable. If a relevant indication exceeds the standard parameters, then it would be a rejectable discontinuity and would be classified as a defect. ‘The other type of indication is a nonrelevant indication, which may be caused by part geometry, design permeability changes, or surface condition, Nonrelevant indications can also be caused by ‘overmagnetization due to the leakage field attracting particles. Abrupt changes in section thicknesses can also cause magnetic flux leakage when lines of force leave or enter the part. Permeability changes may cause nonrelevant indications as in the case of a soft and hard area at the tip of a hardened drill; the junction of the hardened area could cause a nontelevant indication buildup. An experienced examiner will need to consider the following nonrelevant causes when an indication is first observed, ‘+ Banding — caused by the higher concentration of magnetism near the surface contact areas of a yoke or prods; usually prevalent when the contact areas are spaced too close to each other. Also, it can be caused by excessive magnetization. # Permeability variations — local metallurgical variation within a component such as chemistry changes, heat treatment, or cold forming. ‘+ Magnetic writing ~ contact between or rubbing of two or more magnetized parts together. May also be caused by overmagnetizing a part. ‘+ Surface condition — foreign material such as oil, ditt or scale can cause false indications that can, confuse the examiner or may cause a high background thereby masking true indications ‘+ Part geometry — abrupt dimensional changes of a part such as the edges of a square bar can cause leaking fields. Other indications may also be caused by keyways and internal changes such as hidden holes and splines. Overmagnetizing a part, especially in the longitudinal method, can magnify the effects of part geometry. One can more readily define problems associated with nonrelevant indications by the appearance. Normaily a nonrelevant indication will be a fuzzy rather than a sharp indication; however, frequently a fuzzy indication could indicate an intemal discontinuity. Close examination is essential before dismissing an indication as nonrelevant, In many cases, specifications require that any indication believed to be nonrelevant be regarded as relevant until itis proven by reexamination or via surface conditioning that it is truly not a discontinuity. HSB'Y Global Standards 83 Code Services aComplete Magnetic Particle Inspection Workbook (This page intentionally left blank) 3 SB Goal Standards ide ServicesLesson 10~ Section I, Classification & Interpretation of Indications Lesson 10 — Section I, Classification & Interpretation of Indications Quiz 1, The two classes of indications are: a) b) 2, When a relevant indication (discontinuity) exceeds specification criteria it becomes a 3. Magnetic writing can be caused by contact with other parts, and 4A indication is a result of a mechanical discontinuity that attracts particles. 5. Foreign material such as dirt on a part can cause indications, 6. Inmany cases, specifications require that any indication believed to be nonrelevant be regarded as until itis proven by or via conditioning. HSB Y Global Standards 85 Code Services| FSComplete Magnetic Particle Inspection Workbook 6 86 Lesson 10 — Section I, Classification and Interpretation of Indications relevant, nonrelevant defect overmagnetizing relevant nonrelevant relevant; reexamination; surface HSB ¥ Global Standards QUIZ KEY Code ServicesLesson 10 Section Il, Evaluation of Indications Lesson 10 — Section II, Evaluation of Indications i GLOSSARY ASME CODE - Contains rules for manufacturing boilers and pressure vessels. Published by the American Society of Mechanical Engincers to facilitate safe construction of fossil and nuclear power components. LINEAR INDICATION ~ In most specifications, an indication that the length is more than three times the width, ROUNDED INDICATION - In most specifications, an indication that is circular or elliptical in shape, with the length equal to or less than three times the width. HSB'Y Global Standards Code Services wm 87Complete Magnetic Particle Inspeetion Workbook EVALUATION OF INDICATIONS, : EVALUATION After an indication has been determined to be relevant, itis classified as a discontinuity (i.e., crack porosity) and must be judged against an acceptance standard to determine if it is unacceptable due to its shape, type, or location. A discontinuity that exceeds the predetermined limits of acceptance standards imposed by a procedure or specification is regarded as a defect and the specimen must either be rejected or may be reworked to bring the discontinuity within the established acceptance parameters. ‘The generation and accurate use of an acceptance standard is the result of pooling intelligence from: * Material capability - chemical, mechanical, and metallurgical properties, as well asthe fabrication capability of the material. | + Design criteria — high or low stress used on the material and if it will be shear, tensile, compressional, + Service data —how many stress cycles is the material expected to withstand and how well has similar material performed under past service and environmental conditions? / ‘+ Reliability of examination method: ~ capability of the system aceuracy of the equipment reproducibility of the method of the examination method PARTS A TABILITY Parts may be acceptable with certain discontinuities in specific locations because the stress that will be applied is not expected to cause a failure while the partis in service. The same part with the same discontinuity may be rejected if that particular size discontinuity is in an area of high stress. In most cases, acceptanee/rejection standards are based on previous experience with similar components, Each discontinuity must be evaluated according to the specified acceptance standard. following is a partial example of a format used for an acceptance standard that is located in the ASME Boiler and Pressure Vessel Code for magnetic particle and liquid penetrant inspection. on (a) A Tinear indication is one having a length greater than three times the width, indications with major dimensions greater than 1/16 inch shall be considered relevant. (b) A revnded indication is one of circular or elliptical shape with the length equal to or less than three i titaes the width. (c) Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant. | | sg HSB Global Standards Code Services a SSSSSSSSSSSSSSSSSSSSSeFeFeFeFSFSFSSSFSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSshLesson 10~ Section If, Evaluation of Indications All surfaces to be examined shall be free of: (@) relevant linear indications (b) relevant rounded indications greater than 3/16 inch (©) four or more relevant indications in a line separated by 1/16 inch or less (edge to edge) The following acceptance standard is similar to the preceding one except that an additional requirement is imposed by #4 on the list. (a) Only indications with major dimensions greater than 1/16 inch shall be considered relevant. (b) Unless otherwise specified in this subsection, the following relevant indications are unacceptable: (1) any indications that may be characterized as cracks (2) rounded indications with dimensions greater than 3/16 inch (3) four or more rounded indications in a line separated by 1/16 inch or less edge to edge (4) 10 or more rounded indications in any 6 square inches of surface with the major dimensions of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications being evaluated. A third acceptance standard below indicates that the thickness of material becomes a factor in the size of the discontinuity that would be considered acceptable, Acceptance Standards ith major dimensions greater than 1/16 inch shall be considered retevant. (@) Only indications (b) The relevant indications of (1) through (4) below are unacceptable: (1) any linear indications greater than 1/16 inch long for material less than 5/8 inch thick, greater than 1/8 inch long for material from 5/8 inch thick to under 2 inches thick and 3/16 inch long for material 2 inches thick and greater (2) rounded indications with dimensions greater than 1/8 inch for thicknesses less than 5/8 inch and ‘greater than 3/16 inch for thicknesses 5/8 inch and greater (3) four or more indications in a line separated by 1/16 inch or less edge to edge (4) 10 or more indications in any 6 square inches of area whose major dimension is no more than 6 inches with the dimensions taken in the most unfavorable location relative to the indications being evaluated In each of the preceding examples, it was determined by evaluation that the indications were relevant, prior to evaluating the indication is acceptable or rejectable. Relevant Indications If the indication is relevant (major dimensions greater than 1/16 inch), then it must be further evaluated (compared) to the dimensions shown in the standard to determine acceptability. Remember — only discontinuities with major dimensions greater than 1/16 inch are considered to be relevant in these examples. An indication 1/16 inch or less is not relevant and does not have to be considered further. HSB Global Standards 99 Code Services,Complete Magnetic Particle Inspection Workbook ‘The next acceptance standard is for evaluating a weld and the base material within 1/2 inch of the weld. Additional wording is used in #3 and #4 to reinforce the intent of the acceptance standard for the examiner. Example The weld, including the adjacent base material for at least 1/2 inch on each side of weld, shall meet the following criteria: A. Only indications with major dimensions greater than 1/16 inch shall be considered relevant. 1. The following relevant indications are unacceptable: 1. any cracks of linear indications 2, rounded indications with dimensions greater than 3/16 inch 3. four or more rounded indications whose major dimensions are greater than 1/16 inch when the indications are ina line and are separated by 1/16 inch or less edge to edge 4, 10 or more rounded indications whose major dimensions arc greater than 1/16 inch when the indications are in any 6 square inches. of surface with the major dimensions of this area not to execed 6 inches, with the area taken in the most unfavorable location relative to the indications boing evaluated Understanding Dimension Criteria ‘The inclusion of the words “whose major dimensions are greater than 1/16 inch,” is intended to help the cexininer understand that each of the rounded indications must be greater than 1/16 inch. The additional words do net chenge the acceptance criteria - they merely clarify it. Any clarification that will help an examiner to better understand and accomplish the difficult task of evaluating indications should be encouraged, Rejecting a Part or Weld Most portions of the acceptance standards shown previously as examples are fairly easy to understand. Rejecting a part or weld because it contains a linear indication that is greater than 1/16 inch is clear if the ‘examiner knows that a linear indication is present. Rounded indications larger than a specific size would also be reason for rejection, Understanding Unclear Standards Sonic of the acceptance standards are not as clear cut. As an example, in the previous acceptance standard #4 states: “10 or more rounded indications whose major dimensions are greater than 1/16 inch ‘when the indications are in any 6-square-inch surface with the major dimensions of this area not to exceed 6 inches, with the area taken in the most unfavorable location relative to the indications be evaluated.” Fora better understanding, it may be necessary to break the statement into three parts. First, “10 or more rounded indications whose major dimensions are greater than 1/16 inch.” This means there must be 10 or more rounded indications and cach of them must have at least one dimension that is greater than 1/16 inch to he rejected. oo SB Gob Standards Code ServicesLesson 10 ~ Section Ul, Evaluation of Indications ‘The second part of the statement, “when the indications are in any 6 square inches of surface with the ‘major dimension of this area not to exceed 6 inches,” applies two restrictions on the examiner. One restriction is that the examiner is going to evaluate one 6-square-inch. area at a time, And the second restriction is that the longest dimension of that area shall not exceed 6 inches. As the size of the surface area increases, the possibility of rejection increases because the likelihood of 10 ‘or more rounded indications in that area increases. Originators of acceptance standards must determine how large an area and what dimensions will be used to establish the criteria, The third part of the criteria established in #4 is, “with the area taken in the most unfavorable location relative to the indications being evaluated.” This stipulation forces the examiner to evaluate the indications in such a way that the intent of the criteria is not in any way compromised by manipulating the 6-square-inch area or 6-inch dimension to avoid finding the condition unacceptable. Scattered Porosity Asan example, Figure 24 depicts an area of scattered porosity (rounded indications), on the surface of large casting. All the indications are greater than 1/16 inch in diameter, but smaller than 3/16 inch in diameter. Group of Rounded Indications each greater than 1/16 inch in diameter but less than 3/16. Figure 15 - Rounded Indications HSB Y Global Standards * Code Services a 91Complete Magnetic Particle Inspection Workbook 16 shows three rectangles (A-B-C) each one, 6 square inches in area with none of them having a r dimension execeding 6 inches. If each one is overlaid, one at a time, on Figure 26 and an attempt is made to get 10 or more rounded indications in the rectangle, then “A” will accomplish it. As a result, in this example, the area being evaluated is rejectable. Any length and width dimensions can be used, provided the rectangle does not exceed 6 square inches in area and no major dimension is longer than 6 inches. 1s" Figure 16 ~ Three Typical Six-Square-Inch Rectangles 9) SB Global Standards Code ServicesLesson 10 Section If, Evaluation of Indications Ten Rounded Indications in a Six Square Inch Area Figure 17 - Ten Rounded Indications in a Six-Square-Inch Area Experience To accurately evaluate indications, an inspector must have understandable written acceptance standards. Quite often, the people who write these standards know what their intent is, but the inspector may not. ‘Additionally, the inspector must have good visual acuity and should possess a broad background of production processes and basic metallurgy and have the type of personality that can stand continuous attention to detail, HsB'Y Global Standards 2 Code Services, nesComplete Magnetic Particle Inspection Workbook (This page intentionally left blank) og HSB Global Standards Code ServLesson 10~ Section Il, Evaluation of Indications Lesson 10 — Section I, Evaluation of Indications Quiz A discontinuity must be judged against an acceptance to determine if it is unacceptable. ‘The reliability of any examination method depends on four major factors. State them: a) >) °) a) A specific size discontinuity may be unacceptable in one area of a part and be acceptable in a different area of the same part. a True a False An acceptance standard states “only indications with major dimensions greater than 1/16 inch shall be considered relevant.” Which of the following are relevant indications? a) a rounded indication 1/16 inch in diameter b) —_acrack 1/16 inch in length ©) a forging lap 1/16 inch in length 4) porosity 1/8 inch in diameter ©) allofthe above In some acceptance standards the thickness of the material being inspected would be a factor in how large a discontinuity is acceptable. o True 0 False To accurately evaluate indications an inspector must have written standards. HsB'Y Global Standards Code Services 95Complete Magnetic Particle Inspection Workbook Lesson 10 — Section II, Evaluation of Indications QUIZ KEY 1 standard 2. a) capability of the system b) accuracy of the equipment ° reproducibility of the method d knowledge of the examination method 3. ‘Truc 4. porosity 1/8 inch in diameter 5. The 6. avceptance HSB'¥ Global Standards 9% Code ServicesLesson 10 Section Ill, Recording of Indications Lesson 10 — Section III, Recording of Indications GLOSSARY CASTING ~ A product created by melting metal or plastics and pouring them into a mold to create a specific shape, CASTING HOUSE - An establishment (foundry) where articles are cast, usually from metal, DATA SHEET - A form used to record the results of an inspection activity along with other pertinent ‘operational information, HSB’¥ Global Standards Code Services a 97Compivte Magnetic Particle Inspection Workbook RECORDING OF INDICATIONS. For component history as well as for legal reasons, it is important that any nondestructive test results are ivcorded. There are numerous methods of doing so will normally be detailed in the procedure being used hy the examiner, In most cases, magnetic particle test results are recorded on data sheets. However, in many cases, it is desirable to have the indication information available for some type of evidence. Mapping, ‘The most common method of recording indications when evidence is required is via the use of a map. Mapping is an easy process. A drawing is marked up or the examiner draws a map of the component and indicates approximately where the discontinuity is located and the size and length. This is especially common during magnetic particle inspections when a manufacturer is to produce parts forthe first time. The customer may require that initially all indications found by the particular test be mapped out so they can determine how well the process is working. ‘This is common in casting houses where many like components are made and require mapping for the first lot in order to assess how well the new ‘manufacturing process is working, Magnetic Rubber Another method of recording indications is the magnetic rubber examination. Fine magnetic particles are dispersed in special rubber that cures at room temperature. The uncured rubber is applied to the test surface, which is then magnetized, and the particles are attracted to discontinuities similar to normal ‘magnetic particle examination. After the rubber cures, the rubber replica is removed and can be used as a permanent record of the examination. Sometimes, magnetic rubber examination is used not because of its ability to have a permanent record but because it may be difficult to visually sce the results during normal magnetic particle examination; for example, it may be difficult to see inside a hole or spline. But when using magnetic rubber examination, one is able to cure the rubber, take it out of the hole, and see an indication of x discontinuity. The examination is made indirectly by looking at the cured rubber. Asa geneval rule, no safety precautions are required when making a casting using magnetic rubber examination, Magnetic Painti "8 Another form of recording indications is the magnetic painting method. As indicated by the name, ansenetic paint is a mixture of magnetic particles that can be applied with a brush. When the material is , leakage fields cause magnetic particle alignment that makes a discontinuity visible. It is especially useful or field applications where wind and moisture have less effect on the paint than they have on dry partic! Magnetic Py Th magnetic printing, the test article is first sprayed with a white plastic coating. Then, when dry particles are dusted on the surface, a printer is placed near it to establish a pulsating effect on the test plate and the particles. ‘This results in a printing of the plastic over the discontinuities. og SBF Global Standards Cote ServicesLesson 10 ~ Section Ill, Recording of indications Photography A simple method of preserving indications is using photography. Direct photography is quick and portable and can preserve the patterns for a long time. Special equipment is also available for preserving magnetic particle indications when photographing fluorescent indications. ‘Transparent Tape Transfer Another common method is the transparent tape transfer technique, which is another quick and simple procedure, When the indication is dry, the inspector lays a strip of transparent tape over it and presses it down. When the tape is peeled off, the indications stay with the tape, which is then laid on a white piece of paper. HSB¥ Global Standards __________ 99 Code Services aComplese Magnetic Particle Inspection Workbook (This page intentionally left blank) in) CSB Global Standards ode ServicesLesson 10 ~ Section Ill, Recording of Indications Lesson 10 — Section III, Recording of Indications Quiz What are the two most common methods of recording magnetic particle inspections when evidence is required? a) b) First lot examination may require mapping for what purposes? During magnetic rubber examination, the magnetic particles are dispersed in special rubber. oTme a False Magnetic rubber examination is an indirect examination technique. oTrue 0 False In most cases, magnetic particle test results are recorded on data sheets unless actual evidence is required. aTrue o False ‘When using the transparent tape technique, the indications stay on the tape when it is peeled off. aTrue o False HSB '¥ Global Standards Code Services 101Complete Magnetic Particle Inspection Workbook Lesson 10 — Section III, Recording of Indications QUIZ KEY I, mapping, transparent tape transfer 2 To assess how well the new manufacturing process is working. 3. ‘True 4. Te 5. Tue 6. ‘Truc lo) SB Goal Standards Cove ServicesLesson 11 Sample Magnetic Particle Procedure <4Complete Megnetic Particle Inspection Workbook Lesson 11 — Sample Magnetic Particle Procedure GLOSSARY EXAMINATION TEST REPORT ~ A report that details the technique and/or procedure parameters used to perform the examination and to record the results, (Date Sheet) SNT-TC-1A — A recommended practice used as a guideline by employers to establish their written practice for qualification and certification of NDT personnel. Published by the American Society for Nondestructive Testing. or SBF Global Standards Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure SAMPLE MAGNETIC PARTICLE PROCEDURE In order to properly perform a magnetic particle examination, itis necessary to have a procedure available that incorporates the information necessary for an inspector to perform the examination and to properly evaluate the results to a prescribed acceptance criteria. ‘This lesson presents a sample procedure addressing the use of fluorescent and color-contrasting magnetic particles for the examination of materials and welds. It utilizes the following magnetization techniques: © prod + longitudinal (coil) © circular (head shot and central conductor) * yoke (AC or DC) Note that the following procedure is for training purposes alone and should not be used for actual inspection of parts. Each facility must develop its own NDT procedures, which may incorporate customer specified codes, standards, and/or special requirements, HSB Global Standards “Code Services losComplete Magnetic Part Inspection Workbook SAMPLE PROCEDURE FOR TRAINING PURPOSES ONLY 1.0 PURPOSE La 12 To establish the technique and acceptance standards for magnetic particle examination of ‘materials and welds. ‘Types of examination — Either dry or wet ferromagnetic particles/bath shall be used. Examination medium may be either fluorescent or nonfluorescent (color contrasting to background). One or more of the following magnetization techniques shall be used: 124 prod 1.2.2 longitudinal magnetization (coil) 1.2.3 circular magnetization (head shot and central conductor) 124 yoke (AC or DC) 2.0 REFERENCES 24 22 ASME Code, Section III and V HSB Procedure 5.6 “Qualification and Certification Program for Nondestructive rmination Personnel” 3.0 DEFINITIONS BA Magnetic Particle Examination — a method of nondestructive examination utilizing miagnetic leakage fields that provides for detection of discontinuities on or near the surface of ferromagnetic materials. 3.2. Continuous Method ~ a magnetization/examination sequence during which the magnetizing current remains on while the examination medium is being applied and while excess ferromagnetic particles are being removed. 3.3. Indication ~a detectable magnetic particle accumulation. 3.4 False Indication ~ an indication held by nonmagnetic means. 3.5 Nonrclevant Indication ~ an indication formed by magnetic flux leakage or flux fields, but having no relationship to a discontinuity that may constitute a defect. 3.6 Relevant (Truc) Indication — an indication deemed to be a discontinuity requiring evaluation 3.7 Discontinuity - any interruption in the normal physical configuration of a part. 05 18B¥ Global Standards Code Services,Lesson 11 ~ Sample Magnetic Particle Procedure 4.0 PERSONNEL QUALIFICATION 4.1 Each person performing examinations governed by this procedure shall be certified in accordance with Reference 2.2, which incorporates recommended practices SNT-TC-1A, latest edition, 5.0 PRECAUTIONS 5.1 Ferromagnetic particles shall be either dry or wet and either fluorescent or nonfluorescent. Particles used shall be listed on the Approved Suppliers List. 5.2 The color ofthe particles (dry or wet type) shall provide adequate contrast with the surface being examined. 5.3 Dry particle examination shall not be performed if the surface temperature of the part exceeds 500°F. 5.4 Wet particle examination shall not be performed if the temperature of the wet particle suspension or the surface of the part exceeds 130°F, 5.5 Wet particles shall have their concentration in the liquid medium adjusted as follows: Fluorescent 0.1 to 0.5 ml/100 ml of vehicle ‘Nonfluorescent 1.2 to 2.4 ml/100 ml of vehicle 5.6 Particle concentration for fluorescent or nonfluorescent wet particle medium shall be verified by performing a settling test suspension as described in Attachment 1 6.0 LIGHTING 6.1 Fluorescent Particle Examination, using a black light, shall be performed as follows: 6.1.1 ‘The examination shall be performed in a darkened area. For dark adaptation purposes, the examiner shall be in the darkened area for a minimum of five ‘minutes prior to performing the examination 6.1.2 The black light shall be allowed to warm up for a minimum of five minutes prior touse. 6.1.3 The filter on the black light must be properly fitted and the examiner should not, look directly into the black light to avoid temporarily clouding the eyes. 6.1.4 The black light intensity shall be a minimum of 1,000 microwatts/CM’ as measured by a light meter. This measurement shall be taken every eight hours or whenever the work shift is changed. 62 For visible light, a light source shall be sufficient to obtain good visual acuity and contrast at the surface of the object being examined. A minimum light intensity at the inspection of 100 footcandies (1,000 1x) is recommended. HSB Y Global Standards ~ Code Services: 107 - ann cereComplete Magnetic Particle Inspeetion Workbook 7.0 CALIBRATION REQUIREMENTS, TW 72 Frequency 7.1.1 Bach piece of magnetizing equipment having an ammeter shall be calibrated at least every six months or when repairs have been performed. ‘The equipment used for calibration of the ammeter shall be traceable to a national standard Yokes 7.2.1 Yoke lifting power shall be checked at least once per year, or whenever a yoke has been damaged 7.2.2 Yoke energized by alternating current shall be capable of lifting 10 pounds at the ‘maximum pole spacing to be used. Yoke energized by direct current shall be capable of lifting 40 pounds at the maximum pole spacing to be used, 8.0 SURFACE PREPARATIONS 8 82 90 los Magnetic particle examination may be performed on surfaces that are in the as-welded, as-rolled, as-cast, or as-forged conditions, provided that surface irregularities do not interfere with the examiner's ability to interpret indications or do not mask indications or discontinuities. Where surface irregularities interfere, surfaces shall be prepared by grinding or machining. ‘The surfaces to be examined and adjacent areas within at least | inch shall be dry and fice of all dirt, grease, lint, scale, welding flux and spatter, oil, or other extraneous material. Suitable and approved cleaning methods that are not detrimental to the material or the part shall be used, NERAL EXAMINATION PRACTICES Examination shall be done by the continuous method. To ensure most effective detection of discontinuities, each area or section of weld shall be examined at least twice, with the second magnetizing operation having lines of flux approximately 90° to the flux lines obtained in the first operation. All examinations shall be conducted with sufficient overlap to ensure 100 percent coverage of all areas subject to examination, ‘The adequacy of any flux field may be verified by the use of a Magnetic Particle Field Indicator as shown on Attachment II. 9.4.1 When using this indicator, a suitable flux or field strength is indicated when a clearly defined line of magnetic particles forms across the copper face of the indicator when the magnetic particles are applied simultaneously with the ‘magnetizing foree, When a clearly defined line of particles is not formed, or is not formed in the desired direction, the magnetizing technique shall be changed or adjusted HSB'Y Global Standards Cove Services95 Lesson 11 ~ Sample Magnetic Particle Procedure ‘Where residual magnetism can interfere with any subsequent processing operation or the part's final usage, demagnetization shall be performed. 9.5.2 A field strength meter (Gaussmeter) shall be used to verify suitable demagnetization. When the meter shows greater than +2 relative unit, the specimen shall be demagnetized again. 10.0 PROD EXAMINATION 10.1 102 103 10.4 10.5 106 Prod tips and the surface on which they are placed shall be thoroughly cleaned. Arc strikes shall be removed by grinding and the ground areas shall be inspected using an AC yoke. Prod examination may be performed using either direct current or half-wave rectified current. Prods shall be positioned on the area under examination, utilizing a prod spacing of not ‘more than 8 inches. Prod spacings of less than 3 inches are to be avoided, due to banding, of the particles around the prods. ‘The magnetizing current to be used shall be as follows: (1) 110-125 amps per inch of prod spacing for material of 3/4 inch and thicker. (2) 100-110 amps per inch of prod spacing for material less than 3/4 inch. ‘To avoid are strikes, prods shall be properly positioned prior to energizing the ‘magnetizing force and the energizing current shall be turned off prior to removing the prods. During the magnetizing operation, the ammeter shall be monitored to ensure that proper current is maintained. 11.0 YOKE EXAMINATION ma This technique shall only be used to detect discontinuities that are open to the surface. Either direct or alternating current may be used. 12.0 COIL EXAMINATION (LONGITUDINAL MAGNETIZATION) 121 12.2 123 Coil examination may be performed using either direct current or half-wave rectified current, When using a coil for magnetic particle examination, the test piece shall be placed near the side of the coil to obtain the strongest possible magnetic flux. ‘The required magnetizing current shall be based upon the length of the part (L) its diameter (D) and the number of turns in the coil, using the following formulae: HsBY Global Standards. ________— j9 Code ServicesComplete Magnetic Particle Inspection Workbook. (1) For parts whose L/D ratio is equal to or greater than 4, the ampere-tumns shall be calculated as follows Ampere-turns TiDy+d Amperage shall be calculated as follows: mpere = Amere=turns Aner Ne oftrs The amperage used shall be within +10 percent of the calculated value for amperage. (2) Forparts with an L/D ratio of less than 4 but not less than 2, the ampere-turns shall be calculated as follows: 45,000 Ampere-turns = £5000 Ps uD Amperage shall be calculated as follows: Ampere-tuns Ampe No.ofturns ‘The amperage used shall be within +10 percent of the calculated value for amperage. (3) For parts whose configuration docs not lend itself to calculating the L/D ratio, adequate magnetizing amperage shall be established by the use of the Magnetic, Particle Field Indicator as described in Attachment II. 12.4 Long parts shall be examined in sections not to exceed 18 inches and “18” shall be used as L in calculating the required field strength of these parts 13.0 DIRECT CONTACT (CIRCULAR MAGNETIZATION) 13.1 Direct or rectified current shall be used by directly contacting the electrode ends to the part being examined by means of pads or attached clamps. 13.2 _ For parts with unusual configurations, the adequacy of the field shall be established by use of a Magnetic Particle Field Indicator as described in Attachment IL. 13.3 For parts with outer diameters up to 10 inches, a magnetizing current of 700 to 900 amps per inch of diameter shall be used, 13.4 For parts with outer diameters over 10 inches, a magnetizing current of 400 to 600 amps per inch of diameter shall be used. 13.5 For parts which are not cylindrical and for which the cross-sectional dimensions can casily be determined, the current values given above shall be based upon the greatest cross-sectional diagonal in a plane at right angles to the current flow. 10 —______ HSB '¥ Global Standards F Code Services14.0 15.0 16.0 i. Lesson 11 ~ Sample Magnetic Particle Procedure : CENTRAL CONDUCTOR TECHNIQUE 141 142 143 44 14.5 ‘Where examination of the intemal surface of hollow cylindrically shaped objects is required, a central conductor induced magnetic field shall be used. The central conductor may be a bar or cable passed through the bore of the cylinder. Where the inside diameter of the test piece is more than five times the diameter of the central conductor, the central conductor shall be placed close to the surface of the test piece and incremental examination shall be made around the inside diameter of the test piece by rotating the test piece around the central conductor. ‘The current to be used shall be based upon the outside diameter of the test piece and shall follow the same established for the Direct Contact method. If multiple-tum central conductor cables are used, the required current will be decreased proportionately to the number of tums of the central conductor cable. The adequacy of the magnetic flux shall be verified by the use of the Magnetic Particle Field Indicator, as described in Attachment Il INTERPRETATION AND EVALUATION 15.1 15.2 153 ‘Mechanical discontinuities at or near the surface will be indicated by the retention of the examination medium, Any indication that is believed to be nonrelevant shall be regarded as a discontinuity and shall be reexamined to verify whether actual defects are present. Surface conditioning, may precede the reexamination. Relevant indications are indications that result from mechanical discontinuities, Linear indications are those indications where the length is more than three times the width, Rounded indications are any indications that are circular or elliptical with the length less than three times the width. EXTENT OF EXAMINATION AND ACCEPTANCE STANDARDS 16.1 Acceptance criteria is as specified in the referenced appendix. Areas Examined Appendix No. A. Welded Edge Preparation 1 B. Welded Surfaces 2 C. Forgings, Castings, Bars and Plate 3 HSB Y Global Standards Code Services, ntComplete Magnetic Particle Inspection Workbook 17.0 18.0 112 POSTEXAMINATION ~ CLEANING AND DEMAGNETIZATION 17.1 Afier examination, all areas on parts, material, and welds shall be thoroughly cleaned of ‘magnetic particle medium. 17.2 Where residual magnetism may interfere with subsequent processing or end usage, demagnetization shall be accomplished by an approved procedure. RECORDS 18.1 A magnetic particle examination test report (Attachment III or equivalent) shall be used to record examination results and kept for a minimum of five years. 18.2 Items found unacceptable shall be HOLD tagged and segregated. 18.3. Acceptable items shall be individually tagged. Tags shall indicate “MT” and assigned @ serial number. 18.4 Asa minimum, the test report shall contain the following: 18.4.1 Areas examined, or part identification. 18.4.2. Inspection procedure identification, revision, and type of examination. 18.4.3 Identification of equipment used; e.g,, serial or tag number. 18.4.4. Type of particle medium used. 18.4.5. Date of examination, examiner, and certification level 18.4.6 Examination results. HSB Y Global Standards Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure ' APPENDIX 1 WELD EDGE PREPARATION ‘The examination shall be confined to the weld edge prep surface. @ &) Only indications with major dimensions greater than 1/16 inch shall be considered relevant. ‘The following relevant indications are unacceptable: (1) any linear indications greater than 1/16 inch long for material less than 5/8 inch thick, greater than 1/8 inch long for material from 5/8 inch thick to under 2 inches thick, and 3/16 inch long for material 2 inches thick and greater (2) rounded indications with dimensions greater than 1/8 inch for thicknesses less than 5/8 inch, and greater than 3/16 inch for thicknesses 5/8 inch and greater (3) four or more indications in a line separated by 1/16 inch or less, edge to edge HSB'Y Global Standards Code Services — 13Complete Magnetic Particle Inspection Workbook APPENDIX 2 WELD SURFACES ‘The weld surface and adjacent base material for at least 1/2 inch on each side of the weld shall be examined. (a) Only indications with major dimensions greater than 1/16 inch shall be considered relevant. (b) The following relevant indications are unacceptable: (1) any cracks or linear indications (2) rounded indications with dimensions greater than 3/16 inch @) Wg CSB Global Standards Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure APPENDIX 3 FORGINGS, CASTING, BARS, AND PLATE MATERIAL (a) Only indications with major dimensions greater than 1/16 inch shall be considered relevant. (6) The following relevant indications are unacceptable: (1) any linear indications greater than 1/16-inch long for material less than 5/8 inch thick, ‘greater than 1/8-inch long for material from 5/8 inch thick to under 2 inches thick, and greater than 3/16 inch-long for material 2 inches thick and greater (2) rounded indications with dimensions greater than 1/8 inch for thickness less than 5/8 inch and greater than 3/16 inch for thicknesses 5/8 inch and greater (3) four or more indications in a line separated by 1/16 inch or less, edge to edge (4) 10 or more rounded indications in any 6 square inches of surface HsB'Y Global Standards. —_______— 45 ~ Code Services — ooComplete Magnetic Particle Inspection Workbook 16 ATTACHMENT I WET PARTICLE SETTLING TEST (Per ASME V, SE-709) The wet particle examination settling test shall be performed prior to initial wet magnetic particle examination and performed on a daily basis thereafter while wet magnetic particle examinations are being performed. ‘The wet particle suspension bath shall be circulated for at least 30 minutes prior to performing the settling test to assure thorough mixing ofall particles that could have settled on the sump screen or along the sides or bottom of the suspension holding tank. After adequate circulation, a 100 ml portion of the suspension bath shall be withdrawn from the hose or nozzle and allowed to settle in a settling tube (ASTM pear-shaped centrifuge tube with graduations, or equivalent) for approximately 30 minutes. ‘The volume settling out at the bottom of the tube is indicative of the particle concentration in the bath. If the bath concentration is low in particle content, a sufficient amount of particle materials shall be added to obtain the desired concentration; if the bath concentration is high in particle content, a sufficient amount of vehicle (liquid) shall be added to obtain the desired concentration. Ifthe settled particles appear as a loose jumbled mass rather than a solid layer, a second sample shall be taken. Ifthe second sample shows a similar condition, the particles are considered to be ‘magnetized and the entire suspension bath shall be discarded and replaced. HSB Global Standards Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure ATTACHMENT II Typical Magnetic Particle Field Indicator, often called a “pie gage.” Eight low carbon stet pie sections Intersections constitute artifical flaws Copper plate cree HSBY Global Standards __ Code ServicesComplete Magnetic Particle Inspection Workbook ATTACHMENT III TYPICAL MAGNETIC PARTICLE REPORT FORM Technique Sheet and Data Report EQUIPMENT MATERIAL Brand Name Brand Name Serial Number Wet Dry Leg Spacing Utilized Batch Number Current amps AC DC Color Type Component Temperature Next Calibration Date EXAMINATION AREA. DESCRIPTION/REMARKS ‘ACCEPT REJECT ‘TECHNIQUE PARAMETERS SKETCH Upper weld EXAMINER, LEVEL DATE REVIEWER LEVEL, DATE APPROVAL, Authorized Inspector DATE ___. HSB'Y Global Standards 118 ‘Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure (This page intentionally left blank) __ HSB'YGlobal Standards — ig Code Services:Complete Magnetic Particle Inspection Workbook Lesson 11 — Sample Magnetic Particle Procedure Quiz 1. An indication formed due to a keyway would be considered nonrelevant. True 0 False 2. Ifthe surface temperature of the part exceeds 130°F, examination shall not be performed in the particle method. 3. A minimum of 100 footcandles (1,000 Ix) visible light intensity must be maintained at the inspection surface. oTme 0 False 4, Equipment used for calibration shall be traceable to 5. Direct current yokes shall be capable of lifting pounds at maximum used pole spacing. 6 Examination shail only be accomplished by the continuous method. aTme o False 7, What is another term for the Magnetic Particle Field Indicator? 8 A _ shall be used to verify suitable demagnetization, 9. How many amps per inch of prod spacing shall be used for material less than 3/4 inch thick? 10. During coil examination, long parts shall be examined in sections not to exceed inches. 11. A central conductor may be a bar or cable. o True 0 False 12, Define a linear indication. 19 —____________ HSB '¥ Global Standards Code ServicesLesson 11 ~ Sample Magnetic Particle Procedure 13, Appendix No. I covers the acceptance criteria for 14, An inspector observes four rounded indications in a line separated by less than 1/16 inch edge to edge. Each indication is 1/16 inch in diameter. Is this condition acceptable to Appendix II? Yes aNo 15, During a settling test, if the second sample shows a similar condition of a loose jumbled mass, the entire bath must be __ 16, Each area must be examined at least twice with the second magnetizing operation having lines of ‘lux approximately ° to the first operation. HSB YG obal Standards Cone Services 121Complete Magnetic Particle Inspection Workbook 10. 12. 13 14, 15, 16, 12 Lesson 11 - Sample Magnetic Particle Procedure QUIZ KEY True wet True national standards 40 True Pier gage field strength meter (Gauss meter) 100-110 18 True Where the length is more than three (3) times the width. weld edge preparation Yes, per paragraph (a) discarded 90 HSB'Y Global Standards Code Services