Mpi Twi PDF

Magnetic Particle Inspection
TWI
Copyright © 2003, TWI Ltd World Centre for Materials Joining Technology
Magnetism
• Some natural materials strongly attract
pieces of iron to themselves.
• Such materials were first discovered in
the ancient Greek city of Magnesia.
• Magnets were utilised in navigation.
• Oersted found a link between electricity
and magnetism.
• Faraday proved that electrical and
magnetic energy could be interchanged.
1
Magnetic Particle Inspection
(MT or MPI)
• MT is a test method for the detection of

surface and near surface defects in
ferromagnetic materials.
• Magnetic field induced in component
• Defects disrupt the magnetic flux
causing “flux leakage”.
• Flux leakage can be detected by
applying ferromagnetic particles
Permeability (µ)
• Permeability can be defined as the

relative ease with which a material may
be magnetised.
• It is defined as the ratio of the flux
density (B) produced within a material
under the influence of an applied field
to the applied field strength (H)
• µ =B/H
2
Permeability (µ)
• On the basis of their permeability

materials can be divided into 3 groups:
• Diamagnetic
• Paramagnetic
• Ferromagnetic
Permeability (µ)
Diamagnetic: Permeability slightly below 1,
weakly repelled by magnets.
Examples: Gold, Copper, Water
• Paramagnetic: Permeability slightly greater than 1,

weakly attracted by magnets.
• Examples: Aluminium, Tungsten
Ferromagnetic: Very high permeability,

strongly attracted by magnets.
Examples: Iron, Cobalt, Nickel
3
Lines of Flux
Lines of flux
• By convention they flow from North to South
outside and South to North inside
• They form closed loops
• They never cross
• They follow path of least resistance
• Flux density is the number of lines of flux passing

through a unit area.
• Field strength is highest where where flux density is
highest.
4
Electromagnetism
• A current flows through a conductor and
sets up a magnetic field around it
• Field is at 90o to the direction of the
electrical current
Direction
of current
flow
Direction of magnetic field

Right Hand Rule
5
Coil Magnetisation
• Changes circular field into longitudinal

• Increases the strength of the field
Hysteresis
Place an un-magnetised piece of
ferromagnetic material within a coil
Saturation point
B+
Virgin curve
H- H+
B-
6
Hysteresis
B+
Residual magnetism
H- H+
B-
Hysteresis
B+
H- H+
Coercive force
B-
7
Hysteresis
B+
H- H+
Negative saturation
point
B-
Hysteresis
A
B
C F
E
D
8
Hysteresis
Hard ferromagnetic Soft ferromagnetic
Permeability (µ)
• The ease with which a material can be

magnetised
• Opposite of reluctance (difficulty with
which a material can be magnetised)
• µ=B/H
• Permeability of free space = µo
• Relative Permeability (µr) = µ / µo
9
Relative Permeability (µr)
• Paramagnetics Slightly > 1
• Diamagnetics Slightly < 1
• Ferromagnetics 240 +
Hard v Soft Ferromagnetics
Soft Hard
• Typically Low carbon
steel
• Typically high carbon
• High permeability
steel
• Easy to magnetise
• Lower permeability
• Low residual
• More difficult to
magnetism
magnetise
• High levels of
residual magnetism
10
Definitions
• Magnetic field Region in which
magnetic forces exist
Flux Total number of lines

existing in a magnetic
circuit
Flux Density Magnetic flux per unit

area (measured in
Tesla)
Tesla)
Principle of MPI : Flux

Leakage
No Defect Defect
N S N S
Lines of flux follow the path of least resistance

11
LEAKAGE FIELDS
Visibility of Flux Leakage
Depends on:
• Depth of defect
• Orientation of defect shape of defect
• Size of defect
• Permeability of material
• Applied Field Strength
• Contrast
12
Indications
Relevant Indications - Indications due

to discontinuities or flaws
Non-Relevant Indications - Indications

due to flux leakage from design features
Spurious Indications - Indications due

incorrect inspection procedures
Defect Orientation
Defect at 90 degrees to flux : maximum

indication
13
Defect Orientation
>30 Degrees to Flux: Acceptable

indication
Defect Orientation
<30 Degrees to Flux : Weak

indication
14
Defect Orientation
Test 1 Test 2
MPI requires 2 tests at 90o to one another

Equipment
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Permanent Magnet
Longitudinal field between poles

Maximum sensitivity for defects orientated at
90º to a line drawn between poles
Permanent Magnet
Advantages Disadvantages
• No power supply • Direct field only
• No electrical contact • Deteriorate over time
problems • No control over field
• Inexpensive strength
• No damage to test • Poles attract detecting
piece media
• Lightweight • Tiring to use
16
Electromagnetism
• A current flows through a conductor and
sets up a magnetic field around it
• Field is at 90o to the direction of the
electrical current
Direction
of current
flow
Direction of magnetic field

Coil Magnetisation

17
Electromagnets
Maximum sensitivity for defects orientated at 90º
to a line drawn between the poles
Electromagnets
• AC,DC or rectified • Power supply required
• Controllable field • Longitudinal field only
strength • Electrical hazard
• No harm to test piece • Poles attract particles
• Can be used to • Legs must have area
demagnetise contact
• Easily removed
18
Current Flow
Current passed through sample
Defects
Current
Circular
Field
PROD METHOD
19
Threading Bar
• Current passed through brass bar
placed between heads of bench unit
• Circular field generated around bar
• Sample hung from bar
Magnetic Flow
Magnetism passed through sample
Defects
Magnetism
20
Coil Magnetisation

Rigid Coil
Current passed through coil to generate a
longitudinal field Defects
Magnetism
21
MPI Equipment
Portable Fixed
• Permanent magnet Current flow
• Electromagnet Magnetic flow
Threader Bar
• Prods Rigid coil
• Flexible coil Induced current
• Flexible cable
• Clamps and leeches
Current Types
• Direct current (DC)
• Alternating current (AC)
• Half wave rectified current (HWDC or

HWRAC)
• Full wave rectified (FWDC or FWRAC)
22
Direct Current
+
-
Disadvantages
Advantages • No agitation
• Sub-
Sub-surface defects • Less sensitive to
• Availability from surface defects
batteries
Alternating Current
• Availability • Will not detect
• Sensitivity to surface defects sub-
sub-surface
defects
• Agitation of particles
• Demagnetisation
23
Half Wave Rectified Current
• Penetration like DC • Sensitivity to surface
• Agitation defects lower than
• Ease of production AC
• High flux density for less
power
Full Wave Rectified Current
• Penetration like DC • Sensitivity to surface
• Agitation defects lower than
AC
24
3 - PHASE FW RECTIFIED
Direct Current: Field distribution
25
A.C. : Field distribution
SKIN EFFECT
SKIN EFFECT
In order to achieve the same

sensitivity to shallow defects
a DC field must be far more
powerful than a
corresponding
AC field
26
Permanent Magnet and DC Electromagnet
Use the Lift Test

For pole spacing from 75 to 150mm - 18 kg
AC Electromagnets
Use the Lift Test
For pole spacing no more than 300mm - 4.5kg
27
Current Flow
Current passed through sample, typically:
•7.5 Amps / mm diameter
or
• 2.4 Amps / mm perimeter
•For L/D = 1.5 or less, one shot only req’
req’d
Defects
Current
Circular
Field
PROD METHOD
Current passed through
sample, typically:
5 Amps (rms) per mm

of prod spacing
28
Threading Bar
• R (mm) = I / 15 for General
engineering
• R (mm) = I / 56 for aerospace
Increase the current (I) to

increase R, the radius of
R the test zone.
R=I/15 is equivalent to
7.5A per mm of diameter.
R R=I/56 is equivalent to 28A
per mm of diameter.
Threading Bar
Component placed within field and rotated for

complete coverage
29
Magnetic Flow
Magnetism passed through sample
Defects
Magnetism
Field strength can be assessed using a “flux indicator”.

Rigid Coil
K K
NI = I=
L/ D L / D× N
• N = Number of turns in coil
• K = 32,000 for DC (typical)
22,000 for AC or FWR (typical)
11,000 for HWR (typical)
• L/D = Length / Diameter
30
Rigid Coil Conditions
• Cross section of test piece <10% of Coil

(the fill factor)
• Test piece must lie against side or
bottom
• The test zone is the part of the
component which lies within the coil
• L / D must be between 5 and 20
FLUX INDICATORS
Check for adequate flux
density and correct
orientation with Flux
Indicators.
(Do not use with permanent
magnets or DC electromagnets.)
31
ASME V MAGNETIC FLUX INDICATOR
CONSISTS OF 8 STEEL
PIE SEGMENTS
BRAZED TOGETHER
WITH COPPER
FACEPLATE
ASME V MAGNETIC FLUX INDICATOR
32
FLUX INDICATORS - COMMON TYPES
• ASME
• BERTHOLD PENETRAMETER
• BURMAH CASTROL STRIPS
Detecting Media
33
Dry Magnetic Particles
• Iron powder or magnetic iron oxide (magnetite).
• 5 - 200 microns, rounded and elongated shapes
• Colours vary for contrast against component
• Can be used on hot surfaces
• Poor particle mobility, HWDC best, DC or permanent
magnets must never be used
• Greater operator skill required
• Difficult to apply to overhead surfaces especially in
field conditions
• Generally less sensitive than wet particles
Wet Magnetic Particles
Magnetic iron oxide (magnetite) or iron powder

0.1 - 100 microns rounded and elongated shapes
Colour contrast or fluorescent
Water or kerosene based
Concentration important
Good particle mobility
Easier to use
More sensitive
34
Demagnetisation
Demagnetisation
Removal of residual magnetisation
Required for:
• Aircraft parts
• Rotating parts
• Components to be welded,machined or
electroplated
Check for removal with Field strength

meter (magnetometer)
35
How to Demagnetise?
• A constantly reversing and reducing
magnetic field
Flux
Methods of Demagnetisation
• Aperture type coil reversing stepped DC

• Aperture type coil reducing AC
• AC or reversing DC aperture type coil,
withdraw component along the coil axis
• AC electromagnet
• Heating to above the Curie point (about
770°C for steel)
36
MPI Practices
Test Methods
• Continuous or Residual
• Fluorescent or Visible
• Wet or Dry
37
Continuous or Residual?
Continuous Method
• Detecting media applied immediately
prior to & during magnetisation.
Residual
• Detecting media used after the applied
field has been removed.
• Requires high retentivity.
• Less sensitive than continuous.
• Useful for components like ball bearings
Fluorescent or Visible?
Fluorescent Visible
Detecting media No special lighting
dye coated required
More sensitive Higher
Less tiring for concentration of
operators particles
Better for batch Background paint
inspections may be required
38
NB All surface defects form indications
But not all indications are caused by defects
Relevant indications…Linear 3:1
Non-
Non-relevant indications Spurious indications
Due to flux leakage but Not due to flux
arising from design leakage
features • Lint
Changes in section
Changes in permeability • Scale
Grain boundaries • Dirt
Forging flow lines • Hairs
• Magnetic writing
Control and Maintenance Checks

To ensure equipment,ancillaries and
materials are up to standard
• Ink
• Lighting conditions
• Magnetising units
39
• Ink settlement 100 ml
100
4.0
3.0
1.0 ml
2.0
1.0
0.5
0.5 ml
Ink Settlement Test

Fluorescent Ink
• 0.1 - 0.3 %
Non-Fluorescent Ink
• 1.25 - 3.5 %
40
• Ink settlement
• Fluorescent ink check
• Equipment performance check
Equipment Performance Checks
• Current flow test piece

• Magnetic flow test piece
• Cracked component
41
42
• Ink settlement
• Fluorescent ink check
• Equipment performance check
• Viewing efficiency
• Magnetising unit
• Unit tank levels
• Unit ammeters
• Demagnetiser
Control Check Frequency

• Settlement test Daily
• Fluorescent intensity Weekly
• Test piece Daily
• Viewing efficiency Monthly
43
Maintenance Check Frequency
• Magnetising units Weekly
• Tank levels Daily
• UV lamp Monthly
• Ammeters 6 monthly
• Demagnetiser 6 monthly
UV(A)
44
Electromagnetic Spectrum
X-rays &
Gamma
Electric
Microwaves Waves
Ultra Infra
violet red TV
Light
10-10 10-8 10-6 10-4 10-2 1cm 102 104 106 108
Wavelength
Electromagnetic Spectrum
A Damaged
UV-C UV-B UV-A
Black Light
UV-B&C
10 100 200 300 400 500

500 600 700
ULTRAVIOLET VISIBLE
LIGHT LIGHT
45
Fluorescence
UV-A Source : Mercury vapour arc

lamp
+
Filter
Precautions
• Avoid looking directly at the lamp
• Do not use if filter is cracked,
damaged or incorrectly fitted
Fluorescence and the Electromagnetic

Spectrum
Absorbs Emits
10 100 200 300 400 500

500 600 700
ULTRAVIOLET VISIBLE
LIGHT LIGHT
46
Fluorescent v Colour Contrast
• Fluorescent methods are more sensitive.
• Less operator fatigue with fluorescent.
• Background lacquer is not required.
• Fluorescent properties will degrade if exposed to UV
light, acids, alkalis or high temperature.
• Background fluorescence is a problem on rough
surfaces.
• Some oils will produce strong background
fluorescence.
• Low background light levels are required.
Fluorescent v Colour Contrast

Black Particles Fluorescent Particles
47

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Magnetic Particle Inspection

• MT is a test method for the detection of

• Permeability can be defined as the

• On the basis of their permeability

• Paramagnetic: Permeability slightly greater than 1,

Ferromagnetic: Very high permeability,

• Flux density is the number of lines of flux passing

Direction of magnetic field

Right Hand Rule

• Changes circular field into longitudinal

• The ease with which a material can be

• Permeability of free space = µo

• Relative Permeability (µr) = µ / µo

• Paramagnetics Slightly > 1

• Diamagnetics Slightly < 1

Hard v Soft Ferromagnetics

Flux Total number of lines

Flux Density Magnetic flux per unit

Principle of MPI : Flux

Lines of flux follow the path of least resistance

Visibility of Flux Leakage

Relevant Indications - Indications due

Non-Relevant Indications - Indications

Spurious Indications - Indications due

Defect at 90 degrees to flux : maximum

>30 Degrees to Flux: Acceptable

<30 Degrees to Flux : Weak

MPI requires 2 tests at 90o to one another

Longitudinal field between poles

Direction of magnetic field

• Changes circular field into longitudinal

• Changes circular field into longitudinal

• Direct current (DC)

• Alternating current (AC)

• Half wave rectified current (HWDC or

• Full wave rectified (FWDC or FWRAC)

Full Wave Rectified Current

Direct Current: Field distribution

In order to achieve the same

Use the Lift Test

5 Amps (rms) per mm

Increase the current (I) to

Component placed within field and rotated for

Field strength can be assessed using a “flux indicator”.

• Cross section of test piece <10% of Coil

ASME V MAGNETIC FLUX INDICATOR

• BURMAH CASTROL STRIPS

Wet Magnetic Particles

Magnetic iron oxide (magnetite) or iron powder

Check for removal with Field strength

• Aperture type coil reversing stepped DC

Control and Maintenance Checks

Ink Settlement Test

Equipment Performance Checks

• Current flow test piece

Equipment Performance Checks

Control Check Frequency

10 100 200 300 400 500

UV-A Source : Mercury vapour arc

Fluorescence and the Electromagnetic

10 100 200 300 400 500

Fluorescent v Colour Contrast

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