AEROSPACE AMS-I-83387™ REV.

MATERIAL SPECIFICATION Issued 1 999-06

Reaffirmed 2007-02
Revised 2009-07
Stabilized 201 6-01
Superseding AMS-I-83387A

Inspection Process, Magnetic Rubber

RATIONALE

AMS-I-83387B stabilizes this document because it represents mature technology which is not expected to change and
thus no further revisions are anticipated.

STABILIZED NOTICE

AMS-I-83387B has been declared “STABILIZED” by AMS K Non Destructive Methods and Processes Committee. This
document will no longer be updated and may no longer represent standard industry practice. This document was stabilized
because it contains mature technology that is not expected to change and thus no further revisions are anticipated.
Previously this document was revised. The last technical update of this document occurred in September, 2009. Users of
this document should refer to the cognizant engineering organization for disposition of any issues with reports/certifications
to this specification, including exceptions listed on the certification.

__________________________________________________________________________________________________________________________________________
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entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.”
SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and
suggestions.
Copyright © 201 6 SAE International
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1. SCOPE

1 .1 Form

This specification covers both the material and the examination process of an inspection material in the form of a
dispersion of magnetic particles in a controlled viscosity rubber base that cu res at room temperature by ad dition of one or
more curing agents. The test object is magnetized with the uncured rubber covering the area of interest. The magnetic
particles then migrate to the leakage field caused by the discontinu ity. As the rubber cu res, discontinuity indications
remain in place on the ru bber. The product may be supplied in a variety of viscosities and colors.

1 .2 Application

M agnetic Rubber I nspection is a nondestructive inspection technique u sed for d etecting cracks or flaws on or near the
surface of ferromagnetic materials. I ts principal applications are in certain problem areas, such as: Areas having limited
visual or mechanical accessibility; Coated su rfaces; Complex shapes or poor su rface conditions; and, I nspection for
defects that require magnification for detection and interpretation.

1 .3 Safety-H azardou s M aterials:

While the materials, methods, applications, and processes described or referenced in this specification may or may not
involve the use of hazard ous materials, this specification does not address the hazards which may be involved in such
use. I t is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials
and to take necessary precautionary measures to ensu re the health and safety of all personnel involved .

2. APPLI CABLE DOCU MEN TS

The issue of the following documents in effect on the date of the pu rchase order forms a part of this specification to the
extent specified herein. The supplier may work to a su bsequent revision of a document unless a specific d ocu ment issu e
is specified . When the referenced d ocu ment has been cancelled and no supersed ing d ocument has been specified , the
last pu blished issue of that docu ment shall apply.
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2. 1 SAE Publications

Available from SAE I nternational, 400 Commonwealth Drive, Warrend ale, PA 1 5096-0001 , Tel: 877-606-7323 (insid e
U SA and Canad a) or 724-776-4970 (outsid e U SA), www. sae. org.

AM S2825 M aterial Safety Data Sheets

AMS31 67B Solvents, Wipe for Cleaning Prior to Application of Primer and Top Coat Materials, or Sealing
Compou nds
AM S2644 I nspection M aterial, Penetrant

2. 2 ASTM Publications

Available from ASTM , 1 00 Barr H arbor Drive, West Coshohocton, PA 1 9428-2949, Tel: 61 0-832-9585, www. astm. org.

ASTM D 21 96 Rheological Properties of N on-N ewtonian Materials by Rotational (Brookfield) Viscometer

ASTM E 1 444 M agnetic Particle Testing

2. 3 ASN T Pu blications

Available from ASN T, P. O. Box 2851 8, 1 71 1 Arlingate Lane, Colu mbus, OH 43228-051 8, Tel: 800-222-2768 (inside U SA
and Canada) or 61 4-274-6003 (outside U SA), www. asnt. org

SN T-TC-1 A Personnel Qualification and Certification in N ond estructive Testing

AN SI /ASN T Standard CP-1 89 Qualification and Certification of N ondestructive Testing Personnel

2. 4 U . S. Government Publications

Available from the Document Automation and Production Service (DAPS), Building 4/D, 700 Robbins Avenue,
Philadelphia, PA 1 91 1 1 -5094, Tel: 21 5-697-6257, http: //assist. daps. dla. mil/quicksearch/.

M I L-H DBK-6870A I nspection Program Requirements, N on Destru ctive for Aircraft and M issile M aterials and Parts
A-A-59281 A Cleaning Compound, Solvent Mixtu res

2. 5 N AS Publications

Available from Aerospace I ndustries Association of America, I nc. , 1 000 Wilson Boulevard, Suite 1 700, Arlington, VA
22209-3928, Tel: 703-358-1 000, www. aia-aerospace. org.

N AS 41 0 N AS Certification and Qu alificati on of N ond estructive Test Personnel

3. REQU I REM EN TS

3. 1 Materials

When specified on the engineering d rawing, contract, or purchase order, this specification applies to the inspection of
ferromagnetic materials and ferromagnetic materials which have been plated with electrolytic or electro-less platings,
painted, flame spray coated, or covered with other coatings. (Material performance expectations thru coatings shall be
verified by u se of representative reference parts in accordance with ASTM E 1 444). The material shall be a liq uid room-
temperature vulcanizing rubber filled with magnetic particles. After stirring or shaking, the operator shall visu ally observe
the product to ensure a u niform color and a uniform blend free of skins, lu mps and gels or coarse particles There shall be
no separation of ingredients which cannot be read ily re-dispersed. When components are mixed , a smooth uniform
consistency shall resu lt.
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3. 2 Properties

The product shall conform to the following requ irements; tests shall be performed on the product su pplied and in
accordance with specified test procedures:

3. 2. 1 Viscosity

The viscosity of the uncatalyzed product shall be +/- 1 0% of the valu e reported by the manu facturer, determined in
accordance with ASTM D 21 96 at 25 degrees C (77 d egrees F).

3. 2. 2 Cu re Times

The cu re time of the prod uct, following addition of curing agents, shall be +/- 50% of the valu e reported by the
manufacturer, determined in accord ance with 4. 4. 1 .

3. 2. 3 U nd ispersed Particle Size

After mixing and curing the product, there shall be no u ndispersed particle larger than 0. 005 in. (0. 1 3 mm), determined in
accordance with 4. 4. 2.

3. 2. 4 Magnetic Response

The product shall exhibit satisfactory magnetic response, determined in accordance with 4. 4. 3.

3. 3 Equipment

Equipment other than that specified herein may be used, subject to approval of the procuring activity.

3. 4 Magnetizing Apparatu s

Any u se of the stationary magnetic inspection eq uipment shall conform to the requirements of ASTM E 1 444. The
eq uipment shall be maintained in a manner to insu re uniform, controlled inspection operations. All portable permanent
and AC-DC electromagnets shall be capable of reliably providing uniform, controlled magnetic field strengths as requ ired
in the testing of each part. Each magnetizing apparatu s shall be capable of ind ucing in the piece und er inspection a
magnetic flux of suitable intensity in the desired direction.

3. 5 M icroscope

Replica viewing equipment shall consist of a microscope or lens capable of a minimum of 7X magnification, used in
conjunction with a high intensity lamp for replica illumination.

3. 6 Gauss M eter

A portable Gau ss M eter capable of measu ring accurately values up to 1 000 Gauss shall be used to determine proper field
strength in holes and on su rfaces to be inspected. The device shall be equipped with both transverse and axial probes.
Dial or similar type meters of suitable range may be used if capable of providing transverse and axial measu rements.

4. QU ALI TY ASSU RAN CE PROVI SI ON S

4. 1 Responsibility for I nspection

U nless otherwise specified in the contract or purchase order, the supplier is responsible for the performance of all
inspection requ irements as specified herein. Except as otherwise specified in the contract or ord er, the supplier may use
his own or any other facilities suitable for the performance of the inspection req uirements specified herein. The u ser
reserves the right to perform any of the inspections set forth in the specification where such inspections are deemed
necessary to assure supplies and services conform to prescribed requ irements.
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4. 2 Classification of Tests

Tests for all technical requirements are acceptance tests and shall be performed on each lot.

4. 3 Sampling and Testing

Sufficient product shall be selected at random from each lot to perform all required tests.

4. 3. 1 A lot shall be all produ ct produced in a single prod uction run from the same batches of raw material, under the
same fixed conditions, and presented for vend or’s inspection at one time.

4. 4 Test Methods

4. 4. 1 Cure Time

Tran sfer 20 g ram s of fresh l y m i xed m ateri al to a su i tabl e con tai n er an d stabi l i ze at 25 d eg rees C +/- 3 (77 d eg rees F
+/- 5). Ad d curing agents in accordance with (Table 1 ) instructions. Stir thoroughly using a wood en tongue depressor or
any suitable nonferrou s stirrer and pou r into a 38 mm nonferrous di sh. Cu re time is measured starting at the time of the
ad dition of cu ring agents and ending when both top and bottom surfaces of the material are tack free.

4. 4. 2 U n-dispersed Particle Size

The lower surface of the cured material (See 4. 4. 1 ) shall be viewed u nder 1 0 to 1 00X magnification. The size of un-
dispersed particles shall be measu red with a calibrated eye piece micrometer. There shall be no observed particle size in
the cu red replica larger than 0. 005 in. (0. 1 3mm).

4. 4. 3 M agnetic Response

Prepare a magnetic discontinuity as follows:

4. 4. 3. 1 Cut a piece of 0. 025 mm +/- 0. 003 thick nickel foil into a 1 3 by 1 3 mm square. Place the nickel foil in the center
of a 38 by 38 mm piece of 0. 05 mm +/- 0. 005 thick aluminum foil and cover the entire surface of the aluminu m
foil with 0. 025 mm +/- 0. 003 thick mylar tape (See Figure 1 ). Place the prepared foil in the center of a 76 mm
+/-8 by 1 52 mm +/-1 5 sheet of 0. 625 mm +/- 0. 06 thick aluminum sheet with the nickel foil side u p. Tape down
with 0. 025 mm +/- 0. 0003 thick mylar tape, covering the entire surface of the alu minum sheet (See Figure 2).

4. 4. 3. 2 Place the standard discontinu ity on a DC electromagnet yoke so that the position of the nickel foil is mid way
between the poles. Ad just the magnetic field intensity at the position of the nickel foil to 1 00 gauss +/-5 (0. 01 T
+/- 0. 0001 ). Place nonferrou s cup reservoir over the nickel foil and seal with putty (See Figu re 3).

4. 4. 3. 3 Prepare 20 grams of freshly mixed material and add curing agents in accordance with Table 1 instructions.
N ote exact time of addition of curing agents. At exactly 30 second s before the expiration of the pot life
(Table 1 ) with the magnet “on”, pou r the mixture into the reservoir. After a 30-second interval, turn the magnet
“off” and allow the material to cure. Following cure, remove the casting and examine u nder a microscope at 7
to 1 0X magnification. The detection of two dark lines (corresponding to the two ed ges of the nickel foil lying
perpend icular to the magnetic lines of force) indicates satisfactory magnetic response (See Figure 4). Alternate
methods of determining proper field strength, magnetic response, are found in ASTM E-1 444-05, Tool Steel
Ring Specimens for System Performance Test, AS5371 Stand ard N otched Shims or Flexible Laminated Strips.

4. 4. 3. 3. 1 The purpose of the delay between ad dition of cu ring agents and magnetization is to measu re the magnetic
response of the material near the expiration of pot life.
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FI GU RE 1 – PREPARATI ON OF MAGN ETI C DI SCON TI N U I TY – STEP 1

(Taping N ickel Foil to Aluminum Foil)
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FIGURE 2 – PREPARATION OF MAGNETIC DISCONTINUITY – STEP 2

(Taping Foil Assembly to Aluminum Sheet)
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FIGURE 3 – MAGNETIZING MAGNETIC DISCONTINUITY

FIGURE 4 – VIEW OF MAGNETIC RUBBER CASTING SHOWNG EDGES OF NICKEL FOIL

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4. 5 Docu mentation

The engineering specification defines the inspection method , acceptance criteria inclu ding defect type and acceptable
density and distribution, and specific area or areas requiring inspection. Ad ditional applicable d ocuments shall also show:

a. Method of magnetization includ ing fl ux direction and field strength required. (See section 6. 2 ASTM E-1 444)

b. Acceptance Criteria: Disposition of parts, or of product containing indi cations, shall be in accordance with
purchaser’s specified inspection stand ards or, if inspection standards have not been submitted by purchaser, by
purchaser’s authorized personnel.

4. 6 4M anufacturing Processes

When manu factu ring processes are involved which may in any way adversely affect the quality of the material or part,
such as forging, heat treating, plating, cold forming, weld ing, and grind ing, inspection shall be performed su bsequent to
su ch processes. When certain processes are involved which may in any way interfere with this inspection, su ch as heavy
deposits of chrome or nickel electroplating, the inspection shall be performed prior to and after such operations.

4. 7 Record of I nspection

The results of the magnetic rubber inspection shall be appropriately recorded. All recorded results shall be identified,
filed, and made available upon request by the procuring activity.

4. 8 Qualification of I nspection Personnel

M agnetic rubber inspection personnel shall be qualified in accord ance with N AS 41 0, ASN T Recommended Practice N o.
SN T-TC-I A, AN SI /ASN T CP-1 89, or as requ ired by purchaser. Personnel initially establishing proced ures or training
other personnel shall be q ualified to a Level I I I . Personnel examining magnetic rubber replicas for defect indications and
making accept/reject decisions shall be qualified to at l east a Level I I . Personnel performing the processing steps
described in this specification shall be qualified to at least a Level I .

4. 9 Re-sampling and Retesting

I f any sample used in the above tests fails to meet the specified requirements, disposition of the product may be based on
the results of testing three additional samples for each original nonconforming sample. Failure of any retest sample to
meet the specified req uirements shall be cause for rejection of the produ ct represented . Results of all tests shall be
reported.

5. PREPARATI ON OF PARTS FOR I N SPECTI ON

5. 1 Cleaning Before Test

The su rface of all materials and parts shall be free from grease, dirt, sealant, or other matter which might interfere with the
proper distribu tion and concentration of the magnetic particles within the poured rubber. Cleaning shall be performed
using a stiff brush, cheese cloth, and a environmentally compliant solvent which does not damage the material under test.
An air jet shall be u sed to remove loose lint. Removal of fl ame sprayed metal coatings, electroplate, or paint is usually
unnecessary, however, removal of these coatings shou ld be executed when maximum defect sensitivity is requ ired.
N OTE: I f Release Agent is used on inspecti on surface it must be N ON SI LI CON E BASED.

5. 2 Taping and Damming

Tape, putty, plugs and other suitable means may be used to form d ams or encapsulations that will provide for a reservoir
of ru bber to remain in intimate contact with the su rface to be inspected. Depending on geometry and orientation of the
inspection area, allowances may need to be made to allow entrapped air to escape to prevent voids from occurring in the
replica. M aterials used must not contain any constituents that may be harmful to the substrate inspected. Following
examples of method s may be used:
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5. 2. 1 H orizontal H oles

Adhesive tape shall be placed on one sid e of the hole, and a pinhole punched in the tape near the uppermost edge of the
hole for the release of entrapped air upon pouring of the ru bber. An aluminum foil (. 003 inch minimum thickness) cup,
shall be formed and u sed to guide and contain the liquid rubber on the opposite sid e of the hole. The dam may be held in
place with waterproof putty and tape.

5. 2. 2 Flat Surface

5. 2. 2. 1 N on-inverted (U pward Facing)

Putty dams for these types of surfaces may be used for preventing run-off or over-flow of the liq uid rubber test material.

5. 2. 2. 2 I nverted (Downward Facing)

When requ ired, “upside-d own” surfaces shall be inspected with magnetic rubber by forming a putty reservoir beneath the
test area to be inspected and pressu re filling with liqu id rubber. Entrapped air shall be allowed to escape by placing a
small vent hole in the rubber next to the inspection surface.

6. PREPARATI ON OF M AGN ETI C RU BBER

6. 1 M agnetic Rubber Base M aterial

N OTE: This inspection has been prepared based on the proced ures requ ired for use of M R-502, M R-502K and M R-
502Y, magnetic rubber base materials manufactured by the Dynamold Corporation, Fort Worth, Texas. The M R-
502, M R-502K and M R-502Y formulas are proprietary and at the time of writing of this specification, no alternate
formu las exist.

6. 2 Proper Formula Selection

Selection of the proper magnetic rubber formu la for a particular application shall be based on considerations of part
geometry, the magnetic field strength to be applied and the time available for the test. M R-502 is the more viscou s and
slower curing of the three formulations, and provides medium sensitivity. M R-502K has the lowest viscosity and is the
most sensitive. MR-502Y is the identical formula as that of MR-502K, but has a synthetic yellow coloring agent add ed to
the formula. The yellow color background highlights indications, making discontinuities more noticeable to the inspector
reading the replica, thereby improving the probability of detection of very small discontinuities.

6. 3 Mixing and M easu rement Proced ures

6. 3. 1 Shaking

The magnetic rubber base material must be thorou ghly mixed, prior to use, by means of a mechanical shaker.

6. 3. 2 Stirring

Subsequent to shaking, the container of rubber shou ld be opened and the contents stirred thoroughly, inclu ding bottom of
container, with a clean wooden tongu e depressor or spatula until the base material contains no streaks or color variations.
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6. 3. 3 M easurement of Base M aterial

The base material may be either weighed or measured volu metrically; the following equality holds:

1 gram of base material = 1 cubic centimeter (cc) of base material

The proper proportions of base material and catalyst are obtained from Table 1 .

TABLE 1 - M AGN ETI C RU BBER I N SPECTI ON FORM U LA AN D APPLI CATI ON S (1 )

T-1 2 Catalyst (2), T-9 Catalyst (3), Cure Stabilizer, Pot Life, Cure time,
d rops drops d rops minu tes minu tes
Formula for H igh Viscosity, 50 Pas (500 cP) M R-502
1 5 (4) 0 2 8 60
5 0 2 15 1 20
2 0 2 30 240
Formula for Mediu m Viscosity, 1 0. 5 Pas (1 05 cP) M R-502Y
2 2 0 5 1 5-20
3 3 0 3 1 0-1 5
4 4 0 2 5-1 0
1 5 (5) 0 2 1 0 (5) 75 (5)
Formula for Low Viscosity, 1 0 Pas (1 00 cP) M R-502K
1 1 0 5 1 5-20
2 2 0 3 10
1 5 (5) 0 2 1 0 (5) 75 (5)
(1 )—Starting with 1 0 ml (1 0cc) of rubber base
(2) Dibutyl Tin Dilaurate
(3) Stannous Octoate
(4) Do not use more catalyst than indicated for 1 hr. cure. U se only this catalyst system
(5) Very sensitive formula for long pot life

FOOTN OTES TO TABLE 1 :

N ote 1 When using volumetric measu rement, substitute milliliters or cu bic centimeters for grams.

N ote 2 Pot life is the maximum time allowable between addition of catalyst and completion of magnetization.

N ote 3 Cu re time is affected by temperatu re and contamination of the catalyst. When a particu lar batch of base u sed
with a particular batch of catalyst exhibits too fast or too slow curing, the catalyst mix ratio may be adjusted
accordingly. Trial batches shou ld be catalyzed prior to inspection to determine the mixing ratio to obtain the
d esired cure time.
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6. 3. 4 Catalyzing

As specified in Table 1 , the applicable catalyst is ad ded to the measured batch of base material to begin the curing of the
rubber. The resulting mixture mu st then be stirred for 1 5 to 30 second s to assu re a uniform distribution of the catalyst
within the rubber.

6. 3. 5 Pouring

Apply the catalyzed ru bber to the part area to be inspected by pouring or use of a syringe. Do not apply more material
than can be magnetized within its pot life.

7. APPLI CATI ON OF M AGN ETI SM

7. 1 Permanent M agnets

U se of permanent magnets requ ires that they be left in place on the part during the active pot life of the formula. As
permanent magnets provide limited field strength the slower curing formulas are usually required to insure maximu m
migration of magnetic particles during the active pot life. Other formulas such as MR-502K and MR-502Y may be used if
the minimum Gauss requirements for the application are met with permanent magnets. Several permanent magnets may
be grouped together to increase field strength only if the polarity of the pole pieces does not cancel their effective field.

7. 2 Portable Electromagnets

M agnetic rubber inspection methods requ ire comparable magnetizing systems to that of dry or wet magnetic particle
inspections. This system may includ e yoke, prod s, clamps, coils or central cond uctors with alternating or d irect current.
The direct cu rrent yoke is the preferred magnetizing method. I f auxiliary pole pieces are requ ired do to part configuration,
they shall be selected so as to produce a minimum reduction of pole cross section.

7. 3 Stationary Magnetization Equipment

Large, stationary magnetic particle inspection stations may be used when parts to be tested are large or can be more
effectively magnetized.

7. 4 Grou nding

The power supply of any electromagnet used shall be grou nded to the test part prior to inspection to insu re that electrical
arcs are not produced between the part and the pole pieces of the electromagnet.

7. 5 Field Strength and Direction

Field strength will be measured, prior to application of the rubber, with a Gau ss Meter. U nless critical flaw area is known,
each area tested shall be magnetized in at least two d irections, 90 degrees apart. A minimum of 30 second s shall be
allowed before magnetization in the second direction is performed. I n all cases, precautions will be taken so as to insure
that the magnetic lines of force run approximately perpend icular to the anticipated direction of cracks. Field strength and
duration shall be as shown in Table 2. Variations to the values shown in Table 2 may be requ ired for specific
applications.
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TABLE 2 - MAGN ETI C FI ELD STREN GTH AN D DU RATI ON RECOM M EN DATI ON S FOR
VARI OU S I N SPECTI ON APPLI CATI ON S
I N SPECTI ON AREA M RI BASE M ATERI AL FI ELD STREN GTH M AGN ETI ZI N G
(GAU SS DU RATI ON , EACH
DI RECTI ON
H OLE (BARE) MR-502 50-1 00 30 seconds
M R-502K 30-50 30 seconds
M R-502Y 30-50 30 seconds
SU RFACE (BARE) M R-502 1 50 1 minu te
1 00 3 minu tes
50 1 0 minutes
M R-502K 1 00 30 seconds
50 1 minu te
30 2 minu tes
M R-502Y 1 00 30 seconds
50 1 minu te
30 2 minu tes
COATED H OLES AN D Extend M agnetization
SU RFACES d uration from the times
listed above depending on
coating thickness.

8. I DEN TI FI CATI ON OF REPLI CAS

8. 1 M ethod s

All magnetic rubber replicas should be id entified d uring or after curing. I d entification may be accomplished using (1 )
treated paper, (2) alu minum foil impression, or (3) other means that provide permanent, easily read id entification.

9. CU RE PERI OD

9. 1 Movement

Du ring cu re of the rubber replicas, movement of the rubber inspection material must be avoided. Any movement of the
part being inspected mu st be accomplished very carefully.

9. 2 Removal

When removing replicas from holes, a pu sh rod, dowel, or compressed air shall be used to facilitate extraction and to
minimize tearing of the rubber. Add itional cure time must be allowed if the rubber continu es to stick to the part. I f the
inspection area of the replica becomes d amaged, the inspection must be repeated.

1 0. REPLI CA I N TERPRETATI ON

1 0. 1 Visual and M icroscopic

The overall su rface area of a replica shou ld initially be examined visually with no magnification in ord er to detect any
gross d efect indications. The replica(s) shall then be examined under strong illumination with a microscope having a
minimum of 7X magnification. All indications of cracks or flaws on the replica shall be noted and recorded .

1 0. 2 Replica Quality

Where the inspector is in doubt regard i ng the validity of an indication in the rubber, he shall re-cast the replica.
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1 1 . POST I N SPECTI ON PROCEDU RES

1 1 .1 Replica Storage

Replicas, when stored for a long period, may shrink and excrete catalyst. Therefore, for dimensional accuracy, the
measurement of crack lengths, su rface blemishes, tool marks, and similar su rface characteristics from a replica should be
made soon (within 72 hou rs) after its removal from the surface of the part. This is especially important if period ic
inspections are being performed to monitor d imensional change.

1 1 .2 Cleaning

The test part must be cleaned, su bsequ ent to removal of the ru bber replica, with a suitable solvent capable of removing
any residual silicones. Where the part is to be re-plated, re-painted or coated with sealant, this removal and cleaning is
extremely important in restoring the orig inal adhesive properties of the surface.

1 1 .3 Demagnetization

The AC circuit of the electromagnet shall be used to remove any resid ual magnetism left within the part after test.
Demagnetization shall redu ce the level of the field within the part to a satisfactory level consistent with the requirements
for that application.

1 2. N OTES

1 2. 1 A change bar ( l ) located in the left margin is for the convenience of the u ser in locating areas where technical
revisions, not editorial changes, have been made to the previous issu e of this d ocument. An (R) symbol to the left
of the docu ment title indicates a complete revision of the document, includ ing technical revisions. Change bars and
(R) are not used in original publications, nor in docu ments that contain ed itorial changes only.

PREPARED BY AMS COM MI TTEE “K”

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AN ALYSI S OF RU BBER REPLI CA I N DI CATI ON S

Example of low magnetism. Proper magnetism. “H alo” is seen at edge

N ote absence of “halo” at edge. and crack indications are displayed .

Too heavy magnetism. Crack indications are hidden in

heavy magnetic background.

FI GU RE 1 – EVALU ATI ON OF OPTI MU M M AGN ETI SM LEVEL FOR H OLES

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E xa m p l e of l ow m a g n e ti s m . H a l o a t to oth e d g e P rop e r m a g n e ti s m , N ote h e a vy h a l o a t tooth e d g e .

i s l i g h t. (D e p re s se d p orti on of ca s ti n g ) Th i s d o e s n ot i n te rfe re wi th i n d i ca ti on s i n g e a r roo ts .

To o m u ch m a g n e ti s m . C ra ck i n d i ca ti on s h i d d e n i n e xce s s i ve

m a g n e ti c b a ckg rou n d .

F I G U RE 2 – E VALU ATI O N O F O P TI M U M M AG N E TI ZATI O N LE VE LS I N G E AR RO O T I N S P E C TI O N S

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Low m a g n e ti s m . N o m a g n e ti c O p ti m u m m a g n e ti s m . Li g h t m a g n e ti c

b a ckg rou n d s e e n . b a ckg rou n d s e e n i n rou g h a re a s o f s u rfa ce .

Too h e a vy m a g n e ti s m . S m a l l i n d i ca ti on s

co u l d b e h i d d e n i n e xce s s i ve b a ckg ro u n d .

F I G U RE 3 – E VALU ATI O N O F O P TI M U M M AG N E TI ZATI O N LE VE LS O N S U RF ACE S

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F I G U RE 4 - M RI I N D I CATI O N O F CRACK O N E D G E O F H O LE AN D E XTE N D I N G O N TO AD J AC E N T S U RF ACE

F I G U RE 5 A - CRAC K I N D I C ATI O N S O N TAP E D S I D E O F H O LE . S H O U LD B E RE CAS T WI TH TAP E O N

O P P O S I TE E N D TO S E E I F I N D I C ATI O N S E XTE N D ARO U N D E D G E .

F I G U RE 5 B - S AM E H O LE AS S H O WN I N F I G U RE 9 , E XCE P T RE P LI CA RE C AS T O N O P P O S I TE S I D E TO

D I S P LAY I N D I CATI O N E XTE N D I N G ARO U N D E D G E

F I G U RE 5 - E XAM P LE S S H O WI N G TH E N E CE S S I TY O F CO M P LE TE I N S P E CTI O N AP P L I CATI O N S F O R M AXI M U M

F LAW D E TE CTI O N
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F I G U RE 6 A - M RI RE P LI CA C AS TI N G O F B ARE (U N P AI N TE D ) H O LE , S H O WI N G A LARG E

AN D A S M ALL C RACK (M AG N I F I C ATI O N 5 X)

F I G U RE 6 B - RE P LI CA O F S AM E H O LE CO ATE D WI TH . 0 2 0 " O F P AI N T.

N O TE " F U ZZI N E S S " O F C RACK I N D I C ATI O N S TH RO U G H C O ATI N G .

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F I G U RE 7 - RE P LI C A D I S P LAYI N G S U B S U RF ACE I N D I CTI O N

F I G U RE 8 - S O M E TI M E S S U B -S U RF ACE I N D I C ATI O N S ARE D I S P LAYE D AS WH I TE LI N E S .

S U CH I N D I CATI O N S M AY AL S O RE S U LT WH E N S U RF ACE C RAC KS ARE U N D E RM AG N E TI ZE D .

F I G U RE S 7 AN D 8 - E XAM P LE S O F S U B S U RF ACE I N D I CATI O N S

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FI GU RE 9 - M RI REPLI CA OF SU B-SU RFACE PORE

FI GU RE 1 0 - M RI REPLI CA SH OWI N G FLU TE M ARKS I N A H OLE.

TH ESE AN D OTH ER AXI AL TOOL M ARKS ARE DI STI N GU I SH ED FROM CRACKS BY SH APE (STRAI GH T RATH ER
TH AN J AGGED) AN D TOPOGRAPH Y U N DER MAGN I FI CATI ON . TOOL MARKS STOP AT EDGE, WH EREAS
CRACKS U SU ALLY EXTEN D AROU N D EDGE.
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(A) Air bubbles in rubber. These may hide defect indications.

(B) Vapor trails occu r when air moves through rubber. These often resemble crack indications, but
lighter in color. Recast for verification. Vapor trails are redu ced or eliminated by de-aeration.

FI GU RE 1 1 A AN D B - FALSE I N DI CATI ON S AN D POOR QU ALI TY MRI REPLI CA CASTI N GS

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(C) Blend ing artifacts result from pou r mixing of rubber. These may resemble cracks, bu t are broad er and
less distinct and “fan ou t” at the end. Doubtful indications, should be recast.

(D) Debris embedded in rubber resu lts from improper cleani ng. Dark bristles or hair may be mistaken for crack
indications. Debris may be picked out of the rubber wi th a sharp pin, whereas true ind ications may not.

FI GU RE 1 1 C AN D D - FALSE I N DI CATI ON S DU E TO BLEN DI N G ARTI FACTS AN D EMBEDDED DEBRI S