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MAGNETIC PARTICLE TESTING PROCEDURE

Magnetic Particle Testing

Procedure
(Draft)

Name Title Signature Date

Prepared by: Doan Van Tien NDT engineer 21-Nov-2019

Checked by: Florin Ignat NDT Responsible Level 3

Approved by: Florin Ignat NDT Responsible Level 3

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MAGNETIC PARTICLE TESTING PROCEDURE

Table of Contents

1.0 Purpose..................................................................................................................................................... 4

2.0 Scope........................................................................................................................................................ 4

3.0 Reference documents............................................................................................................................... 4

3.1 Internal documents............................................................................................................................. 4

3.2 Customer specifications..................................................................................................................... 4
3.3 National and international standards.................................................................................................. 5
4.0 Definitions and abbreviations.................................................................................................................... 5

4.1 Definitions........................................................................................................................................... 5
4.2 Abbreviations...................................................................................................................................... 6
5.0 Personnel requirements to perform NDT task...........................................................................................6

6.0 Method and Technique............................................................................................................................. 6

7.0 Inspection equipment and materials......................................................................................................... 6

7.1 Inspection equipment......................................................................................................................... 6

7.1.1 Magnetizing equipment................................................................................................................. 6
7.1.2 Equipment effectiveness tests....................................................................................................... 7
7.1.3 Inspection area.............................................................................................................................. 8
7.1.4 Fixed UV light................................................................................................................................ 8
7.1.5 Portable UV light............................................................................................................................ 8
7.1.6 White light...................................................................................................................................... 8
7.1.7 UV light meter................................................................................................................................ 8
7.1.8 White light meter............................................................................................................................ 8
7.1.9 Gauss meters................................................................................................................................ 9
7.1.10 Centrifuge tube.............................................................................................................................. 9
7.1.11 Field indicator................................................................................................................................ 9
7.1.12 Cleaning tools................................................................................................................................ 9
7.1.13 Other accessories.......................................................................................................................... 9
7.2 Fluorescent magnetic particle............................................................................................................. 9
7.2.1 Magnetic particle materials effectiveness tests..............................................................................9
7.2.1.1 Brilliance of fluorescent................................................................................................................. 9
7.2.1.2 Discoloration.................................................................................................................................. 9
7.2.1.3 Concentration................................................................................................................................ 9
7.2.1.4 Contamination Tests.................................................................................................................... 10
7.2.1.5 Water break Tests....................................................................................................................... 10
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MAGNETIC PARTICLE TESTING PROCEDURE

7.2.1.6 pH Measurements....................................................................................................................... 10
7.2.1.7 Tank level.................................................................................................................................... 10
8.0 Preparation for magnetic particle inspection........................................................................................... 11

8.1 Magnetizatizing systems.................................................................................................................. 11

8.1.1 Circular magnetizing.................................................................................................................... 11
8.1.1.1 Using direct electrical contact method – heat shot......................................................................11
8.1.1.2 Using indirect electrical contact method – central conductor.......................................................12
8.1.2 Longitudinal magnetizing using a fixed coil (solenoids)...............................................................12
8.2 Functional verification system.......................................................................................................... 14
9.0 Inspection procedure............................................................................................................................... 14

9.1.2 Part cleaning................................................................................................................................ 15

9.1.3 Demagnetization before inspection............................................................................................. 15
9.2 Inspection process........................................................................................................................... 15
9.2.1 Inspection lighting........................................................................................................................ 15
9.2.2 Apply wet fluorescent particle and magnetizing...........................................................................16
9.2.3 Interpretation and evaluation....................................................................................................... 16
9.2.4 Demagnetization after inspection................................................................................................ 16
9.2.5 Post cleaning............................................................................................................................... 17
9.2.6 Marking inspected parts............................................................................................................... 17
9.2.7 Inspection records....................................................................................................................... 17
9.2.8 Reporting..................................................................................................................................... 18
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MAGNETIC PARTICLE TESTING PROCEDURE

1.0 Purpose
This procedure describes the process of Magnetic Particle Testing using HWAC fixed horizontal unit with
continue wet fluorescent technique.

2.0 Scope

2.1 This procedure establishes the requirements for magnetic particle inspection used to
detect discontinuities on the surface or near-surface of ferromagnetic components during in-process and
final inspections, applies within the Universal Alloy Corporation organization, having the following
locations:

- 244A Principala St., Dumbravita, Maramures, 437145 Romania;

- 62 St., Tautii Magheraus, Maramures, 437345 Romania;
- DaNang Hi-Tech Park, Lot A9, Hoa Vang District, 550000Danang City, Vietnam

2.2 Prior to the application of this process the responsible level 3 shall make sure that the
process is qualified per the customer equirements for which inspection is required.

3.0 Reference documents.

3.1 Internal documents
QM – 01 Quality Manual.
PS-QMS-02.00 Control of records.
PS-NDT-02.00 Penetrant inspection.
MT-NDT-02.00.02 Material and equipment check.
MT-NDT-02.00.03 Penetrant inspection equipment calibration.
PS-PP-02.01 Reporting of production and inspection operations.

3.2 Customer specifications

BSS 7040 Specification for Magnetic particle testing.
BAC 5424 Specification for Magnetic particle testing – Pre-cleaning and product
acceptance requirements.
BAC5408 Vapor Degreasing.
BAC5625 Surface Treatments for Ferrous Alloys.
BAC5652 Inspection of Castings.
BAC5750 Solvent Cleaning.
BAC5751 Cleaning, Descaling and Surface Preparation of Ferrous Alloys.
BAC5758 Cleaning, Descaling and Surface Preparation of Nickel and Cobalt Base
Alloys.
BAC5759 Chemical Milling of Steel, Nickel and Cobalt Alloys.
BAC5763 Emulsion Cleaning and Aqueous Degreasing.
BAC5936 Flash Welding of Low Alloy, Heat Treatable Steel Parts.
BAC5945 Fusion Welding of Ground Handling and Weapons Support Equipment –
Steel.
BAC5966 Inertia Friction Welding.
BAC5975 Fusion Welding of Metals.
BAC5981 Pressure Gas Welding of Low Alloy, Heat Treatable Steel.

3.3 National and international standards

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MAGNETIC PARTICLE TESTING PROCEDURE

Standard Practice for Magnetic Particle Testing.

ASTM E1444
Standard Terminology for Nondestructive Examination.
ASTM E 1316
Magnetic Particles, Fluorescent, Wet Method, Dry Powder.
AMS 3044
Magnetic Particles, Fluorescent, Wet Method Oil Vehicle, Ready-To-Use
AMS 3045
Qualification and Approval of Personnel for Non-Destructive Testing.
EN 4179
Certification and Qualification of Nondestructive Test Personnel.
NAS 410
Measurement Management Systems - Requirements for Measurement
ISO 10012
Processes and Measuring Equipment.
Health and Safety at Work Act.
Law no. 84/2015
NADCAP audit criteria for NDT suppliers accreditation program.
AC 7114
4.0 Definitions and abbreviations.
4.1 Definitions.

Magnetic particle testing a nondestructive test method utilizing magnetic leakage fields and
suitable indicating materials to disclose surface and near-surface
discontinuity indications.
Ferromagnetic a term applied to materials that can be magnetized or strongly attracted
by a magnetic field
Magnetic particles finely divided ferromagnetic material capable of being individually
magnetized and attracted to distortion in a magnetic field.
Near-surface discontinuity a discontinuity not open to, but lying near, the surface of a part
undergoing examination which produces broad, fuzzy, lightly held powder
patterns.
Continuous method a method wherein the indicating medium is applied while the magnetizing
force is present.
Direct contact a technique of magnetizing in which the current is passed through a part
magnetization via prods or contact heads.
Indirect magnetization magnetization induced in a part when no direct electrical contact is made.
Demagnetization the reduction of residual magnetism to an acceptable level.
Coil technique A technique of magnetization in which all, or a portion of the part is
encircled by a current-carrying coil.
Coil, High Fill Factor The cross-sectional area of the coil is less than two times the cross-
sectional area of the part to be inspected.
Coil, Intermediate The cross-sectional area of the coil is between two and ten times the
Fill Factor cross-sectional area of the part to be inspected.
Coil, Low Fill Factor The cross-sectional area of the coil is ten or more times the cross-
sectional area of the part to be inspected.
Head Shot A technique of magnetizing in which current is passed through the
component by means of the contact heads to generate a circular magnetic
field.
Test piece a specimen containing known artificial or natural defects used for checking
the efficiency of magnetic particle flaw detection processes.
Technique Sheet A detailed, written instruction that supplements the instructions of a
general procedure.
4.2 Abbreviations
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MAGNETIC PARTICLE TESTING PROCEDURE

NDT Non Destructive Testing

MT Magnetic Testing

5.0 Personnel requirements to perform NDT task.

a. To perform and fulfill the Penetrant Inspection process as given in this document, the personnel shall
be qualified and certified in accordance with NAS 410 or EN4179.
b. Level I individuals can carry out necessary preparation of parts before and after inspection, perform
equipment and materials standardization, conduct system performance checks in accordance with
the applicable process standard. An individual conducting the check for fluorescence materials of the
magnetic testing does not require specific NDT training.
c. Only level II or higher individuals can perform inspection and make accept or reject decisions of
inspected parts.
d. Level III individuals shall be responsible for the approval of NDT procedures and corresponding
reports. Implementation of this procedure, monitoring, and supervision of the NDT performance shall
be carried out by Level III.

6.0 Method and Technique.

This procedure describes the following method and technique.
a. Magnetization method using fixed wet horizontal unit - Test bench.
- Circular magnetization: Headshot or Central conductor.
- Longitudinal magnetization: Fixed coil – Solenoids.
b. Type of magnetizing current: Haft wave rectified alternating (HWDC).
c. Application of magnetic particle: Wet fluorescent continuous method

7.0 Inspection equipment and materials.

7.1 Inspection equipment.
7.1.1 Magnetizing equipment.
Horizontal wet method particle equipment (Test bench) using in this procedure shall be meet the
requirements below:

a. Arrange the magnetic particle equipment to:

(1) minimize dust and/or other contamination to the inspection materials, equipment or parts.
(2) permit uniform, controlled operations.
(3) provide safe and adequate ventilation for the materials involved.
b. Magnetic particle inspection equipment and associated demagnetizers produce magnetic fields
which may exceed whole body and electronic medical device guidelines. Contact internal safety
organizations for recommendations on sign required and distance between the operator,
bystanders, and equipment.
c. Arc strikes, localized overheating, or burning at the contact points are unacceptable.
d. All current (amperage) meters shall exhibit a re-calibration sticker.
7.1.2 Equipment effectiveness tests.
7.1.2.1 Coil current output check.
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MAGNETIC PARTICLE TESTING PROCEDURE

a. Set the controls for the machine to the maximum and minimum current value. Pulse the current
for both values.
b. Record the results.
7.1.2.2 Headshot current output.
a. At a minimum and maximum current output shall be determined, with a one (1) inch diameter
copper bar, 18 inches long, clamped between the heads. Ensure contact at ends is good.
b. Record the results.
7.1.2.3 Internal short test.
a. The test bench shall be tested for internal shorts at the 6 months intervals.
b. With the current control set above 1000 amperes, the switch set on contacts, and nothing clamped
in the heads, activate the power to the heads. An ammeter reading above 1 or 2 (10 to 20 amps)
indicates an internal short and the equipment shall be repaired prior to running production parts.

NOTE: Some machine ammeter circuits do not reset the reading to zero before each shot, but only
when the current flow is activated. For these machines, set the current control, turn the main
power switch off and then turn the power back on and resume the test.

c. Using the same settings provided in Section 7.1.2.3.b. conduct the test again with a piece of
nonconductive material clamped in the heads. An ammeter reading above 1 or 2 (10 to 20 amps)
indicates an internal short and the equipment shall be repaired prior to running production parts.

7.1.2.4 Ammeter accuracy.

a. Ammeters shall be tested for accuracy at the 6 months intervals.
b. Connect a calibrated ammeter, traceable to the National Institute of Standards and Technology
(NIST) or equivalent national standard, in series with the output circuit.
c. Take comparative readings at a minimum of three output levels covering the entire operating range
of the equipment.
d. An equipment ammeter shall not deviate more than ± 10 percent from the current shown by the
calibrated ammeter or 50 amperes (whichever is greater).
7.1.2.5 Timer control check.
a. On equipment using a timer to control current duration, use a calibrated electronic timer to check
the equipment timer accuracy at 6 months interval.
b. The minimum accuracy requirement is ± 0.1 seconds.
7.1.2.6 Magnetic field quick/ fast break test.
a. On machines so equipped, verify quick/fast break feature operation working proper functioning at 6
months intervals.
b. Perform the test using a suitable oscilloscope, commercially available tester, or other applicable
methods as specified by the equipment manufacturer.
7.1.3 Inspection area.
a. The inspection area shall be check daily. Keep inspection areas clean and free from excessive
clutter and contamination. Viewing booths should be equipped with ventilation.
b. Lighting condition at inspection area shall meet the requirements:
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MAGNETIC PARTICLE TESTING PROCEDURE

1) 1000 μW/cm2 is the minimum black light intensity required at the inspection surface when
fluorescent magnetic particles are used.
2) Maintain ambient light levels at 2 fc (20 lx) or less when using fluorescent magnetic particles.
3) A minimum of 100 fc (1,000 lx) of white light at the inspection surface is required for inspection
using visible magnetic particles and for visual interpretation of indications found with fluorescent
magnetic particles.
7.1.4 Fixed UV light.
Check ultraviolet lights as follows:
a. Use a calibrated blacklight meter that reads in μW/cm2 or W/m2.
b. For standard black lights:
(1) if light intensity at a minimum distance of 15 inches (38 cm) exceeds 1500 μW/cm2 the lights
may be tested weekly.
(2) if light intensity at a minimum distance of 15 inches (38 cm) is less than or equal to 1500
μW/cm2 test the lights daily.
(3) minimum acceptable light intensity at a minimum distance of 15 inches (38 cm) is 1000
μW/cm2.
c. Maintain ambient light levels at 2 fc (20 lx) or less when using fluorescent magnetic particles.
d. Check all other inspection black lights each day prior to use.
7.1.5 Portable UV light.
The portable UV light may be used during an inspection
a. Use a calibrated blacklight meter.
b. Test lights prior to each examination at the inspection site. When using battery-powered lights,
check intensity at the inspection site before and after the inspection.
c. Minimum acceptable light intensity for standard black lights at a minimum distance of 15 inches
(38 cm) is 1000 μW/cm2.
7.1.6 White light.
a. Use a calibrated white light meter.
b. A white light source of at least 100 fc (100 lux) shall be available when inspecting using for
interpretation of indications found with fluorescent particles.
c. Check lighting, ambient/inspection (as required) prior to each use at the inspection site.
7.1.7 UV light meter.
Calibrate light meters used for checking black lights shall be checked at 6 months intervals.
7.1.8 White light meter.
Calibrate light meters used for checking white lights shall ve checked at 6 months intervals.
7.1.9 Gauss meters.
Calibrate/Certify Gauss meters shall be check at 6 months intervals.
7.1.10 Centrifuge tube.
Centrifuge tube 100 mL using for concentration test and contamination test of wet fluorescent
particle.
7.1.11 Field indicator.
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MAGNETIC PARTICLE TESTING PROCEDURE

AS5282 ring and artificial flaw shim (Type 230) shall be used to perform functional verification of the
system.
Indicators used to test for residual magnetic fields shall be calibrated/certified every 6 months.
7.1.12 Cleaning tools.
Appropriate cleaning agents may include degreasers, detergents, paint stripper, brushes, rag.
7.1.13 Other accessories.
Calibrated tape measurement, magnifying glass, marker, mirror if applicable.

7.2 Fluorescent magnetic particle.

a. Use fluorescent magnetic particles that comply with the following
(1) AMS 3044 Magnetic Particle Fluorescent Wet Method, Dry Powder
(2) AMS 3045 Magnetic Particle Fluorescent Wet Method, Oil Vehicle, Ready to Use
b. Liquid vehicle.
(1) When oil is used as the liquid vehicle, use a light oil conforming to AMS 2641, “Magnetic
Particle Inspection Vehicle (Type 1).”
(2) Water with suitable corrosion inhibitors and wetting agents meeting AS 4792, may be used as
a liquid vehicle provided the additives are compatible with the magnetic particles when tested
in accordance with AMS 3044 as applicable.
7.2.1 Magnetic particle materials effectiveness tests.
7.2.1.1 Brilliance of fluorescent.
a. Make a comparison between a standard sample of 'used' testing agent and 'unused' testing agent
under black (UV) light for brilliance of particle fluorescence.
b. Check every shift and record the result.
7.2.1.2 Discoloration.
a. Check the contamination of the suspension for clarity and absence of yellow fluorescence under
black light. Check for lint, dirt or scale.
b. Check every shift and record the result.
7.2.1.3 Concentration.
Test wet suspensions for contamination at the start of each shift or after any period where
agitation of the suspension has been stopped for 10 minutes or longer or whenever the bath is
changed or adjusted.

NOTE: It is recommended to wipe down the sides of the tank and allow the bath to circulate for thirty
minutes prior to taking the sample.

a. Thoroughly agitate and mix by hand all suspension which has settled upon the screen and along
the bottom of the tank and run the pump.
b. Fill centrifuge tube to the 100ml mark with suspension directly from the hose. Demagnetize the
suspension and allow the suspension to stand for 60 minutes for oil-based or 30 minutes for
water-based to settle.
c. Read the volume of the settled suspension in the tube. Concentration of the particles shall comply
with Table I.
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MAGNETIC PARTICLE TESTING PROCEDURE

d. If the settled particles appear as loose clumps, brush tank bottom to lift particles take another
sample. If the second sample appears the same, the bath shall be added magnetic particle to
obtain the required concentration or changed.
7.2.1.4 Contamination Tests.
a. Place a sample of approximately 100 ml of the in-use suspension into a centrifuge tube
conforming to Section 7.2.1.3.b
b. Examine the settled particles in the centrifuge tube under black light for layers, bands or striations
different in color or appearance. Layers, bands, and striations indicate contamination. If the total
volume of contamination exceeds 30 percent of the volume of the settled particles, the bath shall
be replaced.
c. A noticeable reduction of fluorescent brightness or color of the particles is unacceptable.
d. Clouding or fluorescence of the vehicle to the extent that the markings on the centrifuge tube,
between 5 ml and 25 ml, cannot be seen through the vehicle is unacceptable.
e. A milky white or bluish white colored vehicle indicating oil or grease contamination is
unacceptable.
f. Unacceptable conditions require replacement of the bath prior to further processing of parts.
Table I – Fluoresent wet magnetic particle concentrations.
Milliliter of solids per 100 milliliters of suspension
Preferred Range for Standard Inspections 0.15 to 0.25 ml
Recommended Range for Splines and Chrome Plate 0.10 to 0.15 ml
Recommended Range for Raw Forgings and Castings 0.20 to 0.40 ml
Minimum and Maximum Concentration range 0.10 to 0.40 ml

7.2.1.5 Water break Tests.

a. When using a water vehicle, the water break test is acceptable if a continuous, even film forms
over the entire area under test.
b. If there is a break in the suspension film, the part is not properly cleaned or there is insufficient
wetting agent in the bath and the test is unacceptable.
c. Re-clean the part. If a break in the suspension recurs on the cleaned part, add wetting agent to
the bath as necessary until the test is acceptable.
Caution: Excessive wetting agents can cause foaming or jelling of the bath.
7.2.1.6 pH Measurements.
Maintain the pH measurements of the water vehicle between a pH of 6.0 and 10.0. Check at initial
bath makeup and whenever water conditioners are added.
7.2.1.7 Tank level.
This check will be performed at the beginning of every shift.

TABLE II – TESTING AND VERIFICATION INTERVALS

REFERENCE
TEST MAXIMUM INTERVAL
SECTION
I. Equipment
A. Current output 6 Months Section 7.2.1.1
B. Internal Short 6 Months Section 7.1.2.3
C. Ammeter 6 Months Section 7.1.2.4
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MAGNETIC PARTICLE TESTING PROCEDURE

D. Timer 6 Months Section 7.1.2.5

E. Quick/Fast Break 6 Months Section 7.1.2.6
F. Light Meters 6 Months Section 7.1.7
G. Black Lights
1. Fixed Weekly/Daily Section 7.1.4
2. Portable Each use Section 7.1.5
H. White Lights Each shift Section 7.1.6
I. Gauss Meters 6 months Section 7.1.9
J. Field Indicators 6 months Section 7.1.11
II. Wet fluorescent particle
A. Brilliance of fluorescent Each Shift Section 7.2.1.1
B. Discoloration Each Shift Section 7.2.1.2
C. Concentration Each Shift Section 7.2.1.3
D. Contamination Weekly Section 7.2.1.4
E. Water Break Each Use Section 7.2.1.5
F. pH Balance Initial/Add Section 7.2.1.6
G. Tank level Each Use Section 7.2.1.6
III. System Functional test Verification Daily Section 8.2

8.0 Preparation for magnetic particle inspection.

8.1 Magnetizatizing systems.
8.1.1 Circular magnetizing
8.1.1.1 Using direct electrical contact method – heat shot.
a. To inspect a part using a head-shot, the part is clamped between two electrical contact pads of
the machine. Current is passed through the parts and a circular magnetic field is established in
and around the component. Typically, this method is used to inspect the parts with long shaped.
b. Using a Gauss-meter and/or an artificial flaw/flux indicator such as a flaw shim or laminated flux
indicator is required to verify field strength and direction on all parts other than those with simple
configurations. Flaw shims shall be attached with the flaw side towards the part. The proper
current for each shot shall be determined experimentally as above.
c. 300 to 500 amperes per inch [A/in] (12 to 20 amperes per millimeter [A/mm]) of diameter or
diagonal cross-section is sufficient for direct magnetizations.
d. Higher amperages, up to 1,000 A/in (40 A/mm) may be used for detection of subsurface
indications, or to examine low-permeability alloys such as precipitation-hardened steels.
e. Current levels below 300 A/in (12 A/mm) may be used in those situations where only surface
indications are sought and higher amperages may cause burning or excessive background.
f. Gaussmeter magnetic field intensity readings shall be a minimum of 30 Gauss (30 X 10-4Tesla) in
all areas of interest.
g. When inspecting chromium-plated parts for grinding cracks under the chrome, use as high an
amperage as possible (greater than or equal to 60 gausses) that does not cause arcing, over-
heating, or burning of the part and does not produce magnetic flux lines.
h. Arc strikes are unacceptable.
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MAGNETIC PARTICLE TESTING PROCEDURE

8.1.1.2 Using indirect electrical contact method – central conductor.

a. To inspect a part using a central conductor, a central conductor is a nonferrous and high
electrically conductive bar that is usually made of copper or aluminum. The bar is inserted through
the opening of parts and the bar is then clamped between the contact pads. When current is
passed through the central conductor, a circular magnetic field flows around the bar and enters
into the part or parts being inspected. Typically, this method is used to inspect parts that have an
open center, such as gears, tubes, and other ring-shaped.
b. Verify complete part coverage from central conductor magnetizations using appropriate methods
(Gaussmeter, flux indicators, etc.). Perform a minimum of two magnetizations, with the part,
rotated at least 30 degrees to assure that the areas of central conductor/part contact points, drain
and drip lines are inspected.
c. The number of magnetizations and the amperage required for each magnetization shall equal or
exceed the amperage requirements for direct contact magnetization of the part.
d. Provide sufficient separation between multiple parts on a central conductor to permit coverage
with particles and adequate viewing.

8.1.2 Longitudinal magnetizing using a fixed coil (solenoids)

a. The following conditions apply when conducting coil magnetizations:
(1) The minimum length to diameter (L/D) ratio is 2:1. Use one of the following if L/D is less than
2:1.
- Place two or more parts, of similar outside dimensions, end to end to achieve at least a
minimum of 2:1 L/D ratio.
- Use ferromagnetic pole pieces of approximately the same outside diameter to achieve at
least a minimum of 2:1 L/D ratio.
(2) The long axis of the part is aligned with the axis of the coil.
(3) The maximum length inspected by each shot shall not exceed 18 inches.
b. Coil magnetizing current.
(1) Use an L/D ratio of 2 to 15.
(2) If L/D is greater than 15, use 15 in shot calculations.
(3) If L exceeds the width of the coil plus 6 inches on each side of the coil, multiple shots are
required.
(4) The minimum magnetic field overlap for multiple shots shall be 10 percent.
(5) Actual current requirements shall be determined experimentally using one or more field
strength verification methods such as gauss/hall effect meters, flaw shims or laminated flux
indicators.
(6) A gauss meter/hall effect probe may be used to determine field strength by placing the probe
on the part and oriented with the centerline of the coil. A minimum reading of 30 gausses is
required in all areas of interest.
(7) The following formulas may be used as guidelines for simple configurations. Amperages used
for magnetization shall be within ±10 percent of the calculated amperage.
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MAGNETIC PARTICLE TESTING PROCEDURE

- For parts positioned in a low fill factor coil - When the cross-sectional area of the coil is
ten or more times the cross-sectional area of the part being examined, the following
formulae apply:
+ Parts positioned at the side of the coil.
45000
¿=
L
D
+ Part positioned at the center of the coil
43000. R
¿=
6L
( )
D
−5

- For parts positioned in high fill factor coil - When the cross-sectional area of the coil is
less than twice times the cross-sectional area of the part being examined, the following
formulae apply:
35000
¿=
L
( )
[
D
+2]

- For parts positioned in intermediate fill factor coil - When the cross-sectional area of the
coil is between 2 and 10 times the cross-sectional area of the part being examined, the
following formulae apply:
Cross−sectional of coil
¿=¿h ¿ τ=
Cross−sectional of part
- For hollow cylindrical parts and other shapes with hollow portions, D can be replaced with
Deff as follows:
+ For hollow cylinders.

Deff = √(OD)2−(ID)2
+ For parts with hollow portions.

A t− A h
Deff =2
√ π

where:
N = number of turns in the coil (Amperes)
I= Current in Amperes.
R = Radius of the coil in inches.
L = Length of the part.
D = Diameter of the part in the same units as length.
At = Total cross-sectional area of the part.
Ah = Cross-sectional area of the hollow portions of the part
NIh = NI calculated for high fill factor
NIl = NI calculated for low fill factor
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MAGNETIC PARTICLE TESTING PROCEDURE

8.2 Functional verification system.

a. Functional verification system shall be performed each shift. All equipment and materials using for
the inspection will be checked and calibrated at the frequencies specified in section 7
b. Use of use the AS5282 ring (Ketos ring) and artificial flaw shim (Type 230) specimen for system
verification, process as follows:
(1) Use a central non-ferromagnetic conductor 1.00 to 1.25 inches (25 to 31 mm) in diameter and
at least 16 inches (406 mm) long.
(2) Place the ring on a central of conductor and clamp between the heads so that the number one
hole is at the 12 o'clock position and the other holes are facing the inspector.
(3) Attach an artificial flaw shim (Type 230) with the flaw side towards the part, to the ring specimen
approximately 0.5 inches from the number one hole, away from the inspector. The shim may be
placed on the outer radius or the side of the ring.
(4) Apply to the central conductor the amperage (approximately 1,000 amps) required to obtain 30 -
35 Gauss on the outside surface of the ring above the number one hole.
(5) The artificial flaw indication and five holes in the ring specimen shall clearly show.
c. Check parts used for functional verification for residual magnetic particle indications prior to
conducting the test. Residual indications are not acceptable. Demagnetize and clean the test part
and try again.
d. Demagnetize and clean the test part after each verification.

9.0 Inspection procedure.

9.1 Pre-inspection.
9.1.1 Inspection requirements for the part with coating.
When magnetic particle inspection is specified, perform the inspection after completing manufacturing
sequences which might cause or reveal discontinuities, but before operations that may hide
discontinuities, as specified below. Operations that may cause or reveal discontinuities include, but
are not limited to grinding, welding, straightening, machining, forming, heat treating including stress-
relieving. Operations that may hide discontinuities include but are not limited to shot peening,
painting, application of other coatings, and electroplating.
a. Inspection is required before:
(1) shot peening.
(2) protective finishing such as priming, painting, or other non-electroplating type coatings on all
production parts unless otherwise specified on the drawing.
(3) electroplating when final plating thickness will exceed 0.0008 inches (see Table III).
b. Inspection is required after electroplating or grinding of electroplated surface (whichever is last),
unless otherwise specified on the drawing, with the following exceptions:
(1) magnetic particle inspection is not required for plating thicknesses greater than 0.005 inches
unless specifically called out on the drawing (see Table III).
(2) magnetic particle inspection after plating is not required for steels heat-treated to less than or
equal to 160 ksi unless specifically called out on the drawing (see table III).
c. Nonconductive coatings must be removed when electrical contact is to be made
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NOTE: Use caution when inspecting parts with electroplated nickel coating. Non-relevant indications
may form in the nickel plating.
d. In-process inspections shall not be substituted for the final inspection.
Table III – Sequence of magnetic particle inspection for plating
Steel strength, ksi
Plating thickness in inches (mm) Less than or equal to 160 ksi Greater than 160 ksi
Less than or equal to 0.0008 inches (0.0203 mm) MPI before or after MPI after
Greater than 0.0008 inch
(0.0203 mm) through 0.0050 MPI before MPI before and after
inch (0.1270 mm)
Greater than 0.005 inches (0.127 mm) MPI before MPI before

9.1.2 Part cleaning.

Caution: Use abrasive blasting only as necessary to completely remove scale or rust. Excessive
blasting of parts can affect the results of the inspection.
a. Clean parts to remove grease, oil, rust, scale, paint or other substances that could interfere with
the inspection process. When specified, pre-clean parts to the requirements of the applicable
Boeing drawing or specification.
b. A water-break-free surface is required for parts to be inspected using a water vehicle. This
requirement is met if the suspension completely wets the surface.
b. Prevent cleaning materials from becoming entrapped where they cannot be removed. Masking or
other methods may be used.
9.1.3 Demagnetization before inspection.
a. The part shall be demagnetized before an examination if prior operations have produced a
residual magnetic field that may interfere with the examination.
b. This process shall be performed as necessary until field indicator shows the residue magnetism of
the parts is within ± 3 gauss.

9.2 Inspection process.

9.2.1 Inspection lighting.
a. 1000 μW/cm2 is the minimum black light intensity required at the inspection surface when
fluorescent magnetic particles are used.
b. Maintain ambient light levels at 2 fc (20 lx) or less when using fluorescent magnetic particles.
c. A minimum of 100 fc (1,000 lx) of white light at the inspection surface is required for inspection
using visible magnetic particles and for visual interpretation of indications found with fluorescent
magnetic particles.
d. The UV light shall be allowed to warm up a minimum of 5 minutes before use for inspection.
e. Allow 1 minute for dark adaptation of the eyes before beginning the inspection.
f. Inspectors shall not wear eyeglasses with light sensitive (photochromatic) lenses.
9.2.2 Apply wet fluorescent particle and magnetizing.
Note: - Do not magnetize or demagnetize assembled anti-friction bearings.
- Mask or otherwise protect both inspected and non-inspected areas to prevent magnetic
particles or vehicles from becoming entrapped where they cannot be removed. This may
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require extracting components such as bushings, bearings, and inserts from assemblies prior
to testing
- Remove non-conductive coatings where electrical contact shall be made.
a. Wet fluorescent magnetic particles shall be liberally applied either by spraying or flowing over the
areas to be inspected just as the magnetizing field is induced.
b. Apply the magnetizing current at the instant the particle suspension is diverted with a minimum of
two shots of magnetizing current using a minimum duration of 1/2 second each.
c. The current remaining on and the inspection performed with the current remaining on.
d. Examine the part thoroughly for indications following each magnetization. If the length of part
exceeds the width of the coil plus 6 inches on each side of the coil, multiple shots are required.
The minimum magnetic field overlap for multiple shots shall be 10 percent.
e. Examine all surfaces being inspected to the limits of visual accessibility and acuity. Drawing call
outs for supplemental or alternative inspection methods are required for inspection beyond these
limits.
f. Magnifiers of 3X to 10X magnification may be used by inspectors to interpret or evaluate
indications and the locations of the discontinuities shall be marked on the part.
g. Visual aids such as mirrors and borescopes shall be used when geometric configuration prevents
surfaces from being visible with ± 30º of the normal (90º) viewing angle.
h. Prior to acceptance or rejection perform interpretation and evaluation of indications to determine if
acceptance limits are exceeded.
9.2.3 Interpretation and evaluation.
a. Interpretation.
- Interpret all indications. Reprocess parts with excessive background and false or non-relevant
indications which interfere with the detection of relevant indications.
- Verify indications may be used residual method or AC current or re-inspect at 15 to 20 Gauss.
b. Evaluation.
- Measure the indication size using calibrated wire and/or pin gages or plastic fluorescent
comparators.
- Use the actual measured discontinuity size when evaluating relevant indications
- The parts shall be rejected if relevant indications exceeding allowable limits in accordance with
applicable acceptance criteria specified in BAC 5424 – Acceptance criteria for Magnetic particle
Inspection.
9.2.4 Demagnetization after inspection.
All parts shall be demagnetized as follows:
c. With the coil energized, the part shall be held about one foot in front of the AC
demagnetizing coil and then moved slowly through the coil to a point three feet beyond it
when the current will be stopped.
d. When using DC demagnetization, the initial field shall be higher than, and in nearly the
same direction as the field reached during examination. The field shall then be reversed,
decreased in magnitude, and the process repeated (cycled) until an acceptably low value of
residual field is reached.
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e. Parts of complex configuration shall be rotated and tumbled while passing through the
energized coil.
f. This process shall be repeated as necessary until the field indicator shows the residue
magnetism of the parts is within ± 3 gausses.
9.2.5 Post cleaning.
a. Cleaning shall be done with a suitable solvent, air blower, fluids or by other means that will not
damage the part and containing a corrosion inhibitor as necessary.
b. Parts shall be examined to ensure that the cleaning procedure has removed magnetic particle
residues from holes, crevices, passageways, etc. Such residue could have an adverse effect on
the intended use of the part.
c. Care shall be taken to remove all plugs, masking, or other processing aids that may affect the
intended use of the part.
d. Apply temporary protective coatings, as necessary, after final cleaning and drying to prevent
corrosion.
9.2.6 Marking inspected parts.
a. Identify each item inspected and accepted after the final inspection.
(1) Parts with part-specific identifiers shall have an inspection stamp, electronic ID or signature of
the inspector on the parts' permanent record.
(2) Raw materials or parts without part-specific identifiers, when required by contract or drawing
requirements, shall be marked with a stamp or multiple stamps which includes the method,
inspector identification, and company or inspection facility or tagging.
b. Parts with relevant indications exceeding allowable limits shall be rejected and tagged with red
label and shall not be processed further.
9.2.7 Inspection records.
a. Maintain records for all items inspected. Record the part number; part specific identifiers (e.g.
serial number); company or facility identification; parts inspected; parts sample inspected;
disposition of parts; date of inspection; and inspector identification either by an inspection stamp,
electronic ID or signature of the inspector.
b. Maintain records of all equipment and material tests as specified in Section 7.0. Include as a
minimum: dates, measured values, material batch numbers, identification of personnel performing
and/or accepting the test, and replenishment information.
c. Keep records available for review by authorized representatives of the Boeing Company,
government or customer for a minimum of two years after shipment or as otherwise specified by
contractual agreement.
9.2.8 Reporting.
a. The result of the inspection shall be reported. All indications shall be reported, quoting the length
and position on the sketch.
b. The inspection report shall be performed by signing the sheet that accompanies the parts and by
releasing an inspection report which includes the following:
- Reference to the document that requests the inspection.
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- Complete identification of the inspected part: description of the item, manufacturer's

designation, the part number, and serial number.
- Equipment used with serial number and calibration date.
- Equipment settings.
- Classification and manufacturer’s designation of inspection materials used.
- Defect location, size, and description.
- Acceptance criteria calling out the applicable drawing or documentation to each part.
- Status of indications, “Rejectable”, “Acceptable”, “in limits” etc
- Date of inspection.
- Inspector’s name, signature, stamp, and qualification.
- Authorization signature.