SURFACE J420

REV.
MAR91
VEHICLE
400 Commonwealth Drive, Warrendale, PA 15096-0001
INFORMATION Issued 1952-06
REPORT Revised 1991-03

Superseding J420 MAR81

(R) MAGNETIC PARTICLE INSPECTION

1. Scope—The scope of this SAE Information Report is to provide general information relative to the nature and
use of magnetic particles for nondestructive testing. The document is not intended to provide detailed
technical information, but will serve as an introduction to the theory and capabilities of magnetic particle
testing, and as a guide to more extensive references.

2. References

2.1 Related Publications—The following publications are provided for information purposes only and are not a
required part of this document.

2.1.1 SAE PUBLICATION—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

AMS 2640—Magnetic Particle Inspection, 1969.

2.1.2 ASM PUBLICATIONS—ATTN: MSC/Book Order, ASM International, PO Box 473, Novelty, OH 44072-9901.

Metals Handbook, Ninth Edition, Vol. 17, Nondestructive Evaluation and Quality Control, 1987.
Metals Handbook, Eighth Edition, Vol. 11, 1976, pp. 44–75.

2.1.3 ASTM PUBLICATIONS—Available from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959

ASTM E 125—Reference Photographs for Magnetic Particle Indications on Ferrous Castings

ASTM E 269—Standard Definitions for Terms Relating to Magnetic Particle Inspection
ASTM E 709—Recommended Practice for Magnetic Particle Examination

2.1.4 OTHER PULICATIONS

Nondestructive Testing Handbook, Vol. 6, Magnetic Particle Testing, 1989, American Society for
Nondestructive Testing, Columbus, OH 43228
C. E. Betz, "Principles of Magnetic Particle Testing," Magnaflux Corp., Chicago, IL, 1985
MIL-M-6867—Magnetic Inspection Units, Department of Defense
MIL-STD-1949—Inspection, Military Standard, Department of Defense
MIL-STD-410—Qualification of Inspection Personnel, Department of Defense
Programmed Instruction Handbook PI-4-3, Magnetic Particle Testing. Convair Div., General Dynamics
Corp., 1967

SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is 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 reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.

QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243

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SAE WEB ADDRESS http://www.sae.org

Copyright 1991 Society of Automotive Engineers, Inc.

All rights reserved. Printed in U.S.A.
 SAE J420 Revised MAR91

SNT-TC-1A Nondestructive Testing and Certification, 1984, American Society for Nondestructive Testing,
Columbus, OH 43228
Tool and Manufacturing Engineer's Handbook, Vol. 4, Quality Control and Assembly, 1987, Society of
Manufacturing Engineers, Dearborn, MI 48121

3. General—Magnetic particle inspection is a nondestructive means of inspecting ferromagnetic materials such

as iron and steel for discontinuities (cracks, seams, near surface inclusions) by the detection of leakage fields
through the use of magnetic particles.

Magnetic particle inspection is an aid to visual inspection of objects. Surface or near surface discontinuities
that might not be seen with the aid of optical magnification are regularly detected in manufacturing operations
or maintenance. The process is not applicable to nonmagnetic materials. The usual basic steps in magnetic
particle inspection of an object are: clean, magnetize, apply magnetic particles, inspect, and demagnetize.
Post cleaning is frequently done. Magnetic particle inspection is a relatively simple procedure. It is most
effective when the various factors, such as types of magnetization, current, particles, equipment, and method,
are properly selected for the application.

4. Principle—The principle of magnetic particle inspection is the accumulation of particles due to magnetic flux
leakage at discontinuities in a magnetized test object. The material subjected to the inspection is magnetized
in a fashion which will produce north and south poles on opposite edges of a discontinuity. Finely divided
magnetic particles are introduced into the flux leakage field between the poles, and are held there by the
magnetic leakage flux. The visible accumulation of these particles is called an indication.

5. Procedure—A magnetic field is induced in the part to be tested by the application of an electric current
through the part, or through a central conductor inserted through a hole in the part, or by means of a yoke,
prods, or coil. The type of magnetization selected is determined primarily by the need to establish magnetic
flux lines perpendicular to the direction of anticipated surface imperfections. Any discontinuity at or near the
surface of the part will interrupt the magnetic flux induced in the part and a leakage field will be formed at the
surface of the part. Magnetic particles in the vicinity of this leakage field will be attracted to it, forming a visible
indication which, to experienced interpreters, expresses the characteristics of the discontinuity. Following the
creation of the indication, the interpretation of the indication, and the evaluation of the discontinuity, the part is
suitably demagnetized and, where required, cleaned.

Adequate light must be provided for the quick and sure detection of the indications of discontinuities. Lights
should be adjusted to give broad highlights on finished machine parts. If fluorescent lighting is used, the tubes
should be located transverse to the long axis of the parts being inspected. A nominal illumination level of
108 1x (100 ft-c) of white light should be present on the part surface in the case of nonfluorescent inspection.
Personnel should have eyesight, corrected or uncorrected, capable of distant vision of 20/30 in at least one eye
and should be able to read Jaeger Type No. 2 with both eyes at 305 mm (12 in).

An adequate source of long wave ultraviolet light (approximate 3650 Å, colloquially known as black light) must
be provided for inspection when using the flourescent magnetic particle inspection method. A filtered high-
pressure mercury vapor source is generally recommended. The emitted light should have an intensity of 97 1x
(90 ft-c) at a 380 mm (15 in) distance from the source, or no less than 140 mW cm2 (900 mW in2) on the part
surface. For detection of certain fine indications, illumination at the part surface may need to be as high as
270 1x (250 ft-c). Personnel vision requirements are the same as for nonfluorescent inspection, but in addition,
visual acuity in the green-yellow spectrum must be satisfactory.

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 SAE J420 Revised MAR91

Demagnetization consists of removing objectionable residual magnetic fields from parts which have been
subjected to magnetic particle inspection. This must be done to prevent the deflection of adjacent sensitive
instruments and to prevent the attraction of small magnetic chips, or the like, which could cause damage to
contacting surfaces. The most common type of demagnetization consists of drawing the magnetized part
through a high intensity alternating current solenoid. Another type, often used on heavier parts, consists of
passing an alternating current or reversing direct current through the part or through a surrounding solenoid,
and then gradually reducing the current value to near zero. Demagnetization is sometimes effected in
subsequent processing, such as heat treatment, or hot washing, of a part. Effectiveness of the demagnetizing
is usually determined through use of inexpensive meters made for this purpose.

Irons and steels exhibit magnetic characteristics which vary with hardness and composition. Continuous
magnetization during particle application is used on relatively soft steels since they usually do not retain
sufficient magnetism to allow the use of the residual method. These steels are processed for inspection by
introducing the magnetic particles into the leakage fields created at the discontinuities while the magnetizing
force is present. Parts processed in this way are said to be processed by the continuous method. Use of the
continuous method makes possible the successful inspection of irons and steels which do not retain sufficient
magnetism for processing by the residual method. In addition to this, certain subsurface discontinuities are
easily detected in both hardened and unhardened parts by this method when direct current magnetization is
employed.

The residual magnetization test method may be applied to hardened steels, and other highly retentive
materials, since they will retain magnetism after the force has been removed. These remaining magnetic fields
will produce leakage fields adjacent to discontinuities strong enough to hold magnetic particles and produce
indications. Parts processed through the use of these retained fields are said to be processed by the residual
method. Use of the residual method often eliminates nonrelevant indications. It is especially useful for the
detection of surface discontinuities in hardened parts. An adequate level of magnetization is required.

Wet particles used in suspension liquid usually consist of finely ground magnetic iron oxide. These particles
are coated so they can be easily dispersed in a liquid vehicle. They are generally available in powder form
having red or black nonfluorescent colors. They are also available coated with a material which fluoresces
under long wave ultraviolet (black) light. Wet particles are commonly used in maintenance, process, and finish
inspection of machine and engine parts. The wet process offers the advantage of ease of application of the
particles, sensitivity in locating the finest discontinuities, and, especially with the fluorescent particle, rapid
inspection rates.

Dry particles consist of finely divided magnetic material in powder form. These particles are coated so as to be
easily conveyed by air to the part being inspected. They are generally available in many colors for maximum
contrast with the test object. Dry particles are commonly used for the maintenance, process, and finish
inspection of heavy weldments, heavy castings, and heavy forgings. Dry particles are superior for the
inspection of very rough surfaces and for the location of subsurface discontinuities in rough castings, forgings,
and weldments.

Circular magnetization consists of inducing a circular magnetic field in a part so that the magnetic lines of force
take the form of concentric rings about the axis of the current. This is accomplished by passing the current
directly through the part, or by passing the current through a conductor which passes through a hole in the
part, sometimes by use of prods. The circular method is used chiefly to indicate discontinuities radiating from
and parallel to the axis of the current flow.

Longitudinal magnetization consists of inducing a longitudinal magnetic field in a part by making it the core of a
solenoid, such as placing it in a coil or by making it a link in a magnetic circuit through use of a yoke. In a part
so magnetized, the lines of force will be parallel to the axis of the solenoid, and the part will exhibit the
properties of a bar magnet. The longitudinal method is used to indicate discontinuities transverse or
circumferential to the long axis of a part.

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 SAE J420 Revised MAR91

Moving field magnetization consists of inducing fields in a part in more than one direction almost
simultaneously. The fields induced may be a combination of circular and longitudinal or may be a combination
of either type. The moving field method may be used on many parts ordinarily requiring two or more distinct
magnetization and inspection operations. The moving field method, because of the rapidly changing field
directions, makes possible the location of all detectable discontinuities after only one processing. This may, in
some cases, eliminate a great percentage of the time required for the inspection if the parts were processed by
more conventional methods.

Alternating current magnetization is commonly used for moderately stressed parts in production and for the
detection of fatigue discontinuities due to service. Alternating current magnetization is always equal to, and
often superior to, direct current magnetization for the detection of surface discontinuities. Subsurface
discontinuities are not revealed when alternating current is used. In moderately stressed parts, this greatly
simplifies inspection.

Direct current magnetization is commonly used for highly stressed parts. It is able to disclose certain
subsurface discontinuities in addition to surface discontinuities.

Half-wave direct current is commonly used in the inspection of heavy weldments, heavy castings, and heavy
forgings, in conjunction with dry magnetic particles. Half-wave direct current is essentially a pulsating direct
current. The pulsations impart mobility to the magnetic particles, thereby assisting in aligning them in the
weaker leakage fields produced by subsurface discontinuities. Subsurface discontinuities are best revealed by
the use of this type current.

6. Notes

6.1 Marginal Indicia—The change bar (l) located in the left margin is for the convenience of the user in locating
areas where technical revisions have been made to the previous issue of the report. An (R) symbol to the left
of the document title indicates a complete revision of the report.

PREPARED BY THE SAE IRON AND STEEL TECHNICAL COMMITTEE DIVISION 25—
NONDESTRUCTIVE TEST METHODS OF THE SAE IRON AND STEEL TECHNICAL COMMITTEE

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 SAE J420 Revised MAR91

Rationale—Not applicable.

Relationship of SAE Standard to ISO Standard—Not applicable.

Application—The scope of this SAE Information report is to provide general information relative to the nature
and use of magnetic particles for nondestructive testing. The document is not intended to provide
detailed technical information, but will serve as an introduction to the theory and capabilities of magnetic
particle testing, and as a guide to more extensive references.

Reference Section

Nondestructive Testing Handbook, Vol. 6, Magnetic Particle Testing, 1989, American Society for
Nondestructive Testing, Columbus, OH 43228

C. E. Betz, "Principles of Magnetic Particle Testing," Magnaflux Corp., Chicago, IL, 1985

Metals Handbook, Ninth Edition, Vol. 17, Nondestructive Evaluation and Quality Control, 1987, ASM
International, Metals Park, OH 44073

ASTM E 125, Reference Photographs for Magnetic Particle Indications on Ferrous Castings, American
Society for Testing and Materials, Philadelphia, PA 19103

ASTM E 269, Standard Definitions for Terms Relating to Magnetic Particle Inspection, American Society
for Testing and Materials, Philadelphia, PA 19103

ASTM E 709, Recommended Practice for Magnetic Particle Examination. American Society for Testing
and Materials, Philadelphia, PA 19103

Metals Handbook, Eighth Edition, Vol. 11, 1976, pp. 44–75. American Society for Metals, Metals Park,
OH 44073

MIL-M-6867, Magnetic Inspection Units, Department of Defense

MIL-STD-1949, Inspection, Military Standard, Department of Defense

MIL-STD-410, Qualification of Inspection Personnel, Department of Defense

AMS 2640, Magnetic Particle Inspection, SAE, Warrendale, PA, 1969

Programmed Instruction Handbook PI-4-3, Magnetic Particle Testing. Convair Div., General Dynamics
Corp., 1967

SNT-TC-1A Nondestructive Testing and Certification, 1984, American Society for Nondestructive Testing,
Columbus, OH 43228

Tool and Manufacturing Engineer's Handbook, Vol. 4, Quality Control and Assembly, 1987, Society of
Manufacturing Engineers, Dearborn, MI 48121

Developed by the SAE Iron And Steel Technical Committee Division 25—Nondestructive Test Methods

Sponsored by the SAE Iron And Steel Technical Committee