Magnetic Particle Testing

LEVEL 3 (as per ISO 9712)

GENERAL KNOWLEDGE

K. A. S. I Saranath
Scientific Officer
NCNDT

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 1.1 Basic Principles of NDT

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 Definition of NDT

 NDT is a group of inspection

techniques used in industry to
detect defects and evaluate
properties of a material,
component or system without
causing any damage to
material.

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 Overview of NDT

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 Methods of NDT

Visual

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 Basic NDT Methods

• Visual Testing (VT)

• Liquid Penetrant Testing (PT)

• Magnetic Particle Testing (MT)

• Ultrasonic Testing (UT)

• Radiographic Testing (RT)

• Eddy Current Testing (ET)

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 Visual Testing (VT)
• It is a most commonly used NDT method for detecting
and evaluating defects.
• Inspect using human eye.
• Optical equipment use to enhance sensitivity. But
decreases the area of coverage.

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 Visual Testing (VT)
• Requires adequate illumination of the test surface and
proper eye-sight of the tester.

• It is also a fact that all defects found by other NDT

methods ultimately must be substantiated by visual
inspection.

• Visual testing can be classified as direct visual testing,

remote visual testing and translucent visual testing.

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 Visual Testing (VT)
Tools / Equipments

• Lights
• Mirrors
• Magnifiers
• Borescopes
• Rigid Probe Borescopes
• Fiberscopes
• Close Circuit Television (CCTV)

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 Advantages of VT

• Testing is simple

• Testing speed is high

• Cost is low

• Less training

• On-line testing possibility

• Permanent record available

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 Limitations of VT

• Can detect only surface defects

• Difficulty in sizing, depth of defects

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 Liquid Penetrant Testing (PT)

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 Liquid Penetrant Testing (PT)
• This is a method which can be employed for the
detection of open-to-surface discontinuities in any
industrial product which is made from a non-porous
material.
• PT widely used for testing of Non-magnetic materials.

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 Liquid Penetrant Testing (PT)
Basic Steps of PT

• Clean & Dry Component

• Apply Penetrant
• Keep dwell time
• Remove Excess penetrant
• Apply Developer
• Visual Inspection
• Post Cleaning

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 Liquid Penetrant Testing (PT)

• The liquid is allowed to properties of the liquid.

remain on the surface of • Developer aids in drawing
the part for a period of time any entrapped penetrant
called dwell time. from the defect and
• Every step of the penetrant improves background
process is done to promote visibility.
capillary action.
• Capillary Action is the
phenomenon of a liquid
rising or climbing when
confined to small openings
due to surface wetting

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 Liquid Penetrant Testing (PT)
Penetrant Type
According to Penetrant
Type 1: Fluorescent
Use Florescent penetrant and Inspect Under UV Light.
Type 2: Visible
Use Visible Penetrant and inspect under Visible light.

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 Liquid Penetrant Testing (PT)
• Penetrants are also classified by the method of
removing the excess penetrant.

Method A - Water Washable

Method B - Postemulsifiable - Lipophilic
Method C - Solvent Removable
Method D- Postemulsifiable - Hydrophilic

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 Advantages of PT

• Relatively low cost.

• Highly portable NDT method.
• Highly sensitive to fine, tight discontinuities.
• Fairly simple method.
• Can be used on a variety of materials.
• All surface discontinuities are detected in one
operation, regardless of orientation.

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 Limitations of PT
• Test surface must be free of all contaminants (dirt, oil,
grease, paint, rust, etc.).
• Detects surface discontinuities only.
• Cannot be used on porous specimens and is difficult to
use on very rough surfaces.
• Removal of all penetrant materials, following the test is
often required.
• There is no easy method to produce permanent record.

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 Magnetic Particle Testing (MT)

Magnetic Particle Testing (MT) is a non destructive

Inspection (NDI) method used to detect surface and near
surface defects in Ferromagnetic materials.
Example of ferromagnetic materials are iron, cobalt and
nickel.

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 Magnetic Particle Testing (MT)

• Magnetic domains point randomly in demagnetized

material.
• Magnetic domains can be aligned using electrical
current or an external magnetic field.

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 Magnetic Particle Testing (MT)

Theory Behind MT
• When ferromagnetic test specimen is magnetized
specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the
specimen and a leakage field will occur.

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 Magnetic Particle Testing (MT)

• Finely milled iron particles coated with a dye pigment

are applied to the test specimen.
• These particles are attracted to leakage fields and will
cluster to form an indication directly over the
discontinuity.

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 Magnetic Particle Testing (MT)

Basic Steps of MT
1. Component pre-cleaning
2. Magnetize the part
• Using electrical current or an external magnetic field

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 Magnetic Particle Testing (MT)

3. Finely milled iron particles coated with a dye pigment

are then applied to the specimen.
• Magnetic particles are attracted to magnetic flux
leakage fields and will cluster to form an indication
directly over the discontinuity.

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 Magnetic Particle Testing (MT)

4. Interpretation of magnetic particle indications

• This indication can be visually detected under proper

lighting conditions.

5. Demagnetization

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 Magnetic Particle Testing (MT)

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 Advantages of MT

• It does not need very stringent pre-cleaning operation.

• Best method for the detection of fine, shallow surface
cracks in ferromagnetic material.
• Fast and relatively simple NDT method.
• Generally inexpensive.
• Will work through thin coating.
• Few limitations regarding the size/shape of test
specimens.
• Highly portable NDT method.
• It is quicker.

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 Limitations of MT
• Material must be ferromagnetic.
• Orientation and strength of magnetic field is critical.
• Detects surface and near-to-surface discontinuities
only.
• Large currents sometimes required.
• “Burning” of test parts is a possibility.
• Parts must often be demagnetized, which may be
difficult.

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 Ultrasonic Testing (UT)
• UT is one method of NDT to the study and application
of sound wave frequencies higher than those to which
the human ear can respond (greater than 20 KHz) for
detecting defects (Typical frequency range 1MHz –
5MHz).

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 Ultrasonic Testing (UT)

• Ultrasonic waves is mechanical vibrations of high

frequency low energy.
• Ultrasonic waves is created by applying high frequency
electrical pulses to a crystal mounted in a transducer .

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 Ultrasonic Testing (UT)
• A piezoelectric element in the transducer converts
electrical energy into mechanical vibrations (sound),
and vice versa.
• The transducer is capable of both transmitting and
receiving sound energy.

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 Ultrasonic Testing (UT)
 Ultrasonic testing is a very versatile inspection method,
and inspections can be accomplished in a number of
different ways.
 Ultrasonic inspection techniques are commonly divided
into three primary classifications.
• Pulse-echo and Through Transmission
(Relates to whether reflected or transmitted energy
is used)
• Normal Beam and Angle Beam
(Relates to the angle that the sound energy enters
the test article)
• Contact and Immersion
(Relates to the method of coupling the transducer
to the test article)
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 Ultrasonic Testing (UT)
Transducers / Probes / 2.Angle beam transducers
search units In angle beam testing, the
There are two types of sound beam is introduced into
probe. the test article at some angle
1.Normal beam transducers other than 90.
In normal beam testing, the
sound beam is introduced
into the test article at 90
degree to the surface.

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 Ultrasonic Testing (UT)
Pulse-Echo Technique
• High frequency sound waves are introduced into a
material and they are reflected back from surfaces or
flaws.
• Reflected sound energy is displayed versus time, and
inspector can visualize a cross section of the specimen
showing the depth of features that reflect sound.

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 Advantages of UT
• Sensitive to small discontinuities both surface and
subsurface.
• Depth of penetration for flaw detection or measurement is
superior to other methods.
• Only single-sided access is needed when pulse-echo
technique is used.
• High accuracy in determining reflector position and
estimating size and shape.
• Minimum part preparation required.
• Electronic equipment provides instantaneous results.
• Detailed images can be produced with automated systems.
• Has other uses such as thickness measurements, in
addition to flaw detection.

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 Limitations of UT
• Surface must be accessible to transmit ultrasound.
• Skill and training is more extensive than with some other
methods.
• Normally requires a coupling medium to promote transfer of
sound energy into test specimen.
• Materials that are rough, irregular in shape, very small,
exceptionally thin or not homogeneous are difficult to
inspect.
• Cast iron and other coarse grained materials are difficult to
inspect due to low sound transmission and high signal
noise.
• Linear defects oriented parallel to the sound beam may go
undetected.
• Reference standards are required for both equipment
calibration, and characterization of flaws.
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 Radiographic Testing (RT)

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 Radiographic Testing (RT)
• An NDT method that utilizes x-rays or gamma radiation
to detect discontinuities in materials, and to present
their images on recording medium.
• It is mostly used to detect sub surface discontinuities.

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 Radiographic Testing (RT)
• The radiation used in radiography testing is a higher
energy (shorter wavelength) version of the
electromagnetic waves.
• The radiation can come from an X-ray generator or a
radioactive source.

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 Radiographic Testing (RT)

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 Radiographic Testing (RT)

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 Radiographic Testing (RT)

Basic Process of RT

• The part is placed between the radiation source and a

piece of film. The part will stop some of the radiation.
Thicker and more dense area will stop more of the
radiation.
• Then radiographic film is develop.
• The film darkness (density) will vary with the amount of
radiation reaching the film through the test object.
• So we can identify the defects. ( Defects are more
dense)

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 Radiographic Testing (RT)

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 Advantages of RT
• It can be used to inspect large areas at one time.
• It is useful on wide variety of materials.
• It can be used for checking internal malstructure,
misassembly or misalignment.
• It provides permanent record.
• No calibration needed on the job site.
• Devices for checking the quality of radiograph are
available.
• Interpretation of radiographs can be done in
comfortable conditions.

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 Limitations of RT
• X rays and gamma rays are hazardous to human
health.
• It cannot detect planar defects readily.
• Access to both sides of the specimen is required.
• Thickness range that can be inspected is limited.
• Certain areas in many items cannot be radiographed
because of the geometric consideration.
• Sensitivity of inspection decreases with thickness of
the test specimen.
• It is more costly.
• It cannot be easily automated.
• It requires considerable skill for the interpretation of
the radiographs.
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 Eddy Current Testing (ET)

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 Eddy Current Testing (ET)

Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
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 Eddy Current Testing (ET)
• There are three characteristics of the specimen that
affect the strength of the induced eddy currents.
 Electrical conductivity of the material
Magnetic permeability of the material
 Amount of solid material in the vicinity of the test coil

• Information about the strength of the eddy currents

within the specimen is determined by monitoring
changes in voltage and / or current that occur in the coil.
• The strength of the eddy currents changes the electrical
impedance (Z) of the coil.

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 Uses of Eddy Current Testing

• Crack detection (Surface and Near Surface)

• Tube and wire testing

• Condenser tube inspection

• Material sorting

• Weld testing

• Coating thickness measurement

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 Advantages of ET
• Does not require couplant.
• It gives instantaneous response.
• Has uncomplicated steps during set-up.
• Is extremely sensitive to flaws.
• Is very repeatable.
• High scanning speeds can be used.
• Is very accurate for dimensional analysis of flaws or
coating thickness.

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 Limitations of ET
• The theory requires a good academic background in
electrical principles and in mathematics.
• Extremely sensitive to surface variations and therefore
requires a good surface.
• It is applicable to conductive materials only.
• Can be used on non-magnetic and magnetic material
but is not reliable on carbon steel for the detection of
subsurface flaws.
• Its depth of penetration is limited.
• Crack tightness and orientation of eddy current flow to
a crack or linear discontinuity will affect detectability.

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 Common Application of NDT

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 Power Plant Inspection

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Aircraft Inspection
 Pressure Vessel Inspection

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Storage Tank Inspection

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 For More Information on NDT

The Collaboration for NDT Education

www.ndt-ed.org

The American Society for Nondestructive

Testing

www.asnt.org

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 Thank you
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