Magnetic Particle Inspection (MPI): A Closer Look at the Basic Steps
agnetic Particle Inspection (MPI) is a non-destructive testing (NDT) technique for detecting
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surface and subsurface discontinuities in ferromagnetic materials. This report dives deeper into
the four essential steps involved in MPI:
1. Component Pre-Cleaning:
● Importance:A clean surface is crucial for effectiveMPI. Contaminants like dirt, grease, paint,
or moisture can disrupt the magnetic field and hinder the detection of discontinuities.
● Cleaning Methods:
○ Solvents: Degreasers or wipes remove oil, grease, and other non-soluble contaminants.
○ Detergents: For water-soluble contaminants, detergents or alkaline solutions are used for
cleaning.
○ Abrasive Blasting: In extreme cases, abrasive blasting techniques like sandblasting can be
used to remove heavy scaling, paint, or rust.
○ The chosen cleaning method depends on the type and severity of contaminants present.
2. Introduction of Magnetic Field:
● T he Core of MPI:This step involves inducing a strongmagnetic field within the test
component. The type of magnetization technique used depends on the:
○ Shape and size of the object:
■ Simple geometries benefit from the yoke method, where a hand-held electromagnet is
placed on the surface to create a magnetic field.
■ Complex shapes might require the prods method, where direct current is passed
through cables placed strategically on the test object.
○ Direction of discontinuities you are trying to detect:The magnetic field needs to be
aligned to effectively reveal these.
● Magnetization Techniques:
○ Yoke Method:This is a quick and portable method suitablefor flat surfaces or simple
geometries. A yoke electromagnet placed on the surface creates a magnetic field that
passes through the test object.
○ Prod Method:This method offers more flexibility forcomplex shapes. Direct current is
passed through cables placed on the test object, creating a magnetic field along the length
of the cable. This allows for the creation of various magnetic field directions.
○ Bath Method:This method is efficient for large objects.The test object is immersed in a
magnetizing solution while current is passed through the solution, inducing a magnetic
field throughout the entire object.
3. Application of Magnetic Media:
● A ttracting the Discontinuities:Here, finely dividedmagnetic particles are introduced to
interact with the induced magnetic field. There are two main types of magnetic media used:
○ Dry Particles:These are free-flowing, ferromagneticpowders (often iron) dusted or
sprayed onto the magnetized surface.
○ Wet Particles:These are magnetic particles suspendedin a liquid carrier (usually water
r oil). The suspension is sprayed or bathed onto the test object's surface.
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● Choosing the Right Media:The selection between dryand wet particles depends on
several factors:
○ Sensitivity Requirements:Wet particles, with theirenhanced carrier fluid properties,
generally offer higher sensitivity for detecting tight cracks.
○ Portability:Dry particles offer greater portabilitydue to the simplicity of their application.
○ Ease of Cleanup:Wet particles require a cleaningstation with appropriate filtration
systems for proper disposal of the used suspension.
4. Interpretation of Magnetic Particle Indications:
● V isual Inspection:After applying the magnetic media,the surface is thoroughly inspected
under appropriate lighting conditions. Often, black light is used when fluorescent particles are
employed to enhance their visibility.
● Decoding the Pattern:Any accumulation of magneticparticles indicates the presence of a
discontinuity. The inspector analyzes the:
○ Pattern:Linear indications suggest cracks, whilerounded clusters might indicate porosity
or inclusions.
○ Size and intensity:The severity of the discontinuitycan be inferred from the extent of
particle accumulation.
● Experience is Key:Skilled inspectors can interpretthe magnetic particle indications based
on their knowledge of discontinuity types, material properties, and MPI techniques.
y following these essential steps and with proper expertise in interpretation, MPI offers a
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reliable method for ensuring the integrity of ferromagnetic components across various
industries.
