MAGNETIC PARTICLE TESTING

ASME BPVC Section V - Article 7

ASTM E-709, E-1444
 Introduction
• ENERGY = Magnetic Energy

• PRINCIPLE = Leakage in magnetic field & its detection

• DETECTION = By sprinkling finely divided Fe particles

• MATERIALS = Only for Ferro-Magnetic Materials

• APPICATION = Only surface and subsurface flaws

 Principle
A ferromagnetic test specimen is magnetized with a strong
magnetic field created by a magnet or special equipment.

If the specimen is perfect, continuous magnetic flux lines are

established between north and south poles.
If the specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the specimen
and a leakage field will occur.
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.

This indication can be visually detected under proper lighting

conditions.
 Basic Procedure

Basic steps involved:

1. Component pre-cleaning

2. Introduction of magnetic field

3. Application of magnetic media

4. Interpretation of magnetic particle indications

5. Demagnetization
 1. Pre-cleaning
When inspecting a test part with the magnetic particle method it is
essential for the particles to have an unimpeded path for migration to
both strong and weak leakage fields alike.

Contaminants such as oil, grease, or scale may not only prevent

particles from being attracted to leakage fields, they may also
interfere with interpretation of indications.

The surface should be relatively clean but this is not as critical as it is

with liquid penetrant inspection.

Specifications often allow up to 0.076 mm of a nonconductive coating

(such as paint) and 0.025 mm of a ferromagnetic coating (such as
nickel) to be left on the surface.
 2. Introduction of the Magnetic Field

A. PERMANENT MAGNET

B. ELECTROMAGNET

 Flowing an electrical current through the part

 Flowing an electrical current around the part
Relation between Current & Magnetic Field

Direction of current is always

perpendicular to the
direction of magnetic field
created

1. Longitudinal Magnetization

2. Circular Magnetization
 Indirect
Magnetization

CURRENT

Direct
Magnetization
 Importance of Magnetic Field Direction
The best detection of defects occurs when the lines of
magnetic force are established at right angles to the longest
dimension of the defect

This orientation creates the largest disruption of the

magnetic field within the part and the greatest flux leakage at
the surface of the part

No Flux Leakage
An orientation of 45o to 90o between the magnetic field
and the defect is necessary to form an indication

Since defects may occur in various and unknown

directions, each part is normally magnetized in two
directions at right angles to each other
Question 1

? From the previous slide regarding the optimum

test sensitivity, which kinds of defect are easily
found in the images below?

Longitudinal (along the axis) Transverse (perpendicular the axis)

Question 2

? Why are the internal flaws not found out by MPT?

A B

For flaws A & B : Leakage field observed on the surface

But for flaw C : Leakage field is NOT observed on the surface
 Longitudinal Magnetic Fields

They are produced by passing current

around the part.

 Coils

 Yokes
 Coils

A longitudinal magnetic field is usually established by

placing the part near the inside or a coil’s annulus.

Coil on Wet Horizontal Inspection Unit

Conductive Cables
 Yokes

Permanent magnets and electromagnetic yokes are also

often used to produce a longitudinal magnetic field.

The magnetic lines of force run from one pole to the other,
and the poles are positioned such that any flaws present run
normal to these lines of force.
 Circular Magnetic Fields
They are produced by passing current
through the part or by placing the part in a
strong circular magnet fields.

 Headshots
 Central conductors
 Prod Contacts
Head Shot Method
Central Conductors
PROD CONTACTS
 Currents in MPT
 Both AC and DC

 AC = 500 – 800 amps

 Skin effect – suited for surface flaw analysis

 DC = 800 – 1000 amps

 No skin effect, suited for sub-surface analysis

 HWDC, FWDC, 3P AC/DC

 3. Application of Magnetic Media
(Wet Vs Dry)
MPI can be performed using either dry particles, or particles
suspended in a liquid.

With the dry method, the particles are lightly dusted on to the
surface.

With the wet method, the part is flooded with a solution

carrying the particles.

The dry method is more portable.

The wet method is generally more sensitive since the liquid

carrier gives the magnetic particles additional mobility.
Application of Dry Particles

Dust on the dry

magnetic particles with
help of a bulb tly blow
off the excess powder
Application of Wet Particles
 Dry Magnetic Particles
Magnetic particles come in a variety of colors.

Should have LOW Retentivity and HIGH Permeability

Size = 50 – 150 m Shape = Long, slender shape

Recommended Current : AC or HWDC

 Wet Magnetic Particles

Wet particles are supplied as visible or fluorescent

Dry particles dissolved in kerosene or oil

Size = 10 m, Concentration of the suspension

Fluorescent MPT
 4. Interpretation of Indications

After applying the magnetic field, indications that form

must interpreted.

This process requires that the inspector distinguish

between relevant and non-relevant indications.
 Crane Hook with
Service Induced Crack

Fluorescent, Wet Particle Method

 Gear with
Service Induced Crack

Fluorescent, Wet Particle Method

 Drive Shaft with
Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

 Splined Shaft with
Service Induced Cracks

Fluorescent, Wet Particle Method

 Threaded Shaft with
Service Induced Crack

Fluorescent, Wet Particle Method

 Large Bolt with
Service Induced Crack

Fluorescent, Wet Particle Method

 Crank Shaft with
Service Induced Crack Near Lube Hole

Fluorescent, Wet Particle Method

Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

Toe Crack in SMAW Weld

Visible, Dry Powder Method

Throat and Toe Cracks in
Partially Ground Weld

Visible, Dry Powder Method

 5. Demagnetization
• Parts inspected by the magnetic particle method may
sometimes have an objectionable residual magnetic field that
may interfere with subsequent manufacturing operations or
service of the component.

• Possible reasons for demagnetization include:

– May interfere with welding and/or machining operations

– Can effect gauges that are sensitive to magnetic fields if placed in

close proximity.

– Abrasive particles may adhere to components surface and cause

and increase in wear to engines components, gears, bearings
etc.
Demagnetization
 Demagnetization

• First keep the part in EAST – WEST direction

• Then pass reversing and reducing current (AC)

• Reduce the strength of the residual field to an acceptable

level

 Less than 3 gauss

 A field meter is often used to verify that the residual flux

• Takes several hours to some days

Testing Practices
Dry particle testing
 Prepare the part surface

 Apply the magnetizing force

 Dust on the dry magnetic particles

 Gently blow off the excess powder

With the magnetizing force still applied, remove the excess

powder from the surface with a few gentle puffs of dry air. The force
of the air needs to be strong enough to remove the excess particles but
not strong enough to dislodge particles held by a magnetic flux
leakage field.

 Terminate the magnetizing force

 Inspect for indications

Wet particle testing – Fluorescent version

 Prepare the part surface

 Apply the suspension

 Apply the magnetizing force

 Pass the dark light

 Inspect for indications

Continuous Magnetization Technique

Here the magnetizing force is applied and

maintained while the magnetic particles are
dusted or flowed onto the surface of the
component.

Residual Magnetization Technique

Here the magnetizing force is applied to

magnetize the component and then stopped
before applying the magnetic particles.

Only the residual field of the magnetized

component is used to attract magnetic particles
and produce an indication.
The continuous technique is generally chosen when
maximum sensitivity is required.

First, the magnetic flux will be highest when current is

flowing and, therefore, leakage fields will also be strongest.

The second advantage is that when current is used to

generate the magnetizing force, it can provide added particle
mobility.

One disadvantage of the continuous method is that heating

of the component occurs when using direct magnetization.

Materials with high Permeability = Continuous technique

Materials with high Retentivity = Residual technique

Continuous Vs Residual
 Advantages
• Can detect both surface and near sub-surface defects.

• Can inspect parts with irregular shapes easily.

• Precleaning of components is not as critical as it is for some

other inspection methods.

• Fast method of inspection and indications are visible directly

on the specimen surface.

• Considered low cost compared to many other NDT methods.

• Is a very portable inspection method especially when used with

battery powered equipment.
 Limitations
• Cannotinspect non-ferromagnetic materials such as aluminum,
magnesium or austenitic stainless steels.

• Limitedsubsurface discontinuity detection capabilities. Maximum

depth sensitivity is approximately 0.6” (under ideal conditions).

• Demagnetization is often necessary.

• Inspection of large parts may require use of equipment with special

power requirements.

• Some parts may require removal of coating or plating to achieve

desired inspection sensitivity.
Quality Checks
 Field Direction

 It is difficult to detect discontinuities that intersect the magnetic field

at an angle less than 45o.

 When the orientation of a defect is not well established, components

should be magnetized in a minimum of two directions at approximately
right angles to each other.

 Depending on the geometry of the component, this may require

longitudinal magnetization in two or more directions, multiple
longitudinal and circular magnetization or circular magnetization in
multiple directions.

 The pie gage is generally only used to find out the field direction.
 Field Strength

 The applied magnetic field must have sufficient strength to produce a

satisfactory indication, but not so strong that it produces nonrelevant
indications or limits particle mobility.

 If the magnetizing current is excessively high when performing a wet

fluorescent particle inspection, particles can be attracted to the
surface of the part and not be allowed to migrate to the flux leakage
fields of defects.

 When performing a dry particle inspection, an excessive longitudinal

magnetic field will cause furring.

 A field strength of 30 to 60 gauss is required at the surface when the

magnetizing force is applied.
 Length to Diameter Ratio

 When establishing a longitudinal magnetic field in component using a

coil or cable wrap, the ratio of its length to its diameter or thickness
must be taken into consideration.

 If the length dimension is not significantly larger than the diameter or

thickness dimension, it is virtually impossible to establish a field
strength strong enough to produce an indication.

 An L/D ratio of at least two is usually required.

 If the component does not meet the minimum L/D ratio requirement,
end pieces may be used to essentially lengthen the component.
 Yokes Standardization

 A perfect yoke should lift 4.5 Kg when it is

operated with AC current.

 A perfect yoke should lift 18 Kg when it is

operated with DC current.
Process Control
Particle Concentration
 ASTM E-1444-01

Acceptable ranges of deposition are 0.1 to 0.4 ml

for fluorescent particles and 1.2 to 2.4 ml for
visible particles.
Particle Condition

 Brightness and agglomeration

Suspension Contamination

Lighting

Eye considerations
Magnetic Flux Leakage (MFL) Testing

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 MFL is a magnetic method of nondestructive
testing that is used to detect corrosion and
pitting in steel structures, most commonly
pipelines and storage tanks.

 The basic principle is that a powerful magnet

is used to magnetize the steel.

 At areas where there is corrosion or missing

metal, the magnetic field "leaks" from the
steel.

 In an MFL tool, a magnetic detector is placed

between the poles of the magnet to detect the
leakage field.
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 Very fast process (1 m/s)

 Cost effective

 No need of magnetic particles

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