NDT method

Magnetic Particle Inspection

Session -1

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Session Contents

 Fundamentals.
 Brief history of MPI
 Principle of MPI .
 MPI Procedure.
 Classification of MPI.
 MPI method (EM yoke)
 Merits and Demerits of MPI
 Applications.
 Type of defects detected in MPI and evaluation..
 Misconception and clarifications..
 Quiz

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 Some fundamentals

In 1820, Hans Christian Oersted discovered deflection of needle

of compass when placed near current carrying conductor.

Lines of flux travels from North pole to South pole.

These lines flows in a straight line undisturbed.

When magnet is damaged , magnetic poles are created at

junction called Dipoles.

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Some fundamentals

Maxwell Right hand thumb rule

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Mag. Lines of flux

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 MPI History

 William Hoke in 1920.

 Mag particle can be used with
magnetism to detect flaws .
 Shop floor observation.
 Metal grinding forming a
pattern on crack when held
under mag field .
 Fine ferromagnetic powder
formed visible pattern when
placed in mag field.
 1928 first machine developed
by ECO in England.

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Magnetic Materials

Type of magnetic material

 Para magnetic

Slightly magnetic in mag field.

Eg .magnesium, molybdenum,
lithium, and tantalum.
 Dia- magnetic

Repel in magnetic field .

Eg. copper, silver, and gold.

 Ferro Magnetic –
Presence of magnetic domain.
Eg. Iron, nickel, and cobalt 

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 MPI principle
What is MPI ??
 Magnetic particle Inspection (MPI) is a non-
destructive testing (NDT) process for detecting
surface and subsurface discontinuities
in ferromagnetic materials such as iron,
nickel, cobalt, and some of their alloys. ASTM
E709. ASME SEC V.

What is the mechanism ??

 Surface is electro magnetised with AC/DC current.
 Detection media is sprayed on the surface & mag field is applied
 Aligned at greater than 45 deg ( max sensitivity to 90deg) to the direction
of mag fields.
 Particles get aligned in direction of leakage mag field on the edges of
discontinuity.

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 Method -Magnetisation types

 AC – Surface defects. Skin effect .

 HWDC- Near surface.
 FWDC –Sub surface max penetration.

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How Methods are classified

Which
conditions Test
How object is environment
Type of Detection test is
magnetised
current (AC media (Wet conducted Lab or in situ
or DC) suspension or (Visible light (Continuous
or Residual ) (Stationary or
Dry) or Dark portables.)
Room ).

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How MPI is carried out..

Detectio Removal
Surface Magneti n media of Demagn
cleaning zation applicati Excess etization
on media

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EM Yoke method
 Portable for on site inspection.
 Ease of calibration.

 Continuous wet or dry method.

 Longitude and transverse cracks.

 Test object AC (4.5 kg) , DC (18.0 kg)

 Dimension (50 mm*150mm)

 visible light 1000 Lux for analysis of
result.
 Leg spacing 3inch to 8 inch.

 Temp range 200 deg C (dry particles)

& 50 deg C (wet particles).

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 Checking Sensitivity of magnetic field
 Pie gauge
 Copper with internal flaws.
 Magnetized and detection
media is sprayed.
 Flaws become visible.

 Hall effect probes.

 Transverse /Axial probe
 Field strength measurement
using EMI.

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Steps wise EM yoke

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Defects observed in MPI
Fluorescent
method Visible method

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Applications

Fatigue cracks on LPT blades.

HP welding of boiler tubes

Power cycle piping inspection.

Maintenance inspection of structure welding .

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Magnetic particles Properties

Iron powder of Red/Black/Yellow colour.

Ease of flow.

Free from contamination.

Non Toxic & non flammable.

Dry form or suspended in Water/Petroleum distillate.

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Slide
 Merits & Demerits of MPI

Advantages
 Sensitive , Portable & fast method.
 Reliable testing method for detecting linear discontinuities.
 Surface and sub surface defect ( upto 10 mm in ideal conditions)
 Can inspect parts with irregular shapes.
Limitations
 Surface preparation
 Post cleaning & demagnetization reqt.
 Only Ferro magnetic materials. (Allumunium and Austenitic SS)
 Alignment between magnetic flux and defect 

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 Type of discontinuity

 Linear indication  Porous indications

 Length > 3 times width.  Unacceptable >3.17 mm
 Unacceptable: >3.96mm .  Unacceptable CP >12.7 mm
 AWS D1.1  API Std

 Rounded indication
 Width > 3 times length
 Unacceptable : 4 or more less
than 2 mm spacing.
 Dimension > 5mm
unacceptable
 ASME B3.1
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Misconceptions and clarifications
 More current is always better
is magnetism.
 Saturation
 Masking of discontinuity
 All materials magnetized in
same manner  needed
 Susceptibility (S)and
receptivity (R) .
 Iron high S , low R
 Steel low S , high R
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  You can magnetize through
coatings 
 Coating 0.02 to 0.05 mm is
acceptable.
 At point of electrical contact ,no
coating .
 Demagnetize test object not
 arc blow during welding.
 Interfere with compass.
 Abrasive particle cling to
rotating part bearing etc
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Recent trends
Universal WE Multi-Directional Magnetic Wet Bench

Features
• PLC controlled test bench.
• Pump for spraying mag .particles
• 2000 Amps of magnetization current .
• 900 mm long object.
• Advanced process control for current
adjustment.
• Auto magnetization , spraying of
media detection and demagnetization.
• Advance alert and diagnostic system
• Comply with ASTM E1444,E709.
• Upgradable to florescent method in
UV light.

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 Questions
 Which type of materials can be tested with MPI ?
 Demagnetization of material after test is not necessary ? True or
False.
 What sustains magnetism in cracked ferromagnetic material?
 Yoke method is simplest method of MPI. True or false ?
 MPI is a volumetric NDT method ,True or False ?

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Thank You

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