UNIT-3

MAGNETIC PARTICLE TESTING

Department of Mechanical Engineering

MALNAD COLLEGE OF ENGINEERING

HASSAN – KARNATAKA
INDIA- 573 202
 MAGNETIC PARTICLE TESTING

This module is intended to present information on the widely used

method of magnetic particle inspection.
Magnetic particle inspection can detect both production discontinuities
(seams, laps, grinding cracks and quenching cracks) and in-service damage
(fatigue and overload cracks).

MAGNETISUM : A physical phenomenon produced by the motion of

electric charge, which results in attractive and repulsive forces between
objects.
 Introduction to Magnetism

Magnetism is the ability of matter to Magnetic field lines:

attract other matter to itself. Objects that • Form complete loops.
possess the property of magnetism are • Do not cross.
said to be magnetic or magnetized and • Follow the path of least
magnetic lines of force can be found in resistance.
and around the objects. A magnetic pole • All have the same strength.
is a point where the a magnetic line of • Have a direction such that
force exits or enters a material. they cause poles to attract or
repel.

Magnetic lines of force Opposite poles attracting Similar poles repelling

around a bar magnet
According to interaction with magnetic field, materials
can be classified as:

Diamagnetic materials
Weak, negative susceptibility
Slightly repelled
Does not retain magnetic properties
All electrons are paired

Paramagnetic materials
Small, positive susceptibility
Slightly attracted
Does not retain magnetic properties
Some unpaired electrons

Ferromagnetic materials
Large, positive susceptibility
Strong attraction to magnetic fields
Retain their magnetic properties
Strong magnetic properties
Some unpaired electrons
 MAGNETIC HYSTERISIS
Certain ferromagnetic materials when magnetized do not
return to a completely demagnetized state when the
magnetizing force is removed.
To completely demagnetize the material a certain reverse
magnetic force must be applied unless the material is
heated above the Curie point for that material or the
material is mechanically worked. If a variable external
field is applied to a virgin specimen and both the external
field and the degree of magnetization or flux density are
measured, a curve representative of the material can be
plotted as in Figure.
This curve is known as hysteresis curve. Hysteresis is the
retardation of the magnetic effect when the magnetising
force H acting on the ferromagnetic material is changed.
The point at which there is no magnetization and no force
applied is represented by (o). By increasing the
magnetizing force in small increments the flux increases
rapidly at first then slowly until the maximum flux or
saturation point (a) is reached.
Hysteresis loops for typical
ferromagnetic materials
 MAGNETIC HYSTERISIS
A further increase in the magnetizing force H
will not increase the flux density B. The rise in
flux density is shown by the line o-a. If the
magnetic force is now gradually reduced back
to zero the curve (a-b) will show the decrease
in flux density.
However there is still some magnetism
remaining in the specimen represented by
point (b). The amount of this magnetism is
indicated by the distance (o-b) and is called the
residual magnetism.
If the magnetizing current is now reversed and
slowly increased in value the flux density
(residual magnetism) within the specimen
decreases and is back to zero at point (c).
By further increasing the magnetizing force the
specimen becomes magnetized in the opposite
Hysteresis loops for typical
direction until once again saturation is reached
at point (d). ferromagnetic materials
 MAGNETIC HYSTERISIS
If the magnetizing force is again gradually
reduced to zero the flux density is reduced a
certain amount to (e), however, the specimen
will still retain some residual magnetism
represented by o-e.
If we now steadily increase the magnetic force
in its original direction the residual flux
density is reduced to zero at point (f) and
then increases to the original saturation point
(a). The curve represented by the lines a, b, c,
d, e, f, is called a hysteresis curve or hysteresis
loop.

Hysteresis loops for typical

ferromagnetic materials
 How Does Magnetic Particle
Inspection Work?
A ferromagnetic test specimen is magnetized with a strong
magnetic field created by a magnet or special equipment. If
the specimen has a discontinuity, the discontinuity will
interrupt the magnetic field flowing through the specimen
and a leakage field will occur.
 How Does Magnetic Particle
Inspection Work? (Cont.)
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.
 PROCEDURE FOR TESTING

1. Surface Preparation before testing

2. Initial demagnetization
3. Magnetization of the component
4. Application of magnetic particles
5. Inspection
6. Marking of defects
7. De magnetization
8. Removal of ink from component
Introduction of the Magnetic Field
The required magnetic field can be introduced into a component in a
number of different ways.
1. Using a permanent magnet or an electromagnet that contacts the
test piece
2. Flowing an electrical current through the specimen
3. Flowing an electrical current through a coil of wire around the part
or through a central conductor running near the part.
 Direction of the Magnetic Field
Two general types of magnetic fields (longitudinal and
circular) may be established within the specimen. The type of
magnetic field established is determined by the method used
to magnetize the specimen.

• A longitudinal magnetic field has

magnetic lines of force that run parallel
to the long axis of the part.
• A circular magnetic field has magnetic
lines of force that run circumferentially
around the perimeter of a part.
 Importance of Magnetic Field
Direction
Being able to magnetize the part in two directions is Flux Leakage
important because 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. An orientation of 45
to 90 degrees between the magnetic field and the defect
is necessary to form an indication.
No Flux Leakage

Since defects may occur in

various and unknown
directions, each part is
normally magnetized in
two directions at right
angles to each other.
 METHODS OF MAGNETIZATION

• Magnetization using a permanent magnet

• Magnetization using an electromagnet
• Contact current flow method
• Magnetization by using coils
• Magnetization using induced current
 Magnetization using a permanent magnet

The simple way of magnetizing a component is done by

position it across the poles of horse shoe magnet. The
direction of the flux is known.
The intensity can be varied by using a strong or weak
magnet. This methods is especially suited, where the electric
power is not available.
 Magnetization using an electromagnet

Magnetic flux is produced by using electromagnet with flux

path, adjustable to suit the components.
The flux density of the magnetic field produced by the direct
current type can be changed by varying the amount of current
in the coil.
This type of equipment has greater penetration compared
AC type equipment.
 Contact current flow method

By passing current through a component, a magnetic field is

induced at right angles to the current flow.
This method locates defects at right angles to the appllied
magnetic direction.
The complete inspection of complex part can be done by
clamping the part at several points.
 Magnetization by using coils

Single loop or multi loop coils are used for the longitudinal
magnetization of components.
The flux density passing through the interior of the coil is
proportional to the product of current I and the number of
turns in the coil N.
Magnetizing force of such coil can be varied by changing
either current or the number of turns.
Portable magnetizing coils can be used for inspection of
transverse crank in spindle and shafts.
 Magnetization using induced current

It is very difficult to detect radial forces in large rings

because they have unfavorable shapes and don't respond for
testing using coils.
Induced current provides a convenient methods of
generating circumferential magnetizing current in ring shaped
parts without making electrical contact.
 Application of Magnetic
Media (Wet Versus 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.
 Dry Magnetic Particles
Magnetic particles come in a variety of colors. A color
that produces a high level of contrast against the
background should be used.
 Wet Magnetic Particles
Wet particles are typically supplied as
visible or fluorescent. Visible particles
are viewed under normal white light
and fluorescent particles are viewed
under black light.
 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.

The following series of images depict relevant

indications produced from a variety of
components inspected with the magnetic particle
method.
 ADVANTAGES OF
MAGNETIC PARTICLE INSPECTION
 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. Most contaminants within
a flaw will not hinder flaw detectability.
 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 OF
MAGNETIC PARTICLE INSPECTION
 Cannot inspect non-ferrous materials such as aluminum,
magnesium or most stainless steels.
 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.
 Limited subsurface discontinuity detection capabilities.
 Maximum depth sensitivity is approximately 0.6” (under ideal
conditions). Magnetic particle testing can only detect flaws at or
near the surface.
 Post cleaning, and post demagnetization is often necessary.
 Alignment between magnetic flux and defect is important.
APPLICATIONS

Inspection of hollow cylindrical parts:

Inspection of Casting and Forgings
APPLICATIONS

Crane Hook with

Service Induced Crack

Fluorescent, Wet Particle Method

APPLICATIONS

Gear with
Service Induced Crack

Fluorescent, Wet Particle Method

APPLICATIONS

Drive Shaft with

Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

APPLICATIONS

Splined Shaft with

Service Induced Cracks

Fluorescent, Wet Particle Method

APPLICATIONS

Threaded Shaft with

Service Induced Crack

Fluorescent, Wet Particle Method

APPLICATIONS

Large Bolt with

Service Induced Crack

Fluorescent, Wet Particle Method

APPLICATIONS
Crank Shaft with
Service Induced Crack Near Lube Hole

Fluorescent, Wet Particle Method

APPLICATIONS

Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

APPLICATIONS

Toe Crack in SMAW Weld

Visible, Dry Powder Method

APPLICATIONS
Throat and Toe Cracks in
Partially Ground Weld

Visible, Dry Powder Method

 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 (Cont.)
• Demagnetization requires that the residual magnetic field
is reversed and reduced by the inspector.
• This process will scramble the magnetic domains and
reduce the strength of the residual field to an acceptable
level.

Magnetized Demagnetized