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Ned University of Engineering & Technology

NC REPORT

29th April, 2010

Prepared By: Muhammad Faheem Khan M.E Final Year (Fifth Semester)

Magnetic Particle Inspection of Hot Rolled 1045 Carbon steel

Chapter 1 Introduction of MPI

1 1.1 1.2 1.3 1.4

Introduction ---------------------------------------------------------History------------------------------------------------------------------

06-07 07-08

Basic principle ------------------------------------------------------------ 08-09 Advantages ------------------------------------------------------------------- 10 Limitations -------------------------------------------------------------------- 10 Chapter 2 Theory of Magnetism

2 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.5.3 2.6 2.7

Magnetism

-------------------------------------------------------

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Source of Magnetism ------------------------------------------------------- 11 Magnetic domains Magnetic poles ------------------------------------------------------- 11-12 --------------------------------------------------------- 12-13 13

Magnetic material -----------------------------------------------------------

Types of magnetic materials ------------------------------------------------ 14 Diamagnetic materials -----------------------------------------------------14

Paramagnetic materials-------------------------------------------------------- 14 Ferromagnetic materials-------------------------------------------------------- 15 General properties of magnetic lines of force ------------------------------ 15 Magnetic Hysteresis curve ----------------------------------------------16-17

2.8

Basic Magnetic particle testing theory --------------------------------------- 17 Chapter 3 Magnetic Flux Theory

3 3.1 3.2 3.3

Magnetizing Current-----------------------------------------------------------

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Direct Current -------------------------------------------------------------------------------- 18 Alternating Current --------------------------------------------------------------------------- 18 Rectified Alternating Current ------------------------------------------------------------19 2

3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 Half Wave Rectified Alternating Current (HWAC) -------------------------------- 19 -20 Full Wave Rectified Alternating Current (FWAC) (Single Phase)------------------- 20 Three Phase Full Wave Rectified Alternating Current ------------------------------- 20 Circular magnetic field ----------------------------------------------------------------------- 20 Method of inducing circular field -------------------------------------------------------21

Circular magnetic field strength --------------------------------------------------------- - 22 Discontinuity ---------------------------------------------------------------------------------22

Longitudinal magnetic field------------------------------------------------------------- - - 23 Discontinuity ---------------------------------------------------------------------------------24

Chapter 4 selection criteria for inspection

4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6

Method of selection criteria --------------------------------------------------Part geometry ----------------------------------------------------------------------Particle size -----------------------------------------------------------------------Types of discontinuity ----------------------------------------------------------Selection techniques ------------------------------------------------------------Current -----------------------------------------------------------------------------Particle -----------------------------------------------------------------------------Application -----------------------------------------------------------------------Magnetism ------------------------------------------------------------------------Amperage ------------------------------------------------------------------------Equipment and Environment ------------------------------------------------Chapter 5 Method of testing Methods of testing -------------------------------------------------------------5.1 5.2 5.2.1

25 25 25-26 26 26 26 27 27 27 27 27

28 28 28 28

Dry method -----------------------------------------------------------------------Steps in performing an inspection using dry particles ------------------Prepare the part surface ------------------------------------------------------

4 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.3

Apply the magnetizing force -------------------------------------------------Dust on the dry magnetic particles ----------------------------------------Gently blow off the excess powder ------------------------------------------Terminate the magnetizing force --------------------------------------------Inspect for indications---------------------------------------------------------Wet method-----------------------------------------------------------------

28 29 29 29 29 29

5.3.1 5.3.2 5.3.3 5.3.4 5.3.5

1 Steps in performing an inspection using wet suspensions ---------Prepare the part surface------------------------------------------------------Apply the suspension ---------------------------------------------------------Apply the magnetizing force ------------------------------------------------Inspect for indications --------------------------------------------------------Chapter 6 Equipment for MPI

30 30 30 30 30

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12

Portable Magnetizing Equipment for Magnetic Particle Inspection ---- 31 Permanent Magnet ---------------------------------------------------------------Electromagnets------------------------------------------------------------------Prods--------------------------------------------------------------------------------Portable Coils and Conductive Cables -------------------------------------Portable Power Supplies ------------------------------------------------------Stationary Equipment for Magnetic Particle Inspection --------------Lights for Magnetic Particle Inspection ---------------------------------Ultraviolet Light-----------------------------------------------------------------Basic ultraviolet lights -------------------------------------------------------High Intensity Ultraviolet Lights --------------------------------------------Magnetic Field Indicators -----------------------------------------------Gauss Meter or Hall Effect Gage--------------------------------------------31 31-32 32-33 33-34 34 34-35 36 36 37 38 38-39 39
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5 6.13 6.14 6.15

Quantitative Quality Indicator (QQI) ------------------------------------Pie Gage ---------------------------------------------------------------------------Slotted Strips-------------------------------------------------------------------Chapter 7 Experimental work

39-40 40 41

Experimental work -----------------------------------------------------------7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Chemical composition of Hot Rolled 1045 carbon steel --------------Heat treatment -----------------------------------------------------------------Part Geometry ------------------------------------------------------------------Sample preparation ---------------------------------------------------------- Experimental procedure---------------------------------------------------Longitudinal method by yoke --------------------------------------------Results and Discussion -----------------------------------------------------

42 42 42 43 43 43-44 44-45 46

Conclusion-------------------------------------------------------------------46 References --------------------------------------------------------------------- 47

Chapter 1 Introduction to Magnetic particle inspection 1. INTRODUCTION

Magnetic particle testing is used for testing ferromagnetic materials such as steel, wrought iron, and cast iron. Magnetic particle testing is used to confirm suspected cracks or test suspect details. Magnetic particle testing is highly sensitive in detecting tight surface cracks and other small discontinuities. Cracks, lack of fusion, weld-related surface discontinuities, and base metal discontinuities are easily detected. The magnetic particle method utilizes the principle that magnetic lines of force, when present in a ferromagnetic material, will be distorted by a change in material continuity, such as a sharp dimensional change or a discontinuity. If the discontinuity is open to, or close to, the surface of a magnetized material, flux lines will be distorted at the surface causing a condition termed flux leakage. When fine magnetic particles are distributed over the area of the discontinuity when the material is magnetized, they will be held in place and the accumulation of particles will be visible. In magnetic particle testing, one must apply a magnetic field of sufficient strength and predetermined direction to cause flux leakage if discontinuities are present. The inspector detects these leaks by sprinkling the test area with iron filings, blowing away the excess and observing areas where the filings have accumulated. Accumulations indicate a surface, or possibly, a subsurface discontinuity. Magnetic particle test methods and implementation procedures are described as follows: In the dry method, the iron filing powder used as an indicating medium is dry. Commercial powders are available in various colors including red, black, grey, or yellow. The color should be selected to maximize the contrast with the material to be tested. Dry, fluorescent particles are also available for use with a black light. Dry particles are finely divided, ferromagnetic material with high permeability and low retentivity. The powder consists of a mixture of particle sizes, smaller ones being attracted by weak leakage fields, and larger ones for detecting larger discontinuities.

If the test powders or particles are suspended in oil or water, the method is considered wet. Wet suspensions are also available in various colors and fluorescent. They can be sprayed onto the part, or the part can be bathed in a suspension. Wet fluorescent particles
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provide maximum sensitivity if used with the proper current, lighting, and surface preparation. Wet particles are mixed with the suspension in predetermined concentrations and particle sizes. The concentration will affect the test sensitivity. Light concentrations will produce faint indications, and heavy concentrations may provide too much coverage. They are generally smaller in size and lower in permeability than dry particles.

The term continuous procedure is used if a magnetizing force is applied prior to the application of the particles, and terminated only after excess powder has been blown away.

The term residual procedure is used when the particles are applied after the part has been magnetized, and the magnetizing current terminated.

1.1 History of Magnetic Particle Inspection

Magnetism is the ability of matter to attract other matter to itself. The ancient Greeks were the first to discover this phenomenon in a mineral they named magnetite. Later on Bergmann, Becquerel, and Faraday discovered that all matter including liquids and gasses were affected by magnetism, but only a few responded to a noticeable extent.The earliest known use of magnetism to inspect an object took place as early as 1868. Cannon barrels were checked for defects by magnetizing the barrel then sliding a magnetic compass along the barrel's length. These early inspectors were able to locate flaws in the barrels by monitoring the needle of the compass. This was a form of nondestructive testing but the term was not commonly used until some time after World War I .In the early 1920s, William Hoke realized that magnetic particles (colored metal shavings) could be used with magnetism as a means of locating defects. Hoke discovered that a surface or subsurface flaw in a magnetized material caused the magnetic field to distort and extend beyond the part. This discovery was brought to his attention in the machine shop. He noticed that the metallic grindings from hard steel parts (held by a magnetic chuck while being ground) formed patterns on the face of the parts which corresponded to the cracks in the surface. Applying a fine ferromagnetic powder to the parts caused a build up of powder over flaws and formed a visible indication. The image
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shows a 1928 Electyro-Magnetic Steel Testing Device (MPI) made by the Equipment and Engineering Company Ltd. (ECO) of Strand, England In the early 1930s, magnetic particle inspection was quickly replacing the oil-and-whiting method (an early form of the liquid penetrant inspection) as the method of choice by the railroad industry to inspect steam engine boilers, wheels, axles, and tracks. Today, the MPI inspection method is used extensively to check for flaws in a large variety of manufactured materials and components. MPI is used to check materials such as steel bar stock for seams and other flaws prior to investing machining time during the manufacturing of a component. Critical automotive components are inspected for flaws after fabrication to ensure that defective parts are not placed into service. MPI is used to inspect some highly loaded components that have been in-service for a period of time. For example, many components of high performance racecars are inspected whenever the engine, drive train or another system undergoes an overhaul. MPI is also used to evaluate the integrity of structural welds on bridges, storage tanks, and other safety critical structures

1.2 Basic principle

Magnetic particle inspection (MPI) is a relatively simple concept. It can be considered as a combination of two nondestructive testing methods: magnetic flux leakage testing and visual testing. Consider the case of a bar magnet. It has a magnetic field in and around the magnet. Any place that a magnetic line of force exits or enters the magnet is called a pole. A pole where a magnetic line of force exits the magnet is called a north pole and a pole where a line of force enters the magnet is called a south pole

Figure 1: Magnetic field generate from north to south pole When a bar magnet is broken in the center of its length, two complete bar magnets with magnetic poles on each end of each piece will result. If the magnet is just cracked but not broken
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completely in two, a north and south pole will form at each edge of the crack. The magnetic field exits the north pole and reenters at the south pole The magnetic field spreads out when it encounters the small air gap created by the crack because the air cannot support as much magnetic field per unit volume as the magnet can. When the field spreads out, it appears to leak out of the material and, thus is called a flux leakage field.

Figure 2: Flux leakage in the material

If iron particles are sprinkled on a cracked magnet, the particles will be attracted to and cluster not only at the poles at the ends of the magnet, but also at the poles at the edges of the crack. This cluster of particles is much easier to see than the actual crack and this is the basis for magnetic particle inspection.

Figure 3: location of cracks in the metals

The first step in a magnetic particle inspection is to magnetize the component that is to be inspected. If any defects on or near the surface are present, the defects will create a leakage field. After the component has been magnetized, iron particles, either in a dry or wet suspended form, are applied to the surface of the magnetized part. The particles will be attracted and cluster at the flux leakage fields, thus forming a visible indication that the inspector can detect.
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1.3 Advantages Some advantages of magnetic particle testing are 1. Sensitive to detecting very fine surface cracks and near surface discontinuities in ferrous metals 2. Portability for field use 3. Relatively simple and inexpensive to perform 4. Can be performed only thinly coated ,painted or plated parts 5. Process can be automated 6. Can inspect parts with irregular shapes easily 7. Contaminants within a flaw will not hinder flaw delectability. 8. Fast method of inspection and indications are visible directly on the specimen surface 9. Training of personal is not complicated or expensive. 10. Considered low cost compared to many other NDT method 1.4 Limitations

1. Can be used only on ferrous metals. 2. Magnetic field and discontinuity orientation is critical. 3. Limited subsurface discontinuity detection capabilities. Maximum depth sensitivity is approximately 0.6 (under ideal conditions). 4. Inspection of large parts may require use of equipment with special power requirements 5. Post cleaning of parts may be necessary. 6. Amperage requirements on large parts can be very high.

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Chapter 2 Theory of Magnetism 2. Magnetism

Magnets are very common items in the workplace and household. Uses of magnets range from holding pictures on the refrigerator to causing torque in electric motors. Most people are familiar with the general properties of magnets but are less familiar with the source of magnetism. The traditional concept of magnetism centers around the magnetic field and what is know as a dipole. The term "magnetic field" simply describes a volume of space where there is a change in energy within that volume. This change in energy can be detected and measured. The location where a magnetic field can be detected exiting or entering a material is called a magnetic pole. Magnetic poles have never been detected in isolation but always occur in pairs, hence the name dipole. Therefore, a dipole is an object that has a magnetic pole on one end and a second, equal but opposite, magnetic pole on the other. A bar magnet can be considered a dipole with a north pole at one end and south pole at the other. A magnetic field can be measured leaving the dipole at the north pole and returning the magnet at the south pole. If a magnet is cut in two, two magnets or dipoles are created out of one. This sectioning and creation of dipoles can continue to the atomic level. Therefore, the source of magnetism lies in the basic building block of all matter of the atom. 2.1 Source of Magnetism There are four source of magnetism they are permanent magnets, the earths field, mechanically induced magnetism and electrically induced magnetism. Of the four only permanent magnet and electrically induced magnetism are practical for non destructive testing, And of these two, electrically induced magnetism is by far the most practical and widely induced magnetism.

2.2 Magnetic domains

The theory begins with the sub microscopy areas in metals that are called magnetic domains. theory states that these domains have negative and positive ends and are randomly orientated in non magnetized materials. when domain come under the influence of magnetizing force, they
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tend to line up parallel to fields lines of force as shown in the figure 4.the degree that they line up is proportional to the strength of the magnetizing force

(a) Figure 4a show the orientation ofmagnetic Domains of nonmagnetic material . 2.3 Magnetic poles

(b) Figure 4b. magnetic material

Magnetic poles are points on a magnetized piece where the magnetic flux lines enter and leave the piece enter and leave the does not mean that there is an actual flow of magnetism in the part. When a piece of plain paper is placed over a bar magnet and dry colored magnetic particles are lightly dusted onto the paper, the magnetic flux lines can be easily seen. This type of illustration is called magnetograph as seen in the figure 5

Figure 5: Magnetic field surrounding a bar magnet The most notable natural magnet with a north and South Pole is the earth. However the magnetic north and South Pole are not at the same locations at the north and South Pole on a map, but are located slightly off the normal axis of the earth. While the earth magnetic field is not strong, it can cause ferrous materials to become magnetized and in some cases can interfere with
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demagnetization of large parts. opposites attarct and like repel is a principle that applies the magnetic poles.when two nortyh poles are brought into close proximity,they will repel eacth other.the south goes for south poles In addition a bar magnet does not necessarily have just one north and one South Pole. Long bar magnets could have several north and south poles. When this occurs the poles are said to have consequent poles. it is important to know when long part is magnetized with several coil shots, different Poles are established along the axis of the bar. The inspector must be aware of this to ensure that possible non relevant indications caused by these poles are not incorrectly identified 2.4 Magnetic material When a material is placed within a magnetic field, the magnetic forces of the material's electrons will be affected. This effect is known as Faraday's Law of Magnetic Induction. However, materials can react quite differently to the presence of an external magnetic field. This reaction is dependent on a number of factors, such as the atomic and molecular structure of the material, and the net magnetic field associated with the atoms. The magnetic moments associated with atoms have three origins. These are the electron motion, the change in motion caused by an external magnetic field, and the spin of the electrons. In most atoms, electrons occur in pairs. Electrons in a pair spin in opposite directions. So, when electrons are paired together, their opposite spins cause their magnetic fields to cancel each other. Therefore, no net magnetic field exists. Alternately, materials with some unpaired electrons will have a net magnetic field and will react more to an external field. Most materials can be classified as diamagnetic, paramagnetic or ferromagnetic. 2.5 Types of Magnetic materials

2.5.1 Diamagnetic materials

Diamagnetic materials have a weak, negative susceptibility to magnetic fields. Diamagnetic materials are slightly repelled by a magnetic field and the material does not retain the magnetic properties when the external field is removed. In diamagnetic materials properties arise from the realignment of the electron paths under the influence of an all the electron are paired so there is
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no permanent net magnetic moment per atom. Diamagnetic external magnetic field. Most elements in the periodic table, including copper, silver, and gold, are diamagnetic.

2.5.2 Paramagnetic material

Paramagnetic materials have a small, positive susceptibility to magnetic fields. These materials are slightly attracted by a magnetic field and the material does not retain the magnetic properties when the external field is removed. Paramagnetic properties are due to the presence of some unpaired electrons, and from the realignment of the electron paths caused by the external magnetic field. Paramagnetic materials include magnesium, molybdenum, lithium, and tantalum.

2.5.3 Ferromagnetic materials

Ferromagnetic materials have a large, positive susceptibility to an external magnetic field. They exhibit a strong attraction to magnetic fields and are able to retain their magnetic properties after the external field has been removed. Ferromagnetic materials have some unpaired electrons so their atoms have a net magnetic moment. They get their strong magnetic properties due to the presence of magnetic domains. In these domains, large numbers of atom's moments (1012 to 1015) are aligned parallel so that the magnetic force within the domain is strong. When a ferromagnetic material is in the non magnetized state, the domains are nearly randomly organized and the net magnetic field for the part as a whole is zero. When a magnetizing force is applied, the domains of ferromagnetic materials. Components with these materials are commonly inspected using become aligned to produce a strong magnetic field within the part. Iron, nickel, and cobalt are examples magnetic particle method A magnetic field is a change in energy within a volume of space. The magnetic field surrounding a bar magnet can be seen in the magnetograph below. A magnetograph can be created by placing a piece of paper over a magnet and sprinkling the paper with iron filings. The particles align themselves with the lines of magnetic force produced by the magnet. The magnetic lines of force show where the magnetic field exits the material at one pole and reenters the material at another pole along the length of the magnet. It should be noted that the magnetic lines of force exist in three dimensions but are only seen in two dimensions in the image.
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Figure 6: Magnetic field in and around a bar magnet It can be seen in the magnetograph that there are poles all along the length of the magnet but that the poles are concentrated at the ends of the magnet. The area where the exit poles are concentrated is called the magnet's north pole and the area where the entrance poles are concentrated is called the magnet's south pole.

2.6 General Properties of Magnetic Lines of Force

Magnetic lines of force have a number of important properties, which include: 1. They seek the path of least resistance between opposite magnetic poles. In a single bar magnet as shown to the right, they attempt vto form closed loops from pole to pole. 2. They never cross one another. 3. They all have the same strength. 4. Their density decreases (they spread out) when they move from an area of higher permeability to an area of lower permeability. 5. Their density decreases with increasing distance from the poles.

6. They are considered to have direction as if flowing, though no actual movement occurs. 7. They flow from the south pole to the north pole within a material and north pole to south
pole in air.

2.7 Magnetic hysteresis curve

A great deal of information can be learned about the magnetic properties of a material by studying its hysteresis loop. A hysteresis loop shows the relationship between the induced
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magnetic flux density (B) and the magnetizing force (H). It is often referred to as the B-H loop. An example hysteresis loop is shown below.

Figure 7: Hysteresis curve

The loop is generated by measuring the magnetic flux of a ferromagnetic material while the magnetizing force is changed. A ferromagnetic material that has never been previously magnetized or has been thoroughly demagnetized will follow the dashed line as H is increased. As the line demonstrates, the greater the amount of current applied (H+), the stronger the magnetic field in the component (B+). At point "a" almost all of the magnetic domains are aligned and an additional increase in the magnetizing force will produce very little increase in magnetic flux. The material has reached the point of magnetic saturation. When His reduced to zero, the curve will move from point "a" to point "b." At this point, it can be seen that some magnetic flux remains in the material even though the magnetizing force is zero. This is referred to as the point of retentivity on the graph and indicates the remanence or level of residual magnetism in the material. (Some of the magnetic domains remain aligned but some have lost their alignment.) As the magnetizing force is reversed, the curve moves to point "c", where the
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flux has been reduced to zero. This is called the point of coercivity on the curve. (The reversed magnetizing force has flipped enough of the domains so that the net flux within the material is zero.) The force required to remove the residual magnetism from the material is called the coercive force or coercivity of the material. As the magnetizing force is increased in the negative direction, the material will again become magnetically saturated but in the opposite direction (point "d"). Reducing H to zero brings the curve to point "e." It will have a level of residual magnetism equal to that achieved in the other direction. Increasing H back in the positive direction will return B to zero. Notice that the curve did not return to the origin of the graph because some force is required to remove the residual magnetism. The curve will take a different path from point "f" back to the saturation point where it with complete the loop.

2.8 Basic Magnetic particle testing theory

Magnetic particle testing is based on the fact that when magnetizing force is induced into a material a magnetic field is formed. This magnetic field is made up of continuous lines of force are disturbed or distorted they form magnetic flux leakage areas. As ferromagnetic particles are applied to the part, the particles are attracted to the magnetic flux leakage and form indication that can be evaluated for severity

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Chapter 3

Magnetic Flux Theory

3. Magnetizing Current
Electric current is often used to establish the magnetic field in components during magnetic particle inspection. Alternating current and direct current are the two basic types of current commonly used. Current from single phase 110 volts, to three phase 440 volts, are used when generating an electric field in a component. Current flow is often modified to provide the appropriate field within the part. The type of current used can have an effect on the inspection results, so the types of currents commonly used will be briefly reviewed. 3.1 Direct Current Direct current (DC) flows continuously in one direction at a constant voltage. A battery is the most common source of direct current. As previously mentioned, current is said to flow from the positive to the negative terminal. In actuality, the electrons flow in the opposite direction. DC is very desirable when inspecting for subsurface defects because DC generates a magnetic field that penetrates deeper into the material. In ferromagnetic materials, the magnetic field produced by DC generally penetrates the entire cross-section of the component. Conversely, the field produced using alternating current is concentrated in a thin layer at the surface of the component. 3.2 Alternating Current Alternating current (AC) reverses in direction at a rate of 50 or 60 cycles per second. In the United States, 60 cycle current is the commercial norm but 50 cycle current is common in many countries. Since AC is readily available in most facilities, it is convenient to make use of it for magnetic particle inspection. However, when AC is used to induce a magnetic field in ferromagnetic materials, the magnetic field will be limited to narrow region at the surface of the component. This phenomenon is known as the "skin effect" and occurs because the changing

magnetic field generates eddy currents in the test object. The eddy currents produce a magnetic field that opposes the primary field, thus reducing the net magnetic flux below the surface. Therefore, it is recommended that AC be used only when the inspection is
limited to surface defects.

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3.3 Rectified Alternating Current

Clearly, the skin effect limits the use of AC since many inspection applications call for the detection of subsurface defects. However, the convenient access to AC, drives its use beyond surface flaw inspections. Luckily, AC can be converted to current that is very much like DC through the process of rectification. With the use of rectifiers, the reversing AC can be converted to a one directional current. The three commonly used types of rectified current are described below

Figure 8: show the half wave,full wave,rectified AC half and full wave

3.4 Half Wave Rectified Alternating Current (HWAC) When single phase alternating current is passed through a rectifier, current is allowed to flow in only one direction. The reverse half of each cycle is blocked out so that a one directional, pulsating current is produced. The current rises from zero to a maximum and then returns to zero. No current flows during the time when the reverse cycle is blocked out. The HWAC repeats at same rate as the unrectified current (60 hertz typical). Since half of the current is blocked out, the amperage is half of the unaltered AC.

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This type of current is often referred to as half wave DC or pulsating DC. The pulsation of the HWAC helps magnetic particle indications form by vibrating the particles and giving them added mobility. This added mobility is especially important when using dry particles. The pulsation is reported to significantly improve inspection sensitivity. HWAC is most often used to power electromagnetic yokes. 3.5 Full Wave Rectified Alternating Current (FWAC) (Single Phase) Full wave rectification inverts the negative current to positive current rather than blocking it out. This produces a pulsating DC with no interval between the pulses. Filtering is usually performed to soften the sharp polarity switching in the rectified current. While particle mobility is not as good as half-wave AC due to the reduction in pulsation, the depth of the subsurface magnetic field is improved. 3.6 Three Phase Full Wave Rectified Alternating Current Three phase current is often used to power industrial equipment because it has more favorable power transmission and line loading characteristics. This type of electrical current is also highly desirable for magnetic particle testing because when it is rectified and filtered, the resulting current very closely resembles direct current. Stationary magnetic particle equipment wired with three phase AC will usually have the ability to magnetize with AC or DC (three phase full wave rectified), providing the inspector with the advantages of each current form.

3.7 Circular Magnetic field

Materials with a circular field have magnetic field that is contained inside the material and is perpendicular to the longitudinal axis of the material. This type of magnetic field does not have a north and south pole unless there is a interruption of the material. This interruption would cause a north and South Pole to form and result in flux leakage at the interruption. An easy way to determine the direction of magnetic field is to wrap your right hand around the part with your thumb pointing in the direction of current flow. The finger of your hand are in the same direction as the magnetic field. This method is commonly called the right hand rule

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3.8 Method of inducing circular fields

There are two primary methods to induce a circular magnetic field in material. The first method is to apply a current through the material as shown in the figure 9 shows two ways of creating a circular magnetic field by passing current through a material. The first method is accomplished by placing the part between two head stocks and the second method is by using prods to couple the current through the material The other means of introducing a circular magnetic field in a material is by using a central bar conductor as shown in the figure 9.when the current is passed through the conductor, establishing a magnetic field. The magnetic field, preferring to pass through the material rather than air, induces a circular magnetic field in material.central bar induced circular magnetic field are

Figure 9(a): circular magnetization caused by passing a electric current from contact plates
through the test object

Figure 9(b): production of a localized circular field by passing electric current

between contact prods
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Specially effective in detecting discontinuities on the inner surface of hollow parts

3.9 Circular Magnetic field strength

The current requirements for directly inducing circular magnetism are between 300 to 800 A per inch of material cross section. The length of the part is not a factor in determining the current requirement.therefore two parts, one measuring 2 in 8 inc. and other 2in 20 inch would both required between 600 to 1600 A to directly induce a satisfactory circular magnetic field. When using prods to induce the magnetic field the spacing between the prods must be controlled. The amperage required to induce a satisfactory field is directly related to the thickness of the material and the distance between the prods. This tend to be a disadvantages of using prods because at large distance the current requirement can be very high thereby increasing the chance of damaging the material by arcing. When inducing circular magnetic field in hollow parts the amperage required to introduce a satisfactory field depends on several things. First if only the internal surface is to be tested and the central bar conductor is not offset, only the distance between internal surface areas of the part need to be used to calculate the amperage If the central bar Conductor is offset then the amperage requirement is directly proportional to the diameter of the conductor plusplus two times the parts wall thickness,in addition ,when an offsetcentral bar conductor is used the effective distance of satisfactory magnrestim is considered to be four times the diameter of the central bar conductor.this means that the part will have to be magnetized several times with each effective area being overlapped by approximately 10 percent 3.10 Discountinuities Discontinuities found with circular magnetism can be reliable detected when oriented from approximately 45 to 90 degree to the magnetic field. It can also be said that for materials with circular magnetic fields , discontinuities will be parallel to the longitudinal axis of the material.

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3.11 Longitudinal magnetic field

When the length of a component is several times larger than its diameter, a longitudinal magnetic field can be established in the component. The component is often placed longitudinally in the concentrated magnetic field that fills the center of a coil or solenoid. This magnetization referred technique is often to as a "coil shot."

Figure 10: longitudinal magnetization with a coil

The magnetic field travels through the component from end to end with some flux loss along its length as shown in the image to the right. Keep in mind that the magnetic lines of flux occur in three dimensions and are only shown in 2D in the image. The magnetic lines of flux are much more dense inside the ferromagnetic material than in air because ferromagnetic materials have much higher permeability than does air. When the concentrated flux within the material comes to the air at the end of the component, it must spread out since the air can not support as many lines of flux per unit volume. To keep from crossing as they spread out, some of the

magnetic lines of flux are forced out the side of the component. When a component is
magnetized along its complete length, the flux loss is small along its length. Therefore, when a component is uniform in cross section and magnetic permeability, the flux density will be relatively uniform throughout the component. Flaws that run normal to the magnetic lines of flux will disturb the flux lines and often cause a leakage field at the surface of the component

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3.12 Discountinuity
This type of magnetism can detect discontinuities that are approximately 45 to 90 degrees to the longitudinal magnetic lines of force. It can also be said that this method can detect circular or circumferential discontinuities

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Chapter 4 4 Method selection criteria

Selection criteria for Inspection of material

There are few step should be considered for the selection methods of magnetic particle testing which are given below. 4.1 Part geometry When we are dealing with the part geometry so first thing should be considered the type of discontinuity in the part is being tested for and general orientation of the discontinuity should be addressed first for optimal results the discontinuity and the magnetic filed should be oriented 45 to 90 degrees to each other. in some cases the geometry of the part can cause a distortion of the magnetic field. Different diameter sizes in the same part can cause procedure to require multiple shots at increasing amperages. Or a part with a y configuration might require at the same amperage but at different location. Parts with hollow areas may require only the inspection of the external surface but also the inner surface. in this case a central bar conductor test would be required to circular magnetism In addition location of a part that could cause nonrelevant indications should be considered. keyway slots, cotter pin holes, sharp radius or different material junctions,such as heat treated areas,could cause nonrelevant indications 4.2 Particle size Without particles the ability to detect flux leakage created by discontinuity would be next to impossible and would render the magnetic particle testing method ineffective for all but very special applications. Therefore the particles are critical to the testing process. The ability of an indication to be performed during a magnetic particle test is very dependent on the types of particles used to form the indications.dry or wet are the two major classification of particles.dry particles and wet particles in which dry particles are normally visible while wet particles are

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either visible or fluorescent. Of the wet particles fluorescent are used more frequently than visible. There are several factors which have been taken to choose the particles. 1. The particle must be ferromagnetic and must have high permeability and low retentivity. 2. The particle should be mobile.it should have an ability to move the area to the flux leakage 3. The particle should be nontoxic and should not cause damage to item being tested 4.3 Types of discontinuity It is important to know what type of discontinuity is suspected in a part or material to determine the proper process.It has already been pointed out that surface discontinuities are better found with alternating current, while subsurface discontinuity are better found with half wave rectified direct current. Therefore ,by knowing the type of suspected discontinuity, the selection of current can be made with better certainly of finding discontinuity. it is important to note that the part must b detectable when they are in the 45 to 90 degree to the magnetic field. An inspector could adopt the best procedure to know the orientation of discontinuity to detect the defect by induced a magnetic field Another factor to consider is whether the suspected discontinuity is on the outer and inner surface of a hollow part. This knowledge determines if a central bar conductor should be used to induce the circular magnetic field as opposed to head shots. A head shot will produce a strong field at the outside diameter, while a central bar conductor will induce a strong field at the inside diameter 4.4 Selection techniques The selection of the magnetic particle testing techniques to be used on a part must take into consideration several basic factors including type of current,particle method,method of application,type of magnestism,amperage,equipment to be used and testing environment.

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4.4.1 Current The type of current is to a degree dependent on the location of the discountinuity to be detected but also on the equipment available. 4.4.2 Particle It is an important factor to choose the particles which will provide the best sensitivity for the acceptance criteria.For stress cracks,fluorescent particles in a wet bath are preferred.for surface discontinuities in welds,dry,color contrast particles are best. 4.4.3 Application While the continuous method of particle application is very sensitive,there may be valid tests that require residual application 4.4.4 Magnetism Either circular or longitudinal magnetism must also be considered. In some applications only one may be required, while the other both may be required. In addition, depending on the part geometry there may be a need for multiple shots or the use of a central bar conductor Longitudinal should generally be done after circular to aid demagnetization verification 4.4.5 Amperage The amperage used to induce the magnetic field or fields must also be considered. 4.4.6 Equipment and Environment There are numerous type of equipment is used to locate the defect in the metals. It depend upon the environment to conduct the test. The lightening affect the test environment while visible dry particles work well in bright daylight while the fluorescent do not.

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Chapter 5 5. Method of testing

Method of Magnetic Particle Testing

There are two methods is used to detect the discontinuity in the metals.wet and dry method 5.1 Dry method In this magnetic particle testing technique, dry particles are dusted onto the surface of the test object as the item is magnetized. Dry particle inspection is well suited for the inspections conducted on rough surfaces. When an electromagnetic yoke is used, the AC or half wave DC current creates a pulsating magnetic field that provides mobility to the powder. The primary applications for dry powders are unground welds and rough as-cast surfaces. Dry particle inspection is also used to detect shallow subsurface cracks. Dry particles with half wave DC is the best approach when inspecting for lack of root penetration in welds of thin materials. Half wave DC with prods and dry particles is commonly used when inspecting large 5.2 Steps in performing an inspection using dry particles

5.2.1Prepare the part surface

the surface should be relatively clean but this is not as critical as it is with liquid penetrant inspection. The surface must be free of grease, oil or other moisture that could keep particles from moving freely. A thin layer of paint, rust or scale will reduce test sensitivity but can sometimes be left in place with adequate results. Specifications often allow up to 0.003 inch (0.076 mm) of a nonconductive coating (such as paint) and 0.001 inch max (0.025 mm) of a ferromagnetic coating (such as nickel) to be left on the surface. Any loose dirt, paint, rust or scale must be removed.

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5.2.2 Apply the magnetizing force

Use permanent magnets, an electromagnetic yoke, prods, a coil or other means to establish the necessary magnetic flux.

5.2.3 Dust on the dry magnetic particles Dust on a light layer of magnetic particles. 5.2.4 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.

5.2.5 Terminate the magnetizing force

If the magnetic flux is being generated with an electromagnet or an electromagnetic field, the magnetizing force should be terminated. If permanent magnets are being used, they can be left in place.

5.2.6 Inspect for indications

Look for areas where the magnetic particles are clustered.castings for hot tears and cracks. 5.3 Wet method Wet suspension magnetic particle inspection, more commonly known as wet magnetic particle inspection, involves applying the particles while they are suspended in a liquid carrier. Wet magnetic particle inspection is most commonly performed using a stationary, wet, horizontal inspection unit but suspensions are also available in spray cans for use with an electromagnetic yoke. A wet inspection has several advantages over a dry inspection. First, all of the surfaces of the component can be quickly and easily covered with a relatively uniform layer of particles. Second, the liquid carrier provides mobility to the particles for an extended period of time, which allows enough particles to float to small leakage fields to form a visible indication. Therefore, wet inspection is considered best for detecting very small discontinuities on smooth surfaces. On
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rough surfaces, however, the particles (which are much smaller in wet suspensions) can settle in the surface valleys and lose mobility, rendering them less effective than dry powders under these conditions.

5.3.1 Steps in performing an inspection using wet suspensions

5.3.2 Prepare the part surface
Just as is required with dry particle inspections, the surface should be relatively clean. The surface must be free of grease, oil and other moisture that could prevent the suspension from wetting the surface and preventing the particles from moving freely. A thin layer of paint, rust or scale will reduce test sensitivity, but can sometimes be left in place with adequate results. Specifications often allow up to 0.003 inch (0.076 mm) of a nonconductive coating (such as paint) and 0.001 inch max (0.025 mm) of a ferromagnetic coating (such as nickel) to be left on the surface. Any loose dirt, paint, rust or scale must be removed.

5.3.3 Apply the suspension

The suspension is gently sprayed or flowed over the surface of the part. Usually, the stream of suspension is diverted from the part just before the magnetizing field is applied.

5.3.4 Apply the magnetizing force

The magnetizing force should be applied immediately after applying the suspension of magnetic particles. When using a wet horizontal inspection unit, the current is applied in two or three short busts (1/2 second) which helps to improve particle mobility.

5.3.5 Inspect for indications

Look for areas where the magnetic particles are clustered. Surface discontinuities will produce a sharp indication. The indications from subsurface flaws will be less defined and lose definition as depth increases.

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Chapter 6 Equipment for Magnetic particle Inspection of material

6. Portable Magnetizing Equipment

To properly inspect a part for cracks or other defects, it is important to become familiar with the different types of magnetic fields and the equipment used to generate them. As discussed previously, one of the primary requirements for detecting a defect in a ferromagnetic material is that the magnetic field induced in the part must intercept the defect at a 45 to 90 degree angle. Flaws that are normal (90 degrees) to the magnetic field will produce the strongest indications because they disrupt more of the magnet flux Therefore, for proper inspection of a component, it is important to be able to establish a magnetic field in at least two directions. A variety of equipment exists to establish the magnetic field for MPI. One way to classify equipment is based on its portability. Some equipment is designed to be portable so that inspections can be made in the field and some is designed to be stationary for ease of inspection in the laboratory or manufacturing facility. Portable equipment will be discussed first

6.1 Permanent Magnet

Permanent magnets are sometimes used for magnetic particle inspection as the source of magnetism. The two primary types of permanent magnets are bar magnets and horseshoe (yoke) magnets. These industrial magnets are usually very strong and may require significant strength to remove them from a piece of metal. Some permanent magnets require over 50 pounds of force to remove them from the surface. Because it is difficult to remove the magnets from the component being inspected, and sometimes difficult and dangerous to place the magnets, their use is not particularly popular. However, permanent magnets are sometimes used by divers for

inspection in underwater environments or other areas, such as explosive environments, where electromagnets cannot be used. Permanent magnets can also be made small enough to fit into tight areas where electromagnets might not fit.

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6.2 Electromagnets
Today, most of the equipment used to create the magnetic field used in MPI is based on electromagnetism. That is, using an electrical current to produce the magnetic field. An electromagnetic yoke is a very common piece of equipment that is used to establish a magnetic field. It is basically made by wrapping an electrical coil around a piece of soft ferromagnetic steel. A switch is included in the electrical circuit so that the current and, therefore, the magnetic field can be turned on and off. They can be powered with alternating current from a wall socket or by direct current from a battery pack. This type of magnet generates a very strong magnetic field in a local area where the poles of the magnet touch the part being inspected. Some yokes can lift weights in excess of 40 pound s.

Figure 11: yoke detecting a crack in the metal

6.3 Prods Prods are handheld electrodes that are pressed against the surface of the component being inspected to make contact for passing electrical current through the metal. The current passing between the prods creates a circular magnetic field around the prods that can be used in magnetic particle inspection. Prods are typically made from copper and have an insulated handle to help protect the operator. One of the prods has a trigger switch so that the current can be quickly and
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easily turned on and off. Sometimes the two prods are connected by any insulator (as shown in the image) to facilitate one hand operation. This is referred to as a dual prod and is commonly used for weld inspections. If proper contact is not maintained between the prods and the component surface, electrical arcing can occur and cause damage to the component. For this reason, the use of prods are not allowed when inspecting aerospace and other critical components. To help prevent arcing, the prod tips should be inspected frequently to ensure that they are not oxidized, covered with scale or other contaminant, or damaged. The following applet shows two prods used to create a current through a conducting part. The resultant magnetic field roughly depicts the patterns expected from a magnetic particle inspection of an unflawed surface. The user is encouraged to manipulate the prods to orient the magnetic field to "cut across" suspected defects.

Figure 12: contact prods generate a magnetic field

6.4 Portable Coils and Conductive Cables Coils and conductive cables are used to establish a longitudinal magnetic field within a component. When a preformed coil is used, the component is placed against the inside surface on the coil. Coils typically have three or five turns of a copper cable within the molded frame. A foot switch is often used to energize the coil. Conductive cables are wrapped around the
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component. The cable used is typically 00 extra flexible or 0000 extra flexible. The number of wraps is determined by the magnetizing force needed and of course, the length of the cable. Normally, the wraps are kept as close together as possible. When using a coil or cable wrapped into a coil, amperage is usually expressed in ampere-turns. Ampere-turns is the amperage shown on the amp meter times the number of turns in the coil.

Figure 12(a) portable coil 6.5 Portable Power Supplies

12 (b) conductive cable

Portable power supplies are used to provide the necessary electricity to the prods, coils or cables. Power supplies are commercially available in a variety of sizes. Small power supplies generally provide up to 1,500A of half-wave direct current or alternating current when used with a 4.5 meter 0000 cables. They are small and light enough to be carried and operate on either 120V or 240V electrical service. When more power is necessary, mobile power supplies can be used. These units come with wheels so that they can be rolled where needed. These units also operate on 120V or 240V electrical service and can provide up to 6,000A of AC or half-wave DC when 9 meters or less of 0000 cables is used.

6.6 Stationary Equipment for Magnetic Particle Inspection

Stationary magnetic particle inspection equipment is designed for use in laboratory or production environment. The most common stationary system is the wet horizontal (bench) unit. Wet
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horizontal units are designed to allow for batch inspections of a variety of components. The units have head and tail stocks (similar to a lathe) with electrical contact that the part can be clamped between. A circular magnetic field is produced with direct magnetization. The tail stock can be moved and locked into place to accommodate parts of various lengths. To assist the operator in clamping the parts, the contact on the headstock can be moved pneumatically via a foot switch. Most units also have a movable coil that can be moved into place so the indirect magnetization can be used to produce a longitudinal magnetic field. Most coils have five turns and can be obtained in a variety of sizes. The wet magnetic particle solution is collected and held in a tank. A pump and hose system is used to apply the particle solution to the components being inspected. Either the visible or fluorescent particles can be used. Some of the systems offer a variety of options in electrical current used for magnetizing the component. The operator has the option to use AC, half wave DC, or full wave DC. In some units, a demagnetization feature is built in, which uses the coil and decaying AC. To inspect a part using a head-shot, the part is clamped between two electrical contact pads. The magnetic solution, called a bath, is then flowed over the surface of the part. The bath is then interrupted and a magnetizing current is applied to the part for a short duration, typically 0.5 to 1.5 seconds. (Precautions should be taken to prevent burning or overheating of the part.) A circular field flowing around the circumference of the part is created. Leakage fields from defects then attract the particles to form indications. When the coil is used to establish a longitudinal magnetic field within the part, the part is placed on the inside surface of the coil. Just as done with a head shot, the bath is then flowed over the surface of the part. A magnetizing current is applied to the part for a short duration, typically 0.5 to 1.5 seconds, just after coverage with the bath is interrupted. (Precautions should be taken to prevent burning or overheating of the part.) Leakage fields from defects attract the particles to form visible indications .The wet horizontal unit can also be used to establish a circular magnetic field using a central conductor. This type of a setup is used to inspect parts that have an open center, such as gears, tubes, and other ring-shaped objects. A central conductor is an electrically conductive bar that is usually made of copper or aluminum. The bar is inserted through the opening and the bar is, then

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clamped between the contact pads. When current is passed through the central conductor a circular magnetic field flows around the bar and enters into the part or parts being inspected. 6.7 Lights for Magnetic Particle Inspection Magnetic particle inspection can be performed using particles that are highly visible under white light conditions or particles that are highly visible under ultraviolet light conditions. When an inspection is being performed using the visible color contrast particles, no special lighting is required as long as the area of inspection is well lit. A light intensity of at least 1000 lux (100 fc) is recommended when visible particles are used, but a variety of light sources can be used. When fluorescent particles are used, special ultraviolet light must be used. Fluorescence is defined as the property of emitting radiation as a result of and during exposure to radiation. Particles used in fluorescent magnetic particle inspections are coated with a material that produces light in the visible spectrum when exposed to near-ultraviolet light. This "particle glow" provides high contrast indications on the component anywhere particles collect. Particles that fluoresce yellow-green are most common because this color matches the peak sensitivity of the human eye under dark conditions. However, particles that fluorescen red, blue, yellow, and green colors are available.

6.8 Ultraviolet Light

Ultraviolet light or "black light" is light in the 1,000 to 4,000 Angstroms (100 to 400nm) wavelength range in the electromagnetic spectrum. It is a very energetic form of light that is invisible to the human eye. Wavelengths above 4,000A fall into the visible light spectrum and are seen as the color violet. UV is separated according to wavelength into three classes: A, B, and C. The shorter the wavelength, the more energy that is carried in the light and the more dangerous it is to the human cells. Class UV-A UV-B Wavelength Range 3,2004,000 Angstroms 2,8003,200 Angstroms
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UV-C

2,8001,000 Angstroms

The desired wavelength range for use in nondestructive testing is between 3,500 and 3,800A with a peak wavelength at about 3,650A. This wavelength range is used because it is in the UVA range, which is the safest to work with. UV-B will do an effective job of causing substances to fluoresce, however, it should not be used because harmful effects such as skin burns and eye damage can occur. This wavelength of radiation is found in the arc created during the welding process. UV-C (1,000 to 2,800A) is even more dangerous to living cells and is used to kill bacteria in industrial and medical settings. The desired wavelength range for use in NDT is obtained by filtering the ultraviolet light generated by the light bulb. The output of a UV bulb spans a wide range of wavelengths. The short wavelengths of 3,120 to 3,340A are produced in low levels. A peak wavelength of 3650A is produced at a very high intensity. Wavelengths in the visible violet range (4050A to 4350A), green-yellow (5460A), yellow (6220A) and orange (6770A) are also usually produced. The filter allows only radiation in the range of 3200 to 4000A and a little visible dark purple to pass.

6.9 Basic ultraviolet lights

UV bulbs come in a variety of shapes and sizes. The more common types are the low pressure tube, high pressure spot, the high pressure flood types. The tubular black light is similar in construction to the tubular fluorescent lights used for office or home illumination. These lights use a low pressure mercury vapor arc. Tube lengths of 6 to 48 inches are common. The low pressure bulbs are most often used to provide general illumination to large areas rather than for illumination of components to be inspected. These bulbs generate a relatively large amount of white light, which is concerning since inspection specifications require less than two footcandles of white light at the inspection surface. Spot lights, on the other hand, provide concentrated energy that can be directed to the area of inspection. A spot light will generate a six inch diameter circle of high intensity light when held fifteen inches from the inspection surface. One hundred watt mercury vapor lights are most commonly used, but higher wattages are available.

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In the high pressure mercury vapor spot or flood lamps, UV light is generated by a quartz tube inside the bulb. This tube contains two electrodes that establish an arc. The distance between electrodes is such that a starting electrode must be used. A resister limits the current to the starting electrode that establishes the initial arc that vaporizes the mercury in the tube. Once this low level arc is established and the mercury is vaporized, the arc between the main electrodes is established. It takes approximately five minutes to "warm up" and establish the arc between the main electrodes. This is why specifications require a "warm up time" before using the high pressure mercury vapor lights. Flood and spot black lights produce large amounts of heat and should be handled with caution to prevent burns. This condition has been eliminated by newer designs that include cooling fans. The arc in the bulb can be upset when exposed to an external magnetic field, such as that generated by a coil. Care should be taken not to bring the lamp close to strong magnetic fields, but if the arc is upset and extinguished, it must be allowed to cool before it can be safely restarted.

6.10 High Intensity Ultraviolet Lights

The 400 watt metal halide bulbs or "super lights" can be found in some facilities. This super bright light will provide adequate lighting over an area of up to ten times that covered by the 100 watt bulb. Due to their high intensity, excessive light reflecting from the surface of a component is a concern. Moving the light a greater distance from the inspection area will generally reduce this glare. Another type of high intensity light available is the micro-discharge light. This particular light produces up to ten times the amount of UV light conventional lights produce. Readings of up to 60,000 uW/cm2 at 15 inches can be achieved.

6.11 Magnetic Field Indicators

Determining whether a magnetic field is of adequate strength and in the proper direction is critical when performing magnetic particle testing. As discussed previously, knowing the direction of the field is important because the field should be as close to perpendicular to the defect as possible and no more than 45 degrees from normal. Being able to evaluate the field direction and strength is especially important when inspecting with a multidirectional machine, because when the fields are not balanced properly, a vector field will be produced that may not detect some defects.
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There is actually no easy-to-apply method that permits an exact measurement of field intensity at a given point within a material. In order to measure the field strength, it is necessary to intercept the flux lines. This is impossible without cutting into the material and cutting the material would immediately change the field within the part. However, cutting a small slot or hole into the material and measuring the leakage field that crosses the air gap with a Gauss meter is probably the best way to get an estimate of the actual field strength within a part. Nevertheless, there are a number of tools and methods available that are used to determine the presence and direction of the field surrounding a component.

6.12 Gauss Meter or Hall Effect Gage

A Gauss meter with a Hall Effect probe is commonly used to measure the tangential field strength on the surface of the part. As discussed in some detail on the "Measuring Magnetic Fields" page, the Hall effect is the transverse electric field created in a conductor when placed in a magnetic field. Gauss meters, also called Tesla meters, are used to measure the strength of a field tangential to the surface of the magnetized test object. The meters measure the intensity of the field in the air adjacent to the component when a magnetic field is applied. The advantages of Hall effect devices are: they provide a quantitative measure of the strength of magnetizing force tangential to the surface of a test piece, they can be used for measurement of residual magnetic fields, and they can be used repetitively. Their main disadvantages are that they must be periodically calibrated and they cannot be used to establish the balance of fields in multidirectional applications.

6.13 Quantitative Quality Indicator (QQI)

The Quantitative Quality Indicator (QQI) or Artificial Flaw Standard is often the preferred method of assuring proper field direction and adequate field strength. The use of a QQI is also the only practical way of ensuring balanced field intensity and direction in multiple-direction magnetization equipment. QQIs are often used in conjunction with a Gauss meter to establish the inspection procedure for a particular component. They are used with the wet method only, and like other flux sharing devices, can only be used with continuous magnetization.

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The QQI is a thin strip of either 0.002 or 0.004 inch thick AISI 1005 steel. A photoetch process is used to inscribe a specific pattern, such as concentric circles or a plus sign. QQIs are nominally 3/4 inch square, but miniature shims are also available. QQIs must be in intimate contact with the part being evaluated. This is accomplished by placing the shim on a part etched side down, and taping or gluing it to the surface. The component is then magnetized and particles applied. When the field strength is adequate, the particles will adhere over the engraved pattern and provide information about the field direction. When a multidirectional technique is used, a balance of the fields is noted when all areas of the QQI produce indications. Some of the advantages of QQIs are: they can be quantified and related to other parameters, they can accommodate virtually any configuration with suitable selection, and they can be reused with careful application and removal practices. Some of the disadvantages are: the application process is somewhat slow, the parts must be clean and dry, shims cannot be used as a residual magnetism indicator as they are a flux sharing device, they can be easily damaged with improper handling, and they will corrode if not cleaned and properly stored.

6.14 Pie Gage

The pie gage is a disk of highly permeable material divided into four, six, or eight sections by nonferromagnetic material. The divisions serve as artificial defects that radiate out in different directions from the center. The diameter of the gage is 3/4 to 1 inch. The divisions between the low carbon steel pie sections are to be no greater than 1/32 inch. The sections are furnace brazed and copper plated. The gage is placed on the test piece copper side up and the test piece is magnetized. After particles are applied and the excess removed, the indications provide the inspector the orientation of the magnetic field. The principal application is on flat surfaces such as weldments or steel castings where dry powder is used with a yoke or prods. The pie gage is not recommended for precision parts with complex shapes, for wet-method applications, or for proving field magnitude. The gage should be demagnetized between readings. Several of the main advantages of the pie gage are that it is easy to use and it can be used indefinitely without deterioration. The pie gage has several disadvantages, which include: it retains some residual magnetism so indications will prevail after removal of the source of
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magnetization, it can only be used in relatively flat areas, and it cannot be reliably used for determination of balanced fields in multidirectional magnetization.

6.15 Slotted Strips

Slotted strips, also known as Burmah-Castrol Strips, are pieces of highly permeable ferromagnetic material with slots of different widths. They are placed on the test object as it is inspected. The indications produced on the strips give the inspector a general idea of the field strength in a particular area. Advantages of these strips are: they are relatively easily applied to the component, they can be used successfully with either the wet or dry method when using the continuous magnetization, they are repeatable as long as orientation to the magnetic field is maintained, and they can be used repetitively. Some of the disadvantages are that they cannot be bent to complex configuration and they are not suitable for multidirectional field applications since they indicate defects in only one direction.

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Chapter 7 Experimental work 7. Experimental work There are few steps must be considered during the inspection of hot rolled AISI 1045 carbon steels which are highlighted below 7.1 Chemical composition of Hot Rolled 1045 carbon steel C 0.46 Mn 0.75 S 0.020 P 0.007 Cr 0.06 Si 0.25 Ni 0.11 Mo 0.02 Cu 0.25 V 0.001 Al 0.033

7.2 Heat treatment The lot is treated as an annealing procedure on the hot rolled 1045 carbon steel so the heat treatment cycle is highlighted in the table

Lot # 1 Total Samples Heat Treatment Type Holding Temperature Holding Time 02 Annealing 850oC 2 Hrs
850oC 2 Hrs

7.3 Part Geometry The part which is inspected by magnetic particle testing having the given specification.

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Length 4-6 meter, diameter 48 7.4 Sample preparation The part must be free from dirt scale, grease, rust or organic material that would interfere with the development of flux leakage indications and contaminate magnetic particle baths. 7.5 Experimental procedure we take a bar length of 4-6 meter and a diameter of 48 is placed in the stationary bench type Johnson machine is usually used in the laboratory or production environment for wet method analysis. Bench type stationary machine consist of head and tail stock to clamp the material in their jaws to magnetize it. In between the head and tail stock is typically an induction coil, which is used to change the orientation of the magnetic field by 90 from head stock. In wet method the part to be inspected is placed in the bench type machine and allowed to spread over a mixture of water and ink on the hot rolled product 1045 carbon steel that is accumulated on the subsurface crack, seams, laps, discontinuities .when an electric current is passed through the material in order to 1magnetizing force induced into the material, a magnetic field is formed.

Figure 1: Circular magnetic field This magnetic field is made up of continuous lines of force in or around the part. If these continuous lines of force are distorted they form magnetic flux leakage which helped for the
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detection of cracks, seams, laps discontinuity in the metals .These defects can be analyzed by exposing an ultraviolet ray from the ultraviolet lamps.2The current requirement for the directly current inducing magnetism is between 300 to 800 per inch of material cross section.

Figure 2: Detection of longitudinal crack with circular magnetization

7.6 Longitudinal method by yoke: In the longitudinal method the magnetic field induce longitudinally as shown in the figure by using a yoke method. we take a bar of hot rolled 1045 with 2-3m in length and 25 in diameter is placed on the ground to conduct the test. The part to be inspected is thoroughly cleaned through the magnaflux cleaner it takes time to absorb in the material then it wipe out through the clothes The cracks are easily detected through yoke by placing the magnetic field perpendicular to the direction of the current flow and allow to Dry magnetic particles on the parts then energized the yoke by passing current in order to magnetic line of forces passed through the yoke and into the part that create a magnetic lines of forces around the north to south pole of the sample.

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Figure 3 longitudinal magnetic fields If there is flux leakage in the material that help to locate defect in the metal. It is sensitive to fine cracks and gives the information of large cracks The basic formula to calculate the ampere requirement for the longitudinal magnetism

In the above equation the L is the length of the bar and D is the diameter of the bar

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Figure: 4 Leakage Field at a Crack in a Hot rolled 1045 bar

7.7 Results and Discussion

Magnetic particle inspection of hot rolled 1045 carbon steels is conducted through the circular magnetization that help to locate the surface and sub surface cracks, laps, seams, discontinuity of hot rolled 1045 carbon steel. The number of defects has been observed in the sample which is visualized under the electromagnetic spectrum of ultraviolet rays that help to differentiate the morphology of defect either it is forged, cast and hot rolled products. longitudinal method is sensitive to fine cracks and the large cracks observed through the yoke by making the north and south in the hot rolled 1045 carbon steel with the passage of electric current through the yoke into part which is helpful to detect the discontinuity that are approximately 45 to 90 degrees to the longitudinal magnetic line of force.

7.8 Conclusion
Magnetic particle inspection is conducted through circular magnetization in order to reveal the surface and surface crack while in the longitudinal method the part inspected gives the information of large crack under normal light

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References
1. Charles W.Eick ASNT level II Study Guide Magnetic particle testing Method second edition ,chapter 4,page 16 2. Charles W.Eick ASNT level II Study Guide Magnetic particle testing Method second edition chapter 4,page 17
3 Bray, Don E. and Don McBride: Nondestructive Testing Techniques, John Wiley & Sons, Inc., 1992.

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Paul E. Mix Introduction to Nondestructive testing; A training guide, Second edition McMaster, Robert C.: Nondestructive Testing Handbook, Volume II, The Ronald Press Company, New York 1963. ASTM E 1444-93: Standard Practice for Magnetic Particle Examination, American Society for Testing and Materials, 1916 Race St. Phladelphia, PA 18103.
Metals Handbook, Volume 17: Nondestructive Inspection and Quality Control, pp. 89-128, ASM International, Metals Park, OH, 1989.

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