Automotive Engineering

Phd Eng. Marcin Korzeniowski

Non Destructive Evaluation in
Contemporary Manufacturing
Systems

Lecture 3

Magnetic Particle
Testing

Magnetic Testing (MT)

MAGNETIC PARTICLE INSPECTION
Method of locating surface and subsurface discontinuities
in ferromagnetic materials.
When the material or part under test is magnetized,
magnetic discontinuities that lie in a direction generally
transverse to the direction of the magnetic field cause
a leakage field to be formed at and above the surface of
the part.
The discontinuity, is detected by the use of finely divided
ferromagnetic particles applied over the surface, with
some of the particles being gathered and held by the
leakage field.

Magnetic Testing (MT)

Limitation for Magnetic Particle Testing:
The method can be used only on ferromagnetic materials,
For best results, the magnetic field must be in a direction that will
intercept the principal plane of the discontinuity; this sometimes
requires two or more sequential inspections with different
magnetizations,
Demagnetization following inspection is often necessary,
Post cleaning to remove remnants of the magnetic particles clinging
to the surface may sometimes be required after testing and
demagnetization,
Exceedingly large currents are sometimes needed for very large
parts,
Care is necessary to avoid local heating and burning of finished parts
or surfaces at the points of electrical contact
Although magnetic particle indications are easily seen, experience
and skill are sometimes needed to judge their significance.

Magnetic Testing (MT)

FERROMAGNETIC MATERIALS
Metals which conduct magnetic field:
elements:
iron,
nickel,
cobalt,

alloys:
cast iron
carbon steel

Ferromagnetic Materials
A material is considered ferromagnetic if it can be
magnetized. Materials with a significant Iron, nickel or cobalt
content are generally ferromagnetic.
Ferromagnetic materials are made up of many regions in
which the magnetic fields of atoms are aligned. These
regions are call magnetic domains.
Magnetic domains point randomly in demagnetized material,
but can be aligned using electrical current or an external
magnetic field to magnetize the material.
S

Demagnetized

Magnetized

Magnetic Testing (MT)

The physical
background

Magnetic Testing (MT)

Directions of the discontinuities

Magnetic Testing (MT)

Magnetic Testing (MT)

The ways of magnetization

long
i

tuda
l

circular

Producing a Longitudinal Magnetic

Field Using a Coil

A longitudinal magnetic
field is usually established
by placing the part near
the inside or a coils
annulus. This produces
magnetic lines of force
that are parallel to the
long axis of the test part.

Coil on Wet Horizontal

Inspection Unit

Portable Coil

Magnetic Testing (MT)

Magnetized ring
When a magnetic material is
placed across the poles of a
horseshoe
magnet
having
square ends, forming a closed or
ringlike assembly, the lines of
force flow from the north pole
through the magnetic material to
the south pole

Magnetic Testing (MT)

Magnetizing current

Both direct current (dc) and alternating current (ac) are suitable for
magnetizing parts for magnetic particle inspection.
The strength, direction, and distribution of magnetic fields are
greatly affected by the type of current used for magnetization.
The important difference with regard to magnetic particle inspection
is that the fields produced by direct current generally penetrate
the cross section of the part, while the fields produced by
alternating current are confined to the metal at or near the
surface of the part, a phenomenon known as the skin effect.
Therefore, alternating current should not be used in searching for
subsurface discontinuities.

Magnetic Testing (MT)

Magnetizing current
alternate current

rectified
three phase AC

rectified
one phase AC

Magnetic Testing (MT)

Yokes

Two basic types of yokes that

are commonly used for
magnetizing purposes:
permanent-magnet,
electromagnetic yokes.
Both are hand held and
therefore quite mobile.

Magnetic Testing (MT)

Yokes
Permanent-magnet yokes
are used for applications where a source of electric power
is not available or where arcing is not permissible (as in an
explosive atmosphere). The limitations of permanentmagnet yokes include the following:
Large areas or masses cannot be magnetized with enough
strength to produce satisfactory crack indications,
Flux density cannot be varied at will,
If the magnet is very strong, it may be difficult to separate
from a part,
Particles may cling to the magnet, possibly obscuring
indications.

Magnetic Testing (MT)

Yokes

Electromagnetic yokes
Consist of a coil wound around a U-shaped core of soft
iron.
The legs of the yoke can be either fixed or adjustable.
Adjustable legs permit changing the contact spacing
and the relative angle of contact to accommodate
irregularly-shaped parts.
Unlike a permanent-magnet yoke, an electromagnetic
yoke can readily be switched on or off.
This feature makes it convenient to apply and remove
the yoke from the testpiece.

Magnetic Testing (MT)

Electromagnetic yokes

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 ultraviolet light.

Crane Hook with Service Induced

Crack

Fluorescent, Wet Particle Method

Gear with Service Induced Crack

Fluorescent, Wet Particle Method

Drive Shaft with

Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

Splined Shaft with

Service Induced Cracks

Fluorescent, Wet Particle Method

Threaded Shaft with

Service Induced Crack

Fluorescent, Wet Particle Method

Large Bolt with

Service Induced Crack

Fluorescent, Wet Particle Method

Crank Shaft with Service Induced

Crack Near Lube Hole

Fluorescent, Wet Particle Method

Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

Toe Crack in SMAW Weld

Visible, Dry Powder Method

Advantages of Magnetic Particle

Can detect both surface and near sub-surface
Inspection

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).
Post cleaning, and post demagnetization is often
necessary.
Alignment between magnetic flux and defect is
important