INTRODUCTION OF MAGNETIC PARTICLE TESTING (MPI)

Basic Principles

Magnetic particle testing is one of the most widely utilized NDT methods since it is fast and
relatively easy to apply and part surface preparation is not as critical as it is for some other
methods. This method uses magnetic fields and small magnetic particles (iron filings) to detect
flaws in components. The only requirement from an inspect ability standpoint is that the
component being inspected must be made of a ferromagnetic material (a materials that can be
magnetized) such as iron, nickel, cobalt, or some of their alloys.

Objective

To reveal both production discontinuities and in-service damage which a need of combination
magnetic flux leakage and visual testing.

Different Techniques

The technique works by inducing a magnetic field in the component tested. If a surface or near-
surface flaw is present, the magnetic flux is distorted and leaks around the flaw. By dusting the
surface of the tested item with fine magnetic particles such as ferrous iron filings. Techniques for
magnetic particle inspection include:

Bench (Direct current/Head shot/Central Conductor/AC/HWDC)

Permanent magnetic
Yoke (AC/HWDC)
Ring bench
Coil/cable wrap technique
Prod technique
Magnetization Using Indirect Induction (Indirect Magnetization)

Electromagnets in the form of an adjustable horseshoe magnet (called a yoke) eliminate the
problems associated with permanent magnets and are used extensively in industry. Electromagnets
only exhibit a magnetic flux when electric current is flowing around the soft iron core. When the
magnet is placed on the component, a magnetic field is established between the north and south
poles of the magnet.

Figure 1: Yoke use in this experiment.

Alternating current (AC) reverses in direction at a rate of 50 or 60 cycles per second. 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 a thin layer 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.
Experimental Procedures

1. Surface Preparation and pre-cleaning- Clean the sample surface to be examined using
special chemical cleaner/remover (detergents, organic solvents, descaling solutions,
paint removers, vapour degreasing, sand, and grit blasting) and wipe it. The surface Commented [G1]: Inserted: ,

needs to be free of oil, grease, water, or other contaminants. Commented [G2]: Inserted: s

2. Ensure the yoke been calibrated. The yoke needs to produce magnetically capable to Commented [G3]: Inserted: s

lift 10lb (for AC yoke) of steel block before a test. For the test specimen, check the Commented [G4]: Inserted: ally

magnetic field using magnometer which the value of magnometer should be zero. Commented [G5]: Inserted: a

3. Contrast Application- The white contrast spray is applied to the inspected surface of
the part and waited about 10 minutes for the surface to dry. This white contrast will Commented [G6]: Inserted: the

produce an opaque white background, making it easy to see even the

smallest indication.

4. Black Magnetic Ink Application- Applied a thin layer of black magnetic ink onto the
test. At the same time, introduce magnetic field using yoke and deformities will begin Commented [G7]: Inserted: the

to appear clearly in black.

5. Interpret and evaluate any indications by measured the flaw length and location to the
applicable acceptance standard.

6. Turn the yoke 90 degrees form the original position and repeat step 3. Commented [G8]: Inserted: e
Commented [G9]: Deleted:s

7. Clean the test surface area. Repeat the steps for the samples M2631 and M2629.
Data Analysis and Results

1 2

Specimen ID: M2679 (Top surface)

Specimen ID: M2679 (Back surface)

Specimen Cross Section:

Inspection Results
No. Type Measured length Theoretical Distance from 0
(mm) length (mm) (mm)
1 Center line crack 12.5 13 112
2 Center line crack 8 8 191
3 HAZ crack 10 10 122
 1
2

Specimen ID: M2631 (Top surface)

Specimen ID: M2631 (Back surface)

Specimen Cross Section:

Inspection Results

No. Type Measured length Theoretical Distance from 0

(mm) length (mm) (mm)
1 Toe crack 10 10 48
2 HAZ crack 10 10 152
3 Toe crack 8 8 107
 2
1

Specimen ID: M2629 (Top surface)

Specimen ID: M2629 (Top surface)

Specimen Cross Section:

Inspection Results

No. Type Measured length Theoretical Distance from 0

(mm) length (mm) (mm)
1 Toe crack 10 10 23.2
2 Toe crack 16 15 127.2
3 Surface porosity 8 8 117 Commented [G10]: Inserted: r
Commented [G11]: Deleted:s
Discussion and Conclusion

This experiment of Magnet Particle Testing (MPI) can detect both surface and near-surface
indications. Surface preparation is not as critical compared to other NDE methods. Most surface
contaminants will not hinder detection of a discontinuity. A relatively fast method of examination.
Indications are visible directly on the surface. Low-cost compared too many other NDE methods.
A portable NDE method, especially when used with battery-powered yoke equipment. Post-
cleaning generally not necessary. A relatively safe technique; materials generally not combustible
or hazardous. Indications can show relative size and shape of the discontinuity. Easy to use and
requires minimal amount of training.