Professional Documents
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1.0.
INTRODUCTION
The magnetic particle method of non-destructive testing is one of the most
common methods for finding discontinuities in materials. This method is
used for detecting surface and sub-surface discontinuities in Ferro-magnetic
materials. Magnetic particle testing is a relatively easy and simple test
method that can be applied to finished components, billets hot rolled bars,
forgings and castings. It can also be used to check processing operations
such as machining, grinding and heat treatment.
The objective of magnetic particle testing is to ensure product reliability by
providing means of
a. Obtaining a visual of an indication related to a discontinuity in or the
surface of the material.
b. Disclosing the nature of discontinuities without impairing the material.
c. Separating acceptable and unacceptable materials in accordance with
pre-determined standards.
2.0.
YOKE METHOD
PROD METHOD
2.1.
STEPS IN TESTING:
The method involves three essential steps:
a. Magnetising the material or a part under test.
b. Applying the Ferro-magnetic particles over the surface.
c. Examining the surface for powder patterns or indications.
3.0.
METHODS OF MAGNETISATION
Magnetisation of the materials can be carried out principally in two ways
viz. circular magnetization and longitudinal magnetization.
3.1.
CIRCULAR MAGNETISATION:
A circular magnetic field is induced into the component in two ways either
by directly passing the current through the component or indirectly through
a central conductor surrounded by a hollow article.
4.0.
4.1.
MAGNETISING CURRENTS:
Straight direct current (D.C) alternative current (A.C) and half wave
rectified direct current (HWDC) are all used. The following are their
relative merits and demerits.
DIRECT CURRENT (D.C.)
Straight DC is suitable for yokes and solenoids. The penetration power of
DC is more than that of AC. However, DC cannot be stepped up or down
easily.
4.2.
4.3.
J.W.D.C.
Half-wave Direct Current is produced by rectifying an alternative current
during the positive cycles. The use of rectified current has got the following
advantages.
1. AC at any commercial frequency can be used
2. Penetration is directly comparable to that of DC
3. The pulsating effect of the rectified wave is helpful in adding
mobility to the magnetic particles.
4. There is a definite advantage in locating deep seated
discontinuities.
5.0.
CURRENT REQUIREMENTS:
The required amount of magnetizing current is effected by the permeability
of the metal, the shape and thickness of article and the type of discontinuities sought. However, the following can be used as a Rule of
Thumb method:1. Circular magnetization with Head-shot method. 800-1000 C
amps.per inch dia. Or cross section with HWDC 500-600
amps.per inch of dia. or cross section with A.C
2. For circular magnetization with prods:
90-110 amps.per inch of prod-spacing for thickness upto
100-125 amps.per inch of prod-spacing for thickness more than
.
Prod-spacing can be kept between 4 and 8 for effective testing.
3. Longitudinal magnetization using coils:
AMPS. =
45.000
1
-------- x --L/D
T
Where L is the Length and D is the dia.of the article and T is the
number of turns in the coil. (Limitations). L not more than 18
and L/D between 2 & 15.
6.0.
In general, the following are the requirements of the particles used for
magnetic particle testing:
i.
Non-toxic
ii.
Fine divided
iii.
Ferro magnetic
iv.
Free from contaminants
v.
High permeability
vi.
Low-retentivity
vii. High colour contrast
viii. Correct size range
7.0.
SURFACE PREPARATION:
Usually as welded, as cast, as forged or as formed surfaces are suitable for
magnetic particle testing. However, excess scales, ripples, slag etc., may
interfere with the interpretation of the powder patterns. Also, flakes heavy
built up of paints, rust, grease etc., are to be cleaned, sand blasting wire
brushing, filling, grinding etc are used for removing interfering substances.
8.0.
LOCATION OF DISCONTINUITIES:
It is possible with suitable technique to locate discontinuities on the surface
as well as below surface upto 6mm deep. Discontinuities located on the
surface appear as sharp and distinct lines whereas sub-surface discontinuities appear as irregular, rough and fuzzy indication varies with the
depth of its location below the surface. Correct interpretation of the pattern
revealed by sub-surface discontinuities requires a certain skill on the part of
the operator.
9.0.
DEMAGNETISATION:
Since all Ferro-magnetic materials possess retentively there will be certain
amount of residual magnetism left on the material tested. The amount of
residual magnetism depends o the magnetizing current, its strength and
nature (AC or DC) and the permeability of the material. De-magnetisation
is essential for components to be used in space crafts, aeroplanes, bearings
etc., where pick up of iron particles cause damage to the part. Demagnetisation is done by passing the component through an AC field of
gradually reducing current or by periodically reversing and reducing the
DC current.
13.0. APPLICATION:
Magnetic particle Inspection is widely used in process control and in the
maintenance. The root welding of a header butt joint or drum
circumferential seam or similar type joints are magnetic partically tested
after lack of gouging before going for full welding. Magnetic particle
inspection is a widely used method for examining fillet welds. For detecting
any surface cracks after stress relieving magnetic particle inspection is the
best method. All such inspections can be carried-out prod-techniques. Prod
method is one way of circularly magnetising the component by directly
passing the current. Large area can be tested part by part and the direction
of the field can be changed very easily by relocating the prods. Care must
be taken to is see that the prod tips are cleaned properly and current is
switched only after establishing proper contacts; otherwise excessive arcing
will take place and can damage the surfaces. Fillet welds in columns and
beams are another area where magnetic particle inspection can be widely
used. During maintenance operation after shut down of a thermal power
plant again these methods can be put into service quite extensively.