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1. INTRODUCTION
1.2 Magnetism
Unmagnetised state.
Domains randomly
orientated.
Field
Magnetised state.
Domains orientated
in external magnetic
field.
Field
Field
Saturated state.
Domains orientated
in strong external
field.
Field
Residual state.
Domains remaining
orientated in
absence of external
field.
Field
Demagnetised
state.
Domains randomly
orientated in
opposing field
Field
Alloying elements
Carbon content
Heat treatment
Temperature
If a bar magnet is placed under a flat sheet of paper and iron filings
are sprinkled on to the paper, a visual field is created. This is called
a magnetographThe filings are orientated by the magnetic field
created by the lines of force running between the poles of the bar
magnet.
S N
2. Do not cross
2.4 ELECTROMAGNETISM
If the thumb of the right hand is extended in the direction in which the
current is flowing, then the direction of the magnetic field is
represented by the fingers.
Now, if the original conductor carrying the current is bent into a loop,
the magnetic field around the conductor will pass through the loop in
one direction.
The field within the loop has direction and one side will be a north
pole and the other a south pole. By increasing the number of loops, a
coil, or solenoid, is created and the strength of the field passing
through the coil is proportional to the current passing through the
conductor in amperes multiplied by the number of turns in the
solenoid, see Fig.5a.
The word hysteresis is derived from the Greek word for delayed and
is used to describe one quantity lagging behind another. The
variation of B to H follows a hysteresis loop and is characteristic to a
particular ferromagnetic material.
B a
c f
H
o
e
d
Figure 6: Hysteresis
The dotted line o-a is often referred to as the virgin curve. Point a
towards point b is where the hysteresis loop begins.
As the magnetising force is reduced the flux density does not fall
back to zero but follows the line a-b. So at b there is a zero
magnetising force but a flux density o-b remains. The flux is
lagging behind the force and this is what gives ferromagnetics their
permanent magnetism.
The specimen will not be demagnetised until special steps are taken
to achieve that state.
Manganese
with pearlitic
steels
Manganese
with austenitic
steels
Chromium
Nickel
with pearlitic
steels
Nickel
with austenitic
steels
Aluminium
Tungsten
Vanadium
Cobalt
Molybdenum
Copper
Sulphur
Phosphorus
Decrease
Unknown
Flux density
Symbol = B
SI unit = tesla = T
(It has replaced the gauss and 1 tesla = 104 gauss)
Magnetising force
Symbol = H
SI unit = ampere per metre = Am-1
Permeability
Symbol = (mu)
B
H
=
= 4 x 10-7 Henries/metre
r =
Saturation
Coercive force
Remanence
H = O.
Reluctance
Retentivity
Flux lines will take the path of least reluctance, hence the highest
permeability. Figure 8a shows flux lines flowing in a ferromagnetic
bar but having to divert around an air gap, creating a flux leakage.
a. b.
a) Size of defect
b) Shape of defect
c) Volume of defect
d) Orientation of defect
e) Depth below surface
f) Permeability of material
2.7.1 Indications
Relevant
Spurious
Non-Relevant
a) Size
b) Shape
c) Orientation
It has already been said that the magnetic flux lines must run
in a direction so that they can be interrupted at a defect
causing a flux leakage. So, in order to detect defects, the flux
lines should ideally be at 90 to the direction of potential
defects.
Longitudinal Transverse
Magnetising Defect will Defect will
Current not show show
Longitudinal Transverse
Magnetising Defect will Defect will
Current show not show
3. EQUIPMENT
Advantages Disadvantages
3.2 Electromagnets
Advantages Disadvantages
3.3 Prods
Advantages Disadvantages
Advantages Disadvantages
The parallel closed loop is a novel variation which has found some
favour in underwater inspection and the gas industry.
Advantages Disadvantages
Where prods are not suitable because heat damage may be caused,
or the item is too large and awkward, it is often still possible to pass a
current into a specimen. Special 'crocodile' clips with copper woven
braiding on them are one alternative. Another possibility is to use
permanent magnets as leeches to clamp on the job so that the
operator's hands are free to apply the ink or powder. The current is
passed through the leeches and does not affect the permanent
magnetism.
The current required to test a job may be quite low but losses due to
cable length or bulk of specimen may mean that a portable set
cannot produce enough. Paragraphs 3.3 to 3.6 are relevant to
mobile units as well as portables.
Field
Current
Current
Magnetism
Current
4. CURRENT WAVEFORMS
-
Figure 18: Direct Current
Advantages Disadvantages
-
Figure 19: Alternating Current
Advantages Disadvantages
+
-
Figure 20: Half Wave Rectified Current
Advantages Disadvantages
+
-
Figure 21: Direct Current
Advantages Disadvantages
5. MAGNETISING VALUES
It has been explained that different current wave terms are used in MPI, but
not why. Alternating current is simple to transform, when taken from the
electrical mains, and employ. Because the polarity is changing fifty times a
second the magnetic particles are constantly reversing their direction and
this causes them to migrate or 'walk' to flux leakages. This is excellent
because it gives bright clear indications.
Thus, before selecting a magnetising value and wave form for a job, the
type, orientation and depth of likely defects must be deduced.
5.2 AC electromagnets
5.3 Prods
CF3 CF3
Y2
1 7.5 T
4T a) Using direct or rectified current,
the peak value of the current flowing in a cable shall have a
minimum value of:
where
I = peak current
T = wall thickness (in mm) or radius of component if round
Y = the spacing (in mm) between adjacent windings in the coil.
Y2
I 7.5 10
40
where
I = peak current
Y = the spacing (in mm) between adjacent windings in the coil
K
N x I
L
2
D The UK system requires the cable
windings to be spaced. But in the USA it is accepted that
spacing the windings is extremely difficult and thus the
formula in ASME V shown below applies to flexible close
turn coils:
where:
I = coil current
N = number of turns in the coil or cable wrap
L = part length
D = part diameter
K = 35000
I = 30d
d2
d1 d1
r = radius of influence
d1 = distance from surface
d2 = distance of effective cover
N x I = 30d
The values for current flow applications are given in Tables 2 and 3.
When components having varying cross section are tested, a single
current value can be used if the diameters of the larger and small
sections are within a ratio of 1.5:1. The large diameter governs the
value.
If the cross section variation is greater than 1.5:1 then each section
is tested in turn, starting with the smallest.
When the threading bar is placed centrally the current values given
in Tables 2 and 3 may be used.
Alternatively, and when the threading bar is offset from the centre,
the surface under test shall lie totally within a circle centred on the
threading bar. The radius (in mm) (r) of this circle is given by:
1
r
15
general engineering
1
r
56
aerospace application
where
1
r
40
aerospace applications
Test 1
Test 2
Test 5
Test 3
32000 22000
Ip or Irms
L L
xN xN
D D The formulae given by
BS6072 is:
Where
22000
N x Irms
L/ D This can be usefully transposed to read:
2. The test piece should lie against the side or bottom of the coil.
3. L/D ratio of the part must be greater than 5:1 if not, pole
extenders can be clamped to the ends of the testpiece.
4. If the L/D ratio exceeds 20 then the ampere turn value for a
20:1 ratio should be used. The test should be repeated at coil
length intervals.
5. The major axis of the test piece should be parallel with the axis
of the coil.
6. When using rigid coils of helical form the pitch of the helix
shall be less than 25% of the coil diameter.
7. BS6072 implies that only the section in the coil is tested and
the test must be repeated at coil length intervals. In US
instructions the test area extends 6" beyond the coil on each
side.
Formula:
N= number of turns
I= amperage
D= diameter of specimen
L= length of specimen
X= 32 000 for peak
22 000 for AC rms and FWR
11 000 for HWR
A clamp meter is required to find out the value of current induced into
a component. If one is available then the current values used for
current flow apply. However, if the correct type of ammeter is not to
hand, a flux indicator is the alternative.
Field strength meters based on the Hall effect are the best way of
ascertaining adequate field strength at the surface of a test
component. However, they are expensive and the probes used tend
to be fragile. Portable flux indicators are an acceptable alternative.
They:
segment type
foil type
6. TEST METHODS
Black
Red
Grey
Yellow
6.2 Inks
Contrast or fluorescent
Kerosene or water-based
1. price
2. odour reduction
3. health and safety implications
Kerosene based inks are supplied in bulk but to maintain the solid
content at the correct level a small amount of concentrate is added at
intervals. It is not recommended that magnetic inks are made up
with normal kerosene, especially fluorescent inks since:
1. Demagnetise if specified
2. Clean
3. Affix magnetising contacts
4. Apply detecting media
5. Apply magnetising force, 2-3 sec duration
6. Stop detecting media
7. Stop magnetising force
8. Inspect - this should start at operation 5 and
end at 8
9. Demagnetise, if specified
10. Clean
11. Protect
1. Demagnetise
2. Clean
3. Affix magnetising contacts
4. Apply magnetising force, not AC, 2-3 sec
5. Apply detecting media, spray or dip
6. Wait, 30 sec-1 min
7. Inspect
8. Demagnetise
9. Clean
10. Protect
Ultra violet
Infra red TV
10-10 10-8 10-6 10-4 10-2 1cm 102 104 106 108
Wavelength
7. DEMAGNETISATION
Field
Strength
The ink is agitated for 5 min and then a 100ml sample is poured into
the settlement flask. The sample is allowed to settle for 60 min and
the volume of solid is then read off the flask scale.
This test is carried out to find any changes that may have occurred
during the day to day use of the equipment or materials. The test is
carried out at the start of work or at shift change.
To carry out the test the appropriate test piece is processed and the
minimum ammeter readings which give satisfactory build-up of
9.8 Ammeters
9.9 Demagnetiser
Often forgotten until something goes wrong. There does not seem to
be a national standard but a major aerospace manufacturer
recommends that demagnetisers should have a minimum internal
field strength of 5.57kA/m. As with ammeters, the major MPI
equipment manufacturers will provide a service when requested.