Professional Documents
Culture Documents
Particle
Inspection
Table of Contents
Physics of MPI
1. Magnetism
2. Magnetic Materials
3. Magnetic Domains
4. Magnetic and Electromagnetic fields
5. Fields from a Coil
6. Magnetic Properties
7. Hystersis loop
8. Permeability
9. Field Orientation
10. Magnetization of Materials
11.Magnetizing Current
Magnetic Mediums
Defectology
Interpretation of Indications
Demagnetization Methods
This method may be used for all ferromagnetic materials and is superior to
liquid penetrant inspection on ferromagnetic materials.
Relatively easy simple method that can be applied at various stages of
manufacturing and processing operations.
This technique is not a substitute for radiography or ultrasonic when locating
subsurface discontinuities, but may present advantages over radiography in
locating tight cracks and surface imperfections.
It may be used where radiography or ultrasonic is neither available nor
practical to apply because of shape of the specimen or its location.
Limitations
The magnetic particle inspection can be applied to only to ferromagnetic
materials. Difficulties may arise when inspecting weldments where the magnetic
characteristics of the deposited weld metal differ appreciably from those of the
parent material or where the magnetic field is not properly oriented.
Magnetic particle examination should not be relied for
detecting deepseated cavities. These are detected by other internal NDT methods such as
radiography or ultrasonic.
Subsurface porosity and slag inclusions produce discontinuity patterns that
are not clearly defined.
Applications
Objective of Magnetic Particle Inspection
The main objective of magnetic particle inspection is to insure product
reliability by providing means of:
1. Obtaining a visual image of an indication on the surface of the material.
2. Disclosing the nature of discontinuities without impairing the material.
3. Separating the acceptable and unacceptable material with reference to
applicable codes and standards.
Basic Principles
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 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 the at the south pole. The magnetic field spreads out
when it encounter the small air gap created by the crack because the air
can not 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, it is called a flux leakage field.
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 Michael 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 really 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, which were being 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.
In the early 1930s, magnetic particle inspection (MPI) was quickly
replacing the oil-and-whiting method (an early form of the liquid
penetrant inspection) as the method of choice by the railroad to inspect
steam engine boilers, wheels, axles, and the 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
race cars are inspected whenever the engine, drive train and other
systems are overhauled. MPI is also used to evaluate the integrity of
structural welds on bridges, storage tanks, and other safety critical
structures.
Basic Physics of
MPI
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 and, thus, 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...the atom.
Magnetic
Materials
Diamagnetic materials are solids with all paired electron and, therefore, no
permanent net magnetic moment per atom. Diamagnetic properties arise
from the realignment of the electron orbits under the influence of an external
magnetic field. Most elements in the periodic table, including copper, silver,
and gold, are diamagnetic.
Paramagnetic metals have a small and 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 orbits caused by
the external magnetic field. Paramagnetic materials include Magnesium,
molybdenum, lithium, and tantalum.
Ferromagnetic materials have a large and 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 atoms moments (10^12 to 10^15) are aligned parallel so
that the magnetic force within the domain is strong. When a ferromagnetic
Magnetic Domains
Ferromagnetic materials get their magnetic properties not only because
their atoms carry a magnetic moment but also because the material is
made up of small regions known as magnetic domains. In each domain, all
of the atomic dipoles are coupled together in a preferential direction. This
alignment develops as the material develops its crystalline structure during
solidification from the molten state. Magnetic domains can be detected
using Magnetic Force Microscopy (MFM) and images of the domains like
the one shown below can be constructed.
Magnetic Force Microscopy (MFM) image showing the magnetic domains in a
piece of heat treated carbon steel.
During solidification a trillion or more atom moments are aligned parallel so that
the magnetic force within the domain is strong in one direction. Ferromagnetic
materials are said to be characterized by "spontaneous magnetization" since
they obtain saturation magnetization in each of the domains without an external
magnetic field being applied. Even though the domains are magnetically
saturated, the bulk material may not show any signs of magnetism because the
domains develop themselves are randomly oriented relative to each other.
Ferromagnetic materials become magnetized when the magnetic domains
within the material are aligned. This can be done my placing the material in a
strong external magnetic field or by passes electrical current through the
material. Some or all of the domains can become aligned. The more domains
that are aligned, the stronger the magnetic field in the material. When all of the
domains are aligned, the material is said to be magnetically saturated. When a
material is magnetically saturated, no additional amount of external
magnetization force will cause an increase in its internal level of magnetization.
Unmagnetized Material
Magnetized Material
Magnetic and
Electromagnetic Fields
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.
Magnetic Fields in and around Horseshoe and Ring Magnets
Magnets come in a variety of shapes and one of the more common is the
horseshoe (U) magnet. The horseshoe magnet has north and south poles
just like a bar magnet but the magnet is curved so the poles lie in the same
plane. The magnetic lines of force flow from pole to pole just like in the bar
magnet. However, since the poles are located closer together and a more
direct path exists for the lines of flux to travel between the poles, the
magnetic field is concentrated between the poles.
Electromagnetic Fields
Magnets are not the only source of magnetic fields. In 1820, Hans Christian
Oersted discovered that an electric current flowing through a wire caused a
nearby compass to deflect. This indicated that the current in the wire was
generating a magnetic field. Oersted studied the nature of the magnetic field
around the long straight wire. He found that the magnetic field existed in
circular form around the wire and that the intensity of the field was directly
proportional to the amount of current carried by the wire.
He also found that the strength of the field was strongest close to the wire and
diminished with distance from the conductor until it could no longer be
detected. In most conductors, the magnetic field exists only as long as the
current is flowing (i.e. an electrical charge is in motion). However, in
ferromagnetic materials the electric current will cause some or all of the
magnetic domains to align and a residual magnetic field will remain.
Oersted also noticed that the direction of the magnetic field was dependent on
the direction of the electrical current in the wire. A three-dimensional
representation of the magnetic field is shown below. There is a simple rule for
remembering the direction of the magnetic field around a conductor. It is called
the right-hand rule. If a person grasps a conductor in ones right hand with the
thumb pointing in the direction of the current, the fingers will circle the
conductor in the direction of the magnetic field.
For the right-hand rule to work, one important thing that must remembered
about the direction of current flow. Standard convention has current flowing
from the positive terminal to the negative terminal. This convention is
credited to the French physicist Ampere who theorized that electric current
was due to a positive charge moving from the positive terminal to the
negative terminal. However, it was later discovered that it is the movement
of the negatively charged electron that is responsible for electrical current.
Rather than changing several centuries of theory and equations, Ampere's
convention is still used today.
Magnetic
Properties
SI units
(Sommerfiel
d
SI units
(Kennely)
CGS units
(Gaussian)
Field H
A/m
A/m
Oersteds
Flux Density
(Magnetic
Induction)
Weber
Tesla
Gauss
Flux f
Weber
Weber
maxwell
Magnetization M
A/m
--
erg.Oe-1.cm-3
The units for magnetic field strength H are ampere/meter. A magnetic field
strength of 1 ampere/meter is produced at the center of a single circular
conductor of diameter 1 meter carrying a steady current of 1 ampere.
The number of magnetic lines of force cutting through a plane of a given area
at a right angle is known as the magnetic flux density B. The flux density or
magnetic induction has the tesla as its unit. One tesla is equal to 1 Newton/
(A/m). From these units it can be seen that the flux density is a measure of
the force applied to a particle by the magnetic field. The Gauss is CGS unit
for flux density and is commonly used by US industry. One gauss represents
one line of flux passing through one square centimeter of air oriented 90
degrees to flux flow.
The total number of lines of magnetic force
in a material is called magnetic flux (f).
The strength of the flux is determined by the
number of magnetic domains that are aligned
within a material. The total flux is simply the flux
density applied over an area. Flux carries the unit
of a weber, which is simply a tesla-square meter.
may be lower than the retentivity value when the magnetizing force did
not reach the saturation level.
Coercive Force - The amount of reverse magnetic field which must be
applied to a magnetic material to make the magnetic flux return to zero.
(The value of H at point C on the hysteresis curve.)
Reluctance - Is the opposition that a ferromagnetic material shows to the
establishment of a magnetic field. Reluctance is analogous to the
resistance in an electrical circuit.
Permeability
Permeability is a material property that describes the ease with which a
magnetic flux is established in the component. It is the ratio of the flux
density to the magnetizing force and, therefore, represented by the
following equation:
m = B/H
It is clear that this equation describes the slope of the curve at any point
on the hysteresis loop. The permeability value given in papers and
reference materials is usually the maximum permeability or the
maximum relative
This orientation creates the largest disruption of the magnetic field within
the part and the greatest flux leakage at the surface of the part. As can be
seen in the image below, if the magnetic field is parallel to the defect, the
field will see little disruption and no flux leakage field will be produced.
Current is injected into the component as it flows from the contacts. The
current sets up a circular magnetic fields around the path of the current.
The prod electrodes are pressed firmly against the test part. The
magnetizing current is then passed through the prods and into the area of
the part in contact with the prods. This establishes circular magnetic field in
the part around and in between the prod legs, sufficient to carry out localized
magnetic particle inspection.
Extreme care should be exercised to maintain clean prod tips. This is done
to minimize the heat at the point of contact and to prevent arc burns and
local overheating of the material surface. Arc burns cause metallurgical
damage; if the tips are made of solid copper, copper penetration may occur
into the part. Prods should not be used on machined surfaces or on
aerospace component parts.
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.
Magnetizing Current
As seen in the previous pages, 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.
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
when in actuality the electrons flow in the opposite direction. DC is very
desirable when performing magnetic particle inspection in search of
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
to AC, drive 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.
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 (50 or 60 hertz typical).
Since half of the current is blocked out, the amperage is half of the
unaltered AC.
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.
The field strength varies from zero at the center of the component to a
maximum at the surface.
The field strength at the surface of the conductor decreases as the radius
of the conductor increases when the current strength is held constant.
(However, a larger conductor is capable of carrying more current.)
The field strength outside the conductor is directly proportional to the
current strength. Inside the conductor the field strength is dependent on
the current strength, magnetic permeability of the material, and if
magnetic, the location on the B-H curve.
The field strength outside the conductor decreases with distance from
the conductor.
In the images below, the magnetic field strength is graphed versus
distance from the center of the conductor. It can be seen that in a
nonmagnetic conductor carrying DC, the internal field strength rises from
zero at the center to a maximum value at the surface of the conductor. The
external field strength decrease with distance from the surface of the
conductor. When the conductor is a magnetic material, the field strength
within the conductor is much greater that it was in the nonmagnetic
conductor. This is due to the permeability of the magnetic material. The
external field is exactly the same for the two materials provided the current
level and conductor radius are the same.
The magnetic field distribution in and around a solid conductor of a
nonmagnetic material carrying direct current.
As can be seen in the field distribution images, the field strength at the
inside surface of hollow conductor carrying a circular magnetic field
produced by direct. However, a much better method of magnetizing hollow
components for inspection of the ID and OD surfaces is with the use of a
central conductor. As can be seen in the field distribution image to the right,
when current is passed through a nonmagnetic central conductor (copper
bar) the magnetic field produced on the inside diameter surface of a
magnetic tube is much greater and the field is still strong enough for defect
detection on the OD surface magnetization is very low. Therefore, the direct
Equipments
and Materials
Permanent magnets
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.
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, also the magnetic field can be turn 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 magnet touch the part to be
inspected. Some yokes can lift weights in excess of 40 pounds.
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 is 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 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 now allowed when inspecting
aerospace and other critical components. To help to 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 depicted gives an
estimation of the patterns expected with magnetic particle on an unflawed
surface. The user is encouraged to manipulate the prods to orient the
magnetic field to "cut across" suspected defects.
Portable Coils and Conductive Cables
Coils and conductive cables are used to establish a longitudinal
magnetic field within a component. When a performed 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 component. The cable
Portable Coil
Conductive cable
ADVANTAGES AND
DISADVANTAGES
OF VARIOUS
TECHNIUQES
HEADSHOT
TECHNIQUE
current path
Good sensitivity to surface and near
surface discontinuities
Simple and relatively complex parts can be
processed
Complete magnetic path is conducive to
maximizing the residual characteristics of
material
Disadvantages
Possibility of arc burns, if poor
Advantages
Large surface areas can be
Disadvantages
Higher amperage requirements
Disadvantages
Effective limited field to outside
PROD EXAMINATION
WELDS
Advantages
Circular field can be selectively directed
Disadvantages
Only small area can be examined at
a time
Arc burns can occur
Surface must be dry when dry
powder is being used
Disadvantages
Coverage of large areas can be
CENTRAL CONDUCTOR
Advantages
No electrical contact with the part and
Disadvantages
Size of the conductor must be sufficient to
PERMANENT AND
ELECTROMAGNETIC YOKES
Inspection of Large surface areas and
Inspection of Localized areas
Advantages
No electrical contact
Highly portable
Can locate discontinuities in any direction
with proper placement
No electrical contact
Good sensitivity to surface discontinuities
Wet or dry method can be used
AC yokes can also serve as an
demagnetizer in some cases
Disadvantages
Time consuming
Yoke must be systematically re-
COIL METHOD
MEDIUM SIZED PARTS WHOSE LENGTH
PREDOMINATES, SUCH AS
CRANKSHAFT OR CAMSHAFT
Advantages
All generally longitudinal surfaces are
longitudinally magnetized to
transverse discontinuities
Disadvantages
Parts should be centered in the coil
Advantages
Longitudinal field easily attained by
wrapping the part with a flexible
cable
Disadvantages
Multiple processing may be required
because of part shape
Advantages
Easy and fast, especially where
Lights for
Magnetic Particle Inspection
Magnetic particle inspection can be performed using particles that are highly
visible under white lighting conditions or particles that are highly visible
ultraviolet lighting 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 between 300 and 1000 lux
(30 and 100 ftc) is recommended when a 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 the near-ultraviolet light. This "particle glow"
provides a 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 fluoresce red, blue, yellow, and green colors are
available.
Ultraviolet Light
Ultraviolet light or "black light" is light in the 1,000 to 4,000 Angstroms (100
to 400 nm) wavelength range in the electromagnetic spectrum. It is a very
energetic form of light that is invisible to the human eye. Wavelengths above
4,000 Angstroms 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
UV-C
Wavelength Range
3,2004,000 Angstroms
2,8003,200 Angstroms
2,8001,000 Angstroms
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 wave
lengths of 3,120 A to 3,340 A are produced in low levels. A peak wavelength
of 3650 A is produced at a very high intensity. Wavelengths in the visible
violet range (4050 A to 4350 A), green-yellow (5460 A), yellow (6220 A) and
orange (6770 A) are also usually produced. The filter allows only radiation in
the range of 3200 to 4000 angstroms and a little visible dark purple to pass.
Basic Ultraviolet Lights
UV bulbs come in a verity on 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
florescent 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 that is a
concern as inspection specifications require less than two foot candles of
white light at the inspection surface.
Flood lights are also used to illuminate the inspection area as they provide
even illumination over a large area. Intensity levels for flood lamps is
relatively low because the energy is spread over a large area. They
generally do not generate the required UV light intensity at the given
distance that specifications require.
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. 100 watt mercury vapor lights are most commonly used,
but higher wattages are available.
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.
Measuring
Magnetic
Fields
Field Indicators
Field indicators are small mechanical devices that utilize a soft iron vane
that will be deflected by a magnetic field. The X-ray image below shows the
inside working of a field meter looking in from the side. The vane is attached
to a needle that rotates and moves the pointer for the scale. Field indicators
can be adjusted and calibrated so that quantitative information can be
obtained.
However, the measurement range of field indicators is usually small due to
the mechanics of the device. The one shown to the right has a range from
plus twenty gauss to minus twenty gauss. This limited ranges makes them
best suited for measuring the residual magnetic field after demagnetization.
Magnetic
Mediums
As mentioned previously, the particles that are used for magnetic particle
inspection are a key ingredient as they form the indications that alert the
inspector to defects. Particles start out as tiny milled (a machining
process) pieces of iron or iron oxide. A pigment (somewhat like paint) is
bonded to their surfaces to give the particles color. The metal used for the
particles has high magnetic permeability and low retentivity. High
magnetic permeability is important because it makes the particles attract
easily to small magnetic leakage fields from discontinuities, such as
flaws. Low retentivity is important because the particles themselves never
become strongly magnetized so they do not stick to each other or the
surface of the part. Particles are available in a dry mix or a wet solution.
Dry Magnetic Particles
Dry magnetic particles can typically be purchased in are red, black, gray,
yellow and several other colors so that a high level of contrast between
the particles and the part being inspected can be achieved.. The size of
the magnetic particles is also very important. Dry magnetic particle
products are produced to include range of particle sizes. The fine
particles are around 50 mm (0.002 inch) in size are about three times
smaller in diameter and more than 20 times lighter than the coarse
particles (150 mm or 0.006 inch), which make them more sensitive to the
leakage fields from very small discontinuities. However, dry testing
particles cannot be made exclusively of the fine particles.
Wet method magnetic particles products differ from dry powder products in a
number of ways. One way is that both visible and fluorescent particle are
available. Most nonfluorescent particles are ferromagnetic iron oxides, which
are either black or brown in color. Fluorescent particles are coated with
pigments that fluoresce when exposed to ultraviolet light. Particles that
fluoresce green-yellow are most common to take advantage of the peak color
sensitivity of the eye but other fluorescent colors are also available. (For
more information on the color sensitivity of the eye, see the penetrant
inspection material.)
The particles used the wet method are smaller in size than those used in
the dry method for the reasons mentioned above. The particles are typically
10 mm (0.0004 inch) and smaller and the synthetic iron oxides have particle
diameters around 0.1 mm (0.000004 inch).
This very small size is a result of the process used to form the particles and
is not particularly desirable, as the particles are almost too fine to settle out
of suspension. However, due to their slight residual magnetism, the oxide
particles are present mostly in clusters that settle out of suspension much
faster than the individual particles. This makes it possible to see and
measure the concentration of the particles for process control purposes.
The carrier solutions can be water- or oil-based. Water-based carriers form
quicker indications, are generally less expensive, present little or no fire
hazard, give off no petrochemical fumes, and are easier to clean from the
part. Water-based solutions are usually formulated with a corrosion inhibitor
to offer some corrosion protection. However, oil-based carrier solutions offer
superior corrosion and hydrogen embrittlement protection to those materials
that are prone to attack by these mechanisms.
DEFECTOLOGY
FORGINGS
CASTINGS
WELDMENTS
FORGINGS
In forgings of both ferrous and non-ferrous metals, the flaws occur mostly due to
the conditions that exist in the ingot, by subsequent hot working of the ingot or
the billet, and by hot or cold working during forging. Many open-die forgings are
forged from ingots. Many closed-die forgings are forged from rolled billets, or bar
stock. Most of the discontinuities that arise in forgings are due to the
imperfections present in the ingot.
Chemical Segregation
The elements in the alloy are seldom uniformly distributed. Even in unalloyed
elements contain randomly distributed impurities in the form of tramp elements.
Therefore, the composition of metal or alloy will vary. Deviation from the metal
composition at a particular location in a forging is termed as segregation.
Segregations, therefore, produces a metal, having a range of compositions
having no identical properties. Forging can correct the results of segregation by
recrystallizing or breaking the grain structure to provide a more uniform,
homogenous substructure. However, the effects of badly segregated forging
cannot be totally eliminated by forging.
In metals, the presence of localized regions that deviate from the normal
compositions can affect corrosion resistance, forging, and welding
characteristics, mechanical properties fracture toughness, and fatigue resistance.
Nonmetallic Inclusions
They originate in the ingot and are likely to be carried over to the forgings, even though
the material may undergo several intermediate hot-working operations. Most nonmetallic
inclusions originate during solidification from the initial operation. If no further
consumable-re-melting cycles follow, the size, frequency, and distribution of these
inclusions will not be altered. However, if a subsequent vacuum re-melting operation is
used, the inclusions will be lessened in size and frequency and will become more random
in nature.
Two kinds of nonmetallic inclusions are distinguished in metals: Those that are
entrapped in the metal inadvertently and originate exclusively from particles of
matter that are occluded in the metal while it is being molten or being cast; Those
that separate from the metal because of change in temperature or composition.
Inclusions of the latter type are produced by the separation from the metal, when it
is in the liquid or in the solid state. Oxides, sulfides, nitrides and other nonmetallic
compounds are produced in such amounts that their solubility in the matrix is
exceeded.
Of numerous types of flaws present in forgings, nonmetallic inclusions contribute
significantly to service failure. Those used in high-integrity aerospace applications,
these inclusions tend to decrease the ability to withstand the static loads, fatigue
loading and sometimes corrosion and stress-corrosion.
A seam can also result from the result from a defect in the ingot surface, such as a hole,
that becomes oxidized and is prevented from healing during working. In this case, the hole
simply stretches out during forging or rolling, producing a linear crack like seam in the
work piece surface.
Other Surface Defects
Slivers are loose torn pieces of steel rolled into the surface. Rolled-in scale is a scale
formed during rolling. Ferrite fingers are surface cracks that have been welded shut but
still contain the oxides and decarburization. Fins and Overfills are protrusions formed by
the incorrect reduction during hot-working. Under fills are as a result of incomplete working
of the section during reduction.
Flaws Caused by Forging Operation
Flaws produced by forging operation are result of improper setup or control. Proper control
of heating is necessary for forging to prevent excessive scale, decarburization ,
overheating, or burning. Excessive scale, in addition to causing excessive metal loss, can
result in forgings with pitted surfaces. The pitted surfaces are caused by scale being
hammered into the surface and may result in unacceptable forgings.
Internal flaws in forgings often appear as cracks or tears, and may result either from
forging with too light a hammer or from continuing forging after the metal has cooled down
before a safe forging temperature. A number of surface flaws can be produced by the
forging operation. The movement of metal over or upon another surface often causes
these flaws without actual welding or fusing of the surfaces; such flaws may be laps or
folds.
Cold shuts often occur in closed-die forgings. They are junctures of two
adjoining surfaces caused by incomplete metal fill and incomplete fusion of
surfaces. Shear cracks often occur in forgings. They are diagonal cracks
occurring on the trimmed edges and are caused by shear stresses.
CASTING PROCESS AND DEFECTS ASSOCIATED WITH CASTING
PROCESS
Casting is a process of producing metal/ alloy components of desired shape, by
pouring the molten metal/ alloy into a prepared mould and then, allowing the
metal/ alloy to solidify. The piece of alloy/ metal, thus obtained, is known as
Casting.
Foundry men refer to the deviation in less-than-perfect castings as
discontinuities, but these imperfections are more commonly known as Casting
defects. Some casting defects may have no influence on the function and
service life of the cast components, but give an unsatisfactory appearance or
will make further processing, such as machining more costly. Many such
defects can be easily corrected by machining, shot blasting, or grinding, while
other defects, which are too difficult to remove may be accepted in some
locations. The casting designer must understand the se difficulties and write the
procedures to meet the relevant needs.
Metallic projections.
Cavities.
Discontinuities.
Defects.
Incomplete Casting.
Incorrect Dimension.
Inclusions or Structural anomalies.
Metallic Projections are in the form of fins, with or without change in principal
casting dimensions. The projections could be in the form:
Thin fins at the parting line; veins on the casting surface; network of projections
on the surface; or, thin metallic projections located at the re-entrant.
Massive projections.
Swells- excessive metal in the vicinity of the gate; metal projections in the form of
elongated areas in the direction of mold assembly.
Projections with rough surfaces- on the cope surface; on the drag surface; with
rough surfaces on the other areas of the casting; area formed by the core.
Cavities:
Cavities with generally rounded, smooth walls perceptible to naked eye e.g.
pinholes, blowholes.
Cavities internal to the casting and not extending to the surface, are discernable
only by special methods, machining or by fracture of casting. Some of them are
given below:
Descriptions
Common Name
Cavities
*Internal rounded cavities, smooth
walled, of various size, isolated or
grouped irregularly in all areas of
casting.
Blowholes, Pinholes
Blowholes adjacent to
inserts, chaplets etc.
Slag, blowholes.
Surface or sub-surface
blowholes.
Surface pinholes.
Dispersed shrinkage.
Core shrinkage
Discontinuities
Discontinuities, generally at the intersections, caused by mechanical effects
(rupture)
Normal Cracking:
*Normal fracture appearance,
sometimes with adjacent indentation
Breakage (cold)
Hot cracking
Cold tearing
Hot tearing
Interrupted pour
Intergranular corrosion
Metallic Inclusions
Cold shot
Internal sweating
Phospide Sweat
Sand inclusions
Blacking or refractory
Coating inclusions
Black spots
Kish tracks
Hard spots
Isolated Slag Inclusions: Slag or any other matter entrapped during welding. The
defect is of irregular in shape and thus differs from a gas pore. The causes for a
linear inclusion to occur is same for an isolated inclusions, except for the fact
that, isolated indication can be either linear or rounded.
Lack of root fusion: Lack of union at the root of the weld. This may occur due to the
following reasons:
1. Incorrect welding conditions.
2. Too low arc energy.
3. Too high travel speed.
4. Incorrect electrode angle.
5. Molten metal flooding ahead of the arc because of work
position.
6. Electrode diameter too large in manual metal arc welding.
7. Excessive root face and/ or undersize root gap.
If the lack of root fusion is accessible from the root side, dye penetrant system is
used to detect this defect. Considered as detrimental defect, by almost all
codes and standards. If the defective area is accessible from the root side, the
root defect should be cut out or defect line widened and re-welded. If the root
defect is not accessible for the root side, the complete weld must be cut out
and re-welded.
Lack of Sidewall Fusion: Lack of fusion between the weld and the parent metal at a
side of the weld. The common causes for the occurrence of this defect is due to
incorrect welding conditions, such as, arc energy too low; travel speed too fast;
Incorrect electrode angle; molten metal flooding ahead of arc because of work
Lack of Inter-Run Fusion: This is otherwise termed as inter pass lack of fusion.
This is caused due to lack of union between adjacent runs of weld metal in a
multi-pass weld. The common causes for the occurrence of this defect is due
to incorrect welding conditions, such as, arc energy too low; travel speed too
fast; Incorrect electrode angle; molten metal flooding ahead of arc because of
work position.
10.Incomplete root penetration: Failure of weld metal to extend
a joint. This may occur due to the following reasons:
Lamellar Tearing: Lamellar tearing is a form of crack, which occurs in the base
metal of weldments, often outside the transformed HAZ and is generally parallel
to the weld fusion boundary. Lamellar tearing is generally associated with weld
joints in base materials with insufficient short transverse (through thickness)
ductility. It is also associated with elongated or aligned inclusions, which cause
poor short-transverse mechanical properties.
Stress Relief Cracking: This cracking is also known as Reheat Cracking, and is
observed in creep resistant steels containing molybdenum and vanadium. This
crack appears during the stress-relieving treatment given to the weldments, and
is found in the HAZ. This crack is Intergranular in nature and is often
aggravated by the presence of high residual stresses, high stress concentration
due to notches introduced by welding and high restraints in the weldments.
Misalignment: The nonalignment of two abutting edges in a butt joint. The
common causes for this are, inaccuracies in assembly procedures; distortion
from other welds; excessive out of flatness in hot rolled plates or section.
Excess Weld Metal: The extra metal which produces convexity in fillet welds and
weld thicknesses greater than the parent metallate in butt welds. The term
reinforcement is misleading, since he excess does not normally produce a
stronger weld in a butt joint. In certain situations, however, excess metal may
be required for metallurgical reasons. This feature of weld is regarded as a
defect only when the height of the excess metal is greater than the specified
limits.
15.Undercut: During the final pass or cover pass, the exposed upper edges of the
beveled weld preparation tend to melt and run down into the deposited metal in the
groove. Undercutting often occurs when insufficient filler metal is deposited to fill
the resultant grooves at the edge of the weld bead. Excessive welding current,
incorrect arc length, incorrect manipulation etc may cause undercutting.
Burn Through: A burn through is that portion of the weld bead where excessive
penetration has caused the weld pool to be blown into the pipe or vessel. It is
caused by the factors that produce excessive heat in one area, such as high
current, slow rod speed, incorrect rod manipulation etc.
VARIABLES IN
MAGNETIC PARTICLE
INSPECTION
On the other hand, excessive magnetization causes the particles to stick together
to minor leakage fields not caused due to discontinuities.If such leakage occurs
and attracts large number of particles, the result is a false indication and the test
object is said to be over magnetized for this inspection. Such false indications
may result from local permeability changes, which are caused by local stresses in
the test object. In some cases, the flux leakage may be caused by a subsurface
discontinuity and may not be possible to distinguish the cause for the leakage
field without the use of additional NDT methods.
REASONS FOR FORMATION OF INDICATIONS
Surface-breaking discontinuities best detected by magnetic particle testing are
those that expel optimal leakage fields. In order to gain a clearer insight of this, it
is necessary to understand three sets of variables:
How discontinuity parameters affect the external flux leakage;
How magnetic field parameters affect the external flux leakage;
How sensor reacts to passing such fields.
Discontinuity Parameters
The discontinuity parameters are critical and they include depth, width, and angle
to the object surface. In cases where the discontinuity is narrow surface breaking
(seams, laps, quench cracks, and grind tears), the magnetic flux leakage near the
mouth of discontinuity is highly curved.
Surface Discontinuities
The largest and most important category of discontinuity consists of those that are
exposed to the surface. Surface cracks or discontinuities are effectively located
with magnetic particle testing. Surface discontinuities are also the most
detrimental to the service life of the component than subsurface discontinuities
and as a result they are more frequent of inspection. Magnetic particle inspection is
capable of detecting seams, laps, quenching cracks and surface ruptures in
castings, forgings, and weldments. For maximum detectability, the discontinuity
should essentially lie perpendicular to the magnetic field. This is especially true for
a discontinuity that is small and fine. The characteristics of a discontinuity that
enhance its detectability are:
Its depth is at right angles to the surface
Its width at the surface is small
Its length at the surface is large with respect to its width
It is comparatively deep in proportion to the width of its surface opening.
Many incipient fatigue cracks and fine grinding cracks are less than 0.025mm deep
and have surface openings of perhaps 1/10th of thickness or less. Such cracks are
readily detected by wet method. The depth of the crack has a pronounced effect on
its detectability; the deeper the crack, the stronger the indication for a given level
of magnetization. This is because the stronger flux causes greater distortion of the
field in the part. This is effect is particularly not noticeable beyond 6mm. in depth.
If the crack is not tight-lipped, but wide-open at the surface, the reluctance of the
resulting air gap reduces the strength of the leakage field. This combined with the
inability of the particles to bridge the gap results in a weaker indication. Surface
opening also plays a part in detectability. A surface scratch, which may be as wide
at the surface, usually does not produce indications, although they may, at high
levels of magnetization. Thus so many variables influence the formation of a
indication.
There are also certain limitations regarding a crack, which is tightlipped virtually
eliminating the presence of air gap, produce no indications. Sometimes, with careful
interpretation and maximizing techniques, faint indications of such cracks may be
produced. One other type of discontinuity that sometimes poses a problem for its
detectability is a forging or a rolling lap. In this case, the leakage field produced is
weak due to small angle of emergence and the resultant high reluctance gap. Hence
when such conditions, demands its detectability, DC magnetization with the use of
wet fluorescent method is desirable.In general, a surface discontinuity, whose depth
is at least 5 times its opening at the surface, will be detected.
Internal Discontinuities
Magnetic particle inspection is also capable of detecting subsurface discontinuities.
Although radiography and ultrasonic methods are extensively used in the detection
of subsurface discontinuities, the shape of the discontinuities, sometimes, initiates
the requirement for magnetic particle examination.
When multiple variables can affect the outcome of a test, a means should be
used to normalize or standardize the test. This ensures that consistent,
repeatable results are achieved, independent of the machine, operator, or
time of inspection.More often, a form of artificial discontinuity indicator is
used. This is so called the reference standard is designed to help evaluate
several aspects of a magnetic particle test systems performance, including:
Hole No
Diameter mm (inches)
1.78 (0.07)
1.8 (0.07)
1.78 (0.07)
3.6 (0.14)
1.78 (0.07)
5.3 (0.21)
1.78 (0.07)
7.1 (0.28)
1.78 (0.07)
9.0 (0.35)
1.78 (0.07)
10.7 (0.42)
1.78 (0.07)
12.5 (0.49)
1.78 (0.07)
14.2 (0.56)
1.78 (0.07)
16.0 (0.63)
10
1.78 (0.07)
17.8 (0.70)
11
1.78 (0.07)
19.6 (0.77)
12
1.78 (0.07)
21.4 (0.84)
Table: Test indications required when using the tool steel ring
standard
Type of
Magnetic
Particle used
Current (A)
Minimum No. of
Holes
** Wet
suspension
1400
2500
3400
1400
2500
3400
*Dry Powder
Other reference standards include Split Prism test block. Truncated half-prisms
are built with one face at an angle and when two such components are bolted
together, an artificial crack is formed. When current is passed, through the
conductor, the length of the indication is used as a measure of sensitivity.
Magnetic Discontinuity Standards
Pie Gages and Raised Cross Indicators
Pie gages are disks of high permeability material divided into triangular
segments separated by known gaps. The gaps are typically filled with a
nonmagnetic material. The pie gage contains 8 segments, separated by gaps up
to 0.75mm, which run to full depth of the material.
Raised cross indicators contain 4 gaps (in the shape of a cross) approximately
0.13mm (0.5) in width. The segments are cut away so that the known gap is
raised a fixed distance off the test objects surface.
Both of these devices are used to determine the approximate orientation and to a
limited extent, indicate the adequacy of the field strength. However, they do not
measure the internal field strength of the object. The presence of multiple gaps
at different orientations helps reveal the approximate orientation of the magnetic
field. Slots perpendicular to the flux lines produce distinct
indications, while those lying parallel to the magnetic flux give little or no
indications.
Shim Discontinuity Standards
Shim discontinuity indicators are thin foils of high permeable materials
containing well-controlled notch discontinuities. Frequently, multiple shims are
used at different locations and different orientations on the test object to
examine the field distribution.
One popular version of the shim indicator is a strip containing 3 slots of
different widths. The strip is placed in contact with the test object surface and
shares the flux with the test object. The principal limitation of this standard is
that they require 50mm gage length. Shims are most often used while
preparing test procedures, where they help in indicating particular test
configuration. Once the field distribution is found adequate, the testing
procedure is recorded and the components are tested with the parameters
established by the shims.
INTERPRETATION OF
INDICATIONS
CLASSIFICATION OF INDICATIONS
Magnetic particle testing indications are classified as follows:
1. Relevant Indications
2. Nonrelevant Indications
3. False Indications
NONRELEVANT INDICATIONS
Nonrelevant indications are true patterns caused by leakage fields that do not result
from the presence of flaws. Nonrelevant indications have several causes and their
indication is fuzzy as that of a subsurface discontinuity indication. They should not
be interpreted as flaws and therefore require careful evaluation.
SOURCES FOR NONRELEVANT INDICATIONS
Particle patterns that yield Nonrelevant indications can be the result of many factors.
They include the following:
Particle Adherence Due to Excessive Magnetization
The particle adherence at leakage fields around sharp corners, ridges, or other surface
irregularities when magnetized too strongly causes the adherence of powders in
these areas when longitudinally magnetized. The use of too strong current with
circular
magnetization can produce indications of flux lines of the external field. Both of the
above phenomenons are recognized by experienced operators and can be eliminated
by reducing the current and retesting.
Mill Scale
Tightly adhering mill scale will cause particle buildup, not only because of
mechanical adherence, but also due to the difference in permeability between
scale and the test object. In most cases, this can be detected by a visual
inspection prior to carrying out magnetic particle inspection. Additional cleaning
followed by retesting will confirm the absence of true discontinuity.
Configurations
Configurations that result from in a restriction of the magnetic field are a cause
for this type of nonrelevant indication. Typical restrictive configurations are
internal notches such as splines, threads, grooves for indexing, or keyways.
Abrupt Changes in Magnetic Properties
Typical source of this sort of nonrelevant indication is observed in testing welds.
Permeability differences such as those between weld metal base metal, between
two dissimilar metals, result in nonrelevant indications.
The particle may be held loosely or tightly, depending on the degree of change
in permeability. It is necessary for the inspector to have a prior knowledge
about these conditions.
Magnetized Writing
This is another form of nonrelevant indication. Magnetic writing is usually
associated with parts displaying good residual characteristics in the
magnetized state. If such a part is contacted with a sharp corner or edge of
another part, the residual field is locally reoriented, giving rise to a leakage
field and consequently an indication. The point of common nail can be used
as an example to write on a part susceptible to magnetic writing. Magnetic
writing is not always easy to interpret, because the particles are loosely held
and are usually fuzzy or intermittent in appearance. If magnetic writing is
suspected, the only way is to demagnetize the part and retest. If the indication
was due to magnetic writing, it will not reappear.
RELEVANT INDICATIONS
Relevant indications are indications caused due to leakage flux emanating from
the actual discontinuities. They are the result of errors made during or after metal
processing. They may or may not be considered defects.
Terminology
Discontinuity: is any interruption in the normal physical structure or composition
of a part. It can also be termed as an intentional or unintentional lack in
continuity. If the lack in continuity is intentional, such as a case of a design
requirement, then the indication arising from these discontinuities are termed as
Nonrelevant indications. If the lack in continuity is unintentional, the indications
arising from these are termed as Relevant indications. Examples of such type of
indications are cracks, porosity, lack of fusion, lack of penetration, etc.
Defect: is any discontinuity that interferes with the service life or application of
the component is termed as a defect. It can also be defined as an imperfection of
sufficient magnitude to warrant rejection of a part with respect to standards.
Classification of Indications
Relevant indications are further classified as either linear or rounded. The linear
indication is one having a length greater than three times the width.
A rounded indication is one having a length equal to or less than three times its
width. A rounded indication need not be essentially rounded; it may be circular, or
elliptical in shape.
INTERPRETATION OF PATTERNS
The shape, sharpness of the outline, width, and height to which the build up are
the principle features by which discontinuities can be identified and distinguished
from each other.
Surface Cracks
Powder patterns for surface cracks are sharply defined, tightly held and usually
built up heavily. The deeper the crack, the heavier the buildup of the indication.
Crater cracks are recognized by a small indication at the terminal point of the
weld. The indication may be single line or multiple or star-shaped
.
Incomplete Fusion
Accumulation of powder will generally be pronounced and the edge of the weld
indicated. The closer the incomplete fusion is to the surface, the sharper the
pattern.
Undercut
A pattern is produced at the weld edge that adheres less strongly than the
indications obtained from an incomplete fusion. Undercut can also be detected by
visual examination.
Subsurface Discontinuities
The powder patterns have a fuzzy appearance and or not clearly defined. They are
neither strong nor pronounced; yet they are readily distinguished from the
indications of surface conditions.
Slag Inclusions
A fuzzy pattern similar to the subsurface discontinuity or porosity appears when a
high magnetizing field is used and they are present.
Seams
The indications are straight, sharp, and often intermittent. Buildup is small. A
magnetizing current greater than required for the detection of the cracks is
necessary.
ACCEPTANCE
STANDARDS
whether or not an actual discontinuity exists. The surface may be ground are
otherwise conditioned before re-examination.
6.5.1.3 Relevant indications are those caused by actual discontinuities. Linear
indications are those in which the length is more than three times its width.
Rounded indications are those in which the length is three times its width or
less.
ACCPETANCE STANDARDS
Relevant indications shall be unacceptable when any of the following conditions
exists:
1. Linear indications are evaluated as crater cracks or star cracks and exceed
5/32 (3.96mm) in length.
2. Linear indications are evaluated as cracks other than crater cracks or star
cracks.
3. Linear indications are evaluated as Incomplete Fusion and exceeds 1 inch
(25.4mm) in total length in a continuous 12 inches (304.8mm) length of the weld
or 8% of the weld length.
(d) Rounded indications shall be evaluated as follows:
Porosity- Individual or scattered porosity shall be unacceptable when any of the
following conditions exists:
CP that occurs in the finish pass shall be unacceptable when any of the
following conditions exists:
The diameter of the cluster exceeds (12.7mm).
The aggregate length of CP in any 12 continuous weld length exceeds .
An individual pore within a cluster exceeds 1/16 in size.
Magnetic Particle
Indications
One of the advantages that a magnetic particle inspection has over some of
the other nondestructive evaluation methods is that flaw indications
generally resemble the actual flaw. This is not the case with NDT methods
such as ultrasonic and eddy current inspection, where an electronic signal
must be interpreted. When magnetic particle inspection is used, cracks on
the surface of the part appear as sharp lines that follow the path of the
crack. Flaws that exist below the surface of the part are less defined and
more difficult to detect. Below are some examples of magnetic particle
indications.
Demagnetization
Methods
The residual field is in the same direction as the original magnetic field.
The residual field is weaker than the original field.
The original magnetizing force causes the residual field.
When an article has been magnetized in more than one direction, the second
field applied will completely overcome the first field. However, this is only true
if the second field applied, is stronger than the first in magnitude.
special alloys used for permanent magnets. Although it is time consuming and
represents additional expense, the demagnetization of parts is sometimes
necessary in many cases. Demagnetization may be easy or difficult depending
on the type of material. Metals having high coercive force are difficult to
magnetize and once they are magnetized, it is equally difficult to remove the
residual field from it.
The residual fields may sometimes be allowed to remain in the part, without
demagnetizing it. The reasons for not demagnetizing being:
1. Parts made of magnetically soft materials do not retain residual magnetism, as
they have low retentivity properties.
2. If the subsequent manufacturing process calls for the object to be heated above
Curie point, the material will readily be demagnetized as it loses all its magnetic
properties.
3. If the part does not require additional machining and its intended function is not
compromised by the presence of a residual field, then demagnetization becomes
unnecessary.
4. The part is to be re-magnetized for further magnetic particle inspection or for
some secondary operation in which a magnetic plate or chuck may be used to
hold a part.
5. Finally, demagnetization is only required if specified in the drawings,
specifications, or procedures.
Summary of
Demagnetizatio
n Procedures
(a)
(c)
(b)