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Intro to MPI
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Introduction to Magnetic Particle Inspection
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Magnetic particle inspection is a nondestructive testing method used for defect detection. MPI is a
fast and relatively easy to apply and part surface preparation is not as critical as it is for some other Basic Principles
History of MPI
NDT methods. These characteristics make MPI one of the most widely utilized nondestructive testing
methods.
MPI uses magnetic fields and small magnetic particles, such as iron filings to detect flaws in
components. The only requirement from an inspectability standpoint is that the component being
inspected must be made of a ferromagnetic material such iron, nickel, cobalt, or some of their alloys.
Ferromagnetic materials are materials that can be magnetized to a level that will allow the inspection
to be affective.
The method is used to inspect a variety of product forms such as castings, forgings, and weldments.
Many different industries use magnetic particle inspection for determining a component's fitness-foruse. Some examples of industries that use magnetic particle inspection are the structural steel,
automotive, petrochemical, power generation, and aerospace industries. Underwater inspection is
another area where magnetic particle inspection may be used to test such things as offshore structures
and underwater pipelines.
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetization of Mat'ls
Magnetizing Current
Longitudinal Mag Fields
Circular Mag Fields
Demagnetization
Measuring Mag Fields
Equipment & Materials
Protable Equipment
Stationary Equipment
Multidirectional Equipment
Lights
Field Strength Indicators
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Residual Magnetization
Continuous Magnetization
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Intro to MPI
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Basic Principles
Basic Principles
In theory, magnetic particle inspection (MPI) is a relatively simple concept. It can be considered as a
combination of two nondestructive testing methods: magnetic flux leakage testing and visual testing.
Consider
a bar
magnet. It has a magnetic field in and around the magnet. Any place that a magnetic line of force
exits or enters the magnet is called a pole. A pole where a magnetic line of force exits the magnet is
called a north pole and a pole where a line of force enters the magnet is called a south pole.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
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
Protable Equipment
leak out of the material and, thus, it is called a flux
leakage field.
Lights
Magnetic Particles
If iron particles are sprinkled on a cracked magnet,

the particles will be attracted to and cluster not only
at the poles at the ends of the magnet but also at the
poles at the edges of the crack. This cluster of particles is much easier to see than the actual crack and Testing Practices
Dry Particles
this is the basis for magnetic particle inspection.
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Basic Principles
The first step in a magnetic particle inspection is to magnetize the component that is to be inspected.
If any defects on or near the surface are present, the defects will create a leakage field. After the
component has been magnetized, iron particles, either in a dry or wet suspended form, are applied to
the surface of the magnetized part. The particles will be attracted and cluster at the flux leakage
fields, thus forming a visible indication that the inspector can detect.
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History of MPI
History of Magnetic Particle Inspection
Introduction to
Magnetic Particle
Inspection
Introduction
Magnetism is the ability of matter to attract other matter to itself. The ancient Greeks were the first to Introduction
Basic Principles
discover this phenomenon in a mineral they named magnetite. Later on Bergmann, Becquerel, and History of MPI
Michael Faraday discovered that all matter including liquids and gasses were affected by magnetism,
but only a few responded to a noticeable extent.
Physics
Magnetism
The earliest known use of magnetism to inspect an object took place as early as 1868. Cannon barrels Magnetic Mat'ls
were checked for defects by magnetizing the barrel then sliding a magnetic compass along the barrel's Magnetic Domains
Magnetic Fields
length. These early inspectors were able to locate flaws in the barrels by monitoring the needle of the Electromag. Fields
compass. This was a form of nondestructive testing but the term was not really used until some time Field From a Coil
Mag Properties
after World War I.
Hysteresis Loop
Perneability
In the early 1920s, William Hoke realized that magnetic particles (colored metal shavings) could be Field Orientation
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 Magnetizing Current
discovery was brought to his attention in the machine shop. He noticed that the metallic grindings
Circular Mag Fields
from hard steel parts, which were being held by a magnetic chuck while being ground, formed
Demagnetization
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.

Protable Equipment
Lights
Magnetic Particles
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
Testing Practices
time during the manufacturing of a component. Critical automotive components are inspected for
Dry Particles
flaws after fabrication to ensure that defective parts are not placed into service. MPI is used to inspect Wet Suspension
some highly loaded components that have been in-service for a period of time. For example, many Magnetic Rubber
components of high performance race cars are inspected whenever the engine, drive train and other Residual Magnetization
systems are overhauled. MPI is also used to evaluate the integrity of structural welds on bridges,
Mag Field Direction
Mag Field Intensity
storage tanks, and other safety critical structures.
Process Control
Indications
Examples
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History of MPI
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Magnetism
Magnetism
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
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 Basic Principles
History of MPI
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
Physics
"magnetic field" simply describes a volume of space where there is a change in energy within that Magnetism
volume. This change in energy can be detected and measured. The location where a magnetic field Magnetic Mat'ls
can be detected exiting or entering a material is called a magnetic pole. Magnetic poles have never Magnetic Domains
been detected in isolation but always occur in pairs and, thus, the name dipole. Therefore, a dipole is Magnetic Fields
Electromag. Fields
an object that has a magnetic pole on one end and a second equal but opposite magnetic pole on the Field From a Coil
other.
Mag Properties
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.
The Source of Magnetism
All matter is composed of atoms, and atoms are composed of
protons, neutrons and electrons. The protons and neutrons are
located in the atom's nucleus and the electrons are in constant
motion around the nucleus. Electrons carry a negative
electrical charge and produce a magnetic field as they move
through space. A magnetic field is produced whenever an
electrical charge is in motion. The strength of this field is
called the magnetic moment.
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
This maybe hard to visualize on a subatomic scale but

consider electric current flowing through a conductor. When
the electrons (electric current) are flowing through the
conductor, a magnetic field forms around the conductor. The
magnetic field can be detected using a compass. The magnetic field will place a force on the compass
Indications
needle, which is another example of a dipole.
Examples
Since all matter is comprised of atoms, all materials are affected in some way by a magnetic field.
However, not all materials react the same way. This will be explored more in the next section.
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Magnetism
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Magnetic Materials
Diamagnetic, Paramagnetic, and Ferromagnetic

Materials
When a material is placed within a magnetic field, the magnetic forces of the material's electrons will
be affected. This effect is known as Faraday's Law of Magnetic Induction. However, materials can
react quite differently to the presence of an external magnetic field. This reaction is dependent on a
number of factors such as the atomic and molecular structure of the material, and the net magnetic
field associated with the atoms. The magnetic moments associated with atoms have three origins.
These are the electron orbital motion, the change in orbital motion caused by an external magnetic
field, and the spin of the electrons.
In most atoms, electrons occur in pairs. Each electron in a pair spins in the opposite
direction. So when electrons are paired together, their opposite spins cause there
magnetic fields to cancel each other. Therefore, no net magnetic field exists.
Alternately, materials with some unpaired electrons will have a net magnetic field and
will react more to an external field. Most materials can be classified as ferromagnetic,
diamagnetic or paramagnetic.
Diamagnetic metals have a very weak and negative susceptibility to magnetic fields. Diamagnetic
materials are slightly repelled by a magnetic field and the material does not retain the magnetic
properties when the external field is removed. 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.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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.
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Magnetic Materials
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 material is in
the unmagnitized state, the domains are nearly randomly organized and the net magnetic field for the
part as a whole is zero. When a magnetizing force is applied, the domains become aligned to produce
a strong magnetic field within the part. Iron, Nickel, and cobalt are examples of ferromagnetic
materials. Components with these materials are commonly inspected using the magnetic particle
method.
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Magnetic Domains
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.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Magnetic Domains
Unmagnetized Material
Magnetized Material
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Magnetic Field Characteristics

Magnetic Field In and Around a Bar Magnet
As discussed previously a magnetic field is a change in energy within a volume of space. The
magnetic field surrounding a bar magnet can be seen in the magnetograph below. A magnetograph
can be created by placing a piece of paper over a magnet and sprinkling the paper with iron filings.
The particles align themselves with the lines of magnetic force produced by the magnet. The
magnetic lines of force show where the magnetic field exits the material at one pole and reenters the
material at another pole along the length of the magnet. It should be noted that the magnetic lines of
force exist in three-dimensions but are only seen in two dimensions in the image.
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.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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If a bar magnet was placed across the end of a horseshoe magnet

or if a magnet was formed in the shape of a ring, the lines of
magnetic force would not even need to enter the air. The value of
such a magnet where the magnetic field is completely contained
with the material probably has limited use. However, it is
important to understand that the magnetic field can flow in loop
within a material when the concept of circular magnetism is later
covered.
General Properties of Magnetic Lines of Force

Magnetic lines of force have a number of
important properties, which include:
They seek the path of least resistance

between opposite magnetic poles. In a
single bar magnet as shown to the right,
they attempt to form closed loop from
pole to pole.
They never cross one another.
They all have the same strength.
Their density decreases (they spread
out) when they move from an area of
higher permeability to an area of lower
permeability.
Their density decreases with increasing
distance from the poles.
They are considered to have direction
as if flowing, though no actual
movement occurs. They flow from the
south pole to the north pole within the
material and north pole to south pole in
air.
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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.
A word of caution about the right-hand rule
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.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Field from a Coil
Magnetic Field Produced by a Coil
Introduction to
Magnetic Particle
Inspection
Introduction
When a current carrying conductor is formed into a loop or several loops to form a coil, a magnetic field Introduction
develops that flows through the center of the loop or coil along longitudinal axis and circles back around Basic Principles
History of MPI
the outside of the loop or coil. The magnetic field circling each loop of wire combines with the fields from
the other loops to produce a concentrated field down the center of the coil. A loosely wound coil is
Physics
illustrated below to show the interaction of the magnetic field. The magnetic field is essentially uniform Magnetism
down the length of the coil when it is wound tighter.
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
The strength of a coil's magnetic field increases not only with increasing current but also with each loop Residual Magnetization
that is added to the coil. A long straight coil of wire is called a solenoid and can be used to generate a
Mag Field Direction
nearly uniform magnetic field similar to that of a bar magnet. The concentrated magnetic field inside a coil Mag Field Intensity
Process Control
is very useful in magnetizing ferromagnetic materials for inspection using the magnetic particle testing
method. Please be aware that the field outside the coil is weak and is not suitable for magnetize
ferromagnetic materials.
Indications
Examples
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Field from a Coil
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Quantifying Magnetic Properties
Introduction to
Magnetic Particle
Inspection

(Magnetic Field Strength, Flux Density, Total Flux and Magnetization)
Until now, only the qualitative features of the magnetic field have been discussed. However, it is
necessary to be able to measure and express quantitatively the various characteristics of magnetism.
Unfortunately, a number of unit conventions are in use as shown below. SI units will be used in this
material. The advantage of using SI units is that they are traceable back to an agreed set of four base
units - meter, kilogram, second, and Ampere.
SI Units
(Sommerfeld)
A/m
SI Units
(Kennelly)
A/m
CGS Units
(Gaussian)
oersteds
tesla
tesla
gauss
weber
A/m
weber
-
maxwell
erg.Oe-1.cm-3
Quantity
Field
Flux Density
(Magnetic Induction)
Flux
Magnetization
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 . 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.
The magnetization is a measure of the extent to which an object is magnetized. It is a measure of the
magnetic dipole moment per unit volume of the object. Magnetization carries the same units as a
magnetic field; amperes/meter.
Conversion between CGS and SI magnetic units.
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Continuous & Residual Mag
Field Direction & Intensity
Process Control
Light Intensity
Particle Concentration
Suspension Contamination
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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HysteresisLoop
The Hysteresis Loop and Magnetic Properties

A great deal of information can be learned about the magnetic properties of a material by studying its
hysteresis loop. A hysteresis loop shows the relationship between the induced magnetic flux density
B and the magnetizing force H. It is often referred to as the B-H loop. An example hysteresis loop is
shown below.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
The loop is generated by measuring the magnetic flux B of a ferromagnetic material while the
magnetizing force H is changed. A ferromagnetic material that has never been previously magnetized Continuous Magnetization
Mag Field Direction
or has been thoroughly demagnetized will follow the dashed line as H is increased. As the line
Mag Field Intensity
demonstrates, the greater the amount of current applied (H+), the stronger the magnetic field in the Process Control
component (B+). At point "a" almost all of the magnetic domains are aligned and an additional
increase in the magnetizing force will produce very little increase in magnetic flux. The material has
reached the point of magnetic saturation. When H is reduced back down to zero, the curve will move
from point "a" to point "b." At this point, it can be seen that some magnetic flux remains in the
material even though the magnetizing force is zero. This is referred to as the point of retentivity on
the graph and indicates the remanence or level of residual magnetism in the material. (Some of the
magnetic domains remain aligned but some have lost there alignment.) As the magnetizing force is
reversed, the curve moves to point "c", where the flux has been reduced to zero. This is called the
point of coercivity on the curve. (The reversed magnetizing force has flipped enough of the domains
so that the net flux within the material is zero.) The force required to remove the residual magnetism
Indications
Examples
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HysteresisLoop
from the material, is called the coercive force or coercivity of the material.
As the magnetizing force is increased in the negative direction, the material will again become
magnetically saturated but in the opposite direction (point "d"). Reducing H to zero brings the curve
to point "e." It will have a level of residual magnetism equal to that achieved in the other direction.
Increasing H back in the positive direction will return B to zero. Notice that the curve did not return
to the origin of the graph because some force is required to remove the residual magnetism. The
curve will take a different path form point "f" back the saturation point where it with complete the
loop.
From the hysteresis loop, a number of primary magnetic properties of a material can be determined.
1. Retentivity - A measure of the residual flux density corresponding to the saturation induction
of a magnetic material. In other words, it is a material's ability to retain a certain amount of
residual magnetic field when the magnetizing force is removed after achieving saturation.
(The value of B at point B on the hysteresis curve.)
2. Residual Magnetism or Residual Flux - the magnetic flux density that remains in a material
when the magnetizing force is zero. Note that residual magnetism and retentivity are the same
when the material has been magnetized to the saturation point. However, the level of residual
magnetism may be lower than the retentivity value when the magnetizing force did not reach
the saturation level.
3. 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.)
4. Permeability, - A property of a material that describes the ease with which a magnetic flux
is established in the component.
5. 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.
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Permeability
Permeability
As previously mentioned, 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:
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 permeability. The
maximum permeability is the point where
the slope of the B/H curve for unmagnetized
material is the greatest. This point is often
taken as the point where a straight line from
the origin is tangent to the B/H curve.
The relative permeability is arrived at by
taking the ratio of the material's permeability
to the permeability in free space (air).
(relative) =
where:
(material)
Introduction
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= /
Introduction to
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(air)
(air) = 4 x 10^-7 Hm^-1

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The shape of the hysteresis loop tells a great deal about the material being magnetized. The hysteresis
Indications
curves of two different materials are shown in the graph.
Examples
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Permeability
Relative to the other material, the materials

with the wide hysteresis loop has:
Lower Permeability
Higher Retentivity
Higher Coercivity
Higher Reluctance
Higher Residual Magnetism
The material with the narrower loop has:
Higher Permeability
Lower Retentivity
Lower Coercivity
Lower Reluctance
Lower Residual Magnetism.
In magnetic particle testing the level of residual magnetism is important. Residual magnetic fields are
affected by the permeability, which can be related to the carbon content and alloying of the material.
A component with high carbon content will have low permeability and will retain more magnetic flux
than a material with low carbon content.
In the two B-H loops above, which one would indicative of a low carbon steel? Answer
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Field Orientation
Magnetic Field Orientation and Flaw Detectability

To properly inspect a component for cracks or other defects, it is important to understand that
orientation between the magnetic lines of force and the flaw is very important. There are two general
types of magnetic fields that can be established within a component.
A longitudinal magnetic field has magnetic lines of force that run

parallel to the long axis of the part. Longitudinal magnetization of
a component can be accomplished using the longitudinal field set
up by a coil or solenoid. It can also be accomplished using
permanent or electromagnets.
A circular magnetic field has magnetic lines of force that run
circumferentially around the perimeter of a part. A circular
magnetic field is induced in an article by either passing current
through the component or by passing current through a conductor
surrounded by the component.
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The type of magnetic field established is determined by the method used to magnetize the specimen. Equipment & Materials
Protable Equipment
Being able to magnetize the part in two directions is important because the best detection of defects Stationary Equipment
occurs when the lines of magnetic force are established at right angles to the longest dimension of the Multidirectional Equipment
defect. This orientation creates the largest disruption of the magnetic field within the part and the
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greatest flux leakage at the surface of the part. As can be seen in the image below, if the magnetic
Magnetic Particles
field is parallel to the defect, the field will see little disruption and no flux leakage field will be
produced.
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Field Orientation
An orientation of 45 to 90 degrees between the magnetic field and the defect is necessary to form an
indication. Since defects may occur in various and unknown directions, each part is normally
magnetized in two directions at right angles to each other. If the component below is considered, it is
known that passing current through the part from end to end will establish a circular magnetic field
that will be 90 degrees to the direction of the current. Therefore, defects that have a significant
dimension in the direction of the current (longitudinal defects) should be detectable. Alternately,
transverse-type defects will not be detectable with circular magnetization.
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Magnetization
Magnetization of Ferromagnetic Materials

There are a variety of methods that can be used to establish a magnetic field in a component for
evaluation using magnetic particle inspection. It is common to classify the magnetizing methods as
either direct or indirect.
Magnetization Using Direct Induction (Direct Magnetization)
With direct magnetization, current is passed directly through the component. Recall that whenever
current flows a magnetic field is produced. Using the right-hand rule, which was introduced earlier, it
is known that the magnetic lines of flux form normal to the direction of the current and form a
circular field in and around the conductor. When using the direct magnetization method, care must be
taken to ensure that good electrical contact is established and maintained between the test equipment
and the test component. Improper contact can result in arcing that may damage the component. It is
also possible to overheat components in areas of high resistance such as the contact points and in
areas of small cross-sectional area.
There are several ways that direct
magnetization is commonly accomplished.
One way involves clamping the component
between two electrical contacts in a special
piece of equipment. Current is passed through
the component and a circular magnetic field is
established in and around the component.
When the magnetizing current is stopped, a
residual magnetic field will remain within the
component. The strength of the induced
magnetic field is proportional to the amount of
current passed through the component.
A
Introduction to
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Introduction
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Magnetic Domains
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Perneability
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Magnetizing Current
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second technique involves using clams or prods, which are attached or placed in contact with the
component. 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.
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Magnetization
Magnetization Using Indirect Induction (Indirect Magnetization)

Indirect magnetization is accomplished by using a strong external magnetic field to establish a
magnetic field within the component. As with direct magnetization, there are several ways that
indirect magnetization can be accomplished.
The use of permanent magnets is a low cost method of establishing a magnetic field. However, their
use is limited due to lack of control of the field strength and the difficulty of placing and removing
strong permanent magnets from the component.
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.
Another way of indirectly inducting a magnetic field in a material is by using the magnetic field of a
current carrying conductor. A circular magnetic field can be established in cylindrical components by
using a central conductors. Typically, one or more cylindrical components are hung from a solid
copper bar running through the inside diameter. Current is passed through the copper bar and the
resulting circular magnetic field established a magnetic field with the test components.
The use of coils and solenoids is a third
method of indirect magnetization. When the
length of a component is several time larger
than its diameter, a longitudinal magnetic field
can be established in the component. The
component is placed longitudinally in the
concentrated magnetic field that fills the center
of a coil or solenoid. This magnetization
technique is often referred to as a "coil shot."
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Magnetizing Current
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 entire cross-section of the component; whereas, the field produced using
alternating current is concentrated in a thin layer at the surface of the component.
Alternating Current
Alternating current (AC) reverses in direction at a rate of 50 or 60 cycles per second. In the United States,
60 cycle current is the commercial norm but 50 cycle current is common in many countries. 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 narrow region at the surface of the component. This phenomenon is known as "skin effect"
and it occurs because induction is not a spontaneous reaction and the rapidly reversing current does not
allow the domains down in the material time to align. Therefore, it is recommended that AC be used only
when the inspection is limited to surface defects.
View a short video on the AC versus DC (195 KB mov)
Rectified Alternating Current
Clearly, the skin effect limits the use of AC since many inspection applications call for the detection of
subsurface defects. However, the convenient access 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.
Introduction to
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Magnetizing Current
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.
Full Wave Rectified Alternating Current (FWAC) (Single Phase)
Full wave rectification inverts the negative current to positive current rather than blocking it out. This
produces a pulsating DC with no interval between the pulses. Filtering is usually performed to soften the
sharp polarity switching in the rectified current. While particle mobility is not as good as half-wave AC
due to the reduction in pulsation, the depth of the subsurface magnetic field is improved.
Three Phase Full Wave Rectified Alternating Current
Three phase current is often used to power industrial equipment because it has more favorable power
transmission and line loading characteristics. It is also highly desirable for magnetic part testing because
when it is rectified and filtered, the resulting current very closely resembles direct current. Stationary
magnetic particle equipment wire with three phase AC will usually have the ability to magnetize with AC
or DC (three phase full wave rectified), providing the inspector with the advantages of each current form.
Magnetizing Current
Longitudinal Fields
Longitudinal Magnetic Fields

Distribution and Intensity
When the length of a component is several time
larger than its diameter, a longitudinal magnetic field
can be established in the component. The component
is often placed longitudinally in the concentrated
magnetic field that fills the center of a coil or
solenoid. This magnetization technique is often
referred to as a "coil shot."
The magnetic field travels through the component from
end to end with some flux loss along its length as
shown in the image to the right. Keep in mind that the
magnetic lines of flux occur in three dimensions and
are only shown in 2D in the image. The magnetic lines
of flux are much denser inside the ferromagnetic
material than in air because ferromagnetic materials
have much higher permeability than does air. When the
concentrated flux within the material comes to the air at
the end of the component, it must spread out since the
air can not support as many lines of flux per unit
volume. To keep from crossing as they spread out,
some of the magnetic lines of flux are forced out the
side of the component.
When a component is magnetized along its complete length, the flux loss is small along its length.
Therefore, when a component is uniform in cross section and magnetic permeability, the flux density
will be relatively uniform throughout the component. Flaws that run normal to the magnetic lines of
flux will disturb the flux lines and often cause a leakage field at the surface of the component.
Introduction to
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Magnetic Domains
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Electromag. Fields
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Magnetizing Current
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Longitudinal Fields
When a component with considerable length is magnetized using a solenoid, it is possible to

magnetize only a portion of the component. Only the material within the solenoid and about the same
width on each side of the solenoid will be strongly magnetized. At some distance from the solenoid,
the magnetic lines of force will abandon their longitudinal direction, leave the part at a pole on one
side of the solenoid and return to the part at a opposite pole on the other side of the solenoid. This
occurs because the magnetizing force diminishes with increasing distance from the solenoid, and,
therefore, the magnetizing force may only be strong enough to align the magnetic domains within and
very near the solenoid. The unmagnetized portion of the component will not support as much
magnetic flux as the magnetized portion and some of the flux will be forced out of the part as
illustrated in the image below. Therefore, a long component must be magnetized and inspected at
several locations along its length for complete inspection coverage.
Solenoid - An electrically energized coil of insulated wire, which produces a magnetic field within
the coil.
Longitudinal Fields
Circular Magnetic Fields

Distribution and Intensity
As discussed previously, when current is passed through a solid conductor, a magnetic field forms in
and around the conductor. The following statements can be made about the distribution and intensity
of the magnetic field.
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.
Introduction to
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The magnetic field distribution in and

around a solid conductor of a nonmagnetic
material carrying direct current.

around a solid conductor of a magnetic
When the conductor is carrying alternating current, the

internal magnetic field strength rises from zero at the
center to a maximum at the surface. However, the field
is concentrated in a thin layer near the surface of the
conductor. This is known as the "skin effect." The skin
effect is evident in the field strength versus distance
graph for a magnet conductor shown to the right. The
external field decreases with increasing distance from
the surface as it does with DC. It should be
remembered that with AC the field is constantly
varying in strength and direction.

around a solid conductor of a magnetic
material carrying alternating current.
In a hollow circular conductor there is no magnetic field in the void area. The magnetic field is zero
at the inside wall surface and rises until it reaches a maximum at the outside wall surface. As with a
solid conductor, when the conductor is a magnetic material, the field strength within the conductor is
much greater that it was in the nonmagnetic conductor due to the permeability of the magnetic
material. The external field strength decrease with distance from the surface of the conductor. The
external field is exactly the same for the two materials provided the current level and conductor
radius are the same.

around a hollow conductor of a
nonmagnetic material carrying direct
current.

around a hollow conductor of a magnetic
When AC is passed through a hollow circular

conductor the skin effect concentrates the magnetic
field at the OD of the component.

around a hollow conductor of a magnetic
material carrying alternating 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
magnetization is very low. Therefore, the direct method
of magnetization is not recommended when inspecting
the inside diameter wall of a hollow component for
shallow defects. The field strength increases rather
rapidly as one moves in from the ID so if the defect has
significant depth, it may be detectable. 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.

around a nonmagnetic central conductor
carrying DC inside a hollow conductor of a
magnetic material .
Demagnetization
Demagnetization
After conducting a magnetic particle inspection, it is usually necessary to demagnetize the
component. Remanent magnetic fields can:
affect machining by causing cuttings to cling to a component.

interfere with electronic equipment such as a compass.
can create a condition known as "ark blow" in the welding process. Arc blow may causes the
weld arc to wonder or filler metal to be repelled from the weld.
cause abrasive particle to cling to bearing or faying surfaces and increase wear.
Removal of a field may be accomplished in several ways. This random orientation of the magnetic
domains can be achieved most effectively by heating the material above its curie temperature. The
curie temperature for a low carbon steel is 770 degrees C or 1390 degrees F. When steel is heated
above its curie temperature, it will become austenitic and loose its magnetic properties. When it is
cooled back down it will go through a reverse transformation and will contain no residual magnetic
field. The material should also be placed with it long axis in an east-west orientation to avoid any
influence of the Earth's magnetic field.
It is often inconvenient to heat a material above it curie
temperature to demagnetize it so another method that
returns the material to a nearly unmagnetized state is
commonly used. Subjecting the component to a
reversing and decreasing magnetic field will return the
dipoles to a nearly randomly oriented throughout the
material. This can be accomplished by pulling a
component out and away from a coil with AC passing
through it. The same can also be accomplished using an
electromagnetic yoke with AC selected. Also, many
stationary magnetic particle inspection units come in a
demagnetization feature that slow reduce the AC in a
coil in which that component is placed.
A field meter is often used to verifying that the residual
flux has been removed from a component. Industry
standards usually require that the magnetic flux be
reduced to less than 3 gauss after completing a magnetic particle inspection.
Introduction to
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Physics
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Magnetizing Current
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Demagnetization
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Measuring Magnetic Fields
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
When performing a magnetic particle inspection, it is very important to be able to determine the
direction and intensity of the magnetic field. As discussed previously, the direction of the magnetic Basic Principles
History of MPI
field should be between 45 and 90 degrees to the longest dimension of the flaw for best detectability.
The field intensity must be high enough to cause an indication to form, but not too high or
Physics
nonrelevant indications may form that could mask relevant indications. To cause an indication to
Magnetism
form, the field strength in the object must produce a flux leakage field that is strong enough to hold Magnetic Mat'ls
the magnetic particles in place over a discontinuity. Flux measurement devices can provide important Magnetic Domains
Magnetic Fields
information about the field strength.
Since it is impractical to measure the actual field strength within the material, all the devices measure
the magnetic field that is outside of the material. There are a number of different devices that can be
used to detect and measure an external magnetic field. The two devices commonly used in magnetic
particle inspection are the field indicator and the Hall effect meter, which is also often called a Gauss
meter. Pie gages and shims are devices that are often used to provide an indication of the field
direction and strength but do not actually yield a quantitative measure. They will be discussed in a
later section.
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.
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Portable Equipment
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Magnetic Particles
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Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
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Example Indications
Visible Dry Powder
Fluorescent Wet
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Hall-Effect (Gauss/Tesla)Meter
A Hall-effect meter is an electronic device that
provides a digital readout of the magnetic field
strength in Gauss or Tesla units. The meters
use a very small conductive or semiconductor
element at the tip of the probe. Electric current
is passed through the conductor. In a magnetic
field, the magnetic field exerts a force on the
moving electrons which tends to push them to
one side of the conductor. A buildup of charge
at the sides of the conductors will balance this
magnetic influence, producing a measurable
voltage between the two sides of the
conductor. The presence of this measurable
transverse voltage is called the Hall effect after
Edwin H. Hall who discovered it in 1879.
The voltage generated Vh can be related to the external

magnetic field by the following equation.
Vh = I B Rh / b
Where:
Vh is the voltage generated.
I is the applied direct current.
B is the component of the magnetic field that is at a
right angle to the direct current in the Hall element.
Rh is the Hall Coefficient of the Hall element.
b is the thickness of the Hall element.
Probes are available with either tangential (transverse) or
axial sensing elements. Probes can be purchased in a wide
variety of sizes and configurations and with different
measurement ranges. The probe is placed in the magnetic
field such that the magnetic lines of force intersect the major
dimensions of the sensing element at a right angle.
Placement and orientation of the probe is very important and will be discussed in a later section.
Portable MPI Equipment
Portable Magnetizing Equipment for

Magnetic Particle Inspection
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
To properly inspect a part for cracks or other defects, it is important to become familiar with the different
types of magnetic fields and the equipment used to generate them. As discussed previously, one of the
primary requirements for detection of a defect in a ferromagnetic material is that the magnetic field induced inPhysics
Magnetism
the part must intercept the defect at a 45 to 90 degrees angle. Flaws that are normal (90 degrees) to the
Magnetic Mat'ls
magnetic field will produce the strongest indications because they disrupt more of the magnet flux.
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Therefore, for proper inspection of a component, it is important to be able to establish a magnetic field in at
least two directions. A variety of equipment exist to establish the magnetic field for MPI. One way to classify
equipment is based on its portability. Some equipment is designed to be portable so that inspections can be
made in the field and some is designed to be stationary for ease of inspection in the laboratory or
manufacturing facility. Portable equipment will be discussed first.
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. Because it is difficult to remove the
magnets from the component being inspected, and sometimes
difficult and dangerous to place the magnets, their use is not
particularly popular. However, permanent magnets are sometimes
used by a diver for inspection in an underwater environment or
other areas, such as in an explosive environment, where
electromagnets cannot be used. Permanent magnets can also be
made small enough to fit into tight areas where electromagnets
might not fit.

Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
Electromagnets
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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.
Portable yoke with battery pack
Portable magnetic particle kit
View a short movie on portable magnetic yokes (716 KB mov)

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 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 used is typically 00 extra flexible or 0000
extra flexible. The number of wraps is determined by the magnetizing force needed and, of course, the length
of the cable. Normally the wraps are kept as close together as possible. When using a coil or cable wrapped
into a coil, amperage is usually expressed in ampere-turns. Ampere-turns is the amperage shown on the amp
meter times the number of turns in the coil.
Portable coil
Conductive Cable
Portable Power Supplies

Portable power supplies are used to provide the necessary electricity to the prods, coils or cables. Power
supplies are commercially available in a variety of sizes. Small power supplies generally provide up to 1,500
A of half wave direct current or alternating current when used with a 4.5 meter 0000 cable. They are small
and light enough to be carried and operate on either 120 V or 240 V electrical service. When more power is
necessary, mobile power supplies can be used. These unit come with wheel so that they can be rolled where
needed. There units also operate on 120 V or 24o V electrical service and can provide up to 6,000 A of AC or
half-wave DC when 9 meter or less of 0000 cable is used.
Stationary MPI Equipment
Introduction to
Magnetic Particle
Inspection
Stationary Equipment for

Stationary magnetic particle inspection
equipment is designed for use in laboratory or
production environment. The most common
stationary system is the wet horizontal (bench)
unit. Wet horizontal units are designed to allow
for batch inspections of a variety of components.
The units have head and tail stocks, similar to a
lath but with electrical contact that the part can
be clamped between for the production of a
circular magnetic field using direct
magnetization. The tail stock can be moved and
locked into place to accommodate parts of
various lengths. To assist the operator in
clamping the parts, the contact on the headstock can be moved pneumatic via a foot switch.
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
be Measuring Mag Fields
Most units also have a movable coil that can be moved into place so the indirect magnetization can
use to produce a longitudinal magnetic field. Most coils have five turns and can be obtained in a
variety of sizes. The wet magnetic particle solution is collected and held in a tank. A pump and hose
system is used to apply the particle solution to the components being inspected. Either the visible or
fluorescent particles can be used. Some of the systems offer a variety of options in electrical current
used for magnetizing the component. The operator has the option to use AC, half wave DC, for full
wave DC. In some units, a demagnetization feature is built in, which uses the coil and decaying AC.
To inspect a part using a head-shot, the part is clamped
between two electrical contact pads. The magnetic
solution, called a bath, is then flowed over the surface of
the part. The bath is then interrupted and a magnetizing
current is applied to the part for a short duration of 0.2
to 0.5 seconds. A circular field flowing around the
circumference of the part is created. Leakage fields from
defects then attract the particles forming indications.

Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Stationary MPI Equipment
When the coil is used to establish a longitudinal

magnetic field within the part, the part is placed on the
inside surface of the coil. Just as done with a head shot,
the bath is then flowed over the surface of the part. A
magnetizing current is applied to the part for a short
duration of 0.2 to 0.5 seconds just after coverage with
the bath is interrupted. Leakage fields from defects
attract the particles forming visible indications.
The
wet
horizontal unit can also be used to establish a circular magnetic field using a central conductor. This
type of a setup is used to inspect parts that are hollow such as gears, tubes, and other ring-shaped
objects. A central conductor is an electrically conductive bar that is usually made of copper or
aluminum. The bar is inserted through the center of the hollow part and then the bar is clamped
between the contact pads Current is passed through the central conductor and a circular magnetic
field then flows around the bar and jumps into the part or parts being inspected.
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Multidirectional MPI Equipment
Multidirectional Equipment for

Multidirectional units allow the
component to be magnetized in two
directions, longitudinally and
circumferentially, in rapid succession.
Therefore, inspections are conducted
without the need for a second shot. In
multidirectional units, the two fields are
balanced so that the field strengths are
equal in both directions. These quickly
changing balanced fields produce a
multidirectional field in the component
providing detection of defects lying in
more than one direction.
Just as in conventional wet-horizontal
systems, the electrical current used in
multidirectional magnetization may be
alternating, half-wave direct, or full-wave.
It is also possible to use a combination of
currents depending on the test
applications. Multidirectional
magnetization can be used for a large number of production applications, and high volume
inspections.
To determine adequate field strength and balance of the rapidly changing fields, technique
development requires a little more effort when multidirectional equipment is used. It is desirable to
develop the technique using a component with known defects laying in at least two directions, or a
manufactured defect standard. Quantitative quality indicator (QQI) are also often used to verify the
strength and direction of magnetic fields.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Multidirectional MPI Equipment
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Lights for MPI
Lights for
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.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Ultraviolet Light
Ultraviolet light or "black light" is light in the 1,000 to 4,000 Angstroms (100 to 400 nm) wavelength Testing Practices
Dry Particles
range in the electromagnetic spectrum. It is a very energetic form of light that is invisible to the
Wet Suspension
human eye. Wavelengths above 4,000 Angstroms fall into the visible light spectrum and are seen as Magnetic Rubber
Magnetization
the color violet. UV is separated according to wavelength into three classes: A, B, and C. The shorter Residual
the wavelength, the more energy that is carried in the light and the more dangerous it is to the human Mag Field Direction
Mag Field Intensity
cells.
Process Control
Class
UV-A
UV-B
UV-C
Wavelength Range
3,2004,000 Angstroms
Indications
Examples
The desired wavelength range for use in nondestructive testing is between 3,500 and 3,800
Angstroms with a peak wavelength at about 3,650 A. This wavelength range is used because it is in
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Lights for MPI
the UV-A range, which is the safest to work with. UV-B will do an effective job of causing
substances to fluoresce, however, it should not be used because harmful effects such as skin burns,
and eye damage can occur. This wavelength of radiation is found in the arc created during the
welding process. UV-C (1,000 to 2,800) is even more dangerous to living cells and is used to kill
bacteria in industrial 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.
In the high pressure mercury vapor spot or flood lamps, UV light is generated by a quartz tube inside
the bulb. This tube contains two electrodes that establish an arc. The distance between electrodes is
such that a starting electrode must be used. A resister limits the current to the starting electrode that
establishes the initial arc that vaporizes the mercury in the tube. Once this low level arc is established
and the mercury is vaporized the arc between the main electrodes is established. It takes
approximately five minutes to "warm up" and establish the arc between the main electrodes. 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.
Lights for MPI
High Intensity Ultraviolet Lights

The 400 watt metal halide bulbs or "super lights" can be
found in some facilities. This super bright light will
provide adequate lighting over an area of up to ten
times of that covered by the 100 watt bulb. Due to their
high intensity, excessive light reflecting from the
surface of a component is a concern. Moving the light a
greater distance from the inspection area will generally
reduce this glare. Another type of high intensity light
available is the micro discharge light. This particular
light produces up to ten times the amount of UV light
conventional lights produce. Readings of up to 60,000
uW/cm2 at 15 inches can be achieved.
Field Indicators
Magnetic Field Indicators

Coming Soon
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Perneability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Protable Equipment
Lights
Magnetic Particles
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Mag Field Direction
Mag Field Intensity
Process Control
Indications
Examples
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Field Indicators
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Magnetic Particles
Magnetic Particles
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
As mentioned previously, the particles that are used for magnetic particle inspection are a key
Basic Principles
ingredient as they form the indications that alert the inspector to defects. Particles start out as tiny
History of MPI
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
Physics
permeability and low retentivity. High magnetic permeability is important because it makes the
Magnetism
particles attract easily to small magnetic leakage fields from discontinuities, such as flaws. Low
Magnetic Mat'ls
retentivity is important because the particles themselves never become strongly magnetized so they Magnetic Domains
Magnetic Fields
do not stick to each other or the surface of the part. Particles are available in a dry mix or a wet
Electromag. Fields
solution.
Field From a Coil
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 a range of
particle sizes. The fine particles are around 50 m
(0.002 inch) in size are about three times smaller in
diameter and more than 20 times lighter than the coarse
particles (150 m 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.
Coarser particles are needed to bridge large discontinuities and to reduce the powder's dusty nature.
Additionally, small particles easily adhere to surface contamination, such as remanent dirt or
moisture, and get trapped in surface roughness features producing a high level of background. It
should also be recognized that finer particles will be more easily blown away by the wind and,
therefore, windy conditions can reduce the sensitivity of an inspection. Also, reclaiming the dry
particles is not recommended because the small particle are less likely to be recaptured and the "once
used" mix will result in less sensitive inspections.
The particle shape is also important. Long, slender
particles tend align themselves along the lines of
magnetic force. However, research has shown that if dry
powder consists only of long, slender particles, the
application process would be less than desirable.
Elongated particles come from the dispenser in clumps
and lack the ability to flow freely and form the desired
"cloud" of particles floating on the component.
Therefore, globular particles are added that are shorter.
The mix of globular and elongated particles result in a
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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Magnetic Particles
dry powder that flows well and maintain good sensitivity. Most dry particle mixes have particle with
L/D ratios between one and two.
Wet Magnetic Particles
Magnetic particles are also supplied in a wet suspension such as water or oil. The wet magnetic
particle testing method is generally more sensitive than the dry because the suspension provides the
particles with more mobility and makes it possible for smaller particles to be used since dust and
adherence to surface contamination is reduced or eliminated. The wet method also makes it easy to
apply the particles uniformly to a relatively large area.
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 m (0.0004 inch) and smaller and the
synthetic iron oxides have particle diameters around 0.1 m (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. Wet particles are also a mix of long slender and globular particles.
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.
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Suspension Liquids
Suspension Liquids
Suspension liquids used in the wet magnetic particle
inspection method can be either a well refined light
petroleum distillate or water containing additives.
Petroleum-based liquids are the most desirable
carriers because they provided good wetting of the
surface of metallic parts. However, water-based
carriers are used more because of low cost, low fire
hazard, and the ability to form indications quicker
than solvents based carriers. Water-based carriers
must contain wetting agents to disrupt surface films
of oil that may exist on the part and to aid in the
dispersion of magnetic particles in the carrier. The
wetting agents create foaming as the solution is
moved about, so anti-foaming agents must be added. Also, since water promotes corrosion in ferrous
materials, corrosion inhibitors are usually added as well.
Petroleum based carriers are primarily used in systems where maintaining the proper particle
concentration is a concern. The petroleum based carriers require less maintenance because they
evaporate at a slower rate than the water-based carriers. Therefore, petroleum based carriers might be
a better choice for a system that only gets occasional use and adjusting the carrier volume with each
use is undesirable. Modern solvent carriers are specifically designed with properties that have flash
points above 200 degrees F and keep nocuous vapors low. Petroleum carriers are required to meet
certain specifications such as AMS 2641.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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Suspension Liquids
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Dry Particle
Dry Particle Inspection

In this magnetic particle testing technique, dry particles
are dusted onto the surface of the test object as the item
is magnetized. Dry particle inspection is well suited for
the inspections conducted on rough surfaces. When an
electromagnetic yoke is used, the AC or half wave DC
current creates a pulsating magnetic field that provides
mobility to the powder. The primary applications for
dry powders are unground welds and rough as-cast
surfaces.
Dry particle inspection is also used to detect subsurface
cracks. Dry particles with half wave DC is the best
approach when inspection welds for lack-of-root
penetration. Half wave DC with prods and dry particles
is commonly used when inspecting large castings for
hot tears and cracks.
Step in performing an inspection using dry particles
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Prepare the part surface - the surface should be a relatively clean but this is not as critical as it is Portable Equipment
with liquid penetrant inspection. The surface must be free of grease, oil or other moisture that could Stationary Equipment
keep particles from moving freely. A thin layer of paint or rust or scale will reduce test sensitivity but Multidirectional Equipment
Lights
can sometimes be left in place with adequate results. Any loose dirt, paint, rust or scale must be
removed.
Magnetic Particles
Suspension Liquids
Apply the magnetizing force - Use permanent magnets, a electromagnetic yoke, prods, a coil or
other means to establish the necessary magnetic flux.
Testing Practices
Dust on the dry magnetic particles - Dust on a light layer of magnetic particles.
Dry Particles
Gently blow off the excess powder - With the magnetizing force still applied, remove the excess
Wet Suspension
powder from the surface with a few gently puffs of dry air. The force of the air needs to be strong
Magnetic Rubber
enough to remove the excess particle but not strong enough to dislodge particle held by a magnetic Continuous & Residual Mag
flux leakage field.
Terminate the magnetizing force - If the magnetic flux is being generated with an electromagnet or Process Control
an electromagnetic field, the magnetizing force should be terminated. It permanent magnets are being Light Intensity
used, they can be left in place.
Inspect for indications - Look for areas where the magnetic particles are clustered.
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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Wet Suspension
Wet Suspension Inspection

Wet suspension magnetic particle inspection,
or more commonly wet magnetic particle
inspection, involves applying the particle while
they are suspended in a liquid carrier. Wet
magnetic particle inspection is most commonly
performed using a stationary, wet, horizontal
inspection unit but suspensions are also
available in spray cans for use with a
electromagnetic yoke. The wet inspection has
several advantages over a dry inspection. First,
all the surfaces of the component can be
quickly and easily covered with a relatively
uniform layer of particles. Second, the liquid
carrier provides mobility to the particles for an
extended period of time which allows enough
particle to float to small leakage fields to form a visible indication. Therefore, wet inspection is
considered best for detecting very small discontinuities on smooth surfaces. On rough surfaces,
however, the particle (which are much smaller in wet suspensions) can settle in the valleys of surface
features and loose mobility so they are not as effective under these conditions as dry powders.
Step in performing an inspection using wet suspensions
Prepare the part surface - Just as required with dry particle inspections, the surface should be a
relatively clean. The surface must be free of grease, oil or other moisture that could prevent the
suspension from wetting the surface and prevent the particles from moving freely. A thin layer of
paint or rust or scale will reduce test sensitivity but can sometimes be left in place with adequate
results. Any loose dirt, paint, rust or scale must be removed.
Apply the suspension - The suspension is gently sprayed or flowed over the surface of the part.
Usually, the stream of suspension is diverted from the part just before the magnetizing field is
applied.
Apply the magnetizing force - The magnetizing force should be applied immediately after applying
the suspension of magnetic particles. When using a wet horizontal inspection unit, the current is
applied in two or three short busts (1/2 second) which helps to improve particle mobility.
Inspect for indications - Look for areas where the magnetic particles are clustered. Surface
discontinuities will produce a sharp indication and the definition of an indication will decrease with
increasing depth below the of subsurface flaws.
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
Basic Principles
History of MPI
Physics
Magnetism
Magnetic Mat'ls
Magnetic Domains
Magnetic Fields
Electromag. Fields
Field From a Coil
Mag Properties
Hysteresis Loop
Permeability
Field Orientation
Magnetizing Current
Circular Mag Fields
Demagnetization
Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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Magnetic Rubber
Inspection Using Magnetic Rubber
Introduction to
Magnetic Particle
Inspection
Introduction
Introduction
The magnetic rubber technique was developed for detecting very fine cracks and is capable of
Basic Principles
revealing finer cracks than other magnetic techniques. Additionally, the technique can be use to
History of MPI
examine difficult to reach areas, such as the threads on the inside diameter of holes, where the molded
plugs can be removed and examined under ideal conditions and magnification if desired. The
Physics
tradeoff, of course, is that inspection times are much longer.
Magnetism
Magnetic Mat'ls
The techniques uses a liquid (uncured) rubber containing suspended magnetic particles. The rubber Magnetic Domains
Magnetic Fields
compound is applied to the area to be inspected on a magnetized component. Inspections can be
Electromag. Fields
performed using either an applied magnetic field, which is maintained whilst the rubber sets (active Field From a Coil
field), or the residual field from magnetization of the component prior to pouring the compound. A Mag Properties
dam of modeling clay is often used to contain the compound in the region of interest. The rubber is Hysteresis Loop
allowed to sets, which takes from 10 to 30 minutes, and then the rubber cast is removed from the part. Permeability
Field Orientation
The rubber conforms to the surface contours and provides a reverse replica of the surface. The rubber Magnetization of Mat'ls
cast is examined for evidence of discontinuities, which appear as dark lines on the surface of the
Magnetizing Current
molding. The molding can be retained as a permanent record of the inspection.
Circular Mag Fields
Demagnetization
Portable Equipment
Lights
Magnetic Particles
Suspension Liquids
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Process Control
Light Intensity
Electrical System
Example Indications
Visible Dry Powder
Fluorescent Wet
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Intro to MPI

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Introduction to Magnetic Particle Inspection

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If iron particles are sprinkled on a cracked magnet,

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History of Magnetic Particle Inspection

Equipment & Materials

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This maybe hard to visualize on a subatomic scale but

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Diamagnetic, Paramagnetic, and Ferromagnetic

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Magnetic Field Characteristics

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Magnetic Field Characteristics

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Magnetic Field Characteristics

If a bar magnet was placed across the end of a horseshoe magnet

General Properties of Magnetic Lines of Force

They seek the path of least resistance

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Field from a Coil

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Magnetic Field Produced by a Coil

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Field from a Coil

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Quantifying Magnetic Properties

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Quantifying Magnetic Properties

The units for magnetic field strength H are ampere/meter. A

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Quantifying Magnetic Properties

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The Hysteresis Loop and Magnetic Properties

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It is clear that this equation describes the

(air) = 4 x 10^-7 Hm^-1

Equipment & Materials

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