Presenter: S.M.K. Hosseini

hossinim@ioec.
com
Presenter: S.M.K. Hosseini

hossinim@ioec.com
TOPICS TO BE COVERED
Introduction
Physics
Equipment and Materials
Testing Practices
Process Control
Example Indications

hossinim@ioec.com
Introduction
Introduction
Basic Concepts
History of MPI
Physics
Testing Practices
Process Control
Example Indications

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Introduction to Magnetic Particle Inspection
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 effective
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-for-use. 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 items such as offshore structures and underwater pipelines.

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Basic Principles
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 cannot support as much
magnetic field per unit volume as the magnet
can. When the field spreads out, it appears to
leak out of the material and, thus, it is called a
flux leakage field.

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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 this is
the basis for magnetic particle inspection
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
Basic Principles

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History of Magnetic Particle Inspection
In the early 1920s, William Hoke realized that magnetic particles (colored metal
shavings) could be used with magnetism as a means of locating defects. Hoke
discovered that a surface or subsurface flaw in a magnetized material caused the
magnetic field to distort and extend beyond the part. This discovery was brought to his
attention in the machine shop.
He noticed that the metallic grindings from hard
steel parts, which were being held by a magnetic
chuck while being ground, formed patterns on the
face of the parts which corresponded to the
cracks in the surface. Applying a fine
ferromagnetic powder to the parts caused a build
up of powder over flaws and formed a visible
indication.

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Introduction
Physics
Magnetisms, Magnetic Materials
Magnetic Domain and Field, Electromagnetic Fields
Field from a Coil
Magnetic Properties, Hysteresis Loop, Permeability, Field Orientation
Magnetization of Materials, Magnetic Current, Long. and Circular Magnetic Fields
Demagnetization
Measuring Magnetic Fields
Testing Practices
Process Control Example Indications

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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.
Physics

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Diamagnetic, Paramagnetic, and Ferromagnetic Materials
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.
Physics

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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.

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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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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 (1012 to
1015) 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
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

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Ferromagnetic materials become magnetized
when the magnetic domains within the material
are aligned. This can be done by placing the
material in a strong external magnetic field or by
passing electrical current through the material.
Some or all of the domains can become aligned.
The more domains that are aligned, the stronger
the magnetic field in the material. When all of
the domains are aligned, the material is said to be
magnetically saturated. When a material is
magnetically saturated, no additional amount of
external magnetization force will cause an
increase in its internal level of magnetization.
Unmagnetized Material
Magnetized Material
Magnetic Field Characteristics

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Magnetic Field In and Around a Bar Magnet
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

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Magnetic Fields in and around Horseshoe and Ring Magnets
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
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

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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.
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
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.
strength of the field was strongest close to
the wire and diminished with distance from
the conductor until it could no longer be
detected.
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.

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Electromagnetic Fields
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

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When a current carrying conductor is formed into a loop or
several loops to form a coil, a magnetic field develops that flows
through the center of the loop or coil along longitudinal axis and
circles back around the outside of the loop or coil
Magnetic Field Produced by a Coil
The strength of a coil's
magnetic field increases not
only with increasing current but
also with each loop that is
added to the coil. A long
straight coil of wire is called a
solenoid and can be used to
generate a nearly uniform
magnetic field similar to that of
a bar magnet

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Quantifying Magnetic Properties
Quantity
SI Units
(Sommerf
eld)

SI Units
(Kennelly)
CGS Units
(Gaussian)
Field H A/m A/m oersteds
Flux
Density
(Magnetic
Induction)
B tesla tesla gauss
Flux f weber weber maxwell
Magnetizat
ion
M A/m -
erg.Oe-
1.cm-3
(Magnetic Field Strength, Flux Density, Total Flux and Magnetization)

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The Hysteresis Loop and Magnetic Properties
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

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From the hysteresis loop, a number of primary magnetic properties of a material
can be determined.
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.)
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.

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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.)
Permeability, m - A property of a material that describes the ease with which
a magnetic flux is established in the component.
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
the materials with the wide hysteresis loop
has:
Lower Permeability
Higher Retentivity
Higher Coercivity
Higher Reluctance
Higher Residual Magnetism
m = B/H
m(relative) = m(material) / m(air)
where: m(air) = 4p x 10^-7 Hm^-1

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Magnetic Field Orientation and Flaw Detectability
A longitudinal magnetic field has magnetic lines of
force that run parallel to the long axis of the part.
A circular magnetic field has magnetic lines of force
that run circumferentially around the perimeter of a
part
Being able to magnetize the part in
two directions is important because
the best detection of defects occurs
when the lines of magnetic force are
established at right angles to the
longest dimension of the defec

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Magnetic Field Orientation and Flaw Detectability
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 of Ferromagnetic Materials
Magnetization Using Direct Induction (Direct Magnetization)
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.
using clamps or prods, which are attached or
placed in contact with the component.
Electrical current flows through the
component from contact to contact. The
current sets up a circular magnetic field
around the path of the current.

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Magnetization Using Indirect Induction (Indirect Magnetization)
Magnetization of Ferromagnetic Materials
The use of coils and solenoids is a third method of indirect
magnetization. When the length of a component is several times
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
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

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Magnetizing Current
Direct Current
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
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

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Rectified Alternating Current
Magnetizing Current
Half Wave Rectified Alternating Current (HWAC)
Full Wave Rectified Alternating Current (FWAC) (Single Phase)
Three Phase Full Wave Rectified Alternating Current

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Longitudinal Magnetic Fields
Distribution and Intensity
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 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."

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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.
Longitudinal Magnetic Fields
Distribution and Intensity

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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.
create a condition known as "ark blow" in the welding process. Arc
blow may cause 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.
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.

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Measuring Magnetic Fields
Field Indicators

Field indicators are small mechanical
devices that utilize a soft iron vane that
will be deflected by a magnetic field
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

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Introduction
Physics
Portable and Stationary Equipment
Lights
Field Strength Indicators
Magnetic Particles
Suspension Liquids
Testing Practices
Process Control
Example Indications

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Portable Magnetizing Equipment for
Magnetic Particle Inspection
Permanent magnets

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Electromagnets
Portable yoke with battery pack Portable magnetic particle kit
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

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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

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Portable Coils and Conductive Cables
Coils and conductive cables are used to establish a longitudinal magnetic
field within a component. When a preformed 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
Portable Magnetizing Equipment for Magnetic Particle Inspection

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Stationary Equipment for
The most common stationary
system is the wet horizontal
(bench) unit. The units have head
and tail stocks, similar to a lathe
but with electrical contact that
the part can be clamped between
for the production of a circular
magnetic field using direct
magnetization.
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, typically 0.5 to 1.5
seconds

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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, typically 0.5 to 1.5 seconds,
just after coverage with the bath is
interrupted
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.

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Multidirectional Equipment for
Multidirectional units allow the
component to be magnetized in
two directions, longitudinally and
circumferentially, in rapid
succession

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Lights for
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.
Ultraviolet Light
Basic Ultraviolet Lights
High Intensity Ultraviolet Lights

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Dry Magnetic Particles
Magnetic Particles
Dry magnetic particles can typically be purchased in 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
mm (0.002 inch) in size are about three times smaller in diameter
and more than 20 times lighter than the coarse particles (150 mm
or 0.006 inch), which make them more sensitive to the leakage
fields from very small discontinuities

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Wet Magnetic Particles
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. The particles are
typically 10 mm (0.0004 inch) and
smaller and the synthetic iron oxides
have particle diameters around 0.1 mm
(0.000004 inch).

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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.

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Introduction
Physics
Testing Practices
Dry Particles
Wet Suspension
Magnetic Rubber
Continuous and Residual Mag
Filed Direction and Intensity
L/D Ratio
Process Control
Example Indications

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Dry Particle Inspection
The primary applications for dry powders
are unground welds and rough as-cast
surfaces.
Dry particle inspection is also used to
detect shallow subsurface cracks. Dry
particles with half wave DC is the best
approach when inspection welds in thin
materials 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.

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Steps in performing an inspection using dry particles
Prepare the part surface - the surface should be a relatively clean. Specifications
often allow up to 0.003 inch (0.076 mm) of a nonconductive coating, sush as paint,
and 0.001 inch (0.025 mm) of a ferromagnetic coating, such as nickel, to be left on
the surface.
Apply the magnetizing force - Use permanent magnets, a electromagnetic yoke,
prods, a coil or other means to establish the necessary magnetic flux.
Dust on the dry magnetic particles - Dust on a light layer of magnetic particles.


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Steps in performing an inspection using dry particles
Gently blow off the excess powder - With the magnetizing force still applied,
remove the excess powder from the surface with a few gently puffs of dry air. The
force of the air needs to be strong enough to remove the excess particle but not
strong enough to dislodge particle held by a magnetic flux leakage field.
Terminate the magnetizing force - If the magnetic flux is being generated with an
electromagnet or an electromagnetic field, the magnetizing force should be
terminated. It permanent magnets are being used, they can be left in place.
Inspect for indications - Look for areas where the magnetic particles are clustered

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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
surface valleys and loose mobility rendering
them less effective than dry powders under
these conditions
Steps in performing an inspection using wet suspensions
Wet Suspension Inspection

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Wet Suspension Inspection
Prepare the part surface - Just as is required with dry particle inspections, the
surface should be relatively clean. Specifications often allow up to 0.003 inch (0.076
mm) of a nonconductive coating, sush as paint, and 0.001 inch (0.025 mm) of a
ferromagnetic coating, such as nickel, to be left on the surface. 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. The indications from
subsurface flaws will be less defined and loose definition as depth increases

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Introduction
Physics
Testing Practices
Process Control
Example Indications

hossinim@ioec.com
Introduction
Physics
Testing Practices
Process Control
Example Indications
Visible Dry Powder
Fluorescent Wet

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Before and after inspection pictures of cracks
emanating from a hole
Indication of cracks originating at a
fastener hole
Indication of a crack in a saw blade
Examples of Visible Dry Magnetic Particle Indications
Example Indications

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Examples of Visible Dry Magnetic Particle Indications
Indication of cracks running between
attachment holes in a hinge
Indication of cracks in a weldment
Example Indications

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Examples of Fluorescent Wet Magnetic Particle Indications
Magnetic particle wet fluorescent indication
of a cracks in a drive shaft
Magnetic particle wet fluorescent
indication of a crack in a bearing
Example Indications

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indication of a crack at a sharp radius
indication of a crack in the crane hook
Example Indications

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Magnetic particle wet fluorescent indication
of a crack in casting
indication of a cracks at a fastener hole
Example Indications

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