MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION
The magnetic particle examination method is applied to detect
cracks and other discontinuities on the surfaces of ferromagnetic
materials. The sensitivity is greatest for surface discontinuities
and diminishes rapidly with increasing depth of discontinuities
below the surface. Typical types of discontinuities that can be
detected by this method are cracks , laps, seams, cold shuts, and
laminations.
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MAGNETIC PARTICLE
INSPECTION
In principle, this method involves magnetizing an area to be
examined, and applying ferromagnetic particles (the examination’s
medium) to the surface. Particle patterns form on the surface
where the magnetic field is forced out of the part and over
discontinuities to cause a leakage field that attracts the particles.
Particle patterns are usually characteristic of the type of
discontinuity that is detected.
Whichever technique is used to produce the magnetic flux in the
part, maximum sensitivity will be to linear discontinuities oriented
perpendicular to the lines of flux.
For optimum effectiveness in detecting all types of discontinuities,
each area is to be examined at least twice, with the lines of flux
during one examination being approximately perpendicular to the
lines of flux during the other.
MAGNETIC PARTICLE INSPECTION
Advantages
The magnetic particle method is a sensitive means of locating
small and shallow surface cracks in ferromagnetic materials.
Indications may be produced at cracks that are large enough to
be seen with the naked eye, but exceedingly wide cracks will
not produce a particle pattern if the surface opening is too wide
for the particles to bridge.
Discontinuities that do not actually break through the surface
are also indicated in many cases by this method, although
certain limitations must be recognized and understood.
If a discontinuity is fine, sharp, and close to the surface, such
as a long stringer of nonmetallic inclusions, a clear indication
can be produced.
If the discontinuity lies deeper, the indication will be less
distinct. The deeper the discontinuity lies below the surface,
the larger it must be to yield a readable indication and the more
difficult the discontinuity is to find by this method. ed.
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MAGNETIC PARTICLE INSPECTION
Advantages
Magnetic particle indications are produced directly on the
surface of the part and constitute magnetic pictures of actual
discontinuities.
There is no electrical circuitry or electronic readout to be
calibrated or kept in proper operating condition.
Occasional monitoring of field intensity in the part is needed to
ensure adequate field strength.
There is little or no limitation on the size or shape of the part
being inspected.
Ordinarily, no elaborate precleaning is necessary, and cracks
filled with foreign material can be detected.
MAGNETIC PARTICLE INSPECTION
Limitations.
Thin coatings of paint and other nonmagnetic coverings, such
as plating, adversely affect the sensitivity of magnetic particle
inspection.
The method can be used only on ferromagnetic materials
For best results, the magnetic field must be in a direction that
will intercept the principal plane of the discontinuity; this
sometimes requires two or more sequential inspections with
different magnetizations
Demagnetization following inspection is often necessary
Postcleaning to remove remnants of the magnetic particles
clinging to the surface may sometimes be required after testing
and demagnetization
Exceedingly large currents are sometimes needed for very
large parts
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MAGNETIC PARTICLE INSPECTION
Limitations.
Care is necessary to avoid local heating and burning of
finished parts or surfaces at the points of electrical contact
Although magnetic particle indications are easily seen,
experience and skill are sometimes needed to judge their
significance
THEORY OF MAGNETIZATION
An object is magnetized when part or all of its magnetic domains
have their north and south poles oriented as in the sketches
below.
With all of the magnetic domains lined up, the magnetic bar
develops a total force equal to the sum of all of the magnetic
domains.
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THEORY OF MAGNETIZATION
The ability of a magnet to attract or repel is concentrated at the
local areas called POLES.
The north and south poles exhibit attraction and repulsion as
shown in the sketches below.
THEORY OF MAGNETIZATION
These are the MAGNETIC LINES OF FORCE which form a closed
loop or circuit.
All of the lines of force make up the MAGNETIC FIELD.
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THEORY OF MAGNETIZATION
The lines of force associated with permanent magnets have the
following properties:
1. They form closed loops between north and south poles.
2. They do not cross one another.
3. They seek paths of least magnetic resistance.
4. Their density decreases with increasing distance from the
poles.
5. They are considered to have direction; by convention, from
NORTH POLE TO SOUTH POLE EXTERNAL to the magnet, and
from south to north internally.
THEORY OF MAGNETIZATION
The force that attracts other
magnetizable materials to the
magnetic poles is known as
MAGNETIC FLUX.
Magnetic flux is made up of all of
the lines of force.
The horseshoe magnet will attract
other magnetizable material only
where the lines of force leave or
enter the magnet.
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THEORY OF MAGNETIZATION
If a magnet is bent into a complete loop as shown below, the
magnetic field is entirely within, thus NO EXTERNAL FORCE.
However, a crack in the circular magnet will disrupt the flow of
lines of force and create a FLUX LEAKAGE.
Leakage field (flux leakage) are actually magnetic lines of force
that leave the part and pass through air from one pole to the other
of opposite polarity
THEORY OF MAGNETIZATION
REMEMBER that iron particles will be attracted ONLY in places
where lines of force or flux enter or leave the magnet. Since there
are no magnetic poles in circular magnet, there will be no place for
the magnetic lines of force or flux to leave or enter the magnet.
Whenever the leakage field is forced out of the part, iron particles
would be attracted showing an indication of a discontinuity.
Even some subsurface discontinuities may be detected if the
leakage field is strong enough as shown below.
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THEORY OF MAGNETIZATION
Now let's look at a magnet with a shallow surface irregularity, such
as a bowed or cupped surface.
In the area of the shallow, cupped surface above, the lines of force
stay within the magnet. The lines of force tend to follow the path of
least resistance, which is to stay within the magnet. As a result, no
magnetic poles with flux leakage are created.
THEORY OF MAGNETIZATION
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THEORY OF MAGNETIZATION
Diamagnetic Metals – have a small and negative susceptibility to
magnetization (slightly repelled).
Mercury, bismuth, zinc, copper, silver, and gold are examples of
diamagnetic materials.
Paramagnetic Metals – have a small and positive susceptibility to
magnetization (slightly attracted).
Aluminum, platinum, copper sulfate, magnesium, molybdenum,
lithium, and tantalum are examples.
Ferromagnetic Metals – have a large and positive susceptibility to
magnetization, they have a strong attraction and are able to retain
their magnetization after the magnetizing field has been removed.
Iron, cobalt, nickel, and gadolinium are examples of ferromagnetic
metals.
Ferromagnetic materials are the only metals commonly inspected
with magnetic particle testing method.
THEORY OF MAGNETIZATION
MAGNETIC FLUX
The total number of magnetic lines of force existing in a magnetic
circuit is called magnetic flux.
The lines of force in a magnetic circuit are always closed loops.
Therefore a magnetic circuit is always closed as shown below.
FLUX DENSITY
Flux density – or induction is usually designated in “GAUSS” units
and refers to the FLUX PER-UNIT AREA at right angles to the
direction of the flux.
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THEORY OF MAGNETIZATION
RIGHT-HAND RULE
To find the direction of an electrically induced magnetic field,
place your THUMB on the conductor in the direction of “CURRENT
FLOW” and your FINGERS will then point in the direction of the
LINES OF FLOW. The circular magnetic field is produced in the
sketch below.
Figure above shows the right-hand rule which uses current flow
theory. In this current flow theory, electricity is considered to flow
from + to – .
THEORY OF MAGNETIZATION
The sketch below shows how a magnetic field is produced
utilizing a coil. The field is circular around the cable but produces
a longitudinal field in the specimen.
Using Figure “A” below, try the right hand rule (current flow + to -)
to demonstrate the direction of the magnetic field with the “current
flow” theory
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THEORY OF MAGNETIZATION
The following properties of a metal can determine how effective
the magnetic particle method will be in evaluating a part.
1. Permeability – this refers to the ease with which a magnetic
flux is established in the article being inspected.
High permeability – easy to magnetize
Low permeability – difficult to magnetize
2. Reluctance – this is the opposition of a magnetic material to
the establishment of a magnetic flux. A material with high
permeability will have a low reluctance.
3. Residual Magnetism – this refers to the amount of magnetism
retained after the magnetizing force is removed.
4. Retentivity – refers to the ability of the material to retain a
certain amount of residual magnetism.
5. Coercive force – refers to the reverse magnetizing force
necessary to remove the residual magnetism from the part.
MAGNETIZATION TECHNIQUE
CIRCULAR MAGNETIZATION
1. DIRECT INDUCTION
HEAD SHOT
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MAGNETIZATION TECHNIQUE
CIRCULAR MAGNETIZATION
1. DIRECT INDUCTION
PROD
MAGNETIZATION TECHNIQUE
CIRCULAR MAGNETIZATION
1. DIRECT INDUCTION
PROD
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MAGNETIZATION TECHNIQUE
CIRCULAR MAGNETIZATION
2. INDIRECT INDUCTION
CENTRAL CONDUCTOR
MAGNETIZATION TECHNIQUE
LONGITUDINAL MAGNETIZATION
YOKE
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MAGNETIZATION TECHNIQUE
LONGITUDINAL MAGNETIZATION
COIL
MAGNETIZATION TECHNIQUE
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MAGNETIZATION TECHNIQUE
TERIMA KASIH
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