NDT LEVEL I/II COURSE IN

MT

H-85, SECTOR-63
NOIDA- 201301

For the benefit of business and people

SUMMARY
1 Introduction
2 Basic Principle
3 Electromagnetism
4 Test Methods & Technique
5 Diamagnetism
6 Magnetic Particles
7 Equipment & Accessories
8 Interpretation & Evaluation

2
1
> Introduction

3
 1 INTRODUCTION MPT

MAGNETIC PARTICLE TESTING

Definition:
-
 Is a method for locating surface and subsurface discontinuities in
ferromagnetic materials.
 It depends for its operation on the fact that when the material or part under
test is magnetized discontinuities which lie perpendicular to the direction of
the magnetic field will cause a leakage field to be formed at and above the
surface of the part.

Basic Concept
 Magnetizing the material or part under test
 Applying the ferromagnetic particles over the surface
 Examining the surface for powder pattern or indication

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 1 INTRODUCTION ADVANTAGE

Advantages:
 It is the best method and most reliable method available for finding surface
-
and sub-surface cracks, especially very fine and shallow ones.
 It is rapid and simple to operate
 The indications are produced directly on the surface of the part
 Operators can learn the method easily, without lengthy or highly technical
training
 There is little or no limitation due to size or shape of the part being tested
 It will detect cracks filled with foreign materials
 Surface preparation is not as rigid as in the case penetrate testing
 It will work well through the coatings of part

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 1 INTRODUCTION LIMITATION

It is relatively low in operational costs

-
Limitations:
 It does not work on non-ferromagnetic materials
 As the magnetic flux lines should be almost perpendicular to the
discontinuities, many times more than one magnetic field has to be applied
to the part
 Sometimes parts have to be demagnetized after testing
 Post-cleaning to remove remnants of the magnetic particles clinging to the
surface may sometimes be required after testing and demagnetization
 Sometimes, the geometry of the part is a limitation I.e. how to apply the
magnetizing force to produce a field in a proper direction in the matter of
speculation.
 Normally, there is no permanent record of the test.

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 4 INTRODUCTION PROCEDURE

Procedure Adopted in General:

 - Material consideration
 Putting field indicator between the poles of permanent
magnet or yokes
 Magnetization
 Looking for indications on indicator i.e. qualifying
procedure
 Start witnessing with the same method
 Putting the poles or yokes in two perpendicular direction
and looking for indication with iron powder (dry or wet)
or in dark with the help of black ultraviolet light

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2
> BASIC PRINCIPLE

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2 BASIC PRINCIPLE PRINCIPLE

PRINCIPLE OF MPT
- When a ferromagnetic component is magnetized
magnetic discontinuities that lie in a direction approx..
perpendicular to the field direction will result in the
formation of a strong leakage field.

The application of the wet or dry finely divided iron

particle over the surface of the components results in a
collection of magnetic particles at a discontinuity the
magnetic bridge so formed indicates the location, size
and shape of the discontinuity.

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 2 BASIC PRINCIPLE MPT

Various magnetizing method:

 - Residual and continuous
 Induced magnetic fields
 Direct or alternating electric current

Magnetism:
Like magnetic poles repel and unlike magnetic poles attract one
another.

 Paramagnetic
 Diamagnetic

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 2 BASIC PRINCIPLE MAGNETISM

Paramagnetic Diamagnetic
It can be magnetized It cannot be magnetized
-
They are affected by magnetic They are repelled by
field magnetism
It can not be magnetic
particle tested
Ferromagnetic
Can be strongly magnetized and
they are strongly attracted to
magnetic fields
It can be magnetic particle tested
Relative permeability is more Relative permeability is
than 1 less than 1

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 2 BASIC PRINCIPLE MPT

Magnetic Flux

Flux leakage

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2 BASIC PRINCIPLE MPT

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 2 BASIC PRINCIPLE MPT

Permeability
Hysteresis Curve
-

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3
> ELECTROMAGNETISM

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 3 ELECTROMAGNETISM MPT

ELECTROMAGNETISM
 When an electric current passes through a conductor a magnetic filed is formed
- around the conductor

 Direction of the magnetic field (line of force) is at a 90 degree to that of the current in
the conductor
 To determine the direction of electricity induced magnetic field the right hand rule can
be applied.

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 3 ELECTROMAGNETISM MPT

Procedure / process control

-
 Type of current
 Type of magnetic particle
 Method of magnetization
 Direction of magnetization
 Magnitude of applied current
 Equipment
 Demagnetization
 Post cleaning

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 3 ELECTROMAGNETISM MPT

 Solenoid
-
 The formation of magnetic field in a magnetic material placed inside the solenoid,
when a current passing through the solenoid is know as electromagnetism.
 Magnetic Field Characteristics:

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 3 ELECTROMAGNETISM MPT

The magnetizing force or magnetic field in the p circuit winding , is directly

- proportional to magnetizing current Ip in the primary coil.

H = Np I = Np Ip
L L
H - The magnetizing force
Np - The number of turns on the P-circuit and
L - The average circumference of the ring sample

The flux density B as detected by S-circuit, is proportional to the output of

the integrator, according to the relation below:

Ns (BA) = k Eout

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 3 ELECTROMAGNETISM MPT

Ns - the number of turns on the secondary coil

A - cross-sectional area of the metal sample I square meter
-
K - a constant for the integrator and
Eout - the integrator output in volts
B - in tesla (weber per square meter, SI units) or in gauss or kilogauss (in
traditional units)
1 G = 10– T, 1T is 1 Wb¯²m

Type of Current:
 DC - A current which is usually in same direction but may vary or pulsate in
value
 AC - Current which reverse in direction being first positive and then
negative.

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 3 ELECTROMAGNETISM MPT

A. C. Current:
 Skin effect of A.C. current at 50 hz limits its use to the detection of
-
discontinuities open to surface or few thousandth of an inch below the
surface
 Rapid reversal of the magnetic field imparts mobility to the dry particle
 Agitation of the powder helps move to the area of leakage field and form
stronger indication
D.C. Current:
 Magnetizes the entire cross sectional area more or less uniformly in a
longitudinal direction
 Strength wise maximum at the surface to zero at the centre, in cases of
circular magnetization.

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 3 ELECTROMAGNETISM MPT

 Flux penetration is deeper and hence sub surface defects can be

detected.
-

Type of D. C. Current used:

 Straight D.C. (battery)

 Three phase rectified A.C. current with surge

 Half wave rectified single phase A.C. Current

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 3 ELECTROMAGNETISM MPT

21.3
 D (HW AC)

- 17.3 C (DC with Surge)

 B (DC)

14.2

 10.7

7.1

3.5
 AC

200 400 600 800 1000

Magnetizing Current A Vs Distance between defect and surface

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4
> TEST METHODS &
TECHNIQUE

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4 TEST METHOD & MPT
TECHNIQUE

TEST METHODS & TECHNIQUE

-Methods of magnetization
•Longitudinal magnetization
•Coil technique
•Yoke technique

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4 TEST METHOD & MPT
TECHNIQUE

Yoke technique

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4 TEST METHOD & MPT
TECHNIQUE

Circular Magnetism:
•Head shot

•Prods

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4 TEST METHOD & MPT
TECHNIQUE

Central conductor

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4 TEST METHOD & MPT
TECHNIQUE

Current Requirement :
•Coil technique
•L/D ratio
•Calculation
Amperes = 45,000 x 1 for L/D ration not less than 2 and not
L/D T more than 4

Amperes = 35,000 x 1 for L/D ration equal or more than 4

L/D+2 T
L = specimen length
D = Diameter or cross section of specimen
T = number of turns in coil
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4 TEST METHOD & MPT
TECHNIQUE

Yoke:

The field strength is measured by lifting power. Alternating

current electromagnetic yoke shall lift a weight of at least 4.5 kg
(10lb) at the maximum pole spacing to be used. Direct current or
permanent magnetic yoke shall have a lifting power of at least 16.1
Kg. (40 1b) at the maximum pole spacing that will be used.

Head Shot:
Part Outer Diameter or Current per diameter
Cross section (Ampere /in)
Up to 5”

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4 TEST METHOD & MPT
TECHNIQUE

Head Shot:

Part Outer Diameter or Current per diameter

Cross section (Ampere /in)
Up to 5” 700 to 900
Over 5” to 10” 500 to 700
Over 10” to 15” 300 to 500
Over 15” 100 to 230

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4 TEST METHOD & MPT
TECHNIQUE

Prods:

Specimen Thickness Current/ Prod Spacing #

¾ thick or greater 100 - 125 Amp/in

Less than ¾ “ 90 - 110 amp/in

Residual Magnetism
•Establishing a magnetic field in the part
•Subsequently applying the magnetic particle
•For materials having high retentively
•Suitable for only surface defcts
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4 TEST METHOD & MPT
TECHNIQUE

Continuous Magnetism:
•Magnetized continuously while putting the particles
•Suitable for wet methods prevents washing
•Soft material of low remanence must be tested using the
continuous method.

Examination medium:
Dry method
Wet method

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4 TEST METHOD & MPT
TECHNIQUE

Checking Sensitivity
•Field Indicator

Test piece used for Magnetic Yoke

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4 TEST METHOD & MPT
TECHNIQUE

KETO’S Ring

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5
> DEMAGNETISM

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5 DEMAGNETISM MPT

Demagnetization:
There are two techniques of demagnetization
Leave the part inside the coil and reduce the AC or reversed
DC current to zero.
Or
Place the part inside the coil (constant AC current) and
move the part away from the coil, or move the coil away from the
part.
Reason for Demagnetization:
•A strong residual field may interfere with subsequent operations
•Magnetized particle could cause wear

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5 DEMAGNETISM MPT

•Leakage field may interfere with nearby instruments

•Residual fields may interfere with proper cleaning of the specimen
•Specimen is to be magnetized at a lower magnetizing force
Demagnetization is usually not required
•On specimen of soft steel or iron where retentively is low
•If, after the magnetic particle test, the specimen is to be heat-
treated.
•On large castings, weldments, or vessels where residual fields will
have no material effect.
•If the specimen is to be magnetized again
•If the specimen is likely to become demagnetized during handling
being placed on a magnetic chuck or lifted with an electromagnetic
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6
> MAGNETIC PARTICLES

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6 MAGNETIC PARTICLES MPT

MAGNETIC PARTICLES
• Magnetic properties
High magnetic permeability
Low coercive force
Low retentivity
Particle size
Should not be large & heavy
Coarse particle is better for bridging large gaps or cracks
Fine particles will give better sensitivity to small defect but
care to be taken since it adheres to solid areas ad rough surface ad
could lead to false indications.

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6 MAGNETIC PARTICLES MPT

•Particle shape
Long slender particles develop a stronger polarity then spheroidal
particles put they bind together in uneven clumps which reduces mobility
globular / spheroidal particles flow freely as compared to long
slender particles
mix of both is used for better sensitivity
Visibility & control
Particles with colors that are easy to see against the color of the
surface being inspected.
Usual ones for dry powder
- Silver Grey, yellow,red or black
- With a fluorescent coating

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6 MAGNETIC PARTICLES MPT

•Magnetizing field adequacy and direction shall be established using field

indicator
•Ammeter calibration of equipment at least annually or on major break
down, repair
•each A.C. current electromagnetic yoke shall have a lifting power of 4.5 kg
at the maximum pole spacing that will be wed and with D.C. 18.1 kg.
•With prod technical the current shall be minimum 100 amp / in to
maximum 125 A/inch of prod Spacing for thick 19 mm or more for < 19 mm
thick it is 90 amp / in to 110 amp / in of prod spacing
•Prod spacing shall be between 3 inch to 8 inch
•Sufficient overlap to cover 100% surface.

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6 MAGNETIC PARTICLES MPT

For wet particles

- Black & red pigment
- Blue- green or yellow, green, fluorescent powder

•Types
Dry particles
Wet particles

Equipment & accessories:

•Equipment based on electrically generated fields
•Equipment which utilizes permanent magnets

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7
> EQUIPMENT &
ACCESSORIES

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 7 EQPT& ACCESSORIES MPT

Magnetizing equipment:
•Portable and mobile unit
•Stationary unit
•Heavy duty DC units
•Attributes of yokes in MPI
•Small and portable
•May be powered from a battery in areas
•May be used in restricted areas
•Do not tend to produce hard spots

Some limitations in the use of yokes in testing are:

• Yokes tend to overheat particularly when used contiuously
•Since they are not

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 7 EQPT& ACCESSORIES MPT

Some limitations in the use of yokes in testing are:

• Yokes tend to overheat particularly when used continuously
•Since they are not normally equipped with ammeters, the filed
strength cannot be readily related to current flow and must be
measured by other means.
•Some of the more prominent applications of yoke magnetization
are:
•In-service maintenance inspection
•Spot checks of welds, especially between passes
•Investigation of suspect areas (trouble-shooting)
•Permanent Magnets:

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 7 EQPT& ACCESSORIES MPT

ACCESSORIES
•Graduated Tube:
Graduated tube is used for measuring concentration and strength of the
liquid testing medium (bath). The method of test is described below:
- Agitate the bath for 30 min. or more
- The spray nozzle should be run at the same time the bath is
being agitated
- Charge a 100 ml centrifuge tube, to the 100 ml mark from the
spray nozzle
- Demagnetize if necessary
- Let it stand for 30 min. in a vibration-free area
- Read the volume of the precipitate. The volume shall be in
accordance with the required specification. *

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 7 EQPT& ACCESSORIES MPT

Check for contamination by examining the liquid above the

precipitate. The liquid shall not fluoresce.
- Examine the precipitate. If so distinct layers can be seen, reed
the volume of each layer. The top layer is considered to be
contamination, it shall not fluoresce. The acceptable limit of
contamination will be governed by applicable specification.
* ASTM E -138: (With red or black indicating material the recommended
concentration from a 100 ml sample is 1.2 to 2.4 ml. For fluorescent paste, the
recommended concentration is 01. to 0.7 ml).

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 7 EQPT& ACCESSORIES MPT

Black Light:
•Source of black light
•Black light filters
•Black light intensity variation:
New lamps can very as much as 50% in output
The black light intensity varies almost directly with the
applied voltage.
The efficiency of black light bulbs decreases with age
Dust and dirt will reduce intensity.
•Black light intensity measurement
•Practical operation a black light

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8
> INTERPRETATION
EVALUATION

50
8 INTERPRETATION & MPT
EVALUATION

INTERPRETATION AND EVALUATION OF TEST RESULT

•Interpreting

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 8 INTERPRETATION & MPT
EVALUATION

•False Indications

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 8 INTERPRETATION & MPT
EVALUATION

•Magnetic writing
•Longitudinal Magnetization
•Cold working
•Hard or soft spots
•Boundaries of heat treated sections
•Abrupt changes of section
Requirement of Sec. V Art. 7
•With dry particle MPT shall not be carried out it temp. > 3.16°C
•With wet particle temp > 57 °C
•For fluorescent method the examiner shall dark adapt for 5
minutes and minimum 5 minutes for warm up of black light having
source minimum 1000 w/cm².
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 MPT

THANK YOU

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