MAGNETIC PARTICLE TESTING - Tiarasalsabilatoniputri

MAGNETIC PARTICLE TESTING

Introduction This module is intended to present information on the widely used method ofmagnetic particle inspection.Magnetic particle inspection can detectboth production discontinuities (seams,laps, grinding cracks and quenchingcracks) and in-service damage (fatigueand overload cracks).

Outline Magnetism and Ferromagnetic Materials Introduction of Magnetic Particle InspectionBasic Procedure and ImportantConsiderations1. Component pre-cleaning2. Introduction of magnetic field3. Application of magnetic media4. Interpretation of magnetic particleindicationsExamples of MPI Indications

Introduction to MagnetismMagnetism is the ability of matter toattract other matter to itself. Objectsthat possess the property ofmagnetism are said to be magnetic ormagnetized and magnetic lines offorce can be found in and around theobjects. A magnetic pole is a pointwhere the a magnetic line of forceexits or enters a material.Magnetic lines of forcearound a bar magnetMagnetic field lines: Form complete loops. Do not cross. Follow the path of leastresistance. All have the same strength. Have a direction such thatthey cause poles to attractor repel.Opposite poles attractingSimilar poles repelling

Ferromagnetic Materials A material is considered ferromagnetic if it can bemagnetized. Materials with a significant Iron, nickel orcobalt content are generally ferromagnetic. Ferromagnetic materials are made up of many regions inwhich the magnetic fields of atoms are aligned. Theseregions are call magnetic domains. Magnetic domains point randomly in demagnetizedmaterial, but can be aligned using electrical current or anexternal magnetic field to magnetize the material.SDemagnetizedNMagnetized

How Does Magnetic ParticleInspection Work?A ferromagnetic test specimen is magnetized witha strong magnetic field created by a magnet orspecial equipment. If the specimen has adiscontinuity, the discontinuity will interrupt themagnetic field flowing through the specimen and aleakage field will occur.

How Does Magnetic ParticleInspection Work? (Cont.)Finely milled iron particles coated with a dye pigmentare applied to the test specimen. These particles areattracted to leakage fields and will cluster to form anindication directly over the discontinuity. Thisindication can be visually detected under properlighting conditions.

Basic ProcedureBasic steps involved:1. Component pre-cleaning2. Introduction of magnetic field3. Application of magnetic media4. Interpretation of magnetic particle indications

Pre-cleaningWhen inspecting a test part with the magneticparticle method it is essential for the particles tohave an unimpeded path for migration to bothstrong and weak leakage fields alike. The part’ssurface should be clean and dry beforeinspection.Contaminants such as oil,grease, or scale may notonly prevent particles frombeing attracted to leakagefields, they may alsointerfere with interpretationof indications.

Introduction of the Magnetic FieldThe required magnetic field can be introduced into acomponent in a number of different ways.1. Using a permanent magnet or an electromagnet thatcontacts the test piece2. Flowing an electrical current through the specimen3. Flowing an electrical current through a coil of wirearound the part or through a central conductor runningnear the part.

Direction of the Magnetic FieldTwo general types of magnetic fields (longitudinaland circular) may be established within thespecimen. The type of magnetic field established isdetermined by the method used to magnetize thespecimen. A longitudinal magnetic field has magnetic lines of force that runparallel to the long axis of thepart.A circular magnetic field hasmagnetic lines of force that runcircumferentially around theperimeter of a part.

Importance of Magnetic Field DirectionBeing able to magnetize the part in twodirections is important because the bestdetection of defects occurs when the lines ofmagnetic force are established at right angles tothe longest dimension of the defect. Thisorientation creates the largest disruption of themagnetic field within the part and the greatestflux leakage at the surface of the part. Anorientation of 45 to 90 degrees between themagnetic field and the defect is necessary toform an indication.Since defects mayoccur in various andunknown directions,each part is normallymagnetized in twodirections at rightangles to each other.Flux LeakageNo Flux Leakage

Question?From the previous slide regarding the optimumtest sensitivity, which kinds of defect are easilyfound in the images below?Longitudinal (along the axis)Transverse (perpendicular the axis)

Producing a Longitudinal MagneticField Using a CoilA longitudinal magnetic fieldis usually established byplacing the part near theinside or a coil’s annulus.This produces magneticlines of force that areparallel to the long axis ofthe test part.Coil on Wet Horizontal Inspection UnitPortable Coil

Producing a Longitudinal Field UsingPermanent or Electromagnetic MagnetsPermanent magnets andelectromagnetic yokesare also often used toproduce a longitudinalmagnetic field. Themagnetic lines of forcerun from one pole to theother, and the poles arepositioned such that anyflaws present run normalto these lines of force.

Circular Magnetic FieldsMagnetic FieldElectricCurrentCircular magnetic fields are produced bypassing current through the part or byplacing the part in a strong circularmagnet field.A headshot on a wet horizontal test unitand the use of prods are several commonmethods of injecting current in a part toproduce a circular magnetic field.Placing parts on a central conductorscarrying high current is another way toproduce the field.

Application of MagneticMedia (Wet Versus Dry)MPI can be performed using eitherdry particles, or particlessuspended in a liquid. With thedry method, the particles arelightly dusted on to the surface.With the wet method, the part isflooded with a solution carryingthe particles.The dry method is more portable.The wet method is generally moresensitive since the liquid carriergives the magnetic particlesadditional mobility.

Dry Magnetic ParticlesMagnetic particles come in a variety of colors. Acolor that produces a high level of contrastagainst the background should be used.

Wet Magnetic ParticlesWet particles are typically suppliedas visible or fluorescent. Visibleparticles are viewed under normalwhite light and fluorescent particlesare viewed under black light.

Interpretation of IndicationsAfter applying the magnetic field, indications thatform must interpreted. This process requires thatthe inspector distinguish between relevant andnon-relevant indications.The following series of images depictrelevant indications produced from avariety of components inspectedwith the magnetic particle method.

Crane Hook withService Induced CrackFluorescent, Wet Particle Method

Gear withService Induced CrackFluorescent, Wet Particle Method

Drive Shaft withHeat Treatment Induced CracksFluorescent, Wet Particle Method

Splined Shaft withService Induced CracksFluorescent, Wet Particle Method

Threaded Shaft withService Induced CrackFluorescent, Wet Particle Method

Large Bolt withService Induced CrackFluorescent, Wet Particle Method

Crank Shaft withService Induced Crack Near Lube HoleFluorescent, Wet Particle Method

Lack of Fusion in SMAW WeldIndicationVisible, Dry Powder Method

Toe Crack in SMAW WeldVisible, Dry Powder Method

Throat and Toe Cracks inPartially Ground WeldVisible, Dry Powder Method

Demagnetization Parts inspected by the magnetic particle methodmay sometimes have an objectionable residualmagnetic field that may interfere with subsequentmanufacturing operations or service of thecomponent.Possible reasons for demagnetization include:– May interfere with welding and/or machiningoperations– Can effect gauges that are sensitive tomagnetic fields if placed in close proximity.– Abrasive particles may adhere to componentssurface and cause and increase in wear toengines components, gears, bearings etc.

Demagnetization (Cont.) Demagnetization requires that the residual magnetic field isreversed and reduced by the inspector.This process will scramble the magnetic domains andreduce the strength of the residual field to an acceptablelevel.MagnetizedDemagnetized

Advantages ofMagnetic Particle Inspection Can detect both surface and near sub-surfacedefects. Can inspect parts with irregular shapes easily. Precleaning of components is not as critical as itis for some other inspection methods. Mostcontaminants within a flaw will not hinder flawdetectability. Fast method of inspection and indications arevisible directly on the specimen surface. Considered low cost compared to many otherNDT methods. Is a very portable inspection method especiallywhen used with battery powered equipment.

Limitations ofMagnetic Particle Inspection Cannot inspect non-ferrous materials such asaluminum, magnesium or most stainless steels. Inspection of large parts may require use ofequipment with special power requirements. Some parts may require removal of coating orplating to achieve desired inspection sensitivity. Limited subsurface discontinuity detectioncapabilities. Maximum depth sensitivity is approximately0.6” (under ideal conditions). Post cleaning, and post demagnetization is oftennecessary. Alignment between magnetic flux and defect isimportant

Glossary of Terms Black Light: ultraviolet light which is filtered toproduce a wavelength of approximately 365nanometers. Black light will cause certain materials tofluoresce.Central conductor: an electrically conductive barusually made of copper used to introduce a circularmagnetic field in to a test specimen.Coil: an electrical conductor such a copper wire orcable that is wrapped in several or many loops thatare brought close to one another to form a stronglongitudinal magnetic field.

Glossary of Terms Discontinuity: an interruption in the structure of thematerial such as a crack.Ferromagnetic: a material such as iron, nickel andcobalt or one of it’s alloys that is strongly attracted toa magnetic field.Heads: electrical contact pads on a wet horizontalmagnetic particle inspection machine. The part to beinspected is clamped and held in place between theheads and shot of current is sent through the partfrom the heads to create a circular magnetic field inthe part.Leakage field: a disruption in the magnetic field.This disruption must extend to the surface of the partfor particles to be attracted.

Glossary of Terms Non-relevant indications: indications produced dueto some intended design feature of a specimen sucha keyways, splines or press fits.Prods: two electrodes usually made of copper oraluminum that are used to introduce current in to atest part. This current in turn creates a circularmagnetic field where each prod touches the part.(Similar in principal to a welding electrode andground clamp).Relevant indications: indications produced fromsomething other than a design feature of a testspecimen. Cracks, stringers, or laps are examples ofrelevant indications.

Glossary of Terms Suspension: a bath created by mixing particles witheither oil or water.Yoke: a horseshoe magnet used to create alongitudinal magnetic field. Yokes may be made frompermanent magnets or electromagnets.

How Does Magnetic Particle Inspection Work? A ferromagnetic test specimen is magnetized with a strong magnetic field created by a magnet or special equipment. If the specimen has a discontinuity, the discontinuity will interrupt the magnetic field flowing through the specimen and a leakage field will occur.