MAGNETIC PARTICLE

TESTING
 INTRODUCTION
Magnetic Particle Testing (MT) is a Non-
Destructive Testing process for detecting surface
and slightly subsurface discontinuities in
Ferromagnetic materials such as Iron, Nickel,
Cobalt, and some of their alloys.
Detects subsurface discontinuities up to 6mm
depth.
Magnetizing Force and Magnetic Particles (Iron
Powder)are required for testing.
 BASIC PRINCIPLE OF MT
Magnetic Flux Leakage:

Magnetic lines of force which spreads out from

the material due to interruption or discontinuity
is called as Magnetic Flux Leakage.
 BASIC STEPS IN MT
• Pre cleaning/Surface Preparation
• Magnetization of Test material
• Application of magnetic particle
• Inspection, Evaluation & Recording
• De Magnetization
• Post Cleaning
In some cases, a White Contrast Paint is applied
on the test specimen to create a white background
in which brown/black colour magnetic particle
indications can be identified easily.
 PRE CLEANING
Cleaning is done to remove the deposition of
dirt , lint, oil, grease or other contaminants from the
testing material surface.
Various cleaning methods used are:
• Solvent Cleaning(Using volatile solvent cleaners)
• Detergent Cleaning( Using soap solution & water )
• Vapour Degreasing/Steam Cleaning( To remove high
deposition of grease)
• Mechanical Cleaning ( Using Emery paper, Buffing, other Mechanical
means)
• Etching (Removal of outer metal by use of diluted acids)
• Ultrasonic Cleaning( Used for large scale cleaning of small
components)
• Paint Removers ( Special chemicals used to remove paint coating )
 MAGNETISATION OF TEST MATERIAL
• Magnetism is the ability of matter to attract
other matter to itself.
• Magnetic lines of force can be found in and
around the objects.
• A magnetic pole is a point where the a
magnetic line of force exits or enters a
material.
 LAW OF MAGNETISM

Like poles repels and unlike poles attracts each other

Magnetic lines of force Opposite poles attracts Similar poles repels

around a bar magnet
 SOURCE OF MAGNETISM
All matter are 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.
 CREATION OF MAGNETIC FIELD
In most atoms, electrons occur in pairs.
Electrons in a pair spin in opposite directions. So, when
electrons are paired together, their opposite spins cause
their 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 diamagnetic, paramagnetic or ferromagnetic.
ELECTRON MOTION
Magnetic Field Lines/
Magnetic Lines Of Force:

• Form complete loops.

• Do not cross.
• Follow the path of least
resistance.
• All have the same strength.
• Have a direction such that
they cause poles to attract
or repel.
 TYPES OF MATERIAL

Depending on the magnetic property or

magnetic susceptibility ,materials are divided
into:

• Diamagnetic Material
• Para Magnetic Material &
• Ferro Magnetic Material.
 DIAMAGNETIC MATERIAL
• Diamagnetic materials have a weak, negative
susceptibility to magnetic fields.
• They are slightly repelled by a magnetic field
• Material does not retain magnetic property, when
external field is removed.
• In diamagnetic materials, all the electrons are paired so
there is no net magnetic moment per atom.
•Magnetic susceptibility is less than vacuum.
• Most elements in the periodic table, including Copper,
Silver, Gold, Mercury, Bismuth, Aluminum, Zinc are
Diamagnetic.
 PARA MAGNETIC MATERIAL
• Paramagnetic materials have a small, positive
susceptibility to magnetic fields.
• They are slightly attracted by magnetic field.
• Material does not retain magnetic property, when
external field is removed.
• Paramagnetic properties are due to the presence of some
unpaired electrons, and from the realignment of electron
paths caused by external magnetic field.
• Magnetic susceptibility is equal to or slightly greater than
vacuum.
• Paramagnetic materials include Magnesium,
Molybdenum, Lithium and Titanium.
 FERROMAGNETIC MATERIAL
• Ferromagnetic materials have a large, positive susceptibility to
external magnetic field.
• They exhibit a strong attraction to magnetic fields
• They 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.
• Magnetic susceptibility several 1000 times greater than vacuum.

Iron, Nickel & Cobalt are examples of Ferromagnetic

materials. Components with these materials are commonly
inspected using the Magnetic Particle Testing.
 UN MAGNETIZED DOMAINS

In Ferromagnetic materials before applying the

magnetic force, the magnetic domains will be in disordered
positions. When an external magnetic field is applied, the
domain aligns and they creates a strong force of attraction
between each other. The total effect of individual domains
gives high attractive power to the metal.

MAGNETIZED DOMAINS
Magnetizing Force(H):Force required to magnetize a
material. Unit: Ampere/meter
Magnetic Momentum: Strength of a magnetic field.
Magnetic Flux(): Total number of magnetic lines of
force existing in a magnetic circuit. It is always a
closed loop.
Magnetic Flux Density(B):
Flux density refers to flux per unit area at right
angles to the direction of flux. OR
Number of magnetic lines of force passes
perpendicularly over a unit area.
Unit: Tesla
 MAGNETIC PROPERTIES OF A MATERIAL
• Permeability - 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
flux.
• Residual Magnetism – Property of a material to
retain magnetism after the removal of external
magnetic field.
• Retentivity - Ability of material to retain a certain
amount of residual magnetism.
• Coercive force - Amount of reverse magnetizing
force necessary to remove the residual magnetism
from the part. Force required for Demagnetization.
 HYSTERESIS LOOP/ B-H CURVE
A hysteresis loop shows the relationship
between induced Magnetic Flux Density (B) and
Magnetizing Force (H).
A magnetization curve of material thus
plotted is called HYSTERESIS CURVE.

Some ferromagnetic materials when

magnetized, it must be subjected to a reverse
field of a certain strength to demagnetize them.
HYSTERSIS LOOP
 HYSTERSIS LOOP
Relative to other materials, a material with
a wider hysteresis loop has:

• Lower Permeability
• Higher Retentivity
• Higher Coercivity
• Higher Reluctance
• Higher Residual Magnetism
 TYPES OF MAGNETIC FIELDS
Based on the direction of magnetic lines of force
through the material, magnetic field are classified
as:
Longitudinal Magnetic Field : Magnetic field
created parallel to specimens longitudinal axis.
E.g.: Bar Magnet, Horse Shoe Magnet.

Test Specimen’s
Longitudinal Axis
 LONGITUDINAL MAGNETIC FIELD

HORSE SHOE MAGNET BAR MAGNET

 TYPES OF MAGNETIC FIELDS
Circular Magnetic Field:
Magnetic field created circular direction inside the
test specimen.
CIRCULAR MAGNETIC FIELD
 EFFECT OF CRACK ON BAR MAGNET

When small cracks formed at surface, magnetic

poles will create at the edge of cracks.
 DISCONTINUITY’S ORIENTATION

Direction of magnetic field is a critical factor in MT.

For reliable indications during testing, the magnetic
lines of force should be at right angles to the defects to be
detected.
Whenever the Mag. lines of force is perpendicular to the
discontinuity orientation, which causes flux leakage and
optimum results are obtained.
 FLEMINGS RIGHT HAND THUMB RULE
When a current carrying conductor is placed in
your right hand, the thumb points the direction of flow
of current, and the four fingers shows the direction of
flow of magnetic lines of force.
CONDUCTOR

DIRECTION OF
CURRENT FLOW

DIRECTION OF
MAGNETIC LINES
OF FORCE
 TYPES OF MAGNETIZATION CURRENT

ALTERNATING CURRENT DIRECT CURRENT

• AC is used in Magnetic Particle • DC is used in Magnetic Particle
testing as it is the most testing with a Rectifier DC.
commonly available power HWDC current is also used .
source .

• AC due to Skin Effect is used • HWDC being pulsating current is

to find defects open to the used to find sub-surface defects
and the best combination with Dry
surface and the best particles. By using DC, defects up
combination would be with to 6 mm from surface can be
Wet particles detected
CREATING LONGITUDINAL MAGNETIC FIELD

Longitudinal Magnetic field can be created

in a test material by using:

i. Permanent Magnet
ii. Electro Magnetic Yoke
iii. Coil/Solenoid Method.
 PERMANENT MAGNET
Cheapest and easiest method to create Longitudinal
Magnetic Field.

Advantage:
• No electric power source required.
Limitations:
• Very difficult to place and replace.
• Magnetic strength cannot be controlled.
Because of the above reasons, Permanent Magnet
method is not widely used.

Permanent Magnet is used only when there is no

access to electric power source to create magnetic field.
PERMANENT MAGNET
PERMANENT MAGNET
 ELECTRO MAGNET YOKE METHOD
Electro Magnetic Yoke has mainly two parts:
i. Horizontal Bar: Horizontal bar is made of core iron.
Insulated coils are winded over the bar.
ii. Two Adjustable Legs: are made of soft, low
Retentivity iron. When power is applied, yoke will
acts as a temporary horse-shoe magnet.
Current is passed through the coil winded
over the horizontal bar. As a result a magnetic field
is induced and is utilized for testing.
Two types of Electro magnetic yokes are
available based on power supply:
AC Yoke & DC Yoke.
ELECTRO MAGNETIC YOKE
ELECTRO MAGNETIC YOKE
 COIL /SOLENOID METHOD
• Widely used to check lengthwise job.
• An insulated copper coil is winded over the job and
current is passed through the coil. As a result of the
current flow, a magnetic field is created and this
field affects the test material in longitudinal
direction.
• If job length is greater than 18”, more than 1 coil
shot is required.
 AMPERE- TURNS VALUE
If L/D ratio equal to or greater than 4,
NI = 35000
L/D +2
If L/D ratio less than 4, but not less than 2,
NI = 45000
L/D
Where, L: length of the test object
D: diameter of the test object
N: number of coil turns
I: current in amperes
• Using Ampere Turns equation, Calculate:
• I=? Where N=5,L=10, D=5
• N=?, where I=500A, L=6, D=2.
 CREATING CIRCULAR MAGNETIC FIELD

Circular Magnetic field can be created in a

test material by using:

i. Head Shot Method

ii. Prod Tech Method
iii. Central Conductor Method.
 HEAD SHOT METHOD
• Direct Magnetization method, hence current is passed
directly through the test material.
• Discontinuities in longitudinal direction can be
determined.
At most care should be taken to avoid:
i. Electric shock due to the passing of high current.
ii. Excess amount of current will damage the test material.
Current applied: for 1” diameter/thickness: 700A to 1200A
 PROD TECH METHOD

Two prods are placed in a testing material. Current

is passed through the first prod and through material and is
taken out through the second prod. As a result of the current
flow and due to Flemings right hand thumb rule, a circular
magnetic field is created in the test material, which is utilized
for testing.
 PROD TECH METHOD (Continuation…)
For optimum results, Prod to Prod distance should
be between 6-8 inches.
Applying Current depends on:
i. Prod to Prod distance
ii. Test material thickness.
PRODS FOR CIRCULAR MAGNETIZATION
 CENTRAL CONDUCTOR METHOD
• Indirect magnetization method.
• Used to test hollow materials
 CENTRAL CONDUCTOR METHOD
(Continuation…)
A conductor is placed concentrically inside
the test object and current is passed through the
conductor.
As a result of current flow, a circular magnetic
field is created. This field is utilized for testing.
Discontinuities present in longitudinal direction
can be determined.
For 0.125 mm thickness 250A current is used.
CENTRAL CONDUCTOR METHOD
 APPLICATION OF MAGNETIC PARTICLE
Iron or Iron oxide is used as magnetic particle
for testing. These are made to fine particles by
machining or filing.
TYPES OF MAGNETIC PARTICLE
• Wet magnetic particles
– Visible Wet Particle (Black or Grey colour)
– Fluorescent Wet Particle (Fluorescent Green colour)
• Dry magnetic particles (Reddish Brown colour)
• DRY COLOUR: • DRY-50 MICRONS
RED,GREEN • WET-20 MICRONS
• WET: GREY,BLACK • ROUND-MOBILITY
• Available in VISIBLE, MORE, ATTRACTION
FLOURESCENT LOW
• SHAPE: ROUND o ELONGATED-MOBILITY
/ELONGATED LOW, ATTRACTION HIGH
• PROPERTIES REQUIRED- o PARTICLE SIZE IS SMALL
HIGH PERMEABILITY, GIVES MORE
LOW RETENTIVITY SENSITIVITY
 MAGNETIC POWDER APPLICATIONS
DRY POWDER APPLICATION WET POWDER APPLICATION
DEMAGNETISATION
 Demagnetization
Parts inspected by the magnetic particle method may
sometimes have an objectionable residual magnetic field
that may interfere with subsequent manufacturing
operations or service of the component.
Possible reasons for demagnetization include:
May interfere with welding and/or machining operations
Can effect gauges that are sensitive to magnetic fields if
placed in close proximity.
Abrasive particles may adhere to components surface
and cause and increase in wear to engines components,
gears, bearings etc.
 Demagnetization (Cont.)
Demagnetization requires that the residual magnetic
field is reversed and reduced by the inspector.
This process will scramble the magnetic domains and
reduce the strength of the residual field to an acceptable
level.

Magnetized Demagnetized
 Demagnetization
• Reducing

• Reversing

• Heating
 The temperature above which a ferromagnetic substance loses
its ferromagnetism and becomes paramagnetic

• Substance Curie temp °C

• Iron (Fe) 770
• Cobalt (Co) 1130
• Nickel (Ni) 358
• Iron Oxide (Fe2O3) 622
• DEMAGNETISATION WITH AC
• DEMAGNETISATION WITH DC
MAGNETIC PARTICLE TEST
INDICATIONS
INSPECTION, EVALUATION & RECORDING
Indications are formed by the accumulation of magnetic
particles on the test surface that forms during inspection.
Indications are classified into:
Relevant Indications/ True Indications:
Indications which are true, formed from actual flaw.
Non Relevant Indications:
Caused by flux leakage. Weak and not at all defect.
Indications obtained at Riveted Joints, Threaded areas etc.
False Indications:
Particle patterns are held by gravity or surface roughness.
No magnetic attraction is involved. Obtained due to
improper cleaning, Excess of Magnetic Particle &
Magnetizing Force etc.
INSPECTION, EVALUATION & RECORDING
True Indications are obtained as:
Continuous Line Indications
Intermittent Line Indications
Rounded Indications
Small Dots etc.
DISCONTINUITY/ FLAW/ IMPERFECTION
• Interruption in the normal physical configuration
or composition of a part.
• It may not be a defect
DEFECT
• Discontinuity that interferences with the utility
or service of a part.
 CLASSIFICATION
• SURFACE DISCONTINUITIES
• SUB SURFACE DISCONTINUITIES
 INDICATIONS
• NON METALLIC INCLUSIONS
• NON PLASTIC INCLUSIONS
• SURFACE SEAMS
• COOLING CRACKS
• LAMINATIONS
• FORGING LAPS
• FATIGUE CRACKS
• GAS POROSITY
• INCOMPLETE WELD PENETRATION
• HEAT TREAT CRACKS
• GRINDING,PLATING OR ETCHING CRACKS
Limitations:

1. Materials being inspected must be

ferromagnetic
2. Will only detect surface and slightly subsurface
flaws
3. Material need to be demagnetized after testing
4. Coating may mask indications
5. Material permeability may affect results.
Advantages
1. Economical
2. Aid to VT
3. Can be fixed or portable equipment
4. Instant repeatable results
5. Effective inspection method
6. Contrast or fluorescent consumables.
 BLACK LIGHT
• Indications are only visible under ultraviolet or
black light illumination. Ultraviolet light is defined
as light above the visible spectrum having a very
short wavelength invisible to human eye. The
evaluation is performed in a darkened
environment to heighten the visibility of the
fluorescent indications. Black light wavelength is
365nm and emitted fluorescent light wavelength
is approximately 700 nm (visible light wavelength
is between 400 to 700 nm)
MAGNETIC POWDER INDICATIONS
DRY POWDER INDICATIONS WET POWDER INDICATIONS
 Examples of Magnetic Particle Indication
Before and after inspection pictures of cracks emanating from a hole

Examples
Examples of Magnetic Particle Indication

Indication of cracks running between

attachment holes in a hinge
Examples of Magnetic Particle Indication
Indication of cracks originating at a
fastener hole
Examples of Magnetic Particle Indication
Magnetic particle wet fluorescent indication of
a crack in a bearing
Examples of Magnetic Particle Indication
Magnetic particle wet fluorescent indication of
a cracks in a drive shaft
 Crane Hook with
Service Induced Crack

Fluorescent, Wet Particle Method

 Gear with
Service Induced Crack

Fluorescent, Wet Particle Method

 Drive Shaft with
Heat Treatment Induced Cracks

Fluorescent, Wet Particle Method

 Splined Shaft with
Service Induced Cracks

Fluorescent, Wet Particle Method

 Threaded Shaft with
Service Induced Crack

Fluorescent, Wet Particle Method

 Large Bolt with
Service Induced Crack

Fluorescent, Wet Particle Method

 Crank Shaft with
Service Induced Crack Near Lube Hole

Fluorescent, Wet Particle Method

Lack of Fusion in SMAW Weld

Indication

Visible, Dry Powder Method

Toe Crack in SMAW Weld

Visible, Dry Powder Method

Throat and Toe Cracks in
Partially Ground Weld

Visible, Dry Powder Method