Magnetic Particle Testing : Magnetic particle testing is a non destructive testing method for detection of surface and near

surface discontinuities in ferromagnetic materials. Ferromagnetic materials are materials that can be magnetized to a level that will allow the inspection to be effective. They are, Iron, Cobalt, Nic el and their magnetic alloys. Magnetic particle testing can detect, surface and near surface crac s seams, laps, cold shuts in castings, laminations, lac of fusion near the surface, undercuts, deep scratches and fatigue crac s are indicated. !inear inclusions and porosity at or very near the surface may produce indications. The techni"ue uses the principle, that during the magnetization of a ferromagnetic material, magnetic lines of force # magnetic flu$ lines % pass through this magnetically conducting medium. If the magnetic flu$ lines hit an area of different magnetic permeability such as a crac near the surface, a portion of these flu$ lines gets diverted and lea out above the surface of the material. & magnetic lea age field emerges from the part. To show this lea age field, colored finely divided iron particles are sprayed to the area under e$amination. The lea age field attracts and accumulates some of these iron powder particles and essentially creates a powder caterpillar worm ' li e visual indication for the human eye. The indication is produced directly on the surface of the part and above the discontinuity. There are variations in the way the magnetizing field is applied, but they are all dependant on the above principle. &ll surface and near surface crac li e defects which produces a lea age field at the test surface can be detected. No elaborate precleaning is necessary, and surface defects filled with foreign material can be detected. Characteristics of a discontinuity that enhances its detection are, Its depth is at right angles to the surface (idth of the surface opening small, so that the air gap created Is narrow Its length at the surface is large with respect to its width It is comparatively deep in proportion to the width of its opening. In general reliable detection re"uires that the width ' depth ' length dimensions of the discontinuities correspond to the ratio ) * + * ),. The lowest detection limits are a )-m crac width, with a ), -m depth of cut. .ptimum crac detection occurs when the magnetic flu$ lines flow at right ' angles to the length of the defect. To form a detectable lea age field, the angle between the field direction and the e$pected defect/s length shall not be greater than 0+, . 1isadvantages * It can be used only on ferromagnetic materials, has certain application which re"uire large amounts of electrical current and re"uires the magnetic field to be properly oriented in relation to the discontinuities anticipated. 2aint coatings and nonmagnetic coverings affect the sensitivity of e$amination. 1emagnetization of the parts following e$amination may be re"uired. 2ost cleaning to remove the magnetic particle materials from the test surface is re"uired. 1etectability of 1efects * 1etectability depends on formation of a strong lea age field which is dependent on surface opening of the discontinuity and its depth through the part thic ness. & shallow surface scratch which may be as wide as it is deep, usually does not produce an indication. If a crac is wide open at the surface, the reluctance of the air gap in the crac opening reduces the strength of the lea age field. This, combining with the inability of the particles to bridge the air gap, fails to form an indication. !aps emerge at an acute angle to the surface and a wide air gap is created between its lip and the part surface. The lea age field may be "uite wea because very little lea age flu$ ta es the path out through the surface lip of the lap to cross this high reluctance gap. If the faces of a crac are tightly forced together under compressive stress, the almost complete absence of an air gap may produce so little lea age field that no particle indication is formed.

The surface structure of a test piece has a significant influence on the detectability of defects. The surface cutting depth of a defect should be at least twice the associated surface roughness. 1efect detectability can be further reduced by false indications arising from magnetic stray fields, accumulation of powder due to surface roughness, part configuration, scratches, scales, slots etc. Cases can occur where It is difficult to generate the force re"uired for a positive defect indication. 3urface irregularities and scratches can give misleading indications. Therefore it is necessary to ensure careful preparation of the surface before magnetic particle testing is underta en. 1etectability of 3ub 3urface 1efects * Magnetic particle testing can detect near ' surface discontinuities of favorable position and ade"uate size, but the possibility of an indication rapidly decreases when the discontinuity is more than .= mm below the surface. 1etection sensitivity increases with increase in magnetic field strength, but with very high field strength magnetic particles will be attracted to defect free areas of the surface as well as to defects. The depth below the surface at which a sub surface defect may be detected is of the order of > to ? mm when direct current magnetization is used, but this will also depend on the size, shape and orientation. Therefore, 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. Crac s below a non magnetizable surface layer up to 0, -m are detectable.

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