Magnetic Particle Testing

Magnetic particle testing
* principle of magnetic particle testing
* basics of electricity
* basics of magnetism
* equipment for magnetizing

* methods for magnetizing
* test fluid
* documentation of indications
* methods to demagnetize
O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing ; fl

No reproduction without prior permission! '.A
principle of magnetic particle testing
applicable for
surface defects
surface near defects
ferromagnetic materials (Fe, Co, Ni)
principle of function:
generation of a magnetic field in the test object
permanent magnet
O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

No reproduction without prior permission!
yoke magnetization
O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

magnetic leakage field at a surface crack
the magnetic resistance of air is higher than the magnetic resis-

tance of ferromagnetic materials.
permeability of air:
Pr,air =1
permeability of ferromagnetic materials:

Fe-CO-alloys: vr = 2000 - 6000
Fe-Ni-alloys: p, = 15 000 - 300 000
castings: p r = 350- 1400

detection of magnetic leakage fields

with the help of magnetic inspection powder
magnetic inspection powder:

iron (grey)
Fe203 (rust red)
Fe304 (black)
magnetic inspection powder is applied dry when testing at high

temperatures (up to 300•‹C)
magnetic inspection powder is prayed onto the surface in form of a
suspension
. cle
white, quick drying varnish improves the contrast for magnetic parti-
testing
p~ - -

ntals of electricit
the electric circuit
current
lamp with
) resistance R
/
'
conductor
fundamentals of electricity
I electric loading
electric charge
Q = nxe, e=1,602xl 0-l9C
= elemental load)
1 electron has a load of
-1,602~1 0-l' C
amperage Amount of moving loading per
time unit
1A = 1Cls
electric voltage aim to equalise different loads
I
electric resistance I resistance against movement

of loads
specific resistance characteristic property of a
material for the calculation of
1 electric power
its electric resistance
the electric power can be
transformed in mechanical
energy, in heat (welding
equipment) or in electro-
chemical processes (electro-
plating)

No reproduction without prior permiss~on!
A conductor made of copper with a length of 2m and a cross-section of A = 70

mm2
Please calculate the resistance of the conductor!
solution: the specific resistance of copper is:
material p [flmmLlm]
aluminium 0,0278
lead -
0.208
iron 0,1
gold 0,0222
copper 0,0175
specific resistance of different materials.

please calculate the amperage in the conductor of example 1! The directed cur-
rent is 1V.
solution: I = UIR
Attention!
Depending on the conductor cross-section it leads to a amperage of 29 ~ l m m * .

the conductor has to have a sufficient cross-section.
please calculate the electric power which is transformed in heat in the conduc-
tor in example 2!
solution: Pel= U x 1 = 1 V x 2000 A = 2000 W

basics of magnetism
lines of magnetic flux in different magnets
picture of iron filings at a bar magnet
lines of magnetic flux at a bar magnet (schematic).
lines of magnetic flux at a horseshoe magnet in two views (schematic)

model of magnetising ferromagnetic materials
statistic orientation of magnetic elemental magnets in nonmagnetic material.
statistic orientation of magnetic elemental magnets in magnetized material.
density of lines
of magnetic flux
[magnetic field saturation
in the material)
-
field strength H [Nm]
(electric generated
magnetic field)
saturation I
hysteresis curve (schematic)

the electromagnet
direction of magnetic field
actor
i
direction of the current
,,right hand rule" - magnetic field around a conductor
lines of magnetic field in a conducted coil (schematic)

Magnetic particle testing 12
characteristics of a magnetic field
formula 1 dimension designation meaning
magnetic flux all lines of the mag-

netic flux
density of lines number of lines of
of magnetic flux magnetic flux per unit
of area
field strength cause for the mag-
netic flux, e.g. electric
magnet
absolute coeffi- PO=~ T T Iom7
cient of magnetic
fields
relative perme- characteristic value of
ability a material which de-
scribes the conduc-
tivity of a material for
the magnetic flux e.g.
Fe-Ni-alloys:
-
(1, = 15 000 300 000
castings:
U, = 350 - 1400
important formula: B = po x prx H

field direction
absence of leakage field in the case of identical directions of the magnetic field
and the orientation of the defect .
direction of the
t~rnagneticflux
mientati on
of the defect
directions of detectable imperfections.
detection of imperfections in all orientations by magnetizing

in two directions approximately perpendicular
63 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

methods to magnetize
DIN 54 130 shows a table of different methods to magnetize and the nota-
tions
I methods of magnetizing notation

yoke magnetizing permanent yoke magnet I
--electric yoke magnet JE
magnetizing with a con- coil LS
ductor other conductors (ca- LK
--bles)
magnetizing by con- using prods (electrodes) SS
ducted test object I SI
-inductive

yoke magnetizing (JE)
ongitudinal crack
,-/ magnetic field
position of the likbs of a yoke magnet for detecting imperfections in all

directions in one examination area.

equipment:
control of the suspen- iece field strength: 2-6 KA/m

sion:
testing parameters: I
viewing conditions: >
deviations from test specification:
I acceptable acc. to the standard &ot acceptable acc. to the standard

1
date and place of examina-
tion:
1 examiner:

Magnetic particle testing 17
back of the test report

Magnetic particle testing side 18
magnetizing by conducted cables
a) magnetizing with coils (LS)
C-ccC---I-- lines of
4 magnetic field
r'
4
I
€
*---
testobject
b) other conductors (cable) (LK )
* . . .
. ) I . *
. . . I
. I . . " . * .
1 . w .
. . .
I
*
.
.
"
.
.
I
e
* * C 1 .
O 2001 SLV Duisburg Niederlassung der GSImbH Magnetic particle testing

magnetizing by using prods (electrodes) (SS)
prods for magnetic particle testing by conducting the test object.
crack
lines of magnetic field when magnetizing by using prods.
02001 SLV Duisburg Niederlassung dcr GSImbH Magnetic particle testing

f\ '
4
20 bis 30•‹
k
examining a butt weld for longitudinal cracks by magnetizing with prods.
examining a butt weld for transverse cracks by magnetizing with prods.
Attention! - bad contact between prods and surface of the testobject

can cause sparks leading to cracks because of superheating this
area.
O 2001 SLV Duisburg Nicderlassung der GSImbH Magnetic particle testing

No rcproduclion without prior permission!
b) induction current for testing (SI)
testing r ing-shaped
~ testobjects by means of inducticIn current
O 2001 SLV Duisburg Niedcrlassung dcr GSImbH Magnetic particle testing

No reproduction without prior pcmission!
combined processes :
test object
combination of magnetization by a current and a yoke for testing longitudinal

and transverse cracks in a test object.

field strength
low field strength -+ weak leakage field
field strength too high -+indication of surface roughness

(false indication)
,,the density of magnetic flux in the surface of a test object should be not less
than 1 T. This den tic flux is reached in low carbon steels by
applying a field stren
measuring instrument with hall probe for the field strength.

No reproduction w~thoutprior permission!
the magnetic particle suspension
suspensions:
* the magnetic inspection powder is mixed in a carrier liquid (e.g. water).

* the average grain size breadth or the expected cracks.
* fluorescent powder send out a yellow-green light when it is radiated with
ultraviolet rays. The intensity of the radiation should be at least 10 w/m2 .
(prEN 1956).
* the magnetic particle suspension can be applied with a spray tin (from a
producer) or it can be poured over the surface (self mixed suspensions).
dry powder:
* applicable for high temperatures up to 300•‹C(e.g. testing interpasses of

multilayer welds at a high temperature)
checking the magnetic particle suspension:
* magnetic test pieces with artificial cracks show a typical pattern of cracks
when they are wetted with the magnetic particle suspension.
test piece No. 3 (MTU-test piece)

No reproductton without prior permission!
the application of the magnetic particle suspension
post-magnetization
on
off
period of on
magnetization off

N o reproduction without prior permission!
recording of indications
description in writing
sketches with zero-point and scale (clear definition of orientation
and size of indications
photography
transparent adhesive tape
a
transparent varnish for ,,freezing the indication on the surface
tested.
video-recording -
magnetic tapes
e.g. for shafts
electronic scan
O 2001 SLV Du~sburgNiedcrlassung der GSImbH Magnetic particle testing

No reproduct~onwithout pnor p m ~ s s ~ o n l
remanence in the testobject can have negative effects:
* deflection of the arc when welding

* magnetic filings when machining the test object (bad quality of
the surface)
-+ demagnetising
density of
magnetic field B
A
-
strength H
time t
demagnetization by changing the direction of the magnetic

field and simultaneous decreasing the field strength.

Standards relating to the magnetic particle inspection
viewing conditions for penetrant testing

and magnetic particle testing (august 1995)
testing with UVA-radiation at 365 nm +, 20 nm

the lamp has to be switched on 10 minutes beaver testing
minimum UVA-radiation: 10 wlm2
intensity of illumination less then 20 Lx for fluorescent testing
intensity of illumination for testing with colour contrast
measuring instruments have to be calibrated after a period of 24 month
magnetic particle testing

general basics
personnel has to be qualified and certified according to EN 473.

the tested area has to be free from contaminations like dirt, cinder, spatters,
grease and oil.
the thickness of coatings should not exceed 50 pm.
the minimum value of the density of the magnetic field should be 1 Tesla - at
low-carbon steels it leads to a field strength of 2 kA/m (or 20 Alcm).
an imperfection can be detected when the angle of its major axis with respect
to the direction of the magnetic field is more then 30".
how to prove the correct magnetization:
* test pieces with small natural or artificial defects
* measuring the field strength as near as possible on the surface
* calculating

No reproduclion without prior permission!
a tenside effects a better wetting ability if water is used as carrier liquid.

when testing with colour contrast the intensity of illumination must exceed
500 Ix
the UV lamp has to be switched on at least 5 minutes before testing.
linear indications have a length greater than three times its with.
non linear indications have a length less than, or equal to three times its with
information to the test report

formula to the calculation of the field strength.
extend of examination (depending on the material).

linear indications which can be attributed to separation of the material are not
permissible.
isolated pores are permissible.
content of a test report
AD HP 513 - appendix 1
the weld and the heat affected zone shall be clean and free from scale.
is there any suspection of cracks or if cracks have already appeared, the test
shall be performed on surfaces which have be ground.
direction of magnetisation: 2 different direction which should differ from each
other by 90"
field strength 2kAlm - 6,5 kA/m
overheated areas should be avoided. If they nevertheless occur they shall be
tested with yoke magnetization.
O 2001 SLV Duisburg Nicderlassung dcr GSImbH Magnetic particle testing

No rcproduct~onwithout prior permission!
prEN I S 0 9934-3
equipment for the magnetic particle testing
DIN 1690 part 2
magnetic particle testing of casts
DIN EN 10228-1
magnetic particle testing of forged pieces

No reproductmn without prior permission!

Magnetic Particle Testing

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Magnetic Particle Testing

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Magnetic particle testing

Magnetic particle testing

* principle of magnetic particle testing

* equipment for magnetizing

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing ; fl

principle of magnetic particle testing

generation of a magnetic field in the test object

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

magnetic leakage field at a surface crack

the magnetic resistance of air is higher than the magnetic resis-

permeability of ferromagnetic materials:

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

detection of magnetic leakage fields

magnetic inspection powder:

magnetic inspection powder is applied dry when testing at high

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

the electric circuit

electric resistance I resistance against movement

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

A conductor made of copper with a length of 2m and a cross-section of A = 70

Please calculate the resistance of the conductor!

solution: the specific resistance of copper is:

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

Depending on the conductor cross-section it leads to a amperage of 29 ~ l m m * .

solution: Pel= U x 1 = 1 V x 2000 A = 2000 W

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

lines of magnetic flux in different magnets

picture of iron filings at a bar magnet

lines of magnetic flux at a bar magnet (schematic).

lines of magnetic flux at a horseshoe magnet in two views (schematic)

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

model of magnetising ferromagnetic materials

statistic orientation of magnetic elemental magnets in nonmagnetic material.

statistic orientation of magnetic elemental magnets in magnetized material.

hysteresis curve (schematic)

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

direction of magnetic field

,,right hand rule" - magnetic field around a conductor

lines of magnetic field in a conducted coil (schematic)

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

characteristics of a magnetic field

formula 1 dimension designation meaning

magnetic flux all lines of the mag-

important formula: B = po x prx H

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

directions of detectable imperfections.

detection of imperfections in all orientations by magnetizing

63 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

I methods of magnetizing notation

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

yoke magnetizing (JE)

,-/ magnetic field

position of the likbs of a yoke magnet for detecting imperfections in all

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

control of the suspen- iece field strength: 2-6 KA/m

deviations from test specification:

I acceptable acc. to the standard &ot acceptable acc. to the standard

O 2001 SLV Duisburg Niederlassung der GSlrnbH Magnetic particle testing

back of the test report

O 2001 SLV Duisburg Niederlassung der GSlmbH Magnetic particle testing

magnetizing by conducted cables