Magnetic particle inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and slightly subsurface discontinuities

in ferroelectric materials such as iron, nickel, cobalt, and some of their alloys. The process puts a magnetic field into the part. The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs when the electric current is passed through the test object and a magnetic field is formed in the material. Indirect magnetization occurs when no electric current is passed through the test object, but a magnetic field is applied from an outside source. The magnetic lines of force are perpendicular to the direction of the electric current which may be either alternating current (AC) or some form of direct current (DC) (rectified AC). The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to leak. Ferrous iron particles are applied to the part. The particles may be dry or in a wet suspension. If an area of flux leakage is present the particles will be attracted to this area. The particles will build up at the area of leakage and form what is known as an indication. The indication can then be evaluated to determine what it is, what may have caused it, and what action should be taken, if any.
Contents
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1 Types of electrical currents used 2 Equipment 3 Demagnetizing parts 4 Magnetic particle powder

4.1 Magnetic particle carriers

5 Inspection 6 Standards 7 Further reading 8 References

[edit]Types

of electrical currents used

There are several types of electrical currents used in MPI. For a proper current to be selected one needs to consider the part geometry, material, the type of discontinuity one is looking for, and how far the magnetic field needs to penetrate into the part.

Alternating current (AC) is commonly used to detect surface discontinuities. Using AC to detect subsurface discontinuities is limited due to what is known as the skin effect, where the current runs along the surface of the part. Because the current alternates in polarity at 50 to 60 cycles per second it does not penetrate much past the surface of the test object. This means the magnetic domains will only be aligned equal to the distance AC current penetration into the part. The frequency of the alternating current determines how deep the penetration.

Direct current (DC, full wave DC) is used to detect subsurface discontinuities where AC can not penetrate deep enough to magnetize the part at the depth needed. The amount of magnetic penetration depends on the amount of current through the part.[1] DC is also limited on very large cross-sectional parts how effective it will magnetize the part.

Half wave DC (HWDC, pulsating DC) work similar to full wave DC, but allows for detection of surface breaking indications. HWDC is advantageous for inspection process because it actually helps move the magnetic particles over the test object so that they have the opportunity to come in contact with areas of magnetic flux leakage. The increase in particle mobility is caused by the pulsating current, which vibrates the test piece and particles.

Each method of magnetizing has its pros and cons. AC is generally always best for discontinuities open to the surface and some form of DC for subsurface. [edit]Equipment

A wet horizontal MPI machine with a 36 in (910 mm) coil

An automatic wet horizontal MPI machine with an external power supply, conveyor, and demagnetizing system; its used to inspect engine cranks.

A wet horizontal MPI machine is the most commonly used mass production inspection machine. The machine has a head and tail stock where the part is placed to magnetize it. In between the head and tail stock is typically an induction coil, which is used to change the orientation of the magnetic field by 90 from head stock. Most of the equipment is customized and built for a specific application.

Mobile power packs are custom-built magnetizing power supplies used in wire wrapping applications. Magnetic yoke is a hand-held devices that induces a magnetic field between two poles. Common applications are for outdoor use, remote locations, and weld inspection. The draw back of magnetic yokes are they only induce a magnetic field between the poles so inspection is time consuming are on large parts. For proper inspection the yoke needs to be rotated 90 degrees for every inspection area to detect horizontal and vertical discontinuities. Yokes subsurface detection is limited. These systems used dry magnetic powders, wet powders, or aerosol cans.

[edit]Demagnetizing

parts

A pull through AC demagnetizing unit

After the part has been magnetized its needs to be demagnetized. This requires special equipment that works the opposite of magnetizing equipment. Magnetizing is normally done with high current pulse that very quickly reaches a peak current and instantaneously turns off leaving the part magnetized. To demagnetize a part the current or magnetic field needed, has to be equal or greater than the current or magnetic field used to magnetized the part, the current or magnetic field then is slowly reduced to zero leaving the part demagnetized.

AC demagnetizing

Pull through AC demagnetizing coils: seen in Fig 3 are AC powered devices that generate a high magnetic field where the part is slowly pulled through by hand or on a conveyor. The act of pulling the part through and away from coil's magnetic field slows drops the magnetic field in the part. Note many AC demagnetizing coils have power cycles of several seconds so the part must be passed through the coil and be several feet (meters) away before the demagnetizing cycle finishes or the part will have residue magnetism.

AC step down demagnetizing: This is built in only a few MPI equipment, the process is where the part is subjected to equal or greater AC current, the current is reduced by X amps in several sequential pulses till zero current is reached. The number of steps required to demagnetizing a part is a function of amount current to magnetize the part.

Reversing DC demagnetizing: The simply reverses the current flow of magnetizing pulse canceling the magnetic flow. Note: This is built in the MPI equipment by the manufacturer.

[edit]Magnetic

particle powder

A common particle used to detect cracks is iron oxide, for both dry and wet systems.

Wet system particle range in size from <0.5 to 10 micrometres for use with water or oil carriers. Particles used in wet systems have pigments applied that fluoresce at 365 nm ( Ultraviolet A) requiring 1000 W/cm2 (10 W/m2) at the surface of the part for proper inspection. If the particles do not have the correct light applied in a Dark Room the particles can not be detected/seen. Its industry practices to use UV goggles/glasses to filter the UV light and amplify the visible light spectrum normally Green and Yellow created by the fluorescing particles. Green and Yellow fluorescence was chosen because the human eye reacts best to these colors.

Dry particle powders range in size from 5 to 170 micrometres, designed to be seen in white light conditions. The particles are not designed to be used in wet environments. Dry powders are normally applied using hand operated air powder applicators

Aerosol applied particles are similar to wet systems, sold in premixed aerosol cans similar to hair

spray. [edit]Magnetic

particle carriers

It is common industry practices to use specifically designed oil and water-based carriers for magnetic particles. Deodorized kerosene, andmineral spirits have not been commonly used in the industry for 40 years. It is very dangerous to use kerosene or mineral spirits as a carrier to due to their low flash points, and inhalation of fumes by the operators. [edit]Inspection

The following are general steps for inspecting on a wet horizontal machine: 1. Part is cleaned of oil and other contaminants 2. Necessary calculations done to know the amount of current required to magnetize the part. See ASTM E1444-05 for formulas.

3. The magnetizing pulse is applied for 0.5 seconds during which the operator washes the part with
the particle, stopping before the magnetic pulse is completed. Failure to Stop prior to end of the magnetic pulse will wash away indications.

4. UV light is applied the operator looks for indications of defects that are 0 to +/- 45 degrees from
path the current flowed through the part. Defects only appear that are 45 to 90 degrees the magnetic field. The easiest way to quickly figure out which way the magnetic field is running is grab the part with either hand between the head stocks laying your thumb against the part (do not wrap your thumb around the part) this is called either left or right thumb rule or right hand grip rule. The direction thumb points tell us the direction current is flowing, the Magnetic field will be running 90 degrees from the current path. On complex geometry like an engine crank the operator needs to visualize the changing direction of the current and magnetic field created. The current starts at 0 degrees then 45 degrees to 90 degree back to 45 degrees to 0 then -45 to -90 to -45 to 0 and repeats this for crankpin. So inspection can be time consuming to carefully look for indications that are only 45 to 90 degrees from the magnetic field. 5. The part is either accepted or rejected based on pre-defined accept and reject criteria 6. The part is demagnetized

7. Depending on requirements the orientation of the magnetic field may need to be changed 90
degrees to inspect for defects that can not be detected from steps 3 to 5. The most common way is change magnetic field orientation is to a use Coil Shot. in Fig 1 a 36 inch Coil can be seen then steps 4, 5, and 6 are repeated [edit]Standards International Organization for Standardization (ISO)

ISO 3059, Non-destructive testing - Penetrant testing and magnetic particle testing - Viewing conditions

ISO 9934-1, Non-destructive testing - Magnetic particle testing - Part 1: General principles ISO 9934-2, Non-destructive testing - Magnetic particle testing - Part 2: Detection media ISO 9934-3, Non-destructive testing - Magnetic particle testing - Part 3: Equipment ISO 17638, Non-destructive testing of welds - Magnetic particle testing

ISO 23279, Non-destructive testing of welds - Magnetic particle testing of welds - Acceptance levels

European Committee for Standardization (CEN)

EN 1330-7, Non-destructive testing - Terminology - Part 7: Terms used in magnetic particle testing EN 1369, Founding - Magnetic particle inspection EN 10228-1, Non-destructive testing of steel forgings - Part 1: Magnetic particle inspection EN 10246-12, Non-destructive testing of steel tubes - Part 12: Magnetic particle inspection of seamless and welded ferromagnetic steel tubes for the detection of surface imperfections

EN 10246-18, Non-destructive testing of steel tubes - Part 18: Magnetic particle inspection of the tube ends of seamless and welded ferromagnetic steel tubes for the detection of laminar imperfections

American Society of Testing and Materials (ASTM) ASTM E1444-05 ASTM A 275/A 275M Test Method for Magnetic Particle Examination of Steel Forgings ASTM A456 Specification for Magnetic Particle Inspection of Large Crankshaft Forgings ASTM E543 Practice Standard Specification for Evaluating Agencies that Performing Nondestructive Testing ASTM E 709 Guide for Magnetic Particle Testing Examination ASTM E 1316 Terminology for Nondestructive Examinations ASTM E 2297 Standard Guide for Use of UV-A and Visible Light Sources and Meters used in the Liquid Penetrant and Magnetic Particle Methods Canadian Standards Association (CSA) CSA W59

Society of Automotive Engineers (SAE) AMS 2641 Magnetic Particle Inspection Vehicle AMS 3040 Magnetic Particles, Nonfluorescent, Dry Method AMS 3041 Magnetic Particles, Nonfluorescent,Wet Method, Oil Vehicle, Ready-To-Use AMS 3042 Magnetic Particles, Nonfluorescent, Wet Method, Dry Powder AMS 3043 Magnetic Particles, Nonfluorescent, Wet Method, Oil Vehicle, Aerosol Packaged AMS 044 Magnetic Particles, Fluorescent, Wet Method, Dry Powder AMS 3045 Magnetic Particles, Fluorescent, Wet Method, Oil Vehicle, Ready-To-Use AMS 3046 Magnetic Particles, Fluorescent, Wet Method, Oil Vehicle, Aerosol Packaged5

AMS 5062 Steel, Low Carbon Bars, Forgings, Tubing, Sheet, Strip, and Plate 0.25 Carbon, Maximum AMS 5355 Investment Castings AMS I-83387 Inspection Process, Magnetic Rubber AMS-STD-2175 Castings, Classification and Inspection of AS 4792 Water Conditioning Agents for Aqueous Magnetic Particle Inspection AS 5282 Tool Steel Ring Standard for Magnetic Particle Inspection AS5371 Reference Standards Notched Shims for Magnetic Particle Inspection

United States Military Standard A-A-59230 Fluid, Magnetic Particle Inspection, Suspension [edit]Further

reading

Liquid Penetrant and Magnetic Particle Testing at Level 2, International Atomic Energy Agency, 2000 (pdf, 2.5 MB). [

Magnetic Particle Testing

The Magnetic Particle Inspection method of Non-Destructive testing is a method for locating surface and sub-surface discontinuities in ferromagnetic material. It depends for its operation on the face that when the material or part under test is magnetized, discontinuities that lie in a direction generally transverse to the direction of the magnetic field, will cause a leakage field, and therefore, the presence of the discontinuity, is detected by use of finely divided ferromagnetic particles applied over the surface, some of these particles being gathered and held by the leakage field, this magnetically held collection of particles forms an outline of the discontinuity and indicates its location, size, shape and extent. Dry magnetic particle examinations and wet fluorescent magnetic particle examinations are performed on ferromagnetic materials to detect surface and slight subsurface discontinuities. Specialized wet fluorescent magnetic particle techniques are available for black light internal examinations of equipment through borescopes.

Magnetic Particle Inspection

Magnetic particle inspection is a nondestructive inspection methods used for defect detection. The method is used to inspect a variety of product forms such as castings, forgings, and weldments. The only requirement from an inspectability standpoint is that the component being inspected must be made of a ferromagnetic material such iron, nickel or cobalt, or some of their alloys. Ferromagnetic materials are materials that can be magnetized to a level that will allow the inspection to be effective. Many different industries use magnetic particle inspection for determining a component's fitness-for-use.

Some examples of industries that use magnetic particle inspection are the structural steel, automotive, petro-chemical , power generation and aerospace industries. Underwater inspection is another area where magnetic particle inspection may be used to test such things as offshore structures and underwater pipelines. The magnetic particle inspection method along with liquid penetrant inspection is one of the oldest and most widely utilized forms of nondestructive testing currently in use today. Magnetic particle testing uses magnetic fields and small magnetic particles, such as iron filings to detect flaws in components. In theory, it is a relatively simple concept. When a bar magnetis broken in the center of its length, two complete bar magnets with magnetic poles on each end of each magnet will result. If the magnet were cracked but not broken completely in two, a north and south pole will form at each edge of the crack, just as though the break had been completed. If iron particles were then sprinkled on this cracked magnet, these particles will be attracted not only to the ends of the magnets poles but also to the edges of the crack. In magnetic particle inspection there are primarily two types of magnetic fields used to inspect parts, longitudinal and circular. Longitudinal magnetic fields are typically created by placing the part in a strong external magnetic field generated by a conducting copper wire that has been looped or wrapped to form a coil. A coil would be used to inspect such things as a steel rod or a valve from a car engine that might have cracks or inclusions in it. A magnetizing coils is a standard feature on a wet horizontal inspection unit but smaller field portable coils are also available. A wet horizontal unit is a large stationary piece of equipment that not only has head-shot and central conductor fixtures but also has a coil permanently mounted to it. The magnetic particles are held in a suspension of either water or oil and are supplied by a pump and hose on the system. These particles are of either the visible type, which means that they can be seen in normal white light, or the fluorescent type. Fluorescent particles require the use of a blacklight, which causes the particle indications to illuminate. This is much the same as causing a blacklight poster to glow in the dark.

Application of magnetic nano- and microparticles in biosciences

Separation technology is one of the most complex and important areas of biotechnology. Cost-effective separation techniques are a crucial factor in industrial biotechnology production or molecular biological routine diagnostic procedures. Biomagnetic separation techniques are becoming increasingly important with a wide range of possible applications in the biosciences. Magnetic micro- or nanospheres can be separated easily and quickly by magnetic forces and will be used together with bioaffine ligands, e.g. antibodies or proteins with a high affinity to the target. The targets can be cells, bacteria or DNA/RNA. The special advantages of magnetic separation techniques are the fast and simple handling of a sample vial and the opportunity to deal with large sample volumes without the need for time-consuming centrifugation steps. This also makes biomagnetic separation ideal for automated assay / analysis systems which will play a very important role in the near future.

Magnetic properties
Magnetic particles for bioseparation consist of one or more magnetic cores with a coating matrix of polymers, silica or hydroxylapatite with terminal functionalized groups. The magnetic core generally consists either of magnetite (Fe3O4) or maghemite (gamma Fe2O3) with superparamagnetic or ferromagnetic properties. On request, we can produce magnetic cores made with magnetic ferrites, such as cobalt ferrite or manganese ferrite. Superparamagnetism is when the dipole moment of a single-domain particle fluctuates rapidly in the core due to the thermal excitation so that there is no magnetic moment for macroscopic time scales. Thus, these particles are non-magnetic when an external magnetic field is applied but do develop a mean magnetic moment in an external magnetic field.

Superparamagnetic particles under the influence of an external magnetic field

Superparamagnetic particles in absence of an external magnetic field, monodisperse particle distribution In contrast, ferromagnetism means that the particles have a permanent mean magnetic moment. Here, the larger effective magnetic anisotropy suppresses the thermally activated motion of the core-moments.

Ferromagnetic particles under the influence of an external magnetic field

Ferromagnetic particles in absence of an external magnetic field, lattice form Advantages of the superparamagnetic particles are easy resuspension, large surface area, slow sedimentation and uniform distribution of the particles in the suspension media. Once magnetized, the particles behave like small permanent magnets, so that they form aggregates or lattice due to magnetic interaction. Advantages of ferromagnetic particles are very strong magnetic properties and therefore the fast separation with an external magnetic field even in viscous media.

We recommend ferromagnetic particles for the separation of DNA/RNA (SiMAG/MP-DNA), whereas superparamagnetic particles are more suitable for all other applications.

Definition of particle size

The particle size (particle diameter) is given as hydrodynamic diameter, which includes the core diameter and two times the diameter of the cover matrix. The hydrodynamic diameter is determined by Dynamic Light Scattering (DLS) also known as Photon Correlation Spectroscopy (PCS). As fluidMAG particles offer a very hydrophilic with water molecules filled polymer matrix a smooth transition appears between the matrix and the surrounding liquid of the suspension. Hence no exact defined surface edge is given. However SiMAG particles possess a solid cover matrix. Therefore a distinct transition between the solid matrix and liquid suspension medium exist and the hydrodynamic diameter is accurately determinable.

Definition of weight of volume

The weight of volume is defined by the amount of magnetic particles in gram per volume unit and is gravimetrically determined from a well measured volume of the suspension medium. The weight of volume is not identical with the particle concentration as the numbers of particles per volume unit in a suspension will change due to the force of gravity. Useful Literature

Magnetic Particle Inspection Explained

by Kevin Walker March 25, 2008

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This technique lends itself to automation and high-volume production inspectionand is less expensive than other more sophisticated methods of quality assurance.
Source: Magnaflux

By definition, nondestructive testing is the collective name given to repeatable processes applied to components or structures interrogate their integrity, in such a way as to not impair their ability to operate or perform.

At the turn of the 20th century, such tests were crude, relatively insensitive and not widely used. There was eyeball examinat

aided by low-power magnifying glasses. Also, hearing tests were performed by tapping metal parts with a hammer and listeni for any difference in the ringing sounds produced.

In the early 1920s, X-ray, which previously had been used only by physicians, was shown to be applicable to inanimate materials. While radiography can detect subsurface or interior defects in metals, a reliable, inexpensive testing method was greatly needed to locate surface cracks and discontinuities in high quantities of machine and structural parts.

That method was magnetic particle testing, based on the principle of using a piece of magnetized metal and applying magneti particles to find invisible defects, without harming the part in any way.

Magnetic particle inspection is a nondestructive test method that provides for the detection of linear, surface and near surface

discontinuities in ferromagnetic (material that can be magnetized) test materials. A linear indication is any indication having a length dimension at least 3-times greater than its width (L= 3 x > W).

FAQs

Here are some frequently asked questions about magnetic particle inspection:

Q: What are the advantages of magnetic particle inspection? A: The test method process is quick and simple in

This image is a bolt with a longitudinal crack.Source: Magnaflux

principle and application. It is highly sensitive to the detection of surface and slightly subsurface linear indications, and indications appear on the actual test part. The test method process may often work through contaminant layers and coating

thickness, and the method lends itself to automation and high-volume production inspection. Finally, it is less expensive than other more sophisticated methods of quality assurance.

Q: What are the limitations of magnetic particle inspection?

A: First, the test material must be ferrous. It provides limited and variable potential for detection of subsurface indications. Ca is required to avoid burning and arcing of test part surface at points of electrical contact. The magnetic field direction must intercept the major dimension of the discontinuity. Complex test part geometry may sometimes pose problems with correct

amperage determination and magnetic field intensity. Finally, demagnetization of the test part following the inspection is often necessary.

There are different types of magnetic particles: dry method non-fluorescent, wet method non-fluorescent and wet method fluorescent.

Q: What are the properties of dry powder and wet suspension magnetic particles?

A: They are iron oxide particles, finely divided in sizes varying between 0.125 and 60 microns with a high permeability (easily

magnetized) and low retentivity (ability to stay magnetized). Dry particles are chemically dyed to provide contrast against the

background of the test surface. Stock colors are gray, red, black and yellow. Application is either with a squeeze bulb or spray gun. Wet suspension particles are suspended in an oil-based or water-based liquid vehicle or carrier. With water, operators must add conditioners in addition to a wetting agent and corrosion inhibitors.

Q: What is the sensitivity comparison between wet vs. dry methods? A: Wet method provides improved sensitivity for the detection of very fine surface flaws. Dry method provides improved sensitivity for the detection of subsurface flaws.

This illustrates a bolt with a crack under the head.Source: Magnaflux

Q: What is the maximum depth that magnetic particles can detect a discontinuity? A: 1/4 inch, however 0.050 to 0.100 inch is a more realistic depth.

Magnetic particle inspection has a lot going for it. Along with being a quick test method, it is also less expensive than other mo sophisticated methods of quality assurance. ndt

Glossary Alternating Current (AC). Electric current flows through a conductor in a back and forth direction at specific intervals.

Note: It provides the best sensitivity for the detection of surface discontinuities only.

Direct Current (DC). Electric current flows through a conductor in only one direction at all times. Note: DC from a battery source has been phased out in favor of rectified forms of AC for surface and subsurface flaw detection. Flux Density (B). Magnetic field strength per unit volume within a ferromagnetic test part measured in gauss. Flux Field Penetration. The ability to establish and drive high-density magnetic lines of force deep into the test part. Full-Wave Rectified (FWDC). Electric current flows through a conductor in one direction only with an increased rate of

pulsating surges and drops at specific intervals. Note: FWDC is recommended for effective surface and subsurface flaw detecti when using the wet method of inspection.

Half-Wave Rectified (HWDC). Electric current flows through a conductor in one direction only with pulsating surges and

drops at specific intervalshence the name half wave. Note: It is most effective for surface and subsurface flaw detection whe using the dry powder method of inspection. Linear Indication. Any indication having a length dimension at least three times greater than its width. Magnetic Domains. Ferrous material atoms or molecules normally illustrated as small bar magnets with north and south poles. Magnetism. A form of energy directly associated with electrical current, and characterized by fields or lines of force. Magnetizing Force (H). Magnetic field strength per unit volume in air, measured in oersteds. Particle Mobility. The ability to establish activity or motion to the magnetic particles applied to the test part surface. Permeability. The ease with which a material can be magnetized. The ability of a material to conduct magnetic lines of force. Reluctance. The opposition of resistance by a material to conduct magnetic lines of force. Retentivity. The ability of a material to retain magnetic lines of force following magnetization.

Right Hand Rule. Magnetic lines of force will always travel perpendicular or 90 degrees to the direction of electrical curren flow.