ME367
by Dr. Mubarak Ali, TKMCE
Non Destructive Testing
Module 3
Magnetic Particle Inspection
by Dr. Mubarak Ali
Assistant Professor
Department of Mechanical Engineering
TKM College of Engineering, Kollam
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 22
Introduction
by Dr. Mubarak Ali, TKMCE
• Magnetic Particle inspection is governed by the laws of
magnetism and is therefore restricted to the inspection of
materials that can support Magnetic flux lines. Materials are
generally classified as
• Ferromagnetic: are those that are strongly attracted to a
magnet and can become easily magnetized eg: Fe,Ni,Co
• Paramagnetic: Materials are those that are weekly attracted
by magnetic force of attraction. eg: Austenitic Stainless steel
• Diamagnetic: Materials are slightly repelled by a magnet and
cannot be [Link]: Bi,Au,Sb
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• Magnetic particle inspection (MPI) is a non-destructive testing method used
for defect detection. MPI is fast and relatively easy to apply, and part
surface preparation is not as critical as it is for some other NDT methods.
These characteristics make MPI one of the most widely utilized non-
by Dr. Mubarak Ali, TKMCE
destructive testing methods.
• The method is used to inspect a variety of product forms including castings,
forgings, and weldments. 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, petrochemical, power generation, and aerospace industries.
• Underwater inspection is another area where magnetic particle inspection
may be used to test items such as offshore structures and underwater
pipelines.
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Principles of MPI
by Dr. Mubarak Ali, TKMCE
• In theory, magnetic particle inspection (MPI) is a relatively simple concept.
It can be considered as a combination of two non-destructive testing
methods: magnetic flux leakage testing and visual testing.
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Fine Iron Particles with Bar Magnet
by Dr. Mubarak Ali, TKMCE
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 23
Fine Iron Particles with Horse Shoe Magnet
by Dr. Mubarak Ali, TKMCE
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Flux Leakage
by Dr. Mubarak Ali, TKMCE
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Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 25
• When a bar magnet is broken in the center of its length, two complete bar
magnets with magnetic poles on each end of each piece will result. If the
magnet is just cracked but not broken completely in two, a north and south
pole will form at each edge of the crack. The magnetic field exits the north
by Dr. Mubarak Ali, TKMCE
pole and re enters at the south pole.
• When the field spreads out, it appears to leak out of the material and, thus
is called a flux leakage field.
• If iron particles are sprinkled on a cracked magnet, the particles will be
attracted to and cluster not only at the poles at the ends of the magnet, but
also at the poles at the edges of the crack. This cluster of particles is much
easier to see than the actual crack and this is the basis for magnetic particle
inspection.
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MPI
by Dr. Mubarak Ali, TKMCE
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 26
Magnetic Particle Inspection
by Dr. Mubarak Ali, TKMCE
M
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 27
Types of defects that can be identified by MPI
by Dr. Mubarak Ali, TKMCE
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 28
Basic Physics of Magnetism
1. Polarity: Polarity refers to the orientation of north and south
poles space
by Dr. Mubarak Ali, TKMCE
[Link] force: It is a force of attraction or repulsion that one
body has upon another
3. Magnetic field: It is the area around a magnet which the
magnetic forces are Observable
4. Permeability: Permeability is the case with which a material
can be magnetised .Exp---µ=B/H (henry per meter H/M)
5. Flux Density: Flux density is defined as the number of lines of
force per unit area. Measured in Gauss (B)
[Link] Force: The total number of line of force making
up a magnetic field determines the strength of the force of
attraction or repulsion that can be exerted by magnet. Exp—(H)
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7. Coercive Force: Is a measure of Ability of a ferromagnetic
material to withstand an external magnetic field without becoming
demagnetised.
by Dr. Mubarak Ali, TKMCE
8. Retentivity: The ability of a coil to retain some of its magnetism
within the core after the magnetism process has stopped is known
as retentivity.
9. Hysteresis Loop: By exposing an magnetised piece to magnetic
current. We can plot the flux density B of the field induced by the
applied magnetizing force H and the resultant curve is called the
hysteresis loop.
[Link] Magnetism: It is defined as the amount of magnetism
left behind after removing the eternal magnetic field from the
circuit. 7
Methods of Magnetisation
by Dr. Mubarak Ali, TKMCE
The Basic principles of magnetisation is to produce magnetic lines of force
across the expected direction of cracks. If the likely crack direction is
unknown , then test must be performed in two directions at right angles.
The basic magnetisation methods are.
Magnetic Flow: To make the component of a magnetic circuit by effectively
using it as the bridge of a permanent or electromagnet.
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Current flow: To pass an electric current through the specimen,
broadly along the direction and through the region in which
by Dr. Mubarak Ali, TKMCE
cracks are to be expected.
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Induced current flow: Used for ring specimens, by effectively
making them the secondary of a main transformer. This method
has no application to weld inspection.
by Dr. Mubarak Ali, TKMCE
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Electromagnetic Induction: To pass an electric current through a
conductor which is threaded through a hollow specimen or placed
adjacent to or wrapped around it.
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Magnetization Techniques
by Dr. Mubarak Ali, TKMCE
1. Head Shot Technique:
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[Link] Shot Technique
by Dr. Mubarak Ali, TKMCE
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3. Central Conductor Technique
by Dr. Mubarak Ali, TKMCE
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4 Magnetisation Using yoke:
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Magnetization Techniques
by Dr. Mubarak Ali, TKMCE
There are 4 techniques of Magnetization
1. Head Shot Technique
2. Coil Shot Technique
3. Central Conductor Technique
4. Magnetization using yoke
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 29
Methods of Magnetization
by Dr. Mubarak Ali, TKMCE
There are two methods of Magnetization
1. Direct Method of Magnetization
2. Indirect Method of Magnetization
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 30
Direct Method of Magnetization
by Dr. Mubarak Ali, TKMCE
• Current is passed directly through the component
• Flow of current causes circular magnetic field in and around the
conductor
• Direction of magnetic field is given by right hand rule
• The strength of the induced magnetic field is proportional to the
amount of current passed through the component.
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 31
Contd…
by Dr. Mubarak Ali, TKMCE
Commonly used Direct Methods of Magnetization are
1. Clamping the component between two electrical conductor (Head
shot Technique)
2. Using prods or clamps
(Head shot Technique)
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 32
Contd…
by Dr. Mubarak Ali, TKMCE
Using Prods or Clamps
• Prods are made from copper and have insulated handle.
• One of the Prods has a trigger switch so that the current can be quickly turned
ON/OFF
• Sometimes the two prods are connected by an insulated so that it can be handled
by one hand. Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 33
Disadvantages of Direct Method of
Magnetization
by Dr. Mubarak Ali, TKMCE
• Very good electrical contact must be established and maintained
between the test equipment and test component
• If the electrical contact is not good, then it leads to
(a) Overheating of the components
(b) Arching at high resistance points
In head shot technique, the head can cause a burn in the a
part if the high current is passing through a small contact area
To avoid this,
1) the contact faces on the heads should be flexible and
2) the tips of the prods should have a low melting point in order to
spread the thermal load.
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 34
Indirect Method of Magnetization
by Dr. Mubarak Ali, TKMCE
Indirect Magnetization is accomplished by using a strong
external magnetic field to establish a magnetic field within
the component.
Different methods of Indirect Magnetization are
1. Using Permanent Magnet
2. Using Electromagnets Yoke
3. Using Central Conductor
4. Using Coils or Solenoids
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 35
Using Permanent Magnet
by Dr. Mubarak Ali, TKMCE
Refer:
[Link]
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 36
Using Electromagnet Yoke
by Dr. Mubarak Ali, TKMCE
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 37
Using Central Conductor
by Dr. Mubarak Ali, TKMCE
• Circular magnetic field can be produced in cylindrical components
using a central conductor.
• Conductor carrying high amperage current is passed through the
cylindrical component
• Circular magnetic field
is produced
• Reveals radial and
longitudinal defects
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 38
Using Coils or Solenoids
by Dr. Mubarak Ali, TKMCE
When the length of the component is several times larger than its
diameter then we can produce longitudinal magnetic field
Dr. Mubarak Ali, Mechanical Engineering TKMCE, Kollam 39
