Magnetic particle inspection

Magnetic particle Inspection (MPI) is a nondestructive testing (NDT) process for detecting surface
and slightly subsurface discontinuities in ferromagnetic
materials such as iron, nickel, cobalt, and some of
their alloys. The process puts a magnetic eld 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 eld is formed in the material. Indirect
magnetization occurs when no electric current is passed
through the test object, but a magnetic eld 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) (rectied AC).

A close-up of the surface of a (dierent) pipeline showing indications of stress corrosion cracking (two clusters of small black
lines) revealed by magnetic particle inspection. Cracks which
would normally have been invisible are detectable due to the
magnetic particles clustering at the crack openings. The scale
at the bottom is numbered in centimetres.

1 Types of electrical currents used

There are several types of electrical currents used in Magnetic particle inspection. 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 eld 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 eect, 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.

A technician performs MPI on a pipeline to check for stress corrosion cracking using what is known as the black and white
method. No indications of cracking appear in this picture; the
only marks are the 'footprints of the magnetic yoke and drip
marks.

The presence of a surface or subsurface discontinuity in

the material allows the magnetic ux to leak, since air
cannot support as much magnetic eld per unit volume
as metals. Ferrous iron particles are then applied to the
part. The particles may be dry or in a wet suspension.
If an area of ux 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.

Full Wave DC (FWDC, 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 crosssectional parts in terms of how eectively 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 and has more magnetic penetration into the part than FWDC. HWDC is advantageous for inspection process as it actually helps

A popular name for magnetic particle inspection is or

used to be magnauxing; The company of the same name
was one of the early manufacturers of equipment and materials for the process.
1

3
move the magnetic particles during the bathing of
the test object. The aid in particle mobility is caused
by the half-wave pulsating current waveform. In
a Typical mag pulse of 0.5 seconds there are 15
pulses of current using HWDC. This gives the particle more of an opportunity to come in contact with
areas of magnetic ux leakage.

Each method of magnetizing has its pros and cons. AC is

generally the best for discontinuities on the surface, while
some form of DC is better for subsurface defects.

Equipment

DEMAGNETIZING PARTS

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 eld
by 90 from head stock. Most of the equipment is
customized and built for a specic application.
Mobile power packs are custom-built magnetizing
power supplies used in wire wrapping applications.
Magnetic yoke is a hand-held device that induces a
magnetic eld between two poles. Common applications are for outdoor use, remote locations, and
weld inspection. The draw back of magnetic yokes
is that they only induce a magnetic eld between the
poles so large-scale inspections using the device can
be time-consuming. 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.

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

Using a similar machine, a U.S. Navy technician sprays

magnetic particles on a test part under ultraviolet light.

A pull through AC demagnetizing unit

An automatic wet horizontal MPI machine with an external

power supply, conveyor, and demagnetizing system; it is used to
inspect engine cranks.

A wet horizontal MPI machine is the most commonly used mass production inspection machine.

After the part has been magnetized it needs to be demagnetized. This requires special equipment that works the
opposite way of the magnetizing equipment. The magnetization is normally done with a high current pulse that
reaches a peak current very quickly and instantaneously
turns o leaving the part magnetized. To demagnetize a
part, the current or magnetic eld needed has to be equal
to or greater than the current or magnetic eld used to
magnetize the part. The current or magnetic eld is then
slowly reduced to zero, leaving the part demagnetized.
AC demagnetizing

3
Pull through AC demagnetizing coils: seen in 4 Magnetic particle powder
the gure to the right are AC powered devices
that generate a high magnetic eld where the A common particle used to detect cracks is iron oxide,
part is slowly pulled through by hand or on a for both dry and wet systems.
conveyor. The act of pulling the part through
and away from the coils magnetic eld slows
Wet system particle range in size from less than 0.5
drops the magnetic eld in the part. Note that
to 10 micrometres for use with water or oil carriers.
many AC demagnetizing coils have power cyParticles used in wet systems have pigments applied
cles of several seconds so the part must be
that uoresce at 365 nm (ultraviolet A) requiring
passed through the coil and be several feet
1000 W/cm2 (10 W/m2 ) at the surface of the part
(meters) away before the demagnetizing cycle
for proper inspection. If the particles do not have
nishes or the part will have residual magnetithe correct light applied in a darkroom the particles
zation.
cannot
be detected/seen. It is industry practice to
AC Decaying demagnetizing: this is built into
use
UV
goggles/glasses to lter the UV light and ammost single phase MPI equipment. During
plify
the
visible light spectrum (normally green and
the process the part is subjected to an equal
yellow)
created
by the uorescing particles. Green
or greater AC current, after which the current
and
yellow
uorescence
was chosen because the huis reduced over a xed period of time (typiman
eye
reacts
best
to
these
colors.
cally 18 seconds) until zero output current is
reached. As AC is alternating from a positive
to a negative polarity this will leave the magnetic domains of the part randomized.
AC Demag does have signicant limitations on
its ability to demag a part depending on the
geometry and the alloys used.
Reversing Full Wave DC demagnetizing: this is a
demagnetizing method that must be built into the
machine during manufacturing. It is similar to AC
decaying except the DC current is stopped at intervals of half a second, during which the current is
reduced by a quantity and its direction is reversed.
Then current is passed through the part again. The
process of stopping, reducing and reversing the current will leave the magnetic domains randomized.
This process is continued until zero current is passed After applying wet magnetic particles, a U.S. navy technician exthrough the part. The normal Reversing DC demag amines a bolt for cracks under ultraviolet light.
cycle on modern equipment should be 18 seconds
or longer. This method of demag was developed
to overcome the limitations presented by the AC
Dry particle powders range in size from 5 to 170
Demag method where part geometry and certain almicrometres, designed to be seen in white light conloys prevented the AC Demag method from workditions. The particles are not designed to be used
ing.
in wet environments. Dry powders are normally applied using hand operated air powder applicators.
Halfwave DC demagnetizing (HWDC): this process
is identical to full-wave DC demag except the wave Aerosol applied particles are similar to wet systems,
form is halfwave. This method of demagnetization
sold in premixed aerosol cans similar to hair spray.
is new to the industry and only available from a single manufacturer. It was developed to be a costeective method to demagnetize without needing
a full-wave DC bridge design power supply. This 4.1 Magnetic particle carriers
method is only found on single-phase AC/HWDC
power supplies. HWDC demag is just as eective as It is common industry practice to use specically defull-wave DC without the extra cost and added com- signed oil and water-based carriers for magnetic particles.
plexity. Of course, other limitations do apply due to Deodorized kerosene and mineral spirits have not been
inductive losses when using HWDC waveform on commonly used in the industry for 40 years. It is very
large-diameter parts. Also, HWDC eectiveness is dangerous to use kerosene or mineral spirits as a carrier
limited past 16 inches in diameter using a 12-volt due to their low ash points, and inhalation of fumes by
the operators.
power supply.

6 STANDARDS

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. Refer ASTM
E1444/E1444M 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.

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 10893-5, Non-destructive testing of steel tubes.
Magnetic particle inspection of seamless and welded
ferromagnetic steel tubes for the detection of surface
imperfections
ISO 17638, Non-destructive testing of welds - Magnetic particle testing

ISO 23279, Non-destructive testing of welds - Mag4. UV light is applied while the operator looks for innetic particle testing of welds - Acceptance levels
dications of defects that are 0 to +/- 45 degrees from
path the current owed through the part. Indica- European Committee for Standardization (CEN)
tions only appear 45 to 90 degrees of the magnetic
eld applied. The easiest way to quickly gure out
EN 1330-7, Non-destructive testing - Terminology which way the magnetic eld is running is grab the
Part 7: Terms used in magnetic particle testing
part with either hand between the head stocks laying your thumb against the part (do not wrap your
EN 1369, Founding - Magnetic particle inspection
thumb around the part) this is called either left or
right thumb rule or right hand grip rule. The direc EN 10228-1, Non-destructive testing of steel forgings
tion the thumb points tell us the direction current is
- Part 1: Magnetic particle inspection
owing, the Magnetic eld will be running 90 degrees from the current path. On complex geometry American Society of Testing and Materials (ASTM)
like an engine crank the operator needs to visualize the changing direction of the current and magnetic eld created. The current starts at 0 degrees
ASTM E1444/E1444M Standard Practice for Magthen 45 degrees to 90 degree back to 45 degrees to
netic Particle Testing
0 then 45 to 90 to 45 to 0 and repeats this for
crankpin. So inspection can be time consuming to
ASTM A 275/A 275M Test Method for Magnetic
carefully look for indications that are only 45 to 90
Particle Examination of Steel Forgings
degrees from the magnetic eld.
ASTM A456 Specication for Magnetic Particle In5. The part is either accepted or rejected based on prespection of Large Crankshaft Forgings
dened accept and reject criteria.
ASTM E543 Practice Standard Specication for
6. The part is demagnetized.
Evaluating Agencies that Performing Nondestructive Testing
7. Depending on requirements the orientation of the
magnetic eld may need to be changed 90 degrees
to inspect for indications that can not be detected
from steps 3 to 5. The most common way to change
magnetic eld orientation is to use a Coil Shot. In
Fig 1 a 36 inch Coil can be seen then steps 4, 5, and
6 are repeated.

Standards

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

International Organization for Standardization (ISO) Canadian Standards Association (CSA)

CSA W59
ISO 3059, Non-destructive testing - Penetrant testing
and magnetic particle testing - Viewing conditions

Society of Automotive Engineers (SAE)

5
AMS 2641 Magnetic Particle Inspection Vehicle
AMS 3040 Magnetic Particles, Nonuorescent, Dry
Method
AMS 3041 Magnetic Particles, Nonuorescent, Wet
Method, Oil Vehicle, Ready-To-Use
AMS 3042 Magnetic Particles, Nonuorescent, Wet
Method, Dry Powder
AMS 3043 Magnetic Particles, Nonuorescent, 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, Classication 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

References

[1] Betz, C. E. (1985), Principles of Magnetic Particle Testing

(PDF), American Society for Nondestructive Testing, p.
234, ISBN 978-0-318-21485-6.

Further reading
Liquid Penetrant and Magnetic Particle Testing at
Level 2 (PDF) (PDF). International Atomic Energy
Agency. 2000.

External links
Video on Magnetic Particle Inspection, Karlsruhe
University of Applied Sciences

10

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