Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.

: Mohammad Hassan Abdel‐Gawad 

       
 

MAGNETIC PARTICLE TEST

(MT)
LEVEL II

Prepared by:
Eng.: Mohammad Hassan Abdel-Gawad

1 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
CH 1: Introduction to Magnetic Particle Testing
INTRODUCTION
Magnetic particle testing is a relatively easy and simple test method that can be applied at various
stages of manufacture and processing operations.

The objective of magnetic particle testing is to insure product reliability by providing a means of:

a) Obtaining a visual image of an indication on the surface of a material.

b) Disclosing the nature of discontinuities without impairing the material.
c) Can detect both surface and near sub-surface defects.
d) Precleaning of components is not as critical as it is for some other inspection methods.
e) Fast method of inspection and indications are visible directly on the specimen surface.
f) Considered low cost compared to many other NDT methods.
g) Is a very portable inspection method especially when used with battery powered equipment.
Limitations of magnetic particle testing:
– Nonmagnetic materials cannot be tested.
– Magnetic particle testing will not detect discontinuities that are deeper than approximately
¼'' below the surface.
– Post cleaning, and post demagnetization is often necessary.

Theory of Magnetization

 An object is magnetized when part or all of its magnetic domains have their north and south
poles oriented as in the sketch below.

 The ability of a magnet to attract or repel is concentrated at the local areas called poles. The
north and south poles exhibit attraction and repulsion as shown below.
 

 
2 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 
 
 
 

 With all of magnetic domains lined up, the magnetic bar develops total force = Sum of all of the
magnetic domains 
 These are the magnetic lines of force which form a closed loop or circuit 
 All of the lines of force make up the magnetic field.
 Magnetic flux is made up of all of the lines of force.
 magnetic flux: Force that attracts other magnetizable materials to the magnetic poles.
 Magnet will attract other magnetizable material
only where the lines of force leave or enter the
magnet.
 If a magnet is bent into a complete loop as shown
below, the magnetic field is completely inside
material, thus no external force.
 A crack in the circular magnet will disrupt the flow of lines of force and create a flux leakage. 

 Leakage fields (flux leakage) are actually magnetic lines of force that leave the part and pass
through air from one pole to the other of opposite polarity.
 Whenever the leakage field is forced out of the part, iron particles would be attracted
showing an indication of a discontinuity.
 Even some subsurface discontinuities may be detected if the leakage field is strong enough
as shown below.

3 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 

Magnetic Materials
 Diamagnetic metals: have a small and negative susceptibility to magnetization (slightly
repelled).

– Copper, silver, and gold are examples of diamagnetic materials.

 Paramagnetic metals: have a small and positive susceptibility to magnetization (slightly

attracted).

– Magnesium, molybdenum, lithium, and tantalum are examples.

 Ferromagnetic metals: have a large and positive susceptibility to magnetization.

They have a strong attraction and are able to retain their magnetization after the
magnetizing field has been removed.

– Iron, cobalt, and nickel are examples of ferromagnetic metals. Ferromagnetic materials
are the only metals commonly inspected with the magnetic particle testing method.

 Magnetic flux: the total number of magnetic lines of force existing in a magnetic circuit
is called magnetic flux.
 Flux density or induction is usually designated in “gauss” units and refers to the
flux per unit area at right angles to the direction of the flux.

Right Hand Rule VS Left Hand Rule

 According to "current flow" theory right hand rule is used, this theory assumed the current
flow from (+) to (-).

4 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 If the more commonly accepted "electron flow" theory were used, it would be necessary to
use the left hand rule.

 The “electron flow” theory considers electricity to flow from (–) to (+).
 The two methods of determining the flow of electricity result in a magnetic field flowing in the
same direction.
*********************************

CH 2: Circular Magnetization

A circular magnetic field is induced into a specimen by:

 Direct induction of a circular field into an article:

o This is accomplished by passing a current through the article as shown in the
head shot as shown below.

 Direct induction using prods:

o Prod magnetization is used where the size or location of an article does not
permit the use of ahead shot.
   

 Indirect induction of a circular field.

5 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
o This is accomplished by placing a current-carrying conductor into the specimen. This
method is known as the central conductor technique and is illustrated below. 

   

 Circular magnetization will detect discontinuities that are between 45 and 90 degrees to
the lines of force.
 A crack that runs parallel to the lines of force will not attract particles because no poles
or flux leakage exists at the crack (see left fig.).
 The circular magnetization created with prods will also only detect discontinuities that
are essentially perpendicular to the lines of force (see right fig.).

Longitudinal Magnetization

A longitudinal magnetic field is induced into a specimen by:

 Coil: when the length of the specimen is several times

its diameter or cross section, the specimen can be
successfully magnetized by placing it lengthwise in
the field of the coil & Parts being magnetized should
be placed near the inside surface of the coil.
 Yoke: yoke may be used to magnetize a specimen longitudinally.

6 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
o The yoke is essentially a temporary horseshoe magnet. It is made of soft, low Retentivity iron,
which is magnetized by a small coil wound around its horizontal bar.   

 As number of turns of coil increase, the flux density increase in the longitudinal
direction. 

*******************************

CH 3: Magnetizing Current 

Alternating current (AC): is the most widely used power source for conducting magnetic
particle testing.

AC can be readily converted to the low

voltages used in magnetic particle
inspection by the use of transformers.

AC has little penetrating power and provides the best detection of surface discontinuities. It is
not effective for subsurface. Since AC is continuously reversing direction, the magnetic field
has a tendency to agitate or make the iron particles more mobile. Current reversal is illustrated
below.

Direct current (DC): single phase AC can be rectified to produce half wave alternating current
(HWAC) commonly called half wave direct current (HWDC).

7 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
HWDC means that the reverse polarity or negative portion of the sine curve is
eliminated as below.

 Hysteresis Loop

The permeability of a material can be determined by increasing the magnetizing force (electric
current strength) until the material reaches its saturation point.

Each type of material has a point of maximum

flux density (saturation).

If we place a piece of steel in a coil, through

which alternating current is flowing, we can
plot the relation between magnetizing current
''H'' and the flux density ''B'', The result is a
hysteresis loop as shown:

 Each increase of the force ''H'' there is an increase in flux density ''b'' until the saturation
point is reached which any increase in the magnetizing force does not increase the flux
density (point a).
 The dashed line above (points 0 - a) shows the maximum flux density and is often referred
to as the virgin curve.

8 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 As the magnetizing force is reduced to zero (from point a to b), the flux density slowly
drops until the magnetizing force (current) is zero.
 The ability of the steel to
retain a certain amount of
residual magnetism is called
Retentivity, as shown
between points 0 and b.
 When the magnetizing force is reversed, as
always happens with AC, the flux density is
reduced to zero at point C as shown.
 Coercive force is the reverse magnetizing
force required to remove residual magnetism
from the material.
 Hardened steel would require a stronger
reverse magnetizing force to remove the
residual magnetism.
 As the reverse magnetizing force is increased
beyond point C, the flux density increases to the
saturation point in the reverse direction shown
in point d.
 Point e shows the residual magnetic field in
the reverse direction.
 The force required to remove this residual
field is shown between points 0 and F
again called coercive force.
 The hysteresis loop is completed as the
magnetizing force is again increased to a
maximum flux density at point a.
 Hysteresis loop is formed with every complete cycle of 60 cps current.
9 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 A hysteresis loop could also be used to describe the magnetization or demagnetization with
dc where the current is either manually or
automatically reversed between straight (+)
polarity and reverse (-) polarity.
 A wide hysteresis loop indicates a material that
is difficult to magnetize (one with a high
reluctance).

The following properties of a metal can determine how effective the magnetic particle
method will be in evaluating a part:

 Permeability: this refers to the ease with which a magnetic flux is established in the
article being inspected.
 Reluctance: this is the opposition of a magnetic material to the establishment of a
magnetic flux. A material with high permeability will have a low reluctance.
 Residual magnetism: this refers to the amount of magnetism re-tained after the
magnetizing force is removed.
 Retentivity: refers to the ability of the material to retain a certain amount of residual
magnetism.
 Coercive force: refers to the reverse magnetizing force necessary to remove the residual
magnetism from the part.
 A Hard steel would have the following qualities and would produce a wide Hysteresis
Loop:
1. Low permeability - hard to magnetize.
2. High Retentivity - retains a strong residual magnetic field.
3. High coercive force - requires a high reverse magnetizing force to remove the residual
magnetism.
4. High reluctance - high resistance to magnetizing force.
5. High residual magnetism - retains a strong residual magnetic field.

10 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 A thin hysteresis loop indicates a material of low Retentivity.
 The loop shows the qualities of a soft material such as low
carbon steel. 

A soft or low carbon steel would have the following qualities:

1. High permeability easy to magnetize.

2. Low Retentivity - retains a weak residual magnetic field.
3. Low coercive force - requires a low reverse magnetizing force to
remove the residual magnetism.
4. Low reluctance - low resistance to magnetizing force.
5. Low residual magnetism - retains a weak residual magnetic field.

****************************

CH 3: Current Requirements

 Amount of current will vary with the shape and permeability of the material being tested.
 A test specimen with a typical indication is a good method to assure that only enough current
is used to show the indication.
 Too much current will burn the part or may cause heavy accumulations of iron particles.
 Too little current may not provide sufficient flux leakage to attract the iron particles.
Current Requirements for Circular Magnetization:
  Rule used to determine the current needed:
(800 to 1000) * Article Thickness or Diameter
Example: 1-what amperage would be used on the following part?
Steel bar 10 x 3 x 2 inches thick
Answer: 1600 to 2000 amps

  2-what amperage range is required to circularly

magnetize the bar shown in the head shot below?

Answer: 800 - 1000 = for first shot &

2000 - 2500 for second shot
11 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
Current Requirements for Longitudinal Magnetization:

The effective field it creates is determined by the product of the number of amperes and the
number of turns in the coil

The amount of current needed for longitudinal magnetization with a coil is controlled
by the formula:

I = current in amperes

N = number of turns in coil

L = length of article D = diameter or thickness of article

*************************

CH 5: Magnetic Particle Testing Equipment

  Wet horizontal equipment

– Specimen is clamped between the head and tail stocks.

– For longitudinal magnetization the coil is moved so that the area to be tested is encircled by the
coil.

– Wet horizontal unit usually accommodates both AC and HWDC magnetization.

 Wet continuous field method has three basic steps:

– 1. Flow bath through nozzle and over entire surface of part.

– 2. Stop bath flow.

– 3. Apply current at the instant bath flow is stopped.

12 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 Dry continuous field method:

1. Apply magnetizing current.

2. Blow powder particles over magnetized area.

3. Blow excess powder off part.

4. Shut off magnetizing current.

• The powder should float to the magnetized area so the particles will be attracted to any flux
leakage.

Magnetic Particle mediums and their preparation

 When the medium, whether dry or liquid, is applied to the specimen while the magnetizing
current is flowing, the procedure is known as the continuous method.
 If the medium is applied after the magnetizing current is shut off, the procedure is known
as the residual method.
 In the dry method, the powder is applied by sprinkling or dusting the specimen.
 In the wet method, the medium is mixed with a liquid (kerosene or oil) to make a bath,
which is then applied to the surface of the specimen.

Particles of the testing medium must possess two important properties:

1. High permeability 2. Low Retentivity

Magnetic particles containing these characteristics will give maximum response in a leakage
field, but will not remain magnetized when the field is removed.

 The size of the particles used in the dry method varies but they will usually all pass through100
MESH screen.
 The shape of the magnetic particle should be spherical and must have a high degree of mobility
and still have substantial attractive power.

– Round smooth particles offer good mobility but have low attractive power.

– Long, slender particles have excellent attractive power, but do not have the mobility to move
in a leakage field.
13 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
 The particle size must be small in the wet method to permit the particles to remain in
suspension in the liquid
 Mobility is important because when the particles are brought into a leakage field they
must be able to move to form a pattern or indication.
 In the wet method mobility is greatly assisted because the particles are suspended in a liquid
bath.
 Visibility is important in magnetic particle testing and a good light source is essential.
 Magnetic particles are usually available in grey, red, and black, and the choice of color is
determined by the best contrast with the specimen surface.
 Fluorescent particles are commonly used in the wet method to aid visibility, but this requires
the use of a black light.

*************************** 

CH 6: Magnetic Particle Applications 

 Surface Preparation

Cleaning may involve removal of flake, slag, heavy build-up of paint, rust, grease or other
organic material that may interfere with the test results.

 Location of discontinuities

Discontinuities located on the surface appear as sharp, distinct lines, whereas discontinuities
located below the surface appear as irregular, rough, hazy indications.

 Application of magnetic particle

testing procedures
 Magnetization of a solid cylindrical
specimen 

14 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
Head shot (circular magnetization): inspect for
discontinuities showing a longitudinal
indication.

Coil shot (longitudinal magnetization): inspect

for transverse indications.

 Magnetization of short hollow cylinders:

Head shot (circular magnetization) with

central conductor or by placing in a coil, this
will produce a longitudinal field which will
detect discontinuities
in the direction shown.

 Magnetization of a large Gear

What methods must be used to find all of the discontinuities in

the gear ?

Head shot (circular magnetization) with central conductor - inspect for

discontinuities perpendicular to the circular field.

15 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
Head shot (circular magnetization) using at least two shots and turning the gear 90O

 Magnetization of hollow cylindrical

specimens

What methods must be used to find the

discontinuities on the inside and outside of this
cylinder?

 Magnetization of large weldments or castings

Circular magnetization of large specimens is usually accomplished with the use of prods.

Longitudinal magnetization of large specimens is usually done with a yoke.

16 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 
************************

CH 7: discontinuities that can be evaluated with MT

Discontinuities can be divided into three general categories:

1. Inherent discontinuities: are usually formed when the metal is molten.

– Inherent wrought discontinuities relate to the melting and solidification of the original
ingot before it is formed into slabs, blooms, and billets.
– Inherent cast discontinuities relate to the melting, casting, and solidification of a cast
article. Usually caused by inherent variables such as inadequate feeding, gating,
excessive pouring temperature, and entrapped gases

2.   Processing discontinuities: are usually related to the various manufacturing processes such

as machining, forming, extruding, rolling, welding, and heat treating.

3. Service discontinuities: are related to the various service conditions such as stress, corrosion,
fatigue, and erosion.

 The greatest aid in interpretation is a knowledge of what is likely to be present in any

given instance.

 Non relevant indications can be caused by the following:

1. Excessive magnetizing current.

2. Structural design of the article.

3. Variances of permeability within the article.

17 
 
   Rev.00                                                                 MAGNETIC PARTICLE TEST (MT)                              Prepared by: Eng.: Mohammad Hassan Abdel‐Gawad 

       
 

problems in identifying non relevant

indications can be reduced if the operator
remembers that:

1. they can be identified by a fuzzy, rather than a sharp indication.

2. They are usually associated with some feature of construction like a keyway or sharp corner.

3. They are usually uniform in direction and size.

*********************

Certification of NDT
 It is important that the technician and supervisor be qualified in the: magnetic particle
method before the technique is used and test results evaluated.
 The American society for nondestructive testing recommends the use of its document
recommended practice no. SNT- TC-1 A.
 Certification of NDT personnel is the responsibility of the employer and is usually at three
levels:

• Level I: perform specific calibrations, specific tests, and specific evaluations according to
written instructions.

• Level II: set up and calibrate equipment and interpret and evaluate results with respect to codes,
standards and specifications. Must be able to prepare written instructions and report test results.

• Level III: responsible for establishing techniques, interpreting codes, and designating the test
method and technique to be used. Must have a practical background in the technology and be
familiar with other commonly used methods of NDT.

18