MAGNETIC PARTICLE TESTING

One of the most effective surface NDT methods for examination of material forms in ferro-magnetics To detect surface & sub-surface flaws Sensitivity is greatest for surface discontinuities that are linear and oriented normal to induced flux-lines Sensitivity decreases for sub-surface discontinuities located beneath with increasing depth Typical flaws detected: Cracks, Lack of fusion, Incomplete penetration, Lamination on weld groove faces

PRINCIPLE IN BRIEF

Weld area to be examined is magnetized, establishing magnetic flux lines on surface & near surface During magnetization ferromagnetic particles (wet or dry) are applied on the weld and adjacent base metal surface Discontinuities oriented normal to magnetic flux lines distort the fields induced, cause flux-leakages on material surfaces to attract magnetic particles and form patterns (indications) These patterns are characteristic of type of flaw revealed Each weld area is examined twice so that Lines of flux during one examination is approximately perpendicular to the flux lines of other examination

CHOOSING MAGNETIC PARTICLE TEST First choice When welds are Ferro-magnetic When groove faces need be examined for laminations To assess Root conditions in multi-pass groove welds When the intention is to find out spherical flaws such as porosity

SELECTION OF EQUIPMENT

Magnetization method Magnetisation current (AC,HWDC or both) Amperage requirement Wet or Dry Method Flaws that are soughtSurface or subsurface Part requirements Accessibility &

PORTABLE KITS-YOKES

For site locations & parts located at heights When very fine surface flaws are sought to be detected When No arcing is required on weld/base metal When Wet medium is required to be used When Smooth & fine surface conditions exist

MOBILE EQUIPMENT
PRODS INSPECTION UNITS For Shop-floor fabrication When Sub-surface flaws are required to be detected When Dry powder use is required When surfaces are Rough (Weld surfaces)

EXAMINATION MEDIUM

Both dry & wet Particles used Particles imparted color to provide sufficient contrast for increased visibility against background examination surface DRY PARTICLES Have high permeability & low retentivity Mixture of spherical & elongated shapes Particle sizes range 0.060 mm to 0.150 mm; 75% of which in the range of 0.080 mm 0.100 mm Used under extreme environmental conditions; Heat Resistant & can be used upto 315 C Some particles lose color at high temperatures & lose contrast Not affected by cold

WET PARTICLES
Fluorescent &Non-fluorescent Oxides of iron & have relatively lower permeability than Dry particles Particle sizes range 0.005 mm to 0.030 mm Suspended in Conditioned water/light petroleum distillate When suspended in petroleum bases used upto 50 C Affected by freezing cold conditions CONCENTATION Verified with ASTM centrifuge tube Non-fluorescent suspension: 1.2 to 2.4 mL/100 mL Fluorescent suspension: 0.2 to 0.4 mL/100 mL

APPLICATION AREAS

Welds in Boiler, Piping & Pressure vessels Finished Butt & Corner welds & intermediate stage examination for thick welds to avoid major repairs at later time Branch welds in piping SURFACE CONDITION General Surface Condition: As welded is sufficient Excessive ripples & undercut mask indications from discontinuities lying beneath Shall be clean, dry & free from organic and inorganic contaminants that interfere with test Examination area: 25 mm on each side of weld, HAZ & base metall

SURFACE CONDITIONING

Grinding, Machining, grit blasting or abrasive methods for organic contaminants Organic solvents for organic contaminants CONDUCTIVE & NON-CONDUCTIVE COATINGS: SURFACE CONTRAST ENHANCEMENT coatings- may be applied tentatively on surfaces to improve contrast For non-conductive paintingcoating thickness not to exceed 50 m Coating removed at points where contact is to be made by prods For coating thickness that exceeds 50 m or material forms that have CONDUCTIVE coatings Procedure verified with cracks introduced in blocks with such coating & coating thickness for detection

MAGNETISING CURRENT

Rectified current HWDC used for deep penetration of parts Current selection primarily depends on prod spacing For Material thick < 20 mm 90 to 110 amps/25 mm prod spacing For Material thick > 20 mm 110 to 125 amps/25 mm prod spacing Prod spacing: Min.75 mm; Max: 200 mm MAGNETISING STRENGTH: The prods technique introduce circular magnetic field on the surface around the prods The field strength developed on part is influenced by Material permeability, Weld size & shape, Magnetization technique. Field adequacy is verified utilizing Gauss/Tesla meters or ASTM pie-gauge field indicator

TECHNIQUES FOR WELD EXAMINATION

PROD TECHNIQUE: Prod Technique-Dry Yoke Technique-wet non fluorescent Prod tips to be kept clean & dressed free from oxides Al or Pb or Fe tipped prods used to avoid cu deposits on material If Cu prods used open-circuit voltage need be < 24V Prods pressed against test surface normal to it Angulation of prods results distorted fields Prods provided with remote contact switch to make electrical contact after firmly positioned

FIELD STRENGTH & DIRECTION

VERIFICATION of field: ASTM Pie gauge is positioned on the examination surface with brazed piesections toward the examination surface. A clearly defined line or lines when particles are applied simultaneously with magnetizing force indicates adequate strength.
MEASURING FIELD STRENGTH: Hall-effect tangential probe positioned on the surface The peak-value of tangential field is measured when magnetizing force is applied Value of 30 to 60 Gauss (2.4 k to 4.8 k Amps /meter) indicates adequacy of field

MAGNETISING DIRECTION

The direction of magnetization is verified using ASTM pie-gauge Pie gauge is positioned so that brazed pie-sections toward the examination surface Cu plate away form surface. A clearly defined line or lines in the desired direction when particles reapplied simultaneously with magnetizing force fulfills the requirement of field direction

DRY CONTINUOUS

APPLICATION OF DRY PARTICLES :

Flow of magnetizing current initiated Cloud of Dry particles floated with low velocity upto the surface Application of current terminated after the application of powder has been completed and any excess has been blown-off. Build-up of indication observed as the particles are being applied used for examination.

YOKE TECHNIQUE
To detect discontinuities open to surface Yokes have TWO adjustable legs Adjustable legs permit changing the contact space in between the legs and improved contact area with surface Legs of yoke are positioned similar to prods & pressed against surface The discontinuities anticipated should be centrally located in the area between pole pieces The effective inspection area space in between the legs is the area of examination Lateral area of 38 mm on each side of the center-line of yoke legs Depends on part geometry and qualified using Hall-effect gauss meter

ELECTRO-MAGNETIC YOKES

A single leg used in areas of tight access Flux lines for single leg yoke flow radially producing radial magnetization ELECTRO-MAGNETIC YOKES: DC yoke has greater penetration while AC yoke concentrates the field on the surface of weld providing greater sensitivity At maximum pole spacing used for examination the minimum Lifting power of AC yokes shall be:4.5 kg; DC yokes:18.1 kg. The yoke techniques produce LONGITUDINAL magnetic field on the surface in between the pole-pieces

PERMANENT YOKES

Permanent yokes used where no electric power is available or where arcing is not permitted The strength of any yokes is determined by its lifting power At maximum pole spacing used for examination he minimum Lifting power of Permanent yoke shall be:18.1 kg

MAGNETISING STRENGTH
Field adequacy is verified utilizing Gauss/Tesla meter or artificial flaw shims Yoke can be switched ON or OFF at will which helps to remove the yoke-leg from part The flux density introduced into part can be varied by varying the amount of current in the coil

YOKE-FIELD STRENGTH
VERIFYING USING SHIMS

The shims are foils of low carbon steel 50 m thick that contains a notch or notches chemically etched or machined to 30% of foil thickness. Shims are attached to part such that the artificial flaw is toward the examination surface. A clearly defined line or lines when wet particles are flowed over the shim simultaneously with magnetizing force indicates adequate field strength
MEASURING USING GAUSS METER Hall-effect tangential probe positioned on the surface The peak-value of tangential field is measured when magnetizing force is applied Value of 30 to 60 Gauss (2.4 k to 4.8 k Amps /meter) indicates adequacy of field

MAGNETISING DIRECTION

FIELD DIRECTION

The direction of magnetization is verified using ASTM pie-gauge Pie gauge is positioned brazed pie-sections are toward the examination surface Cu plate away form surface. A clearly defined line or lines in the desired direction when particles are applied simultaneously with magnetizing force fulfills the requirement of field direction

WET PARTICLE APPLICATION

Wet continuous

Flow of magnetizing current initiated After thorough agitation wet particles are applied by spraying or flowing over the entire weld area to be examined Multiple current shots (2 or 3) applied. The last shot applied while particle bath is still on part. Wet particles accumulate at the site of discontinuities & produce indication characteristic of its nature

DETECTABLE DISCONTINUITY
LIGHTING CONDITIONS Day light or artificial lights used for dry powder and non-fluorescent applications Min 500 Lux /1000 lux needed for critical applications Black Lightfor fluorescent wet particles DETECTABLE DISCONTINUITIES: Discontinuity at right angles to the surface and its Depth five times its opening width ;Length > width & >1 mm flaw width creating small air gap Incipient cracks less than 0.025 mm deep and have surface openings of onetenth of its width are detectable by wet particle inspection Correct interpretation of indications caused by subsurface discontinuities requires skill.

CONDITIONS FOR DIFFICULTY IN DETECTION

If the faces of a crack tightly forced together by compressive stresses the absence of air gap produces little leakage field that no particle indication is formed. If the crack is not close-lipped but wide open at the surface Shallow Cracks Magnetic Reluctance of air gap reduces strength of the leakage field, combined with inability of the particles to bridge the gap, results in a weaker indication.

INTERPRETATION
INTERPRETATION OF INDICATIONS:

The accumulation pattern of dry/wet particles that forms on material surface during examination is INDICATION Any indication has to be ascertained whether RELEVANT, false or non-relevant Discontinuities located on surface appear sharp & distinct Discontinuities located below the surface appear broad & fuzzy NDICATION is characterized

FALSE & NON-RELEVANT INDICATIONS

False Indications Do not arise from flaws as there is no magnetic attraction Particle patterns are held by gravity or surface roughness. Non-relevant indications Caused by flux leakage, not due to breaks in metal Excessive magnetization force, part configuration, mill scales are possible causes Abrupt changes in magnetic properties between base metal & weld metal Toe of the welds, Edges of fillet welds, in Heat Affected Zone Indications appear wide, loose & lightly adhering particle pattern

RELEVANT INDICATIONS

Relevant indications Relevant indications arise from discontinuity sizes as defined in standards APPEARANCE OF FLAW INDICATIONS Porosity Appear more or less round indications, as spherical in shape Cracks in weld/Base Metal Longitudinal, Transverse & crater Fairly straight & twisty as continuous linear indication

EVALUATION

Evaluation Determine severity of discontinuity, whether detrimental for intended use Pass judgment based on well defined acceptance standards Provide Disposition of examined weld-Accept/Repair/Reject Post-cleaning Sometimes demagnetized, Blown off using compressed air for Dry powder Sometimes demagnetized, hand wipe with solvents and cleaned for wet particles

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