Selection of the equipment

The decision on the selection of the equipment depends on size, shape, number and variety of
parts to be tested. For production testing of numerous parts which are relatively small, use of
horizontal bench type stationary units with clamping head contacts for circular magnetization
and a built-in movable coil for longitudinal magnetization is commonly made. If the parts are
large, portable units using prods or C-clamp contacts and hand wrapped coils may be a
convenient choice.
Type of current
The choice is dictated by the location of defects, whether they are open to the surface of the part
or located wholly below the surface. Choice of current lies between AC and some form of DC
(Full wave rectified or half wave rectified (HWDC). For surface open defects, AC is the first
choice whereas for deeper penetration ability of straight DC or rectified half wave and full wave,
the use of later is made. Thus the magnetizing equipment to be used should also have the ability
to generate the type of current desired.
Selection of inspection media
The selection has to be decided between dry and wet method and secondarily among the various
colours that are available, including fluorescent particles. This decision is principally influenced
by the following considerations:
1. Whether the defect sought is on the surface or wholly below the surface: For deep-lying
defects dry powder is more sensitive.
2. The size of the defect, if on the surface: The wet method is usually best for very fine and
shallow defects.
3. Convenience: Dry powder with a portable half wave rectified unit, for instance, is easy to
use for occasionally large parts in the shop or foundry, or for field inspection work.
Field detection
It is very essential to ascertain during magnetic particle inspection the adequacy of field strength
and direction. This is an essential requirement for producing a good indication of existing
defects. It is thus very important for the operator to ensure that a field of sufficient intensity and
of desired direction exists within the magnetized job. Flux meters help in determining
experimentally the flux density within the part. Similarly other meters are available which
measure the existing flux on a point just above the part. Use of Berthold field indicator is very
conveniently made by placing them on the job at the site of interest during magnetization. The
formation of the pattern on the face of the indicator shall ensure the adequacy of the existing
field strength and direction.
Intensity
For achieving the desired level of magnetic field intensity during the use of different techniques,
use of certain relationships is made. A brief picture of some such guidelines is as under.
Electromagnetic yoke The field intensity is dependent on the thickness of the job and the
distance between its poles. It decreases with the increase of the pole separation and
thickness of the job.
Prod magnetization The field intensity is dependent upon the separation of prod tips and
thickness of job. Prod spacing of up to 8 inch (200 mm) and a minimum of 3 inch (75
mm) is recommended.
Coil magnetization The field generated is longitudinal and the value of direct or rectified
current is based on the ratio of length to diameter of the job. For non-cylindrical jobs,
diameter value is the maximum cross-sectional diagonal. Depending upon the values of
L/D, different relationship are used for calculating the value of magnetizing current.
Head shot The current is passed directly into the jobs, the resultant field is circular in
nature. The value of current is dependent on the outside diameter of the job. The value of
current is the same as for central conductor or threading bar.
Sequence of testing
The sequence of operation in magnetic particle testing applies to the relationship of timing and
application of particles and magnetizing current. Two basic techniques apply, continuous and
residual, both of which are commonly employed in industry today.
Wet continuous magnetization
The technique is applied for most applications utilizing either dry or wet particles. The sequence
of operation for the wet and dry continuous magnetization techniques are significantly
different. The `wet' continuous magnetization technique generally applies to those parts
processed on a horizontal wet bench type unit. In practice it involves bathing the part with the
inspection medium and terminating the bath application simultaneously with the initiation of the
current. Thus there is no application of inspection medium while the current is flowing.
Typically there may be a slight overlap relative to cessation of bath application and flow of the
magnetizing current.
Dry continuous magnetization
In this method, the initiation of the current is done prior to the application of the dry powder, and
terminated after the application of the powder has been completed and excess powder blown off.
Residual magnetization
In this case the examination medium is applied after the magnetizing force has been
discontinued. The method has some usefulness for retentive materials.
Demagnetization
All ferromagnetic materials will retain some residual magnetism, the strength of which is
dependent on the retentivity of the part. Residual magnetism does not affect the mechanical
properties of the part. However, a residual field may permit chips to adhere to the surface
affecting subsequent machining operations, as well as painting or plating. Additionally, if the
part will be used in locations near sensitive instruments, high residual fields could affect the
operation of these instruments. Furthermore, a strong residual magnetic field in a part to be arc
welded could interfere with this operation. Residual fields may also interfere with subsequent
magnetic particle examination. Demagnetization is required only if specified in the drawings,
specification or purchase order. When required, an acceptable level of residual magnetization
and the measuring method shall also be specified.
The ease of demagnetization is dependent on the coercive force of the metal. In general,
demagnetization is accomplished by subjecting the part to a field equal to or greater than that
used to magnetize the part, then continuously reversing the field direction while gradually
decreasing it to zero.
Effectiveness of demagnetization
It can be indicated by the use of appropriate magnetic field indicators or field strength meters.
However, a part may retain a strong residual field after having been circularly magnetized and
exhibit little or no external evidence of this field. Therefore, the circular magnetization should be
conducted before longitudinal magnetization if complete demagnetization is required.
Post inspection cleaning
Post-test cleaning is necessary where magnetic particle materials could interfere with subsequent
processing or with service requirements.
Typical post cleaning techniques employed are: (1) the use of compressed air to blow off
unwanted dry magnetic particles; (2) drying of wet particles and subsequent removal by brushing
or compressed air; and (3) removal of wet particles by flushing with solvent. Other suitable
posttest cleaning techniques may be used if they will not interfere with subsequent requirements.
Acceptance standards
The acceptability of parts examined is not specified herein. Acceptance standards are a matter of
agreement between the manufacturer and the purchaser and should be stated in a referenced
specification or code.