Training Training

Magnetic Particle Inspection Magnetic Particle Inspection

Equipments & Accessories Equipments & Accessories
Calibration Calibration
Introduction Introduction
This session aims to educate all of you about This session aims to educate all of you about
equipments and the quality control needed for equipments and the quality control needed for
the equipment and the necessary processes. the equipment and the necessary processes.
We will be going through: We will be going through:
Machines Machines
Accessories Accessories
Calibration Calibration
Agenda Agenda
Portable type. Portable type.
Mobile type. Mobile type.
Stationary Type. Stationary Type.
Automatic Type. Automatic Type.
Black Light type. Black Light type.
Light Light sensitive instruments. sensitive instruments.
Malfunctioning of equipments. Malfunctioning of equipments.
Calibration of equipment. Calibration of equipment.
Portable Machines Portable Machines
Permanent Yoke
Electro-Magnetic Yoke
Prod type 750 to 1000 ampere
Reasons for Portable Machines Reasons for Portable Machines
Portability (Light weight & Easy to carry ) Portability (Light weight & Easy to carry )
Power not available. Power not available.
Large Components to be tested. Large Components to be tested.
On site work. On site work.
Yokes Yokes
Permanent Magnetic yoke. Permanent Magnetic yoke.
When no power is available and advantage to be used where no voltage to be When no power is available and advantage to be used where no voltage to be
used. Explosive areas. (Safety question.) used. Explosive areas. (Safety question.)
Electro Electro--magnetic yoke Available both in AC / DC output magnetic yoke Available both in AC / DC output
Battery operated also used now Battery operated also used now-- days. Used where no power is available. days. Used where no power is available.
The field can be regulated. The field can be regulated.
They have articulated legs that can be adjusted as per the test location. They have articulated legs that can be adjusted as per the test location.
Main advantage light weight. Main advantage light weight.
Can be used on finished products without causing arc burns. Can be used on finished products without causing arc burns.
The yokes can be also used for demagnetizing components by AC The yokes can be also used for demagnetizing components by AC
magnetizing field. magnetizing field.
Portable Prod type Portable Prod type
Prod type equipments pass the current through the component through Prod type equipments pass the current through the component through
prods. prods.
They are more sensitive to detect sub They are more sensitive to detect sub--surface defects compared to yokes. surface defects compared to yokes.
They produce both AC & HWDC magnetizing current. They produce both AC & HWDC magnetizing current.
They are limited to maximum output current from 750 amperes to 1500 They are limited to maximum output current from 750 amperes to 1500
amperes. amperes.
They weigh between 20 kilos to 40 kilos. They weigh between 20 kilos to 40 kilos.
The shorter the secondary cables the better the output and lighter the The shorter the secondary cables the better the output and lighter the
equipment. equipment.
The equipment can be also used as a demagnetizer in the AC mode. The equipment can be also used as a demagnetizer in the AC mode.
The prods to be kept clean to avoid arc burns. The prods to be kept clean to avoid arc burns.
Precaution to be taken to be used on finished component (they can used with Precaution to be taken to be used on finished component (they can used with
copper braided tips or lead tips), it is better to be avoided if alternate option is copper braided tips or lead tips), it is better to be avoided if alternate option is
available. available.
The portable units along with cables can be also for coil magnetizations, by The portable units along with cables can be also for coil magnetizations, by
wrapping the cables around the component. wrapping the cables around the component.
Mobile Type Machines Mobile Type Machines
Reasons for Mobile Machines Reasons for Mobile Machines
Mobility Mobility
Can produce large amount of Current. Can produce large amount of Current.
Capable of Demagnetization Circuits. Capable of Demagnetization Circuits.
Mobile Units Mobile Units
They are similar to prod portable unit. They are similar to prod portable unit.
Mobile units can produce current from 2000 amperes to 8000 amperes. Mobile units can produce current from 2000 amperes to 8000 amperes.
They are also used as a power pack for stationary equipments. They are also used as a power pack for stationary equipments.
They can produce AC/ HWDC/ FWDC currents. They can produce AC/ HWDC/ FWDC currents.
They are mostly used where large current is required for massive components. They are mostly used where large current is required for massive components.
for cable wrapping technique. for cable wrapping technique.
Sometime the components cannot be moved so long cables are used for the Sometime the components cannot be moved so long cables are used for the
required output or to test at high altitudes. required output or to test at high altitudes.
Cables as long as 40 meters are used sometimes. Cables as long as 40 meters are used sometimes.
This units can also have in This units can also have in-- built demagnetization facilities. built demagnetization facilities.
The only disadvantage they need high input current. The only disadvantage they need high input current.
Stationary Machines. Stationary Machines.
Stationary Machines Stationary Machines
Bench or stationary units are generally used for high volume production . Bench or stationary units are generally used for high volume production .
They are mostly designed as wet method inspection units. They are mostly designed as wet method inspection units.
They are available in two models Current & coil Series, Current & Yoke They are available in two models Current & coil Series, Current & Yoke
series. series.
They produce AC/ HWDC/ FWDC & 3 FWDC. They produce AC/ HWDC/ FWDC & 3 FWDC.
These machine produce both circular & longitudinal magnetization. These machine produce both circular & longitudinal magnetization.
Care should be taken for setting the current in Multi Care should be taken for setting the current in Multi-- Directional units since Directional units since
they produce both fields. they produce both fields.
These units in some cases have in These units in some cases have in-- built demagnetization facility. built demagnetization facility.
These units come with automatic loading, magnetization, spraying, and These units come with automatic loading, magnetization, spraying, and
automatic unloading. automatic unloading.
The output current used in this product ranges from 1000 to 20000 amperes. The output current used in this product ranges from 1000 to 20000 amperes.
These machine usually have a head stock & movable tail stock. These machine usually have a head stock & movable tail stock.
Usually they have one coil, for longitudinal magnetization. Usually they have one coil, for longitudinal magnetization.
The coils used in these machine are standard 5 turn coil or as per customers The coils used in these machine are standard 5 turn coil or as per customers
requirement. requirement.
The sizes of the coils also vary from 6 inches to 36 inches. The sizes of the coils also vary from 6 inches to 36 inches.
Test Bench Test Bench
Some have separate demagnetizers for faster production output. Some have separate demagnetizers for faster production output.
The test benches also vary in sizes from 450mm bed length between heads to The test benches also vary in sizes from 450mm bed length between heads to
5000mm. 5000mm.
In many automated systems the headstock have rotating heads for the In many automated systems the headstock have rotating heads for the
rotation of the components at the time of inspection. rotation of the components at the time of inspection.
The Black light also moves along with the inspector in automated systems for The Black light also moves along with the inspector in automated systems for
easy inspections. easy inspections.
The latest machines have feedback system. The latest machines have feedback system.
They also come with retention facility and digital ammeter. They also come with retention facility and digital ammeter.
In some particular cases the complete visual system eliminates the man for In some particular cases the complete visual system eliminates the man for
inspection. inspection.
Special machine with multiple contact heads (multi direction)are used to Special machine with multiple contact heads (multi direction)are used to
magnetize the component so that time can be saved. magnetize the component so that time can be saved.
These machine have rotation base for inspection. These machine have rotation base for inspection.
Automatic Machines Automatic Machines
Nuts Nuts
Billets. Billets.
Bars. Bars.
Similar component with same Similar component with same
measurements. measurements.
Crankshaft. Crankshaft.
Camshaft. Camshaft.
Other similar components Other similar components
Conveyor systems Conveyor systems
Multi directional Magnetization Multi directional Magnetization
Special Equipment for special large Special Equipment for special large
components. components.
Machine with visual inspection system Machine with visual inspection system
Future Magnetic Crack Detectors Future Magnetic Crack Detectors
Automatic Feeding. Automatic Feeding.
Automatic spraying Automatic spraying
Automatic Current application. Automatic Current application.
Set Current values will be the output irrespective Set Current values will be the output irrespective
of the impedance. of the impedance.
Automatic Program controlled current selection Automatic Program controlled current selection
for various parts. for various parts.
Automatic Segregation with marking system. Automatic Segregation with marking system.
Digital printout with recording facilities. Digital printout with recording facilities.
Introduction to Demagnetization. Introduction to Demagnetization.
All ferromagnetic materials, after having been All ferromagnetic materials, after having been
magnetized, will retain a residual magnetic field to magnetized, will retain a residual magnetic field to
some degree. This field may be negligible in some degree. This field may be negligible in
magnetically soft materials, but in hard metals it magnetically soft materials, but in hard metals it
may be comparable to intense fields associated may be comparable to intense fields associated
with the special alloys used for permanent with the special alloys used for permanent
magnets. magnets.
It is not always necessary to demagnetize parts It is not always necessary to demagnetize parts
after magnetic after magnetic--particle inspection. However, particle inspection. However,
although demagnetization involves time and although demagnetization involves time and
expense, it is essential in many instances. expense, it is essential in many instances.
Demagnetization may be easy or difficult, Demagnetization may be easy or difficult,
depending upon the type of metal. Metals with depending upon the type of metal. Metals with
have high coercive forces are most difficult to have high coercive forces are most difficult to
demagnetize. High retentivity is not necessarily demagnetize. High retentivity is not necessarily
related directly to high coercive force, so that the related directly to high coercive force, so that the
strength of the retained magnetic field is not strength of the retained magnetic field is not
always an accurate indicator of the ease of always an accurate indicator of the ease of
demagnetizing. demagnetizing.
It is better to keep the demagnetizer coil opening It is better to keep the demagnetizer coil opening
facing East facing East West. West.
Reasons for Demagnetizing. Reasons for Demagnetizing.
There are many reasons for demagnetizing the part after There are many reasons for demagnetizing the part after
magnetic magnetic--particle inspection (or, for that matter, after particle inspection (or, for that matter, after
magnetization for any reason). Demagnetization is magnetization for any reason). Demagnetization is
necessary if: necessary if:
The part will be used in an area where residual magnetic The part will be used in an area where residual magnetic
field will interfere with the operation of instruments that field will interfere with the operation of instruments that
are sensitive to magnetic field or may affect the accuracy of are sensitive to magnetic field or may affect the accuracy of
instruments incorporated in assembly that contains instruments incorporated in assembly that contains
magnetized parts. magnetized parts.
During subsequent machining, chips may adhere to the During subsequent machining, chips may adhere to the
surface being machined and adversely affect surface finish, surface being machined and adversely affect surface finish,
dimensional and tool life. dimensional and tool life.
During cleaning operations, chips may adhere to the During cleaning operations, chips may adhere to the
surface and interfere with subsequent operation such as surface and interfere with subsequent operation such as
painting or plating. painting or plating.
Abrasive particle may be attracted to the magnetized part Abrasive particle may be attracted to the magnetized part
such as bearing surfaces, bearing raceways, or gear teeth, such as bearing surfaces, bearing raceways, or gear teeth,
resulting in abrasion or galling, or may obstruct oil holes resulting in abrasion or galling, or may obstruct oil holes
and grooves. and grooves.
During some electric arc During some electric arc--welding operations, strong welding operations, strong
residual magnetic fields may deflect the arc away from the residual magnetic fields may deflect the arc away from the
point at which it should be applied. point at which it should be applied.
A residual magnetic field in a part may interfere with re A residual magnetic field in a part may interfere with re--
magnetization of the parts at a field intensely too low to magnetization of the parts at a field intensely too low to
over come the remanent fields in the part. over come the remanent fields in the part.
It is also frequently required when parts, after use of It is also frequently required when parts, after use of
magnetic chucks or lifting magnets. magnetic chucks or lifting magnets.
Different Methods of Demagnetization. Different Methods of Demagnetization.
AC Current Decay method. AC Current Decay method.
Reducing the field method. Reducing the field method.
DC reversal technique. DC reversal technique.
AC yoke. AC yoke.
Demagnetizers Demagnetizers
Accessories Accessories
Future UV source. Future UV source.
LED Lights. LED Lights.
Light weight. Light weight.
Easy to carry. Easy to carry.
Available in both AC & Battery operated. Available in both AC & Battery operated.
Very High intensity upto 20,000 micro watts. Very High intensity upto 20,000 micro watts.
Life 20,000 average hours. Life 20,000 average hours.
Magnetic Crack Detector check points. Magnetic Crack Detector check points.
Electrical System Checks Electrical System Checks
Changes in the performance of the electrical system of a magnetic particle inspection Changes in the performance of the electrical system of a magnetic particle inspection
unit can obviously have an effect on the sensitivity of an inspection. Therefore, the unit can obviously have an effect on the sensitivity of an inspection. Therefore, the
electrical system must be checked when the equipment is new, when a malfunction is electrical system must be checked when the equipment is new, when a malfunction is
suspected, or every six months. Listed below are the verification tests required by suspected, or every six months. Listed below are the verification tests required by
ASTM E ASTM E--1444. 1444.
Maximum Unit Output Maximum Unit Output
A magnetic particle unit should be checked regularly (daily) to verify that the A magnetic particle unit should be checked regularly (daily) to verify that the
maximum current output of its electrical system has not changed over time. This check maximum current output of its electrical system has not changed over time. This check
is performed by placing a large diameter (typically 1 inch or more) copper or aluminum is performed by placing a large diameter (typically 1 inch or more) copper or aluminum
bar between the contacts and energizing the circuit with the current control set to the bar between the contacts and energizing the circuit with the current control set to the
maximum value. The maximum amperage as recorded by the system's ammeter should maximum value. The maximum amperage as recorded by the system's ammeter should
be noted and compared to the value obtained when the unit was last certified or be noted and compared to the value obtained when the unit was last certified or
calibrated. A significant drop or gradual decay indicates a problem with the unit that calibrated. A significant drop or gradual decay indicates a problem with the unit that
should be corrected. should be corrected.
Internal Short Test Internal Short Test
The internal short circuit testing is required to determine the if current is "leaking past" The internal short circuit testing is required to determine the if current is "leaking past"
the test article. Internal electrical leakage will cause the test equipment to indicate the test article. Internal electrical leakage will cause the test equipment to indicate
current is flowing through the component when it is actually bypassing the current is flowing through the component when it is actually bypassing the
component. The process for checking equipment for this condition is to energize the component. The process for checking equipment for this condition is to energize the
system with nothing between the contact heads and the amperage set to the highest system with nothing between the contact heads and the amperage set to the highest
output. If the ammeter shows any current flow, internal shorting should be suspected. output. If the ammeter shows any current flow, internal shorting should be suspected.
Calibration of the Machine Calibration of the Machine
Ammeter Check Ammeter Check
It is important that the ammeter provide consistent and correct readings. If the meter is reading It is important that the ammeter provide consistent and correct readings. If the meter is reading
low, over magnetization will occur and possibly result in excessive background fluorescence. If low, over magnetization will occur and possibly result in excessive background fluorescence. If
ammeter readings are high, flux density could be too low to produce detectable indications. To ammeter readings are high, flux density could be too low to produce detectable indications. To
verify ammeter accuracy, a calibrated ammeter is connected in series with the output circuit and verify ammeter accuracy, a calibrated ammeter is connected in series with the output circuit and
values are compared to the equipment's ammeter values. Readings are taken at three output levels values are compared to the equipment's ammeter values. Readings are taken at three output levels
in the working range. The equipment meter is not to deviate from the calibrated ammeter more in the working range. The equipment meter is not to deviate from the calibrated ammeter more
than +/ than +/ -- 10 percent or 50 amperes, whichever is greater. If the meter is found to be outside this 10 percent or 50 amperes, whichever is greater. If the meter is found to be outside this
range, the condition must be corrected. It should be noted that when measuring half range, the condition must be corrected. It should be noted that when measuring half--wave wave
rectified current, the readings should be doubled. rectified current, the readings should be doubled.
Quick Break Test Quick Break Test
A quick break circuit is primarily used in three A quick break circuit is primarily used in three--phase, full phase, full--wave rectified systems to ensure wave rectified systems to ensure
longitudinal magnetic fields maintain their strength to the end of a component. Quick break longitudinal magnetic fields maintain their strength to the end of a component. Quick break
circuits cause the current to abruptly collapse or drop to zero at the end of the activation cycle. By circuits cause the current to abruptly collapse or drop to zero at the end of the activation cycle. By
doing this, low frequency eddy currents are produced close to the surface of a component. These doing this, low frequency eddy currents are produced close to the surface of a component. These
eddy currents help extend the useable longitudinal field to the ends of the component. To eddy currents help extend the useable longitudinal field to the ends of the component. To
determine if a quick break system is functioning properly, an oscilloscope is often used. By determine if a quick break system is functioning properly, an oscilloscope is often used. By
observing the sine wave of the current, it can be determined if current drops abruptly when the observing the sine wave of the current, it can be determined if current drops abruptly when the
circuit is interrupted. circuit is interrupted.
Shot Timer Check Shot Timer Check
When a timer is used to control the shot duration, the timer must be calibrated. ASTM E When a timer is used to control the shot duration, the timer must be calibrated. ASTM E--1444 1444 --
01 requires the timer be calibrated to within +/ 01 requires the timer be calibrated to within +/ -- 0.1 second. A certified timer should be used to 0.1 second. A certified timer should be used to
verify the equipment timer is within the required tolerances. verify the equipment timer is within the required tolerances.
Yoke calibration is done by dead weight . AC 4.5 Kilo. DC 18.1 kilo. Yoke calibration is done by dead weight . AC 4.5 Kilo. DC 18.1 kilo.
Lighting Lighting
Magnetic particle inspection predominately relies on visual inspection to detect any Magnetic particle inspection predominately relies on visual inspection to detect any
indications that form. Therefore, lighting is a very important element of the inspection indications that form. Therefore, lighting is a very important element of the inspection
process. Obviously, the lighting requirements are different for an inspection conducted process. Obviously, the lighting requirements are different for an inspection conducted
using visible particles than they are for an inspection conducted using fluorescent using visible particles than they are for an inspection conducted using fluorescent
particles. The lighting requirements for each of these techniques, as well as how light particles. The lighting requirements for each of these techniques, as well as how light
measurements are made, are discussed below. measurements are made, are discussed below.
Light Requirements When Using Visible Particles Light Requirements When Using Visible Particles
Magnetic particle inspections that use visible particles can be conducted using natural Magnetic particle inspections that use visible particles can be conducted using natural
or artificial lighting. When using natural lighting, it is important to keep in mind that or artificial lighting. When using natural lighting, it is important to keep in mind that
daylight varies from hour to hour. Inspector must constantly stay aware of the lighting daylight varies from hour to hour. Inspector must constantly stay aware of the lighting
conditions and make adjustments when needed. To improve the uniformity of lighting conditions and make adjustments when needed. To improve the uniformity of lighting
from one inspection to the next, the use of artificial lighting is recommended. Artificial from one inspection to the next, the use of artificial lighting is recommended. Artificial
lighting should be white whenever possible and white flood or halogen lamps are most lighting should be white whenever possible and white flood or halogen lamps are most
commonly used. The light intensity is required to be 100 foot commonly used. The light intensity is required to be 100 foot--candles at the surface candles at the surface
being inspected. It is advisable to choose a white light wattage that will provide being inspected. It is advisable to choose a white light wattage that will provide
sufficient light, but avoid excessive reflected light that could distract from the sufficient light, but avoid excessive reflected light that could distract from the
inspection. inspection.
UV or Black light UV or Black light
Light Requirements When Using Fluorescent Particles Light Requirements When Using Fluorescent Particles
Ultraviolet Lighting Ultraviolet Lighting
When performing a magnetic particle inspection using fluorescent particles, When performing a magnetic particle inspection using fluorescent particles,
the condition of the ultraviolet light and the ambient white light must be the condition of the ultraviolet light and the ambient white light must be
monitored. Standards and procedures require verification of lens condition monitored. Standards and procedures require verification of lens condition
and light intensity. Black lights should never be used with a cracked filter as and light intensity. Black lights should never be used with a cracked filter as
the output of white light and harmful black light will be increased. The the output of white light and harmful black light will be increased. The
cleanliness of the filter should also be checked regularly since a coating of cleanliness of the filter should also be checked regularly since a coating of
solvent carrier, oil, or other foreign material can reduce the intensity or light solvent carrier, oil, or other foreign material can reduce the intensity or light
by as much as 50%. The filter should be checked visually and cleaned as by as much as 50%. The filter should be checked visually and cleaned as
necessary before warming necessary before warming--up the light. up the light.
For UV lights used in component evaluations, the normally accepted intensity For UV lights used in component evaluations, the normally accepted intensity
is 1000mwatts/ cm2 when measured at 15 inches from the filter face is 1000mwatts/ cm2 when measured at 15 inches from the filter face
(requirements can vary from 1000 to 1200mwatts/ cm2). The required check (requirements can vary from 1000 to 1200mwatts/ cm2). The required check
should be performed when a new bulb is installed, at startup of the inspection should be performed when a new bulb is installed, at startup of the inspection
cycle, if a change in intensity is noticed, or every eight hours if in continuous cycle, if a change in intensity is noticed, or every eight hours if in continuous
use. Regularly checking the intensity of UV lights is very important because use. Regularly checking the intensity of UV lights is very important because
bulbs lose intensity over time. In fact, a bulb that is near the end of its bulbs lose intensity over time. In fact, a bulb that is near the end of its
operating life will often have an intensity of only 25% of its original output. operating life will often have an intensity of only 25% of its original output.
Black light intensity Black light intensity
will also be affected by voltage variations, so it is important to provide will also be affected by voltage variations, so it is important to provide
constant voltage to the light. A bulb that produces acceptable intensity at constant voltage to the light. A bulb that produces acceptable intensity at
120/ 230 volts will produce significantly less at 110/ 200 volts. 120/ 230 volts will produce significantly less at 110/ 200 volts.
Ambient White Lighting Ambient White Lighting
When performing a fluorescent magnetic particle inspection, it is important to When performing a fluorescent magnetic particle inspection, it is important to
keep white light to a minimum as it will significantly reduce the inspectors keep white light to a minimum as it will significantly reduce the inspectors
ability to detect fluorescent indications. Light levels of less than 2fc are ability to detect fluorescent indications. Light levels of less than 2fc are
required by most procedures and some procedures require it to be less than required by most procedures and some procedures require it to be less than
0.5fc at the inspection surface. Some specifications require that a white light 0.5fc at the inspection surface. Some specifications require that a white light
intensity measurement be made at 15 inches from a UV light source to verify intensity measurement be made at 15 inches from a UV light source to verify
that the white light is being removed by the filter. that the white light is being removed by the filter.
White Light for Indication Confirmation White Light for Indication Confirmation
While white light is held to a minimum in fluorescent inspections, procedures While white light is held to a minimum in fluorescent inspections, procedures
may require that indications be evaluated under white light. The white light may require that indications be evaluated under white light. The white light
requirements for this evaluation are the same as when performing an requirements for this evaluation are the same as when performing an
inspection with visible particles. The minimum light intensity at the surface inspection with visible particles. The minimum light intensity at the surface
being inspected must be 100fc. being inspected must be 100fc.
Light Measurement Light Measurement
Light intensity measurements are made using a radiometer. A radiometer is an Light intensity measurements are made using a radiometer. A radiometer is an
instrument that translates light energy into an electrical current. Light striking a silicon instrument that translates light energy into an electrical current. Light striking a silicon
photodiode detector causes a charge to build up between internal layers. When an photodiode detector causes a charge to build up between internal layers. When an
external circuit is external circuit is
connected to the cell, an electrical current is produced. This current is linear with connected to the cell, an electrical current is produced. This current is linear with
respect to incident light. Some radiometers have the ability to measure both white and respect to incident light. Some radiometers have the ability to measure both white and
UV light, while others require a separate sensor for each measurement. The sensing UV light, while others require a separate sensor for each measurement. The sensing
area should always be kept clean and free of materials that could reduce or obstruct area should always be kept clean and free of materials that could reduce or obstruct
light reaching the sensor. light reaching the sensor.
Radiometers are relatively unstable instruments and readings often change Radiometers are relatively unstable instruments and readings often change
considerably over time. Therefore, they must be calibrated regularly. They should be considerably over time. Therefore, they must be calibrated regularly. They should be
calibrated at least every six months. A unit should be checked to make sure its calibrated at least every six months. A unit should be checked to make sure its
calibration is current before taking any light readings. calibration is current before taking any light readings.
Ultraviolet light measurements should be taken using a fixture to maintain a minimum Ultraviolet light measurements should be taken using a fixture to maintain a minimum
distance of 15 inches from the filter face to the sensor. The sensor should be centered distance of 15 inches from the filter face to the sensor. The sensor should be centered
in the light field to obtain the peak reading. UV spot lights are often focused which in the light field to obtain the peak reading. UV spot lights are often focused which
causes intensity readings to vary considerable over a small area. White lights are causes intensity readings to vary considerable over a small area. White lights are
seldom focused and, depending on the wattage, will often produce in excess of the seldom focused and, depending on the wattage, will often produce in excess of the
100fc at 15 inches. 100fc at 15 inches.
Daily Test to be done. Daily Test to be done.
Check the Maximum output of the Machine. Check the Maximum output of the Machine.
Check the intensity of the Black / UV light . Check the intensity of the Black / UV light .
Proper agitation of the bath. Proper agitation of the bath.
Check with ASTM Pie field for the optimum current used(field adequacy & direction Check with ASTM Pie field for the optimum current used(field adequacy & direction
of magnetization). of magnetization).
Check with digital gauss meter with Hall probe meter for proper field strength for Check with digital gauss meter with Hall probe meter for proper field strength for
some special cases. some special cases.
Check with QQI shim or Castrol strips in Multi directional machine for optimum field Check with QQI shim or Castrol strips in Multi directional machine for optimum field
strength at all places. strength at all places.
Check with Ketos ring for sufficient sub Check with Ketos ring for sufficient sub--surface sensitivity of the Machine, for surface sensitivity of the Machine, for
machines having HWDC/ FWDC / 3 Phase Full wave DC machine. machines having HWDC/ FWDC / 3 Phase Full wave DC machine.
Check the concentration strength of the Bath. Check the concentration strength of the Bath.
Check for the contamination of the Bath. Check for the contamination of the Bath.
Check proper demagnetization with the help of Residual field meter or Digital meter. Check proper demagnetization with the help of Residual field meter or Digital meter.
Check for any loose collection . Check for any loose collection .
safety safety
Ensure the UV filter glass is not cracked or broken. Ensure the UV filter glass is not cracked or broken.
Use UV spectacles for protecting your eye and better indications. Use UV spectacles for protecting your eye and better indications.
The person inspecting should not wear dark glasses or photo chromic glasses. The person inspecting should not wear dark glasses or photo chromic glasses.
Ensure the person is inside the dark room before inspection with Fluorescent particle. Ensure the person is inside the dark room before inspection with Fluorescent particle.
Use hand protective cream when using oil base powder. Use hand protective cream when using oil base powder.
Use hand gloves if necessary. Use hand gloves if necessary.
Please try to get the MSDS from the suppliers for all the chemicals & oils used. Please try to get the MSDS from the suppliers for all the chemicals & oils used.
Precaution against inhalation , eye contact , skin irritation should be taken. Precaution against inhalation , eye contact , skin irritation should be taken.
When using oil base please know the flash point of the liquid used. When using oil base please know the flash point of the liquid used.
Never keep the Residual field indicator close to any magnetic field. Never keep the Residual field indicator close to any magnetic field.
The open output voltage in the MPI machine should not exceed more than 24 The open output voltage in the MPI machine should not exceed more than 24 --28 28
Volt. Volt.
Ensure there is no electrical leakage, proper grounding should be done. Ensure there is no electrical leakage, proper grounding should be done.
Ensure unnecessary use of high current . Ensure unnecessary use of high current .
Avoid improper contact of parts , heavy arcing might take place. Avoid improper contact of parts , heavy arcing might take place.
Questions Questions
1. 1. Which is the best magnetic particle to be used Which is the best magnetic particle to be used
at a temperature above 100 C? at a temperature above 100 C?
2. 2. What is the difference between Residual Field What is the difference between Residual Field
Meter & Digital Gauss meter? Meter & Digital Gauss meter?
3. 3. The best current for Sub The best current for Sub-- surface defect ? surface defect ?
Why? Why?
4. 4. The best Demagnetization Technique? Or The best Demagnetization Technique? Or
Process. Process.
5. 5. Batch of nuts & bolts, the best & the fastest Batch of nuts & bolts, the best & the fastest
method of demagnetization? method of demagnetization?
Questions Questions
1. 1. Quick break circuit when is it used? Quick break circuit when is it used?
2. 2. White light emission from the black light or a White light emission from the black light or a
UV source should not exceed? UV source should not exceed?
3. 3. The best magnetization current for weld The best magnetization current for weld
inspection & the particle? inspection & the particle?
4. 4. Best method of inspection Continuous or Best method of inspection Continuous or
Residual ? Residual ?
5. 5. Which particle Dry or Wet has got better Which particle Dry or Wet has got better
permeability ? Mobility ? permeability ? Mobility ?
Questions Questions
1. 1. Toroidal Technique why is it used ? Toroidal Technique why is it used ?
2. 2. Output voltage should be within Output voltage should be within------ ------ in a MPI in a MPI
machine. machine.
3. 3. In Multi direction machine the First Magnetic In Multi direction machine the First Magnetic
Field to be given in the component is? Field to be given in the component is?
4. 4. The second field ? & why? The second field ? & why?
5. 5. When is Demagnetization not required after When is Demagnetization not required after
magnetizing the component. magnetizing the component.
6. 6. The best direction of the Demagnetizer coil The best direction of the Demagnetizer coil
opening. opening.
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Compiled Compiledby by
RR..Vivekh Vivekh..