A REPRINT FROM MACHINERY LUBRICATION MAGAZINE - SEPTEMBER-OCTOBER 2005

Applications and Benefits

of Magnetic Filtration
BY J. BENNETT FITCH, NORIA CORPORATION

O machinery
il filtration in automotive and industrial or steel particles). Typically, one or both lubri-
is essential to achieving cated sliding or rolling surfaces will have iron or
optimum performance, reliability and longevity. steel metallurgy. These include frictional
Lubricant cleanliness is highly important and surfaces in gearing, rolling-element bearings,
lubrication practitioners are provided with piston/cylinders, etc.
numerous options for filtering and controlling
contamination, including disposable filters, Oil Flow Oil Flow
cleanable filters, strainers and centrifugal sepa-
rators. This article discusses the mechanism of
particle separation and reviews the many
applications of magnetic filters and separators
in the lubrication industry today. A brief guide
to commercial filtration products is also
presented.
From its origin in the beneficiation of iron Pattern of
Flux Distribution
ores, the magnet has played a prominent role in
the separation of ferrous solids from fluid
streams. Even in the control of contamination
from in-service lubricants and hydraulic fluids,
magnetic separation and filtration technology
has found a useful niche. Currently, there are a
Iron Particles Ceramic Magnets
number of conventional and advanced products
on the market that employ the use of magnets
in various configurations and geometry. Region of Highest
Magnetic Gradient

Role of Magnetic Filters

Car owners, car mechanics, equipment oper-
ators, maintenance technicians and reliability
engineers know the importance of clean oil in
Wall of Enclosure or
achieving machine reliability. Tribologists and Flow Guide Tube
used oil analysts are also aware that in some
machines as much as 90 percent of all particles Non Ferrous Sheaths

suspended in the oil can be ferromagnetic (iron Figure 1. Magnetic filter showing pattern
of flux distribution and the collected dirt.
 While it is true that conventional mechanical
filters can remove particles in the same size
range as magnetic filters, the majority of these
filters are disposable and incur a cost for each
gram of particles removed. There are other
penalties for using conventional filtration,
including energy/power consumption due to
flow restriction caused by the fine pore-size
filter media. As pores become plugged with
particles, the restriction increases proportion-
ally, causing the power needed to filter the oil
to escalate.
How do Magnetic
Filters Work?
While a large number of configurations exist,
most magnetic filters work by producing a
magnetic field or loading zones that collect
Figure 2. Drain Plug Filter Figure 3. Tank Magnet
Figure 4a. Canisters Figure 4b. Low-efficiency Collection Pot
magnetic iron and steel particles. Magnets are
geometrically arranged to form a magnetic field
having a nonuniform flux density (flux density
is also referred to as magnetic strength) (Figure
1). Particles are most effectively separated
when there is a strong magnetic gradient (rate
of change of field strength with distance) from
low to high. In other words, the higher the
magnetic gradient, the stronger the attracting
magnetic force acting on particles drawing
them toward the loading zones. The strength of
the magnetic gradient is determined by flux
density, spacing and alignment of the magnets.
Various types of magnets can be used in these
filters (see sidebar). Magnets used in some
filters can have flux density (magnetic
strength) as high as 28,000 gauss. Compare this
level to an ordinary refrigerator magnet of
between 60 and 80 gauss. The higher the flux
density, the higher the potential magnetic
gradient and magnetic force acting on nearby
iron and steel particles.
While there are many configurations of
magnetic filters and separators used in process
industries, the following are general classifica-
tions for common magnetic products used in
lubricating oil and hydraulic fluid applications.
Magnetic Plug. The most basic type of
magnetic filter is a drain plug (Figure 2), where
a magnet in the shape of a disc or cylinder is
attached to its inside surface (typically by
adhesion). Periodically, the magnetic plug
(mag-plug) is removed and inspected for ferro-
magnetic particles, which are then wiped from
the plug. Today, such plugs are commonly used
in engine oil pans, gearboxes and occasionally in
hydraulic reservoirs. One useful advantage of
mag-plugs relates to examining the density of
wear particles observed as a visual indication of
the wear rate occurring within the machine
over a fixed period of running time. The
appearance of these iron filings on magnets are
often described in inspection reports using
terms such as peach fuzz, whiskers or
Christmas trees. If one normally sees peach
fuzz, but on one occasion sees a Christmas tree
instead, this would be a reportable condition
requiring further inspection and remediation.
After all, abnormal wear produces abnormal
amounts of wear debris, leading to an abnormal
collection of debris on magnetic plugs.
Rod Magnets. While magnetic plugs are
inserted into the oil below the oil level (for
example, drain port), rod magnets may extend
down from reservoir tops (Figure 3), special
filter canisters (Figure 4) or within the center-
tube of a standard filter element. These
collectors consist of a series of rings or toroidal-
shaped magnets assembled axially onto a metal
rod. Between the magnets are spacers where
the magnetic gradient is the highest, serving as
the loading zone for the particles to collect.
Periodically the rods are removed, inspected
and wiped clean with a rag or lint-free cloth. A
conceptual example of a particular rod magnet
filter is shown in Figure 1. When the rod is
removed, the sheath or shroud can be slid off
the magnet core to remove the collected debris.
This debris can then be prepared for micro-
scopic analysis to aid in assessing machine
condition.
Flow-through Magnetic Filters. Figure 5
illustrates an example of a commercially avail-
able flow-through filter. In this configuration,
sold by Fluid Condition Systems under the
MAGNOM trademark, the magnets are sand-
wiched between metal collection plates that
have specific flow slots (Figure 6). As fluid
passes through the slots, ferromagnetic parti-
cles accumulate in the gap between the plates.
However, they do not interfere with flow (clog-
ging), or risk particles being washed off by
viscous drag. One advantage of flow-through
magnetic filters is the large amount of debris
they hold before cleaning is required. The
cleaning process typically involves removing
the filter core and blowing the debris out from
between the collection plates with an air hose.
Spin-on Filter Wraps. There are several
suppliers of magnetic wraps, coils or similar
devices intended for use on the exterior of spin-
on filter canisters (Figures 7a-c). Spin-on filters
are commonly used in the automotive industry
but are also utilized in a number of low-pres-
sure industrial applications. These wraps
transmit a magnetic field through the steel
filter bowl (can) in order for ferromagnetic
debris to be held tightly against the internal
surface of the bowl, allowing the filter to
operate normally while extending the service
life. Unlike the conventional filter element, the
magnetic filter wrap can be used repeatedly.
Factors Influencing
Magnetic Separating Action
There are a variety of magnets and ways in
which magnetic filters and separators can be
configured in a product’s design. In fact, there
is much more to their performance than simply
the strength or gradient of the magnetic field.
For instance, the size and design of the flow
chamber, total surface area of the magnetic
loading zones, and the flow path and residence
time of the oil are all important design factors.
These factors influence the rate of separation,
the size of particles being separated and
the total capacity of particles retained by the
separator.
The magnetic force acting on a particle is
proportional to the volume of the particle, but
is disproportional to the diameter of the
particle (magnetic force varies with the cube of
the particle’s diameter). For instance, a two-
micron particle is eight times more attracted to
a magnetic field than to a one-micron particle.
This means large ferromagnetic particles are
disproportionately easier to separate from a
fluid compared to smaller particles.
The separating force is proportional to the
magnetic field gradient and also to the particle
magnetization (magnetic susceptibility). Particle
magnetization relates to the degree to which the
particle’s material composition is influenced by a
magnetic field. The most strongly attracted
materials are particles made of iron and steel,
however, red iron oxide (rust) and high-alloy steel
(for example, stainless steel) are weakly attracted
to magnetic fields. Conversely, some nonferrous
compounds such as nickel, cobalt and certain
ceramics are known to have strong magnetic
attraction. Materials that cannot be picked up
with a magnet (such as aluminum) are called
paramagnetic substances.
There are also competing forces which resist
particle separation from the fluid. One such

Figure 5. Flow-through Filter
Figure 6. Collection Plates
7a. Combo Mechanical and Magnetic Filters
force is oil velocity which imparts inertia and
viscous drag on the particle in the direction
of the fluid flow. Depending on the design of
the magnetic filter, the fluid velocity may send
the particle on a trajectory toward or away from
the magnetic field or perhaps in a tangential
direction.
The competing viscous force is also propor-
tional to both the particle’s diameter and the
oil viscosity. If the particle’s diameter or the
oil’s viscosity doubles, then the hydrodynamic
frictional drag doubles accordingly (resistance
to separation). Complicating the situation
further, as mentioned above, the magnetic
attraction increases by a factor of eight when
a particle’s diameter doubles, while the
competing viscous drag sees only a 2X multiple.
This further emphasizes the fact that larger
particles are more easily separated than small
particles, even in an environment of consider-
able viscous drag.
Particle capture efficiency by magnetic tech-
nology can be narrowed down to these
fundamental factors:
1. Particles that are the easiest to separate are
large (100 microns vs. 5 microns) and highly
magnetic (for example, iron and low-alloy
steel).
2. The fluid conditions that best facilitate the
separation of magnetic particles are low oil
viscosity (ISO VG 32 vs. ISO VG 320 for
instance) and low oil flow rate (2 GPM vs. 50
GPM). Even extremely small, one-micron
particles can be separated from the oil if both
of these fluid conditions exist concurrently.
3. The most effective magnetic filters employ
high-flux magnets and are arranged in such a
way that a high-gradient magnetic field
develops.
Pros and Cons
of Magnetic Filters
The decision to use magnetic technology in a
given application depends on various machine
conditions and fluid cleanliness objectives.
These include the expected concentration of
ferrous particles, type of oil used, operating
temperature, surge flow and shock and machine
design. Because of the numerous commercial
products, configurations and applications,
certain items on the lists of advantages and
disadvantages may not apply. Nonetheless, this
list can serve as a starting point for making the
decision whether magnetic technology is a good
choice in a given application:
Possible Advantages
• Reusable Technology – The cost of removing
a gram of particles from the oil with magnetic
technology is low compared to disposable
filters.
• Limited Flow Restriction – Unlike conven-
tional filters, most magnetic filters exhibit
little to no increase in flow restriction (pres-
sure drop) as it loads with particles. While
conventional filters can go into bypass when
they become plugged with particles,
magnetic filters (including mag-plugs and
rods) continue to remove particles and allow
oil flow. For instance, most diesel and gaso-
line engines provide no indication of a filter
that has gone into bypass. In such cases,
the oil may go for an extended period of
time without being filtered. Common
causes of premature plugging of engine filters
include coolant leaks, poor combustion, poor
air filtration and overextended oil drains.
• Extended Life of Conventional Filters –
When used in conjunction with conventional
mechanical filters (Figure 8), an increase in
effective filter service life may be experienced.
In certain cases, two to three times life exten-
sion may be experienced.
• Improved Reliability of Electro- hydraulic
Valves – Servovalves and solenoid valves are
adversely affected by particles that are magnetic
(iron and steel) due to the electromagnets
deployed when actuating these valves. The
continuous and efficient removal ofthese
particles by magnetic filters can substantially
enhance the reliability of these valves.

Types of Magnets
NdFeB (Neodymium-Iron-Boron)
This is the strongest in magnetic strength of all the magnets known to mankind. Neodymium, with a number 60 on the
periodic table, was first thought to be a rare earth element, due to its inclusion in the “rare earth” elements between 57 and
71 on the periodic table. NdFeB was first developed and commercialized in the mid 1980s. Over the years, the strength of this
composition has increased due to new developments.

SmCo (Samarium Cobalt)

Also being one of the “rare earth” elements, Samarium Cobalt can produce magnetic strength near that of NdFeB. It became
available in the 1970s but was rarely used. Due to its expensive composition, fragility and difficulty to manufacture, it is used
only for its benefits of being able to withstand high temperatures and corrosion.

Ferrite (Ceramic)
Today’s refrigerator magnet - ceramic magnets with Barium or Strontium Ferrite - is the most common of all magnets. It is
considerably inexpensive but it contains a lower strength compared to the other magnets. Developed in the 1960s, it was the
“useful” magnet, used everywhere. This type of magnet is cost-effective and resistant to corrosion and demagnetization.

AlNiCo (Aluminum-Nickel-Cobalt)
One of the first magnets developed after plain steel, this magnet has a lower strength rating. It is sensitive to
demagnetization and can be destroyed if stored incorrectly or if it comes in contact with Neodymium-Iron-Boron. It has
excellent machinability and has about half the strength of a ceramic magnet.

Reference: www.wondermagnets.com
 • Lower Risk of Oil Oxidation – Iron and steel
particles are known to promote oil oxidation
by their catalytic properties. Premature oil
oxidation can lead to varnish, sludge and
corrosion. Everything else being equal, the
continuous and efficient removal of iron and
steel particle by magnetic filters should have
a positive impact on oil service life, and over
time, reduce oil consumption if oil is changed
on condition.
• Enhanced Wear Particle Identification –
Traditionally, wear particle identification is
performed microscopically by examining parti-
cles extracted from oil samples (analytical
ferrography). Those particles that have
7b. Combo Mechanical and Magnetic Filters evaded filters have often been reworked
Clean Oil Flow to Engine (comminution) by traveling through heavily
loaded rolling and sliding dynamic machine
Oil Flows Into Filter -
Magnet Circuit clearances. Once ground up, crushed and
pulverized, they are more difficult to analyze to
Filter Canister determine the source location, cause and
severity of wear. However, particles removed
from mag-plugs, magnetic rods and magnetic
Iron Particles filters are often in their original “virgin” state
which can greatly enhance the accuracy of
Halex Coil
machine condition analysis.
• Quick Wear Metal Inspections – Mag-plugs
and rods can be removed for visual inspection
(daily, weekly, etc.) without stopping the
machine or removing a filter. They provide a
High Power
dual service of contaminant removal and
Neodymium Magnet condition monitoring (from the density of
wear particles observed).
7c. Combo Mechanical and Magnetic Filters
• Oil Flow Not Required – Many machines are
lubricated by oil splash, bath, flingers,
slingers and paddles. Without access to a
pump and oil flow, conventional onboard
filters cannot be used to keep the oil clean
and optimize machine reliability (reduce
wear) and lubricant service life (reduce oil
oxidation). However, magnetic plugs and
rods do not require oil to flow in pipes and
lines. They require the oil only to agitate and
circulate in a sump, reservoir or oil pan. This
movement causes these particles to migrate
to a loading surface of the magnetic separator.

8. Combo Mechanical and Magnetic Filters

• Can be Used in Gravity Flow Drain Lines – messy and involves the use of an air hose.
Most wear metal production comes from the Specific cleaning safety precautions must be
business end of a machine (bearings, gears, taken. Magnetic rods and plugs generally
cams, etc.). Oil often returns to tank down need to be wiped clean only at each service
drain lines and headers (flooded or partially interval.
flooded) by gravity. Due to the lack of oil • Separation is not by Size-exclusion
pressure, it is nearly impossible to locate fine Mechanics – As previously discussed, separa-
filtration on gravity drains to catch wear tion is based on physics considerably
debris before it enters the reservoir. different from size-exclusion – the method
However, magnetic filters, rods and plugs which defines the performance of conven-
generally do not restrict flow, enabling these tional mechanical filters. Instead, the capture
particles to be quickly and conveniently efficiency of magnetic separators
removed directly in oil drains. is based on many factors
including the collective influ-
Possible Disadvantages ence of particle size, magnetic
• Detached Particle Agglomerations – A susceptibility, flow rate, viscosity
common risk associated with using magnetic and magnetic field gradient.
separators is the possibility of particles
becoming detached from the magnet and As such, magnetic filters are not
washed downstream in mass, potentially known for having well-defined
entering a sensitive component. This concern micronic particle separation capa-
bility. Therefore, it is important to
is reduced if the magnetic separator is located
determine what micron filter rating
on a drain line or if a conventional filter is posi-
tioned downstream to trap migrating debris.
Risk of debris being washed off is highest Suppliers of Magnetic Filtration Equipment
under surge flow conditions, cold starts, shock, Supplier Plug Rod Flow-through Spin-on
Filters Filter Wraps
high oil viscosity and/or high oil flow rates.
C.G. Enterprises x
• Magnetized Transient Particles – Adding to Automotive Inc.
the risk of particle washoff is the chance of Control Power Co. x
these particles becoming magnetized while General Plug and x
they were attached to the permanent magnet. Manufacturing
After floating downstream, they might adhere Great Lakes x
Hydraulics Inc.
magnetically to frictional surfaces such as
Halex Development
bearings, causing wear. They could also lodge x
and Distribution, LLC
into narrow flow passages, orifices, glands and Hydro-Craft Inc. x
oilways, thus restricting flow. Kebby Industries, Inc. x
• Nonmagnetic Particles Remain Unchecked – Lisle Corporation x
Indeed, magnetic separators will have little Magna-Guard, Inc. x
effect on controlling nonferrous particles Parker Hannifin x x
composed of silica, tin, aluminum or bronze. MAGNOM x
Other types of filters and separators must be S.G. Frantz Company x
used. One Eye Industries, Inc. x x x x
• Cleaning Requirement – Unlike conventional Tiger Mag / FilterMag x
filter elements that are thrown away after Turbo-mag x
becoming plugged, magnetic filters are Twinmagnet / SynLube x
reusable and therefore must be cleaned. The Vescor Corporation x
cleaning procedure varies but typically is Suppliers of Magnetic Filtration Equipment
is needed by the tribological components in the
system, considering the oil viscosity, fluid flow
rate through the filter, the properties of the
challenge particles, etc. Experience shows that
most modern hydraulic components need
protection of at least five microns or greater.
Studies conducted some 20 years ago at the
Fluid Power Research Center at Oklahoma
State University for the Office of Naval
Research showed that no magnetic filter at that
time could satisfy this requirement when used
alone. In such cases, the best choice might be a
combination of conventional and magnetic
filters.
Best Applications
for Filters and Separators
It is logical that the leading applications for
magnetic separators are those where a high
percentage of the particle contamination is
ferromagnetic and the conditions favor a
successful performance of a properly selected
and installed magnetic filter or separator. As
previously discussed, low oil viscosity
combined with low flow rate help to facilitate
the separation process (where applicable). It’s
a good idea to review the lists of advantages
and disadvantages in regards to each applica-
tion and separator type (mag-plug, rod,
flow-through, wrap) considered. Possible uses
for magnetic technology include the following:
• Gearboxes (including final drives, differen-
tials, etc.), both forced-circulating and
splash-fed
• Large diesel engines, especially where the
full-flow filter may prematurely go into
bypass without indication
• Any machine with ferrous frictional surfaces
but no forced oil circulation with filtration
• Applications where the use of magnetic
filters will substantially extend the life of
conventional filters already in use
• Applications where iron particles are known
to be a major contributor to oil oxidation
problems (particularly hot running machines)
• Hydraulic systems, particularly those using
electrohydraulic valves
• In situations requiring better precision in
recognizing abnormal wear particle genera-
tion (and wear particle type)
Many commercial products and suppliers of
magnetic technology for contamination control
of lubricating oils are listed in the sidebar.
Specific questions regarding applications and
these products should be directed to these
suppliers.
Editor’s Note:
The author wishes to thank his father, Jim C. Fitch and
his grandfather, Dr. Ernest C. Fitch, for their help in
writing this article. This article with complete references
can be viewed online at www.machinerylubrication.com