Good Practices User Guide

MAGNETIC PARTICLES TESTING

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TABLE OF CONTENTS
Topic sheet M01
General points Main processes of magnetic particles testing

Topic sheet M02

Products used for manual inspection Accessories and devices for quality control for manual inspection of magnetic particles testing

Topic sheet M03

Constraints and environmental risks Risks for the operator associated with the implementation of magnetic particles inspection

Topic sheet M04

Approach to reduce the environmental footprint of the magnetic particles testing Practices to minimize risks of accidents Improvements for a greener manual magnetic particles testing Other techniques for improving magnetic particles testing

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Magnetic Particles Testing

Topic Sheet

M01 General points

Magnetic particles testing (MT) is a method of non-destructive testing which consists of developed an intense magnetic flux inside a ferromagnetic material. With the penetrant testing, this technique represent 50% of the non-destructive field. During the magnetization of a ferromagnetic part, a defect close to the surface disturbs the magnetic field lines, creating a leakage flow highlighted by using magnetic particles which can be dry powders or in suspension in an aqueous or organic liqueur.

Magnetic particles testing can only be performed on ferromagnetic material This technique allows the detection of surface or underlying defects

The defect appears as a magnetic indication visible to the naked eye under white or UV light (particles with fluorescent pigments). To optimize its detection, the defect direction should be perpendicular or slightly disoriented compared with the direction of the created magnetic field. Magnetic particles testing reveals surface defects, such as : Cracks. Lacks of fusion. Forging folds. This technique does not allow to detect porosity or pitting (holes). Magnetic particles testing requires the use of chemicals almost at every step of the implementation.

Local modification of the trajectory Large variation of field

North

South

Change in section

Defect

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Main process of magnetic particles testing

They are different processes of magnetization:

Topic Sheet

M01

Longitudinal magnetization (detection of transverse defects)

Transverse magnetization (detection of longitudinal defects)

Electromagnetic field lines Electromagnetic field lines

Magnetic particles testing bench:

Electric current flowing directly into the part

Solenoid

Electromagnetic field lines

Can detect longitudinal defects by current flowing in the part Can detect transverse defects by magnetic flux flowing in the part

Solenoid

Conductor

Circumferential magnetization by mean of a central conductor

Electromagnetic field lines

Electromagnet

Electromagnet

Magnetization using handheld electrodes

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Magnetic Particles Testing

Topic Sheet

M02 Products used for manual inspection

Types of products:
Cleaning products: Cleaning products are used in order to facilitate the mobility of magnetic particles on the surface of the part and to prevent the appearance of spurious magnetic images. Main cleaner products used: ethyl acetate, acetone, isopropyl alcohol, ... There are other types of cleaning processes: chemical, mechanical (blasting, sandblasting). They are generally not allowed or implemented with great caution (may occasionally plug the defects). Contrasting paints: In the case of a white light inspection, application of a white contrasting paint to increase the sensitivity of defects detection.

Magnetic products: Magnetic particles are oriented along the leakage flux, allowing defect detection. Magnetic products used: dry powders, organic or aqueous magnetic inks.

Product packagings:
Aerosol cans. Bulk.

Application methods of magnetic indicators:

Spraying magnetic inks. Powdering for dry powder indicators.

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Accessories and devices for quality control for the manual inspection of magnetic particles testing.
Accessories :
Equipments for magnetization by magnetic flux: Electromagnets : Directly mains supply or power supply by transformer or batteries. - Magnetization or demagnetization coils. - Possibility of using coils with quick opening and closing system.

Topic Sheet

M02

Coils :

Contact electrodes for electrical current flowing in the part. Electric power source (electric current generator) : Can generate electric currents of different intensities, frequencies and waveform depending on the parts to control.

Lighting equipments : White lighting. UV lighting (fluorescent penetrant testing).

Devices for quality control:

Magnetic field measurement and quality control of the magnetization: Ensure that the magnetic field strength is optimal for the detection of the defects Luxmeter and UV radiometer : Allow to ensure that the control is carried out under recommended lighting conditions.

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Magnetic Particles Testing

Topic Sheet

M03 Constraints and environmental risks

Ecological impact of penetrant and magnetic particles testing in France per year: 100 000 tons of organic products. 200 000 tons of waste. MkWh 1000 is 200 million tons CO2 equivalent. In Europe : these figures are multiplied almost by 10. Products used for magnetic particles testing present significant risks to the operator and the environment. These products are: In general flammable (organic products) and explosives (spray cans). Toxic to the aquatic environment. Hazardous to health operators (must not be inhaled / ingested or in contact with eyes or skin). Usually contain volatile organic compounds (VOCs) with a potentially greenhouse effect. In general, the magnetic particles testing operation produces a large quantity of wastes (effluent, rags, empty cardboard packing).

VOCs are the cause of the ozone layer destruction. The ISO 14001 and the related European Directives, lead each company to reduce its VOC emissions.

The implementation of magnetic particles inspection required large amount of energy particularly for magnetization and demagnetization of parts.

Environmental challenges and objectives of the Green Testing project: Reduce environmental pressures (energy consumption, greenhouse gases and VOCs emission, waste production by 20% to 30%), potential risks to operators health and arduousness tasks. Reduce drastically inspection costs (from 20% to 40%). Reduce environmental pollution (by 90%) through the provision of alternative technologies.

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Risks for the operator associated with the Topic implementation of magnetic particles Sheet inspection
Indirect risks: Risks associated with handling parts (parts dropping, fingers jamming).
Risk of burns associated with current flow in parts and hot parts.

M03

Electrical hazards : Electrocution hazards due to the use of both electrical sources and the water simultaneously to achieve the magnetic particles inspection.

Risks of explosion due to spray cans: Care must be taken when using aerosols near direct heat sources (welding, hot parts, for example) because of the flammability of materials used and the risk of explosion of spray cans.

Risks related to vapours exposure of magnetic particles testing materials (solvents and organic products): Exposure to solvent and organic product vapours is deemed hazardous to health.

Risks related to UV radiation:: Skin aging and cancer. Eyes problems(cataract).

Risks due to electric and magnetic fields: Indirect risks : fires, explosions, projection of ferromagnetic objects Direct risks : modification the electrocardiogram, malaise (high intensity fields), health effects(decrease of melatonin secretion, leukemia, immune
system changes, visual disturbances)

Low frequency electromagnetic fields (less than 100 kHz) are classified as potentially carcinogenic to humans (group 2B). However, it has not been possible so far to establish a causal link between exposures and occurrence of leukemia. However, studies are insufficient to conclude definitively whether the carcinogenicity of low frequencies electromagnetic fields.

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Magnetic Particles Testing

Topic Factsheet Sheet

M04 04

Approach to reduce the environmental footprint of the magnetic particles testing

To manage the environment in everyday life:

Generally speaking, companies must invest in a policy of proactive protection, for example by setting up an Environmental Management System (EMS).

The eco approach within the company has been built according to a structured set of steps and controlled at each level of their implementation.

Making an environment diagnosis : Waste diagnosis: waste management by controlling the processing costs; waste reduction and establishment of a sorting and selective collection at the source ... Energy diagnosis: hunt wasting; energy saving solutions; energy recovery solutions (heat). Gaseous and liquid effluents diagnosis: optimized choice costs / performances of the treatment system ; reducing the amount of effluents at the source ; reusing treated wash water; recovering excess of used materials. Other possible diagnoses: dusts and particles; odors; noises.

To inform and educate the different agents or stakeholders

Monitoring: nuisance registry to record incidents occurred and responses relative to the environment feedback.

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Approach to reduce the environmental footprint of the magnetic particles testing

To reduce incomings and outgoings:

Topic Sheet

M04

In every industrial process, all incoming and outgoing parts have a greater or lesser impact on the environment, that it is necessary to minimize as possible.

The incomings: Cleaning products. Products required for the implementation of the magnetic particles testing process (contrasting paint, magnetic inks or dry magnetic powders). Electrical energy required mainly for magnetization operations of parts. Water used for cleaning operations and to prepare dilute solutions ready for use (magnetic inks).

The outgoings: Wastes (cartons, empty spray cans, rags and papers, damaged control equipments : UV or white lightings, electrical cables used for the magnetization,). Sewages and residual cleaning products contaminated by organic or solid debris (magnetic inks, residual oil and grease).

Other possible nuisances: Odors caused by chemicals used or from effluent treatment plant. Noise due to control devices (ventilation noise of magnetization equipment) Noise due to the handling parts in production control plant (falling of parts in the waste / good containers at the end of the testing line for example). Electric, magnetic and electromagnetic fields implemented in the magnetic particles testing, knowing that the demagnetization operations of parts at the end of the inspection generate additional environmental pollution (electrical and magnetic fields) equivalent to those of the magnetization.

fvrier 2012

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Practices to minimize risk of accidents and impact on operators health

Solutions to reduce risks of accident:

Topic Sheet

M04

Collective protective equipments: Ventilation and purifying of atmosphere at the workplace. To delimit / or mark the access to dangerous areas. Protection by recording a dangerous function during interventions. Identification of dangerous products to prevent inadvertent use. Hazard signs To delimit work areas.

Personal protective equipments: Safety shoes and helmets. Goggles. Gloves, protective clothes. Masks or breathing equipments . Hearing protection (falling of parts in the scrap good containers at the end
of the testing line for example).

Give a sens of responsability at the operators : To take into consideration the user sheet of chemicals (by referencing to the company doctor who has at disposal the health and safety sheets ). To know the location of the fire extinguishers and their functionary use. Dont leave tools or parts on ground in the workshop. To keep working equipment and accessories at their place and clean the working place.

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Improvements for a greener manual magnetic particles testing

Magnetic particles products:
Purchase products in bulk rather than spray cans: Diminution of the quantities of packaging and aerosol cans.

Topic Sheet

03

Ecologic inspection products

Give priority to water-based products rather than organic-based products: Reduction of VOC emissions. Non-flammable products. Effluent treatment simplified and maintenance costs reduced (low fouling). Eliminating inherent risks due to the use of organic solvents (harmful, vapors, skin irritation, ...).

Lighting systems:
Preferred LED (white light or UV) to conventional bulbs: Greater light intensity. Energy consumption 50 times smaller than for mercury vapor lamps (2.5 W instead of 100W). Longer life (over 10,000 hours). Less hazardous waste to the environment (especially mercury vapor
lamps UV lamps).

Spray systems:
To prefer rechargeable spray systems (with an adapted spray nozzle and mechanical pressure by pumping): Waste quantity reduced. Quantity of MPI products reduced by 4 compared to the use of an aerosol. Does not require propulsive gas.

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Improvements for a greener manual magnetic particles testing

Magnetization systems and demagnetization system:
To improve the effectiveness of controls through better magnetic coupling between the magnetization system and the inspected part: To match, for exemple the size of the coil to one of the part. To ensure the regular maintenance of the magnetizing benches as well as their accessories and testing equipment (i.e. heating of cables and control materials (heating cables due to poor electrical contacts for the circulation of the current in the parts). To allows substantial energy savings.

Topic Sheet

P04

Ecologic inspection products

Using equipment of new generation, generating low frequencies: Reduces energy consumption (reduction of harmonics, cos close to 1, no heat losses in the thyristors). Reducing exposure to risk by lowering the electromagnetic Maxwell frequency).

Use of inspection kit powered with batteries: Ergonomic system, lighter than a conventional electromagnet. Operator Safety: for inspection in elevation and inside metallic enclosures.

Effluent recovery systems :

Using cleaning fountains with recycling of cleaning products by debris filtration: Reduces the amount of solvent required for cleaning. Use of recovery equipment and wastewater filtration (activated carbon): Prevents the spread of effluents into the environment and allows their treatment. Use vacuum and filtering systems of organic vapors: Prevents the spread of toxic vapours into the atmosphere. Protects the operator against toxic vapours inhalation.

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Other techniques for improving magnetic particles testing

Low frequency magnetic particles testing:
Advantages of this technique: Allow to detect deeper defects. Better contrast of magnetic indications. To limit operators exposure by using a low frequency magnetization (the acceptability thresholds are higher). Magnetic particles testing without contact by rotary field can be used with low frequency magnetic field.

Topic Sheet

M04

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