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When a bar magnet is broken in the center of its length, two complete bar
magnets with magnetic poles on each end of each piece will result. If the
magnet is just cracked but not broken completely in two, a north and south
pole will form at each edge of the crack. The magnetic field exits the north
pole and reenters at the south pole. The
magnetic field spreads out when it
encounters the small air gap created by
the crack because the air cannot support
as much magnetic field per unit volume as
the magnet can. When the field spreads
out, it appears to leak out of the material
and, thus is called a flux leakage field.
As seen in the previous pages, electric current is often used to establish the
magnetic field in components during magnetic particle inspection. Alternating current
and direct current are the two basic types of current commonly used. Current from
single phase 110 volts, to three phase 440 volts, are used when generating an
electric field in a component. Current flow is often modified to provide the appropriate
field within the part. The type of current used can have an effect on the inspection
results, so the types of currents commonly used will be briefly reviewed.
Direct Current
Direct current (DC) flows continuously in one direction at a constant voltage. A
battery is the most common source of direct current. As previously mentioned,
current is said to flow from the positive to the negative terminal. In actuality, the
electrons flow in the opposite direction. DC is very desirable when inspecting for
subsurface defects because DC generates a magnetic field that penetrates deeper
into the material. In ferromagnetic materials, the magnetic field produced by DC
generally penetrates the entire cross-section of the component. Conversely, the field
produced using alternating current is concentrated in a thin layer at the surface of the
component.
Alternating Current
Alternating current (AC) reverses in direction at a rate of 50 or 60 cycles per second.
In the United States, 60 cycle current is the commercial norm but 50 cycle current is
common in many countries. Since AC is readily available in most facilities, it is
convenient to make use of it for magnetic particle inspection. However, when AC is
used to induce a magnetic field in ferromagnetic materials, the magnetic field will be
limited to narrow region at the surface of the component. This phenomenon is known
as the "skin effect" and occurs because the changing magnetic field generates
eddy currents in the test object. The eddy currents produce a magnetic field
that opposes the primary field, thus reducing the net magnetic flux below
the surface. Therefore, it is recommended that AC be used only when the
inspection is limited to surface defects.
A field meter is often used to verify that the residual flux has been removed
from a component. Industry standards usually require that the magnetic flux
be reduced to less than 3 gauss after completing a magnetic particle
inspection.
Liquid penetrant inspection is a method that is used to reveal surface
breaking flaws by bleedout of a colored or fluorescent dye from the flaw.
The technique is based on the ability of a liquid to be drawn into a "clean"
surface breaking flaw by capillary action. After a period of time called the
"dwell," excess surface penetrant is removed and a developer applied. This
acts as a blotter. It draws the penetrant from the flaw to reveal its
presence. Colored (contrast) penetrants require good white light while
fluorescent penetrants need to be used in darkened conditions with an
ultraviolet "black light".
Additional information on the human eye can be found by following the links
below.
Primary Advantages
Primary Disadvantages
The penetrant materials used today are much more sophisticated than the
kerosene and whiting first used by railroad inspectors near the turn of the
20th century. Today's penetrants are carefully formulated to produce the
level of sensitivity desired by the inspector. To perform well, a penetrant
must possess a number of important characteristics. A penetrant must:
Penetrant materials come in two basic types. These types are listed below:
Penetrants are then classified by the method used to remove the excess
penetrant from the part. The four methods are listed below:
An interesting note about the sensitivity levels is that only four levels were
originally planned. However, when some penetrants were judged to have
sensitivities significantly less than most others in the level 1 category, the ½
level was created. An excellent historical summary of the development of
test specimens for evaluating the performance of penetrant materials can
be found in the following reference.
Emulsifiers
1. Method A: Water-Washable
2. Method B: Post-Emulsifiable, Lipophilic
3. Method C: Solvent Removable
4. Method D: Post-Emulsifiable, Hydrophilic
Method C relies on a solvent cleaner to remove the penetrant from the part
being inspected. Method A has emulsifiers built into the penetrant liquid
that makes it possible to remove the excess penetrant with a simple water
wash. Method B and D penetrants require an additional processing step
where a separate emulsification agent is applied to make the excess
penetrant more removable with a water wash. Lipophilic emulsification
systems are oil-based materials that are supplied in ready-to-use form.
Hydrophilic systems are water-based and supplied as a concentrate that
must be diluted with water prior to use .
The role of the developer is to pull the trapped penetrant material out of
defects and spread it out on the surface of the part so it can be seen by an
inspector. The fine developer particles both reflect and refract the incident
ultraviolet light, allowing more of it to interact with the penetrant, causing
more efficient fluorescence. The developer also allows more light to be
emitted through the same mechanism. This is why indications are brighter
than the penetrant itself under UV light. Another function that some
developers perform is to create a white background so there is a greater
degree of contrast between the indication and the surrounding background.
Developer Forms
The AMS 2644 and Mil-I-25135 classify developers into six standard forms.
These forms are listed below:
The developer classifications are based on the method that the developer
is applied. The developer can be applied as a dry powder, or dissolved or
suspended in a liquid carrier. Each of the developer forms has advantages
and disadvantages.
Dry Powder
Unless the part is electrostatically charged, the powder will only adhere to
areas where trapped penetrant has wet the surface of the part. The
penetrant will try to wet the surface of the penetrant particle and fill the
voids between the particles, which brings more penetrant to the surface of
the part where it can be seen. Since dry powder developers only stick to
the area where penetrant is present, the dry developer does not provide a
uniform white background as the other forms of developers do. Having a
uniform light background is very important for a visible inspection to be
effective and since dry developers do not provide one, they are seldom
used for visible inspections. When a dry developer is used, indications tend
to stay bright and sharp since the penetrant has a limited amount of room
to spread.
Water Soluble
Water Suspendable
Nonaqueous
Special Applications
Plastic or lacquer developers are special developers that are primarily used
when a permanent record of the inspection is required.