TYPES OF MAGNETIZING CURRENT

By Arthur R. Lindgren

There are four types of magnetizing currents used in Magnetic Particle Inspection with typical
uses for each:

1) Alternating current (AC)

2) Half wave current (HWDC)
3) Single phase, full wave current (lFWDC)
4) Three phase, full wave current (3FWDC)

It is important that the MPI inspector know the pluses and minuses of each and on what
application they find their best use. Multi direction magnetizing will be discussed as a separate
subject.

5.1 ALTERNATING CURRENT (AC)

(Fig. 5.1) The current rises to a peak in one direction, falls to zero, reverses direction and
repeats the cycle in the other direction. The cycle continues 60 times per second. Since this type
of current is passing through zero 120 times per second, the magnetic field it generates is not
able to penetrate very far beneath the surface of the part. The current and the field generated
stay near the skin of the part, no matter how high the value of current used. This is called “skin
effect”. AC works very well for locating defects open to the surface. This includes most fatigue
cracks, grinding cracks, heat treat cracks, thermal cracks found in multi pass welds, handling
cracks in gray iron castings and all cracks which occur in malleable castings. Under production
like conditions, using the wet method, AC should not be relied on to disclose inclusions more than
.010 inches (0.250 mm) below the surface, although the field itself might penetrate a bit further.

(Fig. 5.1) Alternating Current (AC)

5.2 HALF WAVE RECTIFIED CURRENT (HWDC)

(Fig. 5.2) HWDC current is a form of direct current since it flows in only one direction. It is
“pulsed” with wide intervals between pulses. The DC provides good penetration and the pulsing
makes particle mobility excellent when used with dry magnetic particles. It is great for dry
powder multipass weld inspection locating not only thermal cracks but also other defects like slag
inclusions, root cracks, undercuts and incomplete fusion. An experienced inspector, using dry
powder and the “continuous” method, can easily detect flaws .250 inches (6.35 mm) below the
surface.

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 (Fig. 5.2) Half Wave Rectified (HWDC)

When used with the wet method, HWDC current looses its deep penetrating detection qualities
since particle mobility now is controlled by bath flow rather than the pulsing. However, it can be
relied on to find near surface defects defined as those just out of range with AC, slightly deeper
than .010 inches (0.250 mm). Examples would be a forging lap or a fatigue crack when the
surface has been cold worked, closed up and fused. Near surface defects also include grinding
cracks where the surface has gone into compression. These cannot be located with AC but may
sometimes be located with HWDC. Under production like conditions, using the wet method
HWDC should not be relied on to disclose subsurface defects more than .025 inches (0.650 mm)
below the surface.

5.3 SINGLE PHASE FULL WAVE CURRENT (1FWDC)

(Fig. 15.3) Rectifier circuitry changes the direction of current flow during the “negative” portion of
the AC cycle so that current always flows in one direction. Single phase full wave DC is very
close to pure DC. Like HWDC it is also “pulsed”, but the pulses are twice as frequent with no
interval between. For this reason particle mobility is only fair. It is seldom used with prods and
dry powder since HWDC is far superior for locating deep seated defects. Penetration is excellent
on wet applications. For production work, it can be relied on to locate flaws .050 inches (1.3 mm)
below the surface and maybe a bit deeper if conditions are ideal.

(Fig. 5.3) Single Phase Full Wave Rectified (1 FWDC)

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Its overall sensitivity, when used with the wet method, is equal to that which can be attained using
three phase full wave current (3FWDC). Repeated tests have shown that the slight difference in
“ripple” between single and three phase does not affect inspection sensitivity when using the wet
method.

The manufacture of magnetizing equipment producing 1FWDC over 6000 amperes is impractical
due to the heavy primary current required; therefore all 10,000 and 20,000 ampere units use
3FWDC current.

(Fig. 5.4) On three phase full wave units, all phases of the input line circuit are used. They are
each rectified and then combined into one output for use in magnetization. The resulting current
output has very good penetration nearly equivalent to pure DC. Sensitivity wise, it compares with
1FWDC current. For production work it can be relied on to locate flaws .050 inches (1.3 mm)
below the surface and perhaps a bit deeper. Three phase is found in the larger 6000 to 20,000
ampere units, such as those used on heavy aerospace parts.

5.5 SENSITIVITY ESTIMATE

AC HW FWDC
Field Poor Excellent Good
Penetration
Defect found Surface to Surface to 0.650 mm Surface to
Wet Method 0.250 mm (0.025 inches) 1.3 mm
(.01 inches) (.050 inches)
Dry Method Surface to Surface to Surface to
0.250 mm 6.35 mm 1.3 mm
(.01 inches) (.250 inches) (.050 inches)

(Table 5.1)
Sensitivity Estimate
Defect Depth/Current Type

The above numbers will vary by product and type of defect. Use with discretion until your own
product line values are established.

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