Magnetic Particle Inspection Training Course Syllabus

Magnetic Particle Inspection Training Course Syllabus - Level II

1. HISTORY AND DEVELOPMENT OF MPI

2. GLOSSARY OF TERMS
Important terms used in MPI

3. CLASSIFICATION OF MATERIALS
Ferromagnetic, diamagnetic, paramagnetic.

4. TYPICAL MATERIAL FLAWS DETECTED BY MPI
All defect types, primary, secondary, fabrication, processing, whether surface or sub-surface.

5. MAGNETS, MAGNETIC FIELDS, ELECTRICAL THEORY
Nature of fields, lines of force, flux density, theory of magnetism, atoms, electrons, domains, Maxwell, Oersted, Gauss, field strength, magnetizing force.

6. LEAKAGE FIELDS
Cause, nature, density, direction, location, measurement.

7. MAGNETIC FIELDS - CREATION OF
Currents, circular magnetism, longitudinal magnetism, right hand rule, effect on compass, in and around a conductor.

8. HYSTERISIS
Total description B/H ratio, different materials, loops, curves, permeability, retentivity, reluctance, coercive force.

9. WAVEFORMS
Currents and how produced. Currents required, values, alloys, penetration, effect of waveforms, wet and dry, platings, coating, skin effect.

10. DEFECT DIRECTION
Maximum sensitivity, angle, size, shape. Depth breaking flux lines, AC, DC, swinging fields, area position.

11. METHODS OF MAGNETISM
Current flow, magnetic flow, threader bar, coil, induction, impulse, threading coil, flexible threading bar, prods, longitudinal, circumferential. Direction of each method and preferred defect direction to give maximum sensitivity.

12. MAGNETIZING UNITS
Machine types, universal, power packs, crabs, cables etc. Use of contact areas, ammeters, coils, burning, insulation of threader bars, time, wet, dry, portable equipment.

13. INKS
Wet, dry, fluorescent. Agitation, mobility, visibility, carrier fluids, flash points, working temperature, types, brands, BS and other specifications, requirements,
concentrations, particle size, shape, permeability, retentivity, colors. Methods of application. Agitation.

14. OPERATION SEQUENCE
Basic principles. Selection of correct flux density value. Selection of suitable test procedure. Application of current. Knowledge of work piece.

15. PREPARATION OF PARTS
Degreasing, demagnetization, surface finish color, background, sprays, shot/grit blast, pickling, coatings, platings, forged machined, cast, formed.

16. INSPECTION
Black, fluorescent. Handling, rotation, viewing aids, white and black light levels. Light spectrum. Booths, curtains. Ambient or required light. Frequency and number of inspections. Corrosion and protection.

17. INTERPRETATION OF INDICATIONS
Relevant and non-relevant. All indicated by flux leakage fields. Cracks, grinding, fatigue, heat treatment, etc. Inclusions, stringers, scores, machine marks, brazed joints, over magnetization, grain boundaries, etc.

18. DEMAGNETIZATION
AC reducing, AC/DC yoke, DC yoke, principles and methods. Object material, object geometry, homogeneity, harness, field intensity during magnetization, coercive force, curie point. Residual checks and equipment. Stages carried out and reasons.

19. CONTROL CHECKS
Ammeters, black light, test bars, ink checks, demagnetizers, monitors, housekeeping, check charts, ancillaries, component markings, functional checks.

20. LIMITATION OF MPI
Penetration, section change, blind holes, welds.

21. PRECAUTIONS
Smoking. Trichloroethylene, inks and carrier fluids, mixing of inks, component arcing, black light exposure equipment and handling. General housekeeping, eye protection, protective clothing.

22. REPLICAS
Various types, hot and cold, tapes, polyvinyl chloride paste. Production of a replica, equipment required, quality advantages, limitations.

23. TECHNIQUE PREPARATION
Basic shapes leading to technique build up, coverage clarity, expediency, contact areas, problems.

24. EQUIPMENT
Use of check ammeters, taking ink samples, using equipment, using power packs, portables, use of flux indicators, mixing inks, current flow, threader bar, induction, etc. Surface finishes, rotation of components.

25. PRACTICAL
The practical section of this course will be conducted on typical samples of cast, wrought and welded products.
The use of comparators and quality assurance facilities will be encountered.

26. PRACTICAL SPECIFIC TRAINING
Practical training based on the controlling Specifications to include, control and maintenance checks (calibration of test pieces, ammeters, plant performance checks, control of detection media etc.), current values, current selection with regard to wave form, processing parameters, sequence, technique preparation, use of Quality Acceptance standards . This training is to be conducted at the Candidate’s place of work

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