Alternating Current Versus Direct Current. In an experiment designed to compare the effectiveness of 60-Hz
alternating current and three types of direct current, 12 holes representing artificial defects were drilled in a 127 mm (5
in.) OD by 32 mm (1 in.) ID by 22 mm ( in.) thick ring made of unhardened O1 tool steel (0.40% C). The 12 holes,
1.8 mm (0.07 in.) in diameter and spaced 19 mm ( in.) apart, were drilled through the ring parallel to the cylindrical
surface at increasing distances from that surface. The centerline distances ranged from 1.8 to 21.3 mm (0.07 to 0.84 in.),
in increments of 1.8 mm (0.07 in.). A central conductor, dry magnetic particles, and continuous magnetization were used
for this test. The three types of direct current were straight direct current from batteries, three-phase rectified alternating
current with surge, and half-wave rectified single-phase 60-Hz alternating current. The threshold values of current
necessary to give readable indications of the holes in the ring are plotted in Fig. 17.
Current levels as read on the usual meters were varied from the minimum needed to indicate hole 1 (1.8 mm, or 0.07 in.,
below the surface) for each type of current, up to a maximum of over 1000 A. To produce an indication at hole 1 using
alternating current, about 475 A was required, and at hole 2 (3.56 mm, or 0.14 in., below the surface), over 1000 A. Hole
3 (5.33 mm, or 0.21 in., below the surface) could not be revealed with alternating current at any current level available.
Indications at hole 2 were produced using 450-A straight direct current, 320-A direct current preceded by a surge of twice
that amperage, and 250-A half-wave current. Indications were produced at hole 12 (21.3 mm, or 0.84 in., below the
surface) using 750-A half-wave current, while 975-A straight direct current was required for hole 10 (17.8 mm, or 0.70
in., below the surface).
The current levels needed to produce indications using wet particles were somewhat higher. For example, an indication
for hole 1 using direct current and wet particles required approximately 440 A, and for hole 3, approximately 910 A. Over
625 A was required to detect hole 1 using alternating current and wet particles.
The hardness of the testpiece also had an effect on the current level needed to produce indications. At a hardness of
63 HRC, to produce an indication at hole 1, approximately 200 A of half-wave current, 300 A of direct current with surge,
and 450 A of direct current were needed. For hole 3, the current levels needed for the three types of current were
approximately 1300, 1875, and 2700 A, respectively. Tests similar to the one described above have been performed on
ring specimens made of 1020 and 4130 steels (Ref 1).
For the inspection of finished parts such as machined and ground shafts, cams, and gears of precision machinery, direct
current is frequently used. Alternating current is used for detecting fine cracks that actually break the surface, but direct
current is better for locating very fine nonmetallic stringers lying just beneath the surface.
Method of Magnetization
The method of magnetization refers to whether residual magnetism in the part provides a leakage field strong enough to
produce readable indications when particles are applied or if the part must be continuously magnetized while the particles
are applied.
Residual Magnetism. The procedure for magnetic particle inspection with residual magnetism, using either wet or dry
particles, basically consists of two steps: establishing a magnetic field in the part and subsequently applying the magnetic
particles. The method can be used only on parts made of metals having sufficient retentivity. The residual magnetic field
must be strong enough to produce leakage fields at discontinuities that in turn produce readable indications. This method
is reliable only for detecting surface discontinuities.
Either the dry or the wet method of applying particles can be used with residual magnetization. With the wet method, the
magnetized parts can either be immersed in a gently agitated bath of suspended metallic particles or flooded by a curtain
spray. The time of immersion of the part in the bath can affect the strength of the indications. By leaving the magnetized
part in the bath or under the spray for a considerable time, the leakage fields, even at fine discontinuities, can have time to
attract and hold the maximum number of particles. The location of the discontinuity on the part as it is immersed has an
effect on particle buildup. Buildup will be greatest on horizontal upper surfaces and will be less on vertical surfaces and
horizontal lower surfaces. Parts should be removed from the bath slowly because rapid removal can wash off indications
held by weak leakage fields.
Continuous Magnetism. In the continuous method, parts are continuously magnetized while magnetic particles are
applied to the surfaces being inspected. In the dry-particle continuous method, care must be taken not to blow away