PRC-6505 Rev E

Process Specification for Magnetic Particle

Inspection

Engineering Directorate

Structural Engineering Division

April 2020

National Aeronautics and

Space Administration

Lyndon B. Johnson Space Center

Houston, Texas

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 PRC-6505 Rev E

Process Specification for Magnetic Particle

Inspection
Revised and
Reviewed by: Signature on File 04/08/2020
Ajay Koshti Date
Materials and Processes Branch/ES4

Revised and
Reviewed by: Signature on File 04/07/2020
David Stanley Date
Materials and Processes Branch/ES4

Revised and
Reviewed by: Signature on File 04/07/2020
Norman Ruffino Date
Materials and Processes Branch/ES4

Revised and
Reviewed by: Signature on File 04/07/2020
Miles Skow Date
Materials and Processes Branch/ES4

Approved by: Signature on File 04/17/2020

Brian Mayeaux Date
Materials and Processes Branch/ES4

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 PRC-6505 Rev E

REVISIONS
VERSION CHANGES DATE
Baseline Original version 7/22/99
A Reviewed document per QMS requirements. Updated 12/19/02
division name, organization codes, and document
numbers.
B Deleted SNT-TC-1A and MSFC-STD-1249. Added 02/14/07
NASA-STD-5009 and NASA-STD-5019.
C Revised 4.0 References (added SNT-TC-1A and SOP 02/23/10
009.86), 9.0 Training and Certification of Personnel
(added SNT-TC-1A and SOP 009.86)
D Deleted SOP-009.86 from paragraph 4.0. Revised 6/29/2011
paragraph 9.0 for uniformity across all NDE PRCs.
E Reviewed document per QMS requirement. Updated 04/1/2020
document signatures. Added requirements for Standard
Magnetic particle inspection per NASA-STD- 5009. 1.0
Scope – Added “detection of surface or slightly
subsurface discontinuities”. 2.0 Applicability – Added
“detect cracks, laps, seams, inclusions”. 3.0 Usage –
Added “Continuous Method” in inspection note for flight
hardware. 3.1 Inspection Sequence – Replace “should”
with “shall”. Added “Fasteners with ultimate tensile
strength of 160 ksi (36 HRC) or higher that are
electroplated shall be inspected after the electroplating
operation”. 3.2 Special NDE of Fracture Critical
Components added “Continuous Method” in Special
NDE inspection note. 6.1 General – Added “A
Quantitative Quality Indicator (QQI) shall be used to
validate local field intensities. Hall Effect probes are
acceptable provided they are verified with a QQI”. 6.3
Fracture Critical Components – deleted “c”; added
“When a Hall Effect probe is used to validate field
intensities, readings shall be correlated with a QQI in an
equivalent part location”. 7.0 Special NDE Qualification
deleted “NASA-STD-5003 or SSP 30558”.
10.0 Definitions – 90/95 deleted “lower” and “bound”.

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 PRC-6505 Rev E

1.0 SCOPE

This process specification establishes the minimum requirements for magnetic

particle inspection used for the detection of surface or slightly subsurface
discontinuities in ferromagnetic materials and components.

2.0 APPLICABILITY

This specification is applicable to in-process, final, and in-service magnetic particle

inspections to detect cracks, laps, seams, inclusions, and other discontinuities on or
near the surface. Magnetic particle inspection is not applicable to nonferromagnetic
metals and alloys.

3.0 USAGE

This specification shall be invoked by including an inspection note on the applicable

engineering drawing or by reference in a Process Specification, Task Performance
Sheet, Discrepancy Report/Material Review Record, or other appropriate work
authorizing document. The engineering drawing or referencing document shall
specify the criteria by which components are judged acceptable. Where acceptance
criteria are not otherwise specified the criteria in Section 3.3 shall apply. Other
acceptance criteria, such as those in MIL-STD-1907, may be used as appropriate.
When there are different acceptance criteria for different areas on a component, the
drawing shall be zoned with the acceptance criteria identified for each zone. If the
number of components to be inspected and the amount of coverage of each
component is not specified, all components shall be examined and shall receive 100
percent magnetic particle coverage.

The magnetic particle inspection note for flight hardware and critical ground
equipment is given below.

PERFORM WET, FLUORESCENT, CONTINUOUS METHOD MAGNETIC

PARTICLE INSPECTION PER JSC PRC-6505.

A magnetic particle inspection note for non-critical ground equipment using the
acceptance criteria in MIL-STD-1907 is given below.

PERFORM MAGNETIC PARTICLE INSPECTION PER JSC PRC-6505.

ACCEPTANCE CRITERIA PER MIL-STD-1907, GRADE A.

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 PRC-6505 Rev E

3.1 INSPECTION SEQUENCE

The stage in the manufacturing process where magnetic particle inspection is

performed shall be specified on the engineering drawing or in the referencing
document. Final magnetic particle inspection shall be performed after completion of
all manufacturing operations that can generate surface or near surface
discontinuities. These operations include, but are not limited to, forging, heat treating,
plating, passivation, cold forming, welding, grinding, straightening, machining, and
proof loading. In general, components should be inspected prior to the application of
any coatings. Components other than fasteners heat treated to an ultimate tensile
strength of 180 ksi (40 HRC) or higher that are subsequently electroplated shall be
inspected after the electroplating operation. Fasteners heat treated to an ultimate
tensile strength of 160 ksi (36 HRC) or higher that are subsequently electroplated
shall be inspected after the electroplating operation.

3.2 SPECIAL NDE OF FRACTURE CRITICAL COMPONENTS

When implementation of fracture control requirements necessitates Special

Nondestructive Evaluation (NDE) of a fracture critical component, the requirement
for Special NDE shall appear in the inspection note as shown in below. When Special
NDE is required, the specific inspection procedure and inspector shall be qualified in
accordance with Section 7.0.

PERFORM WET, FLUORESCENT, CONTINUOUS METHOD MAGNETIC

PARTICLE INSPECTION PER JSC PRC-6505. SPECIAL NDE
CERTIFICATION REQUIRED.

3.3 ACCEPTANCE CRITERIA

The engineering drawing or referencing document shall indicate the criteria by which
components are judged acceptable. Where acceptance criteria are not otherwise
specified the following criteria shall apply:

a. Linear indications – all linear indications, regardless of length, shall be

cause for rejection of the component.

b. Single rounded indications – a single rounded indication greater than 0.030 inches in
diameter shall be cause for rejection of the component.

c. Multiple rounded indications - two or more rounded indications each less than
0.030 inches in diameter but separated by less than 0.030 inches shall be
cause for rejection of the component.

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 PRC-6505 Rev E

4.0 REFERENCES

The following specifications, standards, and handbooks form a part of this document
to the extent specified herein. All documents listed are assumed to be the current
revision unless a specific revision is listed. In the case of conflict between this
specification and the technical requirements cited in other referenced documents,
the requirements of this document take precedence.

ASTM E 1444 Standard Practice for Magnetic Particle Inspection

MIL-STD-1907 Inspection, Liquid Penetrant and Magnetic

Particle,Soundness Requirements for Materials, Parts, and
Weldments

NASA-STD-5009 Nondestructive Evaluation Requirements for Fracture

Critical Metallic Components

NAS 410 NAS Certification & Qualification of

Nondestructive Test Personnel

SNT-TC-1A Personnel Qualification and Certification in

Nondestructive Testing

The following references were used to develop this process specification:

JPR 8500.4 Engineering Drawing System Requirements

SOP-007.1 Preparation and Revision of Process Specifications

(PRC’s)

5.0 MATERIAL REQUIREMENTS

Inspection materials shall meet the requirements in ASTM E 1444.

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 PRC-6505 Rev E

6.0 PROCESS REQUIREMENTS

6.1 GENERAL

Magnetic particle inspections shall be performed in accordance with ASTM E 1444

except as modified by this specification. Unless otherwise specified, the wet,
fluorescent, continuous method shall be used for flight hardware and critical ground
equipment. A Quantitative Quality Indicator (QQI) shall be used to validate local field
intensities. Hall Effect probes are acceptable provided they are verified with a QQI.

6.2 WRITTEN PROCEDURES

A detailed written procedure shall be prepared for each part to be inspected. The
procedure shall meet the requirements of this specification and shall ensure the
consistency and reproducibility of the inspection at the required sensitivity level.
General procedures covering a variety different parts may be used provided they
meet the requirements of this specification and clearly apply to the parts to be
inspected. When general procedures are used, a written part specific technique shall
be prepared. At a minimum, the part specific procedure or the general procedure and
part specific technique shall cover all the information required by ASTM E 1444.

For work performed at JSC facilities, written procedures should consist of Detailed
Process Instructions (DPIs) selected for use from the DPI-6505-XX series of work
instructions.

6.3 FRACTURE CRITICAL COMPONENTS

Magnetic particle inspection of fracture critical flight hardware shall be performed in

accordance with the process requirements in NASA-STD-5009. Requirements not
explicitly covered in NASA-STD-5009 include the following:

a. Examination surfaces must be easily accessible with a surface roughness of

125 RMS or better.

b. Inspections shall be performed prior to the application of any coatings.

c. When a Hall Effect probe is used to validate field intensities, readings shall
be correlated with a QQI in an equivalent part location. Pie gages are not
acceptable for verifying field strength.

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 PRC-6505 Rev E

When Special NDE is specified by the engineering drawing or referencing document,

the inspection procedure and inspector shall be qualified in accordance with Section
7.0.

7.0 SPECIAL NDE QUALIFICATION

Use of Special NDE in accordance with NASA-STD-5009 requires formal

demonstration of the capability to detect flaws at least as small as the critical initial
crack size for the specific component to a 90/95 detection level. Each procedure,
procedure application, and operator must demonstrate the required capability.
Requests for Special NDE qualification shall be directed to the JSC Materials and
Processes Branch (ES4).
8.0 DEVIATIONS AND WAIVERS
Any deviations or waivers regarding the use of this process specification shall be
requested in writing. This request shall be directed to the JSC Materials and
Processes Branch (ES4) with the appropriate justification and rationale. A written
response will be provided upon such a request.

9.0 TRAINING AND CERTIFICATION OF PERSONNEL

Personnel performing acceptance inspections of Class I, II, IIIW and GSE hardware
shall be qualified and certified, at a minimum, to Level 2 in accordance with NAS 410.
Personnel performing acceptance inspections requiring Special NDE shall also be
qualified and certified for Special NDE in accordance with NASA-STD-5009.

Personnel performing acceptance inspections of Class III, STE/D, mockup, and

facility hardware shall be qualified and certified in accordance with either NAS
410 or SNT-TC-1A. Personnel making accept/reject decisions shall, at a minimum,
be certified to Level 2. Level 3 personnel making accept/reject decisions shall have
successfully completed a hands-on practical examination equivalent to the
examination required for Level 2. Level 1 personnel may perform acceptance
inspections under the direct supervision of a Level 2 but shall not make accept/reject
decisions.

Formal qualification and certification is not required for personnel performing

engineering evaluation inspections.

10.0 DEFINITIONS

90/95 The point where the 95% lower confidence bound on the
Probability of Detection (POD) vs. flaw size curve crosses
90% POD or 90% POD with 95% confidence.

Discontinuity An intentional or unintentional interruption in the physical

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 PRC-6505 Rev E

structure or configuration of a material or component that

may be detectable by nondestructive testing; a flaw.
Discontinuities are not necessarily rejectable.

Final Inspection The final inspection performed for the acceptance of the
component.

Fracture Critical Classification which assumes that fracture or failure of the

Component component resulting from the occurrence of a crack will
result in a catastrophic hazard. Fracture critical components
will be identified as such on the engineering drawing.

Indication Evidence of a discontinuity that requires interpretation to

determine its significance.

In-Process Inspections which occur during manufacturing before a

component is in final form.

In-Service Inspections performed on components that are in use or

storage.

Linear Indication Penetrant indication with a length to width ratio of 3:1 or

greater.

Rounded Indication Penetrant indication with a length to width ratio of less than
3:1.

Special NDE A fracture control term denoting nondestructive inspection

personnel, procedures, and equipment with a demonstrated
capability to reliably (90/95) detect flaws smaller than those
normally detected by typical procedures.

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