MPT Defects and Standards

Magnetic Particle Testing (MPT) is a non-destructive testing method used to detect surface and
near-surface defects in ferromagnetic materials. Here are some common types of defects found
during MPT, along with their corresponding standards and acceptance criteria:

1. Surface Cracks:
 Standard: ASTM E709 - Standard Guide for Magnetic Particle Testing
 Acceptance Criteria: Acceptance criteria may vary depending on the specific application
and industry standards. The size and orientation of the crack, as well as the material being
tested, are considered in evaluating acceptability.
 Subsurface defects can be found in structures such as aircraft components, bridges, and
oil and gas equipment.
 Subsurface defects can be found in structures such as aircraft components, bridges, and
oil and gas equipment.
2. Subsurface Defects:
 Standard: ASTM E1444 - Standard Practice for Magnetic Particle Testing
 Acceptance Criteria: The evaluation of subsurface defects involves considering their
depth, size, and proximity to the surface. Acceptance criteria are typically specified by
relevant codes, standards, or engineering specifications.
 Subsurface defects can be found in structures such as aircraft components, bridges, and
oil and gas equipment.
3. Weld Defects:
 Standard: AWS D1.1/D1.1M - Structural Welding Code - Steel (for steel welds)
 Acceptance Criteria: The acceptance criteria for weld defects will depend on the specific
welding code or standard being used, and may include limits on the size and type of
defects allowed.
 Weld defects can be found in a variety of structures, including pressure vessels, pipelines,
and bridges

4. Fatigue Cracks:
 Standard: ASTM E709 - Standard Guide for Magnetic Particle Testing
 Acceptance Criteria: Fatigue cracks are evaluated based on their size, location, and
severity. The criteria for acceptance depend on the application and the safety
requirements of the component being inspected.
 Fatigue cracks can be found in structures such as aircraft components, bridges, and wind
turbines.
5. Inclusions and Discontinuities:
 Standard: ASTM E1444 - Standard Practice for Magnetic Particle Testing
 Acceptance Criteria: The evaluation of inclusions and discontinuities considers their size,
shape, and location in relation to specified acceptance limits.
 Inclusions and discontinuities can be found in a variety of structures, including pressure
vessels, pipelines, and machinery.
6. Heat Treatment Cracks:
 Standard: ASTM E709 - Standard Guide for Magnetic Particle Testing
  Acceptance Criteria: The acceptance criteria for heat treatment cracks depend on their
size, location, and potential impact on the structural integrity of the material.
 Heat treatment cracks can be found in structures such as automotive components, aircraft
components, and machinery.

It is important to note that acceptance criteria may vary based on the specific industry,
application, and regulations governing the inspection process. Qualified personnel, such as
certified NDT (non-destructive testing) inspectors, are responsible for interpreting the test results
and determining whether the detected defects meet the acceptance criteria set forth by the
relevant standards and codes.

Magnetic Particle Testing (MPT) is a non-destructive testing method used to detect surface and
subsurface defects in ferromagnetic materials. Some of the common types of defects that can be
detected using MPT include:

Cracks

Fatigue cracks

Lack of fusion

Porosity

Inclusions

Welding defects

Corrosion

The acceptance criteria for these defects depend on the specific standard or specification being
used for the inspection. Some of the commonly used standards for MPT include:

ASTM E1444 - Standard Practice for Magnetic Particle Testing

ASME Section V, Article 7 - Nondestructive Examination

ISO 9934-2 - Non-destructive testing -- Magnetic particle testing -- Part 2: Detection media

The acceptance criteria for the defects detected during MPT depend on several factors such as
the size, location, and orientation of the defects, as well as the type of material being inspected.
These criteria are usually specified in the relevant standard or specification being used for the
inspection.
For example, ASTM E1444 specifies that the acceptance criteria for surface-breaking cracks
should be based on the length and width of the crack, as well as the type of part being inspected.
The standard also specifies different acceptance levels for different types of parts, such as
castings, forgings, and welds.

Similarly, ASME Section V, Article 7 specifies acceptance criteria for different types of defects
based on the type of material being inspected, the thickness of the material, and the type of
inspection being performed.

Overall, the acceptance criteria for defects detected during MPT depend on the specific standard
or specification being used for the inspection, as well as the specific factors related to the type of
material and defect being inspected.

 examples of acceptance criteria for defects in welds according to ASTM E1444?

ASTM E1444 provides specific acceptance criteria for defects in welds detected through
magnetic particle testing (MPT). The acceptance criteria vary depending on the type of weld and
the position of the defect within the weld. Here are some examples of acceptance criteria for
weld defects based on ASTM E1444:

1. Surface-breaking cracks in welds:

 For fillet welds: cracks longer than 1/8 inch and located within 1/8 inch of the toe of the
weld are not acceptable.
 For groove welds: cracks longer than 1/8 inch and located within 1/8 inch of the surface
are not acceptable.

2. Subsurface cracks in welds:

 For fillet welds: cracks longer than 1/2 inch are not acceptable.
 For groove welds: cracks longer than 1 inch are not acceptable.

3. Lack of fusion and incomplete penetration in welds:

 For fillet welds: lack of fusion or incomplete penetration that exceeds the thickness of the
thinner member being joined is not acceptable.
  For groove welds: lack of fusion or incomplete penetration that exceeds 10% of the
thickness of the thinner member being joined is not acceptable.

4. Porosity in welds:
 For fillet welds: total porosity exceeding 3% of the weld length is not acceptable.
 For groove welds: total porosity exceeding 3% of the weld volume is not acceptable.

ASTM E1444 is a widely used standard for magnetic particle testing (MPT), which is a non-
destructive testing method used to detect surface and subsurface defects in ferromagnetic
materials. The standard provides guidelines for the inspection of welds using MPT and includes
specific acceptance criteria for various types of weld defects.

In addition to the examples I provided earlier, here are some additional acceptance criteria for
weld defects based on ASTM E1444:

5. Incomplete fusion in welds:

 For fillet welds: incomplete fusion that exceeds the thickness of the thinner member
being joined is not acceptable.
 For groove welds: incomplete fusion that exceeds 1/8 inch in depth is not acceptable.

6. Undercut in welds:
 For fillet welds: undercut that exceeds 1/32 inch in depth is not acceptable.
 For groove welds: undercut that exceeds 1/32 inch in depth or 1/32 inch in width is not
acceptable.

7. Overlap in welds:
 For fillet welds: overlap that exceeds 1/16 inch in height or width is not acceptable.
 For groove welds: overlap that exceeds 1/16 inch in height or width is not acceptable.

8. Excessive convexity or concavity in welds:

  For fillet welds: excessive convexity or concavity that exceeds 1/8 inch in height is not
acceptable.
 For groove welds: excessive convexity or concavity that exceeds 1/8 inch in depth or
1/16 inch in width is not acceptable.

9. Crater cracks in welds:

 For fillet welds: cracks longer than 1/8 inch and located within 1/8 inch of the toe of the
weld are not acceptable.
 For groove welds: cracks longer than 1/8 inch and located within 1/8 inch of the surface
are not acceptable.

10. Underfill in welds:

 For fillet welds: underfill that exceeds 1/32 inch in depth or 1/16 inch in width is not
acceptable.
 For groove welds: underfill that exceeds 1/8 inch in depth or 1/16 inch in width is not
acceptable.

11. Misalignment in welds:

 For fillet welds: misalignment that exceeds 1/16 inch in height or width is not acceptable.
 For groove welds: misalignment that exceeds 1/8 inch in depth or 1/16 inch in width is
not acceptable.

12. Burn-through in welds:

 For fillet welds: burn-through that exceeds 1/8 inch in depth is not acceptable.
 For groove welds: burn-through that extends beyond the root of the weld is not
acceptable.

13. Arc strikes in welds:

 Arc strikes that exceed 1/16 inch in length or width and are located within 1 inch of the
weld zone are not acceptable.

14. Spatter in welds:

 Spatter that exceeds 1/16 inch in diameter and is located within 1 inch of the weld zone is
not acceptable.
15. Weld reinforcement in welds:

 Excessive weld reinforcement that exceeds 1/8 inch is not acceptable.

16. Weld profile in welds:

 The weld profile should be smooth and consistent, with no abrupt changes or
irregularities that exceed 1/32 inch.

17. Weld size in welds:

 The weld size should be consistent with the requirements of the welding procedure
specification (WPS) and the relevant code or standard being used.

18. Root concavity in welds:

 For groove welds: root concavity that exceeds 1/16 inch in depth or 1/16 inch in width is
not acceptable.

19. Undercut at the root of the weld in welds:

 For groove welds: undercut at the root of the weld that exceeds 1/32 inch in depth or 1/16
inch in width is not acceptable.

20. Incomplete fusion at the root of the weld in welds:

 For groove welds: incomplete fusion that exceeds 1/16 inch in depth or 1/16 inch in
width at the root of the weld is not acceptable.

21. Penetration in welds:

 For groove welds: penetration that exceeds the thickness of the thinner member being
joined is not acceptable.

22. Excessive reinforcement in welds:

 Excessive reinforcement that exceeds the thickness of the thinner member being joined is
not acceptable.

23. Crack-like indications in welds:

 Indications that resemble cracks but do not meet the acceptance criteria for cracks may
still require further evaluation to determine their significance.

24. Reinforcement profile in welds:

  The reinforcement profile should be consistent with the requirements of the welding
procedure specification (WPS) and the relevant code or standard being used.

25. Crater pipe in welds:

 For fillet welds: crater pipes that exceed 1/8 inch in depth or 1/16 inch in width are not
acceptable.
 For groove welds: crater pipes that exceed 1/8 inch in depth or 1/8 inch in width are not
acceptable.

26. Arc strikes at the root of the weld in welds:

 For groove welds: arc strikes at the root of the weld that exceed 1/32 inch in depth or
1/16 inch in width are not acceptable.

27. Incomplete joint penetration in welds:

 For groove welds: lack of joint penetration that exceeds 1/16 inch in depth or 1/16 inch in
width is not acceptable.

28. Incomplete root fusion in welds:

 For groove welds: incomplete root fusion that exceeds 1/16 inch in depth or 1/16 inch in
width is not acceptable.

29. Underfill at the root of the weld in welds:

 For groove welds: underfill at the root of the weld that exceeds 1/16 inch in depth or 1/16
inch in width is not acceptable.

30. Cracks in heat-affected zone (HAZ) in welds:

 Cracks located in the HAZ that exceed 1/8 inch in length are not acceptable.

31. Porosity in HAZ in welds:

 Total porosity exceeding 3% of the weld volume in the HAZ is not acceptable.

32. Incomplete fusion in HAZ in welds:

 Incomplete fusion in the HAZ that exceeds 1/16 inch in depth or 1/16 inch in width is not
acceptable.

33. Lack of fusion in HAZ in welds:

  Lack of fusion in the HAZ that exceeds the thickness of the thinner member being joined
is not acceptable.

34. Lamellar tearing in welds:

 Lamellar tearing that exceeds the acceptance criteria specified in the relevant code or
standard is not acceptable.

35. Joint mismatch in welds:

 Joint mismatch that exceeds the tolerance specified in the relevant code or standard is not
acceptable.

It's important to note that the specific acceptance criteria for weld defects may vary depending on
the type of material being welded, the welding process being used, and the specific requirements
of the inspection. The standard provides guidelines for the inspection and acceptance of welds
based on the industry best practices, and it's up to the inspector to ensure that the weld meets the
relevant standards and specifications.

It's important to note that these are just examples of acceptance criteria for weld defects based on
ASTM E1444, and that the specific criteria may vary depending on the type of material being
welded and the specific requirements of the inspection.

Some examples of relevant standards and specifications for magnetic particle testing in various
industries:

1. Aerospace industry: The aerospace industry typically follows the standards set by the
National Aerospace and Defense Contractors Accreditation Program (NADCAP) for
magnetic particle testing. The specific standards and specifications used by NADCAP
may vary depending on the type of aerospace component being inspected, but they
generally meet the requirements of the Aerospace Material Specification (AMS) 3040
standard.

2. Automotive industry: The automotive industry typically follows the standards set by the
International Organization for Standardization (ISO) for magnetic particle testing. The
specific standard used is ISO 9934-2, which outlines the requirements for magnetic
particle testing of ferromagnetic materials.
 3. Oil and gas industry: The oil and gas industry typically follows the standards set by the
American Petroleum Institute (API) for magnetic particle testing. The specific standard
used is API RP 5A5, which outlines the requirements for magnetic particle testing of drill
stem elements, such as drill pipes, casing, and tubing.

4. Power generation industry: The power generation industry typically follows the standards
set by the American Society of Mechanical Engineers (ASME) for magnetic particle
testing. The specific standard used is ASME Section V, Article 7, which outlines the
requirements for magnetic particle testing of welds in power generation equipment, such
as boilers, pressure vessels, and piping.

5. Structural steel industry: The structural steel industry typically follows the standards set
by the American Welding Society (AWS) for magnetic particle testing. The specific
standard used is AWS D1.1/D1.1M, which outlines the requirements for magnetic
particle testing of welds in structural steel components, such as buildings, bridges, and
towers.

It's important to note that these are just a few examples of relevant standards and specifications
for magnetic particle testing in various industries. The specific standards and specifications used
may vary depending on the type of component being inspected, the location where the inspection
is taking place, and the applicable regulations and codes. The inspector should be familiar with
the relevant standards and specifications and ensure that the inspection meets the applicable
requirements.

To ensure that an inspection meets the applicable requirements, an inspector should follow these
steps:

 Review the relevant standards and specifications: The inspector should review the
relevant standards and specifications that apply to the component being inspected. This
will help the inspector understand the acceptance criteria, inspection procedures, and
other requirements that need to be followed.
  Develop an inspection plan: Based on the standards and specifications, the inspector
should develop an inspection plan that outlines the inspection procedures, methods, and
acceptance criteria.

 Conduct the inspection: The inspector should conduct the inspection using the procedures
and methods outlined in the inspection plan. The inspector should also use appropriate
equipment and techniques to ensure that the inspection is accurate and reliable.

 Evaluate the results: After conducting the inspection, the inspector should evaluate the
results to determine whether the component meets the acceptance criteria specified in the
relevant standards and specifications. If the inspection reveals any defects, the inspector
should determine whether they exceed the acceptance criteria and whether any repairs or
rejections are required.

 Document the inspection: The inspector should document the inspection results,
including any defects and their locations, the inspection procedures used, and any repairs
or rejections that were required. This documentation should be maintained for future
reference and may be required for regulatory compliance or quality control purposes.

By following these steps, the inspector can ensure that their inspection meets the applicable
requirements and that any defects are identified and addressed in a timely and effective manner.