Magnetic Particle Inspection Course

Lesson 1 • Hysteresis and Residual Magnetism

Introduces the B-H curve, coercive force, and retentivity to explain residual magnetism after field removal. Prepares students to choose between continuous and residual MPI techniques.

Lesson 2 • Regulatory and Standards Framework

Surveys international MPI standards, personnel qualification requirements, and written practice obligations. Establishes the compliance mindset needed throughout the course.

Lesson 3 • Magnetic Flux and Leakage Fields

Explains how flux travels through a part and leaks at discontinuities to attract particles. Directly links flux leakage magnitude to discontinuity detectability.

Lesson 4 • Basic Principles of Magnetism

Covers magnetic domains, permeability, and flux density as they apply to ferromagnetic materials. Builds the conceptual foundation required for understanding flux leakage and indication formation.

Lesson 1 • Circular and Longitudinal Magnetisation

Explains how circular magnetisation detects longitudinal defects and longitudinal magnetisation detects transverse defects. Reinforces the 45–90-degree rule for optimal defect detection.

Lesson 2 • Equipment Calibration and Performance Checks

Details ammeter verification, yoke lift tests, and system performance checks required before inspection. Ensures students maintain equipment in a qualified state throughout service.

Lesson 3 • Current Types Used in MPI

Compares AC, HWDC, FWDC, and DC current types for their penetration depth and particle mobility effects. Guides students in matching current type to inspection requirements.

Lesson 4 • Stationary and Portable MPI Equipment

Surveys bench-type wet horizontal units, portable yokes, prods, and coil systems. Students match equipment capability to part size, location, and production volume.

Lesson 1 • Carrier Fluids and Dry Application Media

Examines water-based and oil-based carriers, their viscosity requirements, and dry application conditions. Guides students in selecting media compatible with part material and environment.

Lesson 2 • Bath Concentration and Quality Control

Teaches ASTM settling tests, concentration measurement, and bath contamination assessment procedures. Ensures students maintain bath quality to preserve inspection sensitivity.

Lesson 3 • Particle Application Techniques

Covers spray, flow, and immersion application methods and their effect on indication formation. Links application technique to magnetising method and part geometry.

Lesson 4 • Fluorescent vs. Visible Particle Techniques

Compares sensitivity, lighting requirements, and application domains of fluorescent and visible techniques. Prepares students to justify technique selection based on defect criticality and environment.

Lesson 1 • Determining Magnetising Current Levels

Applies ampere-turn rules, field indicator tools, and pie gauge verification to set adequate field strength. Connects correct field strength to reliable detection of target discontinuities.

Lesson 2 • Continuous vs. Residual Technique Selection

Defines when continuous application is mandatory versus when residual magnetism provides sufficient sensitivity. Ties technique choice to material coercive force and defect type.

Lesson 3 • Inspection Sequence and Coverage Verification

Establishes systematic inspection sequences to ensure 100% coverage of critical areas. Addresses overlap requirements and documentation of coverage maps.

Lesson 4 • Part Preparation and Pre-Inspection Checks

Addresses cleaning, coating removal, and surface condition assessment before magnetisation. Establishes that inadequate preparation is a leading cause of missed indications.

Lesson 1 • Factors Affecting Indication Formation

Analyses how field strength, particle concentration, surface condition, and geometry influence indication sharpness. Helps students diagnose weak or diffuse indications during inspection.

Lesson 2 • Discontinuity Types and Their Indications

Correlates cracks, laps, seams, porosity, and inclusions to their characteristic MPI indication patterns. Enables students to infer probable discontinuity type from indication morphology.

Lesson 3 • Types of Indications in MPI

Defines relevant, non-relevant, and false indications and the mechanisms that produce each type. Establishes the classification framework used throughout evaluation and disposition.

Lesson 4 • Indication Sizing and Recording

Teaches linear and rounded indication measurement, sketching, photography, and lift-off tape methods. Produces accurate records needed for accept/reject decisions and trend analysis.

Lesson 1 • Understanding Acceptance Standards

Reviews acceptance criteria from aerospace, structural, and general industry standards for MPI indications. Establishes that criteria vary by application and must be specified before inspection.

Lesson 2 • Post-Inspection Cleaning and Part Protection

Covers removal of particle media, carrier fluid, and temporary coatings after inspection. Prevents corrosion and contamination that could compromise part integrity or subsequent processes.

Lesson 3 • Accept, Reject, and Repair Decisions

Defines the decision workflow from indication evaluation through final part disposition. Reinforces that disposition authority and criteria must be pre-defined in the inspection procedure.

Lesson 4 • Nonconformance Reporting and Corrective Action

Guides students through nonconformance documentation, root cause analysis, and corrective action follow-up. Connects individual inspection outcomes to quality system improvement.

Lesson 1 • Threaded and Keyway Component Inspection

Applies central conductor and coil techniques to threaded fasteners, shafts, and keyway components. Addresses geometric masking and the need for multiple magnetisation directions.

Lesson 2 • MPI of Welds and Heat-Affected Zones

Addresses weld surface preparation, prod spacing, and yoke positioning for full weld coverage. Identifies weld-specific discontinuities including undercut, lack of fusion, and toe cracks.

Lesson 3 • Inspection of Castings and Forgings

Covers casting and forging discontinuity types, surface conditions, and technique adaptations for complex shapes. Addresses shrinkage, cold shuts, and forging laps as target discontinuities.

Lesson 4 • Large Component and Structural Inspection

Addresses inspection of large structural members, pressure vessels, and heavy forgings using cable wrap and coil techniques. Covers shot sequencing for full coverage of large surface areas.

Lesson 1 • Internal Audits and Continuous Improvement

Guides students through MPI audit checklists, finding classification, and corrective action tracking. Embeds a culture of continuous improvement into daily inspection operations.

Lesson 2 • MPI Programme Management and Oversight

Defines the roles of Level III personnel, written practice administration, and supplier oversight in an MPI programme. Builds competency in managing inspection programmes across multiple sites or contracts.

Lesson 3 • Advanced Magnetisation Techniques

Covers swinging field, multidirectional, and induced current techniques for single-shot full-coverage inspection. Addresses equipment requirements and limitations of advanced magnetisation systems.

Lesson 4 • Probability of Detection and Reliability

Introduces POD concepts, hit/miss and signal response analysis, and their use in validating MPI procedures. Connects statistical reliability to inspection system qualification.