Process Specification

PCS-3100
Issue: 3
Date: 27th January 2009

MAGNETIC PARTICLE INSPECTION

CONTROLE MAGNETOSCOPIQUE

Issue N° Date Changes

1 12/13/2005 Creation of PCS-3100.

2 22/09/2006 Changes to reflect customer requirements.

3 27/01/2009 Minor changes following NUCAP audit.

Compiled by B. ROSSITER: M-DL Level 3 (UK) approved on file

approuvé sur dossier
approved on file
C. THOMAS: M-DL Responsible Level 3 (UK) approuvé sur dossier
approved on file
Agreed by M. O’BRIEN: Supplier Quality Engineer Level 3 (C) approuvé sur dossier
approved on file
M. SOLE: MD-SA Responsible Level 3 (F) approuvé sur dossier

Specification prime P. TAYLOR: Materials and Processes Laboratory Manager approved on file
owner (F) approuvé sur dossier

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 Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

INDEX

Page

1. SCOPE 3

2. ASSOCIATED DOCUMENTS 4

3. DEFINITIONS 5

4. HEALTH AND SAFETY 6

5. GENERAL PRACTICE 6

6. PERSONNEL QUALIFICATIONS 9

7. WRITTEN PROCEDURE 9

8. FACILITIES AND EQUIPMENT 9

9. QUALITY CONTROL 12

10 SYSTEM PERFORMANCE TESTS 15

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

PCS-3100
Magnetic Particle Inspection

1. Scope

A. This specification describes the magnetic particle inspection process that is

applied to both non-electroplated parts and electroplated parts at Messier-Dowty
(M-D).

B. This specification may be implemented immediately, but must be implemented

within 3 months from the date this specification is re-issued.

C. Magnetic particle inspection is used to detect cracks, laps, seams, inclusions and
other discontinuities on or near the surface in parts made of Ferro-Magnetic
materials, including most steels (except austenitic stainless steels). It may also be
applied to nickel-based alloys.

D. Magnetic particle Inspection may be applied to raw material, finished and semi-
finished parts, welds and in-service parts. For production parts, magnetic particle
Inspection shall be performed after completion of all grinding, machining, forming,
straightening, welding, heat treatment and stress relieve operations and prior to
shot peening or the application of protective finishing such as, priming or painting.

E. When specified, magnetic particle Inspection shall also be performed after

electroplating, in accordance with sections 1.E and/or 1.F, as applicable, and 8.B
of this specification, and when specified, penetrant inspected in accordance with
PCS-3002.

F. When specified, electroplated parts, heat-treated to 1450 MPa (210 ksi) and
above, with plating thickness of 50 µm (0.002 in) or less, which is not
subsequently machined or ground, shall be examined in accordance with this
specification, this operation shall be carried out immediately after completion of
plating and de-Embrittlement.

NOTE: The above requirement is applicable for all Boeing 787 Program
parts.

G. When specified, electroplated parts, heat treated to 1450 MPa (210 ksi) and
above, with a plating thickness in excess of 50 µm (0.002 in), which are
subsequently ground, shall be examined, using current values stated in section
8.B.(4), to this specification and penetrant inspected in accordance with
PCS-3002.

H. In-process inspections on semi-finished parts shall not be substituted for the final
inspection.

I. Magnetic particle inspection shall be carried out to a detailed written procedure.

The procedure may consist of a General Procedure, which contains the basic
instructions and a Technique Sheet with detailed instructions for specific parts.

J. Where requests for deviations are made against this specification, if there is an
impact upon the ‘end customer’ requirements then the request shall also be
passed onto the ‘end customer’.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
K. All Class 1 parts shall have all accessible surfaces and parts inspected 100%.

L. If not stated on the finished drawing, sampling of Class 2 or 3 parts may be

carried out, when approved by M-D.

M. This specification cancels and supersedes IFC40-052-01MD, M-DLNDT2 and

M-DLNDT3, Part 1.

N. This specification meets or exceeds the requirements of ASTM E 1444.

2. Associated Documents

A. Messier-Dowty Specifications
Specification Reference
PCS-2610 Grit Blasting with Aluminium Oxide
PCS-2620 Hot Degreasing
PCS-2621 Alkaline Degreasing of Parts
PCS-2800 Temporary Component Protection
PCS-3002 Non-Destructive Testing of Coated Parts
M-DLPS507 Fusion Welding of Steels, Aluminium, Aluminium Alloys
and Magnesium Alloys
PCS-3010 Determination of Alloy Segregation of Ferromagnetic
Alloys
PCS-3600 Etch Inspection of high Strength Steel Parts
B. Other Specifications
Specification Reference
ASTM E 1444 Standard Practice for Magnetic Particle Testing
AMS 2175 Castings, Classification and Inspection
ASTM A 275 Standard Test Method for Magnetic Particle
Examination of Steel Forgings
AMS 2442 Magnetic Particle Acceptance Criteria for Parts
EN 4179 Qualification and Approval of Personnel for Non
Destructive Testing
NAS 410 NAS Certification and Qualification of Nondestructive
Test Personnel
AMS 3044 Magnetic Particles, Fluorescent Wet Method, Dry
Powder
AMS 3045 Magnetic Particles, Fluorescent Wet Method, Oil
Vehicle, Ready-to-Use
AMS 3046 Magnetic Particles, Fluorescent Wet Method, Oil
Vehicle, Aerosol Packaged
AMS 2641 Vehicle, Magnetic Particle Inspection Petroleum Base
AS 5282 Tool Steel Ring for Magnetic Particle Inspection
AS 5371 Reference Standards Notched Shims for Magnetic
Particle Inspection
ANSI/NCSL Z 540-1 General Requirements for Calibration Laboratories and
Measuring Test Equipment
ISO 10012-1 Quality Assurance Requirements for Measuring
Equipment

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
NOTE: All specifications/procedures shall be used at the latest issue.

3. Definitions

A. Competent Authority: Person (or group of persons) within Messier-Dowty

authorised to take decisions for granting exceptions to the present standard. This
(these) person(s) is (are) defines as follows:
“When there is a request for any deviation from the requirements of this
specification, the request shall be processed via the Quality Department
responsible for the surveillance of the area/site of manufacture. All queries
relating to any technical aspect of the component must be addressed to the
technical design office responsible for the design of the part within Messier-
Dowty. Technical design office means the combination of design analysis, stress,
performance and materials competencies within Engineering. Decisions on parts
where the component design, base material, it’s processing, or treatments are
concerned, will be provided via the route. When the query addressees issues
which will not affect the life or function of the part, eg “cosmetic” variations, the
decision will be given by the responsible Quality Department. (Please note that
surface finish, protective treatment variances and profile variations must not be
interpreted as “cosmetic“)“.

B. Inspection:

(1) In Process – Inspections performed after completion of some, but not all,
manufacturing operations, which may cause or reveal discontinuities. Used to
ensure part quality before investing in further processing.

(2) Final – Inspection performed after completion of all manufacturing operations,

which may cause or reveal discontinuities.

(3) In-Service – Inspection performed on parts, which are in use or storage for
their intended purpose.

C. Written Procedure: A detailed procedure. The procedure may consist of a

General Procedure, which contains the basic instructions and a Technique Sheet
with detailed instructions for specific parts.

D. Technique Sheet: A detailed, written instruction that supplements the instructions

of a general procedure.

E. Interpretation: The process of classifying indications as false, non-relevant or

relevant.

F. Linear Indication: An indication having a length of three or more times its width.

G. Crack: A break, rupture or fissure, which is relatively narrow and deep. The edges
are normally jagged when viewed with magnification.
H. Inclusion: Normally a linear indication (not a crack), which is non-metallic and
formed during the melting process.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
I. Boeing 787 Program: A letter “Z” within the part number shall identify the parts
applicable to this program.

4. Health and Safety

A. It is the Department Manager’s responsibility to develop safe working practices

and to adequately train operators in accordance with local legislation
requirements.

B. Inspection personnel must not wear sunglasses or glasses with light sensitive
(photo chromic) lenses, which change colour in sunlight, as this will have an
adverse effect on viewing capability.

C. Spectacles designed to absorb UV wavelength radiation are suggested for close,

high black light intensity inspection.

5. General Practice

A. Magnetic particle equipment shall be arranged to minimise dust or other

contaminants to the inspection materials, equipment or parts and permit safe,
uniform and controlled operations.

B. The working practice for inspection will be as follows,

(1) Demagnetise in accordance with section 8.D (if required) when residual field
strength is over 3 gauss (3 x 10-4 Tesla [T] or 240 A/m).

(2) Pre-clean in accordance with PCS-2620, PCS-2621 or other approved

process. Parts shall be clean, dry and free of oil, scale or other contaminants
or conditions, which may interfere with the efficiency of the
examination/inspection process.

(3) Magnetise as per approved technique/procedure.

(4) Inspection – All indications shall be evaluated. All parts, which show
excessive background, and/or false and non-relevant indications, which
interfere with the inspection, shall be re-processed.

NOTE: An eye adaptation time of minimum 1 minute is required before

inspection is carried out.

(5) Demagnetise in accordance with section 8.D.

(6) Clean and protect to PCS-2800.

(7) Unless otherwise stated, parts, which have been accepted using magnetic
particle inspection, shall have all relevant paperwork ink stamped. The unique
stamp number shall be preceded with a letter “M” with a circle around both
letter and unique number.

(8) Records of all parts processed through magnetic particle inspection shall be
kept in accordance with document retention procedures and shall be stored
for a minimum of 5 years, from delivery of the parts. These records shall be
made available to authorised customer representatives and regulatory
authorities when requested.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

C. Acceptance Requirements

(1) Acceptance standards that are detailed within this specification regarding to
non-metallic inclusions shall be applied.

(2) If the acceptance class is not stated on the finish drawing, this shall be
referred to the Messier-Dowty Materials and Processes Laboratory.

(3) Acceptance standards for the acceptance of forgings shall be stated on the
M-D forging drawing/inspection schedule

(4) Acceptance standards for the acceptance of castings as per AMS 2175

(5) The acceptance criteria for non-metallic inclusions in all parts shall be in
accordance with Table 1.

(6) Acceptance standard for the inspection of welded fabrications shall be as per
M-DLPS507

(7) Acceptance standard for all parts that contain alloy segregation shall be
achieved by PCS-3010.

(8) Any parts that are sentenced as un-acceptable to this specification shall be
rejected in accordance with the company procedure and a non-conformance
label/tag shall be attached to the component(s).

(9) Acceptance standard AMS 2442 shall be applied where called for on the
engineering component drawing.

(10)No cracks, laps, folds or seams are permitted on production parts or in-
service parts.

(11)When any questionable indications are identified, the parts shall be

segregated and referred to the M-D Level 3 and when required, the M-D
Materials and Processes Laboratory.

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 Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

Table 1

Non-Metallic Inclusion Acceptance Criteria Classes

1 2 3 4

Indications not exceeding a length of (mm) are not 2 2 1 0.5

taken into account

Max length (mm) of an isolated indication 20 8 4 2

Max length (mm) of aligned indications 40 16 8 3

Max length (mm) of cumulated indications over 1 dm² 50 30 15 5

Min distance between two inclusions (*) on the same 5L 5L 5L 5L

generator (L = length of the longest indication)

Maximum number of inclusions in 1 sq decimetre, (4 15 10 7 5

in square, approx)

NOTE: (*) Otherwise, both inclusions are counted as one, of a length equal
to the total of the lengths of both inclusions.

These criteria are applicable on new program if not specified on the technical
definition.

Class 4: For all parts made of steels or stainless steel re-melted under
vacuum or slag with UTS >1450 MPa (210 KSI). eg: 300M, Custom
465, 17-7PH

Class 3: a) For all other parts of UHTS steels (UTS >1450 MPa (210 KSI)
or HRC >50) or stainless steel UTS >1300 MPa (189 KSI)

b) For all parts made of steels or stainless steel 15-5PH; 17-4PH;

304L and 4340

c) For all class 1 parts

Class 2: For all class 2 parts with UTS <1450 MPa (210 KSI)

Class 1: For accessory parts (Class 3 parts)

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

6. Personnel Qualifications

A. Personnel performing examinations and inspection in accordance with this

specification shall be qualified in accordance with:

(1) EN4179 Qualification and Approval of Personnel for Non-destructive

Testing

or

(2) NAS 410 NAS Certification and Qualification of Non-destructive Test

Personnel

7. Written Procedure

A. Written procedures shall be raised that are applicable to the part or group of parts
that are to be inspected and shall include all relevant data as listed in this
specification.

8. Facilities and Equipment

A. Magnetisation Method

(1) The type of magnetising current shall be suitable for the type of component
that is to be tested, with the exception that for final and in-service inspection
of parts, only full-wave rectified alternating (FWDC) current or half wave
rectified alternating (HWDC) current.

(2) AC current may be used to verify surface indications.

(3) The wet continuous method is preferred for locating surface and slightly sub-
surface discontinuities and shall be used unless specific application requires
the use of another method. Proper sequencing and timing of the part
magnetisation and application of the particle suspension are required to
obtain the proper formation and retention of indications. This requires that the
stream of suspension be diverted from the part simultaneously with, or
slightly before, energising the magnetic circuit. The magnetising current shall
be applied, with a minimum of 2 shots being used. The second shot shall
follow the first in rapid succession. It should come after the flow of
suspension has been interrupted and before the part is examined for
indications.

(4) Permanent magnets and yokes may only be used for specific procedures
when authorised by the M-D Level 3. When these magnets are used,
adequate magnetic field strength shall be established.

(5) Magnetic field direction - Parts shall be magnetised in a minimum of two

directions at right angles to each other to ensure detection of all
discontinuities. Component geometry shall also be considered when
establishing an inspection procedure.

(6) Multi-directional magnetisation may be used when authorised by the M-D

Level 3.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
(7) The use of prods is prohibited on production parts.

(8) When a blind bore is inspected using direct current, it shall be ensured that all
parts are free from burning (arcing).

B. Magnetic Field Strength and Current levels

(1) Field strength and direction shall be established and verified with a Gauss
Meter (Hall Effect Meter) or artificial flaw/flux indicator in accordance with the
applicable method stated in ASTM E 1444, sections X2, X3 and X4, for all
parts. When using a Gauss Meter (Hall Effect Meter), field strength readings
of 30 Gauss (30 x 10-4 Tesla [T]) minimum are required, however readings of
30 to 60 Gauss (30 to 60 x 10-4 Tesla [T] or 2400 A/m to 4800 A/m) are
normally considered adequate for either parts which are not electroplated and
parts which are electroplated, with a plating thickness of less than 0.002 in,
when the plating is not subsequently machined or ground.

(2) The correct current values for each shot shall be determined experimentally.
current levels of 500 to 800 amperes per inch (20 to 32 amperes per mm of
diameter) are usually adequate for direct circular magnetisation and when
using a centrally located conductor for circular magnetisation.

(3) Some part configurations may allow a current value of 300 amperes per inch
(12 amperes per mm), or less, for direct circular magnetization, the M-D Level
3 shall approve this.

(4) When specified, parts, which are electroplated, with plating thickness in
excess of 50 µm (0.002 in) and the plating is subsequently machined or
ground, current values shall be used to achieve 60 Gauss (60 x 10-4 Tesla [T]
or 4800 A/m) minimum.

(5) When using an offset conductor the current values of section (2) shall apply,
except that the total diameter shall be the sum of the diameter of the
conductor plus twice the wall thickness of the part. The distance along the
part circumference (interior) that may be effectively examined shall be 4 times
the diameter of the conductor, up to 360 degrees, provided the presence of
suitable field(s) is verified. The entire circumference shall be examined by
rotating the part on the conductor, allowing a 10% magnetic field overlap.

(6) Current levels, to create longitudinal fields for coils and cable wraps, shall be
calculated in accordance with the applicable application, per ASTM E 1444,
section X5.

(7) Longitudinal fields created with use of the magnetic flow method may be used
when approved by the M-D Level 3.

NOTE: All parts that are subjected to direct contact circular magnetisation
shall be visually inspected for ‘arc burns’. Any parts found to have arc
burns shall be reported to the M-D Level 3.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

C. Magnetic Detection Media (Ink and Powders)

(1) Magnetic ink particles that conform to AMS 3044, AMS 3045, and AMS 3046
only shall be used.

(2) For the inspection of raw materials, castings and forgings the use of a water-
based vehicle with suitable conditioner may be used.

(3) For the in-process and final inspection of finished or semi fished machined
parts, oil-based inks are the preferred methods. The oil used for the liquid
vehicle shall conform to AMS 2641. Water-based vehicles shall only be used
when approved by the M-D Level 3.

(4) Particle concentration shall be in the range detailed in Table 2, per 100 ml
bath sample. This shall be verified and recorded at intervals stated in Table 4.

Table 2

Surface Condition Particle Concentration Range

Part Machined/Forged/Cast/Grit 0.1 to 0.4 ml per 100 ml

blasted

Finish Machined 0.1 to 0.25 ml per 100 ml

D. Demagnetisation

(1) When using AC demagnetisation, the part(s) shall be subjected to a field with
a peak value greater than, and in nearly the same direction as the field used
during the examination. This AC field is then decreased gradually to zero.
When using an AC demagnetising coil, hold the part approximately 12 in (30
cm) in front of the coil and move it slowly and steadily through the coil and at
least 36 in (100 cm) beyond the coil while the current is flowing. Parts with
complex configuration may be rotated while passing through the coil. The
process may be repeated as necessary.

(2) When using DC demagnetisation, the initial field shall be higher than, and in
nearly the same direction as the field used during the examination. The field
shall then be reversed, decreased in magnitude and if required, repeated until
the residual field is at an adequate level.

(3) After demagnetisation, a magnetic strength meter shall not detect a residual
field value above 3 Gauss (3x10-4 T, 240 A/m) anywhere on the part.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

9. Quality Control

A. Magnetic particle inspection equipment shall be checked for performance and

accuracy when installed, at intervals stated in Table 4, after malfunction or when
maintenance may affect accuracy. Inspection measuring and test equipment shall
be calibrated and certificated having a known valid relationship to National
Institute of Standards and Technology (NIST) in accordance with ANSI Z 540-1,
or system conforming to ISO 10012-1.

B. Any equipment, which fails any of these tests, is unacceptable. Any unacceptable
equipment shall be corrected or replaced before performing further processing of
parts. It shall be determined if parts inspected prior to the test failure should be
re-inspected.

(1) Machine Ammeter Accuracy

(a) Ammeters shall be tested for accuracy at intervals stated in Table 4.

(b) A calibrated ammeter and shunt, which is traceable to a national

standard, shall be connected, in series with the output circuit.

(c) Take comparative readings at a minimum of 5 output levels covering the

entire operating range of the ammeter.

(d) A machine ammeter reading that deviates more than +/-10% from the
current shown by the calibrated ammeter or 50 amperes (whichever is
greater) is not acceptable.

(2) Machine Shot Timer

(a) The machine shot timer control switch shall be checked and recorded at
intervals stated in Table 4. A Current duration of 0.5 to 1 second is
preferred, however longer pulse duration may be used when approved by
the M-D Level 3. The pulse timer shall be checked to within +/-0.1 second
using a suitable calibrated electronic shot timer.

(3) Internal Short Check

(a) A machine internal shorting test shall be performed at intervals stated in

Table 4. With the machine set to at least 1000 amperes, place a piece of
non-conductive material (wood) and clamp between the heads. An
ammeter reading above 10 to 20 amperes when the current is activated
indicates an internal short. The equipment shall be repaired prior to
processing any production parts.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
(4) Quick/Fast Break Check

(a) For machines fitted with quick/fast break equipment, verify operation at
intervals stated in Table 4. This shall be carried out in accordance with
the manufacturer’s instructions.

(5) Gauss Meters (Hall Effect Meters)

(a) Calibrate Gauss Meters at intervals stated in Table 4, this shall be carried
out to the manufacturers requirements at a minimum of 3 positions
through the working range.

(6) Field Indicators

(a) Field indicator meters used to check residual magnetic fields shall be
either calibrated/certified yearly, or compared to a calibrated source
weekly.

(7) Light Meters

(a) Light Meters used for both black and white light measurement shall be
calibrated at intervals stated in Table 4.

(b) Light Meters shall be digital readout. For black light, read in microwatts
per centimetre or watts per square meter. For white light read in foot-
candles (fc) or lux.

(c) Light Meters shall be checked at 3 positions minimum across the working
range, to an accuracy of +/-5% when checked.

(d) UV Light Meters shall have a spectral response in the range of 320 to
400 nm.

(8) Lighting

(a) Standard Inspection black lights – The minimum acceptable intensity is

1200 µW/cm2 at a distance of 15 in (38 cm) from the front face of the filter
to the sensor. No lamp fitted with a ‘self filtered’ bulb may be used for
inspection purposes. This shall be verified at intervals stated in Table 4.

(b) Portable Inspection lights – The minimum acceptable intensity is

1000 µW/cm2 at a distance of 15 in (38 cm). This shall be verified prior to
use.

(c) Ambient White light - Ambient white light levels in the inspection areas
shall be verified at intervals stated in Table 4 and must not exceed 20 lux
(2 ft candles) in the viewing position.

(d) White light – Visible white light used for the interpretation of indications
found with fluorescent magnetic particles, shall have a minimum light
intensity of 1000 lux (100 fc) at the inspection surface. This shall be
verified at intervals stated in Table 4.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009

(e) Special black light equipment may be used for portable inspection when
necessary. Compensate for drop off in light intensity by positioning the
light source closer to the part surface. The minimum black light intensity
requirements specified in 9.B.(8)(b), do not need to be achieved as
equipment may be used at distances closer than 150 mm (6 in) from the
inspection surface.

(9) Materials

(a) Magnetic inks shall meet the requirements of Section 8.C. In addition,
they shall meet the following requirements and be verified at intervals
stated in Table 4. When new suspensions are mixed, a sample of the
new mix shall be kept in darkened conditions for reference. For facilities
performing this process less frequently, the shift/daily/weekly checks may
be extended, but must be checked prior to use.

(b) Concentration/Contamination Tests

(c) This test shall be carried out on wet suspensions at the start of each shift,
after any period where the agitation of the suspension has been stopped
for 10 minutes or longer or whenever the bath is changed or adjusted.

1 Allow the bath to circulate for 30 minutes minimum prior to taking the
sample.

2 Place a 100 ml sample of the in-use suspension in a centrifuge tube.

3 Demagnetise the sample and allow to stand for a minimum of 30

minutes for water based inks and 60 minutes minimum for oil based
inks.

4 Read the volume of particles, which have settled. This shall conform
to the requirements of Section 8.C, Table 2.

5 Examine the settled particles in the tube, under both black and white
lighting, for layers, bands or striations different in colour or
appearance. These layers, bands or striations indicate
contamination. If the contamination exceeds 30% of the settled
particles, the bath shall be replaced.

6 Any noticeable reduction in fluorescent brightness or colour, when

compared with an as-new sample, is unacceptable.

7 A milky white coloured suspension indicates oil or grease

contamination and is unacceptable.

8 When any unacceptable condition is identified, the suspension must

be changed prior to further processing of parts.

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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
(d) Water Break Test

1 When using a water vehicle for the inspection of raw materials,

castings and forgings, a water break test shall be performed and
verified at intervals stated in Table 4.

2 The water break test is acceptable if an even, continuous film forms

over the entire area under test. If there is a break in the film, the part
has not been cleaned correctly or there is insufficient wetting agent in
the bath and the test is unacceptable. The part(s) shall be re-cleaned
or wetting agent added to the bath to make the test acceptable.

10. System Performance Test

A. Test Pieces Current Flow

(1) The ring specimen complying with AS 5282 is the preferred method for
system verification as per the ASTM 1444. This shall be performed daily.
The following methods are both acceptable means of compliance.

(2) The required results as per ASTM 1444 are as per Table 3.

Table 3

Type of Suspension Amperage HWDC or Minimum number of hole

FWDC Indicated

Fluorescent Oxide (wet) 500 3

1000 5

1500 6

2500 7

3500 9

Or

(3) Place the ring on a central conductor and clamp between the headstocks.

(4) Use a central conductor 1.00 to 1.25 in (25 to 31 mm) diameter and at least
16 in (406 mm) long.

(5) Place the ring so that the number one hole is at the 12 o’clock position and
the other holes are facing the inspector/operator.

(6) Attach an artificial shim, Type CX (AS 5371), to the ring specimen
approximately 0.5 in (12 mm) from the number one hole, away from the
inspector. The shim may be placed on the outer radius or the side of the
ring.

page 15/16E
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Process Specification
PCS-3100
Issue: 3
Date: 27th January 2009
(7) Apply the amperage to obtain 30 Gauss (+/-5 Gauss) (240 A/m
+/- 40 A/m) on the surface of the ring, to the central conductor. The
following is an acceptable result.

(8) The artificial shim and five holes in the ring specimen shall show.

C. One of the following test pieces may also be used for current flow system
verification – AISI 01 Ketos Ring, TP 1 – 3 or known defective part. Other test
pieces may be used when agreed by the M-D Level 3.

D. Test Pieces Magnetic Flow/Coil – A standard test piece shall be developed for
the verification of the process (RR TP 4 or similar). The current value, position
(within the coil) shall be established. These parameters shall then be used daily
for the performance test.
Table 4
Testing and Verification Intervals
TEST MAXIMUM INTERVAL REFERENCE

Machine Ammeter 6 Monthly 9.(1)

Shot Timer 6 Monthly 9.(2)

Internal Shorting 6 Monthly 9.(3)

Quick/Fast Break 6 Monthly 9.(4)

Gauss Meter 6 Monthly 9.(5)

Field Indicators Yearly/Weekly 9.(6)

Light Meters 6 Monthly 9.(7)

Black Lights-Standard Daily 9.(8)

Black Lights-Portable Prior to Use 9.(8)

White Light-Portable Prior to Use 9.(8)

Ambient White Light Weekly 9.8)

Ink Concentration Each Shift 9.(9)

Ink Contamination Each Shift 9.(9)

Water Break Test Prior to Use 9.(9)

System Performance Daily 10

Test

page 16/16E
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