DESIGN OF A NEW GENERATION WET METHOD MAGNETIC PARTICLE TESTING DEVICE FOR NON-DESTRUCTIVE TESTING

Abstract

Wet method magnetic particle inspection (MPI), which is one of the non-destructive testing (NDT) methods, relies heavily on operator skill in applications performed with conventional MPI devices, leading to potential misinterpretations. In this study, to improve the inspection process, a low-cost, domestically developed, bench-top prototype MPI device with advanced smart control and imaging capabilities has been designed and manufactured. The prototype device consists of an automatic part clamping system, a magnetic fluid transfer unit, an adjustable current transformer, and an imaging system (UV lamp and camera). While the embedded control system optimizes the magnetization parameters, the digital image processing techniques applied at the software layer enhance the visibility of surface defects and detection accuracy. The performance of the prototype device was validated through verification tests using reference blocks and test bars compliant with the ASTM E1444 standard. The tests and calibration studies demonstrated that the device can detect surface and/or near-surface cracks with high sensitivity and offers a competitive cost advantage compared to similar systems on the market. The prototype MPI device developed in this study provides an accessible automation solution with high reporting capability that minimizes operator error in critical sectors such as aerospace, automotive, defense, rail systems, and energy.

Keywords

• Embedded Software Development
• Magnetic Particle Inspection
• Non-Destructive Testing
• Prototype Design
• Smart Device

Supporting Institution

The Scientific and Technological Research Council of Türkiye

Project Number

5210092

Ethical Statement

We declare that all stages of the study comply with research and publication ethics, and all ethical rules and scientific citation standards were strictly followed.

Thanks

This study was supported by the Scientific and Technological Research Council of Türkiye (TÜBİTAK) under the 1505 University-Industry Collaboration Support Program (TEYDEB-TEMEG) with project number 5210092.

TAHRİBATSIZ MUAYENEDE ISLAK METOT YENİ NESİL MANYETİK PARÇACIK TEST CİHAZI TASARIMI

Abstract

Bu Tahribatsız muayene (NDT) yöntemlerinden biri olan ıslak metot manyetik parçacık testi (MPI), konvansiyonel MPI cihazlar ile yapılan uygulamalarda test süreci yüksek oranda operatör becerisine dayanmakta ve bu durum hatalı tespitlere yol açmaktadır. Bu çalışmada, test sürecini iyileştirmek amacıyla; düşük maliyetli, ileri düzey akıllı kontrol ve görüntüleme yeteneklerine sahip ıslak metot tezgâh tipi bir prototip MPI cihaz tasarlanmış ve üretilmiştir. Prototip cihaz; otomatik parça tutturma, manyetik sıvı transfer ünitesi, ayarlanabilir akım trafosu, görüntüleme sisteminden (UV lamba ve kamera) oluşmaktadır. Gömülü kontrol sistemi, manyetizasyon parametrelerini optimize ederken; yazılım katmanında uygulanan dijital görüntü işleme teknikleri, yüzey kusurlarının görünürlüğünü ve tespit doğruluğunu artırmaktadır. Prototip cihazın performansı, ASTM E1444 standardına uygun referans blok ve test çubuk ile doğrulama testleri yapılmıştır. Yapılan testler ve kalibrasyon çalışmaları, cihazın yüzey ve/veya yüzeye yakın çatlakları yüksek hassasiyetle tespit edebildiğini ve piyasadaki benzer sistemlere oranla rekabetçi bir maliyet avantajı sunduğunu ortaya koymuştur. Bu çalışma ile geliştirilen prototip MPI cihaz; havacılık, otomotiv, savunma, raylı sistemler ve enerji gibi kritik sektörlerde operatör hatasını minimize eden, raporlama kabiliyeti yüksek ve erişilebilir bir otomasyon çözümü sunmaktadır.

Keywords

• Akıllı Cihaz
• Gömülü Sistem Yazılımı
• Manyetik Parçacık Testi
• Prototip Tasarım
• Tahribatsız Muayene

Supporting Institution

TÜBİTAK

Project Number

5210092

Ethical Statement

Çalışmanın tüm süreçlerinin araştırma ve yayın etiğine uygun olduğunu, etik kurallara ve bilimsel atıf gösterme ilkelerine uyduğumuzu beyan ederiz.

Thanks

Bu çalışma, TÜBİTAK tarafından 1505 Üniversite-Sanayi İşbirliği Destek Programı (TEYDEB-TEMEG) tarafından 5210092 proje numarası ile desteklenmiştir.

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