Inspecting motorsport components by magnetic particle testing
Overview
This standard identifies the competences you need to carry out magnetic particle tests on ferromagnetic motorsport components, materials or structures, in accordance with approved procedures. You will be required to prepare the components, materials or structures for the magnetic particle testing activities and check that the equipment complies with the specification requirements, and is safe to use and fit for purpose. You must ensure that the ambient conditions are satisfactory for the tests to proceed and you will set up the equipment according to the non-destructive testing (NDT) instructions and requirements. You will carry out the specified tests using the correct procedures and observe and record the test indications. You will complete the tests by preparing/completing a NDT test report containing the required test information and data along with your interpretation of the test indications. You will be expected to mark up the components, materials or structures to show where there are indications of surface defects. The completed inspection report will be passed to the appropriate person in accordance with organisational procedures.
Your responsibilities will require you to comply with organisational policy and procedures for the magnetic particle testing activities undertaken, and to report any problems with the equipment in use, that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your actions and the quality and accuracy of the work that you carry out.
Your underpinning knowledge will show a good understanding of your work, and will provide an informed approach to the inspection of motorsport components, materials or structures using magnetic particle testing methods/techniques. You will have a working knowledge of the principles of magnetic particle testing, including the methods of generating magnetic fields. You will understand the different types of equipment, their advantages, limitations and care, and the methods of calibration and performance checks. You will have a detailed knowledge of testing practice and understand why this method has significant limitations on its flaw detecting capabilities. Your knowledge will include an appreciation of hazards and safe working practice, and you will understand the risks posed by material defects and the consequences of failure. The importance of compiling accurate and legible reports will also be a key issue in completing this standard.
You will understand the safety precautions required when carrying out the magnetic particle testing activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibility you owe to yourself and others in the workplace
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the correct specification for the product or equipment being inspected
- identify and confirm the inspection checks to be made and acceptance criteria to be used and carry out the inspection using appropriate equipment
- carry out all required inspections as specified
- identify any defects or variations from the specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- how to obtain the necessary job instructions and testing specifications, and how to interpret them
- the reasons why some components, materials or structures require to be tested using non-destructive testing methods
- why it is sometimes necessary to use a range of different non-destructive testing methods (magnetic particle, penetrant flaw detection, ultrasonic and radiography)
- the various types of magnetic particle detection equipment used (to include portable and fixed machines)
- the various components that make up the equipment (contact prods and heads, rigid and flexible coils, permanent magnets, electromagnets)
- the basic concepts of magnetic particle testing (including creating the magnetic field, magnetisation of the component, the use of a magnetic flux, disruption of the flux by discontinuities/flaws in the components and imaging of the disruption by the magnetic media)
- how to check that the testing equipment is within current calibration dates
- the types of check that can be carried out on the equipment (such as sensitivity assessment, functional tests, operation of flux indicators and field strength meters, ammeters and quality of detecting medium)
- the different detecting mediums that are used (to include inks and powders), the methods of applying them and their removal on completion
- how to set up the equipment parameters for the testing activities undertaken (to include selection of magnetising technique, field strength, direction of current flow, calculation of magnetising current required and flux density required)
- the preparations to be carried out on the components, materials or structure test area (degreasing, grinding, filling, polishing and other mechanical operations and where appropriate the application of contrast aid paint)
- how to carry out the testing activities (including the application of the magnetic field; application of the detecting media; viewing conditions required such as ambient light or ultraviolet (UV); identification of the displayed defects; defect transfer techniques such as magnetic rubber and photographic)
- the types of defect that are detectable using magnetic particle detection methods
- how to recognise defects in the components, materials or structures from the displayed indications, and how to identify false indication of defects and their cause
- the level of defects that are acceptable in the components, materials or structures; the influence of the defects on the service/performance of the components, materials or structures
- the system of quality control within the company and who is responsible for it
- why is it critical that records of magnetic particle inspections are accurate, comprehensive and maintained legibly
- the person that you need to pass the inspection records to
- the problems that can occur with the NDT activities and how they can be avoided
- the extent of your own responsibility and to whom you should report if you have problems that you cannot solve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the magnetic particle inspection activities:
- obtain and use the appropriate documentation (such as job instructions, NDT testing inspection specifications, test procedures, quality control documentation and other related documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- obtain the required magnetic particle testing equipment and check that it is in a safe, tested and correctly calibrated condition
- provide and maintain safe access and working arrangements for the test area, and ensure that any appropriate environmental conditions can be met
- follow the defined testing procedures and apply safe working practices and procedures at all times
- leave the work area in a safe condition on completion of the activities
- return all tools and equipment to the correct location on completion of the testing activities
- leave the work area in a safe and appropriate condition on completion of the testing activities
Check and confirm that all of the following ambient testing conditions are satisfactory:
- temperature
- humidity
- free from vibration
- free from pollutants
Prepare the components, materials or structures for testing, to include carrying out all of the following:
- identifying and marking the test areas
- removing any contaminants from the test area (such as degreasing)
- preparing the test surface to the specified finish (such as grinding or polishing)
Check that the equipment is fit for purpose and safe to use, by carrying out all of the following checks :
- the condition and security of electrical cables and connections
- the operation of all mechanical functions
- the function of powder/ink application
- the correct operation of all safety devices
Carry out all of the following tests in accordance with instructions:
- setting the equipment parameters to the appropriate levels
- magnetising the components
- applying the detecting medium (ink or powder) correctly
- using magnetic flux indicators
- observing defect indications under correct lighting conditions (ambient light or ultraviolet (UV)
- recording conclusions of observations
- demagnetising and cleaning the components on completion of the test
Carry out magnetic particle testing on one of the following:
- welded joints
- motorsport mechanical components (such as brake discs, cylinder heads, drive shafts)
- motorsport/vehicle structures (such as chassis members)
- other specific components or materials
Identify all of the following:
- defect type
- location of the defect
- dimensional size of the defect
Follow the correct procedure to deal with components, materials or structures which fall into all of the following categories:
- which meet the specification
- with identified defects
- requiring further investigation
- requiring other inspection methods
Complete an NDT report, to include recording all of the following:
- product identification
- material of construction
- geometry, thickness and surface condition where defect indications were found
- equipment settings (where applicable)
- ambient testing conditions
- defects identified
- comparison of flaw data with acceptance criteria
- conclusions and recommendations
- test personnel information
Check complete the inspection activities, to include carrying out all of the following:
- marking up defective components, materials or structures with all relevant information
- recording all the required details of the inspection in the appropriate format
- handing over the inspection details to the appropriate people