Magnetic Particle Inspection System | MPI Crack Detection & Test Lines

Magnetic Particle Inspection Systems (Mpı Test Benches & Lines)

Magnetic Particle Inspection Systems (Mpı Test Benches & Lines)

Product Code :
Category :	Magnetic Testing

Product Features
Explanation

NEXSEN develops custom Magnetic Particle Inspection (MPI) benches designed to meet various part geometries and production line requirements. These systems enable fast, reliable, and repeatable detection of surface and near-surface discontinuities in ferromagnetic materials. The systems can be integrated into manual, semi-automatic, or fully automated production lines, providing high-precision crack detection in serial manufacturing processes and optimizing quality assurance procedures.

Magnetic Particle Inspection Systems (MPI)

Magnetic Particle Inspection (MPI) systems are one of the most effective non-destructive testing (NDT) methods used to detect surface and near-surface discontinuities in ferromagnetic materials.

These systems enable fast and reliable detection of defects such as cracks, cold shuts, forging defects, and welding imperfections, ensuring high-quality standards in industrial production processes.

What is Magnetic Particle Inspection (MPI)?

MPI is based on magnetizing the test component and detecting leakage magnetic fields formed at discontinuities.

Magnetic particles (dry powder or liquid suspension) accumulate in these leakage areas, making defects visible for inspection.

For more detailed information, please refer to our blog on magnetic particle inspection.

How Do MPI Systems Work?

Magnetic particle inspection systems operate through the following steps:

The component is magnetized
Discontinuities disturb the magnetic field lines
Leakage magnetic fields are formed
Magnetic particles gather at defect locations
Defects become visible under UV or white light

This process enables fast and reliable defect detection.

Types of MPI Systems

Manual MPI Systems

Suitable for low production volumes
Operator-controlled inspection
Flexible and cost-effective

Semi-Automatic MPI Systems

Operator-assisted automation
Faster inspection cycles
Repeatable results

Fully Automatic MPI Test Lines

Ideal for mass production
Robotic integration
Minimal operator intervention
High efficiency

Current Types Used in MPI (AC / DC / FWDC / HWDC)

The type of current used directly affects detection capability:

AC (Alternating Current): High sensitivity for surface defects
DC (Direct Current): Detection of subsurface discontinuities
FWDC: Balanced performance for surface and near-surface defects
HWDC: Improves particle mobility and crack visibility

Demagnetization

After inspection, residual magnetism may remain in the component. Demagnetization is applied to remove this magnetic field.

Eliminates residual magnetism
Prevents particle attraction
Ensures suitability for further processing

Modern MPI systems include integrated demagnetization units.

Compliance with International Standards

NEXSEN magnetic particle inspection systems are designed in accordance with internationally recognized standards:

ASTM E1444 / E1444M – Magnetic Particle Testing Standard
ASTM E709 – MPI Practice Guide
ISO 9934-1 / 2 / 3 – Magnetic Particle Testing Standards
EN ISO 9934 – European Standard
ASME Section V, Article 7 – NDT Code

Compliance ensures reliability and suitability for global industrial applications.

Advantages of MPI Systems

Detection of surface and near-surface defects
Fast and reliable inspection
Suitable for automation systems
Compatible with mass production
Reduced operator dependency

Applications

MPI systems are widely used in:

Automotive industry
Aerospace and defense
Forging and heat treatment facilities
Energy and heavy industry
Railway and machinery manufacturing

NEXSEN MPI Solutions

At NEXSEN, we provide customized magnetic particle inspection systems tailored to your needs.

Project-based engineering solutions
Manual, semi-automatic, and fully automated systems
Robotic integration options
Full compliance with international standards

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