Preventing Magnetic Particle Tank

Freezing When Using Water Particle Baths

by Gerald Kulchytsky*
This month's article offers an inexpensive solution to companies
that use magnetic particle testing (MT) during adverse winter
conditions. The simple yet cost effective solution described by the
author has the capability to enhance the integrity of the MT process
and can reduce the risk of equipment downtime due to frozen
plumbing or equipment failure. This article should be of interest to
readers working in a wide range of industries such as forging,
casting foundries and steel mills.
G.P. Singh
Associate Technical Editor

For companies that use magnetic particle testing during the winter months, a simple yet
inexpensive way to heat water based particle baths can now be employed. This simple,
cost effective solution will prevent tank freezing and minimizes the potential risk of flash
freezing on the part surface if part temperature is 273 K (32 F) or less. Equipment
downtime associated with frozen magnetic particle tanks will be eliminated and
premature equipment failure can be significantly reduced. Candidates for this technique
include forging facilities, casting foundries and steel mills where magnetic particle
equipment can be exposed to adverse conditions.

Lower Radiator Hose Heater

To accomplish this, a device known as a lower radiator hose heater can be purchased
from a local automotive parts store. It is a heater that is intended to be used for
automobiles, trucks and farm implements to heat the antifreeze in the engine block to
promote starting in subzero temperatures. These heaters operate using 120 V and are
available in sizes ranging from 25.4, 31.8, 38.1, 44.4 and 50.8 mm (1, 1.25, 1.5, 1.75
and 2 in.; Figure 1). They are easily installed by removing a section of the plumbing and
replacing it with an assembly of heaters joined (in series) to the piping with rubber hose
and clamps.

Figure 1 - Lower radiator hose heaters in a variety of sizes.

A typical wet horizontal bench system may require one to three heaters, depending on
the size of the tank. As a general rule of thumb, conventional magnetic particle tanks will
require at least one heater per 38 L (10 gal) of particle bath in the harshest of
conditions. The number of heaters needed depends on equipment design, outside air
temperature and whether the processing station is enclosed within the test booth or if it
is exposed to the adverse conditions outside the booth. The diameter of the plumbing
(which also dictates the size of the heater used) determines how many heaters are
actually needed due to the fact that the various sized heaters have differing wattage
ratings (that is, different current requirements).

The heaters should be installed in series within the existing plumbing located
below the tank.

The heaters should be installed in series within the existing plumbing located below the
tank. To be effective, it is recommended that the heaters are installed before the
agitation tube and spigot, such that the bath is in constant motion relative to the heating
elements. Although these heaters feature a straight through design, it is good practice to
install such heaters after the particle bath has been filtered to avoid any risk of clogging
(Figures 2 and 3).

Figure 2 - Schematic showing heater installation position following the filter and before
the agitation tube and hose.

Figure 3 - Photo of the heating arrangement.

Observed bath temperatures at our forging facility, with the magnetic particle testing
system idling, is usually between 294 and 305 K (70 and 90 F). Again, this depends on
equipment design, outside air temperature and whether the processing station is
enclosed or not. When left idling during a cold night or over a weekend, clear plastic

sheeting can also be draped over the processing station to trap in heat, such that any
plumbing above the tank is also kept from freezing. The use of plastic sheeting will also
minimize evaporation of the bath. Since heat is constantly being lost to the outside
environment, "overheating" the particles (which can strip the fluorescent pigment)
should not occur provided that the bath is always circulated.
Bath temperature when a magnetic particle testing system is in use during production is
typically cooler, due to the fact that the bath is cooled from cold parts being magnetized
and the cascading action of the particle bath as it drops back into the tank. Observed
bath temperature has ranged between 289 and 300 K (60 and 80 F).

Heater Guidelines
Below are some additional guidelines for using the heaters.

Use heaters only when the circulation pump is running. Although these
heaters are thermostatically controlled, localized heating without the
constant cooling action of the bath can potentially cause the heaters to
malfunction or can cause premature pigment breakdown of the particle
itself. Heaters can continually operate while the pump is operating during
cold winter nights and weekends without any issues.
Use heaters during normal production to minimize the risk of flash freezing
of particle bath on the part surface when part temperature is 273 K (32 F)
or less.
Although multiple heaters can be installed, it can be left to the technician's
discretion as to how many heaters should be plugged in during production.
A single heater can be utilized or multiple heaters can be simultaneously
plugged in to maintain bath temperature at the technician's discretion.
Bath temperature can be periodically checked with a waterproof digital or
bimetal dial thermometer.
Do not plug tank heaters into a circuit that is used for ultraviolet lights or
space heaters. The electrical current necessary to operate the heaters can
exceed the rating of the circuit breaker, thereby overloading the breaker. If
possible, try to use a dedicated breaker/circuit. Be sure to use a breaker
that will not be shut off or tampered with during nights and weekends.
Depending upon the heater size installed, individual heaters can range
from 375 to 600 W each.
Use lower radiator hose heaters that are of aluminum diecast design. This
will allow a maintenance technician an inspector to simply "feel" the heater
housing to ensure that it is indeed operating. The entire aluminum housing
transfers heat, which is easily detected by carefully touching the heater.
Lower radiator hose heaters of the aluminum diecast design also feature a
straight through orifice, therefore reducing the risk of clogging.
Lower radiator hose heaters that are made of the stamped sheet metal
design can be used; however, they are not recommended since the

heating element is in direct contact with the liquid. With this design, it is
difficult to verify by simple means if the heaters are indeed operating. Also,
the heating element extends into the circulation path, thereby increasing
the risk of clogging the plumbing system with debris.
If flash freezing on the part surface is a problem that can affect particle
mobility and overall quality, the particle bath should be heated and bath
temperature should be monitored/recorded regularly as part of the quality
system. As mentioned above, the temperature of the bath can be
measured with a traceable digital or bimetal dial thermometer to verify its
effectiveness in harsh temperatures.
Always use a three prong safety cord with these heaters in the event of
malfunction.
Prior to installing the heaters, verify that the magnetic particle tank/frame
are also electrically grounded in the event of heater malfunction.

Conclusion
Overall, heating the particle bath in such adverse conditions will enhance the integrity of
the magnetic particle process by reducing "flash freezing" and will reduce the risk of
equipment downtime due to frozen plumbing or equipment failure. Another advantage is
that heating the particle bath can help eliminate the need of ethylene glycol as a
supplemental additive, since disposal of ethylene glycol is also an issue.