Hall sensor array based validation of estimation of crack size in metals using magnetic dipole models

Nondestructive evaluation (NDE) is an important methodology for quantifying cracks in engineering structures. In this paper, we propose a dipole model method (DMM) for NDE. The method is used to simulate an alternating magnetic field around a crack on a paramagnetic metal specimen and to estimate the shape and volume of the crack. This method enables faster and simpler evaluation of crack size than the traditional analytical methods. The DMM performance was verified by comparing the simulation results with the experimental results obtained using an AC-type magnetic camera.     

Nondestructive evaluation of cracks in a paramagnetic specimen with low conductivity by penetration of magnetic fluid

This paper proposes a nondestructive testing method for detecting a crack in an Inconel^® specimen. Because of the low conductivity and permeability of Inconel, cracks are difficult to detect using the electromagnetic method, until now. In our method, magnetic fluid penetrates a surface crack in the Inconel specimen, and the distribution of the magnetic field is measured using a scan-type magnetic camera. The magnetic field leakage and induced current methods were examined. With our method, cracks can be evaluated. This research can be used to detect and evaluate cracks on non-ferrous and non-metallic materials such as ceramic, composite, and synthetic resins.     

Modeling of the yoke-magnetization in MFL-testing by finite elements

The yoke-magnetization is very popular in magnetic particle testing of welds. The detectability of a flaw by using this method largely depends on the magnetic flux density passing through a specimen to be examined or on the intensity of magnetic field acting in/on the specimen. In Japan inspectors have to check and confirm the appropriate magnetizing situation of the specimen by using an A-type standard test specimen specified in the standard JIS G 0565-1992. The development of indications by magnetic particles on the standard specimen is influenced by the air gap between the standard specimen and the specimen surface to be examined. Since the height and breadth of an artificial flaw in the standard specimen also influence the leakage of the magnetic flux density from the flaw, the information about the magnetizing situation is complex.In this paper we first identify influences of some factors on the magnetic leakage flux density from an artificial flaw in the standard specimen by using FEM modeling. Since the check with the standard specimen gives not a unique information to the magnetization state we investigate the technique, in which intensity of magnetic field acting on the specimen surface is used to characterize the magnetization. A finite element approach is applied to model the magnetization situation. The effectiveness of the modeling is confirmed by an experiment.     

焊接接头裂纹尖端应变场的云纹干涉法

以海洋平台用钢Ａ５３７采用ＬＢ５２ＮＳ焊条施焊的高匹配中心裂纹试件为例，本文引入一种新的光力学方法－反射式贴片云纹干涉法及其剪切技术，对该方法的基本原理与试验技术进行了系统论述，并结合小型宽板拉伸试验成功地应用于接头裂纹尖端应变场的测试，由于该方法有高灵敏度（虚栅频率≥６００Ｌ／ｍｍ）和极宽的可调量程，对横向应变场的测试更为有利。     

基于DIC与Irwin模型的工业纯钛疲劳裂纹尖端循环应变场表征

为了实现工业纯钛TA2疲劳裂纹尖端循环应变场的表征,采用数字图像相关(digital image correlation, DIC)方法并结合Irwin模型,研究了TA2紧凑拉伸试样在多级疲劳载荷下的裂纹扩展规律、循环应变场的实验划分方法以及循环应变环的演化规律。首先通过多级载荷试验获得了TA2紧凑拉伸试样的疲劳裂纹扩展规律,在此基础上结合DIC和Irwin模型,建立了疲劳裂纹尖端循环应变场的实验划分方法,实现了循环塑性区、单调塑性区和弹性区的划分。另一方面,采用DIC获得不同区域的滞回应变环,讨论了不同区域应变环的差异,从而论证了划分方法的有效性,并且揭示了裂纹扩展过程中裂纹尖端应变场从弹性区、单调塑性区到循环塑性区的演化规律。研究工作实现了TA2疲劳裂纹扩展过程中裂纹尖端循环应变场的表征,能够满足疲劳裂纹扩展研究的需要。     

A fast method for rectangular crack sizes reconstruction in magnetic flux leakage testing

Magnetic flux leakage (MFL) testing is widely used to examine ferromagnetic materials. For the reason of estimating the sizes of cracks in metals is important in piping industries, a fast method based on particle swarm optimization algorithm is proposed for reconstructing the sizes of rectangular crack in this article. Considering the magnetic leakage field intensity is related to the air gap between the inspection specimen and the sensor, we give the reconstruction results in different lift-off values. Besides, the influence of different magnetic conditions to the reconstruction effectiveness has been investigated. The simulation results have shown the rapidity and accuracy of the proposed method.     

Non-destructive testing in the high-temperature regime by using a magneto-optical film

The plane of a polarized light beam is rotated when the beam is transmitted through a magneto-optical film (MOF). Magnetic flux leakage (MFL) occurs around a crack when the specimen is magnetized and affects the magnetic domains. Therefore, a crack can be detected using a polarized lighting system and MOF. The crack detection ability depends on the domain width and saturation magnetization of the MOF. Also, crack detection at high temperatures is essential. The physical properties of the MOF at high temperatures were examined, and a nondestructive testing (NDT) method for detecting cracks at high temperatures was proposed in this paper.     

Composite magnetic flux leakage detection method for pipelines using alternating magnetic field excitation

Pipelines are an important transportation medium for petroleum and chemical products, but defects in the pipelines can present hidden dangers and affect the safe operation of the pipeline. The traditional pipeline magnetic flux leakage (MFL) scanning technique generally adopts the axial magnetization mode, which has increased the difficulty in detection and the possibility of missed detection of axial cracks. In this paper, a new composite MFL method using alternating magnetic field excitation is proposed for the detection of cracks in pipelines. The alternating magnetic field is first superimposed on the MFL magnetization field, which will form a parallel eddy current field perpendicular to the magnetization direction in the pipeline wall. The defects in the pipeline not only cause the flux leakage of the magnetization field, but also lead to the disturbance of the circumferential eddy current field. The disturbance signals can be picked up through a secondary induced magnetic field. Because the magnetic field and the eddy current field are orthogonal, the presented method can implement synchronous detection in two orthogonal directions to avoid missed detection caused by the crack orientation. A series of physical experiments are carried out in this paper. The results show that two orthogonal detection signals can be separated by a simple low pass filter. Therefore, with only one scan, the new detector can obtain the defect characteristics in the axial and circumferential directions to overcome the blind spot problem seen in traditional MFL detectors.     

The application of a differential-type Hall sensors array to the nondestructive testing of express train wheels

A new and unique nondestructive testing (NDT) system able to detect a crack with high-speed and high spatial resolution, is urgently required for inspecting small cracks on express train wheels. We, in this paper, propose a scan-type magnetic camera, which uses two linearly integrated Hall sensor arrays (LIHaS) on a wafer, and a small yoke-type magnetizer, which is positioned on the back of the LIHaS. Two of the LIHaS (hereafter, differential-type LIHaS) are arrayed in parallel. The differential Hall voltages from each sensor in the scanning direction are obtained and amplified. We can achieve high-speed NDT by using the differential-type LIHaS because of the ?V_H/?x value, which provides the most important crack information, can be obtained without buffering or calculation. We verified the effectiveness of this new and unique method by examination of cracks in the wheel specimen model.     

焊接残余应力对7N01铝合金疲劳裂纹扩展影响

焊接残余应力作为平均应力影响裂纹扩展. 将残余应力与外载平均应力分离,通过构建典型焊接残余应力场,借助扩展有限元计算焊接残余应力场的应力强度因子. 开展了紧凑拉伸（CT）试样的疲劳扩展试验,基于Walker公式将裂纹尖端平均应力强度因子K_m（静态量）和应力强度因子幅值ΔK（动态量）分离,获得疲劳裂纹扩展速率da/dN与K_m及ΔK的非线性关系. 结果表明,不同外载荷下,应力比与裂纹长度为非线性关系;残余应力对裂纹扩展存在尺度效应:CT试样裂纹长度小于2 mm时,残余应力场明显影响疲劳裂纹扩展速率;当裂纹长度大于2 mm,外载荷为主导因素.     

DETERMINATION OF SOME PARAMETERS OF CRACK BASED ON FRASTA SIMULATION

A new method, using the fracture-surface topography analysis （FRASTA）, of determining the parameters of rotation factor and CTOA is provided. The fracture surfaces are scanned by laser microscope and the height data is recorded to analyze. By comparing the crack extension, plastic rotation factor and COA obtained by the method of double clip gauge and by this new method respectively, the validity of it is verified. It is then used to determine the CTOA. .The critical CTOA is well determined in this paper. Also by the new method, the variation of crack opening deformation （COA and CTOA） through specimen thickness can be obtained which can＇t be obtained by the usual methods. It also can provide much information of crack extension such as direction and ratio.     

Research on magnetic testing method of stress distribution

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FEM study on the influence of air gap and specimen thickness on the detectability of flaw in the yoke method

The yoke method is usually used as a magnetic testing method of welds. In this paper, we study the influences of the air gap between the magnetic pole and the specimen surface on the average magnetic flux density passing through the specimen, and the specimen thickness on the leakage magnetic flux density from a flaw using finite element method (FEM). When the air gap increases the average magnetic flux density at the center of the specimen length decreases. We can estimate the intensity of the magnetic field on the specimen surface by extrapolating the magnetic flux density in space to that at lift-off being zero. Moreover, the maximum leakage magnetic flux density from a flaw decreases with increase in the specimen thickness even if the average magnetic flux density passing through the specimen is the same.     

SOME PROBLEMS CONCERNING THE J_Ic DETERMINATION BY MEANS OF A SINGLE SPECIMEN

本文主要论述单试样测J_(Ic)法中确定开裂点的方法,提出从P-Δ记录曲线计算加载过程中裂纹长度增长的解析方法和以测量裂纹顶端张开位移量为基础的方法,井用实例证明两法的有效性。本文还针对J积分与形变功间的关系报道了新近的实验结果,证实了对紧凑拉伸试样的滑移线场的假设和对极限载荷P_L所获得的结果,也证实了我们对紧拉试样所提出的J-U关系。     

工业纯钛TA2室温蠕变条件下裂纹尖端的参量表征与估算

通过试验、理论分析和有限元模拟对工业纯钛TA2室温蠕变条件下裂纹尖端应力应变场的参量表征及估算进行了研究。试验研究表明,在室温条件下,工业纯钛TA2存在明显的第1阶段蠕变现象。理论分析和有限元模拟表明,对TA2裂纹体进行保载时,裂纹尖端的应力应变场为HRR场,提出采用与时间相关的J积分来表征,并给出了估算方法。通过有限元计算,获得了TA2室温蠕变条件下CT试样的时间相关J积分值,论证了采用J积分来表征室温蠕变条件下TA2裂纹尖端应力应变场的合理性。将有限元计算与估算方法获得的J积分进行了比较,验证了估算方法的有效性和准确性。     

强交变磁场对冷塑性变形铝合金性能影响的研究

为揭示强交变磁场对金属塑性成形后力学性能的影响规律,采用对比实验的方法,研究了冷塑性变形后LY12铝合金试件在强交变磁场作用前后的残余应力和微观组织变化情况,残余应力测试采用超声波无损检测方法。研究结果表明,在足够强度的交变磁场作用下,可以使经过冷塑性变形后的LY12铝合金发生有利于提高其力学性能的变化,均匀化了由于塑性变形引起的组织缠结,细化了晶粒,并降低了残余应力。强交变磁场可以作为改善冷塑性变形后金属材料力学性能的有效方法。     

A new optical technique for detection of defects in ferromagnetic materials and components

In this paper, we present the details of a new optical technique to detect the defects present in a ferromagnetic material or component, using a ferrofluid emulsion. This new flux leakage probe consists of monodispersed ferrofluid confined between two thin transparent glass slides or in a cuvette and a white light source for illumination. By employing ferrofluid droplets of suitable size and surfactant concentration, one can qualitatively identify the region where the defect is located in the test specimen by visually observing a color change in the ferrofluid cell, in the vicinity of a crack or defect in the test specimen. The origin of this color change in the back scattering direction is due to Bragg scattering from the droplet chains, formed by the leaked magnetic flux in the presence of a defect. We discuss in detail the procedure, the merits and potential uses of this new technique for non-destructive testing and evaluation (NDT and E) applications.     

Thin-skin analysis technique for interaction of arbitrary-shape inducer field with long cracks in ferromagnetic metals

In using the AC field measurement (ACFM) technique for non-destructive evaluation (NDE) of metals, a current-carrying wire structure is used to induce eddy current within a thin layer of the metal and a magnetic field sensor to measure the field perturbations in the vicinity of the metal. The sensitivity of ACFM crack detection and sizing relies on an appropriate design of the wire structure geometry together with a dully placement of the sensor. This paper presents an analytical modeling technique for evaluating the electromagnetic field interaction of an ACFM probe with a long uniform crack in a ferromagnetic metallic slab. The probe in the proposed model can have an arbitrary-shape wire inducer with no restrictions on its relative sensor position. The technique is accurate and very efficient computationally. It first uses the two-dimensional Fourier transform to obtain the field distribution at the metal surface. The Laplacian field distribution above the metal is then determined by satisfying the so-obtained boundary condition at air–metal interface. To demonstrate the accuracy of the model, we consider the special case of a rhombic wire inducer. The comparison of our results with those obtained using the conventional algorithm in the literature validates the accuracy of the model introduced in this paper. To show the generality of the model, we also present theoretical and experimental results associated with a solenoid inducer with a three-dimensional geometry for which no analytical solution is available in the literature. The theoretical prediction of crack signal supported by experimental results is used to develop a model-based method for inverting crack signal into crack depth.     

电弧增材制造钛合金界面处残余应力及其影响研究

采用电弧增材制造方法制备了含增材/基材界面钛合金板,采用轮廓法测量了其残余应力分布。建立了模拟紧凑拉伸(C(T))试样加工和裂纹扩展过程中残余应力发展的有限元模型,缺口状态C(T)试样内残余应力分布与轮廓法测试结果吻合良好。采用该模型讨论了试样内残余应力随裂纹扩展的变化规律及对裂纹扩展的影响。试验和数值分析结果表明:2种类型试样缺口状态的残余应力分布有很大差别,A类试样(缺口位于基材)残余压应力区域靠近缺口根部,C类试样(缺口位于增材)残余压应力区域远离缺口根部;A类试样内残余应力随裂纹扩展迅速释放,残余应力引起的应力强度因子较小;C类试样内残余应力随裂纹扩展变化较小,残余应力引起的应力强度因子较高,降低了疲劳裂纹扩展寿命。     

On the suitability of induction coils for crack detection and sizing in metals by the surface magnetic field measurement technique

The surface magnetic field measurement (SMFM) technique has proved to be an accurate means for crack detection and sizing cracks in ferrous metals. The technique involves the use of two U-shaped current-carrying wires of sufficiently high frequency while measuring the discontinuity in the resultant magnetic field at the crack edge with an appropriate magnetic field sensor. In this work, we describe a mathematical algorithm to obtain the crack signal from the output of an induction coil used in a SMFM probe. We also discuss the measurement errors due to the coil size and shape. To reduce the measurement errors, we present an algorithm in which the crack signal is recovered by appropriate deconvolution of the coil output signal and its spatial transfer function. The algorithm is then used to recover crack signals for various coil shapes and sizes. The study of the results demonstrates the effectiveness of the algorithm in the case of large coils.