Finite-Element Analysis for Remote Field Eddy Current Responses from Near- and Farside Cracks

Results of three-dimensional finite-element analysis investigations of remote field eddy current (RFEC) signal responses from internal and external stress corrosion cracking (SCC) in steel pipes are presented. The fine shallow SCC cracks were simulated by double axial slits located on the near- and farside pipe surfaces under simulated RFEC excitation. Although it is normally a characteristic of RFEC testing that responses to interior or exterior defects are approximately equal, there is a considerable difference between the farside and nearside responses from very fine defects such as SCC cracks.     

Use of magnetically-saturated regions in remote field eddy current tools

The remote field eddy current (RFEC) technique is of potential interest for inspecting pipelines for stress corrosion cracking. Magnetic saturation techniques would allow higher operating frequencies and scanning speeds to be used. The use of selectively-saturated regions (windows) near the exciter and detector offers additional advantages. Finite element, analytic, and experimental measurements are presented in this paper. They show that, while saturation techniques are helpful, the effects are less than initially estimated from simple skin depth approximations.     

Finite element modelling and physics of remote field eddy currentresponses for axially aligned cracks

A simplified physical model for two-dimensional (2-D) finite element analysis of axially aligned crack responses for the remote field eddy current (RFEC) technique is proposed. Two formulations are applied to model the problems. Reasonable agreement between calculated results and some preliminary experimental results is achieved. A hypothesis, based on the physical model, is presented. It explains the RFEC signals from axially aligned cracks and makes some predictions of possible features for future verification     

Longitudinal AC interactions with axial slits in steel pipes

The Remote Field Eddy Current (RFEC) nondestructive inspection technique uses low frequency AC and through wall transmission to inspect pipes and tubes from the inside. In steel pipes, it has generally greater sensitivity to circumferential rather than axial slits because the perturbation of magnetic fields orthogonal to slits dominates. Circumferential AC magnetic fields, generated by passing AC axially along a steel pipe from an external supply, have therefore been tested in order to give greater sensitivity to axially aligned cracks characteristic of stress corrosion cracking in pipe-lines. Anomalous source missing magnetization defect models suggest that, as slit widths are reduced, the importance of magnetic interactions is reduced until eddy current interactions predominate. This suggests that, for very fine axial cracks, true RFEC geometry, which gives circumferential eddy currents, will give stronger signals than circumferential AC magnetic fields.Research supported by Natural Sciences and Engineering Research Council of Canada, Pipetronix Ltd., and Gas Research Institute.     

Method for Removing Secondary Peaks in Remote Field Eddy Current Testing of Pipes

In the remote field eddy current (RFEC) testing of pipes, because the remote eddy current penetrates the pipe’s wall twice, the testing results exhibit two peaks (primary peak and secondary peak) that originate from both the transmitter and receiver passing by the same place in the pipe. The secondary peaks have the same features as the primary peaks that are used to assess defects, and if there is no separation between primary peaks and secondary peaks, incorrect evaluations of defects will be obtained. Considering the benefits of removing secondary peaks in RFEC testing, dual receivers are taken into account. Dual receivers are set in remote fields and are set coaxially to the transmitter to obtain differential signals at the same time. In the proposed method, position dependent response of the differential signals from the dual receivers is calibrated, a Wiener deconvolution filter is used to identify secondary peaks and filter testing noise, and the factors that affect results of removing secondary peaks are also analyzed. To validate the feasibility of the proposed method of RFEC testing, ANSYS is made use of when setting up the analysis model, and an experimental pipe is designed to be identical to ANSYS model. The results of the analysis of ANSYS and experiments both validate the practicality of the proposed method and show the benefits of simplifying the analysis of RFEC signals.     

Finite-Element Calculations of Remote Field Eddy Current Interactions with Slit Defects

Abstract

Remote field eddy current (RFEC) excitation is a promising approach for detection of the very fine axial cracks typical of stress corrosion cracking (SCC) in pipelines. Interactions between adjacent cracks or slits can enhance responses in some cases. Detailed finite-element modeling was undertaken to establish the behavior and interactions of multiple slits such as those occurring in SCC. Three different field/slit configurations are considered, with anomalous source models used to aid interpretation of the results. The study noted that magnetic perturbations generated by ferromagnetic material tend to be vanishingly small, and that the interactions between multiple cracks give minimal enhancement, indicating that eddy current rather than magnetic field excitation is best for the detection of SCC. With eddy current excitation, field perturbations are generated by even very fine slits, and are larger in non-ferromagnetic material. For non-ferromagnetic pipes, the perturbations tend to merge as a circumferential separation between parallel axial cracks decreases, resulting in significant interaction and signal enhancement.     

Anomalous magnetic source defect modelling

Defect-induced field perturbations occurring during electromagnetic testing of ferromagnetic material can be modelled as combinations of anomalous eddy current and missing magnetization sources. At low frequencies, such as are used in Remote Field Eddy Current (RFEC) inspection of steel tubes, the anomalous magnetization defect sources dominate and give strong responses to circumferential slits orthogonal to the axial magnetic field. Here we present the results of finite element calculations and computer animations of the time-varying fields from a missing magnetization model of a slit defect. These are compared with the defect-induced anomalous field patterns obtained by phasor vector subtraction of calculations for slit defect and defect-free problems. It is noted that the ferromagnetic material in which the defect is located must be included in the missing magnetization model.Research supported by Natural Sciences and Engineering Research Council of Canada, Pipetronix Ltd., Province of Ontario, Gas Research Institute and Infolytica Corp.     

Finite-element calculations of remote field eddy current interactions with slit defects

Remote field eddy current (RFEC) excitation is a promising approach for detection of the very fine axial cracks typical of stress corrosion cracking (SCC) in pipelines. Interactions between adjacent cracks or slits can enhance responses in some cases. Detailed finite-element modeling was undertaken to establish the behavior and interactions of multiple slits such as those occurring in SCC. Three different field/slit configurations are considered, with anomalous source models used to aid interpretation of the results. The study noted that magnetic perturbations generated by ferromagnetic material tend to be vanishingly small, and that the interactions between multiple cracks give minimal enhancement, indicating that eddy current rather than magnetic field excitation is best for the detection of SCC. With eddy current excitation, field perturbations are generated by even very fine slits, and are larger in non-ferromagnetic material. For nonferromagnetic pipes, the perturbations tend to merge as a circumferential separation between parallel axial cracks decreases, resulting in significant interaction and signal enhancement.     

Remote Field Eddy Current Technique: Phantom Exciter Model Calculations

Abstract

High resolution results of finite element calculations for remote field eddy current “phantom exciter” simulations of slit defect interactions using single through wall transit are presented. These show that fine circumferential slits cause almost no field perturbations in the case of nonferromagnetic tubes but big perturbations in ferromagnetic tubes where high magnetic H fields occur in the slits. Defect-induced magnetic field perturbations must therefore be considered in addition to eddy current perturbations when ferromagnetic materials are inspected, particularly in the case of fine slits orthogonal to the magnetic field direction. Additional details seen are the funnelling of energy into slits in ferromagnetic pipes and precursor disturbances of fields approaching defects. It is suggested that these are due to the reflection of the electromagnetic waves dictates by boundary conditions at the near side defect boundary.     

螺旋磁场对Sn-Sb合金成分偏析的影响

为了深入研究螺旋磁场解决重力偏析的效果及作用机理,本文选用低熔点Sn-Sb合金,分析不同励磁电流下螺旋磁场对铸锭宏观成分偏析的影响,并与常规条件下及相同工艺参数旋转磁场条件下的凝固组织进行比较.结果表明,螺旋磁场的电磁力分布特点有利于在铸锭内部形成更大区域的均匀搅拌,相比于旋转磁场可以更好地改善铸锭成分的宏观偏析;随着励磁电流的增大,两种磁场改善偏析、细化凝固组织的效果更好;当螺旋磁场励磁电流为100 A时,基本消除铸锭上、下部位由于重力作用导致的成分偏差,β相(SnSb)变得细小且均匀分布在基体内.在金属熔体凝固的过程中施加螺旋磁场可消除重力偏析,效果优于旋转磁场.     

脉冲磁场激励下圆柱导体内瞬态涡流场的快速计算

建立了脉冲磁场激励下圆柱导体内瞬态涡流场的理论模型。实现了瞬态涡流场的快速计算。通过实例表明上述圆柱导体内瞬态涡流场的快速计算方法有效。     

涡流检测中轴对称场的快速计算

本对涡流检测中解析求解轴对称场时遇到的无穷积分给出一种简单有效的数值积分方法,提出一种改进积分收敛性的方法,加速了无穷积分的截断,显提高了轴对称场的计算效率。几组典型数据的计算结果与ＦＥＭ－ＢＥＭ组合法计算结果的比较表明,本的方法是准确、快速的,这一计算方法的高效率使其可应用于涡流无损检测中缺陷的重构。     

Numerical analysis for eddy current characteristics of magnetically saturated ferromagnetic tubes

Magnetic saturation is applied to ferromagnetic tubes inspected by the encircling or inner coil because suppressing magnetic noise is important for the eddy current testing technique. Eddy current signal characteristics in magnetically saturated tubes are different from those in nonmagnetic tubes. In ferromagnetic tubes, defect signal phase angle is not useful for estimating defect depth because it does not depend on the defect depth. In this paper, numerical eddy current analysis has been done in order to explain the relationship between the defect depth and the phase angle in magnetically saturated tubes. This analysis is performed as follows: 1) The magnetic permeability near the defect is calculated as the non-linear magnetostatic problem. 2) The eddy current distribution is calculated as the linear magnetodynamic problem using the incremental permeability value calculated in step 1. The numerical analysis results reveal that the permeability around the defect remains inhomogeneous and it causes the unique eddy current characteristics. Based on these calculated results, a quantitative evaluation method of determining defect depth is proposed. After determining the defect shape by using signal characteristics obtained from the strongly magnetizing state, the defect depth can be estimated by using the signal amplitude.     

Numerical Analysis for Eddy Current Characteristics of Magnetically Saturated Ferromagnetic Tubes

Abstract

Magnetic saturation is applied to ferromagnetic tubes inspected by the encircling or inner coil because suppressing magnetic noise is important for the eddy current testing technique. Eddy current signal characteristics in magnetically saturated tubes are different from those in nonmagnetic tubes. In ferromagnetic tubes, defect signal phase angle is not useful for estimating defect depth because it does not depend on the defect depth. In this paper, numerical eddy current analysis has been done in order to explain the relationship between the defect depth and the phase angle in magnetically saturated tubes. This analysis is performed as follows: 1) The magnetic permeability near the defect is calculated as the non-linear magnetostatic problem. 2) The eddy current distribution is calculated as the linear magnetodynamic problem using the incremental permeability value calculated in step 1. The numerical analysis results reveal that the permeability around the defect remains inhomogeneous and it causes the unique eddy current characteristics. Based on these calculated results, a quantitative evaluation method of determining defect depth is proposed. After determining the defect shape by using signal characteristics obtained from the strongly magnetizing state, the defect depth can be estimated by using the signal amplitude.     

Markov chain Monte Carlo posterior density approximation for a groove-dimensioning purpose

The purpose of this paper is to present a new approach for measurand uncertainty characterization. The Markov chain Monte Carlo (MCMC) is applied to measurand probability density function (pdf) estimation, which is considered as an inverse problem. The measurement characterization is driven by the pdf estimation in a nonlinear Gaussian framework with unknown variance and with limited observed data. These techniques are applied to a realistic measurand problem of groove dimensioning using remote field eddy current (RFEC) inspection. The application of resampling methods such as bootstrap and the perfect sampling for convergence diagnostics purposes gives large improvements in the accuracy of the MCMC estimates.     

ORCHID—A computer simulation of the reliability of an NDE inspection system

CANDU pressurized heavy water reactors contain several hundred horizontally-mounted zirconium alloy pressure tubes. Following a pressure tube failure, a pressure tube inspection system called CIGARette was rapidly designed, manufactured and put in operation. Defects called hydride blisters were found to be the cause of the failure, and were detected using a combination of eddy current and ultrasonic scans. A number of improvements were made to CIGARette during the inspection period. The ORCHID computer program models the operation of the delivery system, eddy current and ultrasonic systems by imitating the on-reactor decision-making procedure. ORCHID predicts that during the early stage of development, less than one blistered tube in three would be detected, while less than one in two would be detected in the middle development stage. However, ORCHID predicts that during the late development stage, probability of detection will be over 90%, primarily due to the inclusion of axial ultrasonic scans (a procedural modification). Rotational and axial slip could severely reduce probability of detection. Comparison of CIGARette's inspection data with ORCHID's predictions indicate that the latter are compatible with the actual inspection results, though the numbers are small and data uncertain. It should be emphasized that the CIGARette system has been essentially replaced with the much more reliable CIGAR system.     

Effect of combined magnetic field on the eliminating inclusions from liquid aluminum alloy

The effect of electromagnetic field on the removal of inclusions in the aluminum alloy was investigated. Primary silicon particles precipitating from the solidification of Al-Si hypereutectic alloy were regarded as inclusions. An experimental apparatus applied with both rotating magnetic field (RMF) and traveling magnetic field (TMF) was employed to study the distribution of silicon particles in Al-Si alloy under magnetic field. The results showed that combined magnetic field (CMF) consisting of RMF and TMF eliminated the silicon particles from the molten alloy. Compared with TMF or RMF, CMF increased the separating effectivity substantially. It was proposed that CMF provided a highly effective approach for metal purification.     

Pulsed Eddy Current Technology: Characterizing Material Loss with Gap and Lift-off Variations

Abstract

Ownership costs of operational aircraft have increased steadily over the years. One of the major cost drivers is structural deterioration due to corrosion. Beyond the economics, finding and characterizing corrosion is essential for the continued airworthiness of aircraft fleets. To this end, the pulsed eddy current technique holds the potential of becoming the primary means of detecting corrosion in multilayered structures. Its wide-band frequency spectrum allows the determination of a large number of parameters, such as defect size and location. Pulsed eddy current is still considered an experimental nondestructive technique because of realistic inspection problems (e.g., probe tilting, protrusion of rivets, and thickness variations in adhesive and paint) have not been addressed in the past. Recent advances change this situation and allow pulsed eddy current to be a credible field technique.     

微通道铝管的涡流探伤方法研究

目前微通道铝管被大量投放市场,但没有很好的质量控制方法,运用科学、有效的在线涡流探伤,及时检出产品上的缺陷并作出标识,加强对微通道铝管的质量控制,是微通道铝管生产厂家和从事涡流探伤技术研究人员所面临的迫切问题。本文根据实践经验并结合自身对涡流探伤理论的研究,阐述3种可用于微通道铝管的在线涡流探伤方法：穿过式单通道探伤方法、穿过式双通道探伤方法和单穿过式加双点探头式三通道探伤方法。通过分析对比这3种探伤方法的优缺点和实现难易度,为微通道铝管的在线涡流探伤提供具有重要推广价值的方法,同时为加强微通道铝管涡流探伤技术的研究进而推动涡流探伤技术的发展提供参考依据。     

乳状液电磁场破乳法的研究

提出了一种利用电磁感应原理产生涡旋电场进行破乳的新方法。将螺线管、磁芯构成的电感器与电容器串联组成Ｌ－Ｃ谐振电路。在此电路中通过高频电流，使其在破乳器内产生高频磁场，从而感生出高频涡旋电场。在此电场的作用下，乳状液滴极化并加速其运动与碰撞，达到破乳的目的。该法在输入信号电压约３００Ｖ、电流几＋ｍＡ、频率２０ｋＨｚ的条件下，可感应出强度为几十＋ｋＶ／ｃｍ的涡旋电场，５ｍｉｎ内静态破乳率大于９８％。在