Detection of back-side pit on a ferrous plate by magnetic flux leakage method with analyzing magnetic field vector
Introduction
Magnetic flux leakage (MFL) testing is one of the most commonly used methods for non-destructive testing, with a long history of applications. To evaluate and inspect flaws in metallic materials using electromagnetic methods, various measurement methods, such as eddy current testing (ECT) [1], MFL [2], [3], [4], [5], [6], [7], [8], remote field testing (RFT) [9], magnetic particle inspection (MPI) and pulsed eddy current (PEC) [10], have been developed. These techniques are categorized into the two methods of eddy current and magnetic flux leakage measurements. ECT, RFT and PEC are based on detecting the eddy current generated by an applied magnetic field. On the other hand, MFL and MPI are based on magnetic flux leakage of the applied magnetic field. Eddy current methods are commonly used to detect flaws at the surface or subsurface of conductive materials, because the eddy current strength decreases with depth due to the skin effect. Recently, low frequency eddy current testing using magnetic sensors, such as a magneto-resistive sensor (MR) [11], [12], [13], [14], [15], [16], [17], Hall sensor [18] or Superconducting Interference Device (SQUID) [19], [20], [21], which can measure low frequency magnetic signals instead of a search coil, have been developed to detect deeper flaws. The skin depth for eddy current generation decreases with increasing frequency, conductivity and permeability. Therefore, the eddy current method is usually applied to non-ferromagnetic materials, since the skin depth in such materials is larger than that in ferromagnetic materials. On the other hand, the magnetic flux leakage method is usually used for ferromagnetic material structures such as steel pipelines, storage tanks, bridges, etc. If a corrosion pit or crack is present in a steel pipe, magnetic flux leakage occurs outside the pipe wall when an applied magnetic field penetrates the wall in a direction parallel to the wall surface. In general, MFL uses a strong magnetization system to yield a measurable magnetic flux leakage from the specimen. The applied magnetic field strength is usually the saturation region of the B–H curve, so that a reduction in the material wall thickness will cause a large flux to leak. However, it is difficult to detect anomaly thick-wall, since it requires a stronger magnetization system to attain saturation. One way to resolve this issue is measurement using a highly sensitive magnetic sensor. When low magnetization is applied and a low magnetic leakage signal is detected, optimization of the measurement and analysis method is necessary, because the signal-to-noise ratio is typically worse in this case. Changes in the strength and phase of the magnetic field caused by an anomaly are usually measured in common MFL, and these parameters have been discussed independently. In this study, we developed an MFL system using MR sensors, measured two-dimensional magnetic field components parallel to the sample surface and analyzed the combination of the magnetic field strength and phase.
Section snippets
Experimental
An MFL system, consisting mainly of a sensor probe, a lock-in amplifier, sensor circuits, a current source for an induction coil and a personal computer, was developed (Fig. 1). The sensor probe consists of a half-shaped yoke, induction coils at both ends of the yoke and two-dimensional MR sensors for detecting x- and y-components. The x-axis was directly perpendicular to the line of both yoke ends, and the y-axis was parallel to both yoke ends. The z-axis was perpendicular to the sample
Results and discussion
Magnetic flux leakage was measured from the back-side of the pit. Scanning was carried out with 10 mm steps. Two (x and y) independent magnetic field components were measured, and the curves of each directly measured magnetic field strength Mmes,i, phase αi, and Mim,i derived from curves were compared. Fig. 3 shows Mmes,i, phase αi curves obtained by measurements on the steel plate with pits 30 mm in diameter and 6 mm in depth. From the directly obtained magnetic field strength and phase, some
Conclusions
We compared two dimensional magnetic field components of leakage. The y-component parallel to the induced magnetic field was suitable for detecting the back-side pit of the ferrous plate. Analysis using the imaginary part of the signal was effective for estimating the size of the pit. The peak height and width of the Mim curve showed a proportional relationship to the pit depth and diameter. The developed MFL system does not require a high power current source because saturation of
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