Metal magnetic memory testing for early damage assessment in ferromagnetic materials

In order to investigate the physical mechanism of metal magnetic memory testing, both the influences of earth magnetic field and applied stress on magnetic domain structure were discussed. Static tension and fatigue tests for low carbon steel plate specimens were carried out on hydraulic servo testing machine of MTS810 type and magnetic signals were measured during the processes by the type of EMS-2003 instrument. The results indicate that the initial magnetic signals of specimens are different before loading. The magnetic signals curves are transformed from initial random to regular pattern due to the effect of two types of loads. However, the shape and distribution of magnetic signal curves in the elastic region are different from that of plastic region in tension test. While in fatigue test those magnetic signals curves corresponding to different cycles are similar. The H_p(y) value of magnetic signals on the fracture zone increases dramatically at the breaking transient time and positive-negative magnetic poles occur on the two parts of fracture zone.

Fatigue damage evaluation by metal magnetic memory testing

Tension-compression fatigue test was performed on 0.45% C steel specimens.Normal and tangential components of magnetic memory testing signals,Hp(y) and Hp(x) signals,with their characteristics,K of Hp(y) and Hp(x)M of Hp(x),throughout the fatigue process were presented and analyzed.Abnormal peaks of Hp(y) and peak of Hp(x) reversed after loading; Hp(y) curves rotated clockwise and Hp(x) curves elevated significantly with the increase of fatigue cycle number at the first a few fatigue cycles,both Hp(y) and Hp(x) curves were stable after that,the amplitude of abnormal peaks of Hp(y) and peak value of Hp(x) increased more quickly after fatigue crack initiation.Abnormal peaks of Hp(y) and peak of Hp(x) at the notch reversed again after failure.The characteristics were found to exhibit consistent tendency in the whole fatigue life and behave differently in different stages of fatigue.In initial and crack developing stages,the characteristics increased significantly due to dislocations increase and crack propagation,respectively.In stable stage,the characteristics remained constant as a result of dislocation blocking,K value ranged from 20 to 30 A/(m·mm)-1,and Hp(x)M ranged from 270 to 300 A/m under the test parameters in this work.After failure,both abnormal peaks of Hp(y) and peak of Hp(x) reversed,K value was 133 A/(m·mm)-1 and Hp(x)M was-640 A/m.The results indicate that the characteristics of Hp(y) and Hp(x) signals were related to the accumulation of fatigue,so it is feasible and applicable to monitor fatigue damage of ferromagnetic components using metal magnetic memory testing(MMMT).

Characterization of Stress Concentration by Tangential Component Hp(x) of Metal Magnetic Memory Signals

The correlation between the stress concentration and the spontaneous magnetic signals of metal magnetic memory(MMM) was investigated via tensile tests. Sheet specimens of the Q235 steel were machined into standard bars with rectangular holes to obtain various stress concentration factors. The tangential component Hp(x) of MMM signals and its related magnetic characteristic parameters throughout the loading process were presented and analyzed. It is found that the tangential component Hp(x) is sensitive to the abnormal magnetic changes caused by the local stress concentration in the defect area. The minimum magnetic field is positively correlated to the magnitude of the load and the distance from the notch. The tangential magnetic stress concentration factor presents good numerical stability during the entire loading process, and can be used to evaluate the stress concentration factor. The results obtained will be a complement to the MMM technique.

Quantitative Detection of Corrosion State of Concrete Internal Reinforcement Based on Metal Magnetic Memory

Corrosion can be very harmful to the service life and several properties of reinforced concrete structures.The metal magnetic memory(MMM)method,as a newly developed spontaneous magnetic flux leakage(SMFL)non-destructive testing(NDT)technique,is considered a potentially viable method for detecting corrosion damage in reinforced concrete members.To this end,in this paper,the indoor electrochemical method was employed to accelerate the corrosion of outsourced concrete specimens with different steel bar diameters,and the normal components Bz and its gradient of the SMFL fields on the specimen surfaces were investigated based on the metal magnetic memory(MMM)method.The experimental results showed that the SMFL experimental Bz curves are consistent with the analytical results of the theoretical model.Furthermore,the crest-to-trough behavior on the Bz signal curve and its zero-point gradient spacing can more accurately indicate the corroded area’s extent.Then,a magnetic characteristic parameter W based on a large amount of experimental data was established to characterize the degree of corrosion of the steel bars.The magnetic characteristic parameter W is linearly related to the maximum cross-sectional area loss rate
of the corroded reinforcement.This paper will lay the foundation for future research on corrosion detection of reinforced concrete structures based on the MMM method and provide a feasible way for non-destructive detection of corrosion independent of the influence of reinforcement diameter and magnetization history.

Variation regularity of metal magnetic memory signals with inspecting time-interval and location

Influences of inspecting time-interval and location on varying behavior of metal magnetic memory (MMM) signals of defects were studied. Different areas in two precracked weldments were inspected at different time-intervals by type TSC-1M-4 stress-concentration magnetic inspector to obtain MMM signals. Mechanisms of MMM signals varying behavior with inspecting time and space were analyzed and discussed respectively. It is found that MMM signals don't change with inspecting time-interval, since stress field and magnetic leakage field maintain unchanged at any time after welding. On the other hand, MMM signals differ greatly for different inspecting locations, because stress field and magnetic leakage field are unevenly distributed in defective ferromagnetic materials.

MMM testing and failure analysis of fastening bolts on reciprocating compressor cylinder cover

To avoid the serious accidents caused by the failure fastening bolts on reciprocating compressor cylinder cover,a new nondestructive testing(NDT) technology,metal magnetic memory(MMM) testing,was applied to safety evaluating and failure analyzing for the fastening bolts.Based on the dynamic stress calculation of the failure bolts,MMM testing was carried out at workshop.Given are the MMM stress distribution characteristics of the failure bolts and fracture faces.It has been found that the MMM signal variation amplitude of the crack transition zone in the fracture surface is minimal,that of the crack initiation zone is in the middle,and that of the tear fracture zone is maximal.The failure reasons were analyzed with MMM effect.The results of the metallographic examination showed that the validity and feasibility of MMM testing and failure analysis.This means MMM technology is a new,fast and validity method of failure analysis.

考虑残余应力影响的典型钢结构对接焊缝缺陷定位研究

对接焊缝为典型的钢结构焊缝形式,其位置处的裂纹和气孔型缺陷的准确检测对于钢结构维护有着重要的意义,使用磁记忆检测技术对焊缝裂纹和气孔型缺陷进行定位时,传统的零点极值理论由于焊接残余应力的影响,难以区分残余应力、焊接裂纹和气孔型缺陷所产生的磁信号,从而在实际检测中造成缺陷定位的误判和漏判,因此,从焊接裂纹和气孔型缺陷和残余应力所在区域磁信号产生机理的不同入手,开展考虑残余应力影响下的焊接裂纹和气孔型缺陷定位检测研究。首先对焊接残余应力与裂纹和气孔型缺陷产生磁信号的机理进行分析,提出采用三维磁模量梯度极值判定方式来区分残余应力与裂纹和气孔型缺陷产生的磁信号;其次再进行焊接缺陷有限元COMSOL模拟,将所得磁信号代入梯度极值特征公式中进行表征判断;最后为了验证模拟表征判断的准确性,人工制作焊接钢板,提取三维磁信号进行分析。研究结果表明,理论分析、数值模拟与试验结果相互吻合,三维磁模量梯度极值能定位焊接缺陷并定量表征缺陷的长度,且裂纹和气孔型的三维磁模量梯度值远远高于无缺陷残余应力区域的梯度值。

金属磁记忆检测技术在双金属复合管道上的探索应用

采用双金属复合管被认为是解决高腐蚀性油气田地面集输管线腐蚀问题的一种相对安全的办法,但目前国内应用过程中存在管道失效及检测难等问题。金属磁记忆检测技术应用于检测埋地双金属复合管,并通过对磁异常危险等级较高位置进行开挖验证,配合测厚和磁饱和-脉冲涡流等无损检测技术,取得了良好的应用效果。检测结果明确了金属磁记忆检测技术在一定程度上可以满足埋地双金属复合管的应力集中程度检测需求,有一定的推广价值。

20钢板焊缝缺陷的磁记忆检测

与磁粉检测和射线检测相比,磁记忆检测灵敏度更高,利用金属磁记忆技术对20钢板的焊缝缺陷进行无损检测评价。研究表明:磁记忆检测法能够有效表征钢板的焊缝缺陷;与磁场强度参数相比,磁场梯度对焊缝缺陷更为敏感,表现为在被测4块钢板的焊缝缺陷处,其磁场梯度的法向分量均出现了明显增加、并呈凸峰状,且在焊缝一些局部应力集中处,也出现了异常磁记忆信号。在实际应用时,可以利用磁记忆检测快速的特点,先对被测构件焊缝的异常信号进行提取,同时与其他无损检测进行比较,有效实现提高缺陷检测准确性与可靠性的目的。

机器学习在金属磁记忆检测中的应用与展望

金属磁记忆检测技术(MMMT)能够检测以应力集中为代表的早期损伤,在铁磁性构件损伤检测领域具有广阔的应用前景。由于金属磁记忆检测信号十分微弱并且具有较强的非线性,在实际检测时容易出现漏检或误检。机器学习方法对信号数据集特征分析具有良好的自学习和自适应性能力,较适合金属磁记忆检测信号的分析与处理。对机器学习技术在金属磁记忆检测中的应用进行了综述,讨论了金属磁记忆信号传统特征提取方法的特点,分析了机器学习在金属磁记忆检测中的特征提取、定量识别及剩余寿命预测等方面的研究现状,指出了机器学习在金属磁记忆检测领域的难点问题,并对其发展方向进行了展望。

基于金属磁记忆的宏观焊接裂纹识别方法

为研究焊接裂纹和其他缺口效应造成的应力集中对金属磁记忆信号的不同影响,利用小波分解的方法提取金属磁记忆信号的细节部分,对细节部分做离散Fourier变换后得到其幅值,该幅值是被测材料应力集中程度的一种反映。研究表明,通过反映应力集中水平的金属磁记忆信号特征,可以实现焊接裂纹金属磁记忆检测信号的自动识别及焊接裂纹的检测。

钻具材料疲劳损伤的磁记忆检测试验研究

为及时准确地确定钻具疲劳损伤及应力集中位置,确定疲劳损伤程度,对42CrMo钢缺口试件进行拉扭疲劳试验及磁记忆在线检测。试验中实时采集磁记忆信号的切向分量,分析其梯度变化趋势,并提取Hp(x)max,Hp(x)sub,Kmax,Ksub等4个磁记忆信号特征参量,研究这4个特征参量在整个疲劳循环过程中的变化规律,并比较在线卸载与在线加载检测各特征参量的异同。试验结果表明,在整个疲劳过程中,各磁记忆信号特征参量具有不同的变化规律,很好地诠释了材料的拉扭疲劳过程,表征出不同疲劳阶段材料的应力集中程度。

自适应小波阈值在磁记忆信号降噪处理中的应用

用金属磁记忆方法检测时信号常常被各种噪声污染,为了降低噪声的干扰,对传统阈值方法的局限性进行了分析,并在改进阈值函数的基础上提出了一种自适应小波阈值降噪方法。通过仿真实验对该方法的性能进行了验证,然后将其应用于磁记忆信号的降噪处理中,结果表明算法较好地剔除了信号中的噪声,提高了重建信号的噪声抑制率,降低了信号的失真率,是一种可行的磁记忆信号降噪方法。

金属磁记忆检测技术的现状与发展

金属磁记忆检测是目前无损检测领域的最新技术 ,适用于铁磁性金属构件失效的早期诊断 ,在疲劳强度和寿命评估研究中极具潜力。介绍了金属磁记忆效应的概念及国内外磁记忆检测技术的现状 ,分析了磁记忆检测技术的特点和发展趋势 ,总结了目前磁记忆检测领域的研究进展。

基于金属磁记忆的局部屈服诊断新方法研究

为研究Q235和20g两种母材静载拉伸过程中磁波动规律,采用微观点应变测量和宏观磁记忆检测相结合的试验方法,实现了屈服与磁畸变对应关系研究,力求获得磁畸变的产生机理,进而证明磁记忆对屈服具有独特的诊断功效。结果表明:两种材料磁畸变规律相同,磁畸变产生于屈服阶段,屈服后基本消失,磁畸变与屈服发生的时间和位置具有一一对应关系;金属磁记忆可对屈服实施定量评价,为在早期缺陷形成前发现安全隐患提供了新途径。

不同检测环境下磁记忆信号变化研究

通过开展中碳45#钢试件的静载拉伸实验,采用磁记忆检测技术,研究了在线及离线2种检测环境下、不同加载阶段试件磁信号变化情况。结果显示:对应不同的检测环境,检测得到的试件磁信号差别显著。在线检测时试件周围磁环境对检测准确性影响较大,磁记忆检测判据——“过零点”失去作用;离线检测时检测效果良好,过零点能够反映试件应力集中部位。同时,对实验过程中的磁场强度变化及过零点漂移现象进行了理论分析。

疲劳损伤磁性无损评估技术研究现状及发展前景

磁性无损检测技术是评估铁磁材料疲劳损伤以及重要结构件可靠性的重要检测手段。针对铁磁材料的疲劳损伤,介绍了几种典型的磁性无损检测技术,如磁巴克豪森噪声(MBN)、磁声发射(MAE)、漏磁(MFL)和金属磁记忆(MMM)等,对其产生机理及应用特点进行了概述;对几种磁性检测技术在疲劳损伤评估领域的研究现状以及取得的主要研究成果进行了综述;最后指出几种技术尚存的问题和进一步的研究方向,并对其发展前景进行预测。

磁记忆梯度张量测量信号预处理方法

为降低磁记忆测量信号中各种噪声干扰,提高磁记忆信号梯度张量解算精度,提出形态滤波和经验模态分解组合的方法消除噪声。首先,根据矢量合成原理将磁分量信号转换成总场幅值和方向信号,保证降噪处理过程中不改变各磁分量之间的内在关系;然后,利用形态滤波器对幅值和方向信号进行处理,消除信号中的瞬时强脉冲噪声;最后,将信号进行经验模态分解降噪,消除低频和局部干扰噪声。将上述方法用于磁记忆实测信号处理,结果表明,提出的方法能有效消除磁分量信号不同类型干扰噪声,解算得到高精度的磁记忆梯度张量数据。

加载方式对28CrMo钢疲劳裂纹扩展的影响

利用疲劳试验机研究了28CrMo钢在三角波、方波和正弦波3种加载方式下三点弯曲疲劳实验过程中疲劳裂纹扩展速度与自发射磁信号的相关性,用扫描电镜对疲劳断口特征进行了研究。结果表明:加载方式不同,疲劳裂纹扩展速度不同,其中三角波加载方式下裂纹扩展速度最快,自发射磁信号最大,正弦波加载方式下裂纹扩展速度最慢,其自发射磁信号最小,方波加载方式则介于两者之间。基于磁荷概念和Ansys模拟结果分析了不同加载方式下疲劳裂纹扩展过程中自发射磁信号的变化规律。断口扫描分析结果表明3种加载方式下的疲劳断口均为类解理断裂。

基于模糊隶属度最大似然估计的焊缝隐性缺陷磁记忆信号识别

针对磁记忆信号在焊缝残余应力集中、隐性损伤识别和定位上的难题,建立了模糊隶属度最大似然估计识别模型。通过疲劳载荷作用下的Q235钢板状焊缝试件磁记忆检测试验,研究了焊缝残余应力集中、隐性损伤直至宏观断裂整个过程的磁记忆信号变化规律,提取多种磁记忆特征值:峰峰值ΔHp(y)、梯度最大值K_(max)、梯度均值K_(ave)、极限状态系数最大值mmax,引入正态分布函数计算其概率,结合半梯形模糊隶属度函数,建立了焊缝隐性损伤的模糊隶属度最大似然估计识别模型,判断疑似缺陷点进而识别隐性损伤并定位缺陷。结果表明:基于多种特征参数基础上的最大似然模糊隶属度估计结果与实际缺陷位置完全一致,验证了该模型可以有效避免误判的发生,为实际工程中应用磁记忆技术进行焊缝隐性损伤识别和定位提供了新的方法。