Abstract
In this study, we aimed to design a coil sensor prototype capable of detecting metallic area loss based on numerical simulations using the magnetic flux leakage (MFL) method. Unlike previous numerical simulation-based studies, which are only conducted to obtain the MFL itself, the main objectives of this study were (1) to acquire the induced current in the coil sensor and (2) to optimize the apparatus based on a time-dependent numerical analysis. As a result, the optimum values of parameters in magnetizing and sensing units were obtained numerically. A magnetic sensor prototype was then fabricated using the optimum parameters obtained by numerical parametric study. Finally, experimental validation tests were conducted on a solid steel rod specimen with a stepwise cross-sectional reduction flaw. It was observed that numerical simulation had approximately 91% precision compared to the experimental test. The results reveal that application of a realistic numerical simulation of an MFL coil sensor can probably provide essential information for MFL-sensor fabrication and allows for preventive measures to be taken before manufacturing failure or defect misdetection.
Highlights
To assess the integrity of structures, structural health monitoring (SHM) for metal members, such as pipelines in the oil and gas industry, load carrying cables in bridges, lifts, cranes, etc., is an essential task and must be done regularly to eliminate any chance of structural failure and economic loss [1]
The results reveal that application of a realistic numerical simulation of an magnetic flux leakage (MFL) coil sensor can probably provide essential information for MFL-sensor fabrication and allows for preventive measures to be taken before manufacturing failure or defect misdetection
There are a variety of conventional methods which are being applied based on non-destructive SHM principles such as visual inspection [6], magnetic flux leakage (MFL) [7,8], eddy current sensing [9,10], acoustic emission [11,12,13,14,15], and guided wave [16,17,18], among other techniques
Summary
To assess the integrity of structures, structural health monitoring (SHM) for metal members, such as pipelines in the oil and gas industry, load carrying cables in bridges, lifts, cranes, etc., is an essential task and must be done regularly to eliminate any chance of structural failure and economic loss [1]. Steel cables and ropes are designed to have high strength, cross-sectional damage and internal breakage and cracks can still occur during their service life and may compromise the entire structural integrity [4]. These types of damages are not detected by the naked eye and visual inspections (e.g., internal breakage of cable in cable-stayed bridges) [5]. There are a variety of conventional methods which are being applied based on non-destructive SHM principles such as visual inspection [6], magnetic flux leakage (MFL) [7,8], eddy current sensing [9,10], acoustic emission [11,12,13,14,15], and guided wave [16,17,18], among other techniques
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