基于磁性技术的无损检测方法研究
摘要
无损检测是利用材料内部结构的异常或缺陷的存在所引起的热、声、光、电、磁等信号的变化，来确定被检测对象的特征及缺陷，以评价构件的使用性能。随着解析技术和计算机技术的发展，无损检测已经成为现代工业生产中质量控制和质量保证的重要的检测与测试手段。无损检测方法中如X射线衍射法、涡流检测以及巴克豪森法、磁记忆法等可探测材料表层信息，能够有效检测已发展成形的宏观缺陷。但是对于在役金属设备及构件的表层以下的结构变化或早期应力集中，特别是尚未形成微裂纹的隐性损伤，难以实施有效的评价。本论文系统研究基于磁力效应（Magnetomechanical effect）的无损检测技术并构建了基于LabView的检测系统，主要研究内容如下：
研究基于磁力效应的无损检测方法及其理论模型，当构件应力水平处于弹性阶段，由于晶粒的强度在相同的受力方向上是不同的，个别薄弱晶粒进入塑性应变状态，屈服的晶粒形成应力集中区。铁磁体的磁化曲线和磁滞回线代表了磁性材料在外磁场作用下的基本磁特性，磁化曲线和磁滞回线上反映的磁特性参数磁导率μ、矫顽力H c、剩磁M R等，灵敏地依赖于磁性材料的微观结构，建立铁磁性材料的磁性参数和材料内应力之间的关系，利用应力引起材料磁特性的变化来确定材料内部的应力分布。
在U型铁芯上缠绕激励和感应线圈是磁力法最常用的探头结构，U型探头使U型铁芯和构件的被测部分构成了一个闭合磁路，测量方便且结构简单。但是U型探头很难保证测量的准确性和重复性，温度、杂散场以及探头和构件间的空气缝隙均对测量结果均有较大影响。为提高U型探头的实用性，使用导磁胶固定探头，减小缝隙磁阻；引入偏置场，使各样品处于相同的磁化状态，屏蔽掉样品表面散射场；对测量结果进行温度补偿，提高系统测量精度；对感应信号的频率进行筛选，找出最佳频率范围。
基于磁力效应的无损检测方法通常是应用单一频率的正弦信号波或低频的三角波信号作为激励信号。本文利用脉冲场作为激励信号，其磁化电流和检测探头感应出的感生电压直接输入由计算机控制的数据采集装置，通过数据处理得到整个磁化过程的磁化曲线和磁滞回线以及各种磁性参数。
利用大电容对低阻的激励线圈放电产生脉冲强磁场。大电流在短时间内通过电感线圈，电流强度大且持续的时间短，应用绝缘栅双极型功率管（IGBT）作为开关，与电容、电感线圈、大功率阻尼电阻构建脉冲强磁场发生装置。同时为了获得完整的磁滞回线，应用微控制器控制不同的IGBT按预定时序导通或截止，控制两个相同容量电容依次对激励线圈放电，产生正反两个方向的脉冲强磁场。利用高速数据采集卡（DAQ）提取激励电流信号i与感应电压信号u，利用LabView提供的各种与实际仪器仪表外观几乎一样的控件、指示器等组成用户需要的仪表界面，获取由脉冲强磁场诱发出的磁性参数。
建立各磁性参数（矫顽力、磁导率、剩磁等）与拉、压应力的关系，各磁性参数中，剩磁对应力反应比较灵敏，并且剩磁不随外磁场幅度的变化而变化，因此更适合来反应材料内部应力分布情况。
测量低碳钢Q235弹性范围内拉应力状态下以及冷作硬化过程中的磁化曲线和磁滞回线，在试样的弹性阶段，外加拉应力使畴壁位移变得容易，材料更易于磁化，拉应力方向剩磁B r增大。外加拉应力超过屈服极限后，随着拉应力的增加剩磁B r快速减小，此时，有两个因素影响磁特性参数，外加拉应力使畴壁位移变得容易，塑性变形产生的大量位错却要阻碍畴壁位移，由于位错的钉扎效应强于外加拉应力的影响，两个因素的综合结果会导致当外加拉应力超过极限应力的后，随着外应力的增加，产生连续的塑性变形，使剩磁B r快速减小。
测量脉冲场作用后试样的表面场强度，判断脉冲场的磁化区域和渗透深度，试样正反两面被磁化区域表面场强度一致，说明此强度的脉冲场渗透深度达到了该试样的厚度。
利用脉冲场作为激励信号探测材料内部缺陷。材料内部缺陷不仅对磁导率和剩磁有影响，对矫顽力的影响也比较大，尤其是距离测量表面比较近的内部缺陷，其磁性参数变化十分明显，根据磁性参数中的矫顽力Hc变化辅助判断材料内部缺陷是否存在，分析内部缺陷距深度。
Non-destructive testing (NDT) technique is to evaluate the performance ofa component based on the changes of thermal, acoustic, optical, electric, andmagnetic signals. The changes are caused by the variation/degradation in amaterial. With modern analytical and computational techniques, NDT hasbecome an important testing means of quality control and quality assuranceinspection in modern industrial production.
Several NDT techniques such as X-ray diffraction, eddy current,Barkhausen emission, and metal magnetic memory can provide a detection ofnear surface and surface defection. But for the sub-surface defectioncharacterisation, especial for the early stages of cracking, these techniquesare limited. In this paper, the magnetomechanical effect is studied for NDT, adetect system based on LabView environment has been designed andfabricated. The main research are listed as follow.
The physical theoretical model of magnetomechanical effect isstudied. When the stress level was in elastic stage, plastic strain appeared atsome weak grain because the strength of the grains is different at the samestress direction. The yield grains formated the stress concentration. Themagnetization curve and magnetic hysteresis loop reflects magneticcharacteristics of a magnet material. The magnetic parameters such ascoercivity, hysteresis loses and permeability were derived from hysteresisloop. These magnetic hysteresis parameters are so sensitive to stress andmicrostructure changes, and the correlations between magnetic parameterswith stress, microstructure, chemical composition have been studied andmodeled.
The widely utilized magnetic sensor for NDT consists of a singleU-shaped yoke, a magnetizing coil, and an induction coil. The two coils aredirectly wound on the yoke. The magnetizing coil and induction coil are forsample magnetization and determination of the system flux, respectively. Thesensor is convenient to use and with simple structure. But the U-shaped probeis hard to ensure the measured precision and reproducibility in magnetic stressmeasurement. Many factors can influence magnetic measurement, such asthe contact quality between yoke and sample, stray field and temperature. Inorder to extend the applicability of active magnetic techniques to industries,many measures were taken. Daubing the magnetism cement between theprobe head can reduce the gap magnetic resistance greatly. Establishing anoffset magnetic field along compressed direction can counteract the stray field.Temperature compensation can improve the system measurement accuracy.The best frequency range of induction signal was chosen.
Most magnetic apparatuses for NDT employ a sinusoidal or a triangularwave as the excitation. Pulsed excitation has been introduced in hysteresismeasurement in recent work. The voltage of induction coil and the current ofmagnetizing coil are measured. Task of computer in the measurement iscontrolling data acquisition cards, saving the measured data andpost-processing of experimental data.
The pulsed field is generated by the discharge of a capacitor over themagnetizing coil. The duration of the generated pulse varies within the limits of10–2to10–3s. In order to obtain a whole hysteresis loop, two capacitors andfour insulated gate bipolar transistors (IGBTs) are used to generate two pulsesin opposite directions. The signals of the excitation current and inducedvoltage in the induction coil are directly fed to a data acquisition card (NationalInstruments, model NI PCI6251). LabView-based software has beendeveloped in order to process the signals and plot the hysteresis loops.
The relationship between magnetic parameters and stress wasestablished. The magnetic properties derived from the loops and curves are sensitive to applied stress. Remanence Br did not change with the externalmagnetic field, so it is more accurate and suitable to characterize the stress ina material.
The hysteresis loops of a test sample were measured when the samplewas under the tensile stress during the cold-working hardening. In elasticstage, the tensile stress facilitated domain walls movement and result in easymagnetization in a material. Remanence Br increased at the tensile stressdirection. In the plastic strain range, with the stress increasing, there are twofactors affecting the magnetic properties, the tensile stress to ease the domainwalls movements and the dislocations caused by the strain to impede them.Because the hindering effect of dislocation on the domain walls movements ismuch stronger than the effect of tensile stress, the combined influences ofthese two factors result in a rapid decrease of Remanence Br with the appliedtensile stress.
The surface magnetic field was measured by a Hall sensor after thepulsed field magnetized a sample. The measurements were performed on thetwo sides of the sample, the samples were made from different thickness. Ifthe surface field strength of the two sides was near consistent, it showed thatthe pulse field penetrating depth reached the sample thickness.
An experiment has been set up to investigate the capabilities of thesystem to detect sub-surface defects. The sub-surface defects had influencenot only on permeability and remanence but also on coercive force. The nearsurface defect had great influence on these magnetic parameters. Accordingto the change of coercive force, the existence of the sub-surface defects couldbe judged and the depth of the defect could been calculated.
研究基于磁力效应的无损检测方法及其理论模型，当构件应力水平处于弹性阶段，由于晶粒的强度在相同的受力方向上是不同的，个别薄弱晶粒进入塑性应变状态，屈服的晶粒形成应力集中区。铁磁体的磁化曲线和磁滞回线代表了磁性材料在外磁场作用下的基本磁特性，磁化曲线和磁滞回线上反映的磁特性参数磁导率μ、矫顽力H c、剩磁M R等，灵敏地依赖于磁性材料的微观结构，建立铁磁性材料的磁性参数和材料内应力之间的关系，利用应力引起材料磁特性的变化来确定材料内部的应力分布。
在U型铁芯上缠绕激励和感应线圈是磁力法最常用的探头结构，U型探头使U型铁芯和构件的被测部分构成了一个闭合磁路，测量方便且结构简单。但是U型探头很难保证测量的准确性和重复性，温度、杂散场以及探头和构件间的空气缝隙均对测量结果均有较大影响。为提高U型探头的实用性，使用导磁胶固定探头，减小缝隙磁阻；引入偏置场，使各样品处于相同的磁化状态，屏蔽掉样品表面散射场；对测量结果进行温度补偿，提高系统测量精度；对感应信号的频率进行筛选，找出最佳频率范围。
基于磁力效应的无损检测方法通常是应用单一频率的正弦信号波或低频的三角波信号作为激励信号。本文利用脉冲场作为激励信号，其磁化电流和检测探头感应出的感生电压直接输入由计算机控制的数据采集装置，通过数据处理得到整个磁化过程的磁化曲线和磁滞回线以及各种磁性参数。
利用大电容对低阻的激励线圈放电产生脉冲强磁场。大电流在短时间内通过电感线圈，电流强度大且持续的时间短，应用绝缘栅双极型功率管（IGBT）作为开关，与电容、电感线圈、大功率阻尼电阻构建脉冲强磁场发生装置。同时为了获得完整的磁滞回线，应用微控制器控制不同的IGBT按预定时序导通或截止，控制两个相同容量电容依次对激励线圈放电，产生正反两个方向的脉冲强磁场。利用高速数据采集卡（DAQ）提取激励电流信号i与感应电压信号u，利用LabView提供的各种与实际仪器仪表外观几乎一样的控件、指示器等组成用户需要的仪表界面，获取由脉冲强磁场诱发出的磁性参数。
建立各磁性参数（矫顽力、磁导率、剩磁等）与拉、压应力的关系，各磁性参数中，剩磁对应力反应比较灵敏，并且剩磁不随外磁场幅度的变化而变化，因此更适合来反应材料内部应力分布情况。
测量低碳钢Q235弹性范围内拉应力状态下以及冷作硬化过程中的磁化曲线和磁滞回线，在试样的弹性阶段，外加拉应力使畴壁位移变得容易，材料更易于磁化，拉应力方向剩磁B r增大。外加拉应力超过屈服极限后，随着拉应力的增加剩磁B r快速减小，此时，有两个因素影响磁特性参数，外加拉应力使畴壁位移变得容易，塑性变形产生的大量位错却要阻碍畴壁位移，由于位错的钉扎效应强于外加拉应力的影响，两个因素的综合结果会导致当外加拉应力超过极限应力的后，随着外应力的增加，产生连续的塑性变形，使剩磁B r快速减小。
测量脉冲场作用后试样的表面场强度，判断脉冲场的磁化区域和渗透深度，试样正反两面被磁化区域表面场强度一致，说明此强度的脉冲场渗透深度达到了该试样的厚度。
利用脉冲场作为激励信号探测材料内部缺陷。材料内部缺陷不仅对磁导率和剩磁有影响，对矫顽力的影响也比较大，尤其是距离测量表面比较近的内部缺陷，其磁性参数变化十分明显，根据磁性参数中的矫顽力Hc变化辅助判断材料内部缺陷是否存在，分析内部缺陷距深度。
Non-destructive testing (NDT) technique is to evaluate the performance ofa component based on the changes of thermal, acoustic, optical, electric, andmagnetic signals. The changes are caused by the variation/degradation in amaterial. With modern analytical and computational techniques, NDT hasbecome an important testing means of quality control and quality assuranceinspection in modern industrial production.
Several NDT techniques such as X-ray diffraction, eddy current,Barkhausen emission, and metal magnetic memory can provide a detection ofnear surface and surface defection. But for the sub-surface defectioncharacterisation, especial for the early stages of cracking, these techniquesare limited. In this paper, the magnetomechanical effect is studied for NDT, adetect system based on LabView environment has been designed andfabricated. The main research are listed as follow.
The physical theoretical model of magnetomechanical effect isstudied. When the stress level was in elastic stage, plastic strain appeared atsome weak grain because the strength of the grains is different at the samestress direction. The yield grains formated the stress concentration. Themagnetization curve and magnetic hysteresis loop reflects magneticcharacteristics of a magnet material. The magnetic parameters such ascoercivity, hysteresis loses and permeability were derived from hysteresisloop. These magnetic hysteresis parameters are so sensitive to stress andmicrostructure changes, and the correlations between magnetic parameterswith stress, microstructure, chemical composition have been studied andmodeled.
The widely utilized magnetic sensor for NDT consists of a singleU-shaped yoke, a magnetizing coil, and an induction coil. The two coils aredirectly wound on the yoke. The magnetizing coil and induction coil are forsample magnetization and determination of the system flux, respectively. Thesensor is convenient to use and with simple structure. But the U-shaped probeis hard to ensure the measured precision and reproducibility in magnetic stressmeasurement. Many factors can influence magnetic measurement, such asthe contact quality between yoke and sample, stray field and temperature. Inorder to extend the applicability of active magnetic techniques to industries,many measures were taken. Daubing the magnetism cement between theprobe head can reduce the gap magnetic resistance greatly. Establishing anoffset magnetic field along compressed direction can counteract the stray field.Temperature compensation can improve the system measurement accuracy.The best frequency range of induction signal was chosen.
Most magnetic apparatuses for NDT employ a sinusoidal or a triangularwave as the excitation. Pulsed excitation has been introduced in hysteresismeasurement in recent work. The voltage of induction coil and the current ofmagnetizing coil are measured. Task of computer in the measurement iscontrolling data acquisition cards, saving the measured data andpost-processing of experimental data.
The pulsed field is generated by the discharge of a capacitor over themagnetizing coil. The duration of the generated pulse varies within the limits of10–2to10–3s. In order to obtain a whole hysteresis loop, two capacitors andfour insulated gate bipolar transistors (IGBTs) are used to generate two pulsesin opposite directions. The signals of the excitation current and inducedvoltage in the induction coil are directly fed to a data acquisition card (NationalInstruments, model NI PCI6251). LabView-based software has beendeveloped in order to process the signals and plot the hysteresis loops.
The relationship between magnetic parameters and stress wasestablished. The magnetic properties derived from the loops and curves are sensitive to applied stress. Remanence Br did not change with the externalmagnetic field, so it is more accurate and suitable to characterize the stress ina material.
The hysteresis loops of a test sample were measured when the samplewas under the tensile stress during the cold-working hardening. In elasticstage, the tensile stress facilitated domain walls movement and result in easymagnetization in a material. Remanence Br increased at the tensile stressdirection. In the plastic strain range, with the stress increasing, there are twofactors affecting the magnetic properties, the tensile stress to ease the domainwalls movements and the dislocations caused by the strain to impede them.Because the hindering effect of dislocation on the domain walls movements ismuch stronger than the effect of tensile stress, the combined influences ofthese two factors result in a rapid decrease of Remanence Br with the appliedtensile stress.
The surface magnetic field was measured by a Hall sensor after thepulsed field magnetized a sample. The measurements were performed on thetwo sides of the sample, the samples were made from different thickness. Ifthe surface field strength of the two sides was near consistent, it showed thatthe pulse field penetrating depth reached the sample thickness.
An experiment has been set up to investigate the capabilities of thesystem to detect sub-surface defects. The sub-surface defects had influencenot only on permeability and remanence but also on coercive force. The nearsurface defect had great influence on these magnetic parameters. Accordingto the change of coercive force, the existence of the sub-surface defects couldbe judged and the depth of the defect could been calculated.
引文
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