基于金属磁记忆法的铁磁材料早期损伤检测与评价的实验研究
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摘要
弹性应力集中、微观塑性变形等引起的早期物理性损伤会降低工程材料和结构的承载能力,甚至最终导致灾难性突发事故的发生,因此对其实现有效监测是确保工业运行安全的关键。传统漏磁检测虽然在工程中已得到广泛应用,但这类强磁检测技术不适用于对材料早期损伤的检测。近十几年来发展起来的金属磁记忆检测法是一种被动式弱磁检测技术,通过检测被测对象由于局部应力集中或损伤形成的表面自发漏磁场确定损伤位置及损伤程度。理论上说该方法可能是目前最有希望可以实现对铁磁材料及结构进行早期诊断的无损检测方法。但是由于该方法发展时间较短,影响因素众多,目前在工程应用中只作为确定缺陷可能存在位置的一种初步检测手段,无法提供定量化结果。本文利用金属磁记忆检测技术测试了含孔铁磁材料试样单向拉伸、非铁磁—铁磁和铁磁—铁磁接触下漏磁信号的变化特征,并在分析漏磁信号变化力磁机制的基础上,提出了相应的损伤判据,根据漏磁信号的梯度曲线获得了损伤评价参数；最后进行了数值模拟,并利用实验提出的损伤判据和评价参数,对损伤区的反演进行了初探。主要内容和结论包括：
(1)针对含孔45号钢试样进行了单向拉伸实验,提出了塑性损伤判据：在应力集中部位,法向漏磁信号发生较明显的波动变化,漏磁梯度出现极值,切向漏磁信号出现一个较为明显的极值,漏磁梯度出现峰—峰值变化并在应力集中的中心位置过零点。
(2)开展非铁磁(铜质)圆压头与45号钢试样间的接触实验,提出了接触应力集中的损伤判据：沿垂直于加载方向,法向漏磁信号的梯度值出现极值,同时切向漏磁信号的梯度值出现峰—峰值变化并在应力集中的中心位置过零点。同时开展了铁磁圆压头与45号钢试样间的接触实验,发现其漏磁信号变化特征与铜质圆压头实验完全不同,相应的损伤判据为：法向漏磁信号出现一个极值,漏磁梯度出现峰—峰值变化并在接触区中心位置过零点；切向漏磁信号出现峰—峰值变化并且过零点,漏磁梯度出现极值。
(3)开展了非铁磁(铜质)和铁磁平压头与45号钢试样的接触实验。其中铜质和退磁处理的铁磁平压头接触实验中漏磁信号的变化曲线均可看作由相同工况下圆压头的结果叠加而成,因此可参照圆压头的情况建立损伤判据。未退磁处理的铁磁平压头接触的漏磁信号特征则有很大的不同,相应的损伤判据为：法向漏磁信号的曲线斜率出现明显的变化,漏磁的梯度出现两个反向的峰—峰值变化并出现两个过零点；切向漏磁信号出现两个明显的峰值,漏磁的梯度出现一个波峰和一个波谷。
(4)由漏磁信号及其梯度曲线均可获得一些特征参量用以评价损伤的情况(包括损伤程度和范围等)。但梯度曲线能够清除外部磁场的影响,且能突出反映损伤局部化的程度。可利用漏磁信号梯度曲线上的峰—峰值、峰—谷值和峰值等参量来评价损伤的局部化程度；相应的峰—峰值宽、峰—谷值宽和峰值过零点的水平间距等参量来评价损伤范围。
(5)利用有限元法对含损伤试样的漏磁信号进行了数值分析研究,结果表明：磁记忆检测对发生在试件表面的损伤更敏感；测量中要尽量保证传感器贴合在试件表面；试件方向对漏磁梯度曲线的变化没有影响；实验结果提出的表征损伤范围的评价参数可用来反演损伤区的大小和形状。
Early physical damage caused by elastic stress concentration, mirco plastic deformation, etc. will certainly lead to lower loading capacity of engineering materials and structures, and sometimes even to catastrophic accidents. Therefore, effective monitoring is the key to ensure the industrial safety. Although the traditional magnetic flux leakage detection has already been widely used in practical engineering, such strong magnetic detection technology is not suitable for the detection of early damages. In the most recent decade, the metal magnetic memory (MMM) method is developed as a passive weak magnetic detection technology, which identifies the damage locations and conditions by detecting the surface spontaneous magnetic leakage field due to the localized stress concentration of damage in the measured object. Theoretically, the MMM method is a prospective method that can realized early nondestructive detection for ferromagnetic materials and structures. However, due to short developing period and various influencing factors, this method, in practical engineering, is only applied as a preliminary testing technique for determining the possible location of defects. This thesis uses the MMM method to detect the magnetic flux leakage signals in uni-axial tensile of a ferromagnetic metal specimen with a hole and contact of nonferromagnetic-ferromagnetic materials and ferromagnetic-ferromagnetic materials, respectively. Furthermore, on the basis of magneto-mechanical analysis of magnetic flux leakage signals, we propose the corresponding damage criteria and get the evaluation parameters based on the gradient of the magnetic flux leakage signals. Finally, we present numerical simulation and discuss the image of the damage shapes by using the damage criteria and evaluation parameters. Detailed contents and main conclusions are as follows:
(1) Magnetic flux leakage experiments for a45#steel specimen with a small hole under the uni-axial tensile are performed. A criterion of plastic damage is developed which states:at the stress-concentration zone, the normal magnetic flux leakage signal has obvious fluctuation, with its gradient exhibiting a peak. Meanwhile, a clear peak appears in the tangential magnetic flux leakage signal; and its gradient follows a peak-peak change with a value of zero at the center of the stress-concentration zone.
(2) Contact test between a cylindrical nonferromagnetic (copper) indenter and a45#steel specimen are performed. The criterion of damage states:along the direction perpendicular to the loading, the normal magnetic flux leakage gradient exhibits a peak, and the tangential magnetic flux leakage gradient follows a peak-peak change with a value of zero at the center of the stress-concentration zone. Meanwhile the contact tests between a cylindrical ferromagnetic indenter and a45#steel specimen are performed. It is found that the features of the magnetic flux leakage signals are totally different from those of a cooper cylindrical indenter. The criterion of damage in this case becomes:the normal magnetic flux leakage signal exhibits a peak, which its gradient following a peak-peak change with a value of zero at the center of the stress-concentration zone. Moreover, tangential magnetic flux leakage signal follows a peak-peak change with a value of zero, and its gradient exhibits a peak.
(3) Contact test between a flat nonferromagnetic (cooper) or ferromagnetic indenter and45#steel specimen are performed. For the contact tests of a flat cooper indenter or demagnetized ferromagnetic indenter, the magnetic flux leakage signal curves can be created as superpositions of the results of cylindrical indenter under the same condition. The criterion of damage may be developed based on those for a cylindrical indenter. The magnetic flux leakage signals in the contact test of a non-demagnetized ferromagnetic indenter are quite different. The criterion of damage is: the normal magnetic flux leakage gradient follows two reverse peak-peak changes with two values of zero. Also, the tangential magnetic flux leakage signal exhibits two peaks, and its gradient shows a peak and a valley.
(4) From the curves of the magnetic flux leakage signals and their gradient, some characteristic parameters can be obtained to evaluate damage degree and region. However, the gradient curves can avoid influence of external magnetic fields, and can highlight the localization of damage. The inhomogeneity of damage can be evaluated through the magnetic flux leakage gradient curves by the peak-peak values, peak-valley values and peaks; and the damage area can be evaluated by the peak-peak widths, peak-valley widths and horizontal distances of zero crossings.
(5) Numerical results of the magnetic flux leakage signals of a specimen which damage are presented. The results show that the MMM method is more sensitive to the damage at the surface of a specimen. In the test, the sensor should approach the specimen surface as closely as possible. The testing direction is of no influence on the magnetic flux leakage gradient curves. The size and shape of the damage area can be imaged by the evaluation parameters.
(1)针对含孔45号钢试样进行了单向拉伸实验,提出了塑性损伤判据：在应力集中部位,法向漏磁信号发生较明显的波动变化,漏磁梯度出现极值,切向漏磁信号出现一个较为明显的极值,漏磁梯度出现峰—峰值变化并在应力集中的中心位置过零点。
(2)开展非铁磁(铜质)圆压头与45号钢试样间的接触实验,提出了接触应力集中的损伤判据：沿垂直于加载方向,法向漏磁信号的梯度值出现极值,同时切向漏磁信号的梯度值出现峰—峰值变化并在应力集中的中心位置过零点。同时开展了铁磁圆压头与45号钢试样间的接触实验,发现其漏磁信号变化特征与铜质圆压头实验完全不同,相应的损伤判据为：法向漏磁信号出现一个极值,漏磁梯度出现峰—峰值变化并在接触区中心位置过零点；切向漏磁信号出现峰—峰值变化并且过零点,漏磁梯度出现极值。
(3)开展了非铁磁(铜质)和铁磁平压头与45号钢试样的接触实验。其中铜质和退磁处理的铁磁平压头接触实验中漏磁信号的变化曲线均可看作由相同工况下圆压头的结果叠加而成,因此可参照圆压头的情况建立损伤判据。未退磁处理的铁磁平压头接触的漏磁信号特征则有很大的不同,相应的损伤判据为：法向漏磁信号的曲线斜率出现明显的变化,漏磁的梯度出现两个反向的峰—峰值变化并出现两个过零点；切向漏磁信号出现两个明显的峰值,漏磁的梯度出现一个波峰和一个波谷。
(4)由漏磁信号及其梯度曲线均可获得一些特征参量用以评价损伤的情况(包括损伤程度和范围等)。但梯度曲线能够清除外部磁场的影响,且能突出反映损伤局部化的程度。可利用漏磁信号梯度曲线上的峰—峰值、峰—谷值和峰值等参量来评价损伤的局部化程度；相应的峰—峰值宽、峰—谷值宽和峰值过零点的水平间距等参量来评价损伤范围。
(5)利用有限元法对含损伤试样的漏磁信号进行了数值分析研究,结果表明：磁记忆检测对发生在试件表面的损伤更敏感；测量中要尽量保证传感器贴合在试件表面；试件方向对漏磁梯度曲线的变化没有影响；实验结果提出的表征损伤范围的评价参数可用来反演损伤区的大小和形状。
Early physical damage caused by elastic stress concentration, mirco plastic deformation, etc. will certainly lead to lower loading capacity of engineering materials and structures, and sometimes even to catastrophic accidents. Therefore, effective monitoring is the key to ensure the industrial safety. Although the traditional magnetic flux leakage detection has already been widely used in practical engineering, such strong magnetic detection technology is not suitable for the detection of early damages. In the most recent decade, the metal magnetic memory (MMM) method is developed as a passive weak magnetic detection technology, which identifies the damage locations and conditions by detecting the surface spontaneous magnetic leakage field due to the localized stress concentration of damage in the measured object. Theoretically, the MMM method is a prospective method that can realized early nondestructive detection for ferromagnetic materials and structures. However, due to short developing period and various influencing factors, this method, in practical engineering, is only applied as a preliminary testing technique for determining the possible location of defects. This thesis uses the MMM method to detect the magnetic flux leakage signals in uni-axial tensile of a ferromagnetic metal specimen with a hole and contact of nonferromagnetic-ferromagnetic materials and ferromagnetic-ferromagnetic materials, respectively. Furthermore, on the basis of magneto-mechanical analysis of magnetic flux leakage signals, we propose the corresponding damage criteria and get the evaluation parameters based on the gradient of the magnetic flux leakage signals. Finally, we present numerical simulation and discuss the image of the damage shapes by using the damage criteria and evaluation parameters. Detailed contents and main conclusions are as follows:
(1) Magnetic flux leakage experiments for a45#steel specimen with a small hole under the uni-axial tensile are performed. A criterion of plastic damage is developed which states:at the stress-concentration zone, the normal magnetic flux leakage signal has obvious fluctuation, with its gradient exhibiting a peak. Meanwhile, a clear peak appears in the tangential magnetic flux leakage signal; and its gradient follows a peak-peak change with a value of zero at the center of the stress-concentration zone.
(2) Contact test between a cylindrical nonferromagnetic (copper) indenter and a45#steel specimen are performed. The criterion of damage states:along the direction perpendicular to the loading, the normal magnetic flux leakage gradient exhibits a peak, and the tangential magnetic flux leakage gradient follows a peak-peak change with a value of zero at the center of the stress-concentration zone. Meanwhile the contact tests between a cylindrical ferromagnetic indenter and a45#steel specimen are performed. It is found that the features of the magnetic flux leakage signals are totally different from those of a cooper cylindrical indenter. The criterion of damage in this case becomes:the normal magnetic flux leakage signal exhibits a peak, which its gradient following a peak-peak change with a value of zero at the center of the stress-concentration zone. Moreover, tangential magnetic flux leakage signal follows a peak-peak change with a value of zero, and its gradient exhibits a peak.
(3) Contact test between a flat nonferromagnetic (cooper) or ferromagnetic indenter and45#steel specimen are performed. For the contact tests of a flat cooper indenter or demagnetized ferromagnetic indenter, the magnetic flux leakage signal curves can be created as superpositions of the results of cylindrical indenter under the same condition. The criterion of damage may be developed based on those for a cylindrical indenter. The magnetic flux leakage signals in the contact test of a non-demagnetized ferromagnetic indenter are quite different. The criterion of damage is: the normal magnetic flux leakage gradient follows two reverse peak-peak changes with two values of zero. Also, the tangential magnetic flux leakage signal exhibits two peaks, and its gradient shows a peak and a valley.
(4) From the curves of the magnetic flux leakage signals and their gradient, some characteristic parameters can be obtained to evaluate damage degree and region. However, the gradient curves can avoid influence of external magnetic fields, and can highlight the localization of damage. The inhomogeneity of damage can be evaluated through the magnetic flux leakage gradient curves by the peak-peak values, peak-valley values and peaks; and the damage area can be evaluated by the peak-peak widths, peak-valley widths and horizontal distances of zero crossings.
(5) Numerical results of the magnetic flux leakage signals of a specimen which damage are presented. The results show that the MMM method is more sensitive to the damage at the surface of a specimen. In the test, the sensor should approach the specimen surface as closely as possible. The testing direction is of no influence on the magnetic flux leakage gradient curves. The size and shape of the damage area can be imaged by the evaluation parameters.
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