多层导电结构的涡流无损检测评价解析法研究
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摘要
涡流检测技术是五大无损检测技术之一,由于具有实时检测速度快,非接触测量和制造成本低等优势,所以在航天制造、核工业和高速列车等精密制造方面应用十分广泛。本毕业论文结合多层金属内部腐蚀无损检测评价研究子课题下,主要对多层导电结构的涡流检测和脉冲涡流检测模型进行了理论和实验研究,并对差分式拾取传感器检测多层导电结构的涡流模型进行了深入的理论研究。主要研究和创新如下：
1、研究了多层导电结构厚度变化的涡流无损检测模型,对Cheng-Dodd-Deeds的无限积分模型和截断域特征模型进行了仿真对比。并对浙江大学范孟豹博士提出的基于电磁波折射反射理论的多层导电模型进行了对比研究,通过实验对比,验证了理论模型的准确性。
2、基于正弦激励的多层导体结构涡流检测模型,建立了脉冲涡流检测的解析法模型。并搭建了脉冲涡流检测实验平台,通过仿真与实验对比,结果十分吻合。
3、基于电磁波的折射反射理论,推导了差分式拾取传感器的多层导电结构检测模型,通过仿真优化,研制了几种新型的检测多层导电结构涡流磁场变化的传感器,能够消除激励线圈产生的激励磁场。该传感器仅仅检测导电结构的涡流磁场信号,避免了激励磁场信号过大掩盖了涡流磁场信号。
4、利用脉冲涡流实验设备对低碳钢的厚度变化进行了实验研究。通过实验结果,可以得出低碳钢对脉冲涡流检测的信号响应特性。
Eddy current nondestructive testing, as one kind of the five main nondestructive testing methods, has the properties of fast detection, non-contact and low cost, which has been widely used in aerospace, nuclear industries and high speed train vehicles manufacture. Supported by the sub-project---pulsed eddy current nondestructive evaluation for inter-erosion of stratified conductive structures, this paper mainly studied on analytical modeling and experiments for harmonic eddy current and pulsed eddy current, and developed analytical model of differential eddy current pick-up sensors for stratified conductive structures. The main researches included:
1. Analytical solutions for coils above stratified conductors were provided. The Extended Truncated Region Eigenfunction Expansion method (ETREE) is applied to stimulate the eddy current response to stratified conductive structures and compared with Cheng-Dodd-Deeds'integral form solutions. Fan followed an original method to study the eddy current field for multilayered conductive structures and developed the model based on the reflection and transmission theory of the electromagnetic waves. We did the experiment and compared the experimental result with the Fan's model, which agreed well.
2. Analytical modeling of pulsed eddy current was developed based on analytical modeling of harmonic eddy current for stratified conductive structures. And the experimental setup was developed to confirm the simulating result of analytical model.
3. In this paper, analytical modeling for differential pick-up sensors was established based on the reflection and transmission theory of electromagnetic wave for stratified conductive structures. New kind of eddy current sensors for detecting multilayered conductive structures were found through the simulation optimization, which can eliminate the magnetic field produced by the isolated coil. This kind sensors only detect the magnetic field change caused by the layered conductive structures, so the signal of the magnetic field change caused by the layered conductive structure avoid being concealed by the signal of the magnetic field produced by the isolated coil.
4. Low carbon steel thickness changes were detected by using pulsed eddy current experimental equipment. And through experimental results, we can get the response characteristics of pulsed eddy current signal for low carbon steel.
1、研究了多层导电结构厚度变化的涡流无损检测模型,对Cheng-Dodd-Deeds的无限积分模型和截断域特征模型进行了仿真对比。并对浙江大学范孟豹博士提出的基于电磁波折射反射理论的多层导电模型进行了对比研究,通过实验对比,验证了理论模型的准确性。
2、基于正弦激励的多层导体结构涡流检测模型,建立了脉冲涡流检测的解析法模型。并搭建了脉冲涡流检测实验平台,通过仿真与实验对比,结果十分吻合。
3、基于电磁波的折射反射理论,推导了差分式拾取传感器的多层导电结构检测模型,通过仿真优化,研制了几种新型的检测多层导电结构涡流磁场变化的传感器,能够消除激励线圈产生的激励磁场。该传感器仅仅检测导电结构的涡流磁场信号,避免了激励磁场信号过大掩盖了涡流磁场信号。
4、利用脉冲涡流实验设备对低碳钢的厚度变化进行了实验研究。通过实验结果,可以得出低碳钢对脉冲涡流检测的信号响应特性。
Eddy current nondestructive testing, as one kind of the five main nondestructive testing methods, has the properties of fast detection, non-contact and low cost, which has been widely used in aerospace, nuclear industries and high speed train vehicles manufacture. Supported by the sub-project---pulsed eddy current nondestructive evaluation for inter-erosion of stratified conductive structures, this paper mainly studied on analytical modeling and experiments for harmonic eddy current and pulsed eddy current, and developed analytical model of differential eddy current pick-up sensors for stratified conductive structures. The main researches included:
1. Analytical solutions for coils above stratified conductors were provided. The Extended Truncated Region Eigenfunction Expansion method (ETREE) is applied to stimulate the eddy current response to stratified conductive structures and compared with Cheng-Dodd-Deeds'integral form solutions. Fan followed an original method to study the eddy current field for multilayered conductive structures and developed the model based on the reflection and transmission theory of the electromagnetic waves. We did the experiment and compared the experimental result with the Fan's model, which agreed well.
2. Analytical modeling of pulsed eddy current was developed based on analytical modeling of harmonic eddy current for stratified conductive structures. And the experimental setup was developed to confirm the simulating result of analytical model.
3. In this paper, analytical modeling for differential pick-up sensors was established based on the reflection and transmission theory of electromagnetic wave for stratified conductive structures. New kind of eddy current sensors for detecting multilayered conductive structures were found through the simulation optimization, which can eliminate the magnetic field produced by the isolated coil. This kind sensors only detect the magnetic field change caused by the layered conductive structures, so the signal of the magnetic field change caused by the layered conductive structure avoid being concealed by the signal of the magnetic field produced by the isolated coil.
4. Low carbon steel thickness changes were detected by using pulsed eddy current experimental equipment. And through experimental results, we can get the response characteristics of pulsed eddy current signal for low carbon steel.
引文
[1]Smith RA, Hugo GR. Transient eddy current NDE for ageing aircraft—capabilities and limitation[J]. Non-Destructive Testing and Condition Monitoring,2001,43(1):14-25.
[2]Hugo L.Libby. Introduction to Electromagnetic Nondestructive Test Methods[M]. USA:Krieger Pub Co,1979.
[3]Jack Blitz. Electrical and Magnetic Methods of Nondestructive Testing[M]. USA: Adam Hilger,1991.
[4]范孟豹.多层导电结构电涡流检测的解析建模研究[博士论文].浙江大学,2009.
[5]Adriana Savin, Rozina Steigmann, et. Eddy current sensor array. application to nondestructive evaluation of carbon-epoxy composites[J].NDT for Safety,2007,12:7-9.
[6]任吉林,林俊明.电磁无损检测[M].北京：科学出版社,200864-120.
[7]R.A. Smith, G.R. Hugo. Transient eddy current NDE for aging aircraft-capabilities and limitations[J]. Insight,2001,43:14-25.
[8]B. Lebrun, Y. Jayet, J.C. Baboux. Pulsed eddy current signal analysis:application to the experimental detection and characterization of deep flaws in highly conductive materials[J].NDT&E Int.,1997,30(3):163-170.
[9]Dodd CV, Deeds WE. Analytical solutions to eddy current probe-coil problems[J]. Appl Phys,1968,39:28-29.
[10]Cheng CC, Dodd CV, Deeds WE. General analysis of probe soils near stratified conductors[J]. Int J Nondestr Test,1971,109.
[11]Li Y, Theodoulidis TP, Tian GY. Magnetic field-based eddy current modeling for multilayered specimens[J]. IEEE Trans Magn,2007,43(11):4010-4015.
[12]Mengbao Fan, Pingjie Huang, et. Analytical modeling for transient probe response in pulsed eddy current testing[J]. NDT&E International,2009,42:(5):376-383.
[13]Young-Kil Shin, Dong-Myung Choi, et. Signal characteristics of differential-pulsed eddy current sensors in the evaluation of plate thickness[J]. NDT&E International,2009,42:215-221.
[14]S. Li, S.L. Huang, W. Zhao. Development of differential probes in pulsed eddy current testing for noise suppression[J]. Sens. Actuators A,2007,135:675-679.
[15]G. Yang, A. Tamburrino, et. Pulsed eddy-current based giant magnetoresistive system for the inspection of aircraft structures[J]. IEEE Trans. Magn,2010,46(3):910-917.
[16]C.C Tai. Characterization of coatings on magnetic metal using the swept-frequency eddy current method[J]. Rev. Sci. Instrum,2000,71:3161-3167.
[17]Rose J.H., Uzal E., Moulder J.C. Pulsed eddy current characterization of corrosion in aircraft lap splices:quantitative modeling[J]. SPIE 2160,1994,164-176.
[18]N. Harfield, J.R. Bowler. Theory of thin-skin eddy current interaction with subsurface cracks[J]. Appl. Phys,1997,82(9):4590-4603.
[19]J.C. Moulder, J.A. Bieber, et. Scanned pulsed eddy current instrument for non-destructive inspection of aging aircraft[J]. SPIE,1996,2945:2-13.
[20]Tai CC, Rose JH, Moulder JC. Thickness and conductivity of metallic layers from pulsed eddy current measurements [J]. Review of Science Instrument,1996,67:3965-3972.
[21]Giguere S, Lepine BA, Dubois JMS. Pulsed eddy current technology: characterizing material loss with gap and lift off variations[J]. Research in Nondestructive Evaluation,2001,13:119-129.
[22]Yang HC, Tai CC. Pulsed eddy-current measurement of a conducting coating on a magnetic metal plate[J]. Measurement and Science Technology,2002,13:1259-1265.
[23]Hung-Chi Yang. The design and application of eddy current nondestructive inspection system[D]. Taiwan, China:National Cheng Kung University,2003.
[24]Sophian A, Tian GY, Taylor D, et. A feature extraction technique based on principal component analysis for pulsed Eddy current ND[J]. NDT&E International,2003, 36:37-41.
[25]Tian GY, Sophian A, Taylor D, et. Wavelet-based PCA defect classification and quantification for pulsed eddy current NDT[J]. IEE Proceeding-Science, Measurement and Technology,2005,152(4):141-148.
[26]Tian GY, Sophian A, Taylor D, et. Pulsed eddy current system for dynamic inspection of defects[J]. Insight,2004,46:256-259.
[27]Tian GY, Sopian A. Defect classification using a new feature for pulsed eddy current sensors[J]. NDT&E Internationa,2005,38:77-82.
[28]Y. Li, G. Y. Tian, A. Simm. Fast analytical modelling for pulsed eddy current evaluation[J]. NDT & E Int.,2008,41 (6):477-483.
[29]Chen TL, Tian GY, Sophian A, et. Feature extraction and selection for defect classification of pulse eddy current NDT[J]. NDT&E International,2008,41:467-476.
[30]R.A. Smith, G.R. Hugo. Deep corrosion and crack detection in aging aircraft using transient eddy current NDE[J]. Rev. Prog. Quant. Nondestruct. Eval,1999,6:1401-1408.
[31]S. Li, S.L.Huang, W.Zhao, P. Yu. Study of pulse eddy current probes detecting cracks extending in all directions[J]. Sens. Actuators A,2008,141:13-19.
[32]Y.Z. He, F.L. Luo, M.C. Pan, et. Pulsed eddy current technique for defect detection in aircraft riveted structures [J]. NDT&E Int,2009,43:176-181.
[33]B. Lebrun, Jayet, J.C. Baboux. Pulsed eddy current application to the detection of deep cracks[J]. Mater. Eval,1995,53(11):1296-1300.
[34]S.N. Rajesh, L. Udpa, S. Udpa. Numerical model based approach for estimating Probability of detection in NDE applications[J]. IEEE Trans. Magn,1993,29(2): 1857-1861.
[35]Dai XW, Ludwig R, Palanisamy R. Numerical simulation of pulsed eddy current nondestructive testing phenomena[J]. IEEE Trans Magn,1990,26(6):3089-3096.
[36]Tsuboi H, Seshima N, et. Transient eddy current analysis of pulsed eddy current testing by finite element method[J]. IEEE Trans Magn,2004,40(2):1330-1333.
[37]J.R. Bowler, F. Fu. Transient eddy current interaction with an open crack[J]. Review of Progress in QNDE,2004,24:329-335.
[38]F. Fu, J.R. Bowler. Transient eddy current response due to an open subsurface crack in a conductive plate[J]. Review of Progress in QNDE,2006,25:337-344.
[39]Theodoulidis TP, Kriezis EE. Eddy current canonical problems (with applications to nondestructive evaluation)[M]. Tech Science Press,2006.
[40]J. Kim, G Yang, L. Udpa, S. Udpa. Classification of pulsed eddy current GMR data on aircraft structures [J]. NDT&E Int.,2010,43:141-144.
[41]G. Panaitov, H. J. Krause, Y Zhang. Pulsed eddy current transient technique with HTS SQUID magnetometer for non-destructive evaluation[J]. Physica C,2002,372-376: 278-281.
[42]Abramowitz M, Stegun I. Handbook of mathematical functions with formulas graphs and mathematical tables[M]. Washington, DC:National Bureau of Standards Applied Mathematics Series 5.5, GPO,1970.
[43]GuiYun Tian, Yong Li, and Catalin Mandache, "Study of Lift-Off Invariance for Pulsed Eddy-Current Signals". IEEE TRANSACTIONS ON MAGNETICS.45, p184,2009
[44]Y Danon, C.Q. Lee, C. Mulligan, et. Characterizing tantalums sputtered coatings on steel by using eddy currents[J]. IEEE Trans.Magn,2004,40(4):1826-1832.
[45]Libii JN. Gibbs phenomenon and its applications in science and engineering[J]. In: Proceedings of the 2005 American Society for engineering education annual conference and exposition, Portland, Oregon, June,2005
[46]C. V. Dodd, W. E. Deeds, et. Some eddy-current problems and their integral solutions," Oak Ridge Nat. Lab., Rep. ORNL-4384, Apr.1969
[47]T. P. Theodoulidis E. E. Kriezis. Series expansions in eddy current nondestructive evaluation[J]. Mater. Process. Technol.,2005,161:343-347.
[48]Adriana Savin, Rozina Steigmann, et. Eddy current sensor array. application to nondestructive evaluation of carbon-epoxy composites[J]. NDT for Safety,2007,12: 07-09.
[49]Chen Huang, Xinjun Wu, Zhiyuan Xu, Yihua Kang. Pulsed eddy current signal processing method for signal denoising in ferromagnetic plate testing[J]. NDT&E International,2010,43:648-653.
[50]Chen Huang, Xinjun Wu, Zhiyuan Xu, Yihua Kang. Ferromagnetic material pulsed eddy current testing signal modeling by equivalent multiple-coil-coupling approach[J]. NDT&E International,2011,44:163-168.
[2]Hugo L.Libby. Introduction to Electromagnetic Nondestructive Test Methods[M]. USA:Krieger Pub Co,1979.
[3]Jack Blitz. Electrical and Magnetic Methods of Nondestructive Testing[M]. USA: Adam Hilger,1991.
[4]范孟豹.多层导电结构电涡流检测的解析建模研究[博士论文].浙江大学,2009.
[5]Adriana Savin, Rozina Steigmann, et. Eddy current sensor array. application to nondestructive evaluation of carbon-epoxy composites[J].NDT for Safety,2007,12:7-9.
[6]任吉林,林俊明.电磁无损检测[M].北京：科学出版社,200864-120.
[7]R.A. Smith, G.R. Hugo. Transient eddy current NDE for aging aircraft-capabilities and limitations[J]. Insight,2001,43:14-25.
[8]B. Lebrun, Y. Jayet, J.C. Baboux. Pulsed eddy current signal analysis:application to the experimental detection and characterization of deep flaws in highly conductive materials[J].NDT&E Int.,1997,30(3):163-170.
[9]Dodd CV, Deeds WE. Analytical solutions to eddy current probe-coil problems[J]. Appl Phys,1968,39:28-29.
[10]Cheng CC, Dodd CV, Deeds WE. General analysis of probe soils near stratified conductors[J]. Int J Nondestr Test,1971,109.
[11]Li Y, Theodoulidis TP, Tian GY. Magnetic field-based eddy current modeling for multilayered specimens[J]. IEEE Trans Magn,2007,43(11):4010-4015.
[12]Mengbao Fan, Pingjie Huang, et. Analytical modeling for transient probe response in pulsed eddy current testing[J]. NDT&E International,2009,42:(5):376-383.
[13]Young-Kil Shin, Dong-Myung Choi, et. Signal characteristics of differential-pulsed eddy current sensors in the evaluation of plate thickness[J]. NDT&E International,2009,42:215-221.
[14]S. Li, S.L. Huang, W. Zhao. Development of differential probes in pulsed eddy current testing for noise suppression[J]. Sens. Actuators A,2007,135:675-679.
[15]G. Yang, A. Tamburrino, et. Pulsed eddy-current based giant magnetoresistive system for the inspection of aircraft structures[J]. IEEE Trans. Magn,2010,46(3):910-917.
[16]C.C Tai. Characterization of coatings on magnetic metal using the swept-frequency eddy current method[J]. Rev. Sci. Instrum,2000,71:3161-3167.
[17]Rose J.H., Uzal E., Moulder J.C. Pulsed eddy current characterization of corrosion in aircraft lap splices:quantitative modeling[J]. SPIE 2160,1994,164-176.
[18]N. Harfield, J.R. Bowler. Theory of thin-skin eddy current interaction with subsurface cracks[J]. Appl. Phys,1997,82(9):4590-4603.
[19]J.C. Moulder, J.A. Bieber, et. Scanned pulsed eddy current instrument for non-destructive inspection of aging aircraft[J]. SPIE,1996,2945:2-13.
[20]Tai CC, Rose JH, Moulder JC. Thickness and conductivity of metallic layers from pulsed eddy current measurements [J]. Review of Science Instrument,1996,67:3965-3972.
[21]Giguere S, Lepine BA, Dubois JMS. Pulsed eddy current technology: characterizing material loss with gap and lift off variations[J]. Research in Nondestructive Evaluation,2001,13:119-129.
[22]Yang HC, Tai CC. Pulsed eddy-current measurement of a conducting coating on a magnetic metal plate[J]. Measurement and Science Technology,2002,13:1259-1265.
[23]Hung-Chi Yang. The design and application of eddy current nondestructive inspection system[D]. Taiwan, China:National Cheng Kung University,2003.
[24]Sophian A, Tian GY, Taylor D, et. A feature extraction technique based on principal component analysis for pulsed Eddy current ND[J]. NDT&E International,2003, 36:37-41.
[25]Tian GY, Sophian A, Taylor D, et. Wavelet-based PCA defect classification and quantification for pulsed eddy current NDT[J]. IEE Proceeding-Science, Measurement and Technology,2005,152(4):141-148.
[26]Tian GY, Sophian A, Taylor D, et. Pulsed eddy current system for dynamic inspection of defects[J]. Insight,2004,46:256-259.
[27]Tian GY, Sopian A. Defect classification using a new feature for pulsed eddy current sensors[J]. NDT&E Internationa,2005,38:77-82.
[28]Y. Li, G. Y. Tian, A. Simm. Fast analytical modelling for pulsed eddy current evaluation[J]. NDT & E Int.,2008,41 (6):477-483.
[29]Chen TL, Tian GY, Sophian A, et. Feature extraction and selection for defect classification of pulse eddy current NDT[J]. NDT&E International,2008,41:467-476.
[30]R.A. Smith, G.R. Hugo. Deep corrosion and crack detection in aging aircraft using transient eddy current NDE[J]. Rev. Prog. Quant. Nondestruct. Eval,1999,6:1401-1408.
[31]S. Li, S.L.Huang, W.Zhao, P. Yu. Study of pulse eddy current probes detecting cracks extending in all directions[J]. Sens. Actuators A,2008,141:13-19.
[32]Y.Z. He, F.L. Luo, M.C. Pan, et. Pulsed eddy current technique for defect detection in aircraft riveted structures [J]. NDT&E Int,2009,43:176-181.
[33]B. Lebrun, Jayet, J.C. Baboux. Pulsed eddy current application to the detection of deep cracks[J]. Mater. Eval,1995,53(11):1296-1300.
[34]S.N. Rajesh, L. Udpa, S. Udpa. Numerical model based approach for estimating Probability of detection in NDE applications[J]. IEEE Trans. Magn,1993,29(2): 1857-1861.
[35]Dai XW, Ludwig R, Palanisamy R. Numerical simulation of pulsed eddy current nondestructive testing phenomena[J]. IEEE Trans Magn,1990,26(6):3089-3096.
[36]Tsuboi H, Seshima N, et. Transient eddy current analysis of pulsed eddy current testing by finite element method[J]. IEEE Trans Magn,2004,40(2):1330-1333.
[37]J.R. Bowler, F. Fu. Transient eddy current interaction with an open crack[J]. Review of Progress in QNDE,2004,24:329-335.
[38]F. Fu, J.R. Bowler. Transient eddy current response due to an open subsurface crack in a conductive plate[J]. Review of Progress in QNDE,2006,25:337-344.
[39]Theodoulidis TP, Kriezis EE. Eddy current canonical problems (with applications to nondestructive evaluation)[M]. Tech Science Press,2006.
[40]J. Kim, G Yang, L. Udpa, S. Udpa. Classification of pulsed eddy current GMR data on aircraft structures [J]. NDT&E Int.,2010,43:141-144.
[41]G. Panaitov, H. J. Krause, Y Zhang. Pulsed eddy current transient technique with HTS SQUID magnetometer for non-destructive evaluation[J]. Physica C,2002,372-376: 278-281.
[42]Abramowitz M, Stegun I. Handbook of mathematical functions with formulas graphs and mathematical tables[M]. Washington, DC:National Bureau of Standards Applied Mathematics Series 5.5, GPO,1970.
[43]GuiYun Tian, Yong Li, and Catalin Mandache, "Study of Lift-Off Invariance for Pulsed Eddy-Current Signals". IEEE TRANSACTIONS ON MAGNETICS.45, p184,2009
[44]Y Danon, C.Q. Lee, C. Mulligan, et. Characterizing tantalums sputtered coatings on steel by using eddy currents[J]. IEEE Trans.Magn,2004,40(4):1826-1832.
[45]Libii JN. Gibbs phenomenon and its applications in science and engineering[J]. In: Proceedings of the 2005 American Society for engineering education annual conference and exposition, Portland, Oregon, June,2005
[46]C. V. Dodd, W. E. Deeds, et. Some eddy-current problems and their integral solutions," Oak Ridge Nat. Lab., Rep. ORNL-4384, Apr.1969
[47]T. P. Theodoulidis E. E. Kriezis. Series expansions in eddy current nondestructive evaluation[J]. Mater. Process. Technol.,2005,161:343-347.
[48]Adriana Savin, Rozina Steigmann, et. Eddy current sensor array. application to nondestructive evaluation of carbon-epoxy composites[J]. NDT for Safety,2007,12: 07-09.
[49]Chen Huang, Xinjun Wu, Zhiyuan Xu, Yihua Kang. Pulsed eddy current signal processing method for signal denoising in ferromagnetic plate testing[J]. NDT&E International,2010,43:648-653.
[50]Chen Huang, Xinjun Wu, Zhiyuan Xu, Yihua Kang. Ferromagnetic material pulsed eddy current testing signal modeling by equivalent multiple-coil-coupling approach[J]. NDT&E International,2011,44:163-168.