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Detection, Verification and Analysis of Micro Surface Defects in Steel Filament Using Eddy Current Principles,

Kim Sang Tran1, Bijan Shirinzadeh1, Armin Ehrampoosh1

  • 1Robotics and Mechatronics Research Laboratory (RMRL), Department of Mechanical and Aerospace Engineering, Monash University, Melbourne, VIC 3800, Australia.

Sensors (Basel, Switzerland)
|November 14, 2023
PubMed
Summary

This study introduces an Eddy current method for detecting micro surface defects in steel filaments. The technique accurately identifies cracks and inclusions, crucial for quality control in advanced manufacturing.

Keywords:
eddy currentinclusionlongitudinal scratchsteel filamentsurface defect

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Area of Science:

  • Materials Science
  • Non-Destructive Testing
  • Industrial Manufacturing

Background:

  • Advanced technologies are essential for defect detection in high-speed steel filament production.
  • Micro surface defects can compromise the integrity and performance of steel filaments.

Purpose of the Study:

  • To develop and validate an innovative methodology for precise detection and verification of micro surface defects in steel filaments.
  • To establish a reliable method for identifying longitudinal scratches and inclusions.

Main Methods:

  • Application of the Eddy current principle using permanent magnets and high-frequency coils.
  • Validation through scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS).
  • Introduction of artificial defects to establish amplitude thresholds (10% FSH for ~20 µm crack depth).

Main Results:

  • Experimental production of 182 samples (38 km) revealed a high defect ratio of 26.37%.
  • Defects were randomly distributed along the filament length.
  • Detected defects primarily consisted of longitudinal scratches and tungsten carbide inclusions.

Conclusions:

  • The Eddy current method demonstrates exceptional precision in detecting micro surface defects in steel filaments.
  • This technique is vital for enhancing quality control in steel filament manufacturing.
  • The findings contribute to the advancement of non-destructive testing in industrial applications.