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Evolution Mechanism and High-Precision Quantitative Identification of MFL Signals from Defects Under Supersaturated

Huiqi Zou1, Jiuxin Wang2,3, Qi Dong1

  • 1School of Science, Xi'an Polytechnic University, Xi'an 710048, China.

Sensors (Basel, Switzerland)
|May 27, 2026
PubMed
Summary

Magnetic flux leakage (MFL) testing under supersaturated magnetization reveals enhanced defect signals. A novel correction method significantly improves defect length measurement accuracy, crucial for equipment safety.

Keywords:
finite element simulationmagnetic flux leakage testingsignal characterization modelsignal correction methodsupersaturated magnetization

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Area of Science:

  • Materials Science and Engineering
  • Non-Destructive Testing (NDT)
  • Electromagnetism

Background:

  • Magnetic flux leakage (MFL) is vital for inspecting ferromagnetic equipment integrity.
  • Current MFL research primarily addresses weak or saturated magnetization states.
  • The behavior of MFL defect signals under supersaturated magnetization remains poorly understood.

Purpose of the Study:

  • To investigate MFL signal evolution under supersaturated magnetization.
  • To develop a high-precision method for quantitative defect identification in this state.
  • To elucidate the physical mechanisms governing MFL signals under supersaturated conditions.

Main Methods:

  • Established a 3D finite element model using COMSOL Multiphysics for MFL testing.
  • Investigated the influence of sensor lift-off, defect depth, length, and burial depth on MFL signals.
  • Validated simulation findings through experimental detection of crack defects and proposed a signal correction technique.

Main Results:

  • MFL signal intensity is significantly enhanced under supersaturated magnetization compared to saturated states.
  • Developed accurate characterization models for key parameters influencing MFL signals.
  • The proposed signal correction method reduced maximum defect length identification error from 14.25% to below 0.3%.

Conclusions:

  • Supersaturated magnetization offers improved MFL defect detection sensitivity.
  • The developed quantitative identification and correction methods enable accurate defect assessment.
  • This research provides a foundation for advanced MFL defect analysis in challenging operational environments.