Electromagnetic non-destructive testing for inspecting the microstructure of high performance ferritic steels

背景：以非接触非破坏性方式测量材料微观结构的新技术可以显著提高对材料及其在加工和使用过程中的行为的理解，以及控制或预测材料性能的能力。该项目将考虑先进的磁性技术，用于在制造和使用过程中检测高价值铁素体钢的微观结构，重点关注对工业具有战略重要性的应用。主要目的是建立强大的微观结构和磁性能之间的关系，并设计传感器，利用这些关系在field.Outline项目范围：本博士研究的目的是开发新的无损检测技术的微观结构在线检测和监测过程中管道制造。在这一领域内，该项目将针对电磁技术的研究，这是大学和行业合作伙伴的专长。无损检测技术发展的具体目标将是（括号内的交付成果）：1.归纳-熟悉当前现有的研究和相关工具。2.对其他地方的任何最新发展进行文献检索。这将包括一种或多种电磁和超声波方法，用于材料表征的特定方面（这将构成第一年年底转移报告的一部分）。进一步制定和完善理论方法（对于简化的情况），以及在EM方法的情况下，使用COMSOL和Ansys麦克斯韦建立正演问题的完整三维有限元模型，重点关注特定的案例研究（报告和附加模型）。4.生产或获取合适的参考材料和具有已知特性或已知电导率分布的组件的实验室校准样品。（硬件/演示文稿）。5.设计和构建具有适当信号调节和数据采集电子器件的实验传感器。（向主管演示）。实验室条件下新传感器性能极限的实验结果（报告/演示）。7.验证实验室装置上的传感器系统响应与有限元预测和正演问题的理论模型。（报告和介绍）。通过调整反问题或数据分析中使用的技术来开发反问题的解决方案（附有MatLab模型的报告）。9.完整的逆解的误差分析，并根据理论结果和实验室测试装置的实验数据进行验证（报告和演示）。10.如果合适的话，协助设计和建造适当的工具，以部署在工业环境中，以进度为准（硬件与CAD图纸）。在适当的情况下，支持在现场部署该技术并分析收集的数据。11.整个系统的测试方案、对报告的评价和对今后部署该技术的建议（报告和介绍）。博士论文的制作（论文和论文答辩）13.向泰纳瑞斯提供季度（或半年）进度报告，并参加季度（或半年）进度会议。该计划是围绕大学和泰纳瑞斯在电磁无损检测技术方面的经验而设计的。此外，曼彻斯特大学拥有将这种方法成功应用于多种工业应用的经验，并开发了一系列电磁有限元法（FEM）模型，以量化各种传感器设计的响应。因此，我们对这些方法的潜力越来越有信心。然而，如果遇到更好的替代解决方案，或目前的技术在实践中证明是不可行的，那么项目计划将进行调整，以解决这些发展。

Background:New techniques to measure the microstructure of a material in a non-contact non-destructive fashion can lead to a dramatic improvement in the understanding of the material and its behavior during processing and in-service, and an ability to control or predict the material properties. This project will consider advanced magnetic techniques for inspecting the microstructure of high value ferritic steels during manufacture and in service, focusing on applications of strategic importance to industry. The key aims are to establish robust relationships between microstructure and the magnetic properties and to devise sensors which exploit these relationships for use in the field.Outline Project Scope:The aim of this doctoral research is to develop new NDE techniques for the inspection and monitoring of microstructure on-line during pipe manufacture. Within this field, the project will target research in electromagnetic techniques, which is a specialism for both the University and industry partners.The specific objectives for the development of an NDE technique would be (deliverables in brackets): 1. Induction - become familiar with the current existing research and relevant tools.2. Conduct a literature search for any recent developments elsewhere. This will include one or more electromagnetic and ultrasonic methods for particular aspects of material characterisation (This will form part of the end of first year transfer report).3. Further formulation and refinement of theoretical approaches (for simplified cases) and, in the case of EM methods, full 3D FEM models for the forward problems using COMSOL and Ansys Maxwell focussing on a particular case study (Report with appended models).4. Production or acquisition of suitable reference materials and laboratory calibration samples of components with known characteristics or for instance known conductivity profiles. (Hardware / presentation).5. Design and construction of experimental sensors with appropriate signal conditioning and data acquisition electronics. (Demonstration to supervisors).6. Experimental results of the performance limits of the new sensors in laboratory conditions (Report / presentation).7. Validation of the sensor system response on the laboratory rigs against the predictions from the FEM and theoretical models of the forward problem. (Report and presentation).8. Development of the solution to the inverse problem by adapting techniques used in inverse problems or data analysis (Report with appended MatLab models).9. Error analysis of the complete inverse solution and validation against theoretical results and experimental data from the laboratory test rig (Report and presentation).10. If appropriate, assist in the design and construction of appropriate tools for deployment in an industrial environment, subject to progress (Hardware with CAD drawings). If appropriate, support deployment of the technique on site and analysis of the collected data. 11. Test programme of the complete system, evaluation of reports and recommendations for future deployment of the technology (Report and presentation).12. Production of PhD thesis (Thesis and Thesis defence)13. Provision of quarterly (or bi-yearly) progress reports to Tenaris and attending of quarterly (or bi-yearly) progress meetings.The plan is designed around the experience at the University and Tenaris on electromagnetic NDT techniques. In addition, the University of Manchester has experience of successfully applying methods of this type to several industrial applications and has developed a series of electromagnetic finite element method (FEM) models to quantify the response of various sensor designs. Consequently, we have increasing confidence in the potential of these approaches. However, if better alternative solutions are encountered, or current techniques prove to be infeasible in practice, then the project plan will be adapted to address these developments.