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

背景：以非接触式、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查高价值铁素体钢的微观结构，重点是对工业具有战略重要性的应用。主要目标是建立微结构和磁性之间的牢固关系，并设计用于现场使用的传感器。概要项目范围：这项博士研究的目的是开发新的无损检测技术，用于管道制造过程中微结构的在线检测和监测。在这一领域内，该项目将以电磁技术研究为目标，这是大学和工业伙伴的专业。开发无损探伤技术的具体目标将是(括号中的可交付成果)：1.感应--熟悉目前的现有研究和相关工具。对其他地方的任何最新发展进行文献搜索。这将包括一种或多种用于材料特性特定方面的电磁和超声波方法(这将构成第一年年终转移报告的一部分)。进一步阐述和完善理论方法(对于简化的情况)，以及在EM方法的情况下，使用COMSOL和Ansys Maxwell为正问题建立完整的三维有限元模型，重点是一个特定的案例研究(带附加模型的报告)。生产或采购具有已知特性或例如已知电导率分布的部件的适当参考材料和实验室校准样品。(硬件/演示)。设计和建造带有合适的信号调理和数据采集电子设备的实验传感器。(向主管示范)。新传感器在实验室条件下的性能极限的实验结果(报告/介绍)。根据正问题的有限元和理论模型的预测，在实验室平台上验证传感器系统的响应。(报告和演示文稿)通过采用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(带有附加的MatLab模型的报告)。完全逆解的误差分析，并对照理论结果和实验室试验台的实验数据进行验证(报告和演示)。如果合适，协助设计和建造适当的工具，以便在工业环境中部署，视进展情况而定(硬件和CAD图纸)。如果合适，支持现场技术部署和对收集的数据进行分析。11.整个系统的测试方案、对今后技术部署的报告和建议的评价(报告和介绍)。撰写博士论文(论文和论文答辩)13.向Tenaris提供季度(或两年一次)进度报告，并参加季度(或两年一次)进度会议。该计划是围绕Tenaris和Tenaris在电磁无损检测技术方面的经验而设计的。此外，曼彻斯特大学有成功地将这类方法应用于几个工业应用的经验，并开发了一系列电磁有限元模型来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。但是，如果遇到更好的替代解决方案，或者目前的技术在实践中证明是不可行的，则项目计划将进行调整，以应对这些发展。

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.