A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets
Surface quality control of hot-dip galvanized sheets is a critical research topic in the metallurgical industry. Zinc dross, the most common surface defect in the hot-dip galvanizing process, significantly affects the sheet’s service performance. In this manuscript, a novel magnetic flux leakage (MF...
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2024-12-01
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| author | Bo Wang San Zhang Jie Wang Liqin Jing Feilong Mao |
| author_facet | Bo Wang San Zhang Jie Wang Liqin Jing Feilong Mao |
| author_sort | Bo Wang |
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| description | Surface quality control of hot-dip galvanized sheets is a critical research topic in the metallurgical industry. Zinc dross, the most common surface defect in the hot-dip galvanizing process, significantly affects the sheet’s service performance. In this manuscript, a novel magnetic flux leakage (MFL) detection method was proposed to detect zinc dross defects on the surface of hot-dip galvanized steel sheets. Instead of using exciting coils in traditional methods, a tiny permanent magnet with a millimeter magnitude was employed to reduce the size and weight of the equipment. Additionally, a high-precision tunnel magnetoresistance (TMR) sensor with a sensitivity of 300 mV/V/Oe was selected to achieve higher detection accuracy. The experimental setup was established, and the x-axis direction (sample movement direction) was determined as the best measurement axis by vector analysis through experiments and numerical simulation. The detection results indicate that this novel MFL detection method could detect industrial zinc dross with an equivalent size of 400 μm, with high signal repeatability and signal-to-noise ratio. In the range of 0–1200 mm/s, the detection speed has almost no effect on the measurement signal, which indicates that this novel method has higher adaptability to various conditions. The multi-path scanning method with a single probe was used to simulate the array measurement to detect a rectangular area of 30 × 60 mm. Ten zinc dross defects were detected across eight measurement paths with 4 mm intervals, and the positions of these zinc dross defects were successfully reconstructed. The research results indicate that this novel MFL detection method is simple and feasible. Furthermore, the implementation of array measurements provides valuable guidance for subsequent in-depth research and potential industrial applications in the future. |
| format | Article |
| id | doaj-art-b8b34dfab2f04a07a8cb8474cc87f8c4 |
| institution | DOAJ |
| issn | 2312-7481 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
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| series | Magnetochemistry |
| spelling | doaj-art-b8b34dfab2f04a07a8cb8474cc87f8c42025-08-20T02:50:59ZengMDPI AGMagnetochemistry2312-74812024-12-01101210110.3390/magnetochemistry10120101A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized SheetsBo Wang0San Zhang1Jie Wang2Liqin Jing3Feilong Mao4Department of Mechanical and Electrical, Yuncheng University, Yuncheng 044000, ChinaSchool of Automation, Xi’an University of Posts & Telecommunications, Xi’an 710121, ChinaMetallurgical Technology Institute, Central Iron and Steel Research Institute, Beijing 100081, ChinaDepartment of Mechanical and Electrical, Yuncheng University, Yuncheng 044000, ChinaDepartment of Mechanical and Electrical, Yuncheng University, Yuncheng 044000, ChinaSurface quality control of hot-dip galvanized sheets is a critical research topic in the metallurgical industry. Zinc dross, the most common surface defect in the hot-dip galvanizing process, significantly affects the sheet’s service performance. In this manuscript, a novel magnetic flux leakage (MFL) detection method was proposed to detect zinc dross defects on the surface of hot-dip galvanized steel sheets. Instead of using exciting coils in traditional methods, a tiny permanent magnet with a millimeter magnitude was employed to reduce the size and weight of the equipment. Additionally, a high-precision tunnel magnetoresistance (TMR) sensor with a sensitivity of 300 mV/V/Oe was selected to achieve higher detection accuracy. The experimental setup was established, and the x-axis direction (sample movement direction) was determined as the best measurement axis by vector analysis through experiments and numerical simulation. The detection results indicate that this novel MFL detection method could detect industrial zinc dross with an equivalent size of 400 μm, with high signal repeatability and signal-to-noise ratio. In the range of 0–1200 mm/s, the detection speed has almost no effect on the measurement signal, which indicates that this novel method has higher adaptability to various conditions. The multi-path scanning method with a single probe was used to simulate the array measurement to detect a rectangular area of 30 × 60 mm. Ten zinc dross defects were detected across eight measurement paths with 4 mm intervals, and the positions of these zinc dross defects were successfully reconstructed. The research results indicate that this novel MFL detection method is simple and feasible. Furthermore, the implementation of array measurements provides valuable guidance for subsequent in-depth research and potential industrial applications in the future.https://www.mdpi.com/2312-7481/10/12/101magnetic flux leakagehot-dip galvanized sheetzinc drossarray measurementtunnel magnetoresistance sensor |
| spellingShingle | Bo Wang San Zhang Jie Wang Liqin Jing Feilong Mao A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets Magnetochemistry magnetic flux leakage hot-dip galvanized sheet zinc dross array measurement tunnel magnetoresistance sensor |
| title | A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets |
| title_full | A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets |
| title_fullStr | A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets |
| title_full_unstemmed | A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets |
| title_short | A Novel Magnetic Flux Leakage Method Incorporating TMR Sensors for Detecting Zinc Dross Defects on the Surface of Hot-Dip Galvanized Sheets |
| title_sort | novel magnetic flux leakage method incorporating tmr sensors for detecting zinc dross defects on the surface of hot dip galvanized sheets |
| topic | magnetic flux leakage hot-dip galvanized sheet zinc dross array measurement tunnel magnetoresistance sensor |
| url | https://www.mdpi.com/2312-7481/10/12/101 |
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