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Size adapted GMR arrays for the automated inspection of surface breaking cracks in roller bearings
(2014)
Their small size together with a remarkable field sensitivity are the most prominent features of present-day GMR sensors paving the way for various applications in automated non-destructive testing (NDT). This work presents a prototype for fast and automated magnetic testing of roller bearings. A local magnetization unit excites the magnetic field inside the bearing. As a result of a design study and the following wafer fabrication the probe was equipped with NDT-adapted GMR sensor arrays in which 48 elements measures the field response. The detection of artificial and 40 µm deep defects could be resolved with a SNR better than 20 dB. In addition, we report of first results of a POD (Probability of Detection) analysis using GMR sensors to investigate bearings with EDM (electronic discharge machining) notches having depths down to 10 µm. Finally, we estimate successfully the depth of a 57 µm notch from the measured data.
Micro-cracks in a magnetized ferromagnetic material cause stray fields that can be observed using giant magnetoresistive (GMR) sensors. This work investigates the applicability of GMR sensors to the non-destructive evaluation of micro-cracks via the observation of stray fields. For this purpose, our measurement setup is assessed using a fast new sensitivity analysis based on adjoint states, employing the finite-element method. A model for the GMR sensor is developed and verified. We are able to resolve micro-cracks with an opening of 3 µm and a depth of 30 µm. GMR positioning inaccuracies are analyzed.