Sprayed Magnetostrictive Coating for Guided Wave Sensing on Complex Surfaces
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Solution Overview
Problem
Conventional magnetostrictive sensors face challenges such as low energy conversion efficiency, weak magnetostrictive effect leading to attenuation of guided waves, and difficulty in adhering to complex structures, especially in harsh environments, due to the use of adhesives like epoxy resin and limitations in fitting with complex structural parts.
Innovation Solution
A method of preparing a magnetostrictive coating by spraying magnetostrictive alloy powder on a pretreated test piece surface, using Fe100-x-yAlxMy, Fe100-x-yGaxMy, or Fe100-x-yNixMy compositions, which are applied via gas atomization, and forming a sensor with a transducer and coils to generate ultrasonic guided waves without the need for coupling agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetostrictive strip is stuck on a test piece using adhesive, then the magnetostrictive effect is enhanced and guided waves are generated, but the adhesive ages or becomes ineffective in harsh environments and the coating cannot fit complex structures well
Solution Approach 1:
The patent removes the adhesive layer from the sensor structure, extracting the problematic component that limited service life. The magnetostrictive coating is applied directly to the test piece surface through spraying, eliminating the adhesive interface that ages and fails in harsh environments.
Solution Approach 2:
The patent replaces the mechanical bonding system (adhesive) with a direct surface coating system. The magnetostrictive material is sprayed onto the test piece surface, forming a direct bond without requiring adhesive chemistry, thus eliminating the reliability issues associated with adhesive aging.
2Ease of operation
If a magnetostrictive strip is used for detection, then non-contact detection is achieved, but it is difficult to fit complex structural parts
Solution Approach 1:
The patent uses a sprayed magnetostrictive coating that forms a thin, conformal layer on the test piece surface. This coating can adapt to complex geometries and irregular surfaces, providing flexibility and conformability that rigid magnetostrictive strips cannot achieve.
Solution Approach 2:
The patent changes the physical state and application method of the magnetostrictive material from a rigid strip to a sprayable coating. This parameter change allows the material to be applied in various forms and conform to different surface geometries, greatly enhancing adaptability to complex structures.
3Length of stationary object
If conventional magnetostrictive sensors are used, then detection range is extended, but energy conversion efficiency is low and signal-to-noise ratio is insufficient
Solution Approach 1:
The patent employs a composite structure consisting of a magnetostrictive coating layer applied directly on the test piece surface. This composite approach combines the magnetostrictive properties of the specialized material with the structural properties of the test piece, improving energy conversion efficiency and signal-to-noise ratio while maintaining extended detection range.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The magnetostrictive coating achieves high energy conversion efficiency and signal-to-noise ratio, enabling effective ultrasonic guided wave detection with improved bonding strength and adaptability to complex shapes, suitable for online monitoring in high-temperature, low-temperature, or dry environments.
Implementation Method 1
The magnetostrictive guided wave detection initially uses the magnetostrictive effect of a ferromagnetic material itself to wind a coil outside the ferromagnetic material, and when an AC excitation signal is transmitted by the coil, an alternating magnetic field is induced in the ferromagnetic material, and ultrasonic guided waves are generated in the member
Implementation Method 2
when an AC excitation signal is transmitted by the coil, an alternating magnetic field is induced in the ferromagnetic material
Data Source
AI summary
The present disclosure provides a magnetostrictive guided wave sensor and a method for preparing magnetostrictive coating, relating to the field of magnetic functional materials and preparations thereof. The method includes: pretreating a surface of a test piece; and spraying magnetostrictive alloy powder on the pretreated surface of the test piece to form a magnetostrictive coating attached to the pretreated surface. In the magnetostrictive guided wave sensor and the method for preparing magnetostrictive coating according to the embodiments of the present disclosure, by spraying the magnetostrictive coating on the test piece, no coupling agent is required between the probe of the magnetostrictive coating sensor and the test piece, and the magnetostrictive coating can be formed on test pieces of any shape. In addition, the coating has a high bonding strength with the test piece, and has good tissue characteristics and magnetostrictive performance.