Automated inspection of surface breaking cracks using GMR sensor arrays

We present a prototype for automated magnetic stray field testing of ferromagnetic roller bearings. For this purpose NDE-adapted GMR sensor arrays (giant magneto resistance) are used for the detection of surface breaking cracks. The sensors are miniaturized down to the lower μm-regime to achieve adequate spatial resolution. In doing so, sensor arrays with up to 48 elements are used to inspect the bearing surface within a few seconds only. In contrast to magnetic particle inspection (MPI), where the global magnetization requires a further inspection step and succeeding demagnetization, the presented prototype only locally magnetize the surface area in the vicinity of the GMR Sensors. For the local magnetization, the applied sub-surface magnetic field was simulated and proofed for detecting flaws with a depth of a few 10 μm. By multiplexing the sensor array with an adapted read out electronics we quasi simultaneously detect the normal field component of about 100μm above the surface. The detection of artificial notches with a depth of 40 μm and more could be resolved with a SNR better than 20 dB. The presented testing facility is fast and provides a step towards automated testing of safety relevant steel components