Contents Applications for Remanufacturing Problems and Prospects Part I Introduction to the Metal Magnetic Memory (MMM) Technique 1 Nondestructive Testing for Remanufacturing 3 1.1 Motivations 3 1.2 Conventional Nondestructive Testing Techniques 5 1.3 MMM Technique 5 1.4 Organization of This Book 7 References 8 2 Theoretical Foundation of the MMM Technique 9 2.1 Background 10 2.2 Microscopic Mechanism 13 2.3 Macroscopic Theoretical Model 13 2.3.1 Magnetomechanical Model 17 2.3.2 Magnetic Charge Model 19 2.3.3 First Principle Theory 23 References 23 3 State of the Art of the MMM Technique 25 3.1 Historical Background 25 3.2 Theoretical Research 26 3.3 Experimental Research 27 3.4 Standard Establishment 30 3.5 Applications for Remanufacturing 31 3.6 Problems and Prospects 32 References 34 Part II Detection of Damage in Ferromagnetic Remanufacturing Cores by the MMM Technique 39 4 Stress Induces MMM Signals 39 4.1 Intxoductioii 39 4.2 Variations in the MMM Signals Induced by Static Stress 40 4.2.1 Under the Elastic Stage 41 4.2.2 Under the Plastic Stage 42 4.2.3 Theoretical Analysis 44 4.3 Variations in the MMM Signals Induced by Cyclic Stress 45 4.3.1 Under Different Stress Cycle Numbers 46 4.3.2 Characterization of Fatigue Crack Propagation 49 4.4 Conclusions 52 References 52 5 Frictional Wear Induces MMM Signals 55 5.1 Introduction 55 5.2 Reciprocating Sliding Friction Damage 56 5.2.1 Variations in the Tribology Parameters During Friction 58 5.2.2 Variations in the Magnetic Memory Signals Parallel to Sliding 60 5.2.3 Variations in the Magnetic Memory Signals Normal to Sliding 62 5.2.4 Relationship Between the Tribology 65 Characteristics and Magnetic Signals 66 5.3 Single Disassembly Friction Damage 68 5.3.1 Surface Damage and Microstructure Analysis 69 5.3.2 Variations in the MMM Signals 73 5.3.3 Damage Evaluation of Disassembly 76 5.3.4 Verification for Feasibility and Repeatability 80 5.4 Conclusions 81 References 81 6 Stress Concentration Impacts on MMM Signals 83 6.1 Introduction 84 6.2 Stress Concentration Evaluation Based on the Magnetic Dipole Model 84 6.2.1 Establishment of the Magnetic Dipole Model 86 6.2.2 Characterization of the Stress Concentration Degree 86 6.2.3 Contributions of Stress and Discontinuity to MMM Signals 91 6.3 Stress Concentration Evaluation Based on the Magnetic Dual-Dipole Model 95 6.3.1 Magnetic Scalar Potential 95 6.3.2 Magnetic Dipole and Its Scalar Potential 97 6.3.3 Measurement Process and Results 100 6.3.4 Analysis of the Magnetic Scalar Potential 103 6.4 Stress Concentration Inversion Method 110 6.4.1 Inversion Model of the Stress Concentration Based on the Magnetic Source Distribution 110 6.4.2 Inversion of a One-Dimensional Stress Concentration 112 6.4.3 Inversion of a Two-Dimensional Stress Concentration 114 6.5 Conclusions 114 References 115 7 Temperature Impacts on MMM Signals 117 7.1 Introduction 117 7.2 Modified J-A Model Based on Thermal and Mechanical Effects 117 7.2.1 Effect of Static Tensile Stress on the Magnetic Field 118 7.2.2 Effect of Temperature on the Magnetic Field 119 7.2.3 Variation in the Magnetic Field Intensity 120 7.3 Measurement of MMM Signals Under Different Temperatures 121 7.3.1 Material Preparation 122 7.3.2 Testing Method 122 7.4 Variations in MMM Signals with Temperature and Stress 123 7.4.1 Normal Component of the Magnetic Signal 125 7.4.2 Mean Value of the Normal Component of the Magnetic Signal 128 7.4.3 Variation Mechanism of the Magnetic Signals Under Different Temperatures 130 7.4.4 Analysis Based on the Proposed Theoretical Model 131 7.5 Conclusions 132 References 132 8 Applied Magnetic Field Strengthens MMM Signals 133 8.1 Introduction 133 8.2 MMM Signal Strengthening Effect Under Fatigue Stress 134 8.2.1 Variations in the MMM Signals with an Applied Magnetic Field 135 8.2.2 Theoretical Explanation Based on the Magnetic Dipole Model 137 8.3 MMM Signal Strengthening Effect Under Static Stress 139 8.3.1 Magnetic Signals Excited by the Geomagnetic Field 140 8.3.2 Magnetic Signals Excited by the Applied Magnetic Field 142 8.4 Conclusions 146 References 147 Part III Evaluation of the Repair Quality of Remanufacturmg Samples by the MMM Technique 9 Characterization of Heat Residual Stress During Repair 151 9.1 Introduction 151 9.2 Preparation of Cladding Coating and Measurement of MMM Signals 153 9.2.1 Specimen Preparation 153 9.2.2 Measurement Method 153 9.2.3 Data Preprocessing 155 9.3 Distribution of MMM Signals near the Heat Affected Zone 156 9.3.1 Magnetic Signals Parallel to the Cladding Coating 156 9.3.2 Magnetic Signals Perpendicular to the Cladding Coating 157 9.3.3 Three-Dimensional Spatial Magnetic Signals 159 9.3.4 Verification Based on the XRD Method 161 9.4 Generation Mechanism of MMM Signals in the Heat Affected Zone 164 9.4.1 Microstructure and Phase Transformation 164 9.4.2 Microhardness Distribution 165 9.5 Conclusions 166 References 167 10 Detection of Damage in Remanufactured Coating 169 10.1 Introduction 169 10.2 Cladding Coating and Its MMM Measurement 170 10.3 Result and Discussion 172 10.3.1 Variations in MMM Signals Under the Fatigue Process 172 10.3.2 Comparison of the Magnetic Properties from Different Material Layers 172 10.3.3 Microstructure Analysis 174 10.4 Conclusions 177 References 178 11 Detection and Evaluation of Coating Interface Damage 181 11.1 Introduction 181 11.2 Theoretical Framework 183 11.2.1 Fatigue Cohesive Zone Model 183 11.2.2 Magnetomechanical Model 184 11.2.3 Numerical Algorithm of the Coupling Model 185 11.2.4 Calculation of the Magnetic Field Intensity 186 11.3 Case Analysis for the Theoretical Model 186 11.3.1 Finite Element Model Setup 186 11.3.2 Finite Element Simulation Results 188 11.3.3 Prediction of Interfacial Crack Initiation 190 11.3.4 Prediction of the Interfacial Crack Propagation Behavior 191 11.4 Experimental Verification 194 11.4.1 MMM Measurement Method 194 11.4.2 MMM Signal Analysis 196 11.4.3 Interfacial Crack Observation 198 11.5 Conclusions 200 References 200 Part IV Engineering Applications in Remanufacturing 12 Detection of Damage of the Waste Drive Axle Housing and Hydraulic Cylinder 205 12.1 Introduction 205 12.2 Application of MMM in the Evaluation of Fatigue Damage of the Drive Axle Housing 206 12.2.1 Relation Between MMM Signals and Fatigue Cycles 206 12.2.2 Relation Between MMM Signals and Deformation Degree 209 12.3 Application of MMM in the Evaluation of Fatigue Damage of Retired Hydraulic Cylinders 210 12.3.1 Threshold Determination Method for Remanufacturability Evaluation 210 12.3.2 Experimental Verification 212 12.4 Conclusions 215 References 216 13 Evaluation of the Repair Quality of Remanufactured Crankshafts 217 13.1 Introduction 217 13.2 Repair Process in Remanufacturing 218 13.3 Evaluation of the Repair Quality of the Remanufactured Coating 219 13.3.1 Optimization of the Processing Parameters 219 13.3.2 Effect of the Processing Parameters on the Microstructure 221 13.3.3 Effect of the Processing Parameters on the Microhardness 223 13.3.4 Effect of the Processing Parameters on the Wear Resistance 223 13.4 Repair Quality Evaluation Based on MMM Measurement 223 13.5 Conclusions 226 References 227 14 Development of a High-Precision 3D MMM Signal Testing Instrument 229 14.1 Introduction 229 14.2 Framework of the Detection System 230 14.3 Detailed Processes of Instrument Development 231 14.3.1 Hardware Design 231 14.3.2 Software Design 232 14.4 Calibration of Self-developed Instrument 234 14.4.1 Static Performance of the Instrument 234 14.4.2 Ability to React to the Geomagnetic Field 235 14.5 Testing of the Self-developed Instrument 237 14.5.1 Testing Method and Process 237 14.5.2 Display and Analysis of MMM Signals 238 14.6 Comparison of the MMM Testing Instruments 238 14.7 Conclusions 240 References 240
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