Accurate 3D reconstruction of complex defects based on combined method of MFL and MFDs

Abstract The two-step strategy for 3D reconstruction of complex defects was updated by combining the magnetic field disturbance (MFD) with magnetic flux leakage (MFL) measurement methods. Firstly, the plane-scanned MFD imaging was employed to achieve high-accuracy reconstruction of the opening outlines of complex defects. Secondly, the finite element simulation model of the defect with the recognized opening outline was established as the forward model for depth profile inversion with the particle swarm optimization algorithm. The performances of the conventional MFL-based and updated strategies were carefully compared through finite element simulation. The results proved that the updated method combining MFD signals with MFL signals had the better performance in accurate 3D reconstruction of complex defects than the conventional MFL-based inversion strategy, displaying smaller errors in opening outline, peak depth and the profile. Experimental results confirmed that the updated strategy could accurately reconstruct the 3D shape of 8-shaped defect and rectangular defect with rounded corners.