Solenoid model for visualizing magnetic flux leakage testing of complex defects

Magnetic flux leakage (MFL) techniques are widely used for nondestructive testing of ferromagnetic materials. An analytical model of the MFL field is essential for precise determination and reconstruction of defects. In this paper, we proposed a solenoid model based on magnetization mechanisms of the magnetic medium to explain the MFL principle and simulate the MFL field. By introducing the interaction of solenoids and the Jiles–Atherton model, this model can accurately calculate the MFL field of complex defects, particularly the field distortion caused by the coupling of the defect's components. The solenoid model was experimentally demonstrated with a Z-shaped defect in the specimen and proved to be valid for precise calculation of the magneto-optical image. This work reveals the MFL testing principle from the viewpoint of the magnetic medium and thus helps elucidate and eradicate the simulation errors. The more accurate simulation than the common magnetic dipole model facilitates the inverse calculation of defects, even if field distortion is involved.