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Nondestructive testing (NDT) of spot welds still poses a great challenge for industrial mass production like automotive body manufacturing or rail vehicle constructions. In these production areas, ultrasonic-based NDT methods with pulse-echo technology have become established. Hitherto, these methods require a lot of experience from the staff, which often makes the results subjective. Furthermore, these methods reach their limits when testing spot welds with deep electrode indentations or huge differences between sheet metal thicknesses. Imaging analysis of the residual magnetic flux density shows great potential especially when addressing the restrictions of the ultrasonic-based NDT methods. Typical spot welds show a characteristic electrode indentation. This indentation influences the measureable magnetic flux density, which depends on the distance between the surface of the spot weld and the sensor. This paper will show the influence of electrode indentation on the test result and presents the resulting restrictions for imaging analysis of the residual magnetic flux density when testing spot welds.

materials testing

NDT of spot welds by imaging analysis of the residual magnetic flux density – Investigation on the influence of electrode indentation on the measurement results