Magnetic flux leakage (MFL) testing is a widely used electromagnetic nondestructive testing (ENDT) method, which has the ability to detect both surface and sub-surface defects in conductive materials. One of its best features is its ability to mathematically model field leakage from the defect area in a magnetized material. In this paper, we propose an optimized FEM model using geometrical weighted tensor (TBFEM), for the calculation of leakage field in MFL. This model using the Einstein’s convention eliminates the bulky nature of traditional FEM based on its matrix algebra formation allowing for easy implementation and fast calculations. The proposed model achieves this by reducing the set of matrix equations into a single equation using suffixes which can then be solved with regular mathematical operations.
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