Design of a Novel Electromagnetic Ultrasonic Transducer for Stress Detection

Accurate stress evaluation of structural components during manufacturing and operation is essential for ensuring the safety and reliability of advanced equipment in aerospace, defense, and other high-performance fields. However, existing electromagnetic ultrasonic stress detection methods are often limited by low signal amplitude and limited adaptability to complex environments, hindering their practical deployment for in situ testing. This study proposes a novel surface wave transducer structure for stress detection based on acoustoelastic theory combined with electromagnetic ultrasonic technology. It innovatively designs a surface wave transducer composed of multiple proportionally scaled dislocation meandering coils. This innovative configuration significantly enhances the Lorentz force distribution and coupling efficiency, which accurately measure the stress of components through acoustic time delays and present an experimental method for applying electromagnetic ultrasonic technology to in situ stress detection. Finite element simulations confirmed the optimized acoustic field characteristics, and experimental validation on 6061 aluminum alloy specimens demonstrated a 111.1% improvement in signal amplitude compared to conventional designs. Through multiple experiments and curve fitting, the average relative error of the measurement results is less than 4.53%, verifying the accuracy of the detection method. Further testing under random stress conditions validated the transducer’s feasibility for in situ testing in production and service environments. Owing to its enhanced signal strength, compact structure, and suitability for integration with automated inspection systems, the proposed transducer shows strong potential for in situ stress monitoring in demanding industrial environments.