The magnetic flux leakage (MFL) method is commonly used as an inspection technique in the petrochemical and metal industries. In this paper, 3D FEM model is used to analyze MFL signal, a generalized potential formulation to the magnetostatic field MFL problem is presented. Optimal operating conditions for MFL testing of steel tube are predicted to obtain the maximum signal to noise ration by using a 3-D FEM model. Typical 3D defects are modeled and MFL signals caused by the defects of different shape are simulated respectively. Sensor signals variations due to defects of different parameters are investigated and the relations between them are also analyzed. Taking the MFL simulation signals, the classification of defect is performed by applying the wavelet analysis approach.
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