This paper is concerned with identifying the inherent Magnetic Flux Leakage (MFL) technology variables that affect the sizing of defects and the repeatability of results. External defect sizing factors such as operator competence and inspection environment are here assumed pacified and so not considered. With these extraneous variables removed saturation, calibration and defect geometry can be investigated, both globally and in the context of the technology employed herein. Under-saturation is revealed to be a major limiting factor in defect sizing. Consequently to overcome the limitations presented by under-saturation a new calibration procedure is proposed. Further suppositions pertaining to defect sizing are then verified empirically and in some cases confirmed via numerical simulation. The paper naturally concludes with a discussion of the results and where possible improvements could be made.
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