Magnetic Barkhausen noise (MBN) represents a powerful non-destructive testing and material characterization methodology enabling quantitative assessment of microstructural features, mechanical properties, and stress states in ferromagnetic materials. This comprehensive review synthesizes recent advances spanning theoretical foundations, sensor design, signal processing methodologies, and industrial applications. The physical basis rooted in domain wall dynamics and statistical mechanics provides rigorous frameworks for interpreting MBN signals in terms of grain structure, dislocation density, phase composition, and residual stress. Contemporary instrumentation innovations including miniaturized sensors, multi-parameter systems, and high-entropy alloy cores enable measurements in challenging environments. Advanced signal processing techniques—encompassing time-domain analysis, frequency-domain spectral methods, time–frequency transforms, and machine learning algorithms—extract comprehensive material information from raw Barkhausen signals. Deep learning approaches demonstrate superior performance for automated material classification and property prediction compared to traditional statistical methods. Industrial applications span manufacturing quality control, structural health monitoring, railway infrastructure assessment, and predictive maintenance strategies. Key achievements include establishing quantitative correlations between material properties and stress states, with measurement uncertainties of ±15–20 MPa for stress and ±20 HV for hardness. Emerging challenges include standardization imperatives, characterization of advanced materials, machine learning robustness, and autonomous system integration. Future developments prioritizing international standards, physics-informed neural networks, multimodal sensor fusion, and wireless monitoring networks will accelerate industrial adoption supporting safe, efficient engineering practice across diverse sectors.

A method for the monitoring of residual stress distribution in steels has been developed based on non-destructive surface magnetic permeability measurements. In order to investigate the potential utilization of the magnetic method in evaluating residual stresses, the magnetic calibration curves of various ferromagnetic alloyed steels’ grade (AISI 4140, TRIP and Duplex) were examined. X-Ray diffraction technique was used for determining surface residual stress values. The overall measurement results have shown that the residual stress determined by the magnetic method was in good agreement with the diffraction results. Further experimental investigations are required to validate the preliminary results and to verify the presence of a unique normalized magnetic stress calibration curve.

High-strength naval steel panels were coated by spraying with five commercial antifouling paints. The first set of coated specimens was subjected to electrochemical measurements and the anticorrosion properties of the paints were evaluated under controlled laboratory conditions. A second series of coated samples was statically exposed for nine months in thirteen different harbors, located in the Mediterranean Sea and the Atlantic Ocean, where their in-field antifouling efficiency was determined. The corrosion performance obtained by the electrochemical measurements provides predictions that best match the fouling protection observed at the field sites. The results indicate that the corrosion’s resistivity values determined in the laboratory were in a good agreement with the fouling level observed by examining the sea samples. The reported complementary data show that the laboratory measurements are representative of the sea-field conditions and confirm the originality of the proposed approach, which might lead to the development of innovative low-drag antifouling coatings for the hulls of ships, vessels, and speed crafts.

This paper describes the development of a new magnetometer calibration device using an active magnetic field compensation technique based on the base quantity of time rather than secondary standard field measurements. The proposed arrangement can be used as a laboratory calibration device that monitors and compensates the ambient dc magnetic field in a magnetically quiet environment. Furthermore, it can be developed to serve as a laboratory primary standard since it is based on the measurement of a base quantity, such as time. The proposed technique is based on the fluxgate magnetization principle and the measurement of the time difference between the two successive output pulses. The laboratory arrangement consists of a long solenoid for 1-D applications, which may be extended to 2-D and 3-D using Helmholtz coils, and a microcontroller for fast signal processing operations, which evaluate and compensate the detected ambient magnetic field using a closed-loop control algorithm. The proposed arrangement is used to obtain the calibration curves of a commercial Hall and a custom-made fluxgate sensor.

This work presents a comprehensive evaluation of corrosion progression in DH36 naval steel through the integration of electrochemical impedance spectroscopy (EIS), weight loss, scanning electron microscopy (SEM), and advanced magnetic non-destructive techniques under artificial seawater (ASW, ASTM D1141) and natural marine conditions. Quantitative correlations are established between corrosion layer growth, electrochemical parameters, and magnetic permeability, demonstrating the magnetic sensor’s capacity for the real-time, non-invasive assessment of marine steel degradation. Laboratory exposures reveal a rapid initial corrosion phase with the formation of lepidocrocite and goethite, followed by the densification of the corrosion product layer and a pronounced decline in corrosion rate, ultimately governed by diffusion-controlled kinetics. Notably, changes in magnetic permeability closely track both the thickening of non-magnetic corrosion products and microstructural deterioration, with declining μmax and increased hysteresis widths (FWHM) sensitively indicating evolving surface conditions. A direct comparison with in situ marine immersion at Rafina confirms that the evolution of corrosion morphology and the corresponding magnetic response are further modulated by biofilm development, which exacerbates the attenuation of measured surface permeability and introduces greater variability linked to biological activity. These findings underscore the robustness and diagnostic potential of magnetic non-destructive sensors for the predictive, condition-based monitoring of naval steels, bridging laboratory-controlled observations and complex real-world environments with high quantitative fidelity to corrosion kinetics, phase evolution, and microstructural transformations, thus guiding the strategic deployment of protection and maintenance regimens for naval fleet integrity.