The aim of this work is to implement a new nondestructive testing (NDT) method based on the metal magnetic memory (MMM) effect into comprehensive diagnostic approach for power-line connectors, which is of great practical importance. Essence of this method lies in detection of stress concentration zones (SCZs) in material of the considered element during its operation (before micro-cracks and fracture occurs). If to compare with the traditional NDT methods, which indicate SCZs after the failure (post factum), this method provides major progress in the field of NDT. In this paper an approach of connection of numerical structural simulation (static and dynamic) with MMM-based testing method is also proposed. SCZs in power-line mechanical connector were evaluated and dynamic analysis of a complete power line, which included the analyzed connector, was carried out by means of MSC.ADAMS. Uniqueness of this analysis consist in integration of FEM analysis, MSC.ADAMS multibody system analysis (for testing of working conditions in advance - during virtual prototyping) and verification using MMM method. This hybrid approach enables to accomplish diagnostic analysis of selected construction elements and provides the possibility to take into consideration actual working conditions (e.g. vibrations) of the element. Proposed diagnostics method can substantially increase operational safety of electrical connectors and lines.
