The magnetic properties of four carbon steels were evaluated using an electromagnetic sensor and correlated with their microstructures. Their composition, microstructure features (such as ferrite volume fraction, grain size, inclusions, etc), and hardness were compared with their saturated magnetic flux density, retentivity, and coercivity. The four steel rods used in this study were hot-rolled AISI 1010, AISI 1018, AISI 1045, and AISI 1045-high manganese/"stress proof." The results show that microstructures have a notable effect on the magnetic properties of the steels. In addition, the effect of variations in cross-section area of the steel rods on the magnetic response was investigated. The steel rods diameters were systematically reduced by machining and then magnetically evaluated. Consistent relationships between metallurgical characteristics of the structural carbon steels and their magnetic properties measured with the electromagnetic sensor were obtained. In addition, the sensor was found to be able to detect changes in magnetic properties due to variations in cross-section area. These results reveal that the electromagnetic sensor has the potential to be used as a reliable nondestructive tool to detect and monitor microstructural and morphological changes occurring during the different stages of steel manufacturing or alterations caused by a degradation mechanism. © 2007 ASM International.