FINE DEFECT DETECTION BY

EDDY CURRENT ARRAY.

PATRICK CABANIS
Senior Application Specialist NDT Level 3.
OLYMPUS INDUSTRIAL SYSTEMS EUROPA
patrick.cabanis@olympus-europa.com
tel : 33 1 45 60 68 40
mobile :+ 33 6 77 88 46 00
 CONTEXT FINE DEFECT

INSPECTION
ECA SOLUTION

WE MUST NEED TO DETECT THE DEFECT

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PRESENTATION PLAN
Omniscan ECA
Eddy current History and Theory
Eddy current array (ECA) technology
ECA equipment
High-frequency applications
Low-frequency applications

Nortec N600

Nortec N2000D

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History

Yesterday

Today

Tomorow

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Historique théorie

e = ∆Φ ∆t or Φ = Li donc ∆Φ = L ∆i
J x = J 0e − (x πµσf )
sin 2πft − x πµσf ( )
θ = 57
δ
x J =100⋅ exp − x ( δ) δ = 50
ρ
fµ
= r
=
U 2 = R2I 2 + L2ω 2 I 2 = ( R2 + L2ω 2 )I 2

D'où U = I R 2 + L2ω 2

Donc Z = U / I = R 2 + L2ω 2
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CONTEXT
Two elements disturbs the EC
The Lift off
The followed profile

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Lift-off effects on the probe sensitivity
The graphic shows the
normalized defect signal for
different lift-off conditions.
– For a 2 mm coil.
– For a 5 mm coil.
– For a 15 mm coil.
1.0
The signal is maximized when 0.8

Normalized defect signal

in contact with the part and
0.6
decreases with lift-off.
0.4
For a small coil, a lift-off of only
0.3
1 mm decreases the defect
signal to 25 % of its maximum
0.2
signal (when the lift-off is 0
mm).
0.1
0.0 1.0 2.0 3.0 4.0 5.0 6.0
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Lift-off distance (mm)
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Eddy Current Array – Basic Concept

In ECA, several eddy current

coils are placed in the same
probe assembly to:
– Allows larger coverage in a
single probe pass while
maintaining a high
resolution.
– Reduces the need for
complex robotics to move
the probe; a simple manual
scan is often enough.
– Improves flaw detection and
sizing with C-scan imaging.
– Inspect complex shape with
a probe made with to the
profile of the parts

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What is Eddy Current Array ?

Eddy current array

technology is the ability to
electronically drive several
eddy current sensors .

Data acquisition is performed

by multiplexing the eddy
current sensors .

Most eddy current probes

and techniques for flaw
detection can be used.

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Equipment

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ECA – Signal Representation
The C-scan can only show one component of the signal at
a time (X or Y component).
In the example below, the C-scan shows the vertical
component of the signal (Y axis) and this is why the lift-off,
which has been rotated horizontally, is almost not visible.

Defects

Lift-off signal

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Fine defect detection application
Tubes inspection
Gaz Turbine
Pipe
Dovetail
Train axis
Doubler edge
FSW (weld)
Blade

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BOEING 757 LAP SPLICE C-SCAN INSPECTION
Calibration Sample
inspection procedure to Part 6, 53-30-06.

NDT 588
5/32 and 6/32 rivet hole

Typical cross-section

EDM notch:
length .1 in from rivet shank
Thickness: through 1st skin

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Results

Good rivet hole Rivet hole with notch

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Method of ECA High-frequency inspection of the
lower skin for scribe mark

0.06 in to 1 in
to the edge

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Method of ECA high-frequency inspection of the
lower skin for scribe mark

One pass inspection

Notch detection from 0.06 to
1 in to the edge
Reliable inspection (100% full
coverage)
Easy interpretation on Cscan
No need for encoder
General procedure
film

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Engine disk dovetail slot Inspection

movie

ECA probe
32 elements
(2 x 16)

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Engine disk dovetail slot Inspection
Inspection in the maintenance shop
CFM56
Disk CHP D1
GE-90
GE-115
GP-7200
Sam-146

Tooling

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GE90 : ECA HF Inspection method
Cscan with EDM notches and calibration notches in the
calibration sample

EDM DEFECTS

LIGNES de CALIBATION

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Gas turbin ECA Flexible probe and holder

Special probe holder

Flex probe 32 elements

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Gaz turbin
•One pass inspection
•Notch detection from 0.06 to 1
in to the edge
•Reliable inspection (100% full
coverage)
•Easy interpretation on Cscan
•No need for encoder

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TUBE INSPECTION

Eca flex probe kit

Custom probe holder

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TUBE INSPECTION
Reference standard

VIDEO

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ECA - Flexible Probe
Flex probe FBB-051-500-032
Frequency 50KHz to 4MHz

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ECA - Flexible Probe
Two mode
Absolut
Need a encoder

Reflection
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ECA –Surface Pipe inspection

Defect orientation

Scan direction

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 ECA –Surface Pipe inspection
Result on standard
Horizontal 45 degre vertical

Good area

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Boeing 737 Skin crack detection at doubler edge
The inspectionreferenced in the NTM737 NDT 53-30-25 part 6, is
done from the outside and crack as small as 0.240” long by 0.010”
deep located at the edge of the doubler need to be detected.
Benefits:
– Simple manual inspection
– C-Scan allows easy location
of the doubler edge for fast
and simple detection of the
initiating cracks
– Better reliability
– Better reproducibility
– Time saving:
» Normal time: 200 hours
» With ECA: 48 hour Inside of
the skin
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Boeing 737 Skin crack detection at doubler edge
The user can see very well the doubler edge represented by the light to
dark green color transition.

Fastener will show up

in light green.

Defect above the

rejection level are in
red like shown in this
picture

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Weld Inspection

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Notches identification on the C-Scan view

length: 6mm, depth: 1,2mm, width: 0.2mm

#1

#1

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Conclusions about ECA

Deployed in the field for many applications

Referenced in procedures for aircraft and engine maintenance
Fast (large area)
Reliable (Full coverage and Cscan imaging)
Many ECA standard probes
Omniscan ECA module compatible with Bondmaster C-Scan.
More to come…

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BEST REGARDS