Middle Technical University

Engineering Technical College-Baghdad

Department of Materials Engineering

Engineering Inspection
Postgraduate Study
Prof. Dr Nasri S. M. Namer

Eddy Current Inspection

Name of the student

Zainab Sabah
Introduction:
Eddy current inspection is based on electromagnetic induction, in which
alternating current generates a changing magnetic field that induces eddy currents
in a conductor when brought into close proximity.
 Other Electromagnetic Nondestructive Testing Methods:
• Eddy current inspection is one of several electromagnetic nondestructive testing
(NDT) procedures, including Remote Field Testing (RFT), Flux Leakage, and
Barkhausen Noise.
 Benefits and Drawbacks:
• Benefits include versatility for diverse inspections, sensitivity to minor flaws,
mobility, minimal part preparation, and applicability beyond flaw detection.
• Limitations: Limited to conductive materials, requires an accessible surface,
requires competence, is sensitive to surface polish, relies on reference standards,
has a limited depth of penetration, and has limitations in identifying specific
delaminations.

The Basis for Eddy Current Inspection:

Eddy Current Inspection Process:
 Eddy Current Generation:
• A magnetic field is produced when a coil probe with alternating current is used to
induce eddy currents in a material.
 Information Extraction:
• Variations in the inductive reactance and coil resistance provide information
about the conductivity, permeability, thickness, and existence of defects in the
material.
 Phase Relationships and Liftoff:
• Liftoff, the distance between the material and the coil, affects mutual inductance
and is measured for things like the thickness of nonconductive coatings.
• Resistance and inductive reactance are involved in phase relationships, which are
essential to comprehending impedance in eddy current inspection.
Eddy Current Inspection System:
• The system involves a coil probe where resistance and inductive reactance
influence the circuit’s total impedance.
• Capacitive reactance is typically negligible in eddy current probes.
 Vector Representation and Impedance Calculation:
• A vector diagram illustrates resistance and inductive reactance, representing
impedance amplitude.
• Impedance is calculated using a specific equation, considering inductive
reactance and, if present, capacitive reactance.
 Impedance and Phase Relationship:
• Ohm’s Law is adapted for circuits with inductive or capacitive reactance, stating
that current is proportional to voltage divided by impedance.
• An applet allows users to observe impedance effects on current and voltage, with
variations in inductance and resistance influencing impedance.
 Eddy Currents and Skin Effect:
• Eddy currents, induced perpendicular to magnetic flux, travel parallel to the
coil’s winding.
• Concentrating near the surface, their strength decreases exponentially with depth,
a phenomenon known as the skin effect.
 Factors Influencing Penetration Depth:
• Penetration depth is affected by excitation current frequency, electrical
conductivity, and magnetic permeability.
• Higher frequency, conductivity, and permeability result in reduced penetration
depth.
 Standard Penetration Depth (δ):
• δ is the depth at which eddy current density decreases to around 37% of the
surface density.
• Influenced by excitation conditions, it’s crucial for flaw detection or conductivity
measurements.
  Eddy Current Sensitivity and Applet:
• Sensitivity relies on eddy current density at defect sites, with frequency selection
crucial for strong indications.
• The applet illustrates eddy current density changes, calculates standard
penetration depth, and includes relative permeability input.
 Phase Lag in Eddy Current Testing:
• Phase lag, a time shift in eddy current response with depth, aids in defect depth
estimation.
• Calculated phase lag is crucial for understanding eddy current signal
characteristics, especially with reference to the standard penetration depth.
 Standard Penetration Depth and Reference Signals:
• Standard penetration depth influences phase lag calculations, with one and two
standard penetration depths having specific phase lags.
• Reference signals, like the liftoff signal, are vital for interpreting eddy current
signals and estimating defect depth.

 Eddy Current Instruments:

1. Common Display Types:

• Includes Analog Meter with a traditional needle, Digital Readout for numerical
information, Impedance Plane for data representation, and Time versus Signal
Amplitude for displaying information over time.
2. Basic Instrument Components:

• Comprises an alternating current source, a connected coil of wire, and a

measurement device (voltmeter or ammeter).
  Probes - Mode of Operation
1. Absolute Probes:
• Utilizes a single coil for both generating and sensing eddy currents, altering
inductive reactance for various measurements, including flaw detection and
conductivity. Includes a fixed “air-loaded” reference coil for compensation.
2. Differential Probes:
• Dual-coil configuration with coils wound in opposition, providing a differential
signal over defects for enhanced sensitivity. Highly sensitive to defects, less
affected by gradual variations, reducing probe wobble signals but challenging
interpretation.
3. Reflection Probes:
• Two-coil design similar to differential probes, allowing separate optimization of
driver and pickup coils. Offers advantages in customization for specific purposes
and improved sensitivity.
4. Hybrid Probes:
• Split D Differential Probe with a driver coil surrounding two D-shaped sensing
coils, operating in reflection mode and highly sensitive to surface cracks. Custom-
designed for specific inspection applications, showcasing versatility with a
conventional coil for eddy current generation and a different sensor (e.g., Hall
effect) for magnetic flux detection.

 Probe- Configuration
 1. Surface Probes:
• Handheld devices for direct contact with the test surface, featuring fine wire
coils in tailored protective housing. Pancake coils detect perpendicular
discontinuities, while wide surface coils scan large areas, providing deeper
penetration but limited small defect detection.
2. Bolt Hole Probes:
• Specialized for Bolt-Hole Scanners, designed for inspecting bolt holes with a
surface coil inside a housing matching the hole’s diameter. Inserted into the hole,
rotated by a scanner for inspection.
3. ID or Bobbin Probes:
• Used in hollow products like pipes for internal inspections, featuring a housing
centering the probe and coils wound around the probe’s circumference. Enables
simultaneous inspection of the entire test object.
4. OD or Encircling Coils:
• OD probes, or encircling coils, inspect from the outside, frequently used for solid
products like bars. Coils encircle the material for examination.

 Probe- shielding and loading:

1. Probe shielding and loading focus on limiting magnetic field spread, aiding in
signal interpretation.
2. Shielding prevents interference from non-relevant features and minimizes
impact from fasteners.
3. Ferrite cores in probe loading enhance sensitivity, concentrate the magnetic
field, and reduce wobble/lift-off effects.

 Reference standards
 1. Crucial Setup Importance:
• Reference standards are vital in eddy current testing for accurate equipment
setup, considering the signal’s sensitivity to various variables.
2. Enhanced Comparison Utility:
• Comparing results from an unknown object to well-characterized features in a
similar object improves the utility of eddy current testing, facilitating accurate
defect assessment.
3. Defect Recognition and Simulation:
• Reference standards, matching material properties, aid in producing recognizable
signals from defects, allowing estimation of defect sizes. Intentional defects
simulate actual damage, commonly using features like narrow notches and drilled
holes.

 Signal Filtering
1. Purpose:
• Signal filtering in eddy current testing serves the crucial purpose of enhancing
the visibility of defect signals, contributing to more accurate flaw detection.
2. Settings Significance:
• The correct configuration of filter settings is paramount, as improper adjustments
can distort or eliminate defect signals, impacting the reliability of the inspection
process.
3. Filter Types and Characteristics:
• Standard filters, including High Pass Filter (HPF), Low Pass Filter (LPF), and
occasionally Band Pass Filter (BPF), are utilized. HPF allows high frequencies,
filtering out low frequencies, while LPF allows low frequencies, filtering out high
frequencies. The chosen filter settings directly impact the appearance of the signal,
and their misuse can result in a reduction of defect signal strength

Applications:
  Surface Breaking Cracks
1. Effective Surface Defect Detection:
• Eddy current inspection excels in detecting surface and near-surface defects
when the defect’s location and orientation are known, with weaker eddy currents
indicating cracks.
2. Key Steps for Successful Detection:
• Successful detection involves understanding defect characteristics, choosing a
fitting probe, selecting an appropriate frequency, and setting up reference
specimens for accurate assessment.

 Surface Crack Detection Using Sliding Probes

1. Efficient Fastener Hole Inspection:
• Sliding probes efficiently inspect numerous fastener holes through a sliding
motion, ensuring a thorough examination.
2. Reflection Mode Operation:
• Typically operated in reflection mode, sliding probes use a driver coil to induce
eddy currents, with a separate receiving coil detecting the response.
3. Unidirectional and Comprehensive Detection:
• Sliding probes excel in unidirectional defect detection, marked by a detection
line. For a complete inspection, two orthogonal scans at 90 degrees are required.
 Probe Types
1. Fixed Sliding Probes for Specific Applications:
• Suitable for thinner materials, fixed sliding probes are ideal for detecting
longitudinal surface or subsurface cracks, particularly in lap joints, with a
maximum penetration of about 1/8 inch.
3. Adjustable Sliding Probes for Versatile Use:
• Well-suited for thick multi-layer structures, adjustable sliding probes, with a
maximum penetration of about 3/4 inch, offer versatility by using spacers for
penetration adjustment, making them suitable for various scanning angles.
4. Spacer Thickness Adjustment and Calibration Standards:
• Spacer thickness adjustment in sliding probes ranges from close surface
inspections to deep penetration, affecting tolerances and gain. Calibration
standards for sliding probes typically involve aluminum plates fastened in a lap
joint configuration, emphasizing matching with aircraft components in material
type and alloy
 Inspection Variables
1. Liftoff Signal Adjustment:
• Liftoff is adjusted to be relatively horizontal, with a curved signal line that may
need upward adjustment for sharp curves.
2. Scan Patterns:
• Centralized scanning over fastener heads is used for axis cracks, while a 90-
degree scan is employed for transverse cracks.
3. Signal Interpretation:
• Vertical movement over a crack with amplitude indicating crack length; dot
movement varies based on location and length. Presence of two cracks influences
dot movement. 4. Probe Scan Deviation:
• Probes designed for narrow indication; deviation from the center affects crack
indication location and amplitude.
4. Crack Angle Deviation:
• Fixed and adjustable sliding probes detect cracks up to 30 degrees off angle, with
a reduction in indication for non-90-degree angles.
5. Electrical Contact:
• New fasteners or standards may show smaller indications; good electrical contact
can make indications disappear. Painting holes before fastener installation is
recommended to prevent this effect