Eddy Current Array Tutorial
Eddy Current Array Tutorial
1.0 Introduction
1.1 General Introduction to Eddy Current (EC) Testing
1.2 History of Eddy Current Testing
1.3 Equipment
Eddy current (EC) testing is a no contact method for the inspection of metallic
parts. Eddy currents are fields of alternating magnetic current that are created
when an alternating electric current is passed through one or more coils in a
probe assembly. When the probe is linked with the part under inspection, the
alternating magnetic field induces eddy currents in the test part. Discontinuities
or property variations in the test part change the flow of the eddy current and
are detected by the probe in order to make material thickness measurements or
to detect defects such as cracks and corrosion.
Over the years, probe technology and data processing have advanced to the
point where eddy current testing is recognized as being fast, simple, and
accurate. The technology is now widely used in the aerospace, automotive,
petrochemical, and power generation industries for the detection of surface or
near-surface defects in materials such as aluminum, stainless steel, copper,
titanium, brass, Inconel, and even carbon steel (surface defects only).
With thousands of units used throughout the world, the R/D Tech OmniScan
MX is Olympus NDT's most successful modular and portable test unit. The
OmniScan family includes the innovative phased array and eddy current
array test units, as well as the eddy current and conventional ultrasound
modules, all designed to meet the most demanding requirements of NDT.
The OmniScan MX offers a high acquisition rate and powerful software
features in a portable, modular mainframe to efficiently perform manual and
automated inspection.
The OmniScan ECA test configuration supports 32 sensor coils (up to 64
with an external multiplexer) working in bridge or transmit-receive mode.
The operating frequency ranges from 20 Hz to 6 MHz with the option of
using multiple frequencies in the same acquisition.
2.0 What is Eddy Current Array (ECA)
Testing?
Eddy current array and conventional eddy current technology share the
same basic principle. Alternating current injected into a coil creates a
magnetic field (in blue). When the coil is placed over a conductive part,
opposed alternating currents (eddy currents, in red) are generated. Defects
in the part disturb the path of the eddy currents (in yellow). This disturbance
can be measured by the coil.
Where:
d = Standard depth of penetration (mm)
p = 3.14
= Test frequency (Hz)
m = Magnetic permeability (H/mm)
s = Electrical conductivity (% IACS)
+ Formula poster
2.3 Multiplexing
Multiplexing is the process by which multiple analog message signals are
combined into one digital signal on a shared medium. When eddy current
array data is multiplexed, the individual eddy current coils are excited at
different times, allowing the system to excite all of the coils in the probe
without ever exciting any two adjacent coils at the same time. An
undesirable effect known as mutual inductance (magnetic coupling between
coils in close proximity) is minimized with the use of an internal multiplexing
system to carefully program the exact time that each coil is excited to
transmit its eddy current signal. The signals are then reassembled before
being displayed as an image. In addition to the enhanced imaging
capabilities of multiplexed data, multiplexing allows any individual coil (data)
channel to be analyzed after inspection. Multiplexing allows an increased
channel resolution, increased coil sensitivity (through the reduction of
mutual inductance), and a reduced noise level. This ultimately leads to an
improved signal-to-noise ratio.
3.1 EC Probes
Olympus NDT`s standard R/D Tech eddy current probes are available in
different configurations:
Probes used to perform eddy current inspections are made with a copper
wire wound to form a coil. The coil shape can vary to better suit specific
applications.
Olympus NDT manufactures R/D Tech ECA probes for a wide range of
applications. Probes can be designed to detect a specific type of flaw or to
follow the shape of the part being inspected. Standard designs are available
to detect defects such as cracks and pitting, and subsurface defects like
cracks in multilayer structures as well as corrosion.
3.3 Probes Design
Surface
Surface probes are made with coils designed to be driven at relatively high
frequencies (typically 50 kHz to 500 kHz). Using higher frequencies results
in less penetration of the eddy current field into the test part, allowing the
area directly below the surface of the part to be inspected. In addition, the
higher frequencies provide a higher resolution for the detection of smaller
defects.
Subsurface
Where:
n = Number of channels
r = Resolution (also depends on the coil configuration)
C = Coverage
Probe Structure
Fig. 1
It sometimes creates a problem when the probe inductance value is not
close enough to the value of the balance coil, and the instrument does not
balance correctly. This happens more often when they are not made by the
same manufacturer. The result is poor performance (noisy or insensitive) or
no response at all (signal saturation).
Fig. 2
In this arrangement, the same coil produces the eddy currents and detects
the impedance changes caused by the defects (or any other variables).
Almost all instruments are able to operate with this type of coil arrangement.
Fig. 4
Bridge or reflection
This is a common question asked by those involved in trying to select the
best probe for an inspection. The answer is "It depends." Let us consider
both systems.
Gain. Reflection probes will give a higher gain, particularly if they are
"tuned" to a specific frequency, but normally the difference is on average
about 6 dB. It is true that t his doubles the signal, but if you consider that
the instruments are able to give this increase of gain easily, it is not so
important. Nevertheless, in critical applications this increase is very
welcomed.
Frequency range. Reflection probes do not need to balance the driver to the
pickup coils. This means that they will give a wider frequency range. As long
as the driver produces eddy currents, the pickup will detect them and some
signal will be displayed. This may not provide good information at certain
frequencies, but the probe is still working!
Bridge type probes used to give a limited frequency span in the older
instruments, as these had to balance an electrical bridge using its other
arms (X and R controls). In modern instruments, the bridge is normally
formed with fixed precision resistors, or a fixed transformer inside it. The
signals detected in this manner are electronically processed without any
"mechanical" adjustments, and this means a greater ability to balance over a
wider frequency range.
Drift: Probe drift is mostly caused by temperature change in the coils. This
may be caused by varying ambient temperature, or the heat produced by
the oscillator current, or both. There are design parameters that can be
optimized to reduce drift, such as wire diameter and ferrite selection, but
reflection probes are normally a good choice to avoid this problem even
more.
In a reflection probe, the driver current does not flow through the pickup
coils; in fact, the magnetic field received back from the specimen is normally
much smaller and, consequently, the current flowing in the pickups is also
reduced. Most probe types (pencil, spot, ring, bolt hole, etc.) can be made
as bridge or reflection. Keep in mind that a reflection probe is almost
invariably more difficult to manufacture and therefore more expensive.
Adapters
To connect a probe with a connector different from the type used in the
instrument, it is necessary to use an adapter. An adapter consists of two
different connectors joined and wired to match the inputs and outputs as
necessary. It is normally housed in a short body that can be positioned at
the instrument's input. Sometimes, it is also possible to have a "cable
adapter," which is made to match a connector located at the probe body.
Depending on the instrument's wiring, it may be possible to have a single
adapter for both bridge and reflection. In other cases, it is necessary to have
two separate adapters or use a switchable type.
3.5 Custom Probes
Each individual eddy current coil in the probe produces a signal relative to
the phase and amplitude of the structure below it. This data is referenced to
an encoded position and time and represented graphically as a C-scan image.
For rivet applications, the eddy current coils that pass over a defective rivet
generate a unique signal response. For coils that are affected by a crack
initiating from the rivet hole, an amplitude change is represented in the C-
Scan display. For coils that detect no change, the color representation
remains constant in the C-scan display.
4.2 Corrosion Detection
Color palettes play a very important role in the imaging of eddy current
array data. Color palettes determine how the data will be displayed. Color
palettes are often linked to the amplitude of the eddy current signals;
however, when required, color palettes can also be linked to the phase angle
of the signals. Color palettes range from a gradual rainbow palette to a
precise, two-color "go/no-go" palette. Black and white palettes are also often
used.
Eddy Current Probes and Application Guide
Introduction
This paper is intended to provide information to help the user in selecting
the right E.C. probe(s) for a given inspection. Using this data, best results
will be achieved by optimizing the frequency and choosing a suitable
instrument.
2. Typical applications
3. New developents
1. COIL TYPES AVAILABLE
The early E.C. coils generally had either no core ( air core) or a ferrite center
core only. Meter instruments were used almost exclusively and sensitivity
was comparatively low, but in most cases adequate. Many inspections are
still being done using this type of comparatively large, low sensitivity coils.
A very widely used type coil is a 100 kHz with a diameter of .1" (2.5mm)
to .2" (5mm) that fits most bridge type older meter instruments (Figure 1).
The sensitivity is acceptable for long cracks that exceed the probe diameter
by a factor of approximately 2, as the field is considerably larger than the
coil size. This also produces a large edge effect.
Figure 1
The older probes were normally calibrated using an infinitely long (to the
coil) notch, .040" (1mm)or ,020" (.5mm), and their sensitivity will drop off
rapidly with shorter notches. The new probes maintain their sensitivity with
a notch approximately the internal diameter of the ferrite shield and will still
detect a shorter one.
Even meter instruments benefit from this type of coil, but probing speed is
limited as the needle needs time to respond. Display-type instruments allow
for much faster scanning. Larger surface type probes respond in a similar
way to the above. Shielding produces similar improvements when looking for
subsurface cracks or corrosion.
Figure 2
Differential coils have the attraction of built-in lift-off compensation. This has
made them useful for many applications.
The older types of coils had no ferrite shield and they were built just by
placing two coils side-by-side (Figure 3). Later types added individual
shields (Figure 4), but the greatest improvement to the sensitivity was
achieved when both coils were placed within a common shield (Figure 5).
Differential type probes are mostly used in small sizes for surface crack
detection only.
Figure 3
Figure 4
Figure 5
Normal scan direction is as shown (Figure 6), giving the typical display
presentation. The double indication is, in fact helpful, as it doubles the size
of the defect in the screen (Figure 7).
Figure 6
Figure 7
The probe body has a line to show the normal scan direction. These coils can
be fitted in pencil, bore hole or molded probes to fit almost any shape.
Figure 9
Figure 10
Reflection probes are also used on special probe designs that rely on the
transmit-receive principle to create a certain size/shape sensitive area (like
the sliding type probes).
2. TYPICAL APPLICATIONS
Surface Cracks
Normal operating frequency:
Probes available
Pencil types - Absolute or differential . Shielded or unshielded
Surface types - Larger diameter probes can sometimes be used
Sliding probes - For cracks starting under fastener heads
Wheel probes - For bead seat radius, molded
Subsurface Cracks
Frequency must be low enough to penetrate the required depth (use slide
rule or graph attached). Minimum usable frequency is 100 HZ. 3
Probes Available :
Surface probes - Normally absolute shielded. Diameter can be as large as
spacing between fasteners
Encircling probes - Give better penetration. I.D. must be close to fastener
head diameter
Sliding probes - For fast directional inspection (reflection)
Probes available:
Absolute - (preferably shielded) in hand operated or scanner versions.
Differential - (shielded or unshielded) - hand operated and scanner versions
Coatings
Conductivity
Corrosion/Thickness
The problem was to inspect aluminum angle for cracks in the opposite side
(not accesible) in one pass and with high sensitivity. In order to cover the
required width, the coil has a lift-off of about .1" (2.5mm).
Lift-off variations and edge effects could be identified as such on the display.
Figure 11
Thin Probe
To inspect between two lugs spaced less than .080" (2mm) apart, the probe
had to be shielded and be completely unsensitive at the back (Figure 12).
Using stainless steel for strength, a shielded coil was placed at the tip . A
nylon handle placed at 45 allowed for better access. Such a flat coil proved
very sensitive to small cracks both in steel and aluminum.
Figure 12
The sensitive area of this type of sliding probe is the distance between the
driver and pick-up sections. The lens is therefore adjusted to the required
width of inspection (Figure 13).
Figure 13
When scanning along a line of fasteners, this distance can also be optimized
for best discrimination between the fastener indication and the defect . With
no lens present, the probe is at its highest gain, but because of this it also
gives a large indication for the fastener (Figure 14).
Figure 14
Figure 15
Sometimes standard types of EC probes are not able to give a large enough
indication for the defect. This may be due to geometry, defect size or a
higher than normal lift-off .
To achieve the extra gain, it is often possible to position a very small hybrid
amplifier circuit within the probe body or in a separate small box close to it
(Figure 17). This pre-amplifier can be tailored to a specific inspection if
needed.
Figure 17
Eddy current array probes can replace one axis of a two-axis scan and offer greater
flexibility in the eddy current setup.
Eddy current array probe and tooling that requires one pass to inspect the dovetail
The use of a C-scan image increases the reliability of the inspection because it
guarantees full coverage of the surface inspected.
By Andre Lamarre
Probes can be designed to detect a specific type of flaw or to follow the shape of
the part being inspected. Standard designs are available to detect surface defects
(such as cracks and pitting) and subsurface defects (such as cracks in multilayer
structures and corrosion).
Imaging
Representation of the data plays a major role in the use of eddy current array. The
Omniscan ECA allows the use of C-scan imaging, which is a color-coded two-
dimensional mapping of the inspected surface. The data from each individual coil
are recorded so the impedance plane is always available. The following image
demonstrates the principle of the image representation. The ECA probe moves
over a flaw and each coil produces an EC signal as shown. The C-scan
representation is the color coded image of the amplitude of the signal. The X axis
represents the movement axis while the Y axis represents the probe axis. So, the
C-scan gives the position of the flaw as well as its size.
Aircraft engines are submitted to a lot of stress. Rupture of rotating parts can
cause catastrophic failure of the engine and the aircraft. The engine disk dovetails
or the blade attachment, being submitted to high stress, are inspected to make
sure there is no crack initiation site within the area of the dovetail. Conventional
eddy current are mainly used for this application. The operator is required to use a
tooling that holds a conventional EC probe. The operator scans the probe along
the dovetail length and index position of the probe approximately 40 times to
assure full coverage. The operator also has to constantly monitor the screen of the
conventional eddy current instrument. This method is long, tedious, and causes
fatigue to the operator.
An eddy current array method was developed specifically for this application
resulting in a significant time-savings. A new eddy current array was developed
composed of 32 sensors shaped in a way to fit the dovetail contour. This probe is
attached to a holder designed for the application. The operator simply puts the
probe in place and pushes it only one time through the dovetail. This one-pass
inspection assures full-coverage of the dovetail areas. The C-scan mapping
displayed on the instrument also helps the operator to localize position of a defect
and to size it. The inspection time is reduced dramatically while the reliability of
the inspection is increased resulting in an important gain for the inspectors.
Conclusion
Eddy current array is a new technology that is used successfully in many different
fields. Portable and easy to operate, the Omniscan ECA makes the use of EC
arrays easy. The main advantages of the ECA technology are increasing inspection
speed, better reliability due to C-scan imaging, and better reproducibility and
probability of detection due to the coverage of the whole surface assured by the
array.