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Eddy Current Testing-Basic

Training

Eddy Current NDT is a technique that


can test metals for flaws either during
the manufacturing process or as a
consequence of age or environment.
It is a highly sensitive technique and
completely Non-Destructive. (No
damage to test object)
It is quick, safe and cost-effective to
use.

Eddy Current Testing-Basic


Training
Eddy Current Theory
When a voltage is applied to a circuit
containing resistive elements,
current flows according to ohms
law
I=V/R or V=I.R

Eddy Current Testing-Basic


Training
Eddy Current Theory
If a circuit consists of more than one element,
the overall voltages, resistance and
capacitance can be calculated as follows

V1=I.R1
V2=I.R2
Vtot = V1+V2=I.R1+I.R2=I(R1+R2)=I.Rtot

Eddy Current Testing-Basic


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Theory Electromagnetic Induction
Current passing through a coil
creates a magnetic field

A moving magnetic field would


induce a voltage in an electrical
conductor

Eddy Current Testing-Basic


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The meter needle will deflect one


way when current is applied and
then back the other way when it is
removed
A voltage is only induced when the
magnetic field is changing.

Eddy Current Testing-Basic


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A voltage is also induced in the


first winding, apposing the change
in the applied voltage
Inductance is defined as
Induced Voltage = L di/dt

Eddy Current Testing-Basic


Training

If an AC current flows through an


inductor,the voltage across the inductor
will be at maximum when the rate of
change of current is greatest.
For a sinusoidal wave, this is at the point
where the actual current is zero

Eddy Current Testing-Basic


Training

The voltage applied to an inductor


reaches its maximum value a
quarter cycle before the current
does

The voltage leads the current by


90 degrees

Eddy Current Testing-Basic


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The value of the voltage and


current can be calculated as follows
V = I.XL

XL = inductive reactance (XL=2 pi f L)


F = frequency in Hz

Eddy Current Testing-Basic


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Current flow in AC Circuits Impedance

Same basic principle as in DC circuits, but


the maximum voltage across the
resistance coincides with the zero voltage
across the inductor and vice versa

Eddy Current Testing-Basic


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Current flow in AC circuits Impedance

Eddy Current Testing-Basic


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We can represent this graphically


using a vector diagram

Eddy Current Testing-Basic


Training
Eddy Current Theory Testing
When an AC current flows in a coil in
close proximity to a conducting
surface, the magnetic field of the
coil will induce circulating(eddy)
currents in that surface.
The magnitude and phase of the
eddy currents will affect the loading
on the coil and thus its impedance

Eddy Current Testing-Basic


Training

Eddy Current Theory - Testing

Eddy Current Testing-Basic


Training

Eddy Current Theory - testing

Eddy Current Testing-Basic


Training

A deep crack in the surface below


the coil will interrupt or reduce the
eddy current flow, thus decreasing
the loading of the coil and
increasing its effective impedence
By monitoring the voltage across
the coil we can detect changes in
the test material

Eddy Current Testing-Basic


Training
Eddy Current Theory Testing
Cracks MUST interrupt the surface
eddy current flow to be detected

Eddy Current Testing-Basic


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Factors affecting Eddy Current
response
Material conductivity
- Greater the conductivity greater
the eddy current flow
- conductivity depends on material
composition, heat treatment, work
hardening etc etc

Eddy Current Testing-Basic


Training
Factors affecting Eddy Current response
Permeability
Described as the ease with which a material
can be magnetised
For nFe metals and austinitic S.Steel, the
permeability (mr)is 1 (as for free space)
For Fe metals the value of mr may be several
hundred, thus influencing the eddy current
response
Permeability may vary within a metal part due
to localised stresses, heating effects etc

Eddy Current Testing-Basic


Training
Factors affecting Eddy Current
response
Frequency

Eddy current response is greatly


affected by the test frequency, but
this property can be controlled

Eddy Current Testing-Basic


Training
Factors affecting Eddy Current
response
Geometry
Curvature,edges,grooves etc will
affect the eddy current response
When the material thickness is less
than the effective depth of
penetration, this will also affect the
eddy current response

Eddy Current Testing-Basic


Training
Factors affecting Eddy Current response
Proximity / Lift-off
The closer the probe coil to the surface,
greater the effect on the coil. This has
two main effects
1. Lift off signal as the probe is moved on
and off the surface
2. A reduction in sensitivity as the coil to
product spacing increases

Eddy Current Testing-Basic


Training
Factors affecting Eddy Current response
Depth of Penetration
The eddy current density is greatest on the
surface of the metal and declines with
depth
Depth of penetration
-decreases with an increase in frequency
-decreases with an increase in conductivity
-decreases with an increase in permeability

Eddy Current Testing-Basic


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Factors affecting Eddy Current


response

Eddy Current Testing-Basic


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Effective Depth of Penetration

It is defined as three times the


standard depth, where eddy
current density has fallen to 3% of
the surface value

Eddy Current Testing-Basic


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The Impedance Plane

This is a graphical representation of


the complex probe impedance
where the X-value represents the
resistance and the Y-value
represents the inductive reactance

Eddy Current Testing-Basic


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The Impedance Plane

Eddy Current Testing-Basic


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The Impedance Plane
The display of CRT instrument represents a
window in to the impedance plane

Above example shows probe on Aluminium

Eddy Current Testing-Basic


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Coil Configurations Absolute (Single Coil)
Surface probes probe axis normal to the
surface
Encircling coils the product to be tested is
inserted through a circular coil
ID probes for heat exchanger inspection
(normally wound with the coil axis along the
center of the tube)
Absolute probes are good for metal sorting
and detection of cracks

Eddy Current Testing-Basic


Training
Coil Configurations Differential (two coils)
Differential probe has two sensing elements
looking at different areas of the material
being tested. The instrument shows the
difference between the eddy current
conditions at the two points
Good for detection of small defects and are
relatively unaffected by lift-off, temperature
changes and external interference

Eddy Current Testing-Basic


Training

Differential probe response

The figure of 8 is formed based on response from first


element and then the second element move over the
defect
The lift off is cancelled out, but there is still wobble
response as the probe is moved and tilted slightly

Eddy Current Testing-Basic


Training

Coil Configurations
Reflection/driver pick-up probes

They have a primary winding driven from the


oscillator and one of more sensor windings
connected to the measurement circuit

Eddy Current Testing-Basic


Training
Coil Configurations Reflection/driver
pickup probes
Advantages
Driver and pickup coils can be
separately optimised for their
intended purpose
Wider frequency range
The larger driver coil gives more even
field, resulting in better penetration
and lift-off characteristics

Eddy Current Testing-Basic


Training

Typical Coil Connections Bridge

The two coils (differential or absolute + balancing coil) form


the legs of the bridge. When the bridge is balanced, the
measured voltage will be zero. Any change in the condition of
either coil will result in an unbalanced bridge, the degree of
imbalance corresponds to the change in coil impedance

Eddy Current Testing-Basic


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Typical Coil Connections Driver pickup

The essential elements are same as bridge type. The


necessary changes can be achieved by simple switching
or probe connection changes

Eddy Current Testing-Basic


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Practical testing requirements
-A suitable probe
-An instrument with the necessary capabilities
-A good idea of size, location and type of flaws
-A suitable test standard to set up the
equipment
-A procedure or accept/reject criteria
-Operator expertise to understand and
interpret the results

Eddy Current Testing-Basic


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Eddy Current Instruments
-Special purpose equipment
-Crack Detectors
-Portable Impedance plane
equipment
-Systems Eddy Current units

Eddy Current Testing-Basic


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Special Purpose Equipment

Coating Thickness Meters,


Conductivity meters etc
Generally designed to give a digital
readout without demanding
interpretation of an indication

Eddy Current Testing-Basic


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Crack Detectors

Generally operates at a restricted


number of frequencies typically
several hundred KHz, meter or
bargraph display
Suitable for surface crack detection
and simple sorting applications

Eddy Current Testing-Basic


Training

Portable Impedance Plane


Equipment

Impedance plane display on CRT,


wide frequency ranges,
multifrequency operation to reduce
specific interfering effects

Eddy Current Testing-Basic


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Systems Eddy Current Units

Intended for factory operation, often


in automatic or semi-automatic
inspection mode.

Eddy Current Testing-Basic


Training
Eddy Current testing Applications
-Surface crack detection
-Non-ferrous metal sorting
-Sub-surface crack/corrosion
detection
-Heat exchanger tube testing
-In-line inspection of steel tubing
-Ferrous Weld Inspection

Eddy Current Testing-Basic


Training

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