EM Lecture Spies Part2

Eddy Current Testing
Eddy-Current Testing
1. Principle
Author: Otto-von-Guericke-Universitt, Institut fr Werkstofftechnik und Werkstoffprfung Editor: Deutsche Gesellschaft fr Zerstrungsfreie Prfung e.V.
2. Eddy-current probes
3. Signal interpretation
4. Equipment
5. Aircraft inspection
6. Material characterisation
Eddy Current Testing - Applications
NDT&E of Materials Using Eddy Current Technique
Spies / FHG-ITWM & University of Saarland Electromagnetic NDT Methods / Master CNDMS
Eddy Current (EC) Technique: General notes
Materials under Test: Ferromagnetic and / or electrically conductive (metals, ...) Typical Applications: Defect Detection (Subsurface and Surface Cracks, Pores, Inclusions) Material Properties (Conductivity , Permeability , Hardness, Hardness Depth, ...) Geometry (Wall/Layer/Film Thickness, )
IZFP
Eddy Current (EC) Technique: Basic sensor arrangement

Transmitter coil i(t)=Icos(t) Receiver coil U(t)
,
Specimen under test
= 2f
f - EC operating frequency - electrical conductivity - magnetic permeability
- Time Alternating Field

IZFP
Z=
U EC - sensor impedance I
Eddy Current (EC) Technique: Signal influencing variables

Sensor Lift Off +
+ Wall / Layer Thickness
- Wall / Layer Thickness
+
IZFP
Conductivity Permeability
Eddy Current Standard Penetration Depth

100
Penetration depth (mm)
10
Copper Aluminum Ferritic steel (=50) r Austenitic steel (=1) r
0.1
P i o e a n t r d p h ) m (
0.01 0.1
10
100
1000
Frequency (kHz)
IZFP
Sensitivity limitations
Sensor & measurement hardware: - noise level, dynamic range - spatial resolution of the sensor Presence of disturbing influences (application-specific): - sensor lift-off / tilt - inhomogenous geometry of the test specimen (surface roughness, edges, ... ) - local variations of material properties (, ) in the test specimen -...
The optimal sensor design strongly depends on the application

IZFP
Inspection trace
Inspection trace
detectable defects
detectable defect
Higher sensitivity Better spatial resolution
vs.
Reduced inspection time Easy operation
IZFP
Quantitative NDT using the EC technique

Demands on the inspection system: Proper sensor design High signal dynamic range and long-time operation stability of the hardware Efficient signal processing algorithm in order to evaluate small signal changes by large disturbing signals Multiple eddy current operating frequencies (EC frequencies) in order to extend the information content
IZFP
Generation and Application of the Numerical Filters for Quantitative Multifrequency EC technique
Measurement data obtained on calibration samples Known values of target function
Calibration
Regression analysis
Filter coefficients
Filter coefficients
Verification
Measurement data obtained on test samples with known values of target function
Recalculation (numerical filtering)
Filtering results: target function evaluation error
Filter coefficients
NDE application
Measurement data obtained on items to be tested
Recalculation (numerical filtering)
Filtering results: target function values
IZFP
Eddy Current Hardware WS98 Board
100 mm
Features
EC frequencies 10 Hz - 10 MHz Operation with multiple frequencies High long-time operation stability 16 Bit A/D-conversion, > 85 dB dynamic range Digital Signal Processor with realtime algorithms Ethernet interface
IZFP
64-Channel Eddy-Current Inspection System
Front End / Main Electronics
IZFP
Application examples
Inspection of Layered Aluminum Aircraft Structures to Detect and Size Hidden Corrosion
Calculation of the Conductivity Gradient: Numerical Modeling of the Inverse Problem
IZFP
EC Inspection of Layered Aluminum Aircraft Structures to Detect and Size Hidden Corrosion
Inspection task:
Non-destructive quantitative evaluation of the corrosion damage depths (or remaining thickness of aluminium) in each layer of the bonded EC sensor
Aluminium Adhesion Aluminium
corrosion
0.7... 1.0 mm
multilayer structure
Adhesion Aluminium corrosion
Solution:
Multifrequency EC technique
0.2... 0.4 mm
IZFP
Calibration specimen
0.3 mm Aluminium sheet thickness 0.7 mm 0.5 0.4 0.3 0.2 0.1 mm
Shallow pits with various depths 0.7 0.6 0.4 0.2 mm
IZFP
Results
Inspection situation: corrosion in the 1st and 3rd aluminium layer Target function: corrosion in the 1st aluminium layer
EC probe
Aluminium Adhesion Aluminium Adhesion Aluminium corrosion corrosion
0.5 0.4 0.3 0.2 0.1 0 corrosion depth [mm]

IZFP
Results
Inspection situation: corrosion in the 1st and 3rd aluminium layer Target function: corrosion in the 3rd aluminium layer
0.6
EC probe
Aluminium Adhesion Aluminium Adhesion Aluminium corrosion corrosion
0.4 0.2 0 corrosion depth [mm]

IZFP
Conclusion
Determination of Layer Thickness using EC Technique: Increasing the Accuracy
Application-optimised sensor arrangement Efficient signal processing & data interpretation
IZFP
Barkhausen Noise and Eddy Current Microscopy A Scanning Probe Technique for Microscale Material Characterization
BEMI - Introduction
BEMI provides high-resolution characterization of residual stress coating thickness and homogeneity microstructure electrical / magnetic surface properties
features / advantages nondestructive, even for coatings as thin as 25 nm high local resolution (10 m) high accuracy (coating thickness: 10 nm) wide range of coating and substrate materials contactless scanning option
Measured Quantities: Magnetic Barkhausen Noise
Barkhausen noise amplitude observed for ferromagnetic materials under alternating field magnetization (< 1 kHz) mainly caused by 180 Bloch wall jumps stress-dependent microstructure-dependent sensitive to lattice defects tensile stress compressive stress
magnetic field strength
Measured Quantities: Eddy Current Influenced Impedance
established NDT method characterizes conductivity and permeability suitable for coating thickness determination sensitive to microstructure
L L0
=0
surface defects permeability changes
lift-off
sub-surface defects wall thickness variations conductivity changes R-R0 L0
BEMI Testing Device

precision 3-d precision 3-d scanner scanner
controlling PC controlling PC
sensor element: miniaturized inductive probe (modified VCR head)
sensor sensor
sample sample stationary electromagnet stationary electromagnet (Barkhausen only) (Barkhausen only) scanner control scanner control eddy current hardware eddy current hardware barkhausen noise hardware barkhausen noise hardware
picks up Barkhausen noise induces eddy currents
cm
Fields of Application
Spatially High-Resolved Characterization of Residual stress Coating thickness and homogeneity Electrical / magnetic surface properties Advantages High spatial resolution ( 10 m) Quick (0.2 2 s / position) and versatile Coating thickness accuracy 10 nm Multi-parameter target calibration Ultra-light low-inertia probe support Surface level compensation for non-contact scans
Probe Design
Probe similar to video recorder head
0.3 m gap width head surface
10 mm
Resolution Test : Barkhausen Noise

Linear scan across microprofiled test sample
8 7 6
MMAX [V]
5 4 3 2 1 0 0 200 400 600 800 x [m] 1000 1200 1400
Resolution Test : Eddy Current

Different materials under test
6-m gaps
permalloy
ferrite
ferrite
copper
200 m 100 m glass 5 m 10 m 20 m 40 m 60 m
20-m gaps
80 m 100 m
Applications: Residual Stress (I)

thermally induced residual stresses in X20Cr13 steel: two laser-treated spots comparison with X-ray method Barkhausen noise area scan
Applications: Residual Stress (II)

residual stresses in tempered Sendust (FeSiAl) 2 m film thickness, scan size: 2x2 mm X-ray stress measurement
scan resolution: 5x5 points total scanning time: 125 hours (dark blue: 310 MPa, red: 396 MPa)
Barkhausen noise area scan

scan resolution: 20x20 points total scanning time: < 30 minutes (maximum noise amplitude shown; dark blue: 1.26 V, bright yellow: 2.84 V)
Applications: Coating Thickness (I)

thickness of polyimide film on ferrite substrate optical image 4x3 mm eddy current area scan 40x30 points surface profilometry: actual thickness: 400-900 nm high correlation with eddy current signal
Applications: Coating Thickness (II)

thickness of Fe coating on Cu substrate
thickness 3120 nm eddy current signal [arb. unit]
eddy current line scan 50 points per sample obtained thickness accuracy: 10 nm (double RMSE)
2600 nm 1540 nm
3 2.5
3 2.5 2 1.5 1 0.5 0 0 50 100
thickness
3120 nm 2600 nm 1540 nm 860 nm 420 nm 100 nm
860 nm 420 nm 4850 100 nm 2 1.5 1 0.5 50 0
3650 2450 1250
x [m]
150
distance from surface [m]
Applications: Coating Thickness (II)
contactless eddy current scanning of a NiCo coated wafer lift-off performance of eddy current signal utilized for surface level interpolation photo of wafer eddy current area scans of 24x24 mm region in center
contact
-25 m
-50 m
Applications: Coating Thickness (III)

thickness of subsurface layers NiFe/Cu/NiFe multilayer for GMI sensors sample arrangement 9 samples used for calibration y
NiFe 82/18 NiFe 90/10 NiFe NiFe-GMI 50/50 82/18
100 / 30 / 100 nm
contactless eddy current scan (100x100 points) absolute thickness display after calibration
nm
GMI
100 nm 200 nm
100 nm
200 nm
100 nm
200 nm
25 nm
25 nm
25 nm
Applications: Residual Stress (III)

residual stresses at a crack tip in Charpy V-notch specimen Barkhausen noise area scan stress-calibrated neural network output
optical image
Applications: Microstructure characterization

cementite needles in austenitic matrix (Spiegel iron)
optical Image
eddy current area scan

3 x 0.8 mm2, 20 m steps, 150 x 42 steps
Selected Applications
Eddy current scan of a 1 EURO coin
100x100 3x3 mm
256x256 pixels 24x24 mm Parameter Im4 3 MHz
Conclusions
BEMI is a quick NDT method for residual stress and coating thickness characterization
residual stress measurement using Barkhausen noise analysis coating thickness measurement using eddy current analysis
local resolution: 10 m, scanning speed: several points per second wide range of materials and coating thickness contactless scanning option eddy current method sensitive to sub-surface and intermediate layers
Flux Leakage Testing - Basics
Flux Leakage at a Gap at Various Magnetisations
Flux Leakage at Material Separations
Flux Leakage at Material Defects

Flux leakage
Gap at surface, perpendicular to magnetic field lines
Gap, parallel to magnetic field lines
Gap below surface, perpendicular to magnetic field lines
Flux Leakage at Crack: Tangential Field in the Outside
Flux Leage Testing

Advantages: Automated defect testing of rotationally symmetric parts (in production line) Testing equipment: Magnetising equipment Flux leakage probes Manipulating equipment Signal evaluation Marking equipment, sorting equipment Magnetisation: Permanent magnets Electromagnets, current generators
Flux Leakage Testing: Total Penetration

Testing object Detectable defect (transverse flaw)
Field direction
Joke
Current
Exciting coil
Flux Leakage Testing: Magnetisation Using a Coil

Joke
Test object Field direction Coil Detectable defect (transverse flaw)
Flux Leakage Testing: Magnetisation Using a Power Cable
Field direction
Test object
Detectable defect (transverse flaw)
Power cable
Flux Leakage Testing: Magnetisation via Self-Penetration

Field direction
Contact electrode
Test object
Flux Leakage Testing: Additional Flux

Test object (pipe) Field direction Conductor (Cu) Detectable defects (longitudinal/radial flaws)
Current
Flux Leakage Testing: Magnetisation Using a Joke

Portable electromagnet (AC or DC)
Test object (e.g. sheet)
Field direction
Flux Leakage Testing - Application
Magnetic Flux Leakage Testing
a: soft iron core b: magnetic flux c: magnetic coil d: flaw indication e: flux leakage f: defect

Hn
Tangential component
Ht
a: soft iron core b: magnetic flux c: magnetic coil d: flaw indication e: flux leakage f: defect Magnetic flux Defect Magnetic sensor
Normal component Flux leakage
Response curve of GMR Sensors
Physical Background of GMR layers
Array 16 GMR-Sensors
Array 16 GMR-Sensors
Response curve of GMR Sensors

Magnetic Flux Leakage from the crack in the ferromagnetic steel sheet measured by GMR-Sensor-Array
2 0 -2 -4 -6

Comparison between magnetic particle testing (left) and magnetic flux leakage testing by using of GMR-Sensors (right) carried on the ferromagnetic cylindrical specimen (~1 m wide)

EM Lecture Spies Part2

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Eddy Current Testing

Eddy Current Testing - Applications

NDT&E of Materials Using Eddy Current Technique

Eddy Current (EC) Technique: General notes

NDT&E of Materials Using Eddy Current Technique

Eddy Current (EC) Technique: Basic sensor arrangement

- Time Alternating Field

NDT&E of Materials Using Eddy Current Technique

Eddy Current (EC) Technique: Signal influencing variables

+ Wall / Layer Thickness

- Wall / Layer Thickness

NDT&E of Materials Using Eddy Current Technique

Eddy Current Standard Penetration Depth

Penetration depth (mm)

Copper Aluminum Ferritic steel (=50) r Austenitic steel (=1) r

NDT&E of Materials Using Eddy Current Technique

The optimal sensor design strongly depends on the application

NDT&E of Materials Using Eddy Current Technique

Higher sensitivity Better spatial resolution

Reduced inspection time Easy operation

NDT&E of Materials Using Eddy Current Technique

Quantitative NDT using the EC technique

NDT&E of Materials Using Eddy Current Technique

Recalculation (numerical filtering)

Filtering results: target function evaluation error

Measurement data obtained on items to be tested

Recalculation (numerical filtering)

Filtering results: target function values

NDT&E of Materials Using Eddy Current Technique

Eddy Current Hardware WS98 Board

NDT&E of Materials Using Eddy Current Technique

64-Channel Eddy-Current Inspection System

Front End / Main Electronics

NDT&E of Materials Using Eddy Current Technique

Calculation of the Conductivity Gradient: Numerical Modeling of the Inverse Problem

NDT&E of Materials Using Eddy Current Technique

NDT&E of Materials Using Eddy Current Technique

Shallow pits with various depths 0.7 0.6 0.4 0.2 mm

NDT&E of Materials Using Eddy Current Technique

0.5 0.4 0.3 0.2 0.1 0 corrosion depth [mm]

NDT&E of Materials Using Eddy Current Technique

0.4 0.2 0 corrosion depth [mm]

Determination of Layer Thickness using EC Technique: Increasing the Accuracy

Application-optimised sensor arrangement Efficient signal processing & data interpretation

Measured Quantities: Magnetic Barkhausen Noise

magnetic field strength

Measured Quantities: Eddy Current Influenced Impedance

surface defects permeability changes

sub-surface defects wall thickness variations conductivity changes R-R0 L0

BEMI Testing Device

sensor element: miniaturized inductive probe (modified VCR head)

picks up Barkhausen noise induces eddy currents

0.3 m gap width head surface

Resolution Test : Barkhausen Noise

5 4 3 2 1 0 0 200 400 600 800 x [m] 1000 1200 1400

Resolution Test : Eddy Current

200 m 100 m glass 5 m 10 m 20 m 40 m 60 m

Applications: Residual Stress (I)

Applications: Residual Stress (II)

Barkhausen noise area scan

Applications: Coating Thickness (I)

Applications: Coating Thickness (II)

3 2.5 2 1.5 1 0.5 0 0 50 100

860 nm 420 nm 4850 100 nm 2 1.5 1 0.5 50 0