CRACK DEPTH MEASUREMENT:

ELECTRIC POTENTIAL DROP TECHNIQUES

1.

INTRODUCTION

1.1

Scope

This

NORDTEST

method

specifies

procedure

for

depth

measurements

of

surface breaking cracks in metallic materials by the use of electric

potential

1.2

drop

techniques.

Acceptance criteria

This NORDTEST method does not specify acceptance criteria. It is

referred to relevant codes or other documents specifying such criteria.

1.3

Extent

of

examination

The NORDTEST method does not specify the extent of examination, in

terms of number of measurements along the detected crack.

published

by

NORDTEST
Tekniikantie 12

FIN-02150
Finland

ESBO

key words

classification

drop techniques
crack depth measurement
test method

UDC 620.179.18
ISSN

0283-720X

- 2 -

1.4

References

Magnetic particle examination

- NORDTEST Doc. 286-81 "Magnetic Particle Examination of welded

joints in steel".

Penetrant

examination

- ISO 3452 "Non-destructive testing. Penetrant inspection. General

principles".

- ISO 3879 "Welded joints. Recommended practice for liquid penetrant

testing".

1.5

Symbols

and

definitions

Symbol

Description

AC

Alternating

ACPD

Alternating

DC

Direct

current

DCPD

Direct

current

A1 and A2

Positions

current
current

of

potential

potential
current

drop

drop

electrodes

for

current supply to test specimen

B1 and B2

Positions

of

measurement
DPE

Dye

potential
of

electric

penetrant

Crack

electrodes
potential

examination

depth

Cross-section

area

Frequency
I

Applied

current

Coefficient

defined

divided

potential

by

MPE

Magnetic

Electrical

particle

by

crack

drop

examination

resistance

depth

for

- 3 -

Symbol

Description

Distance between the two potential

electrodes B1 and B2
Voltage

V0

measured

between

the

electrodes

B1 and B2 without crack in between

Voltage

Vc

measured

between

the

two

potential

electrodes B1 and B2 with a crack present

between them

Skin depth, a measure for the penetration

of current into the test object
Permeability
Relative
Vacuum

permeability
permeability

Conductivity

Specific electrical resistance = l/

Definitions

(i)

Skin

depth

The skin depth is the depth below the metal surface at which
the current density amplitude has dropped to l/e of its amplitude at the surface.

(ii)

Permeability
The magnetic permeability of a substance may be defined as
the ratio of the magnetic induction in the substance to the
magnetizing field to which it is applied.

(iii)

Conductivity
Electric conductivity is a measure for the quantity of electricity tranferred across unit area, per unit potential gradient per unit time. The conductivity is the reciprocal of
the

resistivity.

- 4 -

Ferromagnetic

(iv)

materials

Those materials in which the magnetic moment of atoms or

ions in a magnetic domain tend to be aligned parallel to
one another in zero applied field, below a characteristic
temperature

called

the

Curie

Point.

The

relative

permeabi-

lity is much higher than one, r > 1.

Non-ferromagnetic materials

(v)

Those

paramagnetic

and

diamagnetic

materials

within

which

the magnetic induction is proportional to the applied field

with r 2 1.
2.

APPLICATION

2.1

General

Whenever a crack depth measurement is specified to be performed according

to

this

surface

electrical

Further

document, the

breaking

details

are

restricted

to:

cracks.

conductive

on

applications

metals.

applications

and

restrictions

for

each

individual

technique are described in Chapter 9.

The crack depth measurement can be performed as:

a single spot measurement on a periodic basis.

a monitoring technique to follow crack growth in specimens subject

to

fatique

crack

or

other

profiling

by

crack
using

propagating
several

mechanisms.

potential

measuring

electrodes

along the crack.

2.2

Required information

Reference to this document is insufficient to specify a proper crack

depth measurement. At least the following additional information has
to be given:

(i)

Extent

of

examination, eg the number of measurement points,

and the number of readings at each point.

- 5 -

(ii)

Precautions in case unacceptable cracks are found.

(iii)

Operational Manual for the equipment.

(iv)

Material

quality

stress
Report

(v)

(vi)

information

(magnetic/non-magnetic,

possible

history).
on

crack

dye

penetrant

Any

information

detection, eg

examination,
available

magnetic

eddy
on

particle

current

crack

examination,

examination.

type,

characterization,

and origin.

The operator may ask for additional information which can be helpful
in the evaluation of measurements.

In order to evaluate the crack significance, the acceptance criteria

must also be specified.

3.

PERSONNEL

The

personnel

responsible

for

applying

an

electric

potential

drop

technique to measure crack depths should be thoroughly trained and

qualified to carry out this method of examination. Moreover, the
personnel

concerned

should:

(i)

have adequate experience to carry out the inspection.

(ii)

be familiar with the characteristic properties of the equipment used, the principles on which it operates, and the
checking

(iii)

of

its

performance.

be familiar with the possibilities and the limitations of

the method used to detect the crack, and also other means
to detect surface breaking cracks.

(iv)

be conversant with other methods to measure or estimate crack

depths.

(v)

be adequately familiar with the properties of the material

to be tested.

(vi)

be familiar with the importance of crack type and crack configuration

(vii)

on

the

reliability

of

measured

depth.

be able to independently report the results of the tests.

- 6 -

All the personnel concerned should be of a high integrity and they

should carry out all instructions, procedures

and

stipulations

meticulously and not make any decision contradictory to them.

The personnel in question should keep themselves informed about developments in crack depth sizing.

Whenever
to

4.

necessary, the personnel in question should be submitted

qualification

SURFACE

tests

to

prove

their

proficiency.

PREPATION

The material surface in vicinity of the crack to be sized must allow

for proper contact between the metal surface and the current and
potential
cause

electrodes. Differences

false

in

the

transition

resistance

can

results.

The surface roughness will also affect the reliability and accuracy
of the measured crack values, and this influence will depend on the
frequency

used. Sizing of shallow cracks require high frequency cur-

rent which in turn require smooth surface due to the very small skin
depth (see also Section 6.2).

5.

PERIODIC

CHECK

OF

EQUIPMENT

A quality check of the crack depth measuring equipment shall be performed at intervals not exceeding 6 months. The check shall assure
that all the operating modes function satisfactorily and the following apparatus shall be included:

(i)

the

power

supply, e.g. generator, battery pack, charger.

(ii)

the current electrodes and their cabling to the power supply

(iii)

the control panel, e.g. registration unit, amplifier, crack

depth presentation.

(iv)

the measuring probe with all its potential electrodes and

the cabling to the control panel.

Whenever any of the equipment has been exposed to rough treatment

- 7 -

which could influence on the equipment performance, a quality check

is required.

When required, the operator shall be able to show a certificate of

the quality check.

6.

6.1

TEST METHOD PRINCIPLES

General

The principle of electric potential drop techniques is based on the

measurement of increase in potential drop, caused by an increase in
electric resistance, between two measuring probes in presence of a
surface

crack.

The described crack depth measuring methods do not replace the usual
methods

for

crack

detection, but supplement them in the assessment

of size, which is one of the most important parameters in any fitness

for

purpose

evaluation.

There is, in general, two different versions of the potential drop

technique:

- the alternating current techniques (ACPD), where a surface crack

will interfere with the current, which travels along the test
object surface due to skin effect, causing an increase in current
path and hence in electric resistance.
- the direct current techniques (DCPD), where a crack will give rise
to an increase in the resistance because of the reduction in the
cross

6.2

sectional

Alternating

current

area.

potential

drop

(ACPD)

techniques

When an alternating current (AC) is passed through a metal body, most

of the current is carried in only a thin layer at the metal surface,
or more correctly, the current density will have an exponential decay
as a function of distance below the metal surface. This decay is determined by the skin depth, which also can act as a measure for the
thin

current

carrying

layer.

- 8 -

The skin depth can commonly be expressed as:

(1)

= (l/r0f)1/2
where
r = relative permability
0 = vacuum permability
= 4 x 10-7 H/m
= conductivity
f

frequency

As seen from Eq (1), the skin depth can be altered by varying the
frequency of the applied current. The choice of frequency will therefore influence the applications and limitations of the method.

In order to illustrate the frequency dependency, a typical mild steel

quality (r = 500, = 5.8 x 106 -1 m-1) will have its skin depth
changed from 1.3 mm to 0.13 mm when the frequency is altered from 50
Hz to 5 kHz. Obviously, the crack detection sensitivity and the sizing
accuracy will be affected by such differences in skin depths.

By referring to Fig. 6.1, the crack depth measurement principle is

based on the measured increase in voltage between two potential measuring electrodes caused by the crack as the current will follow the
crack around the crack tip. Generally, the current electrodes (A1 and
A2) should be widely spaced so that a current flow, essentially perpendicular to the suspected crack, is maintained. Further, if the
potential electrodes (B1 and B2) then are placed along a field line,
the potential drop between them will be proportional to the current
path

length

between

them.

Therefore, with a fixed spacing (s) between

the two potential electrodes, the crack depth (d) can be determined
by the following equation, assuming an uniform electric field and a
crack much deeper than the skin depth:

V0/s = Vc/(s+2d)

(2)

or, when expressed as crack depth

d = (Vc/V0-1) s/2

(3)

- 9 -

where
V0 = voltage measured without a crack in between the potential
electrodes.
Vc = voltage measured with a crack in between the potential electrodes.

Hence, by making two potential drop measurements, one in an uncracked

area and one across the crack, and
separation,

knowing

the

potential

electrode

it is possible to determine the crack depth at any point.

Sizing of cracks with depth comparable to the skin depth must be performed (if at all possible) with utmost care and only after a thorough
calibration. The Eq. (2) will not be applicable for such cracks.
Neither does Eq. (2) account for small corrections in the measured
crack depth due to skin depth effects in the corners between specimen
and crack face, and around the crack tip.

current lines

Fig. 6.1 Crack depth measurement by alternating current potential

drop technique (ACPD).

6.3

Direct current potential drop (DCPD) techniques

The DC method involves passing a constant current through the specimen volume to be inspected, and the DC potential drop is a result of
reduction

in

cross

sectional

area, and not of an increase in current

path around the crack tip as for the ACPD method described in Ch. 6.2.
By referring to Fig. 6.2, the current is applied between the electrodes A1 and A2, and the potential increase can be measured between the
electrodes B1 and B2 as a result of the increased electrical resistance.

- 10 -

lines

current lines

Fig. 6.2.

Crack

depth

measurement

by

direct

current

potential

drop

technique (ACPD).

By applying Ohm's Law, the voltage reading at an undamaged surface

will be given by:

V0

= RI
= s I/F

(4)

where
V0 = voltage reading between the two potential electrodes
R = electrical resistance
I = applied current
= specific electrical resistance
s = distance between the potential electrodes
F = cross-section area transversed by current lines

In presence of a crack between the two potential measuring electrodes,

the voltage will increase to read Vc, due to the increased resistance
caused by reduction in cross-section area. The crack depth will now
be a function of the difference between the two voltage readings, i.e:

d = K(Vc - V0)

(5)

where K is a function determined by calibration.

The

equation

(4)

assumes

uniform

field

distribution.

- 11 -

If the current electrodes are placed near the crack, the potential
increase will be significantly more influenced by the distance around
the crack than the reduced cross section area.

7.

INSTRUMENTATION

The

crack

depth

measuring

instrumentation

shall

essentially

consist

of three elements:

1) A current supply.
ACPD
The alternating current supply shall have an amplitude which is
matched to the chosen frequency in such a way that potential
drops will have a sufficiently high value to be measured reliably
by

sensitive

AC

voltmeters.

In general, ACPD instruments available today fall into one of the

two

following

categories:

a) A supply being able to deliver low current (0.3 A to 3.0 A)

with a corresponding high frequency (1 kHz to 10 kHz).
b) A supply being able to deliver high current (at least 300 A)
with a corresponding low frequency of typical 50 Hz.

DCPD
The constant or direct current supply shall have an amplitude
control in order to:
*

adjust the current density as required.

be able to obtain a sufficiently high voltage value to be

measured

reliably

by

sensitive

DC

voltmeters.

In general, DCPD instruments available today have a current supply

need of at least a couple of Ampres. Some instruments are even
based on direct currents exceeding 1 kA.

The current supply may well be an integrated part of the measuring

system, for ACPD as well as DCPD.

- 12 -

2) A voltage (potential drop) measuring device.

The measuring device shall contain a touch probe with two potential

electrodes

for

voltage

measurements,

signal

treatment

elec-

tronics and a crack depth readout. The touch probe can preferably
be equipped with more than the two absolute necessary electrodes
in order to perform differential measurements. This type of measurement is done to compensate for differences in material qualities on each side of the crack, and/or to do reference and crack
measurements

in

one

operation.

3) A calibration block.
A calibration block with notches shall be available in the same
material
bility

quality, as
are

electric

concerned. Further

conductivity
requirements

and
to

magnetic

permea-

calibration

are

described in Chapter 8.

8. EQUIPMENT CALIBRATION

8.1

General

The crack depth reading is strongly dependent on electric conductivity

(or

metry.

resistivity), magnetic

permeability

and

test

object

geo-

It is therefore mandatory to perform a calibration. Generally,

if the test object material quality differs from that of an available

calibration block, slight differences can be balanced out by the instrument zero setting, if such exists, and for DC also by adjusting
the current amplitude from knowledge of the specimen cross section.
Greater

differences

in

material

qualities

can

be

approximately

com-

pensated for by working out a correction factor according to manufacturers

However,

procedure, if such is applicable.

when

crack

depth

measurements

are

requested

according

to

this NORDTEST method, a calibration block as described in Section 8.2

must

8.2

be

available.

Calibration blocks

In order to perform a crack depth measurement in an accurate and reliable way, a

calibration

shall be available.

block

satisfying

the

following

requirements

- 13 -

8.2.1

ACPD
Requirements for an ACPD calibration block will be:
*

conductivity and permeability values similar to that of the material to be examined.

narrow notches with a constant depth over a distance of at least

five times the depth.

calibration block length of at least 200 mm in order to allow

for a current pole separation necessary to obtain a uniform current

field

distribution.

calibration block width of at least 40 mm and always at least

twice the crack depth in order to minimize edge effects.

calibration block thickness of at least 20 mm and always at least

50% more than the notch depth.

8.2.2 DCPD

Requirements for a DCPD calibration block will be:

* specific electric resistivity similar to that of the material to
be inspected.
*

material thickness the same as for the test object.

* narrow notches with a constant depth across the whole width of

the block.
*

the notch depths must not exceed 40% of thickness.

calibration block length of at least 200 mm in order to allow for

a current pole separation necessary to obtain a uniform current
field

distribution, if

independent

current

electrodes

are

used.

calibration block width of at least 100 mm and always at least

four times the crack depth in order to minimize edge effects.
the

configuration

supply
ficantly

electrodes
influence

of

potential

in

the

the

measuring

chosen

dependency

DCPD

electrodes

and

instrumentation

between

the

object

current

will
cross

signisection

area and the depth reading. Therefore, if an unchanged current density

is

required

between

calibration

and

crack

depth

measurements,

the width of the calibration block shall be chosen accordingly.

The required block width will hence depend on current adjustment
capabilities.

- 14 -

8.2.3 NORDTEST Calibration Blocks

The NORDTEST Calibration Blocks for ACPD satisfy the stated requirements in Sections 8.2.1,

and the range of blocks has the following

identification:
* NORDTEST Calibration Block ACPD No. 1 with notch depths between
1 mm and 10 mm in steps of 3 mm (see Fig. 8.1).
* NORDTEST Calibration Block ACPD No. 2 with notch depths between
5 mm and 20 mm in steps of 5 mm.
* NORDTEST Calibration Block ACPD No. 3 with notch depths between
10 mm and 40 mm in steps of 10 mm.

Calibration blocks for even deeper cracks can be specified according

to the same principles.

The NORDTEST calibration blocks for DCPD satisfy the stated requirements in Section 8.2.2 and is schematically shown in Fig. 8.2. The
width should be 100 mm or, if applicable,

as required to achieve a

current density comparable to that expected in the test object. The

block identification DCPD No. 1 means 1 mm slit, DCPD No. 2 a 2 mm
slit and so on.

Fig. 8.1. NORDTEST Calibration Block ACPD No.1.

- 15 -

Fig. 8.2.

NORDTEST Calibration Block DCPD No. 1.

The test block thickness shall be as for the test object
(T) and the width shall be 100 mm. If constant current density is required for reliable measurements, the width shall
by

8.3

Reference

chosen

accordingly.

blocks

The calibration blocks shall be used to calibrate the crack depth

readout from an "ideal" testing situation, i.e, with minimized influence

from

limiting

factors, with

proper

current

field

distribu-

tion and with clearly defined artificial cracks (notches), all in

order to have a standard way of reference for the measurements to
be

performed.

If,

however, the test object represents any limiting factor, as lis-

ted below and also described in Chapter 9, it

is

strongly

recommended

to manufacture a reference block which contains actual limiting

factors.

Such reference blocks will help to establish correction cur-

ves and to compensate for effects not included in the standard calibration.

Many of the limiting factors can be compensated for by in-

strument

adjustments.

block

to

increase

the

Even

so, it is recommended to use a reference

measurement

reliability.

The

reference

should reflect the object to be examined, with respect to:

* physical size (thickness, width, length)

block

- 16 -

surface

geometry

(e.g.

surface

condition

electric conductivity (for AC and DC) and magnetic permeability

(e.g.

curved

surfaces,

smooth,

corners)

rough, electric

contact

conditions)

(for AC)
* position of artificial cracks (e.g. in corners, near edges)
* profile of artificial cracks (e.g. elliptic, semi-circular, more
randomly variable)
*

crack

depths

crack orientation (e.g. normal/oblique to the surface)

Several of the DCPD techniques require constant current density

between the calibration and the crack measurements. In such cases,
the use of a reference block will be of significant value.

9. APPLICATIONS AND LIMITATIONS

9.1

General

In the application of potential drop techniques for sizing of crack

depths there are some restrictions and weaknesses which should be
recognized

by

testing

institutes,

quality

departments,

operators

and

also by those establishing testing specifications and setting up code

requirements.

These

limitations

as

well

as

recommended

applications

are described in the following sections.

9.2

Types of crack

9.2.1

ACPD

The potential drop techniques are all intended for depth measurement
of surface breaking cracks. The crack to be sized must be open, which
means without metallic contact between the two crack faces. Fatique
cracks usually fall into this category.

9.2.2

DCPD

The potential drop techniques are all intended for depth sizing of
surface

breaking

cracks. The DCPD method is not as sensitive as the

- 17 -

ACPD to metallic contact between the two crack faces, if the contact
areas only will be a small fraction of the total crack area. Anyway,
sizing of cracks without metallic bridging, like most fatique cracks,
will be among the most favourable.

9.3

Material

9.3.1

ACPD

quality

It is generally recommended to use the AC technique only on ferromagnetic (ferritic) materials with r > 1.
Crack depth sizing in non-ferromagnetic materials will imply drop in
sensitivity

and

should

only

be

performed

when

recommended

equipment

and procedure are available from the manufacturer, and only after a
thorough

9.3.2

calibration

on

the

same

material

quality.

DCPD

Crack depth sizing with DCPD can be performed in non-ferromagnetic

as well as ferritic materials, but only after a thorough calibration
on the same material quality.

9.4

Specimen

9.4.1

ACPD

size

The AC potential drop techniques do not have any significant limitation with regards to specimen size, because the current is flowing
in a thin surface layer. Hence, an increase in thickness will not reduce

9.4.2

the

sensitivity.

DCPD

The size of the DC potential drop caused by a crack depends on the

crack area combined with the current density in the specimen across
the defect plane. Adequate
achieved

in

small

required

to

produce

current

densities

can

generally

only

be

samples, which means that very large currents are

sufficiently

large

current

densities

for

crack

sizing in large sections. The direct current (DC) method is therefore

impractical

for

larger

components.

- 18 -

9.5

Material surface geometry

The AC and DC potential drop techniques can be used on various surface geometries, such as plates, pipes, other curved surfaces, tubular

joints, T-butt welds and corners of various angles, and on

weldment as well as on parent metal. It is usually a matter of calibration procedure which defines the limits of applications.

One important difference is that the surface geometry much more significantly will affect the DCPD measured results than results obtained
with ACPD.

9.6

Edge effects

9.6.1 General

If a crack runs towards an edge of the specimen, e.g. the specimen

side, and a depth sizing is performed in this area, the depth reading

will

be

significantly

affected

due

to

disturbances

(compression

of current lines) in the current flow.

If a reading has to be performed close to a specimen edge, where

false

readings

are

expected,

correction

curves,

as

illustrated

in

Fig. 9.1, must be established in order to maintain the measurement

reliability,

by using the edge on the calibration block.

D I S T A N C E F R O M EDGE

(MM)

Fig. 9.1. Illustration of correction curves for crack depth measurements close to specimen edges.

- 19 -

9.6.2 ACPD

As a general rule, correct depth will not be indicated unless the

measuring position is located away from the edge by at least the
depth of the crack. For small cracks depths, the distance from the
edge should be even two or three times the depth.

Since the depth of the crack is usually unknown, the distance to be

kept has to be determined by a reading close to the edge, and then
this reading must be used as the basis for probe positioning.

If a crack runs parallel to one of the edges of the test piece, no

significant error in the readings is to be expected, even if the
distance to the edge is no more than that required to apply the probe.

9.6.3 DCPD

As a general rule, correct depth will not be indicated unless the

measuring position is away from the edge by at least 30 mm or at least
the depth of the crack, for depths exceeding 30 mm.

Since the depth of the crack is usually unknown, the distance to be

kept has to be determined by a reading close to the edge and then
this reading must be used as the basis for probe positioning.

9.7

Cracks

9.7.1

ACPD

at

Basically,

oblique

angles

the extension along the crack is measured, and not the

actual projected depth to which it penetrates from the surface, unless the crack is penetrating normally. Hence, if the depth of an
oblique crack is the vital parameter, the oblique angle must be found
by some other gauging procedure, and then the depth can be calculated.

9.7.2

DCPD

Depth sizing of cracks at oblique angles will result in meter readings lying between the depth of the crack as measured along the crack
faces and the projected depth to which it penetrates from the surface.

- 20 -

Reliable measurements can only be expected when correction curves are

established by using a reference block.

9.8

Crack length to depth ratio

If the length of the crack is below a certain multiple of the depth,

the current distribution will be affected in such a way that a misreading (depth underestimation) will be the consequence. For AC this
means that some of the current will not flow below the crack, but
travel around it close to the surface.

Therefore,

it the use of a correction curve shall be avoided, the

crack length-to-depth ratio must exceed five. This applies for AC as

well as DC. For ratios below five
lished

using artifical

Correction curves can be estab-

semi-circular or elliptic notches. An illustra-

tion of such correction curves is shown in Fig. 9.2. Depth corrections can also be based on mathematical models.

MEASURED

Fig. 9.2.

Cracks

DEPTH

(MM)

Illustration of correction curves for short and deep cracks

(small

9.9

CRACK

approaching

length-to-depth

far

side

of

ratios).

material

thickness

If a crack penetrates nearly the whole test piece, the current flow
will be hampered, resulting in a too high measured depth value. The
influence

will

become

significant

when

the

crack

penetrates

more

- 21 -

than

approximately:

* a few skin depths from through-thickness penetration for ACPD.

* 40% of the thickness for DCPD.

The use of a reference block is then recommended to maintain reliable

9.10

depth

measurements.

Multiple cracks

Great care should be taken in presence of multiple cracks. Additional

cracks in the vicinity of the crack to be measured influence the current distribution and can be the reason for erroneous measurements.
As the geometry of the several cracks at first is unknown, no pos-

9.11

sibility

of

proper

Current

supply

correction

exists.

The current amplitude must be kept at a constant level and with a

minimum of fluctuations through all stages of the measurement, the
calibration,

the zero adjustment and the measurement across the

crack.

9.12

Crack

tip

stresses

Crack tip stresses can cause a crack closure, and hence, an underestimation of the crack depth, normally up to approximately 1 mm.
Crack tip stresses will also cause changes in material quality and
therefore also in the skin depth, which

accordingly

will

produce

an error in the depth reading. An applied strain to the test specimen causing the crack to be open is recommended.

9.13

Bridging

A firm metallic contact between areas of the two crack faces will
cause electrical bridging as the current takes the path of least
resistance.

The result is often a considerable depth underestimation.

The ACPD techniques are more sensitive to bridging than the DCPD
techniques.

- 22 -

10. ACCURACY AND RELIABILITY

10.1

General

The accuracy and reliability in crack depth sizing can generally be

affected

by

several

itself, the

crack

factors. Among such factors are the equipment

geometry, the surface geometry as well as varia-

tions in the material quality, e.g. variations

in

the

conductivity

and permeability from base material to welds. The operator and the
measurement

procedure

can

also

significantly

affect

the

results.

In

order to obtain the best achievements on surfaces other than those

plane and smooth, a reference block should be used (see Chapter 8).
A reference block or corresponding correction curves must also be
used

to

minimize

uncertainties

and short cracks, and

other

associated

limiting

with

edge

effects,

deep

factors.

The accuracy in depth sizing will usually also be improved by using

a measuring probe with more than two potential electrodes, for the
purpose of achieving differencial measurements in order to eliminate
material differences in the vicinity of the crack.

Typical achievements for crack depth meters are listed in the two
following

10.2

sections.

ACPD

The accuracy (standard deviation) in sizing will be of order:

- 0.2 mm on artificial cracks, measured in laboratory conditions.
- 1.0 mm on fatigue cracks, measured in in-service environments.

Crack

closure

stresses

can

cause

underestimations

of

crack

depths.

The accuracy and reliability in sizing crack types with a significant

probability

for

electrical

bridging

current

techniques

between

the

crack

faces,

are poor.

The

low

frequency/high

are

more

the high frequency techniques on rough surfaces.

accurate

than

- 23 -

The current supply leads as well as external electromagnetic noise

can cause electromagnetic fields which can be picked up by the voltage probe leads or the probe itself, and
ments.

create

unreliable

measure-

The current supply leads should therefore by widely separated

from the probe cables.

The accuracy in relative measurements will be far better than the

values

for

absolute

measurements

indicated

above.

Relative

measure-

ments can be obtained by monitoring crack growth with the potential

electrodes

10.3

permanently

attached

to

the

specimen.

DCPD

The

measuring

accuracy

(standard

deviation)

is

generelly

within

10%

of the actual crack depth. The use of a thoroughly prepared procedure

can

improve

the

accuracy

significantly.

The accuracy in relative measurements will be far better than the

values

for

absolute

measurements

indicated

above.

Relative

measure-

ments can be obtained by monitoring crack growth with the potential

electrodes

Crack

The

permanently

closure

accuracy

stresses

and

attached

can

to

cause

reliability

are

the

specimen.

underestimations

significantly

of

crack

lowered

when

depths.

sizing

crack types with a probability to have major areas for electrical

bridging between the crack faces.

The surface curvature is of particular importance for the measuring

accuracy when using DCPD.

11.

EXAMINATION

11.1

Crack detection

PROCEDURE

The potential drop techniques described in this NORDTEST method are

primarily designed for crack sizing, not crack detection. Hence, the
detection must be performed with some other means of non-destructive
testing,

and then marked properly on the surface in order to make a

reliable

positioning

of

the

potential

drop

measuring

equipment.

- 24 -

11.2

Preparation

Before the actual crack depth sizing is performed, the following

preparations

should

be

carried

out:

The surface of the test piece, where the measuring probe

(i)

and the current electrodes will make contact, must be properly cleaned to allow for good electric contact (Chapter
4).
(ii)

During set-up of the instrument, a visual check should be

performed to reveal possible damages of the equipment. The

(iii)

(iv)

instrument

set-up

operating

instructions.

The

operator

shall

shall

be

sufficiently

to

obtain

make

trained

reliable

be

performed

according

himself/herself

to

familiar

relevant

with,

and

on, the actual equipment in order

measurements.

The operator shall provide for all information required, as

listed in Section 2.2.
The operator shall ensure the existence of quality check

(v)

documents,

11.3

as described in Chapter 5.

Calibration

The calibration shall be performed on a NORDTEST Calibration Block

or an equivalent block satisfying the requirements listed in Chapter
8. The depths of the notches shall cover the expected measurement
range.

The current electrodes shall be positioned towards the ends of the

calibration block and with an electrode separation of at least 150
mm. In systems were the current electrodes are an integrated part
of

the

measurement

system, the current electrodes shall by placed

as required by the operation manual procedure. The electrodes must

be positioned with one electrode on each side of the notch to be
sized.

The measuring probe must be placed in between the current electrodes,

as indicated in Fig. 6.1. The alignment of the potential electrodes
must be as parallel as possible to the current lines.

- 25 -

The calibration can now be performed by:

* Zero adjustment at an area of the calibration block without notch.
* Establishing a correspondance between instrument readings and real
notch

depths. The alignment of the potential electrodes must be as

perpendicular as possible to the notch length direction, with the

notch in between the two potential drop measuring electrodes.

The

calibration

as

described

is

mandatory.

For AC techniques this calibration must not be altered during a prescribed

measuring

period.

For DC techniques the calibration can be altered as required to fit

the test object size to obtain constant current density.

An introduction of reference blocks to simulate real test conditions

shall not influence the calibration settings, but only be used to
establish

11.4

Crack

correction

curves

referred

to

the

calibrated

values.

sizing

When the required calibration has been carried out, the examination
procedure will be as follows:
The current amplitude and frequency shall not be altered dur-

(i)

ing
(ii)

If

calibration.
applicable, necessary

correction

curves

may

be

established

by measuring depths of artificial cracks manufactored

in a

reference

should

block. The

placement

of

current

electrodes

be similar to that possible at the surface of the test object,

and in accordance with the operating instructions of the
equipment.

The reference values can then be found by:

* zero adjustment at an area of the reference block without

notch, and with a surface geometry similar to the one that
will be used for zero adjustment on the test object.
*

establishing

correspondance

between

instrument

readings

and real notch depths. The alignment of the potential

electrodes must be as perpendicular as possible to the
notch

length

electrodes.

direction, with the notch in between the two

- 26 -

The measuring probe must be placed in between the current

electrodes,

and the alignment of the potential electrodes

must be as parallel as possible to the current lines.

(iii) The sizing of crack depths in the test object can then be
carried out. The placement of current electrodes should be
as for the reference block measurements, if applicable, and
in accordance with the operating instructions of the equipment.

The crack depth values can be found be the following general

procedure (it is referred to the operating instructions for
the

actual

equipment

for

further

* zero adjustment at an untracked

details):
area of the test object,

and at a surface similar to the one used for zero adjustment on the reference block, if applicable.
* carry out crack depth measurements in one or more places
along the crack. The

alignment

of

the

potential

electrodes

must be as perpendicular as possible to the crack length

direction,

with the crack in between the two electrodes.

The measuring probe must be placed in between the current

electrodes,

and the alignment of the potential electrodes

must be as parallel as possible to the current lines.

(iv) All crack depth readings should be corrected according to
the

calibrated

values, according

to

established

correction

curves from a reference block, and according to applicable

procedures

described

in

the

operation

manual.

(v) A new calibration, as described in Section 11.3, shall complete the crack sizing procedure.
(vi) A demagnetization shall be performed, if required,
(vii) The reporting shall be performed according to requirements
listed in Chapter 13.

- 27 -

12.

EVALUATION

OF

RESULTS

The evaluation of results in electric potential drop techniques is

not

matter

of

defining

reporting/registration

levels

since

all

readings of crack depths should be registrated. Normally, the crack

depth reading shall be evaluated according to calibration data, and
in

particular

according

to

readings

obtained

on

reference

objects,

if such have been carried out.

However,

sometimes the readings will be of a character not expected,

and additional information would be required in order to gain confidence in the sizing. Therefore, the

"requirements

to

evaluation"

will more have a character of general advice than strict requirements.

(i)

Such advice may be:

Unreliable readings or successive readings with significant
deviations in depth reading at the same location, and with
unchanged test conditions, could likely be cause by:
*

unstable

electrical

bridging

between

the

two

crack

faces,

or
*

crack

closure

effects

caused

by

stresses.

The general advice, if applicable, would be to apply strain

to the specimen with the purpose to open the crack and simultaneously
(ii)

Readings

measure

indicating

underestimated
face

crack

the

crack

depth

again.

zero

crack

depth

or

significantly

depth, even in presence of verified sur-

indication, would probably be caused by firm and stable

contact between the crack faces, which

again

is

characteristic

of multiple cracks on line (cracks usually produced during

fabrication,

and not by fatigue in operation). An advice in

such cases will be to carry out or verify the sizing by a

different technique, e g, ultrasonics or eddy current techniques.
(iii)

Depth

measurements

showing

strong

variations

along

the

crack

length are probably caused by irregular crack profile.

Reliable depth estimates can then only be obtained by using
correction curves based on artificial crack similar to the
expected

crack

profile.

- 28 -

13.

REPORTING

The results of crack sizing by potential drop techniques shall be

given in a report which should include all the necessary information required to:
(i)

Take decisions on acceptance of the crack revealed by the

ACPD or the DCPD technique.

(ii)

Facilitate

repair

of

unacceptable

cracks.

(iii) Permit the crack sizing to be repeated.

The

report

should

therefore

include

the

following

information:

a) Job identification
b) Test object identification, drawings and dimensions
c) Time and place of the examination
d) Ambient conditions of the examination
e) Name and signature of the operator
f) Relevant material characteristics
g) Surface condition and geometry
h) Data related to equipment, e g, manufacturer, serial no, type
(including ACPD or DCPD), current amplitude, frequency, probe
description
i) Description of calibration block and report on calibration data
j) Description of reference blocks, if used, and report on reference
data
k) Data concerning the results from the examination
l) Additional data which may concern limitations of the examination because of surface geometry, crack geometry or others
m) Specific requirements agreed upon by the parties involved
n) Crack profile description, if required.

- 29 -

Annex A

REFERENCES

1.

Non-Destructive Testing Handbook.

Editor Robert C. McMaster, n, 9,218 (1981).

6.

Hayashi, M. et al.: "Surface crack detection by direct current

potential drop technique". Proc. WCNDT, Las Vegas 1985, p.239.

7.

Hayashi, M. et al.: "DC potential crack detection system for

single edge crack". Proc. WCNDT, Las Vegas 1985, p.245.

8.

Dover, W.D. and Collings, R.: Recent advances in the detection

and sizing of cracks using alternating current field measurements (A.D.F.M.). Br. Journ. of NDT, NovV. 1980, p.298.

9.

Duncumb,

A.C. and MudgCNDT,

7.

Hayashi, M. et al.: DC

potential

single edge crack". Proc.

8.

Las Vegas 1985, p.239.

crack

detection

system

for

WCNDT, Las Vegas 1985, p.245.

Dover, W.D. and Collings, R.: "Recent advances in the detection and sizing of cracks using alternating current field
measurements (A.C.F.M.). Br. Journ. of NDT, Nov. 1980, p.298.

9.

Duncumb, A.C. and Mudge, P.J.: "The

method

for

surface

crack

depth

alternating

measurements".

potential

The

drop

Welding

Research Bulletin, Jan. 1982, p.13.

10. Webborn, T.J.C.: "Crack depth measurements using AC potential

drop": Mat. Eval., Febr. 1982, p.156.

11. Aboutorabi, A.A. and Cowling, M.J.: "Measurement of crack profile of semielliptical surface cracks using AC potential
technique". NDT INTERNATIONAL, Vol 16, No 3, June 1983, p.139.

- 30 -

12. Uemura, T. et al.: "An improved AC electric potential method

and its application to detection of micro fatigue cracks'.
The NDT Journ., Japan, Vol 1, No 3, 1983, p.139.

13.

Tomlinson, F.R.: "Monitoring crack growth by a potential drop

method". Proc. Europ. Conf. on NDT, Mainz 1978, 72/637.

14. Haugen, R. and Rangnes, E.: "A new instrumentation for fatigue
crack depth measurement with AC potential drop technique.
Proc. Europ. Conf. on NDT, Vienna, 1982.

15.

Dalberg, P., Haugen, R. and Myrhaug, 0.: "Crack depth determination. The AC potential drop technique". VERITAS report No 811079, 1981.

16. Hicks, M.A. and Pickard,

experimental

methods

of

A.C.: "A comparison of theoretical and

calibrating

the

electrical

potential

drop technique for crack length determination". Int. Journ.

of

Fracture, 20 (1982), 91-101.

17.

Dover, W.D., Charlesworth, F.D.W. and Taylor, K.A.: "Alternate

current

field

suring

fatigue

measurements. A new method for detecting and meacracks". Advances in Fracture Research, Vol 4,

Cannes, France 1981.

18.

Operating Manual. Crack depth measuring instrument RMG 4011.

Karl

19.

Deutsch.

Operating Instructions. ACPD crack depth gauge U8 Crack Micro

Gauge.

Wells

Krautkramer.

20. Technical data. Universal crack depth meter X-RT 804.

Krautkramer.

21.

CDP3 crack detector. Testwell Ltd. Equipment news. Materials

Evaluation, 44, July 1986, p.922.

22. CGM5 ACPD crack growth monitor. Matalect

Ltd.

Equipment

News.

NDT INTERNATIONAL. June 1986, p.224.

23. Dover, W.D. and Bond, L.J.: "Weld crack characterization on

offshore structures using AC potential difference and ultrasonics". NDT Int. 19, (4), p.243-247, Aug. 1986.