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NDT31
Contents
Section Subject
Preliminary pages
Contents
Standards and Associated Reading
COSHH, H&S, Cautions and Warnings
Introduction to NDT Methods
NDT Certification Schemes
1 Introduction
1.1 The SI units of measurement
1.2 History of eddy current testing
1.3 Definition of non-destructive testing (NDT)
1.4 Choice of method
2 Principles
2.1 Electricity
2.2 Magnetism
2.3 Alternating current theory
2.4 Eddy currents
3 Equipment
3.1 Circuits
3.2 Simple circuits
3.3 Instruments
3.4 Adjustments
3.5 Probes
3.6 Calibration blocks
4 Practices
4.1 Documentation
4.2 Applications
5 AC Theory
5.1 Capacitive reactance
6 Phase Analysis
6.1 Signal/noise separation
6.2 Phase analysis
6.3 Idealised impedance diagram
6.4 Normalised impedance
6.5 Conductivity
6.6 Magnetic permeability
6.7 Thickness
6.8 Frequency
6.9 Probe diameter
6.10 Characteristic parameter
6.11 Characteristic frequency
6.12 Skin effect
6.13 Phase discrimination
6.14 Suppression of undersired effects
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6.15 Multifrequency testing
7 Instrumentation
7.1 Cathode ray oscilloscopes
7.2 Send-receive coils
7.3 Hall effect probes
7.4 Dynamic testing
7.5 Frequency response
8 Material Sorting
8.1 Conductivity meters
8.2 Conductivity effects
8.3 Electromagnetic sorting bridges
8.4 Bridge sorting variables
8.5 Automatic gates
8.6 Standards
9 Crack Detection
9.1 Universal crack detectors
9.2 Surface coils
9.3 Crack detection
9.4 Weld testing
9.5 Rotating probes
10 Tube Testing
10.1 Manufactured tube testing
10.2 Condenser tube inspection
10.3 Probes
10.4 Test frequency
10.5 Coil size
10.6 Signal patterns
10.7 Reference standards
11 Eddy Current for Welding Inspection
11.1 Introduction
11.2 Eddy current application overview
11.3 Basic eddy current theory
11.4 Generation of eddy currents
11.5 Principles governing the generation of eddy currents
11.6 Fundametal properties of eddy current flow
11.7 Electrical circuits and probe impedance
11.8 Resistance and reactance
11.9 Inductive reactance
11.10 Capactive reactance
11.11 Impedance
11.12 Inductance (L)
11.13 Eddy current weld testing
11.14 Probe/coil arrangements
Appendix 1
Appendix 2
Appendix 3
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Preface
These notes are provided as training reference material and to meet the study
requirements for examination on the NDT course to which they relate.
They do not form an authoritative document, nor should they be used as a reference for
NDT inspection or used as the basis for decision making on NDT matters. The standards
listed are correct at time of printing and should be consulted for technical matters.
NOTE: These training notes are not subject to amendment after issue.
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Standards and Associated Reading
ISO 27831-1 Metallic and other inorganic coatings – cleaning and preparation
of metallic surfaces. Part 1. Ferrous Metals and alloys
ISO 27831-2 Metallic and other inorganic coatings – cleaning and preparation
of metallic surfaces. Part 1. Non-Ferrous Metals and alloys
Special Techniques
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Aerospace
prEN 2002 Aerospace Series – Test methods for metallic materials – Part 20:
Eddy Current test on pipes under pressure
Welds
EN 1971 Copper & Copper Alloys – Eddy current test for measuring defects
on seamless round copper and copper ally tubes
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Associated Reading
http://www.ndt-
ed.org/EducationResources/CommunityCollege/EddyCurrents/cc_ec_index.htm
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COSHH, H&S, Caution and Warnings Relevant to TWI Training & Examination
Services
Introduction
The use of chemicals in NDT is regulated by law under the Control of Substances
Hazardous to Health (COSHH) Regulations 2005. These regulations require the School to
assess and control the risk of health damage from every kind of substance used in
training. Students are also required by the law to co-operate with the School’s risk
management efforts and to comply with the control measures adopted.
The School holds Manufacturers Safety Data Sheets for every substance in use. Copies
are readily available for students to read before using any product. The Data Sheets
contain information on:
What is Exposure?
Exposure to a substance is uptake into the body. The exposure routes are by:
Many thousands of substances are used at work but only about 500 substances have
Workplace Exposure Limits (WELs). Until 2005 it had been normal for HSE to publish a
new edition of EH40, or at least an amendment, each year. However with increasing use
of the website facilities the HSE no longer always publishes a revised hardcopy edition,
or amendment.
The web based list which became applicable from 1st October 2007 can now be found at
http://www.hse.gov.uk/coshh/table1.pdf
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Introduction to Non-Destructive Testing
Non-destructive testing (NDT) is the ability to examine a material (usually for
discontinuities) without degrading it or permanently altering the article being tested, as
opposed to destructive testing which renders the product virtually useless after testing.
Other advantages of NDT over destructive testing are that every item can be examined
with no adverse consequences, materials can be examined for conditions internally and
at the surface and, most importantly, parts can be examined whilst in service, giving a
good balance between cost effectiveness and quality control. NDT is used in almost
every industry with the majority of applications coming from the aerospace, power
generation, automotive, rail, oil & gas, petrochemical and pipeline markets, safety being
the main priority of these industries. When properly applied, NDT saves money, time,
materials and lives. NDT as it is known today has been developing since around the
1920s, with the methods used today taking shape later and vast technological
advancements being made during the Second World War. The basic principal methods
are:
In all NDT methods, the interpretation of results is critical. Much depends on the skill and
experience of the technician, although properly formulated test techniques and
procedures will improve accuracy and consistency.
Visual testing begins with the eye; however, the first boroscopes used a hollow tube and
a mirror with a small lamp at the end to investigate the bores of rifles and cannons for
problems and discontinuities. In the 1950s, the lamps were replaced by glass fibre
bundles which were used to transmit the light. These became known as fibrescopes
which were also less rigid, increasing the capabilities of testing. With usage expanding,
many users began to suffer from eye fatigue which led to the development of video
technology. This was first used in the 1970s and relies on electronics to transmit the
images rather than fibreoptics.
Further enhancements to video technology include pan, tilt and zoom lenses, and
mounting cameras to platforms and wheels, all allowing more parts to be tested and
better images for improved inspection. Video devices also allow recordings of inspections
to be taken, meaning permanent records can be kept. This has a number of advantages
such as enabling other inspectors to observe the test as it was performed and allowing
further review and evaluation.
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Advantages Disadvantages
Able to test large parts with a portable kit Careful surface preparation required
A different (though related) method was introduced in the 1940s. The surface under
examination was coated with a lacquer, and after drying, the sample was caused to
vibrate by the tap of a hammer. The vibration causes
the brittle lacquer layer to crack generally around
surface defects. The brittle lacquer (stress coat) has
been used primarily to show the distribution of
stresses in a part and not for finding defects.
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Magnetic particle testing (MT)
Magnetic particle testing is used to locate surface and slightly sub-surface discontinuities
in ferromagnetic materials by introducing a magnetic flux into the material.
Advantages Disadvantages
This form of NDT became much more common after the First World War, in the 1920s,
when William Hoke discovered that flaws in magnetised materials created distortions in
the magnetic field. When a fine ferromagnetic powder was applied to the parts, it was
observed that they built up around the defects, providing a visible indication of their
location.
Magnetic particle testing superseded the oil and chalk method in the 1930s as it proved
far more sensitive to surface breaking flaws. Today it is still preferred to the penetrant
method on ferromagnetic material and much of the equipment being used then is very
similar to that of today, with the only advances coming in the form of fluorescent coating
to increase the visibility of indications and more portable devices being used. In the early
days, battery packs and direct current were the norm and it was some years before
alternating current proved acceptable.
Magnetism
The phenomenon called magnetism is said to have been discovered in the ancient Greek
city of Magnesia, where naturally occurring magnets were found to attract iron.
The use of magnets in navigation goes back to Viking times or maybe earlier, where it
was found that rods of magnetised material, when freely suspended, would always point
in a north-south direction. The end of the rod which pointed towards the North Pole star
became known as the North Pole and consequently the other end became the South
Pole.
Hans Christian Oersted (1777-1851) discovered the connection between electricity and
magnetism, followed by Michael Faraday (1791-1867), whose experiments revealed that
magnetic and electrical energy could be interchanged.
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Historical perspective
Electromagnetic testing – the interaction of magnetic fields with circulating electrical
currents - had its origin in 1831 when Michael Faraday discovered electromagnetic
induction. He induced current flow in a secondary coil by switching a battery on and off.
D E Hughes performed the first recorded eddy current test in 1879. He was able to
distinguish between different metals by noting a change in excitation frequency resulting
from effects of test material resistivity and magnetic permeability.
Advantages Disadvantages
Can detect through surface coatings Will not detect defects parallel to surface
Accurate conductivity measurements Not suitable for large areas and/or complex
geometries
Portability
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History of eddy current testing
The principles of eddy currents arose in 1831 with Faraday’s discovery of
electromagnetic induction; eddy current testing methods have their origins in a period
just after the First World War, when materials with a high magnetic permeability were
being developed for electrical power transformer cores and motor armatures. Eddy
currents are a considerable nuisance in electrical engineering – they dissipate heat and
efforts to reduce their effect led to a discovery that they could be used to detect material
changes and cracks in magnetic materials. The first eddy current testing devices for NDT
were in 1879 by Hughes, who used the principles of eddy currents to conduct
metallurgical sorting tests and the stray flux tube and bar tests.
It was left to Dr Friedrich Förster in the late 1940s to develop the modern day eddy
current testing equipment and formulate the theories which govern their use. The
introduction by Förster of sophisticated, stable, quantitative test equipment and of
practical methods for analysis of quantitative test signals on the complex plane was by
far the most important factor contributing to the rapid development and acceptance of
electromagnetic induction and eddy current testing. Förster is rightly identified as the
father of modern eddy current testing.
By 1950, he had developed a precise theory for many basic types of eddy current tests,
including both absolute and differential or comparator test systems and probe or fork coil
systems used with thin sheets and extended surfaces.
Applications for microcomputer chips abound, from giving lift-off suppression in simple
crack detection to providing signal processing for immediate analysis of condenser tube
inspection. As with other testing methods, improvements to the equipment have been
made to increase its portability and computer-based systems now allow easy data
manipulation and signal processing. Eddy current testing is now a widely used and
understood inspection method for flaw detection as well as for thickness and conductivity
measurements.
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Advantages Disadvantages
The origin of modern ultrasonic testing (UT) is the discovery by the Curie brothers in
1880 that quartz crystals cut in a certain way produce an electric potential when
subjected to pressure - the piezo-electric effect, from the Greek piedzein (to press or
strike). In 1881 Lippman theorised that the effect might work in reverse, and that quartz
crystals might change shape if an electric current was applied to them. He found that
this was so and experimented further. Crystals of quartz vibrate when alternating
currents are applied to them. Crystal microphones in a modern stereo rely on this
principle.
When the Titanic sank in 1912, the Admiralty tried to find a way of locating icebergs by
sending out sound waves and listening for an echo. They experimented further with
sound to detect submarines during the First World War. Between the wars, marine echo
sounding was developed and in the Second World War ASDIC (Anti-Submarine Detection
Investigation Committee) was extensively used in the Battle of the Atlantic against the
U-boats.
In the years after the Second World War, researchers in Japan began to experiment on
the use of ultrasound for medical diagnostic purposes. Working largely in isolation until
the 1950s, the Japanese developed techniques for the detection of gallstones, breast
masses, and tumours. Japan was also the first country to apply Doppler ultrasound, an
application of ultrasound that detects internal moving objects such as blood coursing
through the heart for cardiovascular investigation.
The first flaw detector was made by Sproule in 1942 while he was working for the
Scottish firm Kelvin & Hughes. Similar work was carried out by Firestone in the USA and
by German physicists. Sproule went on to develop the shear-wave probe.
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Initially UT was limited to testing aircraft, but in the 1950s it was extensively used in the
building of power stations in Britain for examining thick steel components safely and
cheaply. UT was found to have several advantages over radiography in heavy industrial
applications:
No health hazards were associated with radiography, and a UT technician could work
next to welders and other employees without endangering them of holding up work.
It was efficient in detecting toe cracks in boilers – a major cause of explosions and
lack of fusion in boiler tubes.
It could find planar defects, like laminations, which were sometimes missed by
radiography.
A UT check on a thick component took no more time than a similar check on a thin
component as opposed to long exposure times in radiography.
Over the next twenty years, improvements focused on accurate detection and sizing of
the flaws with limited success, until 1977 when Silk first discovered an accurate
measurement and display of the top and bottom edges of a discontinuity with the time-
of-flight diffraction (TOFD) technique. Advances in computing technology have now
expanded the use of TOFD as real time analyses of results are now available.
It was also during the 1970s that industries focused on reducing the size and weight of
ultrasonic flaw detectors and making them more portable. This was achieved by using
semiconductor technology and during the 1990s microchips were introduced into the
devices to allow calibration parameters and signal traces to be stored. LCD display
panels and digital technology have also contributed to reducing the size and weight of
ultrasonic flaw detectors. With the development of ultrasonic phased array and increased
computing power, the future for ultrasonic inspection is very exciting.
In UT a sound pulse is sent into a solid object and an echo returns from any flaws in that
object or from the other side of the object. An echo is returned from a solid-air interface
or any solid-non-solid interface in the object being examined. We can send ultrasonic
pulses into material by making a piezo-electric crystal vibrate in a probe. The pulses can
travel in a compression, shear or transverse mode. This is the basis of ultrasonic testing.
However, the information from the returning echoes must be presented for
interpretation. It is for this purpose that the UT set, or flaw detector as it is frequently
called, contains a cathode ray tube.
In the majority of UT sets, the information is presented on the screen in a display called
the A Scan. The bottom of the CRT screen is a time base made to represent a distance -
say 100mm. An echo from the backwall comes up on the screen as a signal, the
amplitude of which represents the amount of sound returning to the probe. By seeing
how far the signal comes along the screen we can measure the thickness of the material
we are examining.
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If that material contains a flaw, sound is reflected back from the flaw and appears on the
screen as a signal in front of the backwall echo (BWE) as the sound reflected from the
flaw has not had so far to travel as that from the backwall.
BWE
BWE
BWE
BWE
Defect
Defect
Ultrasonic signals
Anything that sends back sound energy to a probe to cause a signal on the screen is
called a reflector. By measuring the distance from the edge of the CRT screen to the
signal, we can calculate how far down in the material the reflector lies.
Advantages Disadvantages
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History of radiographic testing
X-rays were discovered in 1895 by Wilhelm Conrad Roentgen
(1845-1923) who was a Professor at Wϋrzburg University in
Germany. Whilst performing experiments in which he passed
an electric current through a Crookes tube (an evacuated
glass tube with an anode and a cathode), he found that when
a high voltage was applied, the tube produced a fluorescent
glow. Roentgen noticed that some nearby photographic plates
became fogged. This caused Roentgen to conclude that a new
type of ray was being emitted from the tube. He believed that
unknown rays were passing from the tube and through the
plates. He found that the new ray could pass through most
substances. Roentgen also discovered that the ray could pass
through the tissue of humans, but not bones and metal
objects. One of Roentgen's first experiments late in 1895 was
a film of the hand of his wife.
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radioactive element which they named ‘radium’, or shining element. Both polonium and
radium were more radioactive than uranium. Due to her lifelong research in this field,
Marie Curie is widely credited with the discovery of gamma radiation and the introduction
of the new term: radio-active.
Since these discoveries, many other radioactive elements have been discovered or
produced. Radiography in the form of NDT took shape in the early 1920s when H H
Lester began testing on different materials. Radium became the initial industrial gamma
ray source. The material allowed castings up to 10 to 12 inches thick to be radiographed.
During the Second World War, industrial radiography grew tremendously as part of the
Navy's shipbuilding programme. In 1946, man-made gamma ray sources from elements
such as cobalt and iridium became available. These new sources were far stronger than
radium and much less expensive. The man-made sources rapidly replaced radium, and
the use of gamma rays increased quickly in industrial radiography.
Direct radiography (DR) systems are also used based upon complementary metal oxide
sensor (CMOS) technology and TFT (thin film transistors). These systems have the
ability to directly convert light into digital format; additionally, they may be coupled with
a scintillator which coats CMOS and charged couple device (CCD) sensors. The
scintillator converts photon energy to light before the sensor and ADC converts to digital
format. Systems which use scintillators in this way are often referred to as indirect
systems.
Quality issues of any digital system are based upon the effective pixel size and the
signal-to-noise ratio (SNR). The benefits of using digital systems are the speed of
inspection and the absence of chemical processing requirements and wet film; however,
the initial equipment costs will be high.
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NDT Certification Schemes
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PCN – Personal Certification in Non-destructive testing
Managed and marketed by the British Institute of Non-Destructive
Testing (BINDT) which owns and operates the PCN Certification Scheme,
it offeres a UKAS accreditied certification of competence for NDT and
condition monitoring in a variety of product sectors.
Both schemes offer NDT certification conforming to BS EN ISO 9712; Qualification and
Certification of NDT personnel, this superseding EN473.
The points below cover extracts from this document which are major items, the full
document can be viewed on the BINDT website – www.bindt.org/certification/PCN.
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References
PCN documents
PSL/4 Examination availability
PSL/8A PCN documents – issue status
PSL/30 Log of pre-certification experience
PSL/31 Use of PCN & UKAS logo
PSL/42 Log of pre-certification on-the-job training
PSL/44 Vision requirements
PSL/49 Examination exemptions for holders of certification other than PCN
PSL/51 Acceptable certification for persons supervising PCN candidates gaining
experience prior to certification
PSL/57C Application for certification, experience gained post examination
PSL/67 Supplementary 56 day waiver
PSL/70 Request for L2 certificate issue to a L3 holder
CP9 Requirements for BINDT authorised qualifying bodies
CP16 Renewal and recertification of PCN Levels 1 & 2 certificates
CP17 Renewal and recertification of PCN Level 3 certificates
CP19 Informal access to authorised qualifying bodies by third parties
CP22 Marking and grading PCN examinations
CP25 Guidelines for the preparation of NDT procedures and instructions in PCN
examinations
CP27 Code of ethics for PCN certificate holders
Set up equipment.
Carry out the test.
Record and classify the results in terms of written criteria.
Report the results.
Level 1 personnel have not demonstrated competence in the choice of test method or
technique to be used, nor for the assessment, characterisation or interpretation of test
results.
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Level 2 personnel have demonstrated competence to perform and supervise non-
destructive testing according to established or recognised procedures. Within the scope
of the competence defined on the certificate, Level 2 personnel may be authorised by the
employer to:
Level 3 personnel are qualified to direct any NDT operation for which they are
certificated and may be authorised by the employer to:
Assume full responsibility for a test facility or examination centre and staff.
Establish, review for editorial and technical correctness and validate NDT instructions
and procedures.
Interpret codes, standards, specifications and procedures.
Designate the particular test methods, techniques and procedures to be used.
Within the scope and limitations of any certification held carry out all Level 1 and 2
duties and;
Provide guidance and supervision at all levels.
Level 3 certificated personnel may be authorised to carry out, manage and supervise
PCN qualification examinations on behalf of the British Institute of NDT.
Where Level 3 duties require the individual to apply routine NDT by a method(s) within a
particular product or industry sector, the British Institute of NDT strongly recommends
that industry demand that this person should hold and maintain Level 2 certification in
the applicable methods and sectors.
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Training
ET 40 40 40
PT 16 24 24
MT 16 24 32
RT 40 80 72
RI N/A 56 N/A
UT 40 80 72
VT 16 24 24
Note 1. Direct access to Level 2 requires the total number of hours shown in Table 1 for Levels 1
and 2, and direct access to Level 3 requires the total number of hours shown in Table 1 for
Levels 1-3. Up to one third of the total specified in this table may take the form of OTJ training
documented using form PSL/42 provided it is verifiable and covered practical application of the
syllabus detailed in CEN ISO/TR 25107:2006.
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Table 2 Minimum duration of experience for certification.
Experience, months
NDT method
Level 1
Level 2 Level 3
ET 3 9 18
MT 1 3 12
PT 1 3 12
RT 3 9 18
UT 3 9 18
RI N/A 6 N/A
VT 1 3 12
Work experience in months is based on a nominal 40-hour week or the legal week of work.
When an individual is working in excess of 40h/week, he may be credited with experience
based on the total hours, but he shall be required to produce evidence of this experience.
Direct access to Level 2 requires the total number of hours shown in Table 2 for Levels 1 and 2,
and direct access to Level 3 requires the total number of hours shown in Table 2 for Levels 1-3
Qualification examination
Table 3 Numbers of general questions.
NDT method Level 1 Level 2
ET 40 40
PT 30 40
MT 30 40
RT 40 40
RI N/A 40
UT 40 40
VT 30 40
BRS 30 N/A
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Re-examination
a A candidate who fails to obtain the pass grade for any examination part (general,
specific or practical) may be re-examined twice in the failed part(s), provided the re-
examination takes place not sooner than one month, unless further training
acceptable to BINDT is satisfactorily completed, nor later than twelve months after
the original examination.
b A candidate who achieves a passing grade of 70% in each of the examination parts
(general, specific or practical) but whose average score is less than the required 80%
may be re-examined a maximum of two times in any or all of the examination parts
in order to achieve an overall average score of 80%, provided the re-examination
takes place not sooner than one month, unless further training acceptable to BINDT
is satisfactorily completed, nor later than twelve months after the original
examination.
c A candidate who fails all permitted re-examinations shall apply for and take the initial
examination according to the procedure established for new candidates.
d A candidate whose examination results have not been accepted for reason of fraud or
unethical behaviour shall wait at least twelve months before re-applying for
examination.
Summary
The PCN scheme is managed and administered by the British Institute of NDT (BINDT)
on behalf of its stakeholders. It meets or exceeds the criteria of BS EN ISO 9712.
1 Aerospace.
2 Castings.
3 Welds.
4 Wrought Products and Forgings.
5 Pre and in-service inspection (multi sector).
6 Railway.
There are many additional supporting documents varying from vision requirements
PSL44 to renewal and recertification (Levels 1 and 2 – CP16; Level 3 – CP17) and so on.
The document defines many terms used in certification of NDT personnel (PCN Gen
Section 3)
The certification body (BINDT) meets the requirements of BS EN ISO 17024 (PCN Gen
section 5)
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BINDT approves authorised qualifying bodies (AQBs) to carry out the examinations (PCN
Gen Section 5)
a The document sets out the Levels of PCN certification and what each level of
personnel is qualified to do (PCN Gen section 6). There are 3 Levels of PCN
certification.
b Candidates for examination must have successfully completed a BINDT validated
course of training at a BINDT authorised training organisation (PCN Gen Section 7).
c Table 1 shows the minimum required duration of training for all Levels and methods
plus a section of notes.
d Table 2 gives the minimum duration of experience for each Level and method.
e A candidate is required to have a vision test of colour perception and a near vision
test (Jaeger Number 1 or N4.5). PCN Gen Section a – the near vision test to be taken
annually.
f Examination applications are made directly with the AQB.
g PCN Level 1s and 2 initial exams comprise general; specific and practical parts.
h Table 3 shows the number of general questions at Levels 1 and 2 examinations.
i There are 30 specific questions on the Level 1 papers.
j There are 36 questions on the Level 2 specific papers.
k A variety of practical samples are tested depending on the method and sector.
l A Level 3 examination comprises a basic and a method examination – however the
basic examination needs to be passed only once. Table 4 shows the number of basic
examination questions. Table 5 shows the number of Level 3 examination questions.
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Table 5 Main method examination.
m A pass is obtained where each part is 70% or over with an average grade of 80% or
over.
n A PCN certificate is valid for 5 years.
o Renewal and recertification requirements are covered in CP16 for Level 1 and Level 2
and CP17 for Level 3.
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Section 1
Introduction
1 Introduction
This section covers the syllabus for PCN approval in eddy current testing of
aircraft components and structures. It also provides a basis for the more
advanced concepts used in tube testing, material sorting and weld testing which
are covered in section 2.
The text for this course is laid out in a manner which it is hoped will make it
easier to follow than conventional course texts.
In general, right hand pages are used for text and left hand pages for flow
charts, diagrams and tables. Looking across the page to the right of a particular
diagram you should find the relevant text.
We have left plenty of space on the pages to encourage you to add notes from
the lectures.
The flow charts, we hope, you will find useful in following the progress of the
course lectures. In eddy current methods there are many concepts and models
that are difficult to comprehend unless they can be put into the context of the
subject as a whole.
Because we are using flow charts there is no index. Each flow chart splits a
subject title into several subheadings, given with a decimal notation for the
paragraph number. Therefore the number 2.2.31 means paragraph number 31,
under subheading number 2 of subject title 2. This makes it easier for us to
change the text. We hope it does not confuse you.
Certainly not all of these units are of relevance to this course but the Table will
be a useful reference.
We shall also be using scientific notation, which is useful shorthand for writing
numbers with a great number of zeros.
For example:
But
m.sˉ¹ = m/s
m.sˉ² = m/s
m.s² = m x s²
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1.2 History of eddy current testing
Eddy current testing methods have their origins in a period just after the First
World War, when materials with high magnetic permeability were being
developed for electrical power transformer cores and motor armatures. Eddy
currents are a considerable nuisance in electrical engineering - they dissipate
heat and efforts to reduce their effect led to a discovery that they could be used
to detect material changes and cracks in the magnetic materials. The first eddy
current testing devices for NDT were by Huges in 1879.
It was left to Frederick Forster in the late 1940s to develop the modern eddy
current testing equipment and formulate the theories which govern their use.
Since then, eddy current methods have developed into a wide range of uses
and are recognised as being the front-runner in NDT techniques today. Modern
electronics have not only reduced the noise levels which made certain test
applications very difficult but they have also improved the methods of signal
presentation. Microcomputer chips abound, from giving lift-off suppression in
simple crack detectors to providing signal processing for immediate analysis of
condenser tube inspections.
In all the NDT methods, results can be misinterpreted easily. For example, MT
may reveal strong indications along the weld toe that are impossible to
distinguish from toe cracks. Much depends on the skill of the operator, although
properly formulated test techniques and procedures will improve test accuracy
and consistency.
Some NDT methods can be destructive. There are, for example, many corrosive
liquids used in penetrants and contrast aids.
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Table 1.1 SI units of measurement
Base quantities Symbol
Length metre m
Mass kilogram kg
Time second sec
Electric current ampere A
Thermodynamic temperature kelvin K
Luminous intensity candela cd
Amount of substance mole mol
Derived units
Frequency hertz Hz 1Hz=1secˉ¹
Force newton N 1N= 1kg.m/sec²
Pressure and stress pascal Pa 1Pa=1N/m²
Work and energy joule J 1J=1N/m
Power watt W 1W=1J/sec
Quantity of electricity coulomb C 1C=1A/sec
e.m.f. and potential volt V 1V=1W/A
difference
Electric capacitance farad F 1F=1A.sec/V
Electric resistance ohm Ω 1Ω=1V/A
Electric conductance siemens S 1S=1Ωˉ¹
Magnetic flux weber Wb 1Wb=1V/sec
Magnetic flux density tesla T 1T=1Wb/m ²
Inductance henry H 1H=1V.sec/A
Luminous flux lumen lm 1lm=cd/sec
Illumination lux lx 1lx=1lm/m ²
Prefixes Symbol
10¹² tera T
10 giga G
10 mega M
10³ kilo k
10² hector h
10 deca d
10ˉ¹ deci d
10ˉ² centi c
10ˉ³ milli m
10ˉ6 nicro µ
10ˉ9 nano n
10ˉ¹² pico p
10ˉ¹5 femto f
10ˉ¹8 atto a
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Penetrant testing (PT)
Penetrant testing locates surface-breaking discontinuities by covering the item
with a penetrating liquid, which is drawn into the discontinuity by capillary
action. After removal of the excess penetrant the indication is made visible by
application of a developer. Colour contrast or fluorescent systems may be used.
Advantages Disadvantages
Applicable to non-ferromagnetics Will only detect defects open to the
surface
Able to test large parts with a portable kit Careful surface preparation required
Batch testing Not applicable to porous materials
Applicable to small parts with complex Temperature dependant
geometry
Simple, cheap, easy to interpret Cannot retest indefinitely
Good Sensitivity to surface defects Compatibility of chemicals
Advantages Disadvantages
Will detect some sub-surface defects Ferromagnetic materials only
Rapid and simple to understand Requirement to test in two directions
Pre-cleaning not as critical as with dye Demagnetisation may be required
penetrant inspection (DPI)
Will work through thin coatings Odd shaped parts difficult to test
Cheap rugged equipment Not suited to batch testing
Direct test method Can damage the component under test
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Eddy current testing (ET)
Eddy current testing is based on inducing electrical currents in the material
being inspected and observing the interaction between those currents and the
material. Eddy currents are generated by coils in the test probe and monitored
simultaneously by measuring the coils electrical impedance. As it is an
electromagnetic induction process, direct electrical contact with the sample is
not required; however, the material must be an electrical conductor.
Advantages Disadvantages
Sensitive to surface defects Very susceptible to permeability changes
Can detect through several layers Only on conductive materials
Can detect through surface coatings Will not detect defects parallel to surface
Accurate conductivity measurements Not suitable for large areas and/or
complex geometries
Can be automated Signal interpretation required
Little pre-cleaning required No permanent record (unless automated)
Portability
Advantages Disadvantages
Gives a permanent record, the radiograph There is a radiation health hazard
Detects internal flaws Can be sensitive to defect orientation and
so can miss planar flaws
Detects volumetric flaws readily Has limited ability to detect fine cracks
Can be used on most materials Access is required to both sides of the
object
Can check for correct assembly Skilled radiographic interpretation is
required
Gives a direct image of flaws Is a relatively slow method of inspection
Fluoroscopy can give real time imaging Has a high capital cost
Has a high running cost
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Introduction 1-5 Copyright © TWI Ltd
Ultrasonic testing (UT) - pulse echo
Ultrasonic testing measures the time for high frequency (0.5-50MHz) pulses of
ultrasound to travel through the inspection material. If a discontinuity is
present, the ultrasound will be reflected to the probe in a time period other than
would be expected of a fault free specimen.
Advantages Disadvantages
Sensitive to cracks at various orientations No permanent record (unless automated)
Portability Not easily applied to complex geometries
and rough surfaces.
Safety Unsuited to coarse grained materials
Able to penetrate thick sections Reliant upon defect orientation
Measures depth and through-wall extent
Reason for inspection. (To detect cracks, to sort between materials, to check
assembly, etc.).
Likely orientation of planar discontinuities, if they are the answer to the
above question.
Type of material.
Likely position of discontinuities.
Geometry and thickness of object to be tested.
Accessibility.
Product knowledge.
Previous failures.
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Ultrasonic testing
The length and position of a discontinuity can be determined. Depth
measurements are more difficult but crack tip diffraction or time-of-flight
techniques can give good results.
Radiography testing
The length and plan view position can be determined. Through-thickness
positioning requires additional angulated exposures to be taken. The through-
thickness dimension of discontinuities cannot readily be determined.
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Introduction 1-7 Copyright © TWI Ltd
Section 2
Principles
2 Principles
2.1 Electricity
Electricity refers to the flow of electrons through simple materials and devices.
The name is derived from the Greek word Elektra, the name given to an exotic
mineral, which when rubbed with a cloth, builds up a static charge which
creates sparks.
It was Benjamin Franklin and his hazardous experiments with flying a kite into
thunder clouds, who hit on the idea that electricity could be described as
something flowing through a conductor from positive to negative electrodes.
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Principles 2-1 Copyright © TWI Ltd
a b
Figure 2.1:
a Hydrogen atom;
b Copper atom;
c Experiment with pith balls and glass rod.
2.1.1 Electrons
The basic building block of all matter is the atom. The nature of the atom and
the electromagnetic forces within it determine the characteristics of matter.
There are 118 different elements known to make up matter and each one has a
characteristic atom.
The simplest atom is hydrogen, which has a nucleus of one proton, or positively
charged particle and one neutron, a neutral particle, orbited by one electron, a
negatively charged particle (Figure 2.1a).
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As the atoms become larger and the number of charged particles increases, so
the electrons arrange themselves in fixed orbits or shells called K,L,M,N,O and
P. The outer shell is the valence shell and it is the number of electrons in this
shell which determines the electrical and chemical properties of an atom.
Copper has only one valance electron. This can be lost easily and for this reason
copper is a good conductor of electricity (Figure 2.1b).
2.1.2 Electrostatics
Electrostatics is the study of electrical forces which exist between charge
particles. In their most fundamental form these forces hold the electron in orbit
around the nucleus of an atom.
The origin of these forces is a mystery but we do know what their effects are.
For example, we know that like charges repel and unlike charges attract. By
convention the electrostatic force lines are drawn pointing away from the
positive charge and towards the negative charge (Figure 2.1c).
The effects of electrostatic fields can be demonstrated using pith balls and a
glass rod. The glass rod is first charged positive by rubbing it with a silk cloth.
This removes the electrons by friction. The rod is then brought close to the
balls, which although initially of neutral charge, will become polarised so that
they are both attracted to the rod. As soon as the rod touches the balls,
electrons are removed from both so that they become positive and repel each
other.
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Figure 2.3 Dry cell.
An electric circuit is a complete path around which electrons can flow. If the
circuit is broken, then the electrons cannot flow and the circuit becomes an
open circuit.
The load provides the pressure against which the electromotive force of the
battery must push the electrons, otherwise the circuit will short.
2.1.4 Battery
A battery is a means of applying a potential difference across a circuit to push
electrons around it.
The simple battery shown is a primary cell and cannot be recharged. Other
types including lead acid and nickel-cadmium batteries can be recharged and
are therefore secondary cells (Figure 2.3).
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In SI units it is a base quantity and therefore defined in absolute terms as that
current which when flowing along two infinitely long parallel conductors, one
metre apart in free space, exert any attraction of 2 x 10ˉ7 Newtons per metre.
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Figure 2.5 Power formulae.
R is in Ohms (Ω).
V is in volts.
I is in amps.
Quantities on either side of the vertical line are multiplied, while quantities
below the horizontal line are divided into quantities above it.
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To use the circle, simply cover the segment you want to find and the position of
the remaining letters tells you the procedure to follow.
P = I X V.
P is in watts.
I is in amps.
V is in volts.
By using Ohm’s law to substitute the variables, the power formulae (Figure 2.5)
can also be written as:
OR
R = R1 + R2…RN
Current has the same value at any point within a series circuit.
1 Total voltage of parallel circuit is the same across each branch of that
circuit.
2 Total current in a parallel circuit is equal to the sum of the individual branch
circuits.
3 Total resistance in a parallel circuit is always less than the value of the
smallest resistive branch.
1 1 1 1
R R1 R2 RN
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Figure 2.8 Series string of lights.
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Principles 2-8 Copyright © TWI Ltd
2.1.12 Parallel and series circuits.
Parallel circuits are an advantage in lighting a Christmas tree with several
bulbs. When they are connected in series and one filament is blown then all the
lights will go out. When connected in parallel, current will continue to flow to
the bulbs even if one of the filaments is blown (Figures 2.8 and 2.9).
The twelve volt battery consisting of six two volt cells in series supplies a
voltage against the car chassis.
For example, to find the resistance of the head-light filament we could measure
the current by connecting an ammeter across the open switch and dividing this
value into the voltage across the bulb. We know this is twelve volts as there are
no other loads in this branch.
To find the voltage across the coil in the spark plug branch, the voltage across
the dropping resistor could be measure and subtracted from twelve volts.
Similarly, when the fan is not accessible, the current in the fan motor branch
could be measured by connecting an ammeter across the open switch and
measuring the voltage across the speed control. The fan voltage could then be
calculated by subtracting the speed control voltage from twelve volts. The
speed motor has three switches, the one without a resistance corresponding to
the fastest fan speed.
The spark plug branch is designed so that when one of the set of points in the
distributor is closed, current rapidly builds up in the coil creating a strong
magnetic field. When the points open, this field collapses suddenly, creating a
high voltage and therefore arc in the spark plug. The buffer capacitor is placed
across the points to prevent similar spark occurring there since it prevents the
coil’s inductive voltage reaching the points.
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Figure 2.11 Meter controls.
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Principles 2-10 Copyright © TWI Ltd
2.1.14 Resistor
Resistors are used to control the amount of current in a circuit. Two variable
resistors, usually called potentiometers or ‘pots’ are shown which set the zero
and control the sensitivity of the meter (Figure 2.11).
2.1.15 Capacitor
A capacitor or condenser is a device for storing electric charge (Figure 2.12). It
consists of two parallel plates separated by a dielectric material.
If the plates are connected to the terminals of a battery, the positive terminal
will take electrons from one plate and the negative terminal will push electrons
onto the other plate. A voltage will build up across the capacitor which will
eventually equal the electromotive force of the battery and the capacitor will be
fully charged.
Q
C=
V
The farad is a very large unit and so common capacitors are rated in
microfarads or picofarads.
1 The size of the capacitor plates. The greater areas of the plates facing each
other, the more charge they can hold.
2 The distance between the plates. The closer they are together, the greater
the capacitance.
3 The nature of the dielectric material that separates the capacitor plates. Not
only does the dielectric prevent charge breaking down the barrier between
the plates, but also the dielectric helps the capacitor to store charge. For
example, glass will allow the capacitor to store eight times more charge
than air, when it is placed between the plates.
Capacitors have a very wide range of uses where a large transient current is
needed, for example, in spot welders, flash guns, ignitions systems and dc
magnetic particle inspection equipment.
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For eddy current testing we are interested in variable capacitors which are used
in alternating circuits to adjust the phase between voltage and current or create
resonance.
1
G=
R
G is in Siemens.
R is in ohms.
10
ρ is in micro-ohms • cm.
is the length in cm.
A is the cross-sectional area of the circuit in cm².
R is in ohms.
1
x 10 8
ợ is in Siemens/m.
ρ is in micro-ohms •·cm.
2.2 Magnetism
The phenomenon called magnetism was discovered in the ancient Greek city of
Magnesia, where naturally occurring magnets were found to attract iron.
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The use of magnets in navigation goes back to the eleventh century, where it
was found that rods of magnetised material, when freely suspended, would
always point in a North-South direction. The end of the rod which pointed
towards the North Pole star became known as the North Pole and consequently
the other end became the South Pole.
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Figure 2.14 Magnetisation curve.
Within the atom there are magnetic forces which are the result of the spinning
and orbiting motions of the electrons. If an external field is applied, then
according to Lenz’s law, any magnetic moments should align themselves to
oppose the applied field. This is the case with diamagnetic elements, a group
which includes copper. The effect is so very slight as to be negligible.
2.2.2 Ferromagnetism
Ferromagnetism is a term used to describe certain materials which exhibit
strong magnetic behaviour. We say that they have high magnetic permeability.
The three most common ferromagnetic elements are iron, cobalt and nickel, but
there are others, for example, gadolinium, which is important for electronics.
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One end of the domain will therefore have a strong north pole and the other a
south pole. The magnetic circuits created by the domains are aligned to reduce
flux leakage to a minimum. They therefore adopt a parallel but opposing
arrangement or lay across each other. Between the domains exists a domain
wall across which the magnetic dipoles twist like a corkscrew.
In the ground state, the domains have no preferred orientations and the
ferromagnetic is unmagnetised. If an external magnetic field is applied in the
direction of the magnetic dipoles in domain A, then this domain will grow at the
expense of domain B by twisting over the dipoles in the domain wall (Figure
2.13). This change is elastic. If the external field is removed the domains will
return to the ground state.
As the external field continues to increase, the domains walls become detached
from dislocations which they tend to follow in the crystal lattice and will latch
themselves to achieve eventually a state of magnetic saturation.
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Figure 2.16 Hysteresis loops for iron and steel.
B
H
r
0
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2.2.4 Magnetic hysteresis
When a ferromagnetic is placed in an alternating magnetic fiend (H), the
variation in the density of flux lines (B) through it, gives rise to magnetic
hysteresis (Figure 2.15).
The word hysteresis is derived from the Greek for delayed and is used to
describe one thing lagging behind another. The variation of B with H follows a
hysteresis loop and is a characteristic of the ferromagnetic material.
Let us take it from the point where all the domains in the ferromagnetic are
aligned with the applied field. This is called the saturation point.
Further increases in H in this direction will then take the domains to saturation
once more, but with the polarity reversed.
The slope of the axes of the two hysteresis loops show that the steel is more
difficult to magnetise than the iron, but that once magnetised, it is more
difficult to demagnetise. The steel would therefore make a better permanent
magnet despite having a smaller remanence. It is much larger coercive force
will make steel much more difficult to demagnetise by shaking and knocking.
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Figure 2.18 Magnetic field through a coil.
2.2.5 Electromagnetism
Whenever electric current flows along a conductor, a magnetic field is set up
around the conductor in a plane with its axis parallel with the flow of electrons.
The magnetic field is there only when electrons are flowing.
The direction of the flow of magnetism is given by the right hand rule (Figure
2.17). If the thumb of the right hand is extended in the direction in which the
conventional current is flowing, then the direction of the magnetic flow is given
by the fingers. Remember that the electron flow is in the opposite direction to
the conventional current flow.
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The larger the current, the stronger the magnetic flow. The further away from
the conductor, the weaker the magnetic flow. The magnetic flow can be
detected by placing a compass needle near the conductor. It will align itself with
the North Pole pointing in the direction of the magnetic flow.
2.2.6 Coils
If a current-carrying wire is looped into several turns, the magnetic field around
each turn link together, giving rise to a strong magnetic field through what is
now a coil (Figure 2.18).
This magnetic field behaves like a bar magnet and will attract ferromagnetic
objects. The polarity of the coil ends is determined by a rule which shows that
when the coil is viewed end-on, if the conventional current is flowing clockwise,
that will be the South Pole. If the conventional current is flowing anti-clockwise,
that end of the coil will be the North Pole.
The intensity of the magnetic field through the coil is a product of the coil
current and the number of coil turns.
Coils can be used to control electrical switches called relays. One typical
application is the ignition switch of a car engine (Figure 2.19). Here a small
control current passes through a coil. When it is switched on the ferromagnetic
plunger moves through the coil and closes the contacts of the starter motor
circuit. This carries an extremely high load, of perhaps one hundred amperes
and it would be extremely hazardous to connect this directly to the key switch.
The electromotive force then becomes the magnetomotive force and is measure
by multiplying the coil current by the number of turns.
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The ration between magnetomotive force and flux is constant as is the ration of
electromotive force to current in an electric circuit. This magnetic equivalent of
Ohm’s law is called Bosanquet’s law and the magnetic equivalent of resistance
is called reluctance, and is given by:
Where
F = Magnetomotive force (Mmf).
= Magnetic flux.
B
A
One tesla is the magnetic flux density of a uniform field that produces a torque
of 1N/m on a plane current loop carrying one ampere and having a projected
area of 1m² in a plan perpendicular to the field.
m.m.f.
H
D
H is in A/m.
mmf is in A • turns (Mmf is the magnetomotive force, also known as magnetic
potential and is analogous to emf or voltage in electricity).
D is the axial distance in metres.
2.2.10 Inductors
Coils have an effect on the current which is passing through them and are
therefore called inductors.
The magnetic field which they create acts as a store of energy, which has been
taken from the electrical current. As long as the current is not changing, the
magnetic field is in a steady state and it has no effect on the current.
If the current is building up, the current finds itself building up the magnetic
field as well and its flow is opposed. This results in the current taking a longer
time to build up in a circuit containing an inductor than in a circuit containing a
resistor only.
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As the current in the inductor decreases, the magnetic field is reconverted to
electrical energy and so slows the rate at which the current in the inductor
decays.
It can be said therefore, that inductors act to oppose any change in the current
through them.
L = Inductance in henrys.
ϒ = A geometric factor.
N = Number of coil turns.
A = Coil’s planar surface area in mm².
l = Coil’s axial length.
The henry is a very large unit. Eddy current coils have inductances of a few
microhenrys.
The change in the current with time can be represented by a sine wave model.
When the capacitors or inductors are placed in an AC circuit we find that the
voltage and current waves do not coincide. We say they are out of phase. To
analyse these phase differences we use vector diagrams.
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Figure 2.21 Sine waves.
In practice the root mean square (RMS) (Figure 2.22) value is measured, which
is defined as that value of steady current which would dissipate heat at the
same rate in a given resistance.
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The power is dissipated in heat is given by:
P = l²R
By plotting the squares of the current values we can find an average, since
negative as well as positive values become positive. To measure the square of
the current we use a moving iron ammeter. This type of ammeter consists of
two iron rods which are forced apart as they are magnetised. Their level of
magnetisation is proportional to the current and therefore the force between
them is roughly proportional to the square of the current. The meter is
calibrated to read the root of the mean to the square values and is therefore
non-linear.
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Figure 2.24 Reactance and resistance.
When the battery is disconnected in circuit A, the light in circuit B flashes for an
instant. Similarly when the battery is reconnected and the current is building up
in circuit A, so the bulb in circuit B flashes. While current is flowing steadily in
circuit A, the light in B is off (Figure 2.23).
The two circuits are not linked electrically but the magnetic field around circuit
A does link through circuit B.
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2.3.4 Lenz’s law
This law states that the electromotive force induced by the variation in
magnetic flux is always in such a direction that if it produces a current, the
magnetic effect of that current opposes the flux variation responsible for both
the electromotive force and the current.
Ohm’s law can be applied to the reactances. The ratio of voltage to current
across each component is constant:
Vc VL
XC XL
I I
When the voltage in the circuit is at maximum, so is the charge in the capacitor.
It is therefore not charging and the current is zero. When the voltage starts to
fall the capacitor is completely discharged and the voltage is zero.
Across an inductor, the voltage leads the current by a quarter cycle (π/2). This
can be explained as follows:
When the current in the circuit is at a maximum, the rate of change in the
magnetic flux in the coil is zero and therefore the self-induced voltage is zero.
When the current in the circuit is at zero so the rate of change in the magnetic
flux is at a maximum and so therefore is the self-induced voltage. When the
current is building up in the positive direction, so the induced voltage will be
slowing down in the positive directions. When the current is building up in the
negative direction, so the voltage is slowing down in the negative direction.
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Figure 2.25 Coil’s equivalent circuit.
V
Z
I
In eddy current testing, the most important impedance is that which exists
across a test coil (Figure 2.25). The coil can be regarded as an indicative
reactance and resistance in series. The capacitive reactance of the coil is
negligible. The impedance (Figure 2.26) in this case has two components which
are vectors that are at right angles to each other.
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Let us say that we know that the inductive reactance of the coil is 4ohms and
its resistance is 3ohms. If the two quantities were scaler we would simply add
them together to find the impedance. However, they are vectors and must be
added together vectorily as described in Section 2.3.8.
To add the two vectors we can draw an impedance diagram as shown, from
which we find that the impedance is 5ohms.
Where j = √-1 and is the mathematical operator which rotates the XL vector
through 90°.
The angle ợ gives the angle between the voltage and current phases in the coil.
This is because the voltage is in phase with the current in resistance and 90°
lead of the current in the inductive reactance. The voltage vector can therefore
be substituted for the impedance vector. The angle ợ can be solved from:
XL
arctan
R
Let us now say that the inductive reactance of the coil is reduced to 3ohms
because of the increased eddy currents in the coil’s magnetic field which
dissipate more heat and therefore increase the coil’s resistance to 4ohms. The
coil’s impedance is still 5ohms, but the phase angle between voltage and
current has changed by 160°. There has been a phase change but no amplitude
change. A simple meter reading circuit would miss this change.
Other facts which we have already realised can be described on the impedance
diagram.
If the coil has no resistance, then it is a pure inductor, the impedance equals
the inductive reactance and the voltage leads the current by 90°.
If the coil has no inductive reactance, then the coil is a pure resistor, the
impedance will equal the resistance and the voltage and current are in phase.
As described in section 2.3.7 this occurs when dc is passed through the coil.
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2.3.7 Frequency
The inductive reactance and the capacitive reactance depend upon the
frequency of the ac current, as can be seen from the following equations:
1
2
2
XL = Inductive reactance.
Xc = Capacitive reactance.
f = Test ac frequency.
L = Circuit inductance.
c = Circuit capitance.
2.3.8 Vectors
Some physical quantities are described by a single number. These are scalar
quantities. Examples of scalar quantities are speed, temperature and weight.
Others have a directional quantity as well and cannot be described by a single
number. These are vector quantities (Figure 2.27). Examples include velocity,
force and coil impedance.
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We can plot the vectors as components in a rectangular (cartesian) co-ordinate
system on a scaled diagram. The resultant vector R and its direction can be
measured from the diagram or calculated.
To begin with the equivalent circuit for a coil, we have an inductive reactance
and resistance in series. The voltage across the resistance is in phase with the
current so we shall replace the x co-ordinate with this. The voltage across the
inductive reactance leads the current by 90° and we shall replace the y co-
ordinate with this.
Initially the voltage across the whole coil is 20 millivolts and leads the current
by 60°. The voltage across the resistance then increases by 30 millivolts and
across the inductive reactance increases by 10 millivolts.
The voltage across the whole coil now becomes 48.4 millivolts and it leads the
current by 34.3°.
For eddy current testing, the magnetic fields are generated by a coil carrying
high frequency AC. When the coil is brought into close proximity with a metal,
the alternating magnetic field induces the eddy currents. The eddy currents are
encircled by their own magnetic fields which are in a direction to oppose the
field from the coil which is generating them. They therefore have a choking
effect on the coil current. The choking effect, which is reflected in the coil’s
impedance, is monitored by the eddy current instrument.
Changes in the eddy current field due to changes in the metals properties near
the surface, cause changes in the coil’s impedance. These are the test signals.
It is difficult to understand the process without the conceptual models of the
physicist. These are enshrined in the classical laws of Faraday and Lenz and in
Maxwell’s equations.
The following sections describe the factors which affect the eddy current field.
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Table 2.1 Conductivities.
Materials IACS% µΩ•cm
Silver 105 1.6
Copper 100 1.7
Gold 75 2.35
Aluminium 61 5.3
Al-6101 56 3.1
Al-5052 35 4.93
7075-T6 32 5.3
Magnesium 37 4.6
Phosphor bronze 15 10.5
Cartridge brass 28 6.2
Admiralty brass 24 7.0
Tungsten 30 5.65
Nickel 23 7.98
98Cu-2Ni 35 4.99
70Cu-30Ni 4.5 37
70Cu-22Ni 5.7 30
Iron 18 9.7
Platinum 16 10.6
Tantalum 14 12.45
Carbon steel 9.5 18
Chromium steel 6.1 29
Cobalt steel 6.3 28
Stainless steel 501 4.5 40
Stainless steel 410 3 57
Stainless steel 304 2.5 70
Lead 8.4 20.6
Monel 3.6 48.2
Zirconium 3.4 50
Titanium 3.1 54.8
Resistivity
100%IACS = 58m/Ω mm² = 5.8 10 / /
10 8
1siemen / m
1 cm
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Principles 2-30 Copyright © TWI Ltd
Conductivity is affected by heat treatment of the material. This feature can be
used in assessing the fitness-for-purpose of aluminium aircraft components
damaged in engine burn-outs and tyre bursts. The hardening of the aluminium
alloy increases its conductivity. However, it must be remembered that at very
high temperatures this effect can be reversed.
Mn steel 1300
As well as introducing high levels of noise to the eddy current test, permeability
also reduces the depth of penetration of the eddy currents to the extent that
only surface discontinuities can be detected.
Magnetic and Relative Permeability are further described in Section 2.2.3 with
maximum values of relative permeabilities given in Table 2.2 above.
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Principles 2-31 Copyright © TWI Ltd
Measurement of magnetic permeability does provide useful information about
ferromagnetic materials. This is the basis of ferrous segregators and
electromagnetic sorting bridges. Permeability is affected by:
The equipment used in these material sorters is based upon the principles of
eddy current testing, but because it is the inductive effects of magnetic
materials in the test coil and not the eddy current effect which dominates over
any given test signal, the methods are referred to as electromagnetic testing
and not eddy current testing. See section 8 for further details.
A typical use for the instrument is to sort out forgings in a batch which have
been case-hardened. The method is surprisingly sensitive to even minor
changes in the case depth.
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Principles 2-32 Copyright © TWI Ltd
Figure 2.30 Standard depths of penetration.
2.4.3 Frequency
The most important test variable is the frequency of the current sent through
the test coil. Eddy current testing is done at frequencies from a few hertz to
several megahertz.
The most important effect of test frequency is upon the depth of penetration
(Figure 2.28) of the eddy current field. As the frequency increases so the depth
of penetration decreases. This is known as skin effect (Figure 2.29) and it can
be defined by the formula:
500
f..
When Eddy Currents flow in a Conducting material magnetic fields are produced
that oppose the primary magnetic field, thus reducing the resultant magnetic
flux and causing a reduction in current flow as the depth below the surface
increases. This is known as the ‘skin effect’.
The standard depth of penetration is defined as the depth below the surface
(Figure 2.30) at which the intensity of the eddy current field has been reduced
1
to a value of e of its intensity at the surface. The function of e is the base of
the natural logarithms. It is equal to 2.718 when taken to three decimal places.
Therefore at the standard depth of penetration, the eddy current field intensity
is at approximately one third of its surface value (36.8%).
NDT31-50316b
Principles 2-33 Copyright © TWI Ltd
What a bizarre way of setting a standard, you may say. Well the intensity of
eddy current field falls exponentially with increasing depth. The equation for a
curve describing this decay is of the form:
Intensity = 8 -depth
The intensity never actually reaches zero, so we take value beyond which the
effect of eddy currents on the test coil is small. The standard depth of
penetration acts as a good reference point to base frequencies used for finding
subsurface discontinuities.
Remember however, that there are eddy currents at greater depths that may
affect coil impedances and that with thin wall tubes and solid bars it is their
geometry that determines the depth of penetration, not the formula. Always
use calibration blocks with discontinuities at known depths when setting
sensitivities for low frequency testing.
The reason for the exponential decay of eddy current intensity with increasing
depth is that each layer of eddy current partially shields the next deeper layer
from the coil’s magnetic field. The rate of decay in intensity falls as the depth
increases and the eddy current intensity decreases, so that in theory the
intensity reaches zero only at infinity.
The formula only applies to the skin depth. High frequency eddy current testers
are made sensitive to surface breaking slots well in excess of the standard
depth of penetration because the eddy currents flow around the slot sides and
tip.
The standard depth of penetration is also dependent upon the conductivity and
permeability of the material. An increase in the conductivity increases the
intensity of the eddy currents at the surface, creating a greater shield against
the coil’s magnetic field. The rate of decay therefore increases.
NDT31-50316b
Principles 2-34 Copyright © TWI Ltd
Figure 2.31 Edge effect. Figure 2.32 Lift-off.
NDT31-50316b
Principles 2-35 Copyright © TWI Ltd
Surface probes are often held in fixtures or jigs that will keep the probe at a
fixed distance from the edge, as it is scanned parallel with the edge. The edge
effect is therefore kept constant. Where a ferromagnetic material abuts the
edge, the edge effect is much stronger and it is necessary to use shielded
probes where the coil’s external magnetic field can be constrained within a
ferrite housing.
For tube testing with different encircling coils, a few millimetres at each end of
the tube cannot be tested because of the edge effect.
2.4.5 Lift-off
Lift-off (Figure 2.32) is the term given to the eddy current test response to
lifting a surface coil from the test surface. As the coil moves away, the magnetic
coupling to the eddy current field weakens very rapidly. Small movements give
a pronounced effect. The noise generated by the test coil as it scans a round
surface would be too high unless measures are taken to lessen lift-off. These
measures include tuning the coil with a capacitor and rotating the lift-off plane
in the impedance diagram in a manner which reduces the lift-off effect.
On the other hand, the lift-off effect can be used to measure the thickness of
non-conductive paint coatings on a metal substrate.
For an internal bobbin coil, the fill factor is measured as the square of the ratio
of the coil diameter over tube diameter. for example:
For an encircling coil, the fill factor is the square of the ration of the tube
diameter over the coil diameter. for example:
The fill factor can never exceed 1.0 and is more usually about 0.7. At high test
speeds, large fill factors will inevitably result in damage to the coil. A fill factor
below 0.6 will result in a low sensitivity. There is an exception in the case of
electromagnetic sorting bridges. The test frequencies are low and the test
signals are caused by the inductive effects of the ferromagnetic testpieces. Fill
factor is then of less importance.
2.4.7 Discontinuities
Only cracks and laminations which distort the eddy current field will give rise to
eddy current test signals. Laminations parallel with the test surface will not be
detected (Figure 2.34).
A surface crack will increase the resistive path of the eddy currents and deflect
them downwards so that their magnetic fields have less effect on the coil.
Changes in both the inductive reactance and resistance of the coil can then be
expected.
NDT31-50316b
Principles 2-36 Copyright © TWI Ltd
Section 3
Equipment
3 Equipment
3.1 Circuits
The circuits used in the eddy current test instruments are designed to amplify
the very small changes in the coil current while keeping noise to a minimum.
Although it is not necessary to know of the complexities of modern electronics it
is both useful and interesting to know something of the principles.
Early high frequency crack detectors have much in common with radio
receivers. The coil is analogous to the radio aerial. The bridge circuit however,
has always formed the basis of low frequency equipment.
NDT31-50316b
Equipment 3-1 Copyright © TWI Ltd
a b
NDT31-50316b
Equipment 3-2 Copyright © TWI Ltd
3.2 Simple circuits
A very simple circuit for detecting changes in the coil impedance would consist
of an oscillator to supply high frequency sinusoidal currents to the coil and a
voltmeter connected across the coil, Figure 3.1a.
The meter would be zeroed with the probe on the test surface so that the eddy
current field affecting the coil’s impedance is in a steady state. As the probe
crosses a crack, the eddy currents flow around the crack tip. The coil impedance
changes creating a deflection in the voltmeter.
These circuits would not make practical eddy current test instruments because
the voltage changes due to quite major cracks would only be of the order of
0.1%.
XL = XC
1
2fL
2fC
1
f
2 LC
f is frequency.
C = capacitance (farads, F).
L = Inductance (henrys, H).
Resonance occurs at a unique frequency and for most practical purposes; this is
done in the kHz-MHz range.
NDT31-50316b
Equipment 3-3 Copyright © TWI Ltd
Taking the example of an L-C-R series circuit, the variable capacitor XC is
adjusted so that the oscillator frequency is the resonance frequency of the
circuit:
Z R2 ( X L X C )2
At resonance Z = R.
A slight change in the coil impedance will displace the resonance frequency
from the oscillator frequency and the circuit voltage will increase dramatically.
High frequency eddy current testers usually have one absolute coil tuned in
parallel with a fixed capacitor and do not have selectable frequencies. To
maintain a reasonably constant coil impedance, the frequency for testing
materials of low conductivity, for example austenitic stainless steel, may be up
to 2MHz whereas for materials of too high conductivity, for example aluminium,
may be no more than 500kHz. To test ferrous materials which have low
conductivity but high permeability, the higher test frequency is used but with a
probe at lower inductance.
NDT31-50316b
Equipment 3-4 Copyright © TWI Ltd
Figure 3.3 Eddy current test AC bridge circuits.
Resistor R is adjusted until the meter reads zero. If current is not flowing
through the meter then the potential at A equals the potential at C:
V AB VCB
V AD VCD
VAB = VCB.
VAD = VCD.
NDT31-50316b
Equipment 3-5 Copyright © TWI Ltd
Since the meter is zero, the current through P must be the same as the current
through R and the current through Q must equal the current through X:
VBC I c Q V I P
and AB A
VCD I c X VAD I A R
Q
X=RX P
Where:
X is the unknown.
R is adjustable.
P and Q are the ratio arms that set the resolution of the bridge.
In AC bridges (Figure 3.3), the resistors are replaced with impedances. These
introduce voltage phases as well as amplitudes into the balancing.
A typical crack detector may have an absolute test coil in one arm and a load in
the other, or alternatively, one half of a differential coil in one arm and the
other half of the differential coil in the other.
For the sorting bridge, one arm contains a coil with the reference standard, the
other arm the coil with the testpiece of unknown properties.
The X and R controls are used to bring the bridges into balance by affecting
both the amplitude and phase of the voltage through the meter.
If the meter is replaced by a cathode ray tube, the sinusoidal voltages from the
standard and test coils are adjusted until they are exactly 180° out of phase.
The trace then appears as a horizontal line.
The primary bridge circuit containing the test coils shown in this case as
differential coils, are connected to a second phase-sensitive bridge which also
receives the reference voltage.
The meter is so arranged that it only receives current through the diodes which
is in phase with the reference voltage. The signal voltage may for example
change in phase only without a change in amplitude by moving to the right on
the A-scan. The meter will respond because the proportion of current now
entering the meter is increased.
NDT31-50316b
Equipment 3-6 Copyright © TWI Ltd
3.3 Instruments
The instruments used in eddy current testing range from pocket-sized paint
thickness gauges to computer-controlled automated test systems. We shall
concentrate on the meter reading and cathode ray tube display types.
NDT31-50316b
Equipment 3-7 Copyright © TWI Ltd
The moving coil is rotated inside a magnetic field by the interaction between the
current in the coil and the magnetic field between the magnets. The direction of
the mechanical force is given by Fleming’s right hand rule and is against the coil
spring. The great the current in the coil, the greater the force.
Moving coil ammeters have a slow response due to the inertia in the spring. The
meter will not respond fully to short eddy current signals generated as the
probe scans the surface. For this reason, light-emitting diodes are incorporated,
set to illuminate at predetermined levels. The diodes respond immediately.
A simple sequence for setting the lift-off compensation is as follows: Figure 3.6
is the impedance diagram for an eddy current test circuit containing a coil, a
variable capacitor and a variable resistor in series. When the coil is placed on
the test surface the impedance meter reads 6 (OA).
When the coil is placed on a thin sheet of cardboard the impedance meter reads
8(OB).
The second Figure in Figure 3.6 shows the changes in impedance with
adjustments to the lift-off control (variable capacitor) and zero control (variable
resistor).
Adjustments
1 With coil on the cardboard, increase LIFT-OFF until meter reads 6(OC).
2 With coil on the test surface, the meter will now read 6.2(OD). Decrease
ZERO until meter reads 6 once more (OE).
3 With coil on the cardboard, the meter will read 5.8(OF). Decrease LIFT-OFF
until meter reads 6 once more (OG).
4 With coil on the test surface, the meter will read 5.9(OH). Increase ZERO
until meter reads 6 once more (OI).
5 Repeat the sequence of adjustments until the meter reads 6 both on the
test surface and on the cardboard.
The locus AB will have moved to A1B1 on the circle of radius 6 as shown in the
third Figure in Figure 3.6.
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Equipment 3-8 Copyright © TWI Ltd
Figure 3.7 Cathode ray storage scope.
NDT31-50316b
Equipment 3-9 Copyright © TWI Ltd
3.3.3 Cathode ray tubes
Cathode ray tubes (Figure 3.7) can be used to analyse changes in the phase
and amplitude of the eddy current test signal.
In storage scopes (Figure 3.7) the illuminated spot on the phosphor screen can
be retained when the electron beam is moved or switched off by flooding the
screen with low speed electrons. These do not illuminate the screen but only
continue to excite the phosphors, which have been hit by the high speed
electrons from the electron gun. To erase the screen, the flood current is
switched off.
The signal voltage is first rectified and then split into sine and cosine
components about an arbitrarily selected phase angle. The sine and cosine
functions are arrived at electronically and of course give two components to the
signal voltage which are 90o to each other.
With the cathode ray tube connected across a bridge circuit, an absolute coil is
one arm and a load coil is the other, the variable capacitor (X) and variable
resistor (R) are adjusted to bring the bridge to a state of balance. In this state,
no current is entering the CRT and rotation of the phase control will have no
effect on the vector point. Most instruments allow automatic balancing of the
bridge circuit.
NDT31-50316b
Equipment 3-10 Copyright © TWI Ltd
The bridge should be balanced with the probe down on the test surface. Lifting
the probe up will show the lift-off plane. This is usually rotated until it moves off
to the left of the screen. The probe can then be moved over slots and towards
the sides of a slotted testblock to give the crack and edge effect signals. The
sensitivity control is used to alter the amplitudes of the signals. The frequency
control will alter the phase angle between the signals.
3.4 Probes
Eddy current test probes come in many forms. When selecting a probe there is
the coil arrangement to consider and its effect on sensitivity. The coil size is
constrained by high inductive reactances at high frequencies. Surface probes
may need to be shaped to reach confined spaces. Encircling probes and internal
bobbin probes should fit the tube as closely as possible. Finally, the probe has
to match the circuitry of the instrument. There is not the ability to interchange
like that is found in ultrasonic test equipment.
Single coils have the same coil both to drive the eddy currents and receive
signals due to changes in the eddy current flow. The meter or cathode ray tube
monitors the voltage across the coil. The circuit is suitable for the simple high
frequency crack detectors where signals are confined to amplitude changes and
noise from the subsurface eddy current field is negligible.
The double coil arrangement has one coil to drive the eddy currents and
another coil to receive the test signals. The voltage in the receiver coil is
induced by eddy currents and the current in the driver coil. It is much less than
the voltage in the driver coil alone and there is a higher signal to noise ratio.
NDT31-50316b
Equipment 3-11 Copyright © TWI Ltd
Differential coils are commonly used in tube testing. The coil is in two different
halves, wound in opposition. The inductive reactance in one half is equal but
opposite to the inductive reactance in the other half. Bipolar signals are
produced when a discontinuity comes through the coil. The wavelength of the
signal is dependent upon the separation of the coil halves and the speed of
travel of the discontinuity. Signals are therefore suitable for modulation
analysis, where only signals of a certain wavelength are allowed through the
filters.
By having a separate drive coil from the differential receiver coil in a double
differential coil arrangement, noise levels are further reduced.
The choice of differential or absolute coils for tube testing is a difficult one.
Differential coils are less prone to temperature drift and ignore gradual changes
in tube dimensions.
Absolute coils give signals that are easier to interpret and do not miss
longitudinal defects throughout the tube length.
NDT31-50316b
Equipment 3-12 Copyright © TWI Ltd
Figure 3.12 Encircling shape.
The simplest surface probes are pencil probes. These are used at high
frequencies to detect surface breaking flaws. The coil is only a few millimetres
long and is wrapped around a ferrite core to increase the flux density. In
shielded pencil probes the coil is in a ferrite housing that pulls in the coil’s
external field to reduce edge effects. The ferrite tip may be protected by stick
PTFE tape. The bolt-hole probe is designed for insertion into a fastener or bolt-
hole. The coil lies perpendicular to the hole bore and the split end will
accommodate a small change in the hole diameter. The holder for the probe
allows rotation at fixed depths within the hole. Manual manipulation of a probe
in fastener holes using static eddy current testers is laborious and has largely
been superseded by rotating probes and dynamic testers.
Lower frequency probes have larger coil diameters and usually double
differential coil arrangements. A ferrite housing is essential if the field width is
to be kept reasonable. These larger probes are called pancake probes.
Ring or doughnut probes are low frequency probes designed for testing around
steel fasteners in a wing skin without the need of removing the fastener for a
bolt-hole probe inspection. The ferrite core of the pancake probe has been
removed and the ferromagnetism of the fasteners is relied upon to draw the coil
flux down into the skin.
NDT31-50316b
Equipment 3-13 Copyright © TWI Ltd
3.4.3 Encircling probes
For tube, rod and wiring testing, the coil is wrapped around the aperture of the
probe and as close to the surface as possible (Figure 3.12). The fill factor (See
Section 2.4.6) should be no less than 0.7 if sensitivity is to be kept high.
Guiding the tube or bar through the coil at high speeds is difficult and this
restricts the maximum fill factor that is attainable without danger of damage to
the probe aperture. Electromagnetic sorting bridges have large coils. Fill factor
is not critical as it is the inductive effects of the ferromagnetic testpiece inside
the coil that dominates the coil impedance and not the eddy current flow.
The detector coils are separated by the equivalent of two or three times the
tube diameter and are equally sensitive to internal and external indications with
tube wall loss being measured through variations in phase.
NDT31-50316b
Equipment 3-14 Copyright © TWI Ltd
Figure 3.15 Ring probe calibration block.
For meter reading instruments, the zero and lift-off are set with the probe on
the block, away from the edge or slots. The probe is then scanned over the
0.5mm slot to obtain the greatest meter deflection and then held steady while
the meter sensitivity is adjusted to give a 40% deflection of full scale.
Proceeding to the 1mm slot, the sensitivity is adjusted to give an 80%
deflection.
Signal deflections from the testpiece can now be compared with those from the
slots. A threshold may be set at 25% of full scale deflection and signals above
this investigated.
Low frequency eddy current instruments for detecting subsurface cracks must
be calibrated with the slots at the required depth below the surface. This may
be accomplished by placing a plate of the test material over the slotted block.
The frequency should be set to give a standard depth of penetration which is
about 110% of the thickness of the cover plate. Depth of penetration has to be
traded off against test sensitivity. It should be just enough to reach the
subsurface slots but not so great as to give poor signal to noise separation.
Moreover, if the eddy current field penetrates too far, noise may be picked up
from features below the layer of interest.
Special blocks have been designed for calibrating ring probes for detecting
cracks emanating from steel fasteners in a wing spar (Figure 3.15). The
frequency is first set to give a standard depth of penetration greater than the
skin thickness. The lift-off and zero of the instrument are set with the ring
probe over a flaw-free fastener. Then the ring probe is moved to a fastener with
one slot and the sensitivity adjusted to give a 50% full scale meter deflection.
Then finally to a fastener with two slots to give a 100% full scale meter
deflection. When moved to the testpiece, noise levels due to variations between
the permeabilities of the fasteners are very high. This makes inspection difficult.
In all cases, the calibration block sets the sensitivity level only. Lift-off and zero
have to be reset when the probe is moved to the testpiece.
NDT31-50316b
Equipment 3-15 Copyright © TWI Ltd
Figure 3.16 Step wedges.
The illustrated step wedge (Figure 3.16) could be used to indicate 50% thinning
in a 2mm thick wing skin by setting the zero, 50 and 100% full scale meter
deflections on the 2.0, 1.5 and 1.0mm steps.
Remember that the eddy current fields respond to volume changes rather than
changes in the residual wall thickness. A deep conical shaped pit may give no
greater meter deflection than a shallow but flat area of thinning.
To assess the depth of thinning, two methods can be used that both involve the
construction on graph paper of calibration curves that note the response of the
meter to known changes in thickness.
In the second, the frequency is adjusted and its value noted at which thinning
to known depths get a response on the meter. This is more suited to pitting.
In either case, the method, although providing useful information, cannot give a
reliable level of accuracy.
NDT31-50316b
Equipment 3-16 Copyright © TWI Ltd
3.5.3 Tube standards
Manufactured tube is usually tested for through defects that may cause leaks
(Figure 3.17). The through drilled hole therefore gives a suitable reference
signal.
For condenser tube inspection, corrosion on the inner tube surfaces has to be
distinguished from corrosion on the outer tube surface. This is done by setting
up the instrument on tubes containing machined slots or flats. The frequency is
set to give a 90° phase difference between the two surfaces as they appear on
the cathode ray tube display. This can be done because an internal groove will
appear as a change in fill factor to an internal bobbin probe, while an external
groove will appear as a change in wall thickness. The f90 frequency as it is
called can be found by analysis of the impedance diagram. It is approximately
110% of one standard depth of penetration. The use of Impedance diagrams is
covered in further detail in Section 6, Phase Analysis.
The use of calibration blocks in tube testing is covered in greater detail within
Section 10 of the course notes.
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Equipment 3-17 Copyright © TWI Ltd
Section 4
Practices
4 Practices
4.1 Documentation
Proper documentation of non-destructive tests is essential if they are to have a
meaningful role in quality control. For eddy current testing this is even more
important because the specifications and procedures which do exist tend to be
ambiguous and the tests must be tied down to more specific requirements,
including applications to products, manufacturing processes and in-service
inspection.
NDT31-50316b
Practices 4-1 Copyright © TWI Ltd
Eddy current methods
Technique sheet
Technique no:
Component identification:
Area of examination:
Purpose of examination:
Preparation of component:
Examination procedure:
a) Instrument calibration
1. Initial setting
2. Sensitivity setting
3. Alarm threshold setting
b) Test procedure
c) Acceptance standard
Reporting procedure:
Additional information:
NDT31-50316b
Practices 4-2 Copyright © TWI Ltd
Techniques
An NDT technique is a way of using an NDT method within the constraints of a
procedure. It is definitive in approach and does not allow the operator to
exercise choice in carrying out the test.
The NDT procedure is a more general document, which describes how, where,
when and why NDT is to be applied.
A good technique will provide coverage, be concise and give clear instructions.
It may have to be modified if experience indicates improvements, even to the
extent of changing the test method. The document must therefore allow for
subsequent amendments and be part of a system in which amendments can be
released to all concerned.
Technique writing requires discipline. The blank form (Figure 4.1) shows the
main subject areas to be covered but the actual document may need to be
extended to several pages to include diagrams of calibration blocks and special
probes, and the extent of probe test coverage.
NDT31-50316b
Practices 4-3 Copyright © TWI Ltd
Eddy current methods
Test report - Practical exercises report sheet
Test operator(s):
Component: Number
Equipment:
Instrument:
Probes:
Test frequency(ies):
Sensitivity setting:
Lift-off setting:
Scanning procedure:
Name: Signature:
Qualification:
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Practices 4-4 Copyright © TWI Ltd
4.1.1 Test reports
Any NDT report should:
If no defects are present, then words should be chosen carefully. Phrases such
as no significant defects are ambiguous. All defects are significant because they
are defined as those flaws which create a substantial risk of failure. They are
therefore outside of specification. Phrases like acceptable to specification or no
indications are preferable.
4.2 Applications
Eddy current testing has an ever-expanding repertoire of applications. The
problem lies in isolating the discontinuities which may be signals in one
application but noise in another.
Eddy current test are the most sensitive of all NDT methods to surface cracks.
High frequencies of the order of 2MHz give high resolution, but the probes are
small and covering large surface areas takes a long time.
Low frequency crack detectors need larger probes to accommodate for suitable
coil inductances. The frequency setting is critical and is in the range 100-
100kHz depending on the depth of penetration that is required. Subsurface
eddy current fields are influenced more by phase changes than amplitude
changes and therefore phase sensing circuits are essential.
Although traditionally they were meter reading instruments, the trend in crack
detectors is towards instruments with cathode ray tube displays for their added
versatility.
NDT31-50316b
Practices 4-5 Copyright © TWI Ltd
4.2.2 Tube and wire testing
Automated eddy current test systems have been developed for the inspection of
tube, bar and wire at speeds of up to 3 metres per second.
Once the operator has calibrated the instrument using a tube or wire with
known flaws, the test installation runs automatically, ejecting defective pieces
from the production line or marking them with paint.
The mechanical handling equipment for the test pieces becomes so complex
that the actual eddy current test instrumentation may appear an insignificant
part. Facilities for magnetic saturation and demagnetisation of ferrous tubes
and wires increase the capital costs considerably.
The constant test speeds and differential coils allow for modulation of the test
signal with the speed and then filtering to remove noise. Unfortunately, when
using differential coils, it is possible to pass through tubes with consistent
defects throughout their whole length, without detection. Because of the edge
effect, tube ends cannot be detected. Extrusion defects along the centre of bar
cannot be detected either because the eddy current field from an encircling coil
is at zero intensity at the centre of a solid cylinder.
Tube thinning is the main defect and by selecting what is known as the f90
frequency, signals from thinning on the outside surface can be set 90o out of
phase from signals from thinning on the inside surface. By recording the X and
Y signals from the impedance diagram on a two-channel strip chart recorder,
the extent of thinning can be ascertained at test speeds of 200-300mm per
second.
A major problem is caused by the baffle plates which separate the condenser
tubes. The tubes are non-magnetic, stainless steel, cupro-nickel or more
recently, titanium. The baffle plates are ferrous and the permeability signal is
enough to obliterate signals from thinning between the tube and baffle plate. To
alleviate this problem, instruments have been developed to operate with two
frequencies simultaneously. The separate signal phases are then mixed in a
manner which removes unwanted permeability effects.
Inspection is usually done with differential coils because they do not drift with
temperature changes. The signal interpretation is more difficult and it is often
necessary to do supplementary tests with absolute coils.
Conductivity meters can be used to sort aluminium and copper alloys, both for
compositional variations and hardness variations.
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Practices 4-6 Copyright © TWI Ltd
Great care has to be taken to ensure that the variation being detected is the
relevant one. For example, the change in the conductivity of an aluminium may
be due to a change in composition or a change in its hardness. Because eddy
current fields penetrate below the surface of the test material, the method does
provide a better sample of material properties than many other material sorting
methods and more importantly it is very rapid.
Recent devices have to some extent overcome these problems. They are being
used to supplement magnetic particle inspections under water, to distinguish
strong spurious indications from toe cracks. The equipment uses a cathode ray
tube with a vector point display and special coil arrangements.
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Practices 4-7 Copyright © TWI Ltd
Table 4.1 Logarithms of numbers 10-49.
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Practices 4-8 Copyright © TWI Ltd
Table 4.2 Logarithms of numbers 50-99.
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Practices 4-9 Copyright © TWI Ltd
Table 4.3 Antilogarithms 00-49.
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Practices 4-10 Copyright © TWI Ltd
Table 4.4 Antilogarithms 50-99.
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Practices 4-11 Copyright © TWI Ltd
Table 4.5 functions of angles 1-45°.
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Practices 4-12 Copyright © TWI Ltd
Section 5
AC Theory
5 AC Theory
Alternating current theory was introduced during section 1 of this course. The
reason for phase leads or lags between voltage and current in an AC circuit is
now explained. For those who are used to mathematical concepts, equations
are introduced for eddy current flow, as is the j notation as a shorthand way of
operating vector quantities. The effects of inductors and capacitors in AC
networks are investigated.
NDT30-50316b
AC Theory 5-1 Copyright © TWI Ltd
5.1 Capacitive reactance
Across a capacitor we are concerned with the build-up of electric charge on the
plates of two electrodes which face each other. The rate of build-up of charge
on the two plates will depend upon the voltage in the circuit. We therefore use
the voltage as our reference and construct the current wave onto it. In the
diagram of an alternating current (Figure 5.1), the voltage is changing at its
greatest rate at A, C and E. At these points the current away from the
electrodes of the capacitor will be at its greatest.
At B, D and F the voltage change is zero and therefore the current will be zero.
From A to B the voltage increasing in the positive direction and therefore the
current will be positive.
From B to C the voltage is decreasing in the positive direction and therefore the
current will be negative.
We can therefore draw the current wave on to the voltage wave and show that
in an AC circuit which has only a capacitive reactance, the current leads the
voltage by 90o.
At B, D and F the rate of change of current is zero and therefore the induced
EMF is zero.
According to Lenz’s law, at A the current is going to positive and therefore the
induced EMF will be negative.
Similarly at C the current is going to negative and therefore the induced EMF
will be positive.
The induced EMF opposes the applied EMF and therefore the voltage. The
current lags the voltage by 90o.
NDT30-50316b
AC Theory 5-2 Copyright © TWI Ltd
Figure 5.3 Eddy current induction.
We can start with a look at Faraday’s laws. The value from current that is
varying sinusoidally with time at any instant given by:
= o sin ( t)
Where:
= instantaneous value of the current at time, t.
o = peak value of the current.
= angular velocity = 2πx frequency in hertz.
Oersted discovered that the amount of magnetic flux in a current carrying coil is
given by:
= N
Where:
= flux.
N = number of turns in the coil.
= coil current.
Faraday’s laws state that there is a voltage induced whenever the flux changes
and that its magnitude is dependent upon that rate of change. Since the voltage
opposes the change, according to Lenz’s law:
d
V=–
dt
NDT30-50316b
AC Theory 5-3 Copyright © TWI Ltd
Figure 5.4 AC series circuit.
Since
NDT30-50316b
AC Theory 5-4 Copyright © TWI Ltd
The impedance (Z) is given by:
R 2 ( XL X C )2
Z=
and arctan
It XL is greater and XC then the circuit is effectively inductive and current lags
the voltage.
If XC is greater than XL then the circuit is effectively capacitive and the current
leads the voltage.
and the voltage and current are in phase in the resistive branch.
and the voltage leads the current by 90o in the inductive branch.
= +
Since Z =
1
1 1
NDT30-50316b
AC Theory 5-5 Copyright © TWI Ltd
Figure 5.6 Parellel L-C circuit.
NDT30-50316b
AC Theory 5-6 Copyright © TWI Ltd
5.1.5 Parallel L-C circuit
Current in the inductive branch is given by and is lagging the voltage by 90°.
From the vector diagram (Figure 5.6), the current voltage may be leading or
lagging the voltage, depending upon whether the inductive reactance or the
capacitive reactance is the greater.
1
1 1
When the frequency is zero (DC condition) the coil reactance is zero so that
only the coil resistance limits the current. The capacitive reactance is infinite
and therefore lC is zero.
As the frequency increase so the coil reactance increases and the current
decrease, lagging at a progressively greater angle from the voltage. On the
other hand, the capacitive reactance decreases so that increases but always
remains 90° leading the voltage. At some frequency XL = XC and resonance will
occur, the circuit impedance will reach a maximum and the circuit current a
minimum.
NDT30-50316b
AC Theory 5-7 Copyright © TWI Ltd
Figure 5.8 Addition of vectors.
5.1.7 j Operator
j is a mathematical operator which rotates a vector clockwise through 90°
without changing its magnitude. For example, we can split the impedance
vector into the inductive reactance and resistance components such that:
XL = Zsin Φ
and R = Zcos Φ
where is the phase angle between impedance and resistance. For the
phase angle has been rotated through 90 degrees and this can be denoted by j.
Thus a commonly used shorthand version of the formula|:
Z=
R 2 X L2
is Z = R + j
Where the underline indicates that we are dealing with vector and not scalar
quantities.
From the diagram it can be seen that two operations of j (=j2) rotate the
phasor through 180o and it in effect becomes -1
j2 = -1
NDT30-50316b
AC Theory 5-8 Copyright © TWI Ltd
Section 6
Phase Analysis
6 Phase Analysis
The signals generated in an eddy current test are vector and not scalar
quantities. That is to say, they are properly described by two quantities, their
amplitude and phase and not just by one quantity, their amplitude. Phase
analysis of the test signal using a cathode ray oscilloscope instead of mere
amplitude measurements with a meter; allow a greater level of differentiation
between relevant signals and unwanted noise. The effect of eddy currents on
the coil impedance is described on the impedance plane diagram and various
analytical standards are introduced. Methods of suppressing undesired noise are
described.
NDT31-50316b
Phase Analysis 6-1 Copyright © TWI Ltd
There are three conventional approaches to the problem:
Firstly, amplitude analysis uses the amplitude of the incoming signal. It may
give a deflection on a meter or strip-chart recorder. There are severe limitations
to this method. Non- relevant signals from lift-off and edge effect may exceed
in amplitude those from the crack.
Secondly, phase analysis uses the phase as well as the amplitude of the signal.
The phase displacement between the output or reference signal and the input
or incoming signal is analysed with a cathode ray oscilloscope in an A-scan,
ellipsoid, or vector point display. The A-scan displays the signal on a time base.
The ellipsoid is created by the interference of the output signal across the X-
plates with the input signal across the Y-plates. The vector point display divides
the signal into real and imaginery components that are sent to the X- and Y-
plates of the oscilloscope. Discrimination is still not possible if the non-relevant
signal has both the same phase and amplitude as the relevant one.
Finally, the frequency of signal may form the basis of an analysis. It must first
be modulated and this is done with the test speed. Either the testpiece passes
the probe at a fixed speed as is usually the case in tube testing or the probe
scans the test surface at a constant speed, as is the case in rotating probes for
bolt hole inspection. Non-relevant signals due to minor dimensional changes will
have a long wavelength and low frequency which can be filtered out from
relevant, relatively high frequency signals from flaws. The test speed must be
chosen carefully for the desired discrimination between signal and noise and
must be constant.
Dynamic testing using signals modulated with the test speed combined with
phase analysis of the filtered signals provides the most sensitive method of
eddy current testing (Figure 6.1).
Although well beyond the scope of this text and arguably often taken beyond
the needs of NDT, impedance analysis is a fascinating subject, allowing greater
insight into the nature of eddy currents and will be dealt with in a simplified
version here.
NDT31-50316b
Phase Analysis 6-2 Copyright © TWI Ltd
Figure 6.2 Idealised impedance.
NDT31-50316b
Phase Analysis 6-3 Copyright © TWI Ltd
6.3 Idealised impedance diagram
The reduction of a complex electrical circuit into a simple equivalent circuit is a
common method of analysis.
We can, for example, regard the test coil as a primary winding of a transformer
and the eddy current field as the secondary winding. The eddy currents
therefore load the current in the test coil as the output voltage loads the input
voltage of a transformer and simple electrical analysis can be done (Figure 6.2).
The eddy currents meet a resistance in the testpiece. This can be transferred
back to the primary circuit by multiplying by the turns ratio squared. If we
regard the eddy current field as a one turn coil only, then the new resistance
will appear in parallel with the coil as a shunt.
1
Z=
2 2
1 1
NP R E L X
NDT31-50316b
Phase Analysis 6-4 Copyright © TWI Ltd
Figure 6.4 Impedance diagram for a surface coil.
NDT31-50316b
Phase Analysis 6-5 Copyright © TWI Ltd
6.5 Conductivity
Figure 6.5 shows how the lift-off impedance planes on a normalised impedance
graph come from unity in the empty coil condition down to the test surface
along a locus of points which show increasing conductivity in a downward
direction.
With the coil in air, the relative impedance is at 1. As the coil comes down onto
the metal the impedance moves along one of the lift-off impedance planes until
it meets the locus of increasing conductivity.
Notice that the separation between lift-off and conductivity is greatest near the
knee of the curve. Lift-off effects and conductivity changes are almost
inseparable at the top of the curve.
The length of the lift-off planes is greater on good conductors than on poor
conductors. The lift-off planes may be calibrated to measure paint thickness on
metal substrates. A high degree of resolution will be attainable on good
conductors.
NDT31-50316b
Phase Analysis 6-6 Copyright © TWI Ltd
Figure 6.6 Impedance diagram for a surface coil.
NDT31-50316b
Phase Analysis 6-7 Copyright © TWI Ltd
Figure 6.8 Impedance diagram for a surface coil.
6.7 Thickness
As the thickness of the test material decreases, so its resistance will increase
and the impedance will be expected to move up the curve (Figure 6.6).
However, we have to take into account skin effect and therefore only a finite
thickness will have an effect. This thickness will depend upon the frequency of
the alternating magnetic field.
The lift-off and thickness impedance planes are at 180o apart on good
conductors and nearly parallel on poor conductors.
6.8 Frequency
Frequency has a similar effect to conductivity. As it increases so the impedance
moves down the graph. At low frequencies, the depth of penetration is greater
and the resistance of the testpiece has a more significant effect on coil
impedance. Generally, frequencies are selected to operate near the knee of the
curve.
Frequency is the most important variable that can be controlled in the test. It
determines the phase angles between different impedance planes and therefore
the ease with which different effects can be discriminated.
NDT31-50316b
Phase Analysis 6-8 Copyright © TWI Ltd
The example (Figure 6.7 and 6.8) shows how the lift-off planes at different
conductivities are more easily discriminated at high frequencies than at low
frequencies. However, at high frequencies there is more noise due to
pronounced lift-off signals and increased skin effect. (Figure 6.8).
NDT31-50316b
Phase Analysis 6-9 Copyright © TWI Ltd
Figure 6.11 Impedance diagram for an encircling coil.
Where:
i.d. o.d.
r = mean coil radius in metres = 4
= angular velocity = 2 radians.
= absolute permeability (for non-magnetics = 4 10 henry/metre).
= electrical conductivity in siemens/metre.
7.9 10
Where:
= resistivity in cm.
r = mean radius in mm.
The solid lines represent PC values increasing from zero to infinity, while
holding the coil at a constant lift-off from the surface.
NDT31-50316b
Phase Analysis 6-10 Copyright © TWI Ltd
Test conditions with the same characteristic parameter will operate at the same
point on the impedance diagram.
It shows, for example, that lift-off can be best discriminated from other effects
at high test frequencies.
The characteristic frequency is the frequency for which the Bessel function
solutions to Maxwell’s equations equals one. Maxwell’s equation describe
electromagnetic induction and the Bessel functions are a way of solving them
(Figure 6.11).
For thick wall tubes and cylinders For thin wall tubes
5066 5066
°
Where: Where:
Do = external diameter, cm. Do = external diameter, cm.
= conductivity in m/ mm2 t = wall thickness.
The equation for thick wall tubes applies when the wall thickness is much
greater than δ. For thin wall tubes it applies when the wall thickness is much
smaller than δ. (ie standard depth of penetration, mm).
Forster’s similarity law states that two eddy current changes will have a similar
effect on the coil impedance if their f/fg ratios are the same.
NDT31-50316b
Phase Analysis 6-11 Copyright © TWI Ltd
Figure 6.13 Eddy current distribution in solid cylinders.
NDT31-50316b
Phase Analysis 6-12 Copyright © TWI Ltd
Each layer of eddy current shields the layer of eddy currents below it, thus
reducing the strength of the magnetic field. The intensity of the eddy currents
at any particular depth will depend upon the intensity of the eddy current above
it, which leads to an exponential decay that can be expressed as:
sin
Where:
lo = eddy current intensity at the surface.
ld = eddy current intensity at depth d.
1
δ = depth at which intensity of eddy currents is reduced to of its value at the
e
surface ie standard depth of penetration (Figure 6.12).
For infinitely thick material and where fields are planar, that is to say induced
by large diameter long coils, then the depth at which the intensity of the eddy
1
currents is (approximately 37%) of its value at the surface is given by:
e
500
f
Where:
δ = standard depth of penetration, mm.
= conductivity, m/ mm2.
= permeability.
f = frequency, Hz.
(See also Section 2.4.3 – Frequency).
1 1
At 2δ the intensity is 2
(13.5%) and at 3δ (5%) of the intensity at the
e e3
surface.
This formula is applicable only under strict conditions. For thin wall tubes the
current intensity drops less quickly and for solid cylinders inside encircling coils
it is always zero at the centre (Figure 6.13).
Although the eddy currents may be restricted within thin strata in a component,
the magnetic field may extend beyond to generate further skins of eddy current
flow. This effect has significant application in, for example, testing wing spars
underneath the skin of an aircraft.
NDT31-50316b
Phase Analysis 6-13 Copyright © TWI Ltd
The phase angle of the eddy currents also changes with depth (Figure 6.14).
∝ sin
d d
or thick material phase lag radians x 57o.
NDT31-50316b
Phase Analysis 6-14 Copyright © TWI Ltd
6.13 Phase discrimination
Successful eddy current test rely to a large extent on adjusting the test
frequency to get as wide a phase angle as possible between impedance planes
due to unwanted noise and impedance planes due to relevant signals.
The impedance diagrams show how a particular frequency has been chosen so
that lift-off and thickness variations (Figure 6.15) are at almost 90° to each
t
other. This occurs when is approximately 0.8. The sensitivity is increased
until the vector point display covers the relevant part of the impedance diagram
that includes the nominal thickness being measured. The whole diagram is then
rotated on the display so that the lift-off plane is horizontal and moves off to
the left of the screen.
The diagrams show bridge null points that have been selected in the right hand
diagram to suppress lift-off effects to measure conductivity and in the left hand
diagram to suppress conductivity effects in order to measure permeability.
NDT31-50316b
Phase Analysis 6-15 Copyright © TWI Ltd
Figure 6.17 Impedance signals at different frequencies.
This is the basis of multifrequency tests. Tests with two frequencies are now
common but even five frequencies can be processed and analysed with the help
of a computer.
NDT31-50316b
Phase Analysis 6-16 Copyright © TWI Ltd
Firstly two frequencies are selected to give good phase discrimination. The one
frequency is likely to be about ten times the other. The phase and sensitivity of
the impedances at each frequency are then adjusted independently on the
vector point display. In the example shown (Figure 6.18), it is the permeability
effect that is to be removed.
When the permeability plane at one frequency is 180° out of phase with the
permeability plane at the other, then they can be mixed to give a third vector
point which has only lift-off (L) and crack planes (C). This can then be adjusted
in the usual way so that the lift-off plane is horizontal and off to the left of the
screen.
NDT31-50316b
Phase Analysis 6-17 Copyright © TWI Ltd
Section 7
Instrumentation
7 Instrumentation
The instruments used for phase analysis have developed quickly in recent
years. Solid state display instruments are improving the portability of eddy
current testing equipment. Cathode Ray Tube (CRT) instruments are still in
common use and are described in Section 7.1.
NDT31-50316b
Instrumentation 7-1 Copyright © TWI Ltd
Figure 7.2 Lissajous Figure.
The cathode ray tube was dealt with in Section 3.3.3. A schematic design of a
cathode ray oscilloscope to give an A-scan vector point or ellipsoid display is
shown.
For an A-scan the input signal from the bridge circuit that contains the test coil
comes in through the Y-amplifier. The attenuator is present to reduce the input
signals in discrete measured amounts if measurements are to be made of signal
amplitude.
For vector point displays, the time base generator is not needed and the X-
amplifier is driven from another signal source. Both the X and Y signals are
rectified and averaged. They are derived by splitting the bridge signal into sine
and cosine components electronically using the phase angle between the coil
voltage and a reference voltage. The sine and cosine components are of course
at 90° to each other and form the axes of the impedance diagram display.
NDT31-50316b
Instrumentation 7-2 Copyright © TWI Ltd
If the X and Y signals are both sine waves of the same frequency, a Lissajous
Figure is obtained (Figure 7.2). The sensitivities of the amplifiers are adjusted
so that the height of the variation of the beam in the Y-direction is equal to the
width of the variation of the beam in the X-direction. If both amplifiers drive the
beam positive at the same time and negative at the same time, they are in
phase and a straight line is seen. If they are 90o out of phase, a circle forms
and if 180o out of phase a straight line across the screen in the other direction
is formed.
If Vx sine ( t ) is the voltage applied to the X-amplifier and Vy sin (t ) is the
voltage applied to the Y-amplifier, then when the voltage at the Y-amplifier is
zero, t 0 and the voltage across the Y-amplifier is Vx and is given by OB.
OA Vx sin
sin
OB Vx
The ratio would therefore give the phase angle between the two signals.
Lissajous figures were commonly used in tube and wire testing, where test
parameters can be selected so that the ellipse would only open up in the
presence of defects.
NDT31-50316b
Instrumentation 7-3 Copyright © TWI Ltd
Figure 7.4 Hall effect transducer.
The receiver coils are two coils wound in opposite directions. The secondary
circuit is connected to a high impedance amplifier and therefore the induced
voltage (proportional to Np ocos t) is not affected by coil resistance either.
In the presence of a conductor the receiver coils receive two signals. One is
transmitted from the primary coil and the other is reflected from the eddy
currents in the conductor. The reflected signal is picked up by the receiver coil
near the conductor, but not by the other coil which is too far away. This state of
imbalance creates the signal.
The hall effect is caused when a magnetic field passes through a special semi-
conductor material transducer across which a current is flowing (Figure 7.4).
The current trajectory is deflected so that electrons tend to build up to one side
of the element creating a voltage. This voltage is proportional to the vertical
component of the magnetic field.
NDT31-50316b
Instrumentation 7-4 Copyright © TWI Ltd
Figure 7.5 Filters.
The filter arrangement illustrated will only accept one frequency. The input
signal first meets an acceptor filter which is a series circuit of capacitance and
inductance set to resonate at the required frequency. It therefore has low
impedance at this frequency, whereas other frequencies are rejected or
diminished depending upon the bandwidth of the filter. The bandwidth is
1
defined between the signal intensities to which they fall to of peak and is
2
dependent upon the Q factor (ratio of reactive power to active power) of the
series circuit.
The second rejector filter, where the capacitance and inductance are resonating
in parallel at the required frequency, prevents more of the unwanted
frequencies reaching the amplifier. At resonance, the parallel resonance circuit
is at maximum impedance and therefore effectively forces the signal into the
amplifier (Figure 7.5).
Therefore if the two halves of an encircling differential coil are d mm wide and
d
the test speed is s mm/sec then the duration of each signal is sec and the
s
s
frequency response will need to be Hz if sensitivity is to be maintained. This
d
should be regarded as a minimum. A frequency response of twice the signal
time is preferable.
NDT31-50316b
Instrumentation 7-5 Copyright © TWI Ltd
Cathode ray tubes have a very high frequency response but it can be reduced
drastically with high levels of input signals. Meters give a poor frequency
response and should therefore be supplemented with a light emitting diode to
give a visible alarm if signals exceed the threshold levels. The frequency
response of chart records varies from 100Hz for ink pen types to 1kHz for
ultraviolet marker types.
NDT31-50316b
Instrumentation 7-6 Copyright © TWI Ltd
Section 8
Material Sorting
8 Material Sorting
There are two properties of metals that can be used for material sorting with
eddy current test equipment. The first is electrical conductivity and the second
is magnetic permeability. The measurements are purely relative however,
relative to some standard for calibration, which must be chosen carefully.
Drawing conclusions about the composition or metallurgical characteristics of a
testpiece from an eddy test is very difficult because of the diversity of variables
which affect conductivity and permeability.
NDT31-50316b
Material Sorting 8-1 Copyright © TWI Ltd
Figure 8.1 Circuit diagram for a conductivity meter.
Figure 8.3 Cold age hardened Al alloys. Figure 8.4 Heat damage to
aluminium.
NDT31-50316b
Material Sorting 8-2 Copyright © TWI Ltd
8.1 Conductivity meters
Conductivity measurements are quite straightforward and do not normally
require a phase analysis. A typical bridge circuit with a meter is shown. The
bridge is unbalanced as previously described to suppress the effects of lift-off.
There are number of causes of error however. If the frequency is low and the
material section being tested is thin, then the measurement will be affected by
thickness variations and the presence of a different conductor in the substrate.
The thickness should be at least 3 .
If the frequency is high then surface inhomogeneities, for example thin oxide
layers, will interfere with the measurement.
Although the double probes used in most conductivity meters are insensitive to
temperature changes, the conductivity of the test material and the reference
standards will be sensitive to ambient temperature (Figure 8.1).
1
1 (1 T )
2
Surface curvature, edge effect and other discontinuities will all affect
conductivity readings.
NDT31-50316b
Material Sorting 8-3 Copyright © TWI Ltd
Figure 8.5 Frequency selection.
NDT31-50316b
Material Sorting 8-4 Copyright © TWI Ltd
8.3 Electromagnetic sorting bridges
Electromagnetic (EM) sorting bridges offer a rapid method of sorting
ferromagnetic materials. Although the magnetic permeability effects
predominate in these tests there is some sensitivity to conductivity changes as
well.
A bridge circuit is used with two test coils. One contains a standard, the other a
testpiece. A CRT with A-scan display shows a sine wave that is the resultant
from summing vectorily the sine waves generate in the coils containing the
standard and testpiece respectively. If the standard and testpiece are identical
then the resultant is a straight line. A degree of difference will produce a
fundamental wave the shape of which will be affected by amplitude and phase
differences in the two waves. Moreover, the presence of harmonics over and
above the fundamental frequency can also be an important distinguishing
feature.
The sensitivity is adjusted to give the required level of distinction between the
grades of material that are being sorted. This is attained by experimentation.
Too high a sensitivity will show up differences in every testpiece. Ideally the
largest spread bands should be symmetrical about a vertical line on the screen.
However, harmonics can be as equally important in distinguishing spread bands
as the fundamental waves (Figures 8.5 and 8.6).
The permeability of the test material is dependent upon the applied magnetic
field strength. On the magnetisation curve, at high levels of (H) the
permeability falls and this should be avoided in bridge sorting.
1 Thermal processing.
2 Mechanical processing.
3 Chemical composition.
4 Internal stresses.
5 Temperature.
NDT31-50316b
Material Sorting 8-5 Copyright © TWI Ltd
Figure 8.8 Automatic bridge sorter.
In carbon steels, increasing carbon content decreases the conductivity and the
permeability but compositional changes are generally overshadowed by heat
treatment.
In low alloy steels there is a significant fall in permeability with increase in alloy
composition.
NDT31-50316b
Material Sorting 8-6 Copyright © TWI Ltd
In the system illustrated, a standard is held stationary in the reference standard
coil while the testpieces move continuously through the test coil. A reading is
taken when the testpiece is in the centre of the coil. This corresponds to the
point of inversion of the sine waves on the CRT. The test speed must be slow
enough for at least 2-3 cycles of the magnetising current to give an impedance
signal. For this reason long coils have been developed for systems in which the
testpiece drops through the coil.
Many automated systems use a vector point display, with the screen divided
into quadrants and monitored. An electronic counter counts the number of
impedances which occur in each quadrant. At the end of the batch of testpieces
the Figures can be analysed statistically to indicate the quality of the batch.
8.6 Standards
The choice of suitable standards for material sorting is vital. They should be of
the same size and shape, with identical composition and heat treatment and
similar surface finish. They should be demagnetised and attention should be
given to any stresses which may be set up due to cold working. Allowance
should be made for temperature increases due to the induced currents. Finally,
play safe and have two or three standards available.
NDT31-50316b
Material Sorting 8-7 Copyright © TWI Ltd
Section 9
Crack Detection
9 Crack Detection
Eddy current tests provide the most sensitive of all the non-destructive
methods for detecting cracks. However, there are considerations of crack
orientation to the eddy current flow to be taken into account and there is very
little penetration, particularly in ferrous materials, below the surface. Moreover,
it is very easy to misinterpret signals. Two recent developments in weld testing
and bolt hole inspection show how eddy current test techniques can be
developed to overcome problems with test noise.
NDT31-50316b
Crack Detection 9-1 Copyright © TWI Ltd
Figure 9.1 CRT with flying dot display. Figure 9.2 Surface coil.
NDT31-50316b
Crack Detection 9-2 Copyright © TWI Ltd
9.1 Universal crack detectors
For use over a wide range of applications a CRT is used with a vector point
display (Figure 9.1). It is connected to a bridge circuit with the test probe
containing an absolute coil in one of the arms or a differential coil in two of the
arms.
The sensitivity control affects the bridge output signal and not the coil current.
It may be calibrated in decibels, a scale in which an increase of 6dB is
equivalent to doubling the signal amplitude. Some instruments do have controls
for the coil current. This compensates for gross imbalances in the bridge when
using coils at very low or very high frequencies.
The quadrature components of the bridge are generated as sine and cosine
phasors of the voltage using the current as datum and dialling in a value for the
phase angle from the phase rotation control. The phase rotation control does
not give an absolute value therefore. It needs a reference which is often taken
as the lift-off plane set horizontally off to the right of the screen.
Ferrite cores are needed to increase the inductances of very small coils; they
provide a small surface contact area and resist wear. The increase in inductance
XL
increases the ratio of the coil and therefore reduces the relative importance
R
of the temperature effects upon R.
When using the flatter pancake probes (Figure 9.3), the directional properties of
the coil become important. As well as being insensitive to laminar flaws, there is
zero sensitivity at the coil centre. There is little sensitivity to flaws parallel with
the coil winding, but there is maximum sensitivity to flaws across the coil
winding.
Gap probes have a magnetic field which shapes the eddy current flow to cross
laminar defects.
Many ingenious coil arrangements have been developed for special applications.
The one shown has four receiver coils dispersed equidistantly around a central
send coil. In the balanced defect-free condition, a uniform eddy current field is
set up around the send coil. When the coils pass along rivets in an aircraft skin
(Figure 9.4), distortions are created which form a regular pattern of signals with
the receive coils. When a crack is present, however, an increased distortion is
created. By suitable selection of test parameters the vector point movement on
the impedance diagram due to normal rivet distortions can be clearly
distinguished from a movement due to crack distortions.
NDT31-50316b
Crack Detection 9-3 Copyright © TWI Ltd
Figure 9.5 Slot depth.
NDT31-50316b
Crack Detection 9-4 Copyright © TWI Ltd
9.3 Crack detection
Surface breaking cracks are not affected by skin depth. They deflect the eddy
currents down and around the tip of the crack. They therefore increase the
resistive path of the eddy currents and change the orientation of the magnetic
field generated by the eddy currents. These have an effect on both the coil’s
inductive reactance and resistance. A phase shift can be detected which rotates
the impedance plane slightly in a clockwise direction as the cracks become
deeper.
Subsurface cracks rotate the impedance plane clockwise. This phase rotation
can be used to assess crack depth below the surface (Figure 9.5).
Very tight cracks may leak the current but when all is said and done, of all the
NDT methods, eddy current test are the most sensitive to cracks.
The permeability variations in the weld toe can be very great due to hardening
in the heat affected zone. Conventional vector point displays drift to such an
extent therefore, that crack signals become impossible to identify.
A recently developed eddy current testing device, however, uses a special coil
arrangement to balance out permeability effects. It displays impedance signals
from cracks in a manner that is readily discernible from noise due to probe
movement to and fro across the weld toe (Figure 9.6).
An A-scan is created on the CRT for every rotation of the coil inside the hole. By
marking it off in degrees from a datum coinciding with a marker on the probe,
the angular position of the crack is indicated. By modulating the signal much
unwanted noise can be filtered away.
The two halves of the differential coil are wrapped in a Figure eight over the
forked ferrite core. Cracks often propagate right through the fastener hole and
if the halves of the differential coil were opposite each other they would both
pass through crack simultaneously and there would not be a signal.
NDT31-50316b
Crack Detection 9-5 Copyright © TWI Ltd
To adjust test frequency and set the phase so that the impedance plane of one
unwanted signal is horizontal and does not appear on the A-scan, a vector point
is used as an alternative display on the CRT.
NDT31-50316b
Crack Detection 9-6 Copyright © TWI Ltd
Section 10
Tube Testing
10 Tube Testing
Eddy current testing has been used to inspect tubes from the very early days in
the development of the method. It is rapid, can be made sensitive to a wide
range of defect conditions and the equipment can be fully automated. There are
two distinct applications; one is for manufactured tube on line and the other is
for condenser (and heat exchangers) tubes in situ. The latter in particular has
captured much attention of late because of its importance in the maintenance of
nuclear (and petrochemical) plant.
NDT31-50316b
Tube Testing 10-1 Copyright © TWI Ltd
Figure 10.2 Condenser tube tester.
The block diagram shows a circuit plan for eddy current test system for
inspecting ferrous tubes. The permeability effects of the ferrous material have
to be overcome to make the tests sensitive to subsurface flaws. This is
accomplished by including DC magnetic saturation coils in the test head,Figure
10.1.
The test probe has a double differential coil arrangement. The primary coils also
generate a reference voltage that is used to discriminate the phase of the
secondary coil voltage.
NDT31-50316b
Tube Testing 10-2 Copyright © TWI Ltd
A Lissajous display is used to calibrate the instrument on a standard tube with
reference flaws. Adjustments are made to test frequency, signal amplitude and
phase to give the best discrimination between signals and noise.
The test results of a condenser tube inspection have in the past been recorded
as X and Y deflections on a two channel strip chart recorder. The several
hundred metres of recorded chart from one heat exchanger are then inspected
visually. There can then be a problem in identifying the defective tube in the
heat exchanger are then inspected visually. There can then be a problem in
identifying the defective tube in the heat exchanger when inspecting the results
of several hundred tube tests. This has led to the development of a real time
testing system that uses a computer to analyse the test results. A backup
recording on a video provides a permanent record.
10.3 Probes
For testing manufactured tubes up to 50mm in diameter, encircling coils are
used. Beyond 50mm the sensitivity to all but gross defects are reduced and
surface coils are needed that orbit the tube. Encircling coils are not sensitive to
purely circumferential planar flaws or laminar flaws. The depth of penetration is
determined by test frequency except in the case of solid cylinders, where the
intensity of eddy current is always zero at the centre despite the test frequency.
Most tube tests are carried out with the differential coil arrangements. These
are not sensitive to temperature drift and gradual insignificant changes in the
tube dimension and are less affected by tube wobble than absolute coils.
However, they only detect the ends of longitudinal flaws and will miss entirely
uniform longitudinal flaws that extend the whole tube length.
This problem has exercised the minds of equipment developers for many years.
Where continuous defects can arise, for example in seam welded tubes, then it
is evidently not worth the risk in having differential encircling coils. Absolute
encircling coils and surface coils, however, are much noisier and test speeds are
greatly reduced.
To test ferrous tubes for internal defects the tube wall must be saturated
magnetically. This can only be done with dc energised fields that are
superimposed upon the AC fields of the test coils. Furthermore, the tube has to
be demagnetised afterwards. The conventional diminishing AC field will only
demagnetise the surface because of skin effect and so a slowly reversing DC
field is necessary. This reduces test speeds considerably.
NDT31-50316b
Tube Testing 10-3 Copyright © TWI Ltd
Figure 10.3 Forster curve for tube.
NDT31-50316b
Tube Testing 10-4 Copyright © TWI Ltd
10.4 Test frequency
The test frequency is the most important variable used in controlling the eddy
current test. It determines the depth of penetration of the eddy current field
and the phase discrimination between noise and signals.
For setting the frequency when testing manufactured tube for through defects
the Forster curves are often employed (Figure 10.3). These were derived by
f
plotting the ration on a normalised impedance diagram. f is the test
fg
frequency and fg is the characteristic frequency defined by:
5066
Where:
= Relative permeability.
= Conductivity, m / mm 2.
Do = External diameter, cm.
t = Wall thickness, cm.
5066
fg
d 2
f
To distinguish ferromagnetic inclusions, then an of about two provides an
fg
almost 90o separation between permeability effects and conductivity changes.
NDT31-50316b
Tube Testing 10-5 Copyright © TWI Ltd
For testing condenser tubes with internal bore probes, it is important to
distinguish between thinning of the tube wall due to corrosion on the inside
surface, from that due to corrosion on the outside surface. This is done at the
f90 frequency, Figure 10.4 and 10.5.
To an internal coil, thinning from the outside of the tube is seen as a reduction
in wall thickness, while thinning from the inside of the tube is seen as a
reduction in fill factor. A frequency can be selected where these two effects
have impedance planes at 90o to each other. It occurs when the nominal wall
thickness is approximately 1.1 of the standard depth of penetration:
3
f90 kHz
t2
Where:
= Resistivity in .cm.
t = Wall thickness in mm.
As can be seen in the normalised impedance diagram, the phase angle between
the internal and external slots varies from a few degrees at low frequencies, to
also 180o at high frequencies. The impedance plane for a hole occurs between
the slots. It coincides with the impedance plane, when thinning from both the
inside and outside surfaces meet and the tube wall disappears. There is a
relationship between amount of thinning and the phase angle that can be used
to determine the residual wall thickness.
NDT31-50316b
Tube Testing 10-6 Copyright © TWI Ltd
Figure 10.7 Tube inspection signal patterns.
2
D
t for encircling probes
Dc
2
D
c for internal probes
Dt
Where:
Dc = coil diameter.
Dt = tube diameter.
=fill factor.
Ideally as in the diagram shown (Figure 10.6), the fill factor should be such that
the gap between coil and tube should be approximately half the wall thickness.
With differential coils, the distance between the differentially wound halves of
the coils should be considered because along with the test speed, it will
determine the frequency of signals. These must not exceed the frequency
response of the instrument and will determine the bandwidths of the filters.
NDT31-50316b
Tube Testing 10-7 Copyright © TWI Ltd
10.6 Signal patterns
The diagram illustrates the signal patters which may be derived from passing an
absolute and a differential coil probe through a stainless steel condenser tube
(Figure 10.7). The signals are derived form an internal slot, an external slot, a
through drilled hole, the ferrous baffle plate, a magnetite deposit and a dent.
Although differential signals are more difficult to analyse, there is no drift in the
balanced vector point that can be expected when using absolute coils.
Drilled holes are more commonly used where through defects that will cause
leaking are sought. Machined flats are more suitable for detecting thinning. If
used to set the f90 frequency, they will need to be on both the inside and
outside surfaces.
NDT31-50316b
Tube Testing 10-8 Copyright © TWI Ltd
Section 11
NDT31-50316b
Eddy Current for Welding Inspection 11-1 Copyright © TWI Ltd
11.2 Eddy current application overview
Eddy current testing is based on inducing electrical currents in the material to
be inspected and observing the interaction between these currents and the
material. The process is as follows:
NDT31-50316b
Eddy Current for Welding Inspection 11-2 Copyright © TWI Ltd
Eddy currents are closed loops of induced current circulating in planes
perpendicular to the magnetic flux, Figure 11.1.
They normally travel parallel to the coils windings and parallel to the surface.
The shape of the induced eddy currents reflects the shape of the coils. Coils
parallel to the surface will induce circular eddy currents. In the weld probe the
coils sit on their rim resulting in an oval shape eddy current field.
Eddy current flow is restricted to the area affected by the primary magnetic
field.
Phase lag is a key parameter in eddy current testing. Phase lag depends on the
same material properties as that governing standard depth of penetration.
X
Phase lag β radians
50√ρ/fμ
At one standard depth of penetration the phase lag is 57° at two standard
depths of penetration the phase lag would be 114°.
NDT31-50316b
Eddy Current for Welding Inspection 11-3 Copyright © TWI Ltd
11.3 Basic eddy current theory
The basic equipment required to produce eddy currents consists of:
The probe coil has many variables and must be specific to the application.
These variables include:
Wire diameter.
Number of turns.
Coil diameter.
Length of coil.
NDT31-50316b
Eddy Current for Welding Inspection 11-4 Copyright © TWI Ltd
There are several configurations of surface probe. These, again, must be
considered specific to the application. In general terms, surface probes may be
one of the following:
Excitation Excitation
coil coil
Hall Effect
Coil Sensor
Sensing coil
Test Material Test Material Test Material
The voltmeter measures changes in the voltage across the coil. These changes
may be the result of:
If the thumb of the right hand is extended in the direction in which the current
is flowing, then the direction of the magnetic field is represented by the fingers.
NDT31-50316b
Eddy Current for Welding Inspection 11-5 Copyright © TWI Ltd
Figure 11.4 Right hand rule.
When the conductor is ferromagnetic, strong magnetic flux lines are created,
also in the direction of the fingers, this is called circular magnetism. Circular
magnetism is not polar and cannot be detected externally on a round
symmetrical specimen.
Now, if the original conductor carrying the current is bent into a loop, the
magnetic field around the conductor will pass through the loop in one direction.
Associated with the magnetic field is the magnetic flux density. This is the
number of lines of force or maxwells, as they are called in cgs units, per unit
area.
The unit of flux density in SI units is the Tesla (T). A Tesla is 1weber per square
metre (Wb/m2).
Or 10 Gauss = 1 Tesla.
Flux density is in the same direction as the magnetic field and its magnitude
depends on its position and amplitude of the current flowing through the
conductor.
Flux density is therefore a field vector quantity and is given the symbol B.
NDT31-50316b
Eddy Current for Welding Inspection 11-6 Copyright © TWI Ltd
Figure 11.5 Current flow along a straight conductor.
NDT31-50316b
Eddy Current for Welding Inspection 11-7 Copyright © TWI Ltd
Figure 11.6 Magnetic flux distribution – single turn coil.
Flux density B varies linearly with electric current in the coil ie. if coil current
doubles the flux density doubles everywhere.
The total magnetic flux Φp contained within the loop is the product of B and the
area of the coil. The unit of magnetic flux in the SI system is the weber (Wb).
NDT31-50316b
Eddy Current for Welding Inspection 11-8 Copyright © TWI Ltd
Figure 11.7 Longitudinal magnetic flux generated from a current carrying coil.
The field within the loop has direction and one side will be a north pole and the
other a south pole. By increasing the number of loops, a coil, or solenoid, is
created and the strength of the field passing through the coil is proportional to
the current passing through the conductor in amperes multiplied by the number
of turns in the solenoid.
NDT31-50316b
Eddy Current for Welding Inspection 11-9 Copyright © TWI Ltd
Current Flow
N – North Pole – Anti-clockwise
Current Flow
S – South Pole – Clockwise
Figure 11.8 Looking at the ends of the coil – direction of current flow.
Ohm’s Law.
Faraday’s Law.
Lenz’s Law.
Ohm’s law
Ohm discovered that the amount of current flowing through a material varies
directly with the applied voltage and inversely with the resistance of the
material.
V
I
R
Where:
R is in Ohms ()
V is in volts (V)
I is in amps (A)
To use the circle, simply cover the segment you want to find and the position of
the remaining letter tells you the procedure to follow.
NDT31-50316b
Eddy Current for Welding Inspection 11-10 Copyright © TWI Ltd
V
I R
In any electrical circuit, current flow is governed by Ohm’s Law and is equal to
the driving (primary circuit) voltage divided by primary circuit impedance.
The application of Ohm’s Law to an alternating current (AC) circuit gives the
formula:
V
Z
I
Where:
Z is the circuit impedance in Ohms ().
V is the voltage in volts (V).
I is the current in amps (A).
NDT31-50316b
Eddy Current for Welding Inspection 11-11 Copyright © TWI Ltd
Figure 11.10 Test material – conductor.
Faraday’s laws
Faraday discovered the inductive effects of rapid changes in the magnetic field.
When current is abruptly switched off in an electrical circuit it will induce an
electromotive force which, if magnetically coupled to another electrical circuit,
will create a current in that circuit.
The two circuits are not linked electrically but the magnetic field around circuit
A does link through circuit B.
NDT31-50316b
Eddy Current for Welding Inspection 11-12 Copyright © TWI Ltd
Faraday went on to define two laws:
Lenz’s law
This law states that the electromotive force (emf or voltage) induced by the
variation in magnetic flux is always in such a direction that if it produces a
current (Is) the magnetic effect of that current opposes the flux variation (Φp)
responsible for both the electromotive force and the current.
Summary
Magnetic flux is created by passing alternating current (AC) through the test
coil. When this coil is brought into close proximity to a conducting material,
eddy currents are induced. The flow of eddy currents results in resistive
(Ohmic) losses.
In addition, the magnetic flux associated with the eddy currents opposes the
coil’s magnetic flux, thereby decreasing the net magnetic flux. This results in a
change of coil impedance and subsequent voltage drop across the coil. It is the
opposition between the primary (coil) and secondary (eddy currents) fields that
provide the basis for extracting information during eddy current testing.
Frequency
The most important test variable is the frequency of the current sent through
the test coil. Eddy current testing is conducted at frequencies from a few hertz
(Hz) to several megahertz (MHz).
NDT31-50316b
Eddy Current for Welding Inspection 11-13 Copyright © TWI Ltd
The most important effect of test frequency is upon the depth of penetration of
the eddy current field. As the frequency increases so the depth of penetration
decreases. The phenomenon known as skin effect is described as follows:
The eddy currents flowing in the test material at any depth produce magnetic
fields, which oppose the primary magnetic field produced by the excitation coil.
The net magnetic field is therefore reduced thus decreasing the current flow as
depth increases. Alternatively, eddy currents near the surface can be viewed as
shielding the coil’s magnetic field thereby weakening the magnetic field at
greater depths and reducing induced eddy currents.
Where:
ρ is electrical resistivity. Units are microhm-centimetres (µΩ.cm).
σ is the electrical conductivity in siemens/metre.
f is the test frequency in hertz (Hz).
µr is relative magnetic permeability, no units – dimensionless.
µ is the absolute permeability of the material, Henry/metre.
NDT31-50316b
Eddy Current for Welding Inspection 11-14 Copyright © TWI Ltd
For air and non-magnetic materials, µ is constant and is denoted by µ0.
Where: µr = µ / µ0.
660
Where:
is the standard depth of penetration in mm.
f is the frequency in hertz.
is the conductivity in IACS (International Annealed Copper Standard).
is the relative permeability.
IACS = 5.8 10 / .
Iron = ~ 18% IACS.
Low Alloy Steel = ~ 11% IACS.
1
f
Where:
is in cm.
= 3.14.
f is the frequency in hertz.
is the conductivity in % IACS.
= 4 x 10-7 H/m.
The standard depth of penetration is defined as the depth below the surface at
which the intensity of the eddy current field has been reduced to a value of of
its intensity at the surface. The function e is the base of natural logarithms. It is
equal to 2.718 when taken to three decimal places.
Therefore at the standard depth of penetration, the eddy current field intensity
is at approximately one third of its surface value. (37%).
Phase lag is a key parameter in eddy current testing. Phase lag depends on
the same material properties as that governing standard depth of penetration.
Phase lag β
√ /
NDT31-50316b
Eddy Current for Welding Inspection 11-15 Copyright © TWI Ltd
Where x is the distance below the surface in mm.
At one standard depth of penetration, the phase lag is 570° at two standard
depths of penetration the phase lag would be 1140°.
However, keep in mind that these values only apply to thick materials
(thickness greater than 5) and planar magnetic excitation fields.
Please also note that the magnetic flux is attenuated across the test material
but not completely. Although the currents are restricted to flow within specimen
boundaries, the magnetic field extends into the air space beyond. This allows
the inspection of multi-layer components such as aircraft wings.
NDT31-50316b
Eddy Current for Welding Inspection 11-16 Copyright © TWI Ltd
11.7 Electrical circuits and probe impedance
Eddy current testing applications consist of monitoring the flow and distribution
of eddy currents in test material. This is achieved indirectly by monitoring probe
(coil) impedance during the inspection. It is therefore necessary that an
appreciation of impedance and associated electrical factors Is gained.
Resistance (R)
The opposition to current flow in direct (DC) and alternating (AC) circuits is
called the resistance. It is rather like friction in mechanics. It opposes the flow
of electrons and generates heat.
Where:
R = Resistance in Ohms ().
= Resistivity in micro-ohms cm.
= Length of conductor.
A = Cross-sectional area of conductor.
V
Ohm’s Law may be applied: R
I
Where:
V is the voltage drop across the resistor (Volts).
I is the current through the resistor (Amps).
900
Voltage
Current
0 1800 0 3600
0
2700
NDT31-50316b
Eddy Current for Welding Inspection 11-17 Copyright © TWI Ltd
11.8 Resistance and reactance
The resistance in an AC circuit represents a loss of electrical energy as heat, as
it does in a DC circuit. In an AC circuit however, there are two other
components which oppose the flow of current and these are called reactances.
One is the capacitive reactance, which creates a voltage across a capacitor and
the other is the inductive reactance which creates a voltage across an inductor
(coil).
The capacitor converts current into electrostatic energy and the inductor
converts current into magnetic energy. As the energy is reconverted to current
when the polarity of the circuit current reverses, neither of the reactances
represents an actual loss in electrical energy.
The effect of the capacitance and inductance in the circuit is to push the voltage
and current out of phase with each other, either lagging or leading as follows:
C I V I L
Capacitance – current Voltage leads current
leads voltage in Inductance
The symbol for Reactance is (X). For inductive reactance the symbol is (XL).
Inductive reactance is calculated using one of the following formulae:
Where:
f is the frequency of alternating current (Hz).
ω is the angular frequency in radians/second.
NDT31-50316b
Eddy Current for Welding Inspection 11-18 Copyright © TWI Ltd
Figure 11.15 Voltage Current across an Inductor.
The symbol for Reactance is (X) for capacitive reactance the symbol is (Xc).
NDT31-50316b
Eddy Current for Welding Inspection 11-19 Copyright © TWI Ltd
Capacitive reactance is calculated using:
1
XC unit is ohms
2fC
Where:
f is the frequency of alternating current (Hz).
C is the capacitance – unit is the farad.
NDT31-50316b
Eddy Current for Welding Inspection 11-20 Copyright © TWI Ltd
11.11 Impedance
The total opposition to alternating current (AC) flow is called Impedance.
2
X R 2 XL
XL
Z
XT = (XL- XC)
XC
N2 A
L R
I
Where:
L is the inductance in henrys.
R is the geometric factor.
N is the number of coil turns.
A is the coil’s planar surface area in mm2.
I is the coil’s axial length.
The henry is a very large unit. Eddy current coils have inductances of a few
micro-henrys (µH).
NDT31-50316b
Eddy Current for Welding Inspection 11-21 Copyright © TWI Ltd
The self-inductance of a coil is proportional to the square of the coil windings
( ) and planar surface area (A) and inversely proportional to coil length (l).
With reference to Figure 11.18 coated weld section, the variables are
reasonably self evident. The coating thickness varies considerably, the thickest
section being on the bottom toe of the weld, exactly where we would expect our
in-service defects such as fatigue cracks to occur.
1
2
4
5
7 8
6
'Lift-off' signal
3&6 corresponding
with coating
4 thickness.
7&8
1&2
'Lift-off' signal horizontal
5
NDT31-50316b
Eddy Current for Welding Inspection 11-22 Copyright © TWI Ltd
The thickness will also change along the length of the weld as the geometry
changes. The K-Node found Offshore is used as a typical example, see Figure
11.19.
NDT31-50316b
Eddy Current for Welding Inspection 11-23 Copyright © TWI Ltd
Types of inspection probes/coils
In general, we can categorise probes into two distinct applications:
In this arrangement the same coil is used to induce eddy currents in the
component and to sense the component's reaction on the eddy currents. The
single coil will test only the area under the coil and does not compare itself with
a reference standard. These probes generally have small coils and operate at
relatively high frequencies. The pencil probes we shall assess have ferrite cores.
These are used to induce a greater magnetic flux and eddy current field. Let us
draw up a specification and/or check list for evaluation of the probes:
NDT31-50316b
Eddy Current for Welding Inspection 11-24 Copyright © TWI Ltd
Figure 11.20:
a Schematic of eddy current surface probe;
b Surface probe and the effect of non-conductive coating thickness on eddy
current distribution in the test material.
Figure 11.21 Schematic of eddy current encircling coil probe showing the
primary excitation coil and the secondard pick up coil.
Figure 11.22 Schematic of eddy current inside coil bobbin probe showing defect
detection in a non-ferrous tube.
NDT31-50316b
Eddy Current for Welding Inspection 11-25 Copyright © TWI Ltd
Figure 11.23 Schematic of eddy current single coil probe showing the effect of a
crack on eddy current distribution (right) compared to a defect free distribution
(left).
TEST INSTRUMENT
NDT31-50316b
Eddy Current for Welding Inspection 11-26 Copyright © TWI Ltd
Appendix 1
Sample Instruction - Amplitude Analysis, Full Length, Internal Defects.
Scope: This instruction is documented as the process by which Condenser Tubes are
inspected over their Full Length for Internal Defects using the Eddy Current Amplitude
Analysis method with a differential coil. The signals are recorded/printed out and the
defects classified.
Area to be tested:
Full Length of 1.5m tubes
All personnel carrying out this instruction shall be qualified to PCN/Level 1/Wrought
Tubes and carry company approval as a minimum.
Safety requirements:
All safety instructions contained in the TWI Health and Safety Manual, which apply to
tube inspections, are to be complied with.
Probe - Air cored Differential bobbin probe, 11mm diameter. Part No.
PID110N05R20K. This probe will give a nominal fill factor of 84%. Any alternative
probe should give a minimum fill factor of 70%.
Calibration tube - Calibration Tube, 0.42m long, 14.2mm O/D, made from 90/10
Cu/Ni Brass, with thru holes to simulate internal metal loss. Part No. CEGB, ESI Type A.
See Figure A1-1.
Chart recorder - Astro Med Dash 2EZ+ and recorder/printer with 80mm paper width.
NDT31-50316b
Sample Instructions A1-1 Copyright © TWI Ltd
Pre-test: Ppreparation of the test area:
Ensure all equipment pre-use checks are carried out in accordance with manufacturers
instructions.
Ensure all equipment calibration certificates are valid and all electrical safety checks are
completed.
Visual: Carry out a visual inspection of tubes and ascertain that they are in a fit
condition for eddy current examination.
Ensure bores of inspection tubes are clean and free of any silt deposits.
Ensure also that bores of tubes are not damaged or dented to an extent that might
restrict probe travel. Note and report such tubes. Every effort is to be made to ensure
probe does not become stuck.
Ensure all tubes are identified for position. It is normal practice to number the tubes
downwards in vertical rows.
NDT31-50316b
Sample Instructions A1-2 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
2 Inspection: Carry out an inspection of first tube in a similar manner, ensuring that
scan speed is constant and that both outlet and inlet signals are produced at either
end of calibration trace.
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NDT31-50316b
Sample Instructions A1-3 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
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If for any reason the parameters of this inspection cannot be complied with, then the
inspection is to be halted and the supervisor informed.
NDT31-50316b
Sample Instructions A1-4 Copyright © TWI Ltd
Recording and classifying results: Action to be taken when defects are detected or
no fault found:
Classify calibration tube - Using the report sheet attached, enter the signal
amplitudes obtained from the calibration tube. The smallest amplitude, (obtained from
the single hole) should be classified as class limit 1 and the others as class limit 2, 3A,
3B, 4 and 5 respectively.
Defect classification - All defect indications appearing on the chart recorder paper
trace, which cannot be attributed to entry, exit or steel support plate indications, are to
be considered as defects and reported.
Assess class of defect by referring to calibration tube class limits. Defects > 8 cross
drilled holes = class 6. All tubes with defects equal to or greater than class 4 are to be
retested and reported separately. Ensure ‘calibrations ‘in’ and ‘out’ are repeated for this
retest.
Reporting the results: Reporting format and essential data required for the report:
All defects are to be reported in accordance with TWI reporting procedure using a copy
of the recording sheet attached to this instruction. Ensure all fields are correctly
annotated with equipment details, tube identification, and defect amplitude,
classification and positional information with reference to a datum.
Defective tubes are to be clearly marked, isolated where possible and supervisor
informed.
Tube entry restrictions: Note and report any tube restrictions, which prevented full
inspection. Where introduction of probe into tube was impossible due to blockage, then
tube to be annotated as ‘UTE’ – unable to enter.
8 6 4 3 2 1 D=0.6
14.2mm OD
0.42m
NDT31-50316b
Sample Instructions A1-5 Copyright © TWI Ltd
Eddy Current Tubes
Inspection Results Recording Sheet
Full Length Test – Differential Mode – Internal Defects
DEFECT SIGNAL
TUBE Amp. COMMENTS
No. mm. Class Location
RETESTS
NDT31-50316b
Sample Instructions A1-6 Copyright © TWI Ltd
Appendix 1B – Sample Instruction - Amplitude Analysis, Inlet End,
Internal Defects
Scope: This instruction is documented as the process by which Condenser Tubes are
inspected at the Inlet end for Internal Erosion/Thinning using the Eddy Current
Amplitude Analysis method with an absolute coil. The signals are recorded/printed out
and assessed against a calibration tube graph of amplitude and thinning.
Area to be tested:
Inlet ends only, in vicinity of where 6" or 7.5" venture inserts may have been fitted.
All personnel carrying out this instruction shall be qualified to PCN/Level 1/Wrought
Tubes and carry company approval as a minimum.
Safety requirements:
All safety instructions contained in the TWI Health and Safety Manual, which apply to
tube inspections, are to be complied with.
Probe - Air cored Absolute bobbin probe, 11mm diameter. Part No. PID110N05R20K
This probe will give a nominal fill factor of 84%. Any alternative probe should give a
minimum fill factor of 70%.
Calibration tube - Calibration Tube, 0.7m long, 14.2mm O/D, made from 90/10 Cu/Ni
Brass, with tapered external annuli to simulate internal metal loss. Part No. CEGB, ESI
Type D, see Figure A1.2.
Chart recorder - Astro Med Dash 2EZ+ and recorder/printer with 80mm paper width.
NDT31-50316b
Sample Instructions A1-7 Copyright © TWI Ltd
Pre-test: preparation of the test area:
Ensure all equipment pre-use checks are carried out in accordance with manufacturers
instructions.
Ensure all equipment calibration certificates are valid and all electrical safety checks are
completed.
Visual: Carry out a visual inspection of tubes and ascertain that they are in a fit
condition for eddy current examination.
Ensure bores of inspection tubes are clean and free of any silt deposits.
Ensure also that bores of tubes are not damaged or dented to an extent that might
restrict probe travel. Note and report such tubes. Every effort is to be made to ensure
probe does not become stuck.
Ensure all tubes are identified for position. It is normal practice to number the tubes
downwards in vertical rows.
NDT31-50316b
Sample Instructions A1-8 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
2 Inspection: Ensure null balance obtained in each tube prior to scan. Carry out an
inspection of first tube in a similar manner, ensuring that scan speed is constant and
that both outlet and inlet signals are produced at either end of calibration trace.
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NDT31-50316b
Sample Instructions A1-9 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
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If for any reason the parameters of this inspection cannot be complied with, then the
inspection is to be halted and the supervisor informed.
NDT31-50316b
Sample Instructions A1-10 Copyright © TWI Ltd
Recording and classifying results: Action to be taken when defects are detected or
no fault found:
Calibration tube – Using the report sheet shown in Figure A1.2, enter the signal
amplitudes obtained from 10, 20, 30, 40 and 50% material losses. Produce a graph of
the calibration tube’s amplitude against percentage thinning.
Inspection defects - All defect indications appearing on the chart recorder paper
trace, which cannot be attributed to entry, exit or steel support plate indications, are to
be considered as defects and reported.
Assess the amount of material loss for each defect using the graph produced from the
calibration tube.
Reporting the results: Reporting format and essential data required for the report:
All defects are to be reported in accordance with TWI reporting procedure using a copy
of the recording sheet attached to this instruction. Ensure all fields are correctly
annotated with equipment details, tube identification, and defect amplitude,
characterisation, classification and positional information, with reference to a datum.
Defective tubes are to be clearly marked, isolated where possible and supervisor
informed.
Tube entry restrictions: Note and report any tube restrictions, which prevented full
inspection. Where introduction of probe into tube was impossible due to blockage, then
tube to be annotated as ‘UTE’ – unable to enter.
NDT31-50316b
Sample Instructions A1-11 Copyright © TWI Ltd
Eddy Current Tubes
Inspection Results Recording Sheet
Inlet End Test – Absolute Mode – Internal Defects
Serial No:
Recorder:
Serial No.:
Probe:
Test Frequency:
Gain Setting:
NDT31-50316b
Sample Instructions A1-12 Copyright © TWI Ltd
Appendix C – Sample instruction - phase analysis, full length, external
defects
Scope: This instruction is documented as the process by which Condenser Tubes are
inspected over their Full Length for External Defects using the Eddy Current Phase
Analysis method with a differential coil. The defect signals are assessed against a graph
of the calibration tube, phase angle and thinning. Printer is used to give positional
information.
Area to be tested:
Full length of 1.5m tubes.
All personnel carrying out this instruction shall be qualified to PCN/Level 1/Wrought
Tubes and carry company approval as a minimum.
Safety requirements:
All safety instructions contained in the TWI Health and Safety Manual, which apply to
tube inspections, are to be complied with.
Probe - Air cored Differential bobbin probe, 11mm diameter. Part No. PID110N05R20K.
This probe will give a nominal fill factor of 84%. Any alternative probe should give a
minimum fill factor of 70%.
Calibration tube - Calibration Tube, 0.7m long, 14.2mm O/D, made from 90/10 Cu/Ni
Brass, with External annuli to simulate external metal loss. Part No. CEGB, ESI Type B,
see Figure A1.3.
Chart recorder - Astro Med Dash 2EZ+ and recorder/printer with 80mm paper.
NDT31-50316b
Sample Instructions A1-13 Copyright © TWI Ltd
Pre-test: preparation of the test area:
Ensure all equipment pre-use checks are carried out in accordance with manufacturers
instructions.
Ensure all equipment calibration certificates are valid and all electrical safety checks are
completed.
Visual: Carry out a visual inspection of tubes and ascertain that they are in a fit
condition for eddy current examination.
Ensure bores of inspection tubes are clean and free of any silt deposits.
Ensure also that bores of tubes are not damaged or dented to an extent that might
restrict probe travel. Note and report such tubes. Every effort is to be made to ensure
probe does not become stuck.
Ensure all tubes are identified for position. It is normal practice to number the tubes
downwards in vertical rows.
NDT31-50316b
Sample Instructions A1-14 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
1 Calibration recording - With calibration as above, obtain signals from the 10, 30
and 50% simulated defects and measure the phase angles of each defect in turn.
The phase angle is measured from the extrpulated peak signal using the flaw dectors
phase control see figure A1.4. Adjust amplitude to approximately 80% FSH in turn in
order to make a correct assessment of phase angles.
2 Inspection - Carry out an inspection of first tube in a similar manner. Defect signals
should be maximised and phase angles recorded, noting defect position, from chart
recorder.
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NDT31-50316b
Sample Instructions A1-15 Copyright © TWI Ltd
Detailed instructions for application of test (continued)
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If for any reason the parameters of this inspection cannot be complied with, then the
inspection is to be halted and the supervisor informed.
NDT31-50316b
Sample Instructions A1-16 Copyright © TWI Ltd
Recording and classifying results: Action to be taken when defects are detected or
no fault found:
Calibration tube - Using the report sheet attached, enter the signal phase angles
obtained from the calibration tube. Draw a graph of the calibration tube defects – phase
angle against percentage thinning.
Inspection defects - All indications, which cannot be attributed to entry, exit or steel
support plate indications, are to be considered as defects and reported. Phase angles
are to be measured and the amount of thinning assessed by using the calibration tube
graph.
Reporting the results: Reporting format and essential data required for the report:
All defects are to be reported in accordance with TWI reporting procedure using a copy
of the recording sheet attached to this instruction. Ensure all fields are correctly
annotated with equipment details, tube identification, defect phase angles and
percentage thinning. Give positional information with reference to a datum.
Defective tubes are to be clearly marked, isolated where possible and supervisor
informed.
Tube entry restrictions: Note and report any tube restrictions, which prevented full
inspection. Where introduction of probe into tube was impossible due to blockage, then
tube to be annotated as ‘UTE’ – unable to enter.
NDT31-50316b
Sample Instructions A1-17 Copyright © TWI Ltd
Calibration Tube Type B – Cupro-Nickel 90/10
External Annuli and Thru Holes to simulate OD defects.
8x0.85mm
thru holes
490mm
90°
0°
NDT31-50316b
Sample Instructions A1-18 Copyright © TWI Ltd
Eddy Current Tubes
Inspection Results Recording Sheet
Full length Test – Differential Mode - External Defects
Serial No:
Recorder:
Serial No.:
Probe:
Test Frequency:
Gain Setting:
NDT31-50316b
Sample Instructions A1-19 Copyright © TWI Ltd
Appendix 2
ESTestMaker Questions
a A mythical quantity.
b An imaginary but useful concept.
c Equal to 1gh mass when converted by Einstein’s equation.
d 1 micron diameter and 10 microns long.
5 Which of the following conditions is not necessary for eddy current testing?
a Electrical contact.
b Specimen conductivity.
c An alternating magnetic field.
d Induced electrical current.
6 Which of the following is not a mandatory component in a basic eddy current test
apparatus?
a An AC source.
b A coil (probe).
c An impedance plane.
d A volt meter.
7 Which of the following is not a probe configuration used in eddy current testing?
NDT31-50316b
ESTestMaker Questions A2-1 Copyright © TWI Ltd
8 The sense or direction of a magnetic field around a conductor is most commonly
determined using:
a Lenz’s Law.
b Ohm’s Law.
c A Rowland Ring.
d The right hand rule.
a Eddy current.
b Impedance.
c Reluctance.
d Magnetic flux density.
a Halves.
b Remains unchanged.
c Doubles.
d Quadruples.
11 If the magnetic flux density for a given location and orientation near a current
carrying conductor is 5 Wb/m2, what is it when the current is cut by half?
a 25T.
b 5T.
c 2.5T.
d 2.25Wb/m2.
12 An increase in which of the following would result in the increase of magnetic flux
density (B) in a solenoid?
a Core permeability.
b Number of coil turns.
c Current in the coil.
d All of the above.
a Faraday’s Law.
b Oersted’s Law.
c Helmholtz’s Theorem.
d Ohm’s Law
NDT31-50316b
ESTestMaker Questions A2-2 Copyright © TWI Ltd
15 The back EMF opposing the inducing EMF is a result of:
a Hysteresis.
b The weak nuclear force.
c Uncompensated electron spin.
d Graviton concentration in the Domain wall.
a Permeability.
b Flux density.
c Pole strength.
d Field intensity.
18 Moving a direct current carrying conductor up and down near a conductive test
piece will result in:
19 When performing thickness or gap testing, what should the operating frequency
be?
a 1 kHz.
b 1 standard depth of penetration (e).
c 3 standard depths of penetration (3e).
d It is not possible to estimate.
20 When gap between plates of the same material is being measured, the probe
should be placed on the thinner of the two plates when possible. Why?
21 The relationship between electric current flow, electromotive force and resistance
to electric current flow is described by:
a Lenz’s law.
b Ohm’s law.
c Faraday’s rule.
d The ampere-ohm equation.
NDT31-50316b
ESTestMaker Questions A2-3 Copyright © TWI Ltd
22 Another term for voltage is:
a Electromotive force.
b Magnetomotive force.
c Potential drop.
d Both a and c.
a Linear.
b Logarithmic.
c Exponential.
d Zero, that is why it is chosen as the standard.
25 In field applications, specific conductivity values are not used; instead a range of
conductivities can be expected from a finished product. Why is this so?
a Variations in alloy.
b Variations in heat treatment time/temperature.
c Variations in fabrication stresses.
d All of the above.
26 What is done to correct for reduced field coupling when making conductivity
measurements on curved surface?
27 When eddy current probes used for restivitiy readings are required to be used on
small surfaces (eg bolt heads), what can be done to overcome edge effects?
28 When does material thickness affect the results of a conductivity test? When:
NDT31-50316b
ESTestMaker Questions A2-4 Copyright © TWI Ltd
29 If temperature of a test piece increases what other eddy current parameter will
likely increase?
a Conductivity.
b Resistivity.
c Frequency.
d Lift-off.
30 Lift-off compensating probes place a compensating coil around the sensing coil.
The purpose of this is:
32 Laminations or disbanding would most likely require you use a (n) probe.
a Gap.
b Pencil.
c Spring.
d Spinning.
34 To eliminate probe wobble using a two frequency multifrequency set up, what
function listed below would be incorrect?
35 Eddy current information is often digitized for transmission and processing. What
is the best resolution possible using 8 bit conversion?
a 0.5%.
b 1.0%.
c 5.0%.
d 8.0%.
NDT31-50316b
ESTestMaker Questions A2-5 Copyright © TWI Ltd
36 Characterising eddy current responses by patterns rather than specific signal
responses is termed:
a Spectrum analysis.
b Signature analysis.
c Waveform analysis.
d Pattern recognition.
a Electrons.
b Positrons.
c Holes.
d Both a and c.
38 The effect that produces signal variations due to variation in coil spacing due to
lateral motion of test specimen when passing through an encircling coil is?
a Lift-off.
b Wobulation.
c Coil clearance.
d Shimmy.
39 The distance in a test specimen that eddy current intensity has decreased 37% of
their surface value is the:
a Depth of penetration.
b Critical distance.
c Exponential distance.
d Coating thickness.
40 The depth beyond which a test system can no longer detect further increase in
specimen thickness is the:
a Skin depth.
b Effective depth of penetration.
c Stand depth of penetration.
d Saturation depth.
a Harmonic distortion.
b Amplitude distortion.
c RF noise.
d Both a and b.
a Inductance.
b Resistance.
c Resistivity.
d Reluctance.
NDT31-50316b
ESTestMaker Questions A2-6 Copyright © TWI Ltd
43 Resistivity of a material is a function of:
44 A change in signal voltage resulting from EMF produced by the relative motion
between test piece and coil is a result of the:
a Edge effect.
b Speed effect.
c Harmonic distortion.
d Fill factor.
a Resistor, series.
b Resistor, parallel.
c Capacitor, series.
d Capacitor, parallel.
46 If the resistance in a 1cm long wire is 2 ohms when it has 0.1cm diameter, what
will the resistance be in a wire of the same length and material but only 0.05cm
diameter?
a 1 ohm.
b 2 ohms.
c 4 ohms.
d 8 ohms.
a R = Ro + T.
b R = Ro + dT.
c R = Ro (1 + a dT).
d None of the above.
48 Given copper at 20oC. With resistivity 5.9 ohm-cm and thermal coefficient of
resistivity of 0.0039, what is the resistivity when the copper is warmed to 40°C.?
a 2.90 ohm-cm.
b 5.80 ohm-cm.
c 6.25 ohm-cm.
d 11.60 ohm-cm.
49 When an eddy current probe is brought near a conductive sample the net
magnetic flux in the system:
a Increases.
b Decreases.
c Remains unchanged.
d Drops to zero when the part is contacted.
NDT31-50316b
ESTestMaker Questions A2-7 Copyright © TWI Ltd
50 Eddy current density in a sample is:
51 Strictly speaking, the standard skin depth equation; J/Jo = (e^- β) sin (wt- β), is
true for only:
a 66%.
b 37%.
c 14%.
d 9%.
53 When inspecting a rod with an encircling coil the eddy current density at the
centre of the rod is zero for δ = standard depth of penetration).
a Xδ.
b x/δ.
c δ /x.
d 57 x/δ.
NDT31-50316b
ESTestMaker Questions A2-8 Copyright © TWI Ltd
57 The equation 2πfL =:
a Inductive reactance.
b Inductance.
c Capacitive reactance.
d Total impedance (electric).
a Inductive reactance.
b Capacitance.
c Capacitive reactance.
d Total impedance (electrical).
a Impedance.
b Resistance.
c Reactance.
d Reluctance.
a Simple addition.
b Simple subtraction.
c Vector addition.
d A weighted average.
61 The method of eddy current testing that uses a dedicated coil to induce eddy
currents in a test piece and another coil to detect eddy current variations in the
test piece is the method.
a Pulse-echo.
b Impedance.
c Send-receive.
d Sing-a-round.
62 When the eddy current test system is represented by the transformer the sample
can be considered the secondary winding with:
a A single turn.
b 10 turns.
c Zero turns.
d None of the above, it is not possible to determine.
a Resistivity of sample.
b Operating frequency.
c Sample conductivity.
d Lift off.
NDT31-50316b
ESTestMaker Questions A2-9 Copyright © TWI Ltd
64 An increase in tube wall or plate thickness will move the operating point on the
impedance curve:
a Up.
b Down.
c Inside the curve.
d Outside the curve.
65 An increase in test frequency will move the operating point on the impedance
curve:
a Up.
b Down.
c To a point inside the original curve.
d To a point outside the original curve.
67 In the send-receive method of eddy current testing the variations in eddy current
flow due to flaws in the test piece are monitored by:
a Upward.
b Downward.
c To a point inside the curve.
d To a point outside the curve.
69 Increasing which of the following parameters will move the operating point up on
the impedance curve?
a Resistivity.
b Thickness (of tube or plate).
c Frequency.
d Diameter of a surface probe.
70 In the impedance method of eddy current testing the impedance phase Ө (in
degrees) is calculated from (w is the angular frequency, L is inductance, R is
resistance):
a Ө = Arcsin (wL/R).
b Ө = Arccos (R/Lw).
c Ө = Arctan (wL/R).
d Ө = Arcsin (R2+L2)^½.
NDT31-50316b
ESTestMaker Questions A2-10 Copyright © TWI Ltd
71 The effect of sample and test parameters can be illustrated using:
a Magnetographs.
b Impedance diagrams.
c Polar projections.
d Polarised light.
72 Given a coil with 50 ohm resistance and 50 microhenries inductance and operated
at 50kHz; what is the coil inductive reactance?
a 0.4 ohms.
b 1.6 ohms.
c 3.9 ohms.
d 15.7 ohms.
73 Given a coil with 2ohms resistance and 20 H inductance and operated at 20kHz,
what is the coil’s inductive reactance?
a 1.59 ohms.
b 2.51 ohms.
c 6.3 ohms.
d 10 ohms.
74 Given a coil with 20ohms and 60 microhenries inductance in air and operated at
50 kHz, when brought next to an inconel sample the probe impedance is 28.5
ohms and impedance phase Ө is 45o, what is the probe’s inductive reactance?
a 20.2 ohms.
b 20.2 microhenries.
c 44.7 ohms.
d Not possible to determine with information given.
a 55 ohms.
b 42.1 ohms.
c 35.3 ohms.
d 5 ohms.
76 If given total impedance of a probe operating on a test sample and know the
impedance phase angle, what equation is used to determine the inductive
reactance of the probe?
a Xp = 2πfL.
b Xp = Zp cos Ө
c Xp = Zp tan Ө
d Xp = Xp sin Ө
NDT31-50316b
ESTestMaker Questions A2-11 Copyright © TWI Ltd
77 Voltage changes across the probe due to a defect in most eddy current
inspections are on the order of:
a 1%.
b 10%.
c 100%.
d 1000%.
a Allow resonance.
b Avoid resonance.
c Set meter type instruments to zero.
d Eliminate the voltage difference between two coils.
a Resistivity.
b Lift-off.
c Resonance.
d Permeability.
a Amplitude.
b Phase.
c Both a and b.
d No form.
81 The result of operating an eddy current test instrument at a point other than
balance point is:
82 In the L-C circuit used by simple meter crack detectors, the circuit is operated:
83 The reactive power of inductance and capacitance in a tuned L-C circuit are:
a Equal.
b Maximum.
c Minimum.
d Zero.
NDT31-50316b
ESTestMaker Questions A2-12 Copyright © TWI Ltd
84 Crack detector type ECT instruments based on resonant circuits detecting surface
defects on low resistivity materials such as aluminium would have operating
frequencies in the range.
a DC.
b 60-100Hz.
c 10-100kHz.
d 10-100MHz.
a Mixing modules.
b Filters.
c Phasors.
d Frequency selectors.
87 Recording of eddy current signals from ECT instruments requires that the
recording instrument:
88 X-Y recorders:
a Probe size.
b Operating frequency of the probe.
c Probe motion (inspection speed).
d None of the above.
90 Most eddy current instruments use some form of for balancing but several
options are available for lift-off compensation.
a Inductor.
b AC bridge.
c DC bridge.
d Potentiometer.
NDT31-50316b
ESTestMaker Questions A2-13 Copyright © TWI Ltd
91 The impedance of probes used in eddy current testing can vary over a range.
Instruments must be able to balance over this range. Most instruments can
handle prove impedances between:
a 50-75 ohms.
b 0.1-100k ohms.
c 10-200 ohms.
d 5-500 ohms.
92 A parallel L-C circuit used in crack detectors has an inductive of 150 ohms. The
capacitive reactance would be about under normal operating conditions.
a 0.1 ohms.
b 75 ohms.
c 150 ohms.
d Not possible to know.
a One coil.
b Two coils.
c More than two coils.
d A DC magnetic field.
95 When two similar coils on the AC bridge of the eddy current instrument sense
with the test material the probe is a (n):
a Absolute probe.
b Differential probe.
c Spring probe.
d Pencil probe.
96 The purpose of spring loading an eddy current probe against the test material is:
NDT31-50316b
ESTestMaker Questions A2-14 Copyright © TWI Ltd
98 In the send-receive probe arrangement where the driver and receiver coil are on
opposite sides of a plate, signal variation will result from:
100 Eddy current flow and its associated magnetic flux are a function of position under
the coil. The relationship could best be described as being proportional to
(r=radial distance from coil centre):
a r.
b 1/r.
c r^/½.
d No relationship exists.
101 For a given sized defect, what significant defect signal change occurs when
testing a plate using the through transmission (send-receive) method and the
defect occurs first 25% of the wall thickness from the transmit coil, then 50% and
75%?
103 Decrease in sensitivity resulting from increasing lift-off is more pronounced for:
NDT31-50316b
ESTestMaker Questions A2-15 Copyright © TWI Ltd
105 At high operating frequencies, the effective coil diameter (sensing diameter) is
approximately equal to:
106 Permeability changes are of greater concern in eddy current testing because:
107 The reversal swirl that is observed on a normalised impedance graph showing the
effects of decreasing thickness is a result of:
108 The phase angle used to estimate defect depth is the angle between the:
109 Which defect parameter will not affect the probe frequency you select to locate a
defect?
a Depth.
b Size.
c Orientation.
d None of the above (ie all are frequency dependant).
110 Using a typical impedance type EC machine with storage monitor, electrical
resistivity determinations are made by:
111 When given a plate sample for resistivity determination, test frequency should be
selected such that skin depth is at least:
NDT31-50316b
ESTestMaker Questions A2-16 Copyright © TWI Ltd
112 Frequency for plate thickness determinations of thin sections can be
approximated by ; where resistivity ( ohm-cm), t=thickness (mm) and
δ=standard depth of penetration (mm).
114 Measuring the thickness of conductive layer on another conductor (neither being
magnetic) requires:
115 Most impedance eddy current instruments will not operate at resonance. This
situation is remedied by:
116 A practical depth limit for flaw detection and location using eddy current test
methods is about:
a 1mm.
b 6mm.
c 12mm.
d 18mm.
117 Which of the following is not an advantage of the eddy current test method?
118 When performing an eddy current test and you encountered a signal that could be
a crack, permeability change or restivity change, you would:
NDT31-50316b
ESTestMaker Questions A2-17 Copyright © TWI Ltd
119 The f90 for tubing and plate are found using similar but different equations. These
equations were determined:
a Empirically.
b By computer simulations.
c From characteristic frequency (fg).
d From the phase lag equation.
121 Encircling probes (or internal probes) are likely to be replaced by surface probes
for tubing with a diameter greater than 50mm. The reason for this is:
122 To increase sensitivity to near surface defects using a bobbin style probe coil
length and thickness are reduced. This however results in:
123 Coil spacing on differential probes for general inspection purposes of tubing is
usually:
a Defect depth.
b Wall thickness.
c Both a and b.
d Not important.
a Encircling.
b Differential.
c Bobbin.
d Absolute.
125 Which of the following is an advantage of the differential probe compared to the
absolute?
NDT31-50316b
ESTestMaker Questions A2-18 Copyright © TWI Ltd
126 Effects of temperature drift are reduced by using:
a Differential probes.
b Probe pre-heat.
c Liquid nitrogen baths.
d Gap probes.
127 The main reason an eddy current coil can detect support plates in heat
exchangers when testing tubes from the inside diameter is:
128 A probe whose operating impedance is not between 20-200 ohms will most likely
in:
129 Assuming resistance is negligible and probe inductance is 80 henries, for a cable
with 5 x 10^-9 farads capacitance, what is resonance frequency?
a 25Hz.
b 250Hz.
c 250kHz.
d 250MHz.
130 If a probe for internal tube testing has an average coil diameter of 11mm, what
size would the tube inside diameter be to give a 0.9 fill-factor?
a 12.2.
b 11.6.
c 11.1.
d 10.9.
131 An encircling coil is used on a 12mm diameter solid rod. What is the fill-factor if
the average coil diameter is 13mm?
a 0.80.
b 0.85.
c 0.92.
d 1.08.
132 Impedance diagrams for cylinders are not the simple semi circular shapes used
for plate. This is a result of:
a Skin effect.
b Phase lag.
c Leakage fields.
d Both a and b.
NDT31-50316b
ESTestMaker Questions A2-19 Copyright © TWI Ltd
133 A tube being tested by an internal probe has an ID to OD ration of 0.8. Under
what conditions does this appear to be a thin wall tube?
134 Test frequency for solid cylinders, maximum sensitivity to defects, resistivity and
dimensions is obtained when f/fg=:
a 2.
b 6.
c 100.
d 400.
135 The f90 frequency has been found empirically from the ratio of thickness and skin
depth. For testing tubing this ratio is:
a 0.08.
b 0.9.
c 1.1.
d 3.
137 Given a brass tube 20mm diameter (OD) with a 3mm wall and the resistivity of
brass is 7.0 ohm-cm, what is the f90 for testing this tubing?
a 1630Hz.
b 2.3kHz.
c 70kHz.
d 128kHz.
138 What is the f90 for an encircling coil used on aluminium tubing, P =5.1 ohm-cm,
wall thickness 5mm, diameter 40mm?
a 612Hz.
b 3.1kHz.
c 14.7kHz.
d 61.2kHz.
139 When tube testing at f90 (internal absolute probe), if ID wall loss moves the
operating point for an absolute coil in a negative X direction, a shallow OD defect
would move the operating point:
a +X.
b –Y.
c +Y.
d Both -X and -Y in equal proportions.
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ESTestMaker Questions A2-20 Copyright © TWI Ltd
140 When tube testing (internal absolute probe) at f90 and setting OD wall loss to
move +Y on the scope, what is the probably source of a +X moving signal?
a ID wall loss.
b Through hole.
c Dent.
d Support plate.
141 When interpreting eddy current signals by quadrature components on strip charts
the X channel information is used for:
142 To eliminate magnetic deposits as a possible cause of defect signals (ie a non-
relevant indication) it is recommended that:
144 Ferromagnetic inclusions on or in normally non magnetic aluminium will arise due
to:
a Non detectable.
b Non-relevant or false indications.
c More critical than their signals indicate.
d Eliminated by small saturating magnets within the coil.
a Gain.
b Phase.
c Frequency difference.
d Both a and b.
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ESTestMaker Questions A2-21 Copyright © TWI Ltd
147 What condition can be eliminated using multifrequency eddy current technique?
148 Metal hardness can be indicated by eddy current testing. This is accomplished by:
149 Which of the following will have the largest resistivity change with change in
temperature (à = thermal coefficient):
a Brass à = 0.0046.
b Copper à = 0.0050.
c Titanium à = 0.0400.
d Platinum à = 0.0040.
150 Degree of cold working of which material can be determined by eddy current
methods monitoring for permeability changes instead of resistivity changes?
151 Which of the following can cause variability in resistivity readings taken for the
purpose of sorting?
a Sample curvature.
b Ambient temperature variation.
c Coatings.
d All of the above.
153 The amount of reverse magnetising force required to eliminate the residual
magnetic flux in a ferromagnetic material is:
a 5.5 kilgauss.
b The coercive force.
c The de-saturating force.
d Hysteresis.
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ESTestMaker Questions A2-22 Copyright © TWI Ltd
154 Which of the following series of stainless steels is not likely to exhibit an increase
in relative permeability with increasing cold working?
a 301.
b 302.
c 304.
d 316.
a Heat and hold the part over the curie temperature for testing.
b Use saturating magnets as part of the probe.
c Both a and b.
d Stress relieve the part prior to testing.
156 If testing a material and you have set up acceptable conditions for phase
separation of 90o for 1mm sample depth when relative magnetic permeability is
1, what depth would the 90° separation occur at if relative magnetic permeability
changed to 20?
a 20mm.
b 10mm.
c 0.1mm.
d 0.05mm.
a 100 Hz.
b 50 kHz.
c 250 kHz.
d 320 kHz.
158 What test frequency has a standard dept of penetration of 1mm for a plate
material with resistivity of 130 ohm-cm and relative magnetic permeability of
500?
a 650Hz.
b 1.20kHz.
c 240khz.
d 320kHz.
159 Magnetic saturation techniques for EC testing that use DC saturation coils are
limited to the amount of saturation achieved by:
a Test frequency.
b Heating of the saturation coil.
c The size of battery used.
d The voltage that can be safely used.
NDT31-50316b
ESTestMaker Questions A2-23 Copyright © TWI Ltd
160 What is a resistivity of 6.2 ohm-cm as a % IACS?
a 27.7.
b 13.1.
c 9.8.
d 6.2.
161 Given the permeability of free space is 4πX10^-7 Wb/A/m and the permeability of
an iron bar is 7X10^-4 Wb/A/m, what is the relative permeability of the iron?
a 12.56.
b 87.9.
c 280.
d 557.
162 Small eddy current sensors in the vicinity of cracks could be used for:
a Heat.
b Magnetic field strength.
c Mechanical force or torque.
d All of the above
a Potential differences.
b Eddy currents.
c Electron flow.
d Strawberry fields.
165 Two insulated wires are wound on a plastic rod such that they are positioned very
close to each other but not touching. The ends of one wire are connected to a
battery; the ends of the other are connected to a galvanometer. If the wire
connected to the battery has 1 amp flowing through it, what will the
galvanometer read?
a 0 A.
b 1 A.
c Just a little less than 1 amp.
d Just a bit more than 1 amp.
166 The time constant of the circuit is a ratio inductance to resistance (L/R). This
accounts for:
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ESTestMaker Questions A2-24 Copyright © TWI Ltd
167 In an eddy current test set-up, magnetic lines of flux from the probe which fail to
couple the test piece:
a Carry no information.
b Cause self inductance in the magnetising coil.
c Are responsive to the spacing of coil and test piece.
d Both b and c.
168 Complex numbers are often used in the analysis of eddy current test systems.
Complex numbers have 2 components, they are:
a Pure inductance.
b Pure resistance.
c All conditions.
d No conditions.
170 The phase angle between applied voltage and resultant current in an AC circuit of
pure inductance is:
a 0°.
b 45°.
c 90°.
d 180°.
173 Measurement of the thickness of a non conductive coating would utilise the
effect.
a Skin.
b Lift-off.
c Hall.
d Bassel.
NDT31-50316b
ESTestMaker Questions A2-25 Copyright © TWI Ltd
174 The inductance in the excitation coil is proportional to the diameter square (D2)
and the number of turns squared (N2). The voltage induced in the pickup coil is
proportional to:
a N and D.
b N2 and D.
c N2 and D2.
d N and D2.
175 The purpose of small diameter and high frequency probes for determining
thickness of thin coatings on conducting substrates is to:
176 The magnetic flux density around an empty test coil is reduced by increases in
when testing non-magnetic materials:
177 The purpose of curved wear pieces (shoes) to guide surface probe assemblies is
to:
178 Magnetic shielding technique provides the magnetic field lines of the eddy current
probe with:
179 Shielding obtained by eddy current skin effect differs from magnetic methods of
shielding in which way?
180 Maximum test sensitivity is obtained at which point on the signal locus of the
complex plane?
NDT31-50316b
ESTestMaker Questions A2-26 Copyright © TWI Ltd
181 What f/fg ration is recommend for testing thin wall non-magnetic tubing for
cracks, alloy variations or wall thickness variations?
a 0.1.
b 1.0.
c 3.6.
d 10.
182 When using an external encircling coil the frequency ration f/fg to obtain
maximum sensitivity to all test variables will be greatest for which variety of
heavy wall tube?
a Solid bars.
b Wall thickness to outside tube radius = 0.5.
c Wall thickness to outside tube radius = 0.01.
d None of the above, f/g is constant for all encircling coil tests.
184 When both a primary (energising) and secondary (pickup) coil are used as an
encircling coil probe, the time varying flux in the test piece induces an AC voltage
in:
185 Phase angle differences of eddy currents greater than about 100° is not
recommended for tube testing with encircling coils because:
a Eddy current density on the inner wall is too low for crack detection.
b There is no sensitivity to ferromagnetic inclusions.
c No discrimination between inner and outer wall is possible.
d Variation in wall thickness and cracks look the same.
186 Which of the following is the direct cause of eddy currents in a test piece placed in
an encircling transducer?
NDT31-50316b
ESTestMaker Questions A2-27 Copyright © TWI Ltd
188 All other conditions being equal for a bar tested in an encircling coil system, an
increase in relative permeability of the bar tested would result in:
189 Locus curves for diameter changes on the test piece are not straight lines on the
normalised impedance plane. Why is this so?
190 Separation of diameter and conductivity effects is better carried out at frequency
ratios greater than 4 because:
191 The complex impedance plane presentation for testing a ferromagnetic bar should
be changed in what way from the same test on a non-ferromagnetic bar? The:
192 When testing ferromagnetic bars with an encircling coil, the effects of changes in
are reduced or eliminated by DC magnetic saturation.
a Resistivity.
b Diameter.
c Relative magnetic permeability.
d Fill factor.
193 Defect effects from tests in the mercury cylinder can be applied to ferromagnetic
materials for practical applications provided:
NDT31-50316b
ESTestMaker Questions A2-28 Copyright © TWI Ltd
194 The through-transmission technique is used for testing of sheet and foil under
certain conditions:
195 For two separate objects with different relative permeabilities and resistivities,
equivalent eddy current tests can be performed by adjusting test frequencies.
This is explained by:
196 Eddy current tests using encircling coils would provide similar test coil
impedances or voltage signals for tests on 100mm diameter aluminium rod and
2mm diameter steel wire if:
197 The best method of measuring the effects of a specific discontinuity totally within
a test specimen but at different depths and orientations is by using:
198 The curve traced on X-Y storage monitor as an active coil is brought up to a
sample of 1100 aluminium (100% pure) is called the:
a Reference curve.
b Coil lift-off locus.
c Aluminium standard arc (ASA).
d Eddy current curve.
199 When a metal sheet is inserted into a through transmission probe arrangement,
the transmission coefficient phasor:
a Remains unchanged.
b Changes in magnitude and phase.
c Changes in real and imaginary values.
d Both b and c.
NDT31-50316b
ESTestMaker Questions A2-29 Copyright © TWI Ltd
200 In a through transmission test of sheet products, why might a metered output
monitor the product of thickness and conductivity (absolute measurement
method)?
201 For a non-magnetic foil thickness D, conductivity σ, the effective coil distance is
found from Aeff = (253,000/fg σ D). Effective coil distance will decrease if:
a Thickness decreases.
b Resistivity increases.
c Both a and b.
d None of the above.
202 The effect of increasing coil diameter on the effective coil distance is:
a A straight line connecting the zero lift-off point to the empty coil value.
b Bent slightly left towards increasing f/fg values.
c Bent slightly right towards increasing f/fg values.
d Bent slightly right towards decreasing f/fg values.
206 The apparent impedance curve for two different metals of the same thickness will
be the same if:
NDT31-50316b
ESTestMaker Questions A2-30 Copyright © TWI Ltd
207 A practical f/fg ratio for thickness measurements would be in the range of
1-7.5. This would provide maximum sensitivity to:
a Conductivity.
b Resistivity.
c Lift-off.
d Both a and b.
a Conductivity.
b Density.
c Lift-off.
d Both a and b.
209 If a sheet was composed of 2 metallic layers with thicknesses D1 and D2 and
conductivities σ1 and σ2, what would the equivalent product be when tested by
through transmission?
a σ D = σ1D1 + σ2D2.
b σ D = σ1σ2 + D1D2.
c σ D = σ1D1)(σ2D2).
d σ D = σ1D1)2 + (σ2D2)2.
211 To discern very shall cracks using a surface coil you would use a relatively high
frequency-conductivity product (σ f). Which of the following would then be true?
212 When inspecting spheres with an encircling coil, what is the equivalent effect of
increasing the coil length?
a A frequency increase.
b A frequency decrease.
c An increase in material conductivity.
d A decrease in fill factor.
NDT31-50316b
ESTestMaker Questions A2-31 Copyright © TWI Ltd
214 When using surface coils for crack detection, shallow cracks and lift-off cannot be
separated unless:
215 The result of using a longer encircling test coil to test a spherical object as
compared to a short coil or hemispherical coil would be:
a Increased sensitivity.
b Reduced fill factor.
c Improved phase discrimination of cracks and conductivity changes.
d All of the above.
216 In remote field eddy current testing, how far does the direct coupling zone extend
from the exciter coil?
217 Remote field eddy current testing is a technique commonly used on:
a Ferromagnetic tubes.
b Laminates sheets of tungsten carbide.
c Paint coatings on aluminium boat hulls.
d Riveted joints on aircraft fuselage.
218 Signals received in the remote field eddy current set-up give two response off
large defects, one occurs due to the receiver coil passes the defect. What causes
the other signal?
a The magnetic field due to skip off the opposite wall phase lagged.
b The electric field due to skip off the opposite wall phase lagged.
c The exciter passing the defect.
d Mode conversion.
219 In the range of about 3-13mm wall thickness, what frequency range would be
used for low frequency remote field eddy current testing of ferromagnetic tubing?
a 10-300Hz.
b 500Hz-2kHz.
c 2-10kHz.
d 10-50kHz.
220 When eddy currents are used for sorting techniques it is usual to establish
impedance values from:
a Probe characteristics.
b Samples of known materials.
c Published information.
d Trial and error methods.
NDT31-50316b
ESTestMaker Questions A2-32 Copyright © TWI Ltd
221 Applying a DC electric field to a ferromagnetic coil is done for what purpose?
223 In general, the edge effect seen as a probe is moved towards edge of a magnetic
test piece as compared to a non-magnetic test piece would be recognised by what
feature?
224 Substitutional solid solutions and interstitial solid solutions of metals are forms of:
225 Alloying metals added to pure base metals result in decreasing conductivity of the
initial value of the pure base metal. Why does this occur even with alloying
metals having higher conductivity than the base metal?
226 Work hardened aluminium has a higher resistivity than annealed aluminium for
what reason?
NDT31-50316b
ESTestMaker Questions A2-33 Copyright © TWI Ltd
228 What would the effect on conductivity signal be as radius of curvature of the test
piece is decreased?
229 Although specimen and standard may be within the recommended 5oC
temperature difference for resistivity measurement, why might the value
determined still be incorrect?
231 What is the effect on eddy current determined properties of aluminium alloys that
have been annealed for an excessive amount of time?
a Increased resistivity.
b Decreased resistivity.
c Both a and b.
d None of the above (no effect).
a A minute increase.
b A significant increase.
c A decrease.
d No change.
234 When a ferromagnetic material has a magnetising force applied to it, the
magnetic flux that builds within the material lags the applied force. The same lag
occurs upon the reduction in magnetising force. What is the lag called?
a Permeability.
b Hysteresis.
c Barkhausen effect.
d Phase shift.
NDT31-50316b
ESTestMaker Questions A2-34 Copyright © TWI Ltd
235 Which of the following is not a method used to manufacture notches in calibration
standards used for eddy current tests of tubing?
236 What is main advantage of foil calibration standards over affixed coatings
calibration pieces?
a Robustness.
b Accuracy.
c Resilience.
d Calibration on curved surfaces.
238 The most common and reliable method of manufacturing artificial cracks for eddy
current standard is by:
239 What is not one of the advantages of drilled holes being used as reference
standard?
a Simplicity.
b Economic.
c Behaves like a crack.
d Provided a good indication of sensitivity.
240 What is the advantage of artificial defects made by the EDM process?
a Speed.
b Cost.
c Accuracy.
d None of the above, EDM is not used to make artificial defects.
NDT31-50316b
ESTestMaker Questions A2-35 Copyright © TWI Ltd
242 What is used to regulate the consistency of the manufacturing of calibration
standards?
243 Which of the following is not a means of suppressing an undesired eddy current
test signal?
244 Which of the following noise sources can be filters with the appropriate electronics
in an eddy current instrument?
245 What limits the scanning speed when using meter display eddy current
instruments?
a Operator response.
b Meter movement (rise time).
c Operating frequency.
d Defect type or coating thickness.
246 What is the most significant drawback of dot matrix displays of EC signals
compared to CRT displays?
a Image stability.
b Resolution.
c Cost.
d Size and power consumption.
247 How many thresholds must be set on the CRT display of an eddy current
instrument in a box gate alarm system?
a 2.
b 3.
c 4.
d 8.
a Single line.
b Box.
c Pie-slice.
d Sinusoid.
NDT31-50316b
ESTestMaker Questions A2-36 Copyright © TWI Ltd
249 Multifrequency can discriminate signals at the same depth because:
251 A circuit block that accepts a binary number and translates it to an analogue
voltage or current proportional to the binary number is a (n):
a CPU.
b Analogue-to-digital converter.
c Digital-to-analogue converter.
d Retro-virus.
252 A circuit block that uses an analogue voltage as an input and outputs, a
proportional binary value is a (n):
a D/A converter.
b A/D converter.
c Motherboard.
d Parallel interface.
253 Hall detectors are used to sense magnetic fields. They detect:
a Electrons.
b Positrons.
c Holes.
d Quarks.
a Electrons.
b Holes.
c Protons.
d Positrons.
NDT31-50316b
ESTestMaker Questions A2-37 Copyright © TWI Ltd
256 The ideal signal voltage in a Hall detector element in the absence of a magnetic
field is:
a Zero.
b Maximum.
c A loc minimum.
d Determined by ambient temperature.
259 Which of the following are Hall effect detectors not sensitive to?
260 Instrumentation for systems using Hall detectors instead of pickup coils are
different in what respect?
261 Eddy current test systems using Hall detectors can accomplish differential tests
by:
262 When using Hall detectors, how are sensitivities to relatively great depths
achieved?
NDT31-50316b
ESTestMaker Questions A2-38 Copyright © TWI Ltd
263 What are slip rings used for in eddy current inspection systems?
264 To avoid rotating parts, probes or test piece, what system would be used to
inspect round bar stock?
a Encircling probes.
b Circumferential array of probes.
c Hall effect exciters.
d Both a and b.
265 A differential transducer with the two windings around perpendicular to each
other used to detect both longitudinal and transverse cracks is called a (n):
266 In what way is eddy current testing more suitable to high speed production tests
on hot metals than ultrasonics?
267 Eddy current testing of hot billets (1,100oC) can be done provided what
precautions are taken?
268 Seamless pipe and tubing are often made from billets made from continuous cast
blooms. The rounds, as the billets are called, are test by eddy current to detect
what types of defect?
a Cracks.
b Ovalities.
c Laps.
d All of the above.
269 When ECT is used to test thickness of coatings having a tolerance range, what is
the minimum number of calibration specimens required to calibrate the
instrument?
a 2.
b 3.
c 4.
d 2 or 4 depending on if the coating is conductive or not.
NDT31-50316b
ESTestMaker Questions A2-39 Copyright © TWI Ltd
270 Truly effective sorting of aluminium alloys by eddy current determination of
resistivity is not possible because:
271 When online testing of ERW welds in steel pipe using eddy current testing, what
problem occurs if the inspection is performed too far from the induction heating
coils used for normalising the weld?
a Increased conductivity.
b Decreased hardness.
c Both a and b.
d No effect.
273 You are given 2 plates of identical size (50x50x10mm) both painted with a thin
coating of black acrylic paint of the same thickness. Eddy current test indicate
both have a conductivity of 37% IACS, yet one is nearly twice as heavy as the
other. How is this possible?
274 What is the most effective way of assessing heat or fire damage to heat-treatable
aluminium on aircraft?
275 Alpha-case forms on titanium and its alloys at elevated temperatures. Eddy
currents are used to establish the depth of case. What is the cause of the
formation of alpha-case?
NDT31-50316b
ESTestMaker Questions A2-40 Copyright © TWI Ltd
276 When a single channel strip charge recorder is used with eddy current testing of
bolt holes using spinning probes, what 2 parameters are recorded?
277 Why are cadmium plated steel bolts used as fasteners on aircraft?
278 Some CRT display eddy current instruments allow X and Y gains to be adjusted
independently. Increasing Y gain and reducing X (eg Y = 0.2 V/div, = 2.0 V/div)
accomplishes what?
279 Low frequency eddy current (100Hz to 5kHz) is commonly used in aircraft
inspections for:
280 What is the biggest advantage eddy current test methods have that make them
the most frequently used NDT method in the automotive industry?
281 Eddy current test methods are more sensitive than x-rays for detection of in
aircraft structures.
a Corrosion.
b Missing fasteners.
c Fatigue cracks.
d Overloading cracks.
282 Finned copper tubing used in air conditioning units has smooth land areas at
regular intervals along the tube. What is the purpose of these land areas?
NDT31-50316b
ESTestMaker Questions A2-41 Copyright © TWI Ltd
283 During evaluation of an indication in a heat exchanger tube, the probe is moved
back and forth over the defect. It is noted that the indication has changed
position along the length of the tube. What is the likely source? A:
a Magnetic deposit.
b Spiral fret.
c Active cracking.
d Probe wire has loosened at the connector.
284 In eddy current inspections of chiller tubes, freeze cracks located at freeze bulges
are often not possible to detect using conventional differential probes because:
285 Generally in multifrequency techniques for in-situ boiler tube inspections, high
frequencies are used to suppress while low frequencies are used to
suppress .
286 In order to do computer modelling of eddy current fields you must provide:
a Increased resistivity.
b Increased conductivity.
c Destabilisation of isotypes.
d No effect on any properties (that’s why they are called insulators).
NDT31-50316b
ESTestMaker Questions A2-42 Copyright © TWI Ltd
290 What is the advantage of eddy current testing over the potential drop method for
sizing surface cracks?
a Accuracy.
b It is non-contacting.
c Cost.
d There is no advantage.
a Curvature should be small within the region directly below the cross-sections
of the coil.
b Frequency of operation should be as low as possible.
c Perspex supports should be arranged to fit the curvature inspected.
d All of the above.
292 How does hysteresis manifest itself when testing ferromagnetic materials?
293 In the 1960s a non-storage type oscilloscope was used for eddy current tests. The
defect free specimen gave a horizontal line. A defective specimen gave a (n):
a Negative Y spike.
b Positive Y spike.
c Ellilpse.
d Angulated line (ie Not horizontal).
294 When an eddy current is balanced for surface testing for flaws, where is the probe
placed?
295 Why are eddy current coils not made using iron wire?
296 The higher the value of inductance for a given frequency the greater the degree
of:
a Balance ability.
b Sensitivity.
c Q factor.
d Capacitive reactance.
NDT31-50316b
ESTestMaker Questions A2-43 Copyright © TWI Ltd
297 The transmit-receive or transformer style probe provides:
298 Inductance increases improve eddy current sensitivity. Why is increasing coil area
not a preferred method of increasing sensitivity even though inductance is
increased?
299 How does the differential (or auto-comparator) coil provide insensitivity to
gradual changes?
a Thin samples.
b Thick samples.
c Rough surfaces.
d Ferromagnetic samples.
302 What degree of accuracy can be expected when using eddy currents to determine
paint thickness 10 m thick?
a 0.01 m.
b 0.1 m.
c 1.0 m.
d 5.0 m.
303 Tubes with a diameter of more than about 50mm are more effectively tested
using than encircling probes.
NDT31-50316b
ESTestMaker Questions A2-44 Copyright © TWI Ltd
304 Multifrequency techniques are performed using:
a Absolute coils.
b Differential coils.
c Both a and b.
d Special multifrequency coils only.
306 Large DC saturation units for eddy current inspection of ferromagnetic tubing are
often required. What technique can be used to avoid use of these heaving DC
saturation units?
307 Using a shielded ferrite coil and the pulsed eddy current technique, penetration of
measurable currents in a metal sample can be increased to (where δ the
standard depth of penetration):
a 2 δ.
b 3 δ.
c 5 δ.
d 10 δ.
308 As conductivity of a material approaches infinity its resistive losses approach zero.
What type of material exhibits such extremes?
a Insulators.
b Semi-conductors.
c Superconductors.
d Gold.
309 On the normalised impedance plane showing the effects of changing conductivity
(σ) the coil’s normalised resistance is zero under what condition?
a σ is zero.
b σ is infinite.
c Both a and b.
d When it equal the normalised inductive reactance.
310 What does an increase in operating frequency do to the probe coil inductance?
a It increases.
b It decreases.
c It may increase or decrease depending where you are on the locus.
d None of the above.
NDT31-50316b
ESTestMaker Questions A2-45 Copyright © TWI Ltd
311 The heating of a ferromagnetic part that occurs when the AC field works to align
the magnetic domains into a preferred magnetic orientation is reduced by:
312 The coil to specimen impedance Z can be defined by (where Zc is coil impedance
and Zs is specimen impedance):
313 The only way to reduce or eliminate the edge effect is by:
a Multifrequency techniques.
b Magnetic focusing probes.
c Spring loaded probes.
d Using remote field eddy current techniques
314 What are the main limiting parameters for a single coil probes dimensions?
a Coil width.
b Number of turns.
c Intended operating frequency.
d Both a and b.
315 During an eddy current inspection of heat exchanger tubing, what is the purpose
of recording a calibration signal with each tube inspected?
316 In what way does computer acquisition and analysis of eddy current signals
(particularly heat exchanger tubing) out-perform humans?
a Detection.
b Reproducibility.
c Accuracy.
d All of the above.
317 The analytical method that consists in correlating changes in amplitude, phase
and/or quadrature components of a complex test signal voltage to
electromagnetic conditions in the test piece is:
a Phase analysis.
b Impedance analysis.
c Differential analysis.
d Absolute analysis.
NDT31-50316b
ESTestMaker Questions A2-46 Copyright © TWI Ltd
318 An instrumentation technique that discriminates between variables in the test
piece by different phase-angle changes these variables produce in the test signal
is:
a Impedance analysis.
b Phase analysis.
c Modulation analysis.
d Frequency analysis.
319 The ration of the square of the diameter of a cylindrical test piece to the square of
the average diameter of the test coil is the:
a Flux ratio.
b Fill factor.
c Physical impedance.
d Test ratio.
320 The frequency providing the highest signal-to-noise ratio for detection of an
individual property of the test piece is the:
a Optimum frequency.
b Test frequency.
c Limit frequency.
d Characteristic frequency.
321 Two or more coils in electrical series opposition arranged so EM conditions not
common to the areas of the specimen being tested produce a bridge imbalance is
a (n):
a Absolute probe.
b Axial probe.
c Differential probe.
d Multipancake probe.
a Skin effect.
b Doppler shift.
c Edge effect.
d Phase shift.
323 The property of a test system that allows separation of signals from defects on
close proximity to each other is:
a Phase separation.
b Amplitude discrimination.
c Defect resolution.
d Multifrequency demodulation.
324 The time required for a test system to return to its original state after it has
received a signal is the:
a Dead time.
b Recovery time.
c Recoil time.
d System delay.
NDT31-50316b
ESTestMaker Questions A2-47 Copyright © TWI Ltd
325 Current flow that is time constant in both direction and amplitude is:
a Direct current.
b Eddy current.
c Induced current.
d Boring.
326 The method whereby desirable frequency signals are separated from undesirable
frequency signals from the modulating envelope of the carrier frequency signal is
called:
a Phase analysis.
b Modulation analysis.
c Filtering.
d Fast fourier transformer.
327 In order that useful results be obtained from an eddy current test, what must be
true about the test specimen?
328 What is the disadvantage of the multi-pancake probe used for internal tube
inspections as compared to the axial bobbin type probe?
329 Test levels used in ECT that establish the group into which a material under test
belongs are termed:
a Acceptance limits.
b Reject level.
c Test criteria.
d Group level options.
a ID coils.
b Bucking coils.
c Annular coils.
d Tandem coils.
331 A test level above or below which test specimens are found to be unacceptable is
called?
NDT31-50316b
ESTestMaker Questions A2-48 Copyright © TWI Ltd
332 A network that passes electromagnetic wave energy over a described range of
frequencies and attenuates energy at all other frequencies is a (n):
a Filter.
b Gate.
c Inductor.
d Grate.
333 The slope of the induction curve at zero magnetising force as the test piece is
being taken from its demagnetised state is the:
a Virgin permeability.
b Initial permeability.
c Maximum permeability.
d Effective permeability.
334 The magnetic condition of a ferromagnetic part based on its previous exposures
to magnetic fields if the part’s:
a Flux density.
b Flux leakage.
c Magnetic history.
d Permeability.
335 An electromagnetic sorting based on a signal response from the material under
test above or below a level established by two or more calibration standards is:
336 Given an encircling coil with an average coil diameter of 10.5mm and testing a
tube 10mm OD with a 1mm thick wall, what is the fill factor of this set up?
a 0.735.
b 0.819.
c 0.907.
d 0.956.
337 Given a tube with a 15mm OD and 1.5mm wall, what size (average diameter) coil
is used to obtain an 85% fill factor for an internal inspection?
a 14mm.
b 13mm.
c 12mm.
d 11mm.
338 What is the standard depth of penetration of 304 stainless steel (68.96 ohm-
cm) having 60% cold work applied ( rel=2) tested at 20kHz?
a 1.1mm.
b 2.1mm.
c 3.1mm.
d 4.4mm.
NDT31-50316b
ESTestMaker Questions A2-49 Copyright © TWI Ltd
339 What is the standard depth of penetration for 301 stainless steel having been
25% cold worked (71
ohm-cm, rel=10) tested at 10kHz?
a 1.3mm.
b 2.3mm.
c 3.4mm.
d 4.6mm.
340 Given a standard depth of penetration of 1.3mm exists for a 10kHz test of navel-
brass (6.63
ohm-cm), what is the effective depth of penetration?
a 1.3mm.
b 3.9mm.
c 5.2mm.
d 6.5mm.
a Resistance.
b Resistivity.
c Probe electrical impedance.
d Specimen thickness.
342 Electromagnetic induction, on which ECT has its foundations, was first discovered
by
a Ampere.
b Faraday.
c Förster.
d Linqvist.
343 The voltage changes used to determine various parameters in eddy current
testing consist of changes in:
344 The right hand rule for determining magnetic field direction around a current
carrying conductor assumes:
345 The left hand rule for determining the magnetic field around a current carrying
conductor assumes:
NDT31-50316b
ESTestMaker Questions A2-50 Copyright © TWI Ltd
346 The product of the magnetic flux density in a loop of a current carrying coil times
the area of that coil gives:
347 Magnetic induction or the force per unit pole in a magnetic field is the magnetic
analog of:
a Electric intensity.
b Electric impedance.
c Electric resistance.
d Electromotive force.
348 An eddy current test system can be considered a form of transformer. As such,
the secondary side would be the:
a Probe.
b Probe and a generator combination.
c Test sample.
d None of the above.
349 As an operating eddy current probe (a coil) is brought near a conductive sample
the induction of eddy currents in the sample causes the probe to:
a Electric fields.
b Magnetic fields.
c Both a and b.
d None of the above, energy conversion by electromechanics is not possible.
351 Faraday’s Law states that the magnitude of the induced voltage in a circuit is:
352 An alternating voltage in a coil brought near a sample that has a finite impedance
will result in:
a A counter EMF.
b Induced eddy current flow.
c Both a and b.
d None of the above.
NDT31-50316b
ESTestMaker Questions A2-51 Copyright © TWI Ltd
353 The intensity of a magnetic field that a unit magnetic pole experiences of a force
of one dyne is one:
a Oersted.
b Telsa.
c Ohm-com.
d Gauss.
a Dyne.
b Oersted.
c Maxwell.
d Tesla.
a Wb/m2.
b Gauss.
c Maxwell’s/cm2.
d All of the above.
356 Alignment of the magnetic domains in iron by an external field result in:
a Hysteresis.
b Eddy currents.
c Magnetisation.
d Permeability.
358 The product of current in amperes times time in seconds gives units of:
a Abvolts.
b Coulombs.
c Electro-stats.
d Hertz.
359 If 20 coulombs of charge passes a point in 5 seconds, the electric current value
would be:
a 4 amperes.
b 100 amperes.
c 0.8 amperes.
d 20 amperes.
360 The purpose of using a radial magnetic field around the current carrying coil in a
galvanometer instead of a parallel magnetic field is:
a To reduce resistance.
b To increase heat dissipation.
c To maintain a simple direct proportionality between current and coil rotation.
d For ease of construction of the instrument.
NDT31-50316b
ESTestMaker Questions A2-52 Copyright © TWI Ltd
361
Given a wire made of copper with resistivity 1.724 ohm-cm, that is 1cm in
length, and has a cross-sectional area of 1cm2, what is the resistance of this
section of wire?
a 1 ohm.
b Micro-ohm.
c 1.724 ohms.
d 2.972 ohms.
a Wire length.
b Cross sectional area of the wire.
c Resistivity of the material the wire is made of.
d All of the above.
a AC power transformers.
b Carbon composite materials.
c Eddy current testing.
d Ultrasonic testing.
364 Which of the following will have an effect on the electrical resistance of a wire?
a Inherent resistivity.
b Length and cross-sectional area.
c Temperature.
d All of the above.
a Negative.
b Positive.
c Zero.
d Unity.
367 In a nonmagnetic material the back EMF produced by the induced eddy currents
has what effect on the probe?
NDT31-50316b
ESTestMaker Questions A2-53 Copyright © TWI Ltd
368 The decrease in eddy current density with increasing depth from the surface is:
a Linear.
b Exponential.
c Logarithimic.
d Sinusoidal.
369 The time dependent component of the skin depth equation indicates:
370 For the calculation for eddy current density to apply, a sample should be
relatively thick. The minimum thickness to allow the simple equation to apply is
about δ (where δ is the standard depth of penetration).
a 0.5.
b 2.
c 5.
d 25.
a Large diameter.
b Long.
c Zig-zag.
d Either a or b depending on whether plate or tube testing is being done.
372 The phase lag, in units of degrees, for an eddy current signal displayed on a
typical impedance plane scope for a void originating 1 standard depth of
penetration below the surface would be:
a 57o.
b 90o.
c 114o.
d 180o.
373 Phase lag in the test sample for a void at 1 standard depth of penetration is:
a 1 radian.
b 90o.
c Both a and b.
d None of the above, it cannot be determined from the given information.
a The sample.
b The probe cables.
c The probe coil.
d All of the above.
NDT31-50316b
ESTestMaker Questions A2-54 Copyright © TWI Ltd
375 The inductive reactance component of an eddy current probe coil’s impedance will
with increasing AC frequency:
a Increase.
b Decrease.
c Remain unchanged.
d React unpredictably.
376 In the eddy current probe circuit the capacitive component of its impedance is
degrees out of phase with its inductive component:
a 0o.
b 90o.
c 180o.
d 270o.
a Arcsin (R/x).
b Arccos (R/x).
c Arctan (R/x).
d Arctan (x/R).
379 On the ideal impedance diagram the effect of reducing mutual coupling between
probe and sample would be to have the impedance point:
a Two coils.
b Changes in voltage across the primary coil.
c Changes in voltage across the secondary coil.
d Spring loaded probes only.
381 As the diameter of the eddy current probe increases, the operating point on the
normalised impedance curve moves (for a surface probe ie not for tube
testing).
a Up.
b Down.
c In.
d Out.
NDT31-50316b
ESTestMaker Questions A2-55 Copyright © TWI Ltd
382 Variations in the flow of eddy currents caused by flaws in the test piece are
monitored as voltage fluctuations in the secondary coil in the:
384 Using the analogy of the coil/sample as a transformer circuit, when the coil is held
far from the sample we can approximate a (n):
a Short circuit.
b Open circuit.
c Resonance circuit.
d None of the above.
385 All other factors constant, increasing lift-off will move the operating point on the
impedance curve:
a Up.
b Down.
c Inside the original curve.
d Outside the original curve
a L D2.
b L D.
c L 1/D.
d L 1/D2
387 An increase in probe diameter will move the operating point on the impedance
curve:
a Up.
b Down.
c To a point inside the original curve.
d To a point outside the original curve.
388 An inductive and a resistance impedance change in the test coil resulting when an
operating eddy current probe is moved near a conductive test sample is
represented on a (n):
NDT31-50316b
ESTestMaker Questions A2-56 Copyright © TWI Ltd
389 The decrease in semicircle radius of the impedance curve display when lift-off
increases indicates:
390 Given a coil with 50 ohm resistance and 50 microhenries inductance and operated
at 50 kHz; what is the impedance phase angle?
a 0o.
b 5.6o.
c 17.4o.
d 90o.
391 The most significant instrument component required to detect the small variation
in probe impedance or voltage caused by detecting defects in eddy current testing
is the .
a Balance button.
b Video filter.
c AC to DC converter.
d Amplifier.
a -14.2°.
b 38.6°.
c 44.4°.
d 51.4°.
394 The impedance phase angle of a probe operating next to a copper test sample is
40o. What is the inductive reactance of the probe in this situation if the total
impedance measured is 30 ohms?
a 19.3 ohms.
b 22.9 ohms.
c 25.2 ohms.
d Not possible to determine with information given.
NDT31-50316b
ESTestMaker Questions A2-57 Copyright © TWI Ltd
395 Given a probe operating at 0.5MHz next to a brass sample, total probe impedance
is measured at 47.2 ohms, if the impedance phase angel is 45o what is the
resistive load of the sample?
396 Given the resistive load of a probe/sample circuit as 5.1 ohms and the resistance
of the probe when operated in air as 15 ohms, what would the impedance phase
angle be if total impedance of this circuit was 24.5 ohms?
a 22o.
b 35o.
c 55o.
d 68o.
398 The typical figure 8 pattern that occurs with a differential probe moving over a
defect is a result of:
399 Quadrature components of the bridge AC output are generated by sampling the
sinusoidal signal at two positions apart on the waveform:
a 45o.
b 90o.
c 180o.
d 270o.
401 Most eddy current instruments can tolerate an impedance mismatch in the AC
bridge on the order of:
a 0%.
b 5%.
c 50%.
d Any amount.
NDT31-50316b
ESTestMaker Questions A2-58 Copyright © TWI Ltd
402 In the L-C bridge circuit used by simple meter crack detectors, the capacitor is
connected in parallel with the in the bridge circuit.
a Probe coil.
b Resistor in the arm adjacent to the probe coil.
c Resistor in the arm opposite the probe coil.
d Oscillator generator.
403 At the resonant frequency of an L-C circuit, output voltage for a given
measurement:
a Zero.
b Minimum.
c Maximum.
d Not useful.
404 On most eddy current instruments using the impedance method, the AC bridge
circuits can usually balance coils having impedances in a range of:
a 5-10 ohms.
b 40-60 ohms.
c 100-200 ohms.
d 10-200 ohms.
405 Test frequencies for crack detectors operating at or close to resonant frequency
are:
a Not selectable.
b Infinitely variable.
c Limited to the khz range.
d Limited to the MHz range.
406 Resonant circuit crack detectors have a meter output and 3 controls:
407 In resonant circuit crack detectors, the lift-off control actually varies:
a Amplifier gain.
b Operating frequency (by less than 25%).
c Bridge resistance.
d None of the above.
408 Which of the following systems has the advantage of being unaffected by
temperature variations?
NDT31-50316b
ESTestMaker Questions A2-59 Copyright © TWI Ltd
409 In send-receive ECT systems, probes with 2 receive coils have those coils would
in opposition. The purpose for this to:
410 Now obsolete, the ellipse and slit methods of eddy current testing:
a FM shielding.
b AM shielding.
c Relative motion between the coil and sample.
d Two send and two receive coils.
412 FM tape recorders have often been used to store eddy current signals for
subsequent retrieval. Frequency response for these instruments is:
413 Frequency response of an instrument is based on the fact that the output signal
of an instrument will be less than the input signal as inspection speed increases.
Instrument frequency response is defined as the frequency where output signal is
-3dB from the input. This would relate to a volt signal out for a 1 volt
signal input:
a 0.9.
b 0.866.
c 0.707.
d 0.5.
414 Given a parallel L-C circuit with a probe inductance of 80 x 10^-6 Henries and
operated at resonance frequency, 252kHz, what is the cable capacitance?
a 126.5 ohms.
b 80 x 10^-6 farads.
c 5 x 10^-9 farads.
d Cannot be determined.
415 Given a parallel L-C circuit with cable capacitance 5 x 10^-9 farads and operating
at a resonance frequency of 2252kHz, what is the inductive reactance of the
probe?
a 5 x 10^-9 henries.
b 126.5 ohms.
c 253 ohms.
d Cannot be determined.
NDT31-50316b
ESTestMaker Questions A2-60 Copyright © TWI Ltd
416 When selecting an eddy current instrument for a particular project you need to
know:
417 Resonance frequency can be determined for a parallel L-C circuit by:
a fr =1/2(π)(LC)^½.
b fr =(2I(π)LC)^ ½.
c fr =L/C.
d fr =2(π)L/C.
418 Which of the following is not a reason for using a ferrite core on the sensing coil
of a pencil probe?
419 Mounting a disc of metal, having similar properties to the test material, next to
the reference coil in an absolute probe has the advantage of:
a Lift-off compensation.
b Temperature compensation.
c Test frequency not affecting relative impedance of the coils.
d Both a and b.
420 To reduce the effective sensing diameter of surface probes operating at relatively
low frequencies, the use of is recommended:
421 In an absolute probe configuration, a second coil, apart from the sensing coil, is
required for:
a Bridge nulling.
b Lift-off compensation.
c Temperature compensation.
d All of the above.
422 The effective probe diameter extends to about beyond the coil diameter.
a 1mm.
b 1 coil radius.
c 1 coil diameter.
d 4 skin depths.
NDT31-50316b
ESTestMaker Questions A2-61 Copyright © TWI Ltd
423 Ferrite cups can be used to obtain without affecting depth of penetration.
a A concentrated field.
b Right angle current changes.
c Reduced lift-off noise.
d Higher frequencies.
424 Which of the following is not a probe parameter affecting impedance results?
a Frequency.
b Coil diameter and core materials.
c Number of turns.
d Length of coil.
425 Normalising probe impedance for impedance graph displays is accomplished by:
426 All other parameters constant, an increase of permeability in the test piece causes
the operating point on a normalised impedance curve to move:
a Up the curve.
b Down the curve.
c Horizontally left.
d Horizontally right.
427 For a thick specimen, test frequency should be selected to provide good
separation from lift-off variations. This is facilitated by setting frequency so that
the greatest expected defect depth is at:
428 Varying frequency for a probe on a given specimen will move the operating point
down the impedance graph with increasing frequency. If the specimen is not
thick, a reversal swirl occurs forming a knee. This is a result of:
429 The characteristic parameter, Pc, used by Deeds and Dodd is primarily a
modelling tool. Test conditions with the same characteristic parameter have the
same:
a Probe parameters.
b Material parameters.
c Operating point on the normalised impedance graph.
d Probe and instrument parameters.
NDT31-50316b
ESTestMaker Questions A2-62 Copyright © TWI Ltd
430 If lift-off is arranged on the eddy current storage monitor so the signal moves
from right to left as the probe is moved away from the sample, an increase in
sample thickness would conventionally move:
a Down.
b Up.
c Right.
d Left.
431 Maximum frequency you would use for determining thickness of a non-conductive
coating on a conductor would be:
a 1MHz.
b 500kHz.
c 1000Hz.
d Limited by probe to instrument impedance matching, cable resonance and
cable noise.
432 When making resistivity measurements on unknown samples, the frequency used
is selected such that the operating point on the impedance graph is:
a Variations in base material as well as coating material will affect the signal.
b Probes must be specially designed.
c The test cannot be done if an air gap exists between the two conductive
materials.
d Both b and c.
435 The problem with overcoming probe-cable resonance by operating above 1.2fg
(fr-resonance frequency) is:
a Phase discrimination.
b Greatly reduced sensitivity.
c Arcing from probe to test piece.
d None of the above, operating at 1.2 times the resonance frequency is the
preferred option.
NDT31-50316b
ESTestMaker Questions A2-63 Copyright © TWI Ltd
436 What is the effective diameter of a surface probe with a 5mm diameter coil used
on a sample with p = 72 ohm-cm and operated at 2MHz. (p is resistivity):
a 5.5mm.
b 6.2mm.
c 7.5mm.
d 10mm.
437 The ration of thickness to skin depth t/δ that provides a 90o separation between
lift-off and thickness change is empirically derived. It is found to be about
for plate testing:
a 0.1.
b 0.8.
c 1.6.
d 4.
439 The phase angle (as measured from the lift-off signal) of a shallow surface or
sub-surface defect is related to the eddy current phase lag á=x/δ (radius), where
x = flaw depth and δ = skin depth. The phase angle seen on the storage monitor
is approximately:
a ½ Ө.
b Ө.
c 2 Ө.
d 3 Ө.
440 A very shallow surface defect can be distinguished from lift-off by:
441 The best way to distinguish between localised resistivity changes and a real defect
is:
442 Encircling or bobbin style probes used for tube testing require careful design of
coil size to optimise sensitivity and coupling. Coil length and coil depth should be
about:
NDT31-50316b
ESTestMaker Questions A2-64 Copyright © TWI Ltd
443 The reference coil in a bobbin style probe can be mounted concentrically inside
the test coil and the probe still be considered and absolute probe because:
444 When using a bobbin type differential probe, sensitivity to near surface defects
can be improved by:
445 Symmetry of a differential signal as the probe is moved over a defect will depend
on:
a Gap probes.
b Absolute probes.
c Differential probes.
d Bobbin style internal probes.
447 If a defect is longer than the spacing between the coils on a differential coil, the
defect can only be recognised as such if:
NDT31-50316b
ESTestMaker Questions A2-65 Copyright © TWI Ltd
450 Operating at frequencies above resonant frequency will result in:
a Decreased sensitivity.
b Current short circuits across the cable instead of going through the coil.
c Both a and b.
d None of the above, sensitivity actually increases above fr.
451 Eddy current flow in a cylinder, using an encircling probe, changes with radial
distance r from the centre of the cylinder. Eddy current flow is proportional
to for cylinder testing.
a R2.
b R.
c 1/r.
d 1/r2.
452 The curl in the impedance locus that results when increasing test frequencies for
inspecting tubing is a result of:
453 Given that a probe operated at 300kHz has an inductive reactance of 475 ohms,
what is the cable’s capacitive reactance if this frequency results in resonance?
a 21.8 ohms.
b 237.5 ohms.
c 475 ohms.
d 21.8 ohms.
454 The effect on the operating point on the impedance diagram of decreasing coil
length for a bobbin type internal probe would be:
455 The characteristic frequency, fg, is the frequency for which the Bessel function
solution to Maxwell’s magnetic field equation is equal to:
a A local maximum.
b A local minimum.
c 1.
d 0.
456 (5.0p)
D2 is the general equation to find (p=resistivity).
a f90.
b Characteristic frequency for tubes.
c Locus operating point.
d Forster’s fixed frequency.
NDT31-50316b
ESTestMaker Questions A2-66 Copyright © TWI Ltd
457 The characteristic frequency ratio, f/fg, is not used for determining a frequency
for phase discrimination in tube testing because the ration is:
458 Given a brass tube to be tested with an internal bobbin probe, resistivity of the
brass is 7.0 ohm-cm. If an operating frequency of 2.3kHz gives 90° phase
separation between ID and OD defects, what is nominal wall thickness of the
tubing?
a 12mm.
b 3mm.
c 4.8mm.
d 7mm.
459 The main disadvantage of multipancake coil probes used as internal tube
inspection probes is:
460 When tube testing at operating frequencies at 2f90 and higher it is difficult to
discriminate probe wobble and:
a ID defects.
b OD defects.
c Dents.
d Permeability changes.
461 When testing brass tubing (internal absolute probe) at f60 a signal moves off to
the right on the scope (+X). If the 5% ID wall loss is set to move –X, what is the
probable source of this signal?
a OD defect.
b Dent.
c External magnetite.
d Internal magnetite.
a Y amplitude.
b X amplitude.
c Fly-back angle.
d Tangent angle from balance to defect signal tip.
463 When using differential probes, defect depth can be estimated from the:
a X-amplitude.
b Y amplitude.
c Fly-back angle.
d Angle difference between f90 and f90.
NDT31-50316b
ESTestMaker Questions A2-67 Copyright © TWI Ltd
464 Circumferential stress corrosion cracking can be detected by normal bobbin style
probes during in-service inspection of heat exchanger tubing because:
a Special probes.
b Multifrequency units.
c Vectorial addition.
d Both b and c.
466 When using multifrequency techniques for tube inspection with an internal probe,
the most effective results are had for:
a Internal erosion.
b Internal pitting.
c External fretting.
d Circumferential cracking.
469 Separation of defect signals from insignificant parameters is the function provided
by multifrequency ECT units. What condition could not be separated by
multifrequency technology?
470 The induced magnetic flux (B) divided by the applied magnetising force (H) gives
what quantity?
a Relative permeability.
b Magnetic permeability.
c Recoil permeability.
d All of the above (ie different name for same value).
NDT31-50316b
ESTestMaker Questions A2-68 Copyright © TWI Ltd
471 For ferromagnetic materials the relative permeability is:
a >1.
b 1.
c 0.
d -1.
472 Which of the following metals, when alloyed with pure aluminium will result in the
alloy having resistivity less than the aluminium?
a Manganese.
b Magnesium.
c Copper.
d None of the above.
473 The primary cause for the increase in resistivity with increase in cold working is:
474 When the induced magnetic flux in a ferromagnetic material increase linearly with
increasing applied magnetising force the material is:
a Paramagnetised.
b Diamagnetised.
c Saturated.
d Unretentive.
476 Changes in permeability with applied stress below the elastic yield strength of
iron are due to:
a Formation of martensite.
b Formation of pearlite.
c Magnetostriction.
d Geomagnetic reversals.
a Increase by 2.
b Increase by 1.414.
c Decrease by 2.
d Decrease by 1.414.
NDT31-50316b
ESTestMaker Questions A2-69 Copyright © TWI Ltd
478 Pulsed saturation techniques used by EF testing to overcome magnetic
permeability superimpose an AC signal and sampling of the eddy current is done:
a Between pulses.
b At peak maximum DC pulse.
c At peak minimum DC pulse.
d Continuously during DC pulses.
479
Given a material with resistivity of 65 ohm-cm a relative magnetic permeability
of 50 and testing at 100kHz, what is the standard depth of penetration?
a 1mm.
b 0.8mm.
c 0.18mm.
d 0.05mm.
480
If an acceptable f90 is achieved with a probe on a slightly magnetic ( r=4) plate
when operating at 50kHz, what frequency must be used to maintain that same
f90 if relative permeability was to drop to 2?
a 12.5kHz.
b 25kHz.
c 100kHz.
d 250kHz.
a 2.4.
b 6.7.
c 7.2.
d 72.
482
Given a sample with 5 ohm-cm resistivity, and a relative magnetic permeability
of 4.1, what is the standard depth of penetration if it is tested at magnetic
saturation at a test frequency of 250 kHz?
a 0.11mm.
b 0.22mm.
c 0.33mm.
d 0.4mm.
483 In order to respond to steady-state magnetic flux conditions eddy current probes
should use:
a Differential coils.
b Magnetodiodes.
c Hall detectors.
d Both b and c could be used.
484 W = Q(V2-V1) describes the work done moving a charge within an electric field. If
W is positive then:
NDT31-50316b
ESTestMaker Questions A2-70 Copyright © TWI Ltd
485 Amperes traversing a cross-sectional area is a useful concept in eddy current
studies. The term used for this measure is:
a Flux modulus.
b Current density.
c AM-meters.
d All of the above.
487 The time constant of a circuit, Tc, is the ration of in a series circuit.
a Current to voltage.
b Inductance to resistance.
c Resistance to voltage.
d Voltage to inductance.
a Resistance.
b Reactance.
c Inductance.
d Capacitance.
489 The time variations of current, voltage and magnetic fields in AC circuits can be
best described by which trigonometric functions(s)?
a Tangent.
b Sine.
c Cosine.
d Both b and c.
a Resistance.
b Reactance.
c Inductance.
d Capacitance.
a Absolute probe.
b Differential probe.
c Array transducer.
d Forked transducer.
NDT31-50316b
ESTestMaker Questions A2-71 Copyright © TWI Ltd
493 The empty coil impedance of an eddy current probe is determined by:
494 When using an eddy current technique to determine the thicknesses on a large
nonconductive plastic sheet you would require a:
a Ferrite cup.
b Conductive non-magnetic backing sheet.
c Differential array probe.
d Saturating magnet.
495 In systems employing automatic feed of test pieces through the test coil, end
effects are limited by:
497 When testing ferro-magnetic materials, coil inductance and inductive reactance
are when lift-off is minimum.
a Minimum.
b Maximum.
c Zero.
d Unaffected.
498 When orbiting eddy current probes are used lift-off may need to be increased to
ensure clearance from moving test pieces, the effects of lift-off are reduced by:
499 Shielding effects used in shielded eddy current probes is provided by which
method?
a Magnetic.
b Active.
c Eddy current.
d All of the above.
NDT31-50316b
ESTestMaker Questions A2-72 Copyright © TWI Ltd
500 The active shielding technique used to shield eddy current probes uses which of
the following principles?
a Other coils.
b Ferrite cups.
c Ferrite cores.
d Highly conductive metal housings.
501 Test frequency ratios less than 0.1 or greater than 10 would be inappropriate for
thin wall tube testing. This is because:
502 When placed on the normalised impedance plane, the operating point for the coil
impedance (empty coil) has the imaginary component equal to:
a 0.
b 1.
c A minimum value.
d A value not possible to determine.
503 When placed on the normalised impedance plane, the operating point for the coil
impedance (empty coil) has a real component to:
a 0.
b 1.
c A maximum value.
d A value not possible to determine.
504 Phase angle between eddy currents on the inside and outside tube wall should lie
between to provide sensitivity to cracks.
a 30-60°.
b 40-100°.
c 89-91°.
d 90-180°.
505 When testing a ferromagnetic tube with an encircling coil at a frequency ration of
1, what is the ration of magnetic field strengths inside to outside (ie Hi/Ho)?
a 0.
b 1.
c <<1.
d Not possible to know.
506 The voltage induced in the secondary winding of an encircling probe (send-
receive):
NDT31-50316b
ESTestMaker Questions A2-73 Copyright © TWI Ltd
507 Characteristic frequency can be given by a) 50p/µd2 or b) 1353.8µăd2. What is
the difference? (p=resistivity σ =conductivity).
508 What is the difference between limit frequency and characteristic frequency?
a 2π.
b 0.5π.
c fc=2fg.
d Units used.
509 Fill factor, n, is a useful parameter that can be used in determining which
quantity?
510 When using eddy current encircling coils for sorting, low frequency rations would
be used for which conditions?
511 High test frequencies are preferred for bar diameter measurements when using
encircling coils, why?
512 Fill factor, affects the secondary coil voltage. If n is not too small, the correction
term 1-n can be ignored for what conditions?
513 In testing of ferromagnetic bars with an encircling coil selection of the appropriate
frequency ration can permit detection of changes in conductivity independent of:
a Diameter.
b Permeability.
c Both a and b.
d None of the above, conductivity cannot be determined in ferromagnetic
materials.
NDT31-50316b
ESTestMaker Questions A2-74 Copyright © TWI Ltd
514 The effective permeability’s, as well as the geometrical distributions of the
magnetic field strength, and the eddy current densities, are the same for two
different test objects if the frequency ration f/fg is the same for each test object.
515 Geometrically similar defects will result in the same eddy current effects and in
the same variations in effective permeability’s, coil impedance or voltage if the
f/fg ration is the same for each test. This principle is explained by:
a Snell’s law.
b The similarity law for eddy current testing.
c The bessel function.
d Bridge circuitry.
516 Use of a mercury filled glass cylinder in eddy current testing is ideal for:
a Noise elimination.
b Signal enhancement.
c Establishing the effects of defect’s shape and orientation.
d Operating at resonance frequencies.
517 Test results found using the mercury model to establish effects of various shapes
and orientations of defects can be applied to bar, rod or wire of any metal
because of what principle?
518 Coil impedance variations for inspection of sheet products would be most similar
to encircling coil inspections of:
a Thin-wall tubing.
b Wire.
c Rod.
d Heavy bar stock.
519 When a sheet of metal is inserted between a transmitting coil and a receiving coil
the voltage in the secondary coil (receiving coil) changes from its empty coil
value. The ratio of the new voltage to the empty coil voltage is:
NDT31-50316b
ESTestMaker Questions A2-75 Copyright © TWI Ltd
521 For through transmission testing of sheet products maximum sensitivity to
conductivity and thickness changes occur at what f/fg ration?
a 1.
b 2.7.
c 48.
d 100.
522 The transmission coefficient used in describing phasors in eddy current tests of
sheets and foils is analogous to which quantity in cylinder testing?
a Lift-off.
b Fill factor.
c Effective permeability.
d Frequency ratio.
523 When calculations are made for f/fg for a single coil testing of sheet products
where the probe is held away from the sheet by prove configuration or
nonconductive coating, what must be done with this lift-off component? It is:
525 The more sharply curved impedance locus traced by a given probe set-up as foil
thickness increases is best explained by what aspect of eddy current theory?
526 What is the effect of increased lift-off on the frequency ration (f/fg)?
a No effect.
b f/fg increases.
c f/fg decreases.
d f/fg is reversed and becomes fg/f for any lift-off greater than zero.
527 To measure foil conductivity independent of thickness effects for sheets in the
range of 1-2mm thick, the σf product should be about (conductivity σ in
m/ohm-mm2 and f in kHz):
a 10-20.
b 100-200.
c 1000-2000.
d 10,000-20,000.
NDT31-50316b
ESTestMaker Questions A2-76 Copyright © TWI Ltd
528 A dual frequency probe coil system has been developed to determine sheet
thickness. If the lower frequency is used to measure the product of conductivity
and thickness, what is the higher frequency used for:
a Conductivity determination.
b Absolute thickness.
c Lift-off.
d Effective coil distance.
530 The influence of plating metal on the apparent impedance of the test coil is
reduced as:
531 Adding increasing thickness of copper to a thick zinc base (Cu=1.7 µohm-cm
Zn=5.9µohm-cm) will cause the operating point on the normalised impedance
plane to move:
533 At some point, the improved signal separation from lift-off for a given crack is lost
or overshadowed by what drawback when increasing test frequency?
NDT31-50316b
ESTestMaker Questions A2-77 Copyright © TWI Ltd
534 When inspecting spheres of very high relative permeability increasing test
frequency (f/fg ratio) will result in:
536 Fill factor for spherical objects tested in spherical test coils is found by where
Ds=diameter of sphere tested and Dc=diameter of the test coil:
a Ds/Dc.
b (Ds/Dc)2.
c (Ds/Dc)^3.
d Ds2/Dc2.
537 Remote field eddy current testing when used on tubular products with an internal
probe set-up utilises a secondary exciter effect from currents occurring:
539 The most difficult aspect of material sorting as compared to discontinuity by eddy
current testing arises from what problem?
540 The magnetic flux moving along the tube outer wall, in remote eddy current
testing, is the amplitude of the inner wall flux at the same distance from
the primary exciter.
a About ½.
b 0.1.
c 0.01.
d 10 times.
NDT31-50316b
ESTestMaker Questions A2-78 Copyright © TWI Ltd
541 In the remote field zone of a remote field eddy current test, the relationship
between phase lag and depth is approximately:
a Linear.
b Exponential.
c Logarithmic.
d Inverse square related.
542 Which of the following is not true of remote field eddy current testing?
543 As a test probe is moved towards the edge of a ferromagnetic test piece the locus
traced on the impedance plane is an arc unlike the straighter lift-off trace. What
AC counts for the arc shape?
545 The edge effect for nonmagnetic material is similar to what other eddy current
phenomenon?
a Resonance.
b Lift-off.
c Skin effect.
d Hysteresis.
546 What effect does annealing have on eddy current tests of nonmagnetic alloys?
a Increasing conductivity.
b Decreasing internal stresses.
c Increasing metal strength.
d Both a and c.
NDT31-50316b
ESTestMaker Questions A2-79 Copyright © TWI Ltd
548 Which of the following would have a similar result on conductivity of an
aluminium alloy as does annealing?
a Quench hardening.
b Cooling the test specimen.
c Cold working.
d Aging treatment.
549 What effect does natural aging of aluminium alloys have on the conductivity of
specimen?
a A significant increase.
b A significant decrease.
c An unpredictable result.
d No effect or a slight decrease.
a 10°C.
b 15°C.
c 20°C.
d 25°C.
552 What is the maximum temperature difference that could be tolerated between
standard and specimen when making resistivity measurements?
a 1°C.
b 5°C.
c 10°C
d 20°C.
553 A probe is made using 4 in-line copper contacts. The contacts are placed on a
sample and current passed through the outer pair of contacts while voltage is
monitored by the inner pair. What application does this have to eddy current
tests?
NDT31-50316b
ESTestMaker Questions A2-80 Copyright © TWI Ltd
554 Comparing two identically shaped samples of the same grade of carbon steel, one
annealed the other quench hardened, which statement would not be correct
concerning hysteresis loop tests?
a A minute increase.
b A significant increase.
c A decrease.
d No change.
556 When manufacturing a test standard for parts that are allowed a tolerance in
parameter such as size, what size should the standards be:
a Minimum allowed.
b Maximum allowed.
c An average or nominal size.
d Standards must be made for all possible variations.
558 Drilled holes are often used when making calibration standards for eddy current
tube testing. What is the most significant potential problem with production of
this artificial defect?
a Conductivity changes.
b Machining burrs.
c Tube distortion.
d Permeability changes.
559 The use of 2 calibration foils, one on top the other, to calibrate for checking
coating thickness should be avoided except for what conditions?
560 If too large a drill size is used when making a drilled hole standard for eddy
current testing, what happens to the response signal?
a Amplitude is unpredictable.
b It resembles the response from edge effect.
c Phase must be rotated 45ø clockwise.
d It is confused with lift-off.
NDT31-50316b
ESTestMaker Questions A2-81 Copyright © TWI Ltd
561 Which method produces the narrowest slot simulating a crack in a test standard?
a EDM.
b Planer fabrication.
c Jet abrasives.
d Diamond saw blade.
562 Which of the following methods used for machining longitudinal notches are
reference standards would be used for making transverse notches?
a EDM.
b Jet abrasives.
c Planning/milling.
d All of the above.
563 An eddy current signal that changes in amplitude only is similar to what other
common technology?
a AM radio.
b Ultrasonic testing.
c Electro-cardiograms.
d Star wars.
564 The degree of suppression of undesired eddy current test signals depend on:
565 Which of the following filter types would most likely be used to enhance
(eliminate noise) from demodulated DC signals on an eddy current instrument?
a Bandpass.
b Low pass.
c High pass.
d Low cut.
566 What advantage does the digital bar graph display have over analogue meter
display EC instruments?
a Ease of interpretation.
b Defect discrimination.
c Signal response time (allows faster scanning speeds).
d Expense.
567 What is the most significant advantage of dot matrix displays of EC signals of CRT
displays?
a Resolution.
b Contrast.
c Size and power consumption.
d Viewing angle.
NDT31-50316b
ESTestMaker Questions A2-82 Copyright © TWI Ltd
568 When is a gate output indication generated?
569 Sequential actuation of multiple box gates is used for what purpose in eddy
current instruments with computer controlled gating with complex impedance
plane displays?
571 What two phenomena occur when a semiconductor is placed in a magnetic field?
572 How is the magnitude of the Hall voltage related to the angle the element normal
makes to the magnetic field?
a V is proportional to cos Ө.
b V is proportional to tan Ө.
c V is proportional to sin Ө.
d V is proportional to cot Ө.
574 External correction circuits are used to reduce the voltage across the Hall element
to zero in the absence of a magnetic field. Why are these circuits needed?
NDT31-50316b
ESTestMaker Questions A2-83 Copyright © TWI Ltd
575 What is the advantage of use 3 Hall effect detectors mounted at mutual right
angles to each other?
a Insensitivity to lift-off.
b Insensitivity to permeability changes.
c Field magnitude and direction determination independent of probe orientation.
d Increased sensitivity to long gradual property changes.
576 Response of an inductive pickup coil is not uniform for what waveform?
a Square waves.
b Pulsed waves.
c Sinusoidal waves.
d Both a and b.
577 Which is not a method used to generate and measure eddy currents at greater
depths using Hall detectors:
579 When a Hall detector is used it is usually within the magnetic field of the
excitation coil. How is this signal used? It is:
580 Which of the following is not a magnetic field vector measured by a magnetic
reaction analyser?
a Elimination of lift-off.
b Locates longitudinal and transverse cracks.
c No requirement for a balancing bridge.
d Allows easier display on isometric plots of amplitude.
NDT31-50316b
ESTestMaker Questions A2-84 Copyright © TWI Ltd
582 Hot billets are possible to inspect with eddy current methods using:
a Differential probes.
b Absolute probes.
c Hall detector probes.
d Essentially any probe provided it is adequately cooled.
584 The advantage of inline eddy current inspection of continuous butt welded pipe is:
585 At the high inspection speeds (100m/s) during the production of steel rod, the rod
often has a significant vertical vibration as it moves horizontally along and
through the eddy current encircling coil. How are defects detected through the
resulting shaking noise?
a Filtering.
b Shock absorbers.
c Spinning probes.
d Gyroscopic mounted probes.
586 Computer analysis of test results and signals are now common. Which process
would most likely be used to separate periodic defect signals from noise to
determine periodicity of repetitive signals?
a Initialising.
b Fast fourier transform.
c Averaging.
d Standard deviation.
588 When the gap between two sheets of aluminium increases to a point past where
no further change is seen on the eddy current instrument, what is being
measured?
a Maximum lift-off.
b Maximum gap.
c Metal thickness of upper plate.
d Nothing is being indicated.
NDT31-50316b
ESTestMaker Questions A2-85 Copyright © TWI Ltd
589 When gap between two plates is to be determined the probe should be placed on
590 How was the 100% IACS value for annealed pure copper determined?
591 Which of the following, when added as an alloy of only 0.1% to copper will
provide the greatest decrease in conductivity?
a Zinc.
b Phosphorous.
c Iron.
d Aluminium.
592 Instruments used for conductivity testing must be checked to ensure they are
free from drift. Drift can be a result of:
593 Having calibrated a flat eddy current probe on a flat conductivity standard you
now move to a radiused surface. What will the effect be on conductivity reading if
we already know the standard and test specimen have identical conductivities?
595 In order that a specimen increase its resistivity as its temperature decreases what
must hold true? The:
NDT31-50316b
ESTestMaker Questions A2-86 Copyright © TWI Ltd
596 Given resistivity of pure annealed copper is 1.72µohm-cm and pure aluminium is
2.78µohm-cm (both at 20°C.), what is the conductivity % IACS of the aluminium
at 55°C if the thermal coefficient of aluminium is 0.0038?
a 49.
b 52.
c 55.
d 61.
597 Nonconductive coatings that are less than or slightly more than 0.08mm will
result in less than variation of 0.5% IACS in conductivity using a standard
conductivity meter. How is this accomplished?
599 Which condition of aluminium heat treatment will provide the maximum
resistivity?
a As quenched.
b Artificially aged.
c Naturally aged.
d Annealed.
600 What is the difference between 2024-T3 and 2024 –T6 aluminium alloy?
a Tempering process.
b Hardness.
c Conductivity.
d All of the above.
601 Oxygen diffusion from the surface of titanium and its alloys at elevated
temperatures is of concern in aircraft industry because:
NDT31-50316b
ESTestMaker Questions A2-87 Copyright © TWI Ltd
602 How are real cracks placed in standards used for calibration of bolt hold
inspection by spinning eddy current probes?
a Fatigue cracks are grown off EDM notches which are later machined away.
b Pre-drilled holes are made in plates that are clamped and dipped in corrosive
liquids to make SCC’s.
c A bolt is placed through a hole and a nut tightened on the bolt creates a
compression crack.
d All of the above.
a Peeling.
b Exfoliation.
c Fretting.
d Pitting.
604 When using low frequency eddy currents to inspect multiple layers of aluminium
corrosion or cracking, what is the maximum thickness of outer layer that can be
tested?
a 6mm.
b 10mm.
c 15mm.
d 25mm.
605 What is the effect of a steel fastener when inspecting multilayer aluminium in the
region of the fasteners? They:
606 The off-null balance technique is used only on meter type phase analysis
instruments. It cannot be used on CRT type instruments because:
607 In the early 1960s what limited the use of eddy current testing to detect
subsurface cracks in aircraft structures?
NDT31-50316b
ESTestMaker Questions A2-88 Copyright © TWI Ltd
608 When performing an eddy current test on finned copper tubing (as in air
conditioning units) single frequency instruments in conjunction with differential
coil probes are used. A 1.3mm fin pitch requires you use a coil space of 5mm.
Why?
609 Inside diameter pitting on heat exchanger tubing can be a result of:
a Forced shutdowns.
b Slow (low volume) leaks.
c Reduced power generating ability from plugging.
d All of the above.
611 In a multifrequency setup, simple subtraction of the mix signal, which is at four
times the primary frequency, will not result in zero output of the undesirable
variable. Why not?
a Cost of training.
b Independence from probe speed.
c Amplitude range of application.
d Freedom from non-linearity effects.
613 In selecting a mixing frequency to suppress internal variables the mix frequency
should be the primary frequency.
614 In selecting a mixing frequency to suppress external variables the mix frequency
should be the primary technique:
NDT31-50316b
ESTestMaker Questions A2-89 Copyright © TWI Ltd
615 Which of the following is not a multifrequency eddy current system for defining
and eliminating a given parameter? The:
a Algebraic method.
b Elemental analysis method.
c Co-ordinate transformation method.
d Combination method.
617 Direct field excitation inspection of steel wire ropes is used to detect:
a Stretched wires.
b Broken wires.
c Internal wire corrosion.
d Both b and c.
618 Alternating field excitation inspection of steel wire ropes is used to detect:
619 On the old sigmaflux instruments which indicated defective parts by displaying
ellipses, how were phase and amplitude indicated?
a Iron.
b Air.
c Solid dieletrics.
d All of the above.
a As low as possible.
b At as low a frequency as possible (DC).
c Grounded to the external protective shell.
d All of the above.
NDT31-50316b
ESTestMaker Questions A2-90 Copyright © TWI Ltd
623 What is the effect of too high a current to the eddy current probe:
624 How does the use of increasing current increase coil inductance?
626 Although 3δ is usually accepted as the maximum depth of eddy current that can
be detected. It has been noted that in some cases depths of 5δ can be achieved.
What determines the increase depth sensitivity? (δ is standard depth of
penetration):
627 What assumption must be made when using eddy currents to determine thickness
of a nonconductive coating on a conductive (non-magnetic) substrate?
628 What do the side drilled holes used for ultrasonic testing, and the round bottom
transverse notch on the OD of a tube for eddy current testing have in common?
629 What type of crack would cause an absolute surface probe to give a figure-eight
display on the storage monitor?
a A fatigue crack.
b A bent crack (major facets in opposite direction).
c A stress corrosion crack.
d No crack can provide such an indication with an absolute probe.
NDT31-50316b
ESTestMaker Questions A2-91 Copyright © TWI Ltd
630 Multifrequency techniques using absolute coils are:
632 When access for inspection of a pipe is from the inside in the remote field eddy
current technique, the receiver coil is:
633 The pulsed eddy current technique has the advantage of producing high magnetic
peak power but still maintaining low average power. This has what effect on the
test piece?
634 What is the main difference between eddy current and flux leakage testing?
635 The point where increasing operating frequency does not increase ohmic losses in
the test material is the:
a Reluctance point.
b Limit frequency.
c Terminal point.
d Fmax.
636 Every part of an electric circuit is acted upon by a force that tends to move it in
such a direction as to enclose the maximum amount of magnetic flux. This
statement is known as:
a Maxwell’s law.
b Len’s law.
c Newton’s fifth law of electric action.
d Planck’s law.
NDT31-50316b
ESTestMaker Questions A2-92 Copyright © TWI Ltd
637 Calibration standards are used in eddy current test to:
638 ACPD (alternating current potential drop) and ECT (eddy current testing) both use
alternating currents to size surface breaking cracks. ECT uses induction to
generate currents in the piece. What does ACPD use?
a Capacitive discharge.
b Mutual induction.
c Physical contact (electrodes).
d Microwaves.
639 Lift-off is used as a reference signal in many eddy current test applications. Why?
a It is easy to produce.
b It does not modify phase of signals.
c It is always 90ø from OD defects.
d Both a and b.
640 Why do holes of different diameter and the same through wall depths have
different calibration phase angles (eg flyback angle for a differential coil)?
641 Multifrequency eddy current techniques should be used whenever possible, even
if the mixing capability is not needed. Why?
642 When a digital output is available on an eddy current instrument, why should the
digitalising rate be at a reasonably high rate?
a Diamagnetic.
b Paramagnetic.
c Ferromagnetic.
d Nonmagnetic.
NDT31-50316b
ESTestMaker Questions A2-93 Copyright © TWI Ltd
644 An acceptable ratio between defect signal amplitude and non-relevant indications
is usually considered to be as a minimum:
a 1:1.
b 3:1.
c 5:1.
d 10:1.
645 External magnetic forces causing an increase in the normal number of electrons
with the same spin, thereby increasing the number of uncompensated spins
results in what property?
a Magnetism.
b Paramagnetism.
c Ferromagnetism.
d Antimagnetism.
a Ferromagnetic material.
b Paramagnetic material.
c Diamagnetic material.
d Both b and c.
a Threshold magnetisation.
b Saturation magnetisation.
c Initial magnetisation.
d Critical magnetisation.
a Bridge.
b L-C circuit.
c Resonance circuit.
d Short circuit.
649 In tubing inspection a tube used to establish acceptance levels with artificial
discontinuities as specified in applicable product standards is a (n):
a Test piece.
b Acceptance standard.
c Comparator tube.
d Short tube.
650 A wave filter with a single transmission band and neither of the cut-off
frequencies being zero or infinity is a:
a Bandpass filter.
b Highpass filter.
c Lowpass filter.
d Half wave filter.
NDT31-50316b
ESTestMaker Questions A2-94 Copyright © TWI Ltd
651 What is the disadvantage of zig-zag coil probes compared to axial bobbin type
probes used for internal tube inspections?
a Non-uniformity of sensitivity.
b Decreased far surface sensitivity.
c Unpredictable phase differences with increasing flaw depth.
d Insensitivity to circumferential cracks.
652 If two or more coils are electrically connected in series such that there is no
mutual inductance between them and no electric or magnetic condition (or both)
that is not common to the test standard and test specimen, will produce an
unbalance and yield an output, this arrangement is called:
a Bucking coils.
b Differential coils.
c Comparator coils.
d Circumferential coils.
a Effective.
b Relative.
c Absolute.
d Initial.
654 An output signal that is proportional to the rate of change of the input signal is a
(n):
a Absolute signal.
b Differentiated signal.
c Harmonic signal.
d Modulation signal.
656 An electromagnetic sorting based on a signal response from the material under
test above or below two levels established by three or more calibration standards
is:
NDT31-50316b
ESTestMaker Questions A2-95 Copyright © TWI Ltd
657 Given the requirement to test tubing, OD 10mm and wall thickness 1mm, using
an encircling coil, what is the average coil diameter if you need to maintain a
90% fill factor?
a 10.25.
b 10.50.
c 10.7.
d 11.00.
658 What is the fill factor of the test using 1.1mm diameter encircling coil to test wire
with a diameter of 1.02mm?
a 0.90.
b 0.86.
c 0.84.
d 0.81.
659 Given a sample of 50% cold worked 304 stainless steel (68.96µohm-cm, µrel=2)
what test frequency would provide a 2mm standard depth of penetration?
a 900Hz.
b 15kHz.
c 22kHz.
d 31kHz.
660 Given a sample of titanium (54.8µohm-cm) what test frequency must be used to
obtain a 1mm standard depth of penetration?
a 35kHz.
b 70kHz.
c 140kHz.
d 280kHz.
661 Given a sample of cold worked stainless steel (71 µohm-cm, µrel=10) tested at
10kHz, what is the effective penetration?
a 1.3mm.
b 3.9mm.
c 5.2mm.
d 6.5mm.
NDT31-50316b
ESTestMaker Questions A2-96 Copyright © TWI Ltd
Appendix 3
ESTestMaker – Answers
5 Which of the following conditions is not necessary for eddy current testing?
a Electrical contact.
6 Which of the following is not a mandatory component in a basic eddy current test
apparatus?
c An impedance plane.
7 Which of the following is not a probe configuration used in eddy current testing?
c Doubles.
11 If the magnetic flux density for a given location and orientation near a current
carrying conductor is 5 Wb/m2, what is it when the current is cut by half?
c 2.5T.
12 An increase in which of the following would result in the increase of magnetic flux
density (B) in a solenoid?
NDT31-50316b
ESTestMaker Answers A3-1 Copyright © TWI Ltd
13 A voltage in induced in a region of space when there exists a changing magnetic
field. This is a statement of:
a Faraday’s law.
b Flux density.
18 Moving a direct current carrying conductor up and down near a conductive test
piece will result in:
19 When performing thickness or gap testing, what should the operating frequency
be?
20 When gap between plates of the same material is being measured, the probe
should be placed on the thinner of the two plates when possible. Why?
21 The relationship between electric current flow, electromotive force and resistance
to electric current flow is described by:
b Ohm’s law.
d Both a and c.
a Linear.
NDT31-50316b
ESTestMaker Answers A3-2 Copyright © TWI Ltd
25 In field applications, specific conductivity values are not used; instead a range of
conductivities can be expected from a finished product. Why is this so?
26 What is done to correct for reduced field coupling when making conductivity
measurements on curved surface?
d Both a and b.
27 When eddy current probes used for restivitiy readings are required to be used on
small surfaces (eg bolt heads), what can be done to overcome edge effects?
c Both a and b.
28 When does material thickness affect the results of a conductivity test? When:
29 If temperature of a test piece increases what other eddy current parameter will
likely increase?
b Resistivity.
30 Lift-off compensating probes place a compensating coil around the sensing coil.
The purpose of this is:
c Both a and b.
32 Laminations or disbanding would most likely require you use a (n) probe.
a Gap.
34 To eliminate probe wobble using a two frequency multifrequency set up, what
function listed below would be incorrect?
35 Eddy current information is often digitized for transmission and processing. What
is the best resolution possible using 8 bit conversion?
a 0.5%.
b Signature analysis.
NDT31-50316b
ESTestMaker Answers A3-3 Copyright © TWI Ltd
37 What are the charge carriers used by Hall effect devices?
d Both a and c.
38 The effect that produces signal variations due to variation in coil spacing due to
lateral motion of test specimen when passing through an encircling coil is:
b Wobulation.
39 The distance in a test specimen that eddy current intensity has decreased 37% of
their surface value is the:
a Depth of penetration.
40 The depth beyond which a test system can no longer detect further increase in
specimen thickness is the:
d Both a and b.
b Resistance.
44 A change in signal voltage resulting from EMF produced by the relative motion
between test piece and coil is a result of the:
b Speed effect.
b Resistor, parallel.
46 If the resistance in a 1cm long wire is 2 ohms when it has 0.1cm diameter, what
will the resistance be in a wire of the same length and material but only 0.05cm
diameter?
d 8 ohms.
c R = Ro (1 + a dT).
NDT31-50316b
ESTestMaker Answers A3-4 Copyright © TWI Ltd
48 Given copper at 20oC. With resistivity 5.9 ohm-cm and thermal coefficient of
resistivity of 0.0039, what is the resistivity when the copper is warmed to 40oC.?
c 6.25 ohm-cm.
49 When an eddy current probe is brought near a conductive sample the net
magnetic flux in the system:
b Decreases.
51 Strictly speaking, the standard skin depth equation; J/Jo = (e^-β) sin (wt- β), is
true for only:
c 14%
53 When inspecting a rod with an encircling coil the eddy current density at the
centre of the rod is zero for δ = standard depth of penetration):
c All conditions.
d 57 x/σ.
a Inductive reactance.
c Capacitive reactance.
a Impedance.
NDT31-50316b
ESTestMaker Answers A3-5 Copyright © TWI Ltd
60 In an AC circuit the total voltage across a resistor and an inductor in series is
found by:
c Vector addition.
61 The method of eddy current testing that uses a dedicated coil to induce eddy
currents in a test piece and another coil to detect eddy current variations in the
test piece is the method:
c Send-receive.
62 When the eddy current test system is represented by the transformer the sample
can be considered the secondary winding with:
a A single turn.
a Resistivity of sample.
64 An increase in tube wall or plate thickness will move the operating point on the
impedance curve:
b Down.
65 An increase in test frequency will move the operating point on the impedance
curve:
b Down.
67 In the send-receive method of eddy current testing the variations in eddy current
flow due to flaws in the test piece are monitored by:
d Both b and c.
a Upward.
69 Increasing which of the following parameters will move the operating point up on
the impedance curve?
a Resistivity.
70 In the impedance method of eddy current testing the impedance phase Ө (in
degrees) is calculated from (w is the angular frequency, L is inductance, R is
resistance):
c Ө = Arctan (wL/R).
NDT31-50316b
ESTestMaker Answers A3-6 Copyright © TWI Ltd
71 The effect of sample and test parameters can be illustrated using:
b Impedance diagrams.
72 Given a coil with 50 ohm resistance and 50 microhenries inductance and operated
at 50kHz; what is the coil inductive reactance?
d 15.7 ohms.
73 Given a coil with 2 ohms resistance and 20 H inductance and operated at 20kHz,
what is the coil’s inductive reactance?
b 2.51 ohms.
74 Given a coil with 20ohms and 60 microhenries inductance in air and operated at
50kHz, when brought next to an inconel sample the probe impedance is
28.5ohms and impedance phase Ө is 45o, what is the probe’s inductive
reactance?
a 20.2 ohms.
c 35.3 ohms.
76 If given total impedance of a probe operating on a test sample and know the
impedance phase angle, what equation is used to determine the inductive
reactance of the probe?
d Xp = Xp sin Ө.
77 Voltage changes across the probe due to a defect in most eddy current
inspections are on the order of:
a 1%.
b Lift-off.
c Both a and b.
81 The result of operating an eddy current test instrument at a point other than
balance point is:
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82 In the L-C circuit used by simple meter crack detectors, the circuit is operated:
83 The reactive power of inductance and capacitance in a tuned L-C circuit are:
a Equal.
84 Crack detector type ECT instruments based on resonant circuits detecting surface
defects on low resistivity materials such as aluminium would have operating
frequencies in the range.
c 10-100kHz.
a Mixing modules.
87 Recording of eddy current signals from ECT instruments requires that the
recording instrument:
88 X-Y recorders:
90 Most eddy current instruments use some form of for balancing but several
options are available for lift-off compensation.
b AC bridge.
91 The impedance of probes used in eddy current testing can vary over a range.
Instruments must be able to balance over this range. Most instruments can
handle prove impedances between:
c 10-200 ohms.
92 A parallel L-C circuit used in crack detectors has an inductive of 150ohms. The
capacitive reactance would be about under normal operating conditions.
c 150 ohms.
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94 An absolute probe requires interact(s) with the test material.
a One coil.
95 When two similar coils on the AC bridge of the eddy current instrument sense
with the test material the probe is a (n):
b Differential probe.
96 The purpose of spring loading an eddy current probe against the test material is:
c To minimise lift-off.
98 In the send-receive probe arrangement where the driver and receiver coil are on
opposite sides of a plate, signal variation will result from:
d Both a and b.
100 Eddy current flow and its associated magnetic flux are a function of position under
the coil. The relationship could best be described as being proportional to
(r=radial distance from coil centre):
a r.
101 For a given sized defect, what significant defect signal change occurs when
testing a plate using the through transmission (send-receive) method and the
defect occurs first 25% of the wall thickness from the transmit coil, then 50% and
75%?
103 Decrease in sensitivity resulting from increasing lift-off is more pronounced for:
d Both b and c.
105 At high operating frequencies, the effective coil diameter (sensing diameter) is
approximately equal to:
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106 Permeability changes are of greater concern in eddy current testing because:
d Both b and c.
107 The reversal swirl that is observed on a normalised impedance graph showing the
effects of decreasing thickness is a result of:
108 The phase angle used to estimate defect depth is the angle between the:
d Both a and c.
109 Which defect parameter will not affect the probe frequency you select to locate a
defect?
c Orientation.
110 Using a typical impedance type EC machine with storage monitor, electrical
resistivity determinations are made by:
111 When given a plate sample for resistivity determination, test frequency should be
selected such that skin depth is at least:
114 Measuring the thickness of conductive layer on another conductor (neither being
magnetic) requires:
115 Most impedance eddy current instruments will not operate at resonance. This
situation is remedied by:
116 A practical depth limit for flaw detection and location using eddy current test
methods is about:
b 6mm.
117 Which of the following is not an advantage of the eddy current test method?
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118 When performing an eddy current test and you encountered a signal that could be
a crack, permeability change or restivity change, you would:
119 The f90 for tubing and plate are found using similar but different equations. These
equations were determined:
a Empirically.
d Both a and b.
121 Encircling probes (or internal probes) are likely to be replaced by surface probes
for tubing with a diameter greater than 50mm. The reason for this is:
122 To increase sensitivity to near surface defects using a bobbin style probe coil
length and thickness are reduced. This however results in:
123 Coil spacing on differential probes for general inspection purposes of tubing is
usually:
c Both a and b.
b Differential.
125 Which of the following is an advantage of the differential probe compared to the
absolute?
a Differential probes.
127 The main reason an eddy current coil can detect support plates in heat
exchangers when testing tubes from the inside diameter is:
128 A probe whose operating impedance is not between 20-200 ohms will most likely
in:
c Both a and b.
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129 Assuming resistance is negligible and probe inductance is 80 henries, for a cable
with 5 x 10^-9 farads capacitance, what is resonance frequency?
c 250 kHz.
130 If a probe for internal tube testing has an average coil diameter of 11mm, what
size would the tube inside diameter be to give a 0.9 fill-factor?
b 11.6.
131 An encircling coil is used on a 12mm diameter solid rod. What is the fill-factor if
the average coil diameter is 13mm?
b 0.85.
132 Impedance diagrams for cylinders are not the simple semi-circular shapes used
for plate. This is a result of:
d Both a and b.
133 A tube being tested by an internal probe has an ID to OD ration of 0.8. Under
what conditions does this appear to be a thin wall tube?
134 Test frequency for solid cylinders, maximum sensitivity to defects, resistivity and
dimensions is obtained when f/fg=:
b 6.
135 The f90 frequency has been found empirically from the ratio of thickness and skin
depth. For testing tubing this ratio is:
c 1.1.
d Both a and b.
137 Given a brass tube 20mm diameter (OD) with a 3mm wall and the resistivity of
brass is 7.0 ohm-cm, what is the f90 for testing this tubing?
b 2.3 kHz.
138 What is the f90 for an encircling coil used on aluminium tubing, P =5.1 ohm-cm,
wall thickness 5mm, diameter 40mm?
a 612 Hz.
139 When tube testing at f90 (internal absolute probe), if ID wall loss moves the
operating point for an absolute coil in a negative X direction, a shallow OD defect
would move the operating point:
c +Y.
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140 When tube testing (internal absolute probe) at f90 and setting OD wall loss to
move +Y on the scope, what is the probably source of a +X moving signal?
c Dent.
141 When interpreting eddy current signals by quadrature components on strip charts
the X channel information is used for:
d Both a and b.
142 To eliminate magnetic deposits as a possible cause of defect signals (ie a non-
relevant indication) it is recommended that:
d Both a and b.
147 What condition can be eliminated using multifrequency eddy current technique?
148 Metal hardness can be indicated by eddy current testing. This is accomplished by:
149 Which of the following will have the largest resistivity change with change in
temperature (à = thermal coefficient):
c Titanium à = 0.0400.
150 Degree of cold working of which material can be determined by eddy current
methods monitoring for permeability changes instead of resistivity changes?
151 Which of the following can cause variability in resistivity readings taken for the
purpose of sorting?
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152 Relative permeability is measured in which units?
153 The amount of reverse magnetising force required to eliminate the residual
magnetic flux in a ferromagnetic material is:
154 Which of the following series of stainless steels is not likely to exhibit an increase
in relative permeability with increasing cold working?
d 316.
c Both a and b.
156 If testing a material and you have set up acceptable conditions for phase
separation of 90° for 1mm sample depth when relative magnetic permeability is
1, what depth would the 90° separation occur at if relative magnetic permeability
changed to 20?
d 0.05mm.
b 50 kHz.
158 What test frequency has a standard dept of penetration of 1mm for a plate
material with resistivity of 130 ohm-cm and relative magnetic permeability of
500?
a 650Hz.
159 Magnetic saturation techniques for EC testing that use DC saturation coils are
limited to the amount of saturation achieved by:
a 27.7.
161 Given the permeability of free space is 4πX10^-7 Wb/A/m and the permeability of
an iron bar is 7X10^-4 Wb/A/m, what is the relative permeability of the iron?
d 557.
162 Small eddy current sensors in the vicinity of cracks could be used for.
d Both a and b.
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163 Eddy current generation to determine material properties use detection of
variations in:
a Potential differences.
165 Two insulated wires are wound on a plastic rod such that they are positioned very
close to each other but not touching. The ends of one wire are connected to a
battery; the ends of the other are connected to a galvanometer. If the wire
connected to the battery has 1 amp flowing through it, what will the
galvanometer read?
a 0 A.
166 The time constant of the circuit is a ratio inductance to resistance (L/R). This
accounts for:
167 In an eddy current test set-up, magnetic lines of flux from the probe which fail to
couple the test piece:
d Both b and c.
168 Complex numbers are often used in the analysis of eddy current test systems.
Complex numbers have 2 components, they are:
b Pure resistance.
170 The phase angle between applied voltage and resultant current in an AC circuit of
pure inductance is:
c 90°.
b Lift-off.
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174 The inductance in the excitation coil is proportional to the diameter square (D2)
and the number of turns squared (N2). The voltage induced in the pickup coil is
proportional to:
c N2 and D2.
175 The purpose of small diameter and high frequency probes for determining
thickness of thin coatings on conducting substrates is to:
176 The magnetic flux density around an empty test coil is reduced by increases in
when testing non-magnetic materials:
177 The purpose of curved wear pieces (shoes) to guide surface probe assemblies is
to:
178 Magnetic shielding technique provides the magnetic field lines of the eddy current
probe with:
179 Shielding obtained by eddy current skin effect differs from magnetic methods of
shielding in which way?
b Skin effect methods attenuate the field rather than change the path.
180 Maximum test sensitivity is obtained at which point on the signal locus of the
complex plane?
181 What f/fg ration is recommend for testing thin wall non-magnetic tubing for
cracks, alloy variations or wall thickness variations?
b 1.0.
182 When using an external encircling coil the frequency ration f/fg to obtain
maximum sensitivity to all test variables will be greatest for which variety of
heavy wall tube?
184 When both a primary (energising) and secondary (pickup) coil are used as an
encircling coil probe, the time varying flux in the test piece induces an AC voltage
in:
c Both a and b.
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185 Phase angle differences of eddy currents greater than about 100° is not
recommended for tube testing with encircling coils because:
a Eddy current density on the inner wall is too low for crack detection.
186 Which of the following is the direct cause of eddy currents in a test piece placed in
an encircling transducer?
188 All other conditions being equal for a bar tested in an encircling coil system, an
increase in relative permeability of the bar tested would result in:
189 Locus curves for diameter changes on the test piece are not straight lines on the
normalised impedance plane. Why is this so?
190 Separation of diameter and conductivity effects is better carried out at frequency
ratios greater than 4 because:
191 The complex impedance plane presentation for testing a ferromagnetic bar should
be changed in what way from the same test on a non-ferromagnetic bar?
c The vertical and horizontal scales are increased by the magnitude of the
relative permeability.
192 When testing ferromagnetic bars with an encircling coil, the effects of changes in
are reduced or eliminated by DC magnetic saturation.
193 Defect effects from tests in the mercury cylinder can be applied to ferromagnetic
materials for practical applications provided:
c Voltages from the mercury tests are multiplied by the relative magnetic
permeability of the ferromagnetic material.
194 The through-transmission technique is used for testing of sheet and foil under
certain conditions:
d Both a and b.
195 For two separate objects with different relative permeabilities and resistivities,
equivalent eddy current tests can be performed by adjusting test frequencies.
This is explained by:
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196 Eddy current tests using encircling coils would provide similar test coil
impedances or voltage signals for tests on 100mm diameter aluminium rod and
2mm diameter steel wire if:
c Both a and b.
197 The best method of measuring the effects of a specific discontinuity totally within
a test specimen but at different depths and orientations is by using:
198 The curve traced on X-Y storage monitor as an active coil is brought up to a
sample of 1100 aluminium (100% pure) is called the:
199 When a metal sheet is inserted into a through transmission probe arrangement,
the transmission coefficient phasor:
d Both b and c.
200 In a through transmission test of sheet products, why might a metered output
monitor the product of thickness and conductivity (absolute measurement
method)?
201 For a non-magnetic foil thickness D, conductivity σ, the effective coil distance is
found from Aeff = (253,000/fg σ D). Effective coil distance will decrease if:
202 The effect of increasing coil diameter on the effective coil distance is:
206 The apparent impedance curve for two different metals of the same thickness will
be the same if:
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207 A practical f/fg ratio for thickness measurements would be in the range of
1-7.5. This would provide maximum sensitivity to:
c Lift-off.
a Conductivity.
209 If a sheet was composed of 2 metallic layers with thicknesses D1 and D2 and
conductivities σ1 and σ 2, what would the equivalent product be when tested by
through transmission?
a σD = σ1D1 + σ2D2.
211 To discern very small cracks using a surface coil you would use a relatively high
frequency-conductivity product (σ f). Which of the following would then be true?
212 When inspecting spheres with an encircling coil, what is the equivalent effect of
increasing the coil length?
d Both b and c.
214 When using surface coils for crack detection, shallow cracks and lift-off cannot be
separated unless:
d Both a and b.
215 The result of using a longer encircling test coil to test a spherical object as
compared to a short coil or hemispherical coil would be:
216 In remote field eddy current testing, how far does the direct coupling zone extend
from the exciter coil?
217 Remote field eddy current testing is a technique commonly used on:
a Ferromagnetic tubes.
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218 Signals received in the remote field eddy current set-up give two response off
large defects, one occurs due to the receiver coil passes the defect. What causes
the other signal?
219 In the range of about 3-13mm wall thickness, what frequency range would be
used for low frequency remote field eddy current testing of ferromagnetic tubing?
a 10-300Hz.
220 When eddy currents are used for sorting techniques it is usual to establish
impedance values from:
221 Applying a DC electric field to a ferromagnetic coil is done for what purpose?
223 In general, the edge effect seen as a probe is moved towards edge of a magnetic
test piece as compared to a non-magnetic test piece would be recognised by what
feature?
c Both a and b.
224 Substitutional solid solutions and interstitial solid solutions of metals are forms of:
b Alloys.
225 Alloying metals added to pure base metals result in decreasing conductivity of the
initial value of the pure base metal. Why does this occur even with alloying
metals having higher conductivity than the base metal?
226 Work hardened aluminium has a higher resistivity than annealed aluminium for
what reason?
c Annealing.
228 What would the effect on conductivity signal be as radius of curvature of the test
piece is decreased?
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229 Although specimen and standard may be within the recommended 5oC
temperature difference for resistivity measurement, why might the value
determined still be incorrect?
c Room temperature.
231 What is the effect on eddy current determined properties of aluminium alloys that
have been annealed for an excessive amount of time?
b A significant increase.
234 When a ferromagnetic material has a magnetising force applied to it, the
magnetic flux that builds within the material lags the applied force. The same lag
occurs upon the reduction in magnetising force. What is the lag called?
b Hysteresis.
235 Which of the following is not a method used to manufacture notches in calibration
standards used for eddy current tests of tubing?
b Electrophoresis.
236 What is main advantage of foil calibration standards over affixed coatings
calibration pieces?
238 The most common and reliable method of manufacturing artificial cracks for eddy
current standard is by:
239 What is not one of the advantages of drilled holes being used as reference
standard?
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240 What is the advantage of artificial defects made by the EDM process?
c Accuracy.
243 Which of the following is not a means of suppressing an undesired eddy current
test signal?
244 Which of the following noise sources can be filters with the appropriate electronics
in an eddy current instrument?
245 What limits the scanning speed when using meter display eddy current
instruments?
246 What is the most significant drawback of dot matrix displays of EC signals
compared to CRT displays?
b Resolution.
247 How many thresholds must be set on the CRT display of an eddy current
instrument in a box gate alarm system?
c 4.
c Pie-slice.
251 A circuit block that accepts a binary number and translates it to an analogue
voltage or current proportional to the binary number is a (n):
c Digital-to-analogue converter.
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252 A circuit block that uses an analogue voltage as an input and outputs, a
proportional binary value is a (n):
b A/D converter.
253 Hall detectors are used to sense magnetic fields. They detect:
d Both a and b.
a Electrons.
b Holes.
256 The ideal signal voltage in a hall detector element in the absence of a magnetic
field is:
a Zero.
c Both a and b.
259 Which of the following are Hall effect detectors not sensitive to?
260 Instrumentation for systems using Hall detectors instead of pickup coils are
different in what respect?
c Both a and b.
261 Eddy current test systems using Hall detectors can accomplish differential tests
by:
262 When using Hall detectors, how are sensitivities to relatively great depths
achieved?
263 What are slip rings used for in eddy current inspection systems?
264 To avoid rotating parts, probes or test piece, what system would be used to
inspect round bar stock?
d Both a and b.
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265 A differential transducer with the two windings around perpendicular to each
other used to detect both longitudinal and transverse cracks is called a (n):
266 In what way is eddy current testing more suitable to high speed production tests
on hot metals than ultrasonics?
267 Eddy current testing of hot billets (1,100°C) can be done provided what
precautions are taken?
268 Seamless pipe and tubing are often made from billets made from continuous cast
blooms. The rounds, as the billets are called, are test by eddy current to detect
what types of defect?
269 When ECT is used to test thickness of coatings having a tolerance range, what is
the minimum number of calibration specimens required to calibrate the
instrument?
b 3.
271 When online testing of ERW welds in steel pipe using eddy current testing, what
problem occurs if the inspection is performed too far from the induction heating
coils used for normalising the weld?
c Both a and b.
273 You are given 2 plates of identical size (50x50x10mm) both painted with a thin
coating of black acrylic paint of the same thickness. Eddy current test indicate
both have a conductivity of 37% IACS, yet one is nearly twice as heavy as the
other. How is this possible?
274 What is the most effective way of assessing heat or fire damage to heat-treatable
aluminium on aircraft?
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275 Alpha-case forms on titanium and its alloys at elevated temperatures. Eddy
currents are used to establish the depth of case. What is the cause of the
formation of alpha-case?
276 When a single channel strip charge recorder is used with eddy current testing of
bolt holes using spinning probes, what 2 parameters are recorded?
277 Why are cadmium plated steel bolts used as fasteners on aircraft?
d Both b and c.
278 Some CRT display eddy current instruments allow X and Y gains to be adjusted
independently. Increasing Y gain and reducing X (eg Y = 0.2V/div, = 2.0V/div)
accomplishes what?
279 Low frequency eddy current (100Hz to 5kHz) is commonly used in aircraft
inspections for:
280 What is the biggest advantage eddy current test methods have that make them
the most frequently used NDT method in the automotive industry?
281 Eddy current test methods are more sensitive than x-rays for detection of in
aircraft structures.
c Fatigue cracks.
282 Finned copper tubing used in air conditioning units has smooth land areas at
regular intervals along the tube. What is the purpose of these land areas?
b The locations at which the tube is roll expanded into the tube supports.
283 During evaluation of an indication in a heat exchanger tube, the probe is moved
back and forth over the defect. It is noted that the indication has changed
position along the length of the tube. What is the likely source? A:
a Magnetic deposit.
284 In eddy current inspections of chiller tubes, freeze cracks located at freeze bulges
are often not possible to detect using conventional differential probes because:
285 Generally in multifrequency techniques for in-situ boiler tube inspections, high
frequencies are used to suppress while low frequencies are used to
suppress .
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286 In order to do computer modelling of eddy current fields you must provide:
b Increased conductivity.
290 What is the advantage of eddy current testing over the potential drop method for
sizing surface cracks?
b It is non-contacting.
a Curvature should be small within the region directly below the cross-sections
of the coil.
292 How does hysteresis manifest itself when testing ferromagnetic materials?
293 In the 1960s a non-storage type oscilloscope was used for eddy current tests. The
defect free specimen gave a horizontal line. A defective specimen gave a (n):
c Ellilpse.
294 When an eddy current is balanced for surface testing for flaws, where is the probe
placed?
295 Why are eddy current coils not made using iron wire?
296 The higher the value of inductance for a given frequency the greater the degree
of:
b Sensitivity.
c Both a and b.
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298 Inductance increases improve eddy current sensitivity. Why is increasing coil area
not a preferred method of increasing sensitivity even though inductance is
increased?
299 How does the differential (or auto-comparator) coil provide insensitivity to
gradual changes?
c Rough surfaces.
302 What degree of accuracy can be expected when using eddy currents to determine
paint thickness 10
m thick?
c 1.0
m.
303 Tubes with a diameter of more than about 50mm are more effectively tested
using than encircling probes.
c Both a and b.
306 Large DC saturation units for eddy current inspection of ferromagnetic tubing are
often required. What technique can be used to avoid use of these heaving DC
saturation units?
d Both a and b.
307 Using a shielded ferrite coil and the pulsed eddy current technique, penetration of
measurable currents in a metal sample can be increased to (where δ the
standard depth of penetration):
d 10 δ.
308 As conductivity of a material approaches infinity its resistive losses approach zero.
What type of material exhibits such extremes?
c Superconductors.
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309 On the normalised impedance plane showing the effects of changing conductivity
(σ) the coil’s normalised resistance is zero under what condition?
c Both a and b.
310 What does an increase in operating frequency do to the probe coil inductance?
311 The heating of a ferromagnetic part that occurs when the AC field works to align
the magnetic domains into a preferred magnetic orientation is reduced by:
312 The coil to specimen impedance Z can be defined by (where Zc is coil impedance
and Zs is specimen impedance):
313 The only way to reduce or eliminate the edge effect is by:
314 What are the main limiting parameters for a single coil probes dimensions?
d Both a and b.
315 During an eddy current inspection of heat exchanger tubing, what is the purpose
of recording a calibration signal with each tube inspected?
316 In what way does computer acquisition and analysis of eddy current signals
(particularly heat exchanger tubing) out-perform humans?
317 The analytical method that consists in correlating changes in amplitude, phase
and/or quadrature components of a complex test signal voltage to
electromagnetic conditions in the test piece is
b Impedance analysis.
b Phase analysis.
319 The ration of the square of the diameter of a cylindrical test piece to the square of
the average diameter of the test coil is the:
b Fill factor.
320 The frequency providing the highest signal-to-noise ratio for detection of an
individual property of the test piece is the:
a Optimum frequency.
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321 Two or more coils in electrical series opposition arranged so EM conditions not
common to the areas of the specimen being tested produce a bridge imbalance is
a (n):
c Differential probe.
a Skin effect.
323 The property of a test system that allows separation of signals from defects on
close proximity to each other is:
c Defect resolution.
324 The time required for a test system to return to its original state after it has
received a signal is the:
b Recovery time.
325 Current flow that is time constant in both direction and amplitude is:
a Direct current.
326 The method whereby desirable frequency signals are separated from undesirable
frequency signals from the modulating envelope of the carrier frequency signal is
called:
b Modulation analysis.
327 In order that useful results be obtained from an eddy current test, what must be
true about the test specimen?
328 What is the disadvantage of the multi-pancake probe used for internal tube
inspections as compared to the axial bobbin type probe?
329 Test levels used in ECT that establish the group into which a material under test
belongs are termed:
a Acceptance limits.
b Bucking coils.
331 A test level above or below which test specimens are found to be unacceptable is
called?
d Both a and b.
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332 A network that passes electromagnetic wave energy over a described range of
frequencies and attenuates energy at all other frequencies is a (n):
a Filter.
333 The slope of the induction curve at zero magnetising force as the test piece is
being taken from its demagnetised state is the:
b Initial permeability.
334 The magnetic condition of a ferromagnetic part based on its previous exposures
to magnetic fields if the part’s:
c Magnetic history.
335 An electromagnetic sorting based on a signal response from the material under
test above or below a level established by two or more calibration standards is:
336 Given an encircling coil with an average coil diameter of 10.5mm and testing a
tube 10mm OD with a 1mm thick wall, what is the fill factor of this set up?
c 0.907.
337 Given a tube with a 15mm OD and 1.5mm wall, what size (average diameter) coil
is used to obtain an 85% fill factor for an internal inspection?
c 12mm.
338 What is the standard depth of penetration of 304 stainless steel (68.96
ohm-
cm) having 60% cold work applied ( rel=2) tested at 20kHz?
b 2.1mm.
339 What is the standard depth of penetration for 301 stainless steel having been
25% cold worked (71
ohm-cm, rel=10) tested at 10kHz?
a 1.3mm.
340 Given a standard depth of penetration of 1.3mm exists for a 10kHz test of navel-
brass (6.63
ohm-cm), what is the effective depth of penetration?
b 3.9mm.
342 Electromagnetic induction, on which ECT has its foundations, was first discovered
by:
b Faraday.
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343 The voltage changes used to determine various parameters in eddy current
testing consist of changes in:
c Both a and b.
344 The right hand rule for determining magnetic field direction around a current
carrying conductor assumes:
345 The left hand rule for determining the magnetic field around a current carrying
conductor assumes:
346 The product of the magnetic flux density in a loop of a current carrying coil times
the area of that coil gives:
347 Magnetic induction or the force per unit pole in a magnetic field is the magnetic
analog of:
a Electric intensity.
348 An eddy current test system can be considered a form of transformer. As such,
the secondary side would be the:
c Test sample.
349 As an operating eddy current probe (a coil) is brought near a conductive sample
the induction of eddy currents in the sample causes the probe to:
c Both a and b.
351 Faraday’s law states that the magnitude of the induced voltage in a circuit is:
352 An alternating voltage in a coil brought near a sample that has a finite impedance
will result in:
c Both a and b.
353 The intensity of a magnetic field that a unit magnetic pole experiences of a force
of one dyne is one:
a Oersted.
c Maxwell.
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355 Magnetic flux density is expressed in:
356 Alignment of the magnetic domains in iron by an external field result in:
c Magnetisation.
c Both a and b.
358 The product of current in amperes times time in seconds gives units of:
b Coulombs.
359 If 20 coulombs of charge passes a point in 5 seconds, the electric current value
would be:
a 4 amperes.
360 The purpose of using a radial magnetic field around the current carrying coil in a
galvanometer instead of a parallel magnetic field is:
361
Given a wire made of copper with resistivity 1.724 ohm-cm, that is 1cm in
length and has a cross-sectional area of 1cm2, what is the resistance of this
section of wire?
c 1.724 ohms.
a AC power transformers.
364 Which of the following will have an effect on the electrical resistance of a wire?
b Positive.
b Some semi-conductors.
367 In a nonmagnetic material the back EMF produced by the induced eddy currents
has what effect on the probe?
d Both a and b.
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368 The decrease in eddy current density with increasing depth from the surface is:
b Exponential.
369 The time dependent component of the skin depth equation indicates:
370 For the calculation for eddy current density to apply, a sample should be
relatively thick. The minimum thickness to allow the simple equation to apply is
about δ (where δ is the standard depth of penetration):
c 5.
372 The phase lag, in units of degrees, for an eddy current signal displayed on a
typical impedance plane scope for a void originating 1 standard depth of
penetration below the surface would be:
c 114°.
373 Phase lag in the test sample for a void at 1 standard depth of penetration is:
a 1 radian.
375 The inductive reactance component of an eddy current probe coil’s impedance will
with increasing AC frequency:
a Increase.
376 In the eddy current probe circuit the capacitive component of its impedance is
degrees out of phase with its inductive component:
c 180°.
d Arctan (x/R).
379 On the ideal impedance diagram the effect of reducing mutual coupling between
probe and sample would be to have the impedance point:
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380 The impedance method of eddy current testing uses:
381 As the diameter of the eddy current probe increases, the operating point on the
normalised impedance curve moves (for a surface probe ie not for tube
testing).
b Down.
382 Variations in the flow of eddy currents caused by flaws in the test piece are
monitored as voltage fluctuations in the secondary coil in the:
384 Using the analogy of the coil/sample as a transformer circuit, when the coil is held
far from the sample we can approximate a (n):
b Open circuit.
385 All other factors constant, increasing lift-off will move the operating point on the
impedance curve:
a L D2.
387 An increase in probe diameter will move the operating point on the impedance
curve:
b Down.
388 An inductive and a resistance impedance change in the test coil resulting when an
operating eddy current probe is moved near a conductive test sample is
represented on a (n):
389 The decrease in semicircle radius of the impedance curve display when lift-off
increases indicates:
390 Given a coil with 50 ohm resistance and 50 microhenries inductance and operated
at 50kHz; what is the impedance phase angle?
c 17.4o.
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391 The most significant instrument component required to detect the small variation
in probe impedance or voltage caused by detecting defects in eddy current testing
is the :
d Amplifier.
393
Given a coil with 2 ohms resistances and 20 H inductance and operated at
20kHz, what is the impedance phase angel (in degrees)?
d 51.4°.
394 The impedance phase angle of a probe operating next to a copper test sample is
40o. What is the inductive reactance of the probe in this situation if the total
impedance measured is 30 ohms?
a 19.3 ohms.
395 Given a probe operating at 0.5MHz next to a brass sample, total probe impedance
is measured at 47.2 ohms, if the impedance phase angel is 45o what is the
resistive load of the sample?
396 Given the resistive load of a probe/sample circuit as 5.1 ohms and the resistance
of the probe when operated in air as 15 ohms, what would the impedance phase
angle be if total impedance of this circuit was 24.5 ohms?
b 35o.
c Both a and b.
398 The typical figure 8 pattern that occurs with a differential probe moving over a
defect is a result of:
399 Quadrature components of the bridge AC output are generated by sampling the
sinusoidal signal at two positions apart on the waveform.
b 90o.
401 Most eddy current instruments can tolerate an impedance mismatch in the AC
bridge on the order of:
b 5%.
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402 In the L-C bridge circuit used by simple meter crack detectors, the capacitor is
connected in parallel with the in the bridge circuit.
a Probe coil.
403 At the resonant frequency of an L-C circuit, output voltage for a given
measurement:
c Maximum.
404 On most eddy current instruments using the impedance method, the AC bridge
circuits can usually balance coils having impedances in a range of.
d 10-200 ohms.
405 Test frequencies for crack detectors operating at or close to resonant frequency
are:
a Not selectable.
406 Resonant circuit crack detectors have a meter output and 3 controls:
407 In resonant circuit crack detectors, the lift-off control actually varies:
408 Which of the following systems has the advantage of being unaffected by
temperature variations?
b Send-receive instruments.
409 In send-receive ECT systems, probes with 2 receive coils have those coils would
in opposition. The purpose for this to:
c allow no net voltage in the receive coils when both sense the same material.
410 Now obsolete, the ellipse and slit methods of eddy current testing:
412 FM tape recorders have often been used to store eddy current signals for
subsequent retrieval. Frequency response for these instruments is.
b Proportional to recording speed (length of tape past the record head per unit
time).
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413 Frequency response of an instrument is based on the fact that the output signal
of an instrument will be less than the input signal as inspection speed increases.
Instrument frequency response is defined as the frequency where output signal is
-3dB from the input. This would relate to a volt signal out for a 1 volt signal
input.
c 0.707.
414 Given a parallel L-C circuit with a probe inductance of 80 x 10^-6 Henries and
operated at resonance frequency, 252kHz, what is the cable capacitance?
c 5 x 10^-9 farads.
415 Given a parallel L-C circuit with cable capacitance 5 x 10^-9 farads and operating
at a resonance frequency of 2252kHz, what is the inductive reactance of the
probe?
b 126.5 ohms.
416 When selecting an eddy current instrument for a particular project you need to
know:
417 Resonance frequency can be determined for a parallel L-C circuit by:
a fr =1/2(π)(LC)^½.
418 Which of the following is not a reason for using a ferrite core on the sensing coil
of a pencil probe?
c Temperature compensation.
419 Mounting a disc of metal, having similar properties to the test material, next to
the reference coil in an absolute probe has the advantage of:
420 To reduce the effective sensing diameter of surface probes operating at relatively
low frequencies, the use of is recommended:
b Ferrite cups.
421 In an absolute probe configuration, a second coil, apart from the sensing coil, is
required for:
a Bridge nulling.
422 The effective probe diameter extends to about beyond the coil diameter.
d 4 skin depths.
423 Ferrite cups can be used to obtain without affecting depth of penetration.
a A concentrated field.
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424 Which of the following is not a probe parameter affecting impedance results?
a Frequency.
425 Normalising probe impedance for impedance graph displays is accomplished by:
c Both a and b.
426 All other parameters constant, an increase of permeability in the test piece causes
the operating point on a normalised impedance curve to move:
a Up the curve.
427 For a thick specimen, test frequency should be selected to provide good
separation from lift-off variations. This is facilitated by setting frequency so that
the greatest expected defect depth is at:
428 Varying frequency for a probe on a given specimen will move the operating point
down the impedance graph with increasing frequency. If the specimen is not
thick, a reversal swirl occurs forming a knee. This is a result of:
429 The characteristic parameter, Pc, used by Deeds and Dodd is primarily a
modelling tool. Test conditions with the same characteristic parameter have the
same:
430 If lift-off is arranged on the eddy current storage monitor so the signal moves
from right to left as the probe is moved away from the sample, an increase in
sample thickness would conventionally move:
a Down.
431 Maximum frequency you would use for determining thickness of a non-conductive
coating on a conductor would be:
432 When making resistivity measurements on unknown samples, the frequency used
is selected such that the operating point on the impedance graph is:
d Both a and c.
a Variations in base material as well as coating material will affect the signal.
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435 The problem with overcoming probe-cable resonance by operating above 1.2fg
(fr-resonance frequency) is:
436 What is the effective diameter of a surface probe with a 5mm diameter coil used
on a sample with p = 72 ohm-cm and operated at 2MHz. (p is resistivity):
b 6.2mm.
437 The ration of thickness to skin depth t/δ that provides a 90° separation between
lift-off and thickness change is empirically derived. It is found to be about
for plate testing:
b 0.8.
439 The phase angle (as measured from the lift-off signal) of a shallow surface or
sub-surface defect is related to the eddy current phase lag á=x/δ(radius), where
x = flaw depth and δ = skin depth. The phase angle seen on the storage monitor
is approximately:
c 2Ө.
440 A very shallow surface defect can be distinguished from lift-off by:
441 The best way to distinguish between localised resistivity changes and a real defect
is:
442 Encircling or bobbin style probes used for tube testing require careful design of
coil size to optimise sensitivity and coupling. Coil length and coil depth should be
about:
443 The reference coil in a bobbin style probe can be mounted concentrically inside
the test coil and the probe still be considered and absolute probe because:
444 When using a bobbin type differential probe, sensitivity to near surface defects
can be improved by:
445 Symmetry of a differential signal as the probe is moved over a defect will depend
on:
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446 Insensitivity to gradual changes in dimensions or properties is both an advantage
and disadvantage, depending on the situation. This feature is exhibited by:
c Differential probes.
447 If a defect is longer than the spacing between the coils on a differential coil, the
defect can only be recognised as such if:
451 Eddy current flow in a cylinder, using an encircling probe, changes with radial
distance r from the centre of the cylinder. Eddy current flow is proportional
to for cylinder testing.
b R.
452 The curl in the impedance locus that results when increasing test frequencies for
inspecting tubing is a result of:
453 Given that a probe operated at 300kHz has an inductive reactance of 475 ohms,
what is the cable’s capacitive reactance if this frequency results in resonance?
c 475 ohms.
454 The effect on the operating point on the impedance diagram of decreasing coil
length for a bobbin type internal probe would be:
455 The characteristic frequency, fg, is the frequency for which the Bessel function
solution to Maxwell’s magnetic field equation is equal to:
c 1.
456 (5.0p)
D2 is the general equation to find (p=resistivity).
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457 The characteristic frequency ratio, f/fg, is not used for determining a frequency
for phase discrimination in tube testing because the ration is:
c Both a and b.
458 Given a brass tube to be tested with an internal bobbin probe, resistivity of the
brass is 7.0 ohm-cm. If an operating frequency of 2.3kHz gives 90° phase
separation between ID and OD defects, what is nominal wall thickness of the
tubing?
b 3mm.
459 The main disadvantage of multipancake coil probes used as internal tube
inspection probes is:
460 When tube testing at operating frequencies at 2f90 and higher it is difficult to
discriminate probe wobble and:
b OD defects.
461 When testing brass tubing (internal absolute probe) at f60 a signal moves off to
the right on the scope (+X). If the 5% ID wall loss is set to move –X, what is the
probable source of this signal?
c External magnetite.
463 When using differential probes, defect depth can be estimated from the:
c Fly-back angle.
464 Circumferential stress corrosion cracking can be detected by normal bobbin style
probes during in-service inspection of heat exchanger tubing because:
a Special probes.
466 When using multifrequency techniques for tube inspection with an internal probe,
the most effective results are had for:
c External fretting.
c Zinc 5.9
ohm-cm.
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468 A conductive deposit (copper) is suspected of being on the OD of a heat
exchanger tube being inspected with an absolute internal bobbin probe. The
evaluation of this signal is best made by:
469 Separation of defect signals from insignificant parameters is the function provided
by multi frequency ECT units. What condition could not be separated by
multifrequency technology?
470 The induced magnetic flux (B) divided by the applied magnetising force (H) gives
what quantity?
b Magnetic permeability.
a >1.
472 Which of the following metals, when alloyed with pure aluminium will result in the
alloy having resistivity less than the aluminium?
473 The primary cause for the increase in resistivity with increase in cold working is:
474 When the induced magnetic flux in a ferromagnetic material increase linearly with
increasing applied magnetising force the material is:
c Saturated.
476 Changes in permeability with applied stress below the elastic yield strength of
iron are due to:
c Magnetostriction.
d Decrease by 1.414.
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479
Given a material with resistivity of 65 ohm-cm a relative magnetic permeability
of 50 and testing at 100kHz, what is the standard depth of penetration?
c 0.18mm.
480
If an acceptable f90 is achieved with a probe on a slightly magnetic ( r=4) plate
when operating at 50kHz, what frequency must be used to maintain that same
f90 if relative permeability was to drop to 2?
c 100kHz.
a 2.4.
482
Given a sample with 5 ohm-cm resistivity and a relative magnetic permeability
of 4.1, what is the standard depth of penetration if it is tested at magnetic
saturation at a test frequency of 250 kHz?
b 0.22mm.
483 In order to respond to steady-state magnetic flux conditions eddy current probes
should use:
484 W = Q(V2-V1) describes the work done moving a charge within an electric field. If
W is positive then:
b Current density.
487 The time constant of a circuit, Tc, is the ration of in a series circuit.
b Inductance to resistance.
c Inductance.
489 The time variations of current, voltage and magnetic fields in AC circuits can be
best described by which trigonometric functions(s)?
d Both b and c.
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491 Current leads voltage in an AC circuit of pure:
d Capacitance.
a Absolute probe.
493 The empty coil impedance of an eddy current probe is determined by:
c Probe design.
494 When using an eddy current technique to determine the thicknesses on a large
nonconductive plastic sheet you would require a:
495 In systems employing automatic feed of test pieces through the test coil, end
effects are limited by:
c Both a and b.
497 When testing ferro magnetic materials, coil inductance and inductive reactance
are when lift-off is minimum.
b Maximum.
498 When orbiting eddy current probes are used lift-off may need to be increased to
ensure clearance from moving test pieces, the effects of lift-off are reduced by:
499 Shielding effects used in shielded eddy current probes is provided by which
method?
500 The active shielding technique used to shield eddy current probes uses which of
the following principles?
a Other coils.
501 Test frequency ratios less than 0.1 or greater than 10 would be inappropriate for
thin wall tube testing. This is because:
502 When placed on the normalised impedance plane, the operating point for the coil
impedance (empty coil) has the imaginary component equal to:
b 1.
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503 When placed on the normalised impedance plane, the operating point for the coil
impedance (empty coil) has a real component to:
a 0.
504 Phase angle between eddy currents on the inside and outside tube wall should lie
between to provide sensitivity to cracks.
b 40-100°.
505 When testing a ferromagnetic tube with an encircling coil at a frequency ration of
1, what is the ration of magnetic field strengths inside to outside (ie Hi/Ho)?
b 1.
506 The voltage induced in the secondary winding of an encircling probe (send-
receive):
508 What is the difference between limit frequency and characteristic frequency?
d Units used.
509 Fill factor, n, is a useful parameter that can be used in determining which
quantity?
510 When using eddy current encircling coils for sorting, low frequency rations would
be used for which conditions?
511 High test frequencies are preferred for bar diameter measurements when using
encircling coils, why?
c Both a and b.
512 Fill factor, affects the secondary coil voltage. If n is not too small, the correction
term 1-n can be ignored for what conditions?
513 In testing of ferromagnetic bars with an encircling coil selection of the appropriate
frequency ration can permit detection of changes in conductivity independent of:
c Both a and b.
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514 The effective permeability’s, as well as the geometrical distributions of the
magnetic field strength and the eddy current densities, are the same for two
different test objects if the frequency ration f/fg is the same for each test object.
515 Geometrically similar defects will result in the same eddy current effects and in
the same variations in effective permeability’s, coil impedance or voltage if the
f/fg ration is the same for each test. This principle is explained by:
516 Use of a mercury filled glass cylinder in eddy current testing is ideal for:
517 Test results found using the mercury model to establish effects of various shapes
and orientations of defects can be applied to bar, rod or wire of any metal
because of what principle?
518 Coil impedance variations for inspection of sheet products would be most similar
to encircling coil inspections of:
a Thin-wall tubing.
519 When a sheet of metal is inserted between a transmitting coil and a receiving coil
the voltage in the secondary coil (receiving coil) changes from its empty coil
value. The ratio of the new voltage to the empty coil voltage is:
b 2.7.
522 The transmission coefficient used in describing phasors in eddy current tests of
sheets and foils is analogous to which quantity in cylinder testing?
c Effective permeability.
523 When calculations are made for f/fg for a single coil testing of sheet products
where the probe is held away from the sheet by prove configuration or
nonconductive coating, what must be done with this lift-off component? It is
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525 The more sharply curved impedance locus traced by a given probe set-up as foil
thickness increases is best explained by what aspect of eddy current theory?
526 What is the effect of increased lift-off on the frequency ration (f/fg)?
b f/fg increases.
527 To measure foil conductivity independent of thickness effects for sheets in the
range of 1-2mm thick, the σf product should be about (conductivity σ in
m/ohm-mm2 and f in kHz):
c 1000-2000.
528 A dual frequency probe coil system has been developed to determine sheet
thickness. If the lower frequency is used to measure the product of conductivity
and thickness, what is the higher frequency used for:
a Conductivity determination.
530 The influence of plating metal on the apparent impedance of the test coil is
reduced as:
533 At some point, the improved signal separation from lift-off for a given crack is lost
or overshadowed by what drawback when increasing test frequency?
534 When inspecting spheres of very high relative permeability increasing test
frequency (f/fg ratio) will result in:
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536 Fill factor for spherical objects tested in spherical test coils is found by where
Ds=diameter of sphere tested and Dc=diameter of the test coil:
c (Ds/Dc)^3.
537 Remote field eddy current testing when used on tubular products with an internal
probe set-up utilises a secondary exciter effect from currents occurring:
539 The most difficult aspect of material sorting as compared to discontinuity by eddy
current testing arises from what problem?
540 The magnetic flux moving along the tube outer wall, in remote eddy current
testing, is the amplitude of the inner wall flux at the same distance from
the primary exciter.
d 10 times.
541 In the remote field zone of a remote field eddy current test, the relationship
between phase lag and depth is approximately:
a Linear.
542 Which of the following is not true of remote field eddy current testing?
543 As a test probe is moved towards the edge of a ferromagnetic test piece the locus
traced on the impedance plane is an arc unlike the straighter lift-off trace. What
AC counts for the arc shape?
d Both a and b.
545 The edge effect for nonmagnetic material is similar to what other eddy current
phenomenon?
b Lift-off.
546 What effect does annealing have on eddy current tests of nonmagnetic alloys?
b Increases conductivity.
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548 Which of the following would have a similar result on conductivity of an
aluminium alloy as does annealing?
549 What affect does natural aging of aluminium alloys have on the conductivity of
specimen?
b Resistivity measurement.
c 20°C.
552 What is the maximum temperature difference that could be tolerated between
standard and specimen when making resistivity measurements?
c 10°C.
553 A probe is made using 4 in-line copper contacts. The contacts are placed on a
sample and current passed through the outer pair of contacts while voltage is
monitored by the inner pair. What application does this have to eddy current
tests?
554 Comparing two identically shaped samples of the same grade of carbon steel, one
annealed the other quench hardened, which statement would not be correct
concerning hysteresis loop tests?
c A decrease.
556 When manufacturing a test standard for parts that are allowed a tolerance in
parameter such as size, what size should the standards be:
558 Drilled holes are often used when making calibration standards for eddy current
tube testing. What is the most significant potential problem with production of
this artificial defect?
c Tube distortion.
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559 The use of 2 calibration foils, one on top the other, to calibrate for checking
coating thickness should be avoided except for what conditions?
560 If too large a drill size is used when making a drilled hole standard for eddy
current testing, what happens to the response signal?
561 Which method produces the narrowest slot simulating a crack in a test standard?
a EDM.
562 Which of the following methods used for machining longitudinal notches are
reference standards would be used for making transverse notches?
563 An eddy current signal that changes in amplitude only is similar to what other
common technology?
a AM radio.
564 The degree of suppression of undesired eddy current test signals depend on:
d Both a and b.
565 Which of the following filter types would most likely be used to enhance
(eliminate noise) from demodulated DC signals on an eddy current instrument?
b Low pass.
566 What advantage does the digital bar graph display have over analogue meter
display EC instruments?
567 What is the most significant advantage of dot matrix displays of EC signals of CRT
displays?
569 Sequential actuation of multiple box gates is used for what purpose in eddy
current instruments with computer controlled gating with complex impedance
plane displays?
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571 What two phenomena occur when a semiconductor is placed in a magnetic field?
572 How is the magnitude of the Hall voltage related to the angle the element normal
makes to the magnetic field?
a V is proportional to cos Ө.
574 External correction circuits are used to reduce the voltage across the Hall element
to zero in the absence of a magnetic field. Why are these circuits needed?
575 What is the advantage of use 3 Hall effect detectors mounted at mutual right
angles to each other?
576 Response of an inductive pickup coil is not uniform for what waveform?
d Both a and b.
577 Which is not a method used to generate and measure eddy currents at greater
depths using Hall detectors:
579 When a Hall detector is used it is usually within the magnetic field of the
excitation coil. How is this signal used? It is:
580 Which of the following is not a magnetic field vector measured by a magnetic
reaction analyser?
582 Hot billets are possible to inspect with eddy current methods using:
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583 Above the curie point (δ is standard depth of penetration, σ is conductivity, µ is
permeability):
d Both a and b.
584 The advantage of inline eddy current inspection of continuous butt welded pipe is:
585 At the high inspection speeds (100m/s) during the production of steel rod, the rod
often has a significant vertical vibration as it moves horizontally along and
through the eddy current encircling coil. How are defects detected through the
resulting shaking noise?
b Shock absorbers.
586 Computer analysis of test results and signals are now common. Which process
would most likely be used to separate periodic defect signals from noise to
determine periodicity of repetitive signals?
588 When the gap between two sheets of aluminium increases to a point past where
no further change is seen on the eddy current instrument, what is being
measured?
589 When gap between two plates is to be determined the probe should be placed on:
590 How was the 100% IACS value for annealed pure copper determined?
591 Which of the following, when added as an alloy of only 0.1% to copper will
provide the greatest decrease in conductivity?
b Phosphorous.
592 Instruments used for conductivity testing must be checked to ensure they are
free from drift. Drift can be a result of:
d Both a and b.
593 Having calibrated a flat eddy current probe on a flat conductivity standard you
now move to a radiused surface. What will the effect be on conductivity reading if
we already know the standard and test specimen have identical conductivities?
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594 1/(πfσµ)^½, 26/(πfσµ)^½ and 1980(p/µf)^ ½ are equations used in eddy
current testing (p is used here as resistivity, σ conductivity and µ permeability
and f frequency), what do they calculate:
595 In order that a specimen increase its resistivity as its temperature decreases what
must hold true?
596 Given resistivity of pure annealed copper is 1.72µohm-cm and pure aluminium is
2.78µohm-cm (both at 20°C.), what is the conductivity % IACS of the aluminium
at 55°C, if the thermal coefficient of aluminium is 0.0038?
c 55.
597 Nonconductive coatings that are less than or slightly more than 0.08mm will
result in less than variation of 0.5% IACS in conductivity using a standard
conductivity meter. How is this accomplished?
599 Which condition of aluminium heat treatment will provide the maximum
resistivity?
a As quenched.
600 What is the difference between 2024-T3 and 2024 –T6 aluminium alloy?
601 Oxygen diffusion from the surface of titanium and its alloys at elevated
temperatures is of concern in aircraft industry because:
b It causes embrittlement.
602 How are real cracks placed in standards used for calibration of bolt hold
inspection by spinning eddy current probes?
a Fatigue cracks are grown off EDM notches which are later machined away.
b Exfoliation.
604 When using low frequency eddy currents to inspect multiple layers of aluminium
corrosion or cracking, what is the maximum thickness of outer layer that can be
tested?
a 6mm.
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605 What is the effect of a steel fastener when inspecting multilayer aluminium in the
region of the fasteners? They:
606 The off-null balance technique is used only on meter type phase analysis
instruments. It cannot be used on CRT type instruments because:
607 In the early 1960s what limited the use of eddy current testing to detect
subsurface cracks in aircraft structures?
608 When performing an eddy current test on finned copper tubing (as in air
conditioning units) single frequency instruments in conjunction with differential
coil probes are used. A 1.3mm fin pitch requires you use a coil space of 5mm.
Why?
d Both a and b.
609 Inside diameter pitting on heat exchanger tubing can be a result of:
611 In a multifrequency setup, simple subtraction of the mix signal, which is at four
times the primary frequency, will not result in zero output of the undesirable
variable. Why not?
613 In selecting a mixing frequency to suppress internal variables the mix frequency
should be the primary frequency.
614 In selecting a mixing frequency to suppress external variables the mix frequency
should be the primary technique.
615 Which of the following is not a multifrequency eddy current system for defining
and eliminating a given parameter? The
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616 Wire rope testing by electromagnetic methods utilises:
617 Direct field excitation inspection of steel wire ropes is used to detect:
d Both b and c.
618 Alternating field excitation inspection of steel wire ropes is used to detect:
619 On the old sigmaflux instruments which indicated defective parts by displaying
ellipses, how were phase and amplitude indicated?
a As low as possible.
623 What is the effect of too high a current to the eddy current probe:
624 How does the use of increasing current increase coil inductance?
626 Although 3δ is usually accepted as the maximum depth of eddy current that can
be detected. It has been noted that in some cases depths of 5δ can be achieved.
What determines the increase depth sensitivity? (δ is standard depth of
penetration):
627 What assumption must be made when using eddy currents to determine thickness
of a nonconductive coating on a conductive (non-magnetic) substrate?
628 What do the side drilled holes used for ultrasonic testing and the round bottom
transverse notch on the OD of a tube for eddy current testing have in common?
NDT31-50316b
ESTestMaker Answers A3-55 Copyright © TWI Ltd
629 What type of crack would cause an absolute surface probe to give a figure-eight
display on the storage monitor?
632 When access for inspection of a pipe is from the inside in the remote field eddy
current technique, the receiver coil is:
c Both a and b.
633 The pulsed eddy current technique has the advantage of producing high magnetic
peak power but still maintaining low average power. This has what effect on the
test piece?
634 What is the main difference between eddy current and flux leakage testing?
635 The point where increasing operating frequency does not increase ohmic losses in
the test material is the:
b Limit frequency.
636 Every part of an electric circuit is acted upon by a force that tends to move it in
such a direction as to enclose the maximum amount of magnetic flux. This
statement is known as:
a Maxwell’s Law.
638 ACPD (alternating current potential drop) and ECT (eddy current testing) both use
alternating currents to size surface breaking cracks. ECT uses induction to
generate currents in the piece. What does ACPD use?
639 Lift-off is used as a reference signal in many eddy current test applications. Why?
d Both a and b.
640 Why do holes of different diameter and the same through wall depths have
different calibration phase angles (eg flyback angle for a differential coil)?
NDT31-50316b
ESTestMaker Answers A3-56 Copyright © TWI Ltd
641 Multifrequency eddy current techniques should be used whenever possible, even
if the mixing capability is not needed. Why?
642 When a digital output is available on an eddy current instrument, why should the
digitalising rate be at a reasonably high rate?
a Diamagnetic.
644 An acceptable ratio between defect signal amplitude and non-relevant indications
is usually considered to be as a minimum:
b 3:1.
645 External magnetic forces causing an increase in the normal number of electrons
with the same spin, thereby increasing the number of uncompensated spins
results in what property?
c Ferromagnetism.
d Both b and c.
b Saturation magnetisation.
a Bridge.
649 In tubing inspection a tube used to establish acceptance levels with artificial
discontinuities as specified in applicable product standards is a (n):
b Acceptance standard.
650 A wave filter with a single transmission band and neither of the cut-off
frequencies being zero or infinity is a:
a Bandpass filter.
651 What is the disadvantage of zig-zag coil probes compared to axial bobbin type
probes used for internal tube inspections?
a Non-uniformity of sensitivity.
NDT31-50316b
ESTestMaker Answers A3-57 Copyright © TWI Ltd
652 If two or more coils are electrically connected in series such that there is no
mutual inductance between them and no electric or magnetic condition (or both)
that is not common to the test standard and test specimen, will produce an
unbalance and yield an output, this arrangement is called:
c Comparator coils.
a Effective.
654 An output signal that is proportional to the rate of change of the input signal is a
(n):
b Differentiated signal.
c Both a and b.
656 An electromagnetic sorting based on a signal response from the material under
test above or below two levels established by three or more calibration standards
is:
657 Given the requirement to test tubing, OD 10mm and wall thickness 1mm, using
an encircling coil, what is the average coil diameter if you need to maintain a
90% fill factor?
b 10.50.
658 What is the fill factor of the test using 1.1mm diameter encircling coil to test wire
with a diameter of 1.02mm?
b 0.86.
659 Given a sample of 50% cold worked 304 stainless steel (68.96µohm-cm, µrel=2)
what test frequency would provide a 2mm standard depth of penetration?
c 22kHz.
660 Given a sample of titanium (54.8µohm-cm) what test frequency must be used to
obtain a 1mm standard depth of penetration?
c 140kHz.
661 Given a sample of cold worked stainless steel (71µohm-cm, µrel=10) tested at
10kHz, what is the effective penetration?
b 3.9mm.
NDT31-50316b
ESTestMaker Answers A3-58 Copyright © TWI Ltd
Eddy Current Testing (ET) Magnetic Particle Testing (MT)
Refresher
Section 1
Magnetic Particle
Magnetism
Testing (MT) or Inspection (MPI)
Some natural materials strongly attract pieces MT is a test method for the detection of
of iron to themselves. surface and near surface defects in
Such materials were discovered near the ferromagnetic materials.
Greek city of Magnesia and in China as early Magnetic field induced in component
as 900BC. Defects disrupt the magnetic flux causing ‘flux
Early in the 19th century Oersted found a link leakage’.
between electricity and magnetism. Flux leakage can be detected by applying
Not long afterwards Faraday proved that ferromagnetic particles.
electrical and magnetic energy could be
interchanged.
1
Theory of Magnetism - Domains Domain Theory
Saturated state All domains fully aligned Magnetising force Residual magnetism
with external field removed remains
Saturated
Residual
2
Magnetic Fields Magnetic Fields
Lines of flux:
Flow from a North Pole to a South Pole outside
a magnet.
Flow from a South Pole to a North Pole inside
a magnet.
Form closed loops.
Repel one another.
Never cross.
3
Magnetic Flux Magnetic Flux Density
Magnetic flux is defined as the total number of Magnetic flux density is defined as the total
lines of flux in a magnetic field or circuit. number of lines of flux passing through each
square metre in a cross section of the
magnetic field.
The S.I. unit of magnetic flux density is the
tesla.
The old CGS unit is the gauss.
Electromagnetism Electromagnetism
4
Coil Magnetisation Hysteresis
Hysteresis Hysteresis
Place an unmagnetised sample of ferromagnetic material in Now slowly decrease the magnetising force (H) to zero.
a slowly increasing magnetic field.
Saturation
Magnetic flux density (B) Tesla
Magnetic flux density (B) Tesla
Virgin Residual
curve magnetism
Hysteresis Hysteresis
Now continue to increase the negative magnetising force (H). Now apply a slowly increasing negative magnetising force (H).
Magnetic flux density (B) Tesla
Magnetic flux density (B) Tesla
Negative Coercive
saturation force
5
Hysteresis Hysteresis
This is the permeability of any material On the basis of relative permeability materials
relative to the permeability of free space. can be divided into three groups:
Free space is basically air.
Permeability of free space = µ° = 1.0 1. Diamagnetic.
Relative permeability (µr) = µ/µ° 2. Paramagnetic.
Absolute permeability is difficult to measure. 3. Ferromagnetic.
6
Relative Permeability (µr) Relative Permeability (µr)
Current (Amps)
7
Root Mean Square (RMS) Electromagnetism
AC
I 0 1.414
HWAC
I 0.637 2
FWAC
I 0.9 1.414
Coil Magnetisation
8
Eddy Current Testing (ET) Flaw Detection
Section 2
Conductor
DC current DC current
Magnetic field
North
+ ve + ve
DC DC
- ve - ve
South
1
Magnetic Field of a Coil Magnetic Field of a Coil
North South
AC
AC
Primary field
South North
Resin housing
PTFE tape
2
Probe Construction Magnetic Field of a Coil
3
Effect of a Magnetic Field Effect of a Magnetic Field
S
S
Electrical conductor Electrical conductor
N
N
Current flow Current flow
Faraday’s Laws of
Effect of a Magnetic Field
Electromagnetic Induction
Moving a magnetic field about the conductor 1. An electro-motive force (EMF) is induced in a
will produce a current flow. conductor when the magnetic field
An alternating current flow can be produced surrounding it changes.
by using a moving (alternating) magnetic 2. The magnitude of the EMF is proportional to
field. the rate of change of the magnetic field.
AC AC
Alternating
(moving)
primary
field
Conductive material
4
Production of Eddy Currents Production of Eddy Currents
AC AC
AC AC
AC AC
Localised alternating
electrical current
5
Production of Eddy Currents Lenz’s Law
Eddy currents
Secondary field
Fault Fault
6
Eddy Current Flaw Detection Eddy Current Flaw Detection
7
Any
questions?
Summary
Eddy currents, are local electrical currents in The current produced, will be proportional
a conductive body, produced by electro- to the rate of change of flux, i.a.w. Faraday’s
magnetic induction. law.
Electro-magnetic induction, is caused by The changing magnetic flux, is created by
lines of magnetic flux cutting a conductor and passing an AC current through the probe coil.
inducing an EMF (electro motive force). It has Called Primary magnetic field.
to be a changing magnetic flux. AC is used to give a constantly changing field
to induce constantly changing eddy currents.
The coil, is wound around a ferrite core to
concentrate the flux field.
Eddy currents, produced in a conductive A change in the eddy current path will
material, generate their own magnetic field. result in the following:
This is known as the secondary magnetic field. 1. A change in the magnitude of the secondary
The secondary magnetic field, opposes the magnetic field.
one that induced it, i.a.w. Lenz’s law. 2. Any change in the secondary magnetic field
is felt back on the primary magnetic field (the
one that induced it).
8
3. This changes the coils impedance
(opposition to current flow in an AC circuit).
4. Any change in the coils impedance, is then
displayed on the instrument, either visually or
as an audible warning.
Any Questions?
9
Eddy Current Testing (ET) Factors Affecting Eddy Currents
Section 3
Ferrite core
Opposing secondary
field
Eddy currents
D.C. AC
Opposing field
No induction
+ Induction creates
secondary AC
_ Primary AC
Current flow
(right hand rule)
1
Eddy Current Inspection Eddy Current Inspection
m/·mm².
Specimen dimensions.
100% I.A.C.S. = 58 m/·mm².
Flaws.
1 m/·mm² = 106 siemens/m.
Permeability Frequency
Has a dominant effect on eddy currents. Affects depth of penetration (skin effect).
The noise created by permeability changes in The standard depth of penetration () = 1e-1 x
ferrous materials make eddy current surface intensity of eddy-currents.
inspection of welds etc difficult. Standard depth of penetration = 660
Magnetic saturation can negate the effect of ƒ
permeability. - SDP (mm).
Measurement of permeability is the basis of ƒ - frequency (Hz).
sorting bridges. - conductivity (% IACS). Note: If m/·mm²
use 500.
- relative permeability.
2
Flaws Factors Affecting Eddy Currents
Material thickness.
Component geometry.
AC
Eddy currents
3
Thickness Effect Thickness Effect
For approximate thickness measurement. The effect that the components edge or sharp
To detect blind side corrosion. changes in geometry have on the eddy
currents.
Can be negated by balancing probe near to
edge and scanning at that distance.
Material loss/corrosion
AC
4
Edge Effect Edge Effect
AC
5
Mass Effect Mass Effect
AC
Ferrous fastener
6
Ferrous Effect Ferrous Effect
7
Lift Off (Proximity) Lift Off (Proximity)
8
Probe Handling Probe Handling
AC
Edge.
Mass.
Ferrous effect.
Lift off.
Probe handling.
9
Review Factors Affecting
Eddy Currents
Can be used to detect:
Flaws and discontinuities.
Material thickness.
Thickness of non-conductive coatings.
Material specification.
10
Eddy Current Testing (ET) Impedance Plane Display
Section 4
The information received by the instrument is Changes in the reaction between primary and
displayed as a flying working spot on an LCD secondary fields cause changes in the coils
display screen. impedance.
This form of information representation is Impedance can be plotted as a graph known
known as impedance plane. as the A-Y curve.
Resistance Resistance
1
The A-Y Curve The A-Y Curve
Typical indications:
2
Typical indications: Typical indications:
Lift-off Lift-off
Impedance Plane
Typical indications: XL
Z
Edge effect Fault Ferrous XT
(XL- XC)
Lift-off
XC
Mass
3
Applications:
Crack detection.
Tube and wire testing.
Condenser tube inspection.
Material sorting.
Weld testing.
Coating thickness measurement.
4
Eddy Current Testing (ET) Basic Electrical Theory
Section 5
Electrolyte
Electrolyte
The atom
+ve -ve
nucleus +ve electron
nucleus
1
Electrical Theory Electrical Theory
Angular
momentum
+ve nucleus
+ve nucleus
Load
R
2
Electrical Theory – Ohm’s Law Electrical Theory – Ohm’s Law
Battery
V
+ -
I R
Conductor
V
I V=IxR
I= V
Load R
R R= V
I
V=IxR
Total resistance in a series circuit is equal to all In a series circuit current remains the same
resistances added together. throughout, but voltage is divided between the
resistances.
Current (I) in circuit = V/R
R1
R1 I = 12/12
I = 1amp throughout
12v R2 R1 = 3 RT = R1 = R2 = R3 R2
12v R1 = 3
R2 = 4 RT = 3 + 4 + 5 Voltage in R1 = 1 x 3 = 3v
R3 R2 = 4
R3 = 5 RT = 12 R3 Voltage in R2 = 1 x 4 = 4v
R3 = 5
RT = 12 Voltage in R3 = 1 x 5 = 5v
12v
3
Resistances in Parallel Parallel Circuit – Voltage Constant
In a parallel circuit total resistance is always less In a parallel circuit it is the voltage which remains
than the value of the lowest single resistor. constant, whilst the current is drawn at varying
rates depending on the value of each resistance.
R1 = 3 1/RT = 1/R1 + 1/R2 + 1/R3
R1 = 3
R2 = 4 1/RT = 1/3 +1/ 4 + 1/5 R2 = 4
12v R3 = 5 1/RT = 20/60 + 15/60 + 12/60 R3 = 5
R3 R2 R1
R3 R R1
1/RT = 47/60 12v 2 Current in R1: I = V/R = 12/3 = 4 Amps.
Peak
Amplitude
4
Alternating Current in a Wire
Current
Amplitude
a b c d e
45° 90° 135° 180° 225° 270° 315° 360°
Primary AC current
Time
90°
Peak
135 ° 45°
+4
Rate of
change
Amplitude
Positive fastest
cycle here
Amplitude
180 °
360°
45° 90° 135° 180° 225° 270° 315° 360°
0
45° 90° 135° 180° 225° 270° 315° 360° 45° 90° 135° 180° 225° 270° 315° Time
Time
Negative
cycle 225 ° 315 °
-4
270 °
One Cycle
5
AC Sine Wave Alternating Current in a Wire
Opposing field
Induction creates
secondary current
Primary AC current
Inductance Inductance
Inductance (L)
D.C. A.C.
The ability of a device to store magnetic energy and oppose
Opposing field changes in the current is called inductance and is calculated
No induction as follows:
Induction creates
+ secondary AC RN 2 A
L
l
Where:
L is the Inductance in Henries.
Primary AC R is a geometric factor to do with the shape of the coil and
_
Current flow gap between windings etc.
(right hand rule) N is the number of turns.
A is the coil’s planar surface area in mm².
Static magnetic field Alternating magnetic field l is the coil’s axial length.
From the formula, it can be seen that factors affecting
inductance in a coil are mostly its physical attributes.
6
Capacitor/Condenser Capacitor/Condenser
Capacitors store electric charge. Used where a large transient current is needed
Capacitance is the amount of stored charge – ie: spot welders, flash guns, ignition
measured in farads. Note; Farad is a very systems etc.
large unit and most capacitors are rated in In ET instruments, variable capacitors are
microfarads. used in AC circuits to adjust the phase
Capacitance is dependent on: between voltage and current to create
Plate size – large plates = large capacity. resonance.
Distance between plates – the closer the plates the
larger the capacitance.
Nature of dielectric material.
CIVIL Current
Amplitude
90 90
45° 90° 135° 180° 225° 270° 315° 360°
Time
In a purely capacitive circuit, current leads the
voltage by 90°.
However, in a purely resistive circuit, voltage
and current are in phase. In a purely resistive circuit, voltage and current are in phase.
7
A Purely Capacitive Circuit A Purely Inductive Circuit
Voltage Voltage
Current
Current
Amplitude
Amplitude
45° 90° 135° 180° 225° 270° 315° 360° 45° 90° 135° 180° 225° 270° 315° 360°
Time Time
CIVIL
Step 3: Take mean
of square I²/2 = 8.
8
90 90
Step 1: Take peak
value I = 4.
4
In a purely capacitive circuit, current leads the 2.828
Step 4: Take root
voltage by 90°. of mean = 2.828.
0
However, in a purely resistive circuit, voltage
and current are in phase.
-4
8
Eddy Current Testing (ET) Equipment Circuits
Section 6
Probe
Simple circuits:
Oscillator Meter
Current
Double
Probe
absolute
circuit
Driver (reflection
probe)
Receiver
1
Equipment Circuits Equipment Circuits
Z
Resonance occurs when:
XL
XL = XC Amplitude
V R
1 .
2fL =
2 f C
XC
XL
f = 1 . XC
R 2 LC
fR f
At resonance Z = R
Bridge circuits - based on the Wheatstone bridge: Bridge circuits - based on the Wheatstone bridge:
4 2
2 Meter
Potential divider 12 v 12 v
4 4
8
Bridge circuits - based on the Wheatstone bridge: Bridge circuits - based on the Wheatstone bridge:
Meter Meter
2
Equipment Circuits Instruments
Primary bridge
3
Eddy Current Testing (ET) Probe Coils
Section 7
Double
Single
1
Probe Coil Arrangements Probe Coil Arrangements
Double
2
Probe Coil Arrangements Probe Coil Arrangements
3
Probe Coil Arrangements Probe Coil Arrangements
4
Eddy Current Testing (ET) Probes
Section 8
Surface probes are coils that are typically mounted Some surface probes are specifically designed for
close to one end of a plastic housing. As the name crack detection of fastener holes. These include
implies, the technician moves the coil end of the sliding probes, ring probes and hole probes.
probe over the surface of the test component.
1
Eddy Current Probes Eddy Current Probes
Finger probe
Outside diameter (OD) probes are coils that are In order to give the eddy current inspector
wound around the circumference of a hollow useful data while conducting an inspection,
fixture. The coil is designed such that the test signals generated from the test specimen
part is ran through the middle of the coil. These must be compared with known values.
probes can be used to inspect bars, rods as well Reference standards are typically
as tubes. manufactured from the same or very similar
material as the test specimen.
Many different types of standards exist due to
the variety of eddy current inspections
performed.
The following slides provide examples of
specific types of standards.
2
Reference Standards Reference Standards
Reference Standards
3
Eddy Current Testing (ET) Tube Testing
Section 9
1
Tube Material Tube Material
Internal defect
2
f90 Frequency Fill Factor
Defect amplitude is a function of its surface area Equivalent to lift off when using encircling coils.
size and depth.
Defect phase is mainly a function of depth. Fill Factor = Coil diameter DC² (internal coil)
f90 frequency – gives good phase lag between Tube diameter DT²
defects and good signal amplitude.
3
Eddy Current Testing (ET) In Service Inspection of Coated Steel Welds
Using Eddy Current Techniques
Introduction Introduction
Traditionally surface crack detection in ferritic Sophisticated probe design and construction,
steel welds with eddy-current techniques has combined with modern electronic equipment,
been difficult due to the change in material have largely overcome the traditional
properties in the heat affected zone. problems and now enable the advantages of
These typically produce signals much larger eddy-current techniques to be applied to in-
than crack signals. service inspection of ferritic steel
structures in the as-welded conditions.
_ Primary AC
Current flow
(right hand rule)
1
Basic Principle of Eddy Currents Basic Principle of Eddy Currents
Ferrite core
Opposing secondary
field
Eddy currents
2
Eddy Current Testing (ET) Practical Exercises
1 The profile will also change along the length of the weld
as the geometry changes. The K-Node found offshore is
2
used as a typical example (figure number 02).
3
3&6
4 4
5
7&8 7 8
6
1&2
Lift-off signal 5
horizontal
0
It is therefore necessary to ensure that the Approach the material samples on the
technique chosen is capable of the following: conductivity block in turn.
Evaluating the material to be tested. Repeat the balance and erase.
Measuring the coating thickness in order that Approach the ferrite sample, adjust the phase
the full extent of the problem is quantified control until the signal generated is in the
and evaluating the constituents of the vertical direction.
coating. Repeat the lift-off on each of the sample pieces
in turn.
The screen presentation should now be the
same as that described in figure number 03.
1
Practical Exercises Practical Exercises
If you now join up the ends of the signals Repeat the exercise changing the frequency
(phasor points) two comma shaped curves are first to 60kHz, then to 100kHz and finally
produced. 25OkHz.
Please note that the top curve represents Reproduce each phasor diagram on the graph
changes in magnetic permeability (µ) and the paper and compare each with respect to:
bottom curve represents changes in electrical
Amplitude of signal.
conductivity (IACS) or resistivity (p).
Angle between signals.
Please also note that the changes in magnetic
Relative position of the material points.
permeability and resistivity trace out the curve
in an anti-clockwise direction whereas increasing
conductivity changes in a clockwise direction.
2
Practical Exercises Practical Exercises
When testing ferro-magnetic material an Please also note that magnetic permeability has the
increase in permeability will move the spot in an same effect as resistivity and therefore these two
anti-clockwise direction up the comma curve. parameters usually cannot be separated when a
surface probe (coil) is used.
Please note that a probe with a ferrite core
yields better magnetic coupling and hence a As a result of the above we conclude that it is possible
to quickly evaluate the material of the component to
larger impedance diagram than a probe with a
be tested by carrying out a series of lift-offs on the
similar air-core coil.
component and comparing the responses to a known
standard such as the 50D calibration block.
The limiting parameters have yet to be evaluated ie
when is the use of the 50D block acceptable and when
is it necessary to use a calibration block manufactured
from material closer to the component to be tested?
1.2. Defining the limiting parameters affecting the When comparing impedance changes due to
use of a specific calibration block. permeability variations in the previous exercise
When contemplating the use of eddy-current we did not consider the possible effect cracks
techniques it is imperative that a calibration block and other discontinuities produce.
representative of the component to be tested in In this exercise we are using spark eroded slots
the three main areas is available. to represent surface breaking defects, the
These factors are compensated for in practical theory being that the signal generated from
terms. similar slots in near matching materials will be
reasonably similar both in amplitude (length)
The main areas are:
and phase (angle from a known reference
Material.
point).
Coatings and geometry.
This exercise will address material variations only.
Start by carrying out lift-offs on the material, lf we now balance on the material equidistant
taking care not to wander close to the slots and from two slots and carry out a series of lift-offs
rotate the phase adjustment until the lift-off you will recognise that the horizontal has shifted
signal is horizontal. 180 degrees from the original lift-off position.
Please note that the initial balance point is very Now please try and run over the slots in turn,
important. commencing with the 0.5mm deep slot.
Balance in air then approach the material, A signal is generated approximately at right
setting the lift-off signal horizontal right to left. angles to the horizontal and the amplitude of the
Keep the probe on the material and try to run signal increases with increasing depth of slot.
over the slots starting with the 0.5mm deep However, the ratio is not uniform. ln order to try
slot. and make the screen as clear as possible we
As you can see it is extremely difficult to see the would recommend the following procedure is
slots on the CRT. followed:
3
Practical Exercises Practical Exercises
Balance the equipment in air. Repeat this exercise at the mid-point between
Adjust the horizontal until it reads +30 and the the end of the block and the 0.5mm deep slot.
vertical until it reads 0. Place the probe onto the When the lift-off is set as described above run
material taking care to keep the probe at right the probe over the 0.5mm deep slot.
angles to the material under test. Note the vertical displacement of the signal and
Balance the equipment. The spot should return the angle the slot signal makes with the lift-off
to the same position ie +30 and O. Commence signal.
lift-offs and whilst doing so adjust the phase
control until the lift-off signal is horizontal going
from the balance point to the left hand side of
the CRT.
Repeat the process with the 1.0mm, 2.0mm, Are the responses uniform? Are they linear?
3.0mm, 4.0mm and 5.0mm deep slots. Is any part of the graph linear, eg from 0-3.0mm
Produce a graph with the x-axis the slot depths or 3.0-5.0mm?
and the y-axis the vertical displacement of the Please make your comments to the above on the
signals obtained from the slots. graph paper under the graph.
With reference to the graph produced are there Consider the variables in each case.
any patterns apparent that may be useful? Jot some thoughts down!
What are the main parameters affecting the
eddy-current responses to the slots?
4
Eddy Current Testing (ET) Practical Exercises 2
Balance point
0 Increasing
layers of
Relative Lift-off signal amplitude
aluminium
No Coating
Aluminium foil
0.5mm coating
ting
1.5mm coa
1
Practical Exercises Practical Exercises
Increasing thickness
of aluminium
1.6 Material and heat affected zone evaluation,
effect of weld geometry.
Up until now we have been using a flat plate as
Lift-off a calibration block and therefore have not taken
Lift-off 50D steel aluminium the possible changes in material properties due
to the heat affected zone of the weld into
Layers of consideration.
aluminium Neither have we considered the possible effects
50 D calibration block of the various geometries made by the
plate/pipe and the weld profile(s) as the weld
Figure number 06 configurations change.
Typical responses from aluminium foil and aluminium/carbon steel
combined using the absolute coil.
6
Lift-off points
5
4 3 2 1
Section 2.0:
Balance point Practical exercises - evaluation of weld probe (tangential,
orthogonal, differential coils).
Lift-off 50D calibration block Exercises to be completed:
2.1. Material evaluation.
2.2. Defining the limiting parameters affecting the use
1
of a specific calibration block.
2
4 2.3. Effect of increasing non-conductive coating
3&5 thickness on defect detectability.
2.4. Measure the distribution (cross section) of the
induced eddy-currents on the surface of the 50d
Figure number 08
carbon steel calibration block.
Responses from component parts of weld section using the
absolute coil. 2.5. Additional tests to be carried out on weld probes
prior to use.
2
Web Probe Coil Configurations Web Probe Coil Configurations
+ + 2
5
2 3
3
1 4
3
Web Probe Coil Configurations Relative Sensitivity Level
Figure number 12
Typical material lift-off responses using the weld probe on
the standard conductivity block.
work to.
β
In ultrasonic testing this reference point would X mm
Y mm Y mm
4
Weld Probe Checks Weld Probe Checks
Signal amplitude
from 1.0mm
deep slot to 1
Graticule vertical.
Balance
point
Figure number 13
Plotting eddy-current distribution on 50d steel block. Mark index point
on the block
Scanning procedures:
For this purpose it is necessary to once again
divide the weld to be tested into component
Signal amplitude parts.
50% from 1.0mm deep
reduction Material and heat affected zone examination.
slot to 6 Graticules
level vertical. Weld cap surface examination.
Balance point
Figure number 14
Plotting eddy-current distribution on 50d steel block.
5
Weld Probe Checks Weld Probe Checks
Balance
level Balance
Individual responses level
from 0.5, 1.0 and
2.0mm deep slots.
Figure number 16
Variation in amplitude from slots in 50D steel calibration block.
α β
The central
coil has come
off the surface
of the metal.
Balance
point
Figure number 17
Variation in signal amplitude in the vertical plane.
h
Balance
point
Figure number 18
0.5mm 1.0mm 2.0mm
Evaluation of lift-off signal.
6
Weld Probe Summary Weld Probe Summary
Defects As you can see, the pencil probe and weld probe
As this technique is to be used as an in-service are complimentary.
tool the defect(s) to be detected and evaluated It is always necessary to use the pencil probe to
are in general terms fatigue cracks. evaluate the coating thickness and/constituents
Again in general terms, these defects are and material relative to the calibration block
directional, initiating in the toe of the weld or prior to using the weld probe for defect
heat affected zone. detection.
They may however take any route if and when By keeping to this sequence the relative
they propagate from the toe of the weld or heat sensitivity level will be maintained by ensuring
affected zone. that the appropriate compensation factors are
added for geometry and coating to the basic
calibration settings.
Balance
point
Optimum angle
of probe
Figure number 19
Optimum angle of coils for weld toe examination.
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Weld Testing Procedures Weld Testing Procedures
Signal amplitude
typically 1 to 1.5 Balance point
graticules high
Figure number 20
Additional scan of the toe of the weld.
Crack 1
2
1
depth
2
0 profile 0
Crack 3
Balance
point Toe crack
4 No Crack
1
3
0
2
α
The central coil
angle must bisect
Figure number 21 the geometry
β
Typical screen presentation from geometry and crack in the toe of angle under test.
the weld.
Figure number 23
Compensation levels for stand-off due to varying weld configurations.
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Weld Testing Procedures Weld Testing Procedures
α
α
Signal 2
β amplitude
β indicative of 1
depth of crack
Balance
point
90° typical weld, stand-off 90° small weld, stand-off
2mm, geometry 2mm, geometry
compensation 3dB. compensation 3dB.
Figure number 22
Typical screen presentation of crack using single pass technique.
2.6. Weld surface examination in addition to Why is it that the signal generated by the toe of
weld configuration. the weld always moves towards seven o'clock?
We have not as yet considered the possible Likewise when the probe is run over the weld
affects of the weld profile(s). It is now necessary profile the signal envelope will, in general terms,
to evaluate the weld probe(s) for weld surface move from seven o'clock to one o'clock. What is
examination in addition to the geometry effect. the reason for this? A general schematic for weld
We require 1 x weld section as illustrated in examination is illustrated in figure number 24.
figure number 7 plus a variety of weld profiles to ln general terms the signal will follow the
run the probe over and quantify the effect. direction of the lift-offs. ln order to try and
Is it possible to predict the signal(s) which will confirm this theory please follow the procedure
be generated by the variable profile of the weld? described below.
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Weld Testing Procedures Weld Testing Procedures
Figure number 24
General schematic for weld inspection.
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Weld Testing Procedures Weld Testing Procedures
Weld cap surface examination It is common to find that the scanning sensitivity
It is necessary to ensure full coverage of the necessary to achieve a relative sensitivity level
weld surface and take into account the likely at the toe of the weld is excessive for weld cap
direction of the fatigue cracks. examination.
In practice this involves the scanning of the weld In general the reason for this is that the coating
surface in two directions ie transverse across the thickness is greatly reduced relative to the toe of
weld looking for longitudinal defects and the weld.
longitudinal looking for transverse defects. If this is the case please adjust the gain in order
ln the event of weld profiles being exceedingly to ensure the signal envelope obtained from the
rough and/or proud it may be necessary to carry weld surface is contained within the screen.
out an additional single pass scan along each
weld inter-run.
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Weld Testing Procedures Weld Testing Procedures
The signal would then re-trace it’s movement As the geometry remains reasonably uniform
when the probe was returned to its original over a relatively short distance the main factor
position. influencing the amplitude of the signal is
In each case we had an equal and opposite obviously the cross section of the defect.
effect. For discussion purposes only let us consider if we
When you introduce a defect in the toe of the had to implant a 1.0mm deep x 20mm long
weld (geometry) the defect signal produced is defect in exactly the same position in the heat
the vector addition of the signals generated by affected zone of three typical weld configurations
these two conditions. and monitor the defect signal generated. What
would be the outcome?
The single pass technique eradicates the majority Weld cap surface examination
of these variables however we must always Having established the signal envelope for the
remember to compensate for the geometry effect weld cap examination (2.6) we should be able to
by adding the appropriate number of dBs gain. distinguish abnormal signals and by further
It is not possible to immediately carry out the investigation establish these are defects and/or
single pass. caused by other conditions such as scale etc.
The material and the heat affected zone must be
examined in detail prior to conducting the single
pass.
The reasons are self evident.
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Weld Testing Procedures Weld Testing Procedures
Under normal circumstances the fatigue defects Please consider the locations and try to establish
will occur in the weld cap in two locations: in your mind the variables existing for each.
Inter-run. Are the variables the same for each location?
Weld run itself. Will the defect signal be the same for each?
What shape will the defect be?
We have tried to establish set patterns for each
component part of the weld (figure number 24).
Let us take each in turn and try to predict the
change to the normal signal pattern and the
probable shape of the defect.
Inter-run fatigue defect We can therefore expect the defect signal to look
The most important consideration is the profile of similar to that generated by a defect occurring in
the weld. the toe of the weld ie the defect signal will be a
If the weld consists of large runs and therefore has a vector addition of the vertical displacement from
rough profile then the defect will be hidden in the the defect itself and the geometry of the trough in
trough between weld runs. which it occurs.
The geometry effect will be pronounced relative to a
smooth contoured weld.
The signal envelope will also be extensive compared to Any abnormal signal can, of course, be confirmed
a relatively smooth weld. The normal signal envelope by carrying out a single pass scan along the inter-
will be going between the geometry effect of the toe of
run.
the weld to the peak of the weld run then to the
geometry effect caused by the trough between the weld
runs until finally we have the geometry effect from the
opposite toe of the weld.
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Additional Scanning Techniques Additional Scanning Techniques
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Eddy Current Testing (ET) Amplitude Analysis, Full length
and Internal defects
Practical
1
Eddy Current Testing (ET) CIVIL Explanation
1
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2
Eddy Current Testing (ET) Differential
Practical
1
Eddy Current Testing (ET) Inlet End
Practical