ET Study Notes

Eddy Current Testing
Eddy-Current Testing 1. Principle
Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Editor: Deutsche Gesellschaft für Zerstörungsfreie Prüfung e.V.
Eddy-Current Testing 2. Eddy-current probes

Eddy-Current Testing 3. Signal interpretation

Eddy-Current Testing 4. Equipment

Eddy-Current Testing 5. Aircraft inspection

Eddy-Current Testing 6. Material characterisation

Eddy Current Testing - Applications
Spies / FHG-ITWM & University of Saarland
Electromagnetic NDT Methods / Master CNDMS
NDT&E of Materials Using Eddy Current Technique
Eddy Current (EC) Technique: General notes
Materials under Test:

Ferromagnetic and / or electrically conductive (metals, ...)
Typical Applications:
Defect Detection (Subsurface and Surface Cracks,
Pores, Inclusions…)
Material Properties (Conductivity σ, Permeability µ,
Hardness, Hardness Depth, ...)
Geometry (Wall/Layer/Film Thickness, …)
IZFP
Eddy Current (EC) Technique: Basic sensor arrangement
Transmitter coil
i(t)=I⋅⋅cos(ω
ωt) Receiver coil
U(t)
σ,µ
Specimen under test

ω = 2πf
f - EC operating frequency
σ - electrical conductivity
µ - magnetic permeability
U EC - sensor impedance
Z=
- Time Alternating Field I
IZFP
Eddy Current (EC) Technique: Signal influencing variables
Sensor −σ
Lift Off
+µ
+ Wall / Layer - Wall / Layer

Thickness Thickness
−µ
σ Conductivity
+σ µ Permeability
IZFP
Eddy Current Standard Penetration Depth
100
Copper
Aluminum
Ferritic steel (µ=50)
Penetration depth (mm)
r
10 Austenitic steel (µ=1)
r
0.1
P
io
e
a
n
trd
p
h
)m
(
0.01
0.1 1 10 100 1000
Frequency (kHz)
IZFP
Sensitivity limitations
Sensor & measurement hardware:

- noise level, dynamic range
- spatial resolution of the sensor
Presence of disturbing influences (application-specific):

- sensor lift-off / tilt
- inhomogenous geometry of the test specimen
(surface roughness, edges, ... )
- local variations of material properties (σ, µ) in the test specimen
-...
The optimal sensor design strongly depends on the application
IZFP
Inspection
Inspection trace
trace
detectable defects detectable defect
Higher sensitivity vs. Reduced inspection time

Better spatial resolution Easy operation
IZFP
Quantitative NDT
using the EC technique
Demands on the inspection system:
• Proper sensor design
• High signal dynamic range and long-time operation stability

of the hardware
• Efficient signal processing algorithm

in order to evaluate small signal changes
by large disturbing signals
• Multiple eddy current operating frequencies (EC frequencies)

in order to extend the information content
IZFP
Generation and Application of the Numerical Filters
for Quantitative Multifrequency EC technique
Measurement data
obtained on calibration samples
Calibration Regression Filter
Known values of target analysis coefficients
function
Filter coefficients
Filtering results:
Recalculation
Verification Measurement data obtained on
(numerical filtering)
target function
test samples with known evaluation error
values of target function
Filter coefficients
Filtering results:
NDE application Recalculation target function
Measurement data obtained (numerical filtering) values
on items to be tested
IZFP
Eddy Current Hardware

100 mm
WS98 Board
Features
• EC frequencies 10 Hz - 10 MHz
• Operation with multiple frequencies
• High long-time operation stability
• 16 Bit A/D-conversion, > 85 dB dynamic range
• Digital Signal Processor with realtime algorithms
• Ethernet interface
IZFP
64-Channel Eddy-Current
Inspection System
Front End / Main Electronics
IZFP
Application examples
Inspection of Layered Aluminum Aircraft Structures

to Detect and Size Hidden Corrosion
Calculation of the Conductivity Gradient:

Numerical Modeling of the Inverse Problem
IZFP
EC Inspection of Layered Aluminum Aircraft Structures
Inspection task:
Non-destructive quantitative evaluation EC sensor

of the corrosion damage depths 0.7... 1.0
(or remaining thickness of aluminium) Aluminium
corrosion mm
in each layer of the bonded Adhesion
multilayer structure
Aluminium
Adhesion
0.2... 0.4
Solution: mm
corrosion
Aluminium
Multifrequency EC technique
IZFP
Calibration specimen
0.3 mm
Aluminium sheet 0.5 0.4 0.3 0.2 0.1 mm
thickness 0.7 mm
Shallow pits
with various depths
0.7 0.6 0.4 0.2 mm
IZFP
Results
Inspection situation:
corrosion in the 1st and 3rd
aluminium layer
Target function:
corrosion in the 0.5
1st aluminium layer
0.4
EC probe 0.3
Aluminium
corrosion 0.2
Adhesion
Aluminium
0.1
Adhesion 0
corrosion
Aluminium
corrosion depth [mm]
IZFP
Results
Inspection situation:
corrosion in the 1st and 3rd
aluminium layer
Target function:
corrosion in the
3rd aluminium layer
0.6
EC probe
0.4
Aluminium
corrosion
Adhesion 0.2
Aluminium
Adhesion 0
corrosion
Aluminium
corrosion depth [mm]
IZFP
Conclusion
Determination of Layer Thickness using EC Technique:
Increasing the Accuracy
Application-optimised sensor arrangement
Efficient signal processing & data interpretation
IZFP
Barkhausen Noise and Eddy Current Microscopy
A Scanning Probe Technique

for Microscale Material Characterization
BEMI - Introduction
BEMI provides high-resolution characterization of…

• residual stress
• coating thickness and homogeneity
• microstructure
• electrical / magnetic surface properties
features / advantages
• nondestructive, even for coatings as thin as 25 nm
• high local resolution (10 µm)
• high accuracy (coating thickness: ≤ 10 nm)
• wide range of coating and substrate materials
• contactless scanning option
Measured Quantities: Magnetic Barkhausen Noise
Barkhausen noise
amplitude
• observed for ferromagnetic materials under tensile stress
alternating field magnetization (< 1 kHz)
• mainly caused by 180° Bloch wall jumps compressive stress
stress-dependent
microstructure-dependent
sensitive to lattice defects
magnetic field strength

Measured Quantities: Eddy Current Influenced Impedance
ωL
ωL0
• established NDT method ω=0
ω surface defects
characterizes conductivity and permeability
permeability changes
suitable for coating thickness determination
lift-off sub-surface defects
sensitive to microstructure
wall thickness variations
conductivity changes
ω→∞ R-R0
ωL0
BEMI Testing Device
precision3-d
precision 3-d sensor element:
scanner controllingPC
controlling PC
scanner miniaturized inductive probe
(modified VCR head)
sensor
sensor
sample
sample
stationaryelectromagnet
stationary electromagnet
(Barkhausenonly)
(Barkhausen only)
• picks up Barkhausen noise
• induces eddy currents
•• scanner
scannercontrol
control
•• eddy
eddycurrent
currenthardware
hardware
•• barkhausen
barkhausennoise
noisehardware
hardware
cm
Fields of Application
Spatially High-Resolved Characterization of

• Residual stress
• Coating thickness and homogeneity
• Electrical / magnetic surface properties
Advantages
• High spatial resolution (≤ 10 µm)
• Quick (0.2 – 2 s / position) and versatile
• Coating thickness accuracy ≤ 10 nm
• Multi-parameter target calibration
• Ultra-light low-inertia probe support
• Surface level compensation for non-contact
scans
Probe Design
Probe similar to video recorder head
0.3 µm gap width
head surface
10 mm
Resolution Test : Barkhausen Noise
Linear scan across micro- 8

profiled test sample
7
MMAX [V]
5
0
0 200 400 600 800 1000 1200 1400
x [µm]
Resolution Test : Eddy Current
Different materials perm- ferrite ferrite

under test alloy
6-µm gaps copper 200 µm

100 µm
glass
5 µm
10 µm
20 µm
40 µm
60 µm
20-µm gaps 80 µm
100 µm
Applications: Residual Stress (I)

thermally induced residual stresses in X20Cr13 steel: two laser-treated spots
comparison with X-ray method

Barkhausen noise
area scan
Applications: Residual Stress (II)
residual stresses in tempered Sendust (FeSiAl) – 2 µm film thickness, scan size: 2x2 mm²
X-ray stress measurement
scan resolution: 5x5 points

total scanning time: 125 hours
(dark blue: 310 MPa, red: 396 MPa)
Barkhausen noise area scan
scan resolution: 20x20 points

total scanning time: < 30 minutes
(maximum noise amplitude shown; dark blue: 1.26 V, bright yellow: 2.84 V)
Applications: Coating Thickness (I)
thickness of polyimide film on ferrite substrate
optical image eddy current area scan

4x3 mm² 40x30 points
surface profilometry:
actual thickness: 400-900 nm
high correlation with

eddy current signal
Applications: Coating Thickness (II)
thickness of Fe coating on Cu substrate
thickness 3120 nm
eddy current line scan 2600 nm
3 3 thickness
50 points per sample
eddy current signal [arb. unit]

1540 nm 3120 nm
2.5 2.5 2600 nm
860 nm 1540 nm
obtained thickness 2 2
420 nm 860 nm
accuracy: ≤ 10 nm
(double RMSE) 100 nm 1.5 1.5 420 nm
4850 100 nm
3650 1 1
2450
0.5 0.5
1250
x [µm] 50 0 0
0 50 100 150
distance from surface [µm]
Applications: Coating Thickness (II)
contactless eddy current scanning of a NiCo coated wafer
lift-off performance of eddy current signal utilized for surface level interpolation
photo of wafer eddy current area scans of 24x24 mm region in center
contact -25 µm -50 µm

Applications: Coating Thickness (III)

thickness of subsurface layers – NiFe/Cu/NiFe multilayer for GMI sensors
sample arrangement contactless eddy current scan (100x100 points)

9 samples used for calibration absolute thickness display after calibration
y nm
NiFe NiFe NiFe NiFe-GMI
82/18 90/10 50/50 82/18
GMI
100 / 30 / 100 nm
200 nm
100 nm
200 nm
100 nm
200 nm
100 nm
25 nm
25 nm
25 nm
x
Applications: Residual Stress (III)
residual stresses at a crack tip in Charpy V-notch specimen
Barkhausen noise stress-calibrated

optical image area scan neural network output
Applications: Microstructure characterization
cementite needles in austenitic matrix („Spiegel iron“)
optical Image
eddy current
area scan
3 x 0.8 mm2, 20 µm steps, 150 x 42 steps

Selected Applications
Eddy current scan 100x100

of a „1 EURO“ coin 3x3 mm²
256x256 pixels
24x24 mm²
Parameter Im4
3 MHz
Conclusions
• BEMI is a quick NDT method for residual stress and coating thickness characterization
• residual stress measurement using Barkhausen noise analysis

• coating thickness measurement using eddy current analysis
• local resolution: 10 µm, scanning speed: several points per second

• wide range of materials and coating thickness
• contactless scanning option
• eddy current method sensitive to sub-surface and intermediate layers
Flux Leakage Testing - Basics
Flux Leakage at a Gap at Various Magnetisations

Flux Leakage at Material Separations

Flux Leakage at Material Defects

Flux leakage
Gap at surface, perpendicular to magnetic field lines
Gap, parallel to magnetic field lines
Gap below surface, perpendicular to magnetic field lines

Flux Leakage at Crack: Tangential Field in the Outside

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

(transverse flaw)
Field direction Joke
Current Exciting coil

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

Field direction
Conductor (Cu)
Detectable defects
(longitudinal/radial flaws)
Current
Flux Leakage Testing: Magnetisation Using a Joke
Portable electromagnet
(AC or DC)
Test object (e.g. sheet)
Field direction Detectable defect (transverse flaw)

Flux Leakage Testing - Application
Magnetic Flux Leakage Testing
a: soft iron core

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

Array 16 GMR-Sensors
Response curve of GMR Sensors

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

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

Sprache

ET Study Notes

Hochgeladen von

Dokumentinformationen

Copyright

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

ET Study Notes

Hochgeladen von

Copyright:

Eddy Current Testing

Eddy-Current Testing 1. Principle

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Author: Otto-von-Guericke-Universität, Institut für Werkstofftechnik und Werkstoffprüfung

Materials under Test:

Specimen under test

+ Wall / Layer - Wall / Layer

Sensor & measurement hardware:

Presence of disturbing influences (application-specific):

The optimal sensor design strongly depends on the application

detectable defects detectable defect

Higher sensitivity vs. Reduced inspection time

Demands on the inspection system:

• Proper sensor design

• High signal dynamic range and long-time operation stability

• Efficient signal processing algorithm

• Multiple eddy current operating frequencies (EC frequencies)

Eddy Current Hardware

Front End / Main Electronics

Inspection of Layered Aluminum Aircraft Structures

Calculation of the Conductivity Gradient:

Non-destructive quantitative evaluation EC sensor

0.7 0.6 0.4 0.2 mm

Application-optimised sensor arrangement

Efficient signal processing & data interpretation

A Scanning Probe Technique

BEMI provides high-resolution characterization of…

Measured Quantities: Magnetic Barkhausen Noise

magnetic field strength

Measured Quantities: Eddy Current Influenced Impedance

BEMI Testing Device

Spatially High-Resolved Characterization of

Probe similar to video recorder head

0.3 µm gap width

Resolution Test : Barkhausen Noise

Linear scan across micro- 8

Resolution Test : Eddy Current

Different materials perm- ferrite ferrite

6-µm gaps copper 200 µm

Applications: Residual Stress (I)

comparison with X-ray method

Applications: Residual Stress (II)

X-ray stress measurement

scan resolution: 5x5 points

(dark blue: 310 MPa, red: 396 MPa)

Barkhausen noise area scan

scan resolution: 20x20 points

Applications: Coating Thickness (I)

thickness of polyimide film on ferrite substrate

optical image eddy current area scan

actual thickness: 400-900 nm

high correlation with

Applications: Coating Thickness (II)

thickness of Fe coating on Cu substrate

eddy current signal [arb. unit]

Applications: Coating Thickness (II)

contactless eddy current scanning of a NiCo coated wafer

photo of wafer eddy current area scans of 24x24 mm region in center

contact -25 µm -50 µm

Applications: Coating Thickness (III)

sample arrangement contactless eddy current scan (100x100 points)

Applications: Residual Stress (III)