Chapter No 3 - Eddy

Current Inspection

3.1) Some Facts

Eddy Current Inspection (ECI) is based on the

principle of Electromagnetic Induction.
Direct electrical contact with the part to be
inspected is not necessary.
It is an adaptable, high speed inspection
method.
Eddy current testing is one of the most
extensively used non-destructive techniques
for inspecting electrically conductive materials
at very high speeds that does not require any
contact between the test piece and the sensor.

3.2) What is Eddy current

Eddy current is created because of electro-magnetic

induction. When alternating current is applied to the
conductor, a magnetic field develops in and around the
conductor.
This magnetic field expands as the alternating current rises
to maximum and collapses as the current is reduced to zero.

Now, suppose an electrical conductor is brought into the

proximity of this changing magnetic field, the reverse effect
will occur. Magnetic field cutting through the second
conductor will cause an induced current to flow in this
second conductor. This induced current is called Eddy
current.
Current Flow

Eddy currents are a form of induced

current that flow in circular paths.
Test Probe

Eddy Currents

3.3) Principle of ECI

A Probe is used to produce Eddy currents. A probe is a electrical

conductor formed in terms of a coil.

As AC is passed trough the probe, a dynamic magnetic field will form

in and around the probe.

If an conductive material is placed near the coil, eddy current will

develop in the conductive material.

Eddy currents flowing in the material will produce their own Secondary
magnetic field which will oppose the Primary magnetic field. This interaction
between the fields causes a back e.m.f. in the coil and hence, a change in the
coil impedance value.

If material is uniform in composition

and dimensions- the impedance
value of the search coil will be the
same at all points.

If material contains discontinuity- the

distribution of eddy currents will
change resulting in the change of coil
impedance value.
this is the principle of ECI.

Hence eddy current Involves measurement

of
changes in coil impedance due to distortion
of
eddy currents in an conducting material due
to defects or discontinuities.

3.4) Operating variables

The main variables of Eddy current
inspection are: Conductivity of a material
Magnetic properties
Coil impedance
Lift-off factor
Edge factor
Skin factor

3.4.1) Conductivity of material

Conductivity is crucial in ECI. Highly

conductive materials like copper, aluminum
will create intense eddy current & hence
cracks in conductive materials will generate
high signals.
Heat treatment causes changes in hardness
which can be related to conductivity. Eddy
currents can detect when pieces have
received a heat treatment as well as the
severity of the treatment.

3.4.2) Magnetic
permeability

Magnetic permeability is a number

that quantifies the degree of
magnetic induction B of materials
when a magnetic field H is applied , B
=H.
High magnetic permeability makes
the standard penetration depth
decrease.
Hence ferromagnetic materials are
inspected at low frequency.

3.4.3) Lift off effect

When an inspection coil is energized in air

a recording instrument always gives an
indication, even in the absence of the
specimen.
As the coil is moved closer to a conductor
the indication will change, and the
magnitude of the current will change till
the coil is directly on the conductor.
this changes in spacing between coil
and conductor are termed lift-off.

3.4.4) Edge effect

At component edges, eddy current

flow is distorted, as eddy currents are
unable to flow beyond this limiting
barrier.
This phenomenon is called as Edge
effect and hence, inspection is
inadvisable close to edges.

EDGE EFFECT

3.4.5) Skin effect

Eddy currents are not uniformly

distributed throughout a part.
They are dense at the component
surface, and become progressively
less dense at depths. This effect is
called as Skin effect.

Standard penetration depth,

S =15900(/rf)

S is the standard penetration depth

(mm)
is the resistivity of material (ohmmtr)
r is the relative magnetic permeability
f is the frequency (Hz)

3.4.6) Coil impedance

AC through a coil two opposing

factors - namely ohmic resistance, R,
of the coil and the inductive
resistance, XL.
The total resistance of the coil is
Z= (R2+ XL2).
The magnitude of the impedence
value will change based on a no of
factors such as conductivity,
magnetic permeability, defects,

3.4.7) CRACK ORIENTATION

3.5) Advantages & Limitations ECI

ECI can be performed to a large no of

conductive-ferrous/nonferrous
materials.
Can be implemented without any
physical contact.
The results of ECI as practically
instantaneous.
Measurement of non-conductive
coating thickness and conductivity
can be done.

oOnly conductive materials can be inspected

oSurface must be accessible to the probe
oSkill and training required is more extensive
than other techniques
oSurface finish and roughness may interfere
oDepth of penetration is limited
oFlaws such as delaminations that lie parallel
to the probe coil winding and probe scan
direction are undetectable.

3.6) Types of coils in ECI

3.6.1) Single primary solenoid type coil
- used for routine inspection of
cylindrical bars & tubes.
- Variations in coil impedance value
as the test piece moves through the
coil will indicate the presence of
flaws.

Single primary coil around bar

Bobbin type

3.6.2) Double primary coil system

- used in tube inspection. Both coils
are identical & connected to adjacent
arms of a bridge network.
- tube is uniform-bridge will be
balanced. When circuit is near a
crack, bridge will be out of balance.

Twin coil bobbin inside tube

3.6.3) Differential coil system

- material is uniform-zero voltage
across AB.
- some flaws is present then a
voltage will exist between AB.

Differential coil system

3.6.4) Probe
- Ferrite core with coil wound around
it.
- Coil is held normal to the surface.

Probes

3.6.5) Other types

3.7) Specific applications of ECI

3.7.1) Material thickness measurement

-only a certain amount of eddy currents

can form in a given volume of material.
-Therefore, thicker materials will support
more eddy currents than thinner materials.
The strength (amount) of eddy currents
Magnetic Field
can be measured and
related to the
From Probe
material thickness.
Test
Material

Eddy
Currents

3.7.2) Crack detection

Magnetic Field
From Test Coil
Magnetic Field
From
Eddy Currents
Crack
Eddy Currents

3.7.3) Nonconductive coating

measurement
The coating displaces the eddy current probe from
the conductive base material and this weaken the
strength of the eddy currents.
This reduction in strength can be measured and
related to coating thickness.
Nonconductive
Coating
Conductive
Base Metal

Eddy Currents

Summary

Some facts about ECI

What is Eddy current

Principle of ECI
Operating variables
Advantages & Limitations of ECI
Types of coils in ECI
Specific applications of ECI