Non-Destructive Techniques Based on Eddy Current Testing

Non-destructive techniques are used widely in the metal industry in order to control the quality of materials. 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. This paper includes an overview of the fundamentals and main variables of eddy current testing. It also describes the state-of-the-art sensors and modern techniques such as multi-frequency and pulsed systems. Recent advances in complex models towards solving crack-sensor interaction, developments in instrumentation due to advances in electronic devices, and the evolution of data processing suggest that eddy current testing systems will be increasingly used in the future

Image-based feature extraction technique for inclined crack quantification using pulsed eddy current

Existing eddy current non-destructive testing (NDT) techniques generally do not consider the inclination angle of inclined cracks, which potentially harms a larger region of a tested structure. This work proposes the use of 2D scan images generated by using pulsed eddy current (PEC) non-destructive testing (NDT) technique in the quantification of the inclination and depth of inclined cracks. The image-based feature extraction technique effectively identifies the crack axis, which consequently enables extraction of features from the extracted linear scans. The technique extracts linear scans from the images to allow the extraction of three novel image-based features, namely the length of extracted linear scans (LLS), the linear scan skewness (LSS), and the highest value on linear scan (LSmax). The correlation of the three features to surface crack inclination angles and depths were analysed and found to be highly dependent on the crack depths, while only LLS and LSS are correlated to the crack inclination angles. © 2019, The Author(s)

Surface and inter-phase analysis of Composite Materials using Electromagnetic Techniques based on SQUID Sensors

In this thesis an electromagnetic characterization and a non-destructive evaluation of new advanced composite materials, Carbon Fiber Reinforced Polymers (CFRP) and Fiber-Glass Aluminium (FGA) laminates, using an eddy-current technique based on HTS dc-SQUID (Superconductive QUantum Interference Device) magnetometer is proposed. The main goal of this thesis is to propose a prototype based on a superconducting sensor, such as SQUID, to guarantee a more accuracy in the quality control at research level of the composite materials employed in the aeronautical applications. A briefly introduction about the superconductivity, a complete description of the SQUID properties and its basic working principles have been reported. Moreover, an overview of the most widely used non destructive technique employed in several industrial and research fields have been described. Particular attention is given to the eddy current testing and the technical improvement obtained using SQUID in NDE. The attention has been focused on two particular application, that are the main topics of this thesis. The first concerns with the investigation of the damage due to impact loading on the composites materials, and the second is the study of the corrosion process on the metallic surface. The electrical and mechanical properties of the tested advanced composite materials, such as Carbon Fiber Reinforced Polymers (CFRPs) and Fiber-glass Aluminium (FGA) laminates are investigated. The experimental results concern the non-destructive evaluation of impact loading on the CFRPs and FGA composites, by means of the electromagnetic techniques; the investigation of the electromechanical effect in the CFRPs using the SQUID based prototype and the AFM analyses; and the study of corrosion activity of the metallic surface using magnetic field measurement

Arbitrary order spline representation of cohomology generators for isogeometric analysis of eddy current problems

The eddy current problem has many relevant practical applications in science, ranging from non-destructive testing to magnetic confinement of plasma in fusion reactors. It arises when electrical conductors are immersed in an external time-varying magnetic field operating at frequencies for which electromagnetic wave propagation effects can be neglected. Popular formulations of the eddy current problem either use the magnetic vector potential or the magnetic scalar potential. They have individual advantages and disadvantages. One challenge is related to differential geometry: Scalar potential based formulations run into trouble when conductors are present in non-trivial topology, as approximation spaces must be then augmented with generators of the first cohomology group of the non-conducting domain. For all existing algorithms based on lowest order methods it is assumed that the extension of the graph-based algorithms to high-order approximations requires hierarchical bases for the curl-conforming discrete spaces. However, building on insight on de Rham complexes approximation with splines, we will show in the present submission that the hierarchical basis condition is not necessary. Algorithms based on spanning tree techniques can instead be adapted to work on an underlying hexahedral mesh arising from isomorphisms between spline spaces of differential forms and de Rham complexes on an auxiliary control mesh

Experimental studies of fabricated eddy current probe / Ilham Mukriz Zainal Abidin

Eddy current testing (ET) is one of the Non destructive testing (NDT) techniques for the detection and evaluation of surface and sub-surface defects in electrically conducting materials. This technique is the most effective technique for the assessment of heat exchanger tubes in monitoring the integrity of a heat exchanger system. In performing the eddy current inspection , probe is the most important component in acquiring information from the heat exchanger system. It is the main factor that determines the success of an eddy current testing for optimum and reliable inspection results. This research work covers the experimental and numerical approach in fabricating an eddy current probe for tube inspection . The aim of the research is to study the physics and engineering parameters which can enable us to produce eddy current probes with the focus of studying the probe coil configuration that affect its sensitivity and resolution for eddy current testing. With the achievement in fabricating an eddy current probe that fulfill the requirement of code and standards for tube inspection, the work is proceed in the study of the effect of inter-coil spacing and coil width to the probe sensitivity and resolution. The sensitivity and resolution of the fabricated probes have been studied by measurement of Vpp values and signal phase separation between internal groove defect (10) & external groove defect (00) wall loss at different intercoil spacing and different coil width. The results obtained by both experimental and numerical work have shown that with reduced inter-coil spacing and coil width, the sensitivity and the resolution of the fabricated probes will be increased thus giving a better inspection reliability and performance. This behavior is mainly attributed to the physical parameter of the probe geometry. With reduced spacing and coil width, the eddy current density becomes denser in the test specimen at a specific region. This reflects that the resistance for the eddy currents to flow in the sample is reduced and the phase will be increased. In addition, with reduced inter-coil spacing between the two coils, the mutual impedance of the two coils will become dominant thus a denser eddy current will be induced in the sample. In eddy current testing, defect detection is based on how the eddy current is disturbed in the sample , with more induced current , more current will be affected by the presence of a defect thus increase the sensitivity and the resolution of the probe. In this study, there are good agreement between the experimental data and numerical model in determining the reliable eddy current probe for engineering application

Multi-layer carbon fiber reinforced plastic characterization and reconstruction using eddy current pulsed thermography

Ph. D. Thesis.Carbon fibre composite materials are widely used in high-value, high-profit applications, such as aerospace manufacturing and shipbuilding – due to their low density, high mechanical strength, and flexibility. Existing NDT techniques such as eddy current testing suffers from electrical anisotropy in CFRP (carbon fibre reinforced plastics). Ultrasonic is limited by substantial attenuation of signal caused by the multilayer structure. The eddy current pulsed thermography has previously been applied for composites NDE (non-destructive evaluation)such as impact damage, which has the ability for quick and accurate QNDE(quantitative non-destructive evaluation) inspection but can be challenging for detection and evaluation of sub-surface defects, e.g., delamination and debonding in multiple layer structures. Developing QNDE solutions using eddy current thermography for addressing subsurface defects evaluation in multi-layer and anisotropic CFRP is urgently required. This thesis proposes the application of eddy current pulsed thermography (ECPT) and ECPuCT (eddy current pulse compression thermography) for tackling the challenges of anisotropic properties and the multi-layer structure of CFRP using feature-based and reconstruction-based QNDE and material characterisation. The major merit for eddy current heating CFRP is the volumetric heating nature enabling subsurface defect detectability. Therefore, the thesis proposes the investigation of different ECPT and their features for QNDE of various defects, including delamination and debonding. Based on the proposed systems and QNDE approach, three case studies are implemented for delamination QNDE, debonding QNDE, conductivity estimation and orientation inverse reconstruction using the two different ECPT systems and features, e.g., a pulse compression approach to increase the capability of the current ECPT system, the feature-based QNDE approach for defect detection and quantification, and reconstruction-based approach for conductivity estimation and inversion. The three case studies include 1) investigation of delamination with different depths in terms of delamination location, and depth quantification using K-PCA, proposed temporal feature-crossing point feature and ECPuCT system; 2) investigation of debonding with different electrical and thermal properties in terms of non-uniform heating pattern removal and properties QNDE using PLS approaches, impulse response based feature

Knowledge-based support in Non-Destructive Testing for health monitoring of aircraft structures

Maintenance manuals include general methods and procedures for industrial maintenance and they contain information about principles of maintenance methods. Particularly, Non-Destructive Testing (NDT) methods are important for the detection of aeronautical defects and they can be used for various kinds of material and in different environments. Conventional non-destructive evaluation inspections are done at periodic maintenance checks. Usually, the list of tools used in a maintenance program is simply located in the introduction of manuals, without any precision as regards to their characteristics, except for a short description of the manufacturer and tasks in which they are employed. Improving the identification concepts of the maintenance tools is needed to manage the set of equipments and establish a system of equivalence: it is necessary to have a consistent maintenance conceptualization, flexible enough to fit all current equipment, but also all those likely to be added/used in the future. Our contribution is related to the formal specification of the system of functional equivalences that can facilitate the maintenance activities with means to determine whether a tool can be substituted for another by observing their key parameters in the identified characteristics. Reasoning mechanisms of conceptual graphs constitute the baseline elements to measure the fit or unfit between an equipment model and a maintenance activity model. Graph operations are used for processing answers to a query and this graph-based approach to the search method is in-line with the logical view of information retrieval. The methodology described supports knowledge formalization and capitalization of experienced NDT practitioners. As a result, it enables the selection of a NDT technique and outlines its capabilities with acceptable alternatives

Shape-based defect classification for Non Destructive Testing

The aim of this work is to classify the aerospace structure defects detected by eddy current non-destructive testing. The proposed method is based on the assumption that the defect is bound to the reaction of the probe coil impedance during the test. Impedance plane analysis is used to extract a feature vector from the shape of the coil impedance in the complex plane, through the use of some geometric parameters. Shape recognition is tested with three different machine-learning based classifiers: decision trees, neural networks and Naive Bayes. The performance of the proposed detection system are measured in terms of accuracy, sensitivity, specificity, precision and Matthews correlation coefficient. Several experiments are performed on dataset of eddy current signal samples for aircraft structures. The obtained results demonstrate the usefulness of our approach and the competiveness against existing descriptors.Comment: 5 pages, IEEE International Worksho

A review of miniaturised Non-Destructive Testing technologies for in-situ inspections

Non-destructive testing (NDT) techniques have become attractive trends of product manufacturing, installation and post-maintenance in the aerospace, automotive and manufacturing industry, because of its benefits such as cost saving, easy to use and high efficiency etc. With the industrial products becoming large-scale, high integration and complication, developing the NDT miniaturisation technique for in-situ inspections is highly demanded and becoming an inevitable trend. However, in-situ inspection using NDT have been limited by a number of factors, such as the heavy weight, large size or complex structure etc. This paper aims to systematically identify and analyse the current state-of-the-art of NDT miniaturisation techniques in research and innovation, and discuss the challenge and prospect of miniaturisation of the commonly used NDT techniques