Pulsed Eddy Current Nondestructive Testing for Defect Evaluation and Imaging of Automotive Lightweight Alloy Materials

Rapid and accurate damage detection of magnesium-aluminum alloy, which is an important material for automotive lightweight, is of great significance. Pulsed eddy current (PEC) is an effective electromagnetic nondestructive testing and evaluation (NDT&E) technique for metal materials. Metal loss evaluation and imaging are one of the most important steps in quality control and maintenance of key components of automobiles. A PEC method based on a rectangular excitation coil and an axial parallel pickup coil is proposed and investigated for the purpose of metal loss evaluation and imaging. Metal loss type of defects with different sections is designed and detected using line scanning technique and C-scan imaging in two scanning directions. Experimental results have illustrated that metal loss depth can be estimated effectively by the peak amplitude of PEC A-scan response. Then, the quantification information of metal loss depth is preliminarily obtained based on the linear fitting equation. Consequently, metal loss evaluation is realized by line scanning peak waves and C-scan pseudo 3D images. At last, the sensitivity comparison shows that the metal loss can be detected in both directions. The proposed method is an effective approach to evaluate the image surface-breaking metal loss in automotive lightweight alloy materials

Investigation of Tx-Rx mutual inductance eddy current system for high lift-off inspection

PhD ThesisEddy current (EC) testing is a popular inspection technique due to its harsh environment tolerance and cost-effectiveness. Despite the immense research in EC inspection, defect detection at high lift-off still poses a challenge. The weakening mutual coupling of EC probe and sample due to the increase in lift-off degrades signal strength and thus reduces the detection sensitivity. Although signal processing can be used to mitigate lift-off influence, it is laborious and time consuming. Therefore, in this study, a Tx-Rx probe system is proposed to deal with high lift-off inspection. The parts of the study of the Tx-Rx EC system includes optimisation of probe configuration, improvement of signal conditioning circuit and comparative study of excitation modes. In optimisation of probe configuration, lift-off and coil gap are optimized to mitigate the offset caused by the direct coupling of Tx-Rx coils. The optimum coil gaps of Tx-Rx probe for different lift-offs are found by observing the highest signal strength. The optimisation of coil gap against lift-off extends the detection sensitivity of the EC system to a lift-off of about 30 mm which is by far higher than 5 mm lift-off limit of a single-coil EC probe. In signal conditioning aspect, a modified Maxwell bridge circuit is designed to remove the offset due to self- impedance of the Rx coil. The proposed circuit mitigates the influence of the self-impedance of Rx coil and improves signal-to- noise ratio SNR. In the excitation mode, pulse and sweep frequency signals are compared to study detection sensitivity, SNR and crack quantification capability. The result of the comparative study reveals that pulse excitation is good for crack sizing while sweep frequency excitation is better for crack detection. Simulations and experimental studies are carried out to show the efficacy of the Tx-Rx EC system in high lift-off crack detection