Assessment of the Effects of Scanning Variations and Eddy Current Probe Type on Crack Detection

Eddy current procedures are currently the most capable, of the nondestructive evaluation (NDE) techniques that are being applied in industry. The performance capability of an NDE procedure is that of the probability of detection as a function of flaw size. Prediction of the performance capability of a given procedure has been inexact, due to the lack of supporting theory, and has therefore been either validated experimentally or has been assumed to be applicable to a test problem by its similarity to a “time proven” application. Rigorous experimental validation of an NDE procedure is laborious and must be repeated for each new application and/or change in NDE parameters. Attention has been focused on this problem and much of the work described in this volume is directed toward the determination of critical characteristics of NDE applications and in the generation of supporting theory to facilitate predictive modeling of NDE performance capability. The experimental work described in this paper expands on previous work on the characterization of eddy current probes, as applied to flaw detection [1,2], and is directed to support the expansion of application theory [3]

Calibration Methods for Eddy Current Measurement Systems

Calibration of eddy current measurement systems is an important factor for attaining the accuracy and precision of measurement that quantitative nondestructive evaluation requires. The quantity of interest in most forms of eddy current inspection is △Z, the change in probe impedance induced by a flaw. Flaw signals produced by surface-breaking cracks are small; typical flaw signals for an air core probe amount to a few tenths of one percent of the probe’s impedance in air. Such small signals are easily obscured by the impedance changes caused by small variations in the height of the probe above the workpiece (lift-off). To discriminate against lift-off, conventional eddy current instruments determine the phase of △Z relative to lift-off and the magnitude of the component of △Z in quadrature with lift-off. But this information is not sufficient to perform flaw signal inversion; rather, the absolute magnitude and phase of △Z are necessary. Thus, quantitative inversion of eddy current signals to obtain flaw sizes requires methods for calibrating eddy current measurement system

Eddy-Current Probe Design

This paper describes theoretical and experimental work directed toward finding the optimum probe dimensions and operating frequency for eddy current detection of half-penny surface cracks in nonmagnetic conducting materials. The study applies to probes which excite an approximately uniform spatial field over the length of the crack at the surface of the material. In practical terms, this means that the probe is not smaller than the crack length in any of its critical dimensions

Eddy-Current Detection Methods for Surface-Breaking Tight Cracks

The eddy-current (EC) NDE method has been in use for quite some time, and efforts have been made to make it a fully quantitative method. To evaluate impedance signals for a given EC inspection system, one has to characterize the system as a whole, including both probes and specimens. In particular, until probes are characterized, the electromagnetic fields cannot be calculated. Naturally, the amount of numerical computation becomes a serious issue during the course of development. It is necessary to choose probes carefully so as to maximize the flaw-characterization capability, while keeping numerical tasks within a reasonable size. Probes that are suitable for quantitative assessment are presumably different in nature from those with maximum detection capability. Among all kinds of existing probes, the simplest characterizable probe is the uniform-field-eddy-current (UFEC) probe. In fact, a series of studies, both theoretical and experimental, were devoted to demonstrating potential capabilities of UFEC probes [1–9]. The present theoretical work is another entry in this series. The numerical procedure developed in this work is limited to the case where cracks are tightly closed. The procedure is nevertheless capable, in principle, of dealing with an arbitrary range of frequencies

Angular Spectrum Analysis Applied to Undercladding Flaws and Dipole Probes

An important class of subsurface cracks occur in nuclear power plant pressure vessels. These pressure vessels, normally made of carbon steel, are protected by a layer of weld material applied directly onto the surface, leaving a highly inhomogeneoue cladding with a rough surface and a very irregular interface. Subsurface cracks originate at the interface between the carbon steel walls of the pressure vessel and the protective cladding layer. The propagation is initially into the carbon steel and eventually into the cladding, and needs to be detected before reaching the surface (Fig. 1). The inhomogeneity of the cladding material and the irregular surfaces pose serious difficulties for ultrasonic detection. These difficulties are less critical for eddy current testing due to the fact that the layered structure of the cladding has more variation in its elastic properties than its electrical conductivity

Improved Probe-Flaw Interaction Modeling, Inversion Processing, and Surface Roughness Clutter

In Reference 1 a first comparison was made of measured eddy current signals with calculations based on nonuniform probe-field interaction theory. These calculations followed the basic analysis developed in Reference 2. They used interrogating field distributions calculated by Dodd and Deeds theory for the air core coils of Reference 3. (Note that Fig. 6 in Reference 1 and Fig. 7 in Reference 3 should be interchanged). In Reference 1 theoretical and experimental plots of the flaw profile curve (a plot of △Z versus distance along the mouth of a surface breaking flaw) were found to be in good agreement, with regard to shape, for several selected EDM notch samples in aluminum. An iterative procedure was also developed for systematically varying the length, depth, and opening width to obtain a best fit to the experimental data.4 In the present paper a full inversion procedure is developed and illustrated for approximately rectangular-shaped EDM notches. The mathematical structure of the inversion problem is first examined and a solution is proposed. Physical reasoning, based on the form of the flaw profile curves, is then used to simplify the approach and to provide guidance in selection of the most suitable probe geometry. Other topics briefly addressed include, possible improvements in the theory for the region with a/§ close to unity and for more realistic flaw shapes (i.e., semi-elliptical, rather than rectangular), inaccuracies due to errors in the probe scan path, and background clutter due to surface roughness, machining marks, and micro-structure

Inversion of Eddy Current Signals in a Nonuniform Probe Field

We present a simple analytical method for predicting the eddy current signal (ΔZ) produced by a surface flaw of known dimensions, when interrogated by a probe with spatially varying magnetic field. The model is easily parameterized, and we use it to construct inversion schemes which can extract overall flaw dimensions from multiposition, multifrequency measurements. Our method is a type of Born approximation, in which we assume that the probe’s magnetic field at the mouth of the flaw can be used as a boundary condition on the electromagnetic field solutions inside the flaw. To simplify the calculation we have chosen a “rectangular” 3-dimensional flaw geometry for our model. We describe experimental measurements made with a new broadband probe on a variety of flaws. This probe operates in a frequency range of 200 kHz to 20 MHz and was designed to make the multifrequency measurements necessary for inversion purposes. Since inversion requires knowledge of the probe’s magnetic field shape, we describe experimental methods which determine the interrogating field geometry for any eddy current probe

Refining Automated Ultrasonic Inspections with Simulation Models

Computer models of ultrasonic beams can be used to accurately predict fields radiated from transducers [1,2]. Given these fields and reciprocity relations [3] the responses from reflectors of known shape can be calculated. Often scan sensitivity for an inspection is quantified relative to the response from a flat bottomed hole (FBH). Because the FBH is a simple known shape, a computer simulation with an ultrasonic measurement model [4] can be used to model and refine the inspection

Real-Time Ultrasonic Determination of Elastic Constants

In the course of processing and use of modern composites it is desireable to be able to determine estimates of their elastic properties. Elastic property information available during processing could be used to determine the state of cure of a composite. This would make possible feedback control of the cure process, thus helping to insure uniform materials. Knowledge of the elastic properties over time of in-use structures such as aircraft, marine, and rocket motor components would also allow quantitative health monitoring of these critical devices

Ultrasonic Backscattering from Polycrystalline Aggregates using Time-Domain Linear Response Theory

The ultrasonic detection of altered microstructures in metals is a difficult, but necessary task. The detection of hard alpha inclusions in titanium jet engine disks is an important, safety related, example of the need. One proposed tool for detecting such altered microstructures involves analyzing changes in the ultrasonic grain noise; i.e., in the incoherent part of the scattered signal