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ven though eddy current testing is one of the oldest nondestructive evaluation methods, it was not widely understood and did not reach full, widespread use until the
1980s (Ref. 1). Whereas portable ultrasonic instrumentation
offering considerable versatility for nondestructive testing
(NDT) has been available since the 1960s, comparable eddy current testing equipment was not widely available until the 1980s.
In addition, eddy current theory did not become available until
the late 1970s. Now, excellent tutorial information is available for
scientists and engineers without advanced degrees.
ing test variables such as sensitivity and penetration. The development of microprocessor-based eddy current instruments in
the 1980s greatly enhanced the potential and user-friendliness
of the method, and allowed for the development of automated
eddy current inspection equipment. Finally, at the turn of the
1. Electromagnetic induction is the generation of an electrical
voltage across a conducting material through stimulation by an
applied alternating magnetic field.
2. Tests used to quickly sort metal alloys with differing chemical or
alloying compositions.
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Fig. 2 Four types of eddy current instruments. A A simple arrangement, in which voltage across the coil is monitored; B typical
impedance bridge; C impedance bridge with dual coils; D impedance bridge with dual coils and a reference sample in the second
coil (Ref. 2). (Reprinted with permission of ASM International. All rights reserved. www.asminternational.org.)
century in the late 1990s and early 2000s, giant magnetoresistive3 sensors were utilized to allow multifrequency techniques at
very low frequencies to probe for flaws deep in multilayer metallic aircraft structures.
Physical Principles
Eddy current NDT is based on the principles of electromagnetic induction for inducing eddy currents4 in a material or part
placed in or adjacent to one or more alternating flux field induction coils (Ref. 2). The system is operated at very low power levels to minimize heating and temperature changes. The loop currents induced in the material produce an additional magnetic
field, and a sensor is used to measure the total magnetic field
near the specimen. The value of the total magnetic field depends
on several factors including the following:
Geometry of the induction coil
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Filed
Transverse Notch
Milled or
Electrical Discharge
Machined Longitudinal Notch
Milled or
Electrical Discharge
Machined Transverse Notch
Drilled Hole
Fig. 5 Several fabricated discontinuities used as reference standards in eddy current inspection (Ref. 2). (Reprinted with permission
of ASM International. All rights reserved. www.asminternational.org.)
Geometry of the specimen
Current and frequency in the coil
Electrical conductivity of the specimen
Magnetic permeability of the specimen.
Types of Discontinuities
There are a number of different discontinuities that can be
detected with eddy current NDT. In metallic structures, welds,
fatigue cracks, voids, hidden corrosion and stress corrosion
cracks can be detected (Fig. 3), and the size of such defects can
also be determined. The geometry of the part and the defect
location dictate the size of the flaw that can be detected. For
example, automated and manual eddy current inspection of gas
turbine engine disks can reliably detect cracks as small as 0.023
in. in length in bolt holes of seventh stage compressor disks
(Ref. 3). Defects such as delaminations, voids, and broken fibers
from impact damage can be detected in graphite epoxy composites. While in carbon/carbon composites for high-temperature use, eddy current NDT can be used to determine the thickness of the silicon carbide (SiC) coating used on carbon/carbon
composite for oxidation protection. In addition, voids caused by
oxidation between the SiC coating and the carbon/carbon base
can be detected and carbon loss due to oxidation can be deter5. Reluctance in a magnetic system is akin to resistance in an
electrical system.
mined using eddy current NDT. Eddy current NDT can be used
on conducting materials including metals, alloys, carbon/epoxy
composites, carbon/carbon composites, and metallic matrix
composites.
Inspection Requirements
There are no special facility requirements for eddy current
NDT, and portable instrumentation is available for field applications such as aircraft inspection, as shown in Fig. 4. Rugged
eddy current equipment is also available for use in manufacturing environments to inspect metallic products as they are being
processed. There is no special material preparation for testing,
but a smooth surface produces optimum results. Eddy current
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Direct
Tube OD
Tube ID
Coupling
Zone
Remote
Field Zone
Detector Array
Exciter Coil
Fig. 7 Schematic showing location of remote-field zone in relation to exciter coil and direct coupling zone (Ref. 2). (Reprinted with
permission of ASM International. All rights reserved. www.asminternational.org.)
Practical Considerations
Commercial, off-the-shelf eddy current equipment is available that is very portable and user-friendly. Training for the
eddy current testing technique is somewhat straightforward
Fig. 6. However, certified NDT inspectors are either recommended or required and the training for a certified inspector
involves more in-depth training than just how to use the instrument and interpret the results. In the United States, eddy current inspectors can be certified by NAS 410 from the Aerospace
Industries Association of America or by the American Society
for Nondestructive Testing (ASNT). Eddy current instruments
range in cost from about $10,000 to about $30,000.
In addition to conventional eddy current NDT techniques,
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Fig. 10 Typical applications for low-frequency eddy current testing. A Interstitial corrosion; B thinning (Ref. 4). (Copyright 2004
The American Society for Nondestructive Testing, Inc. Reprinted with permission from NDT Handbook, third edition, Vol. 5,
Electromagnetic Testing.)
Cracks
Holes
Corrosion
Damage in C/C composites
Depends on geometry, etc., but down to 0.020 in. for jet turbine engine
fatigue cracks at or near the surface
Material must be electrically conducting
Depth of inspection limited by frequency of eddy currents used
Not effective for cracks deep in thick-sectioned metallic structures
Can detect discontinuities that do not break the surface
Quantitative flaw sizing
Can be automated for repetitive inspections
Usually required, with commercial or military training schools available
Depends on application
Certification available through the American Society for Nondestructive
Testing (ASNT)
Except for very simple equipment, must have computer control and
data logging. Automated scanning is also available. Single frequency or
multifrequency equipment is available.
Can be labor intensive if used manually on large areas such as airplane
skins and rivets. Equipment costs vary from a modest amount to
$100,000 or more.
Size of discontinuities
Limitations
Advantages
Equipment
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Conclusions
Eddy current NDT is a mature technology with widespread
availability of user-friendly, affordable, commercial, off-the-shelf
equipment. It can be used on conducting materials and can detect
many types of discontinuities. Eddy current testing has enjoyed
considerable success in a number of applications including, for
example, inspection of nuclear reactor heat exchanger tubes, aircraft engine and metal skin components, and in the manufacturing
plant inspection of a variety of metallic components. In addition,
eddy current NDT is widely used to inspect welds along with X-ray
radiography and ultrasonic testing.
References
1. Hellier, C. J. 2001. Handbook of Nondestructive Evaluation,
Eddy Current Testing. New York, N.Y.: McGraw-Hill, pp.
8.18.7.
2. ASM Metals Handbook, 9th Ed., Vol. 17, Nondestructive
Inspection and Quality Control, Eddy Current Inspection. 1989.
Metals Park, Ohio: ASM International, pp. 164194.
3. Nondestructive Evaluation Capabilities Data Book, 3rd
Edition, Appendix A, Eddy Current Inspection, NTIAC, DB-9702, November 1997.
4. Hagemaier, D. J. 2004. Low frequency eddy current testing
of aircraft structures. Nondestructive Testing Handbook, 3rd Ed.,
Vol. 5; S. S. Udpa and P. O. Moore, editors. Columbus, Ohio:
American Society for Nondestructive Testing, pp. 481485.
General References
Eua-Anant, N., Cai, X., Udpa, L., Chao, J., and Elshafiey, I.
2000. Crack detection in eddy current images of jet engine
disks. Review of Progress in Quantitative Nondestructive
Evaluation, Vol. 19A. Melville, N.Y.: American Institute of
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