FINAL YEAR PROJECT 2

DETECTION OF
SUB-SURFACE DEFECT IN WELDS USING
EDDY CURRENT THERMOGRAPY
TECHNIQUE
Presented by:
MOHD ARIFF BIN ZAKARIA
50249113541

Supervisor:
Dr. AB. RAZAK BIN HAMZAH
(UniKL-MFI)

Co-supervisor:
DR. ILHAM MUKRIZ ZAINAL ABIDIN
(Malaysian Nuclear Agency)
 OUTLINE
1. INTRODUCTION
2. SKIN DEPTH THEORY
3. PROBLEM STATEMENT
4. OBJECTIVE
5. LITERATURE REVIEW
6. METHODOLOGY
7. SYSTEM AND EQUIPMENT
8. SAMPLE
9. HYPOTHESIS
10.SCOPE OF EXPERIMENT
11.RESULT
12.CONCLUSION
13.RECOMMENDATION
 1. INTRODUCTION
1. What is Eddy Current Thermography?

i. Eddy current method excite magnetic flux

ii. Thermography method infrared camera

 1. INTRODUCTION
2. Basic Principle of Eddy Current Thermography
Alternating current flows in a coil
Magnetic field induced eddy current into material
Defect disturb eddy current flow
Defect detection temperature contrast
2. SKIN DEPTH THEORY

= Skin Depth
= pi
= Test Frequency (Hz)
= Magnetic Permeability (H/m)
= Electrical Conductivity (S/m)
 3. PROBLEM STATEMENT
Magnetic particle - Require a lot of consumables to inspect wide range
area

Magnetic particle - No permanent data recorded

Magnetic particle - Cleaning & demagnetize process is necessary

 4. OBJECTIVE

To analyze the acquired images for optimum inspection result of eddy current
thermography

To compare with existing NDT method (Magnetic particle inspection)

 5. LITERATURE REVIEW
Wilson.J et al (2010) with increasing the heating time, detection sensitivity
Eddy Current will not give any improvement in image quality
Thermography steel sample

Weekes et al (2011) extending the excitation period beyond 50ms gave

Eddy Current no appreciable increase in image quality for steel
Thermography steel sample
I.Z.Abidin et al (2012) more heat tend to accumulate within slanted area
Eddy Current between the defect and the sample surface
Thermography aluminum sample

U. Netzelmann et al At 100kHz induction frequency there is only a weak

(2015) Induction contrast, meanwhile 1500hz frequency give sufficient
thermography electromagnetic interaction
Nicolaos J. (2016) Short excitation periods (of 50200 ms) and high
Eddy current exciting frequencies (typically 50500 kHz) are
thermography generally used in eddy current thermography as a
rule
 6. METHODOLOGY
Documentation Material selection Technology Sample preparation
Familiarization
Collecting sources Ferromagnetic Welded sample
Gather the material Matlab software Painting
information Welded carbon steel ECT Equipment Marking

Perform technique
Data analysis
Final report writing Induction heating to the
Subsurface defects
Final result sample
detection Capture heated sample
Conclusion Image analysis images
Recommendation Magnetic particle
Result comparison
testing
 7. SYSTEM AND EQUIPMENT

Induction heater control box Workhead Water pump machine

Excitation Coil Infrared camera Eddy current thermography system

 8. SAMPLE

PROCESS: SMAW
JOINT: SINGLE V BUTT JOINT
MATERIAL: CARBON STEEL
DEFECTS: CRACKS (ROOT,TOE & HAZ)
 9. HYPOTHESIS

The orientation and location of defect gives big influence

to the indication
difficult to indicate if the crack orientation is parallel to the
streamline of eddy current
defect near edge of plate gives edge effect
 10. SCOPE OF EXPERIMENT
Experiment Current (I) Heating time (millisecond)
50ms 70ms 90ms 120ms 140ms
1
2
350amp
3
4
5

Parameter for this experiment:

sample will be tested at 350 ampere with 5 different level of heating time
which is from 50ms 140ms.

Note: previous parameter is not being used because of Insufficient excitation time
and during the actual testing, sample is tested at 350 ampere of current & 200ms of excitation
time.
 11. RESULT (HAZ AREA)
SAMPLE

COIL

DEFECT AREA

Crack indication

SAMPLE

COIL

Linescan profile of free defect & crack area (haz)

Free defect
 11.RESULT(WELD TOE AREA)
SAMPLE

COIL

DEFECT AREA

Crack indication

SAMPLE

COIL

Linescan profile of free defect & crack area (toe)

Free defect
 11. RESULT (ROOT AREA)
COIL

DEFECT AREA

SAMPLE

Crack indication

COIL

SAMPLE

Free defect Linescan profile of free defect & crack area (root)
 11. RESULT(MPI)

14 mm haz crack
16 mm Root crack
21 mm toe crack

Weld Face Weld Root

 12. CONCLUSION
All free defect shows the identical form of contrast and the linescan
profile is comparable between each other
The crack area there is a significant temperature increment that can be
consider as defect indication
 13. RECOMMENDATION
Data from the experiment does not fulfil the detection criteria unless
further experiment gathered and compared with modelling
(simulations). This would provide an alternative solutions towards the
testing and assessment of welding, which is crucial in the maintenance
and overall structural integrity evaluation of industrial components.