LECTURE NOTES FOR LEVEL-1 EDDY CURRENT TESTING COURSE Prepared in accordance with IAEA Technical document TECDOC-628 ing Guidelines in Non-destructive Testing Techniques. BY DR. MOHAMMAD SABIR CH. ASGHAR ALI KHAN NATIONAL CENTRE FOR NON-DESTRUCTIVE TESTING (NCNDT) PAKISTAN ATOMIC ENERGY COMMISSION ISLAMABADCHAPTER -1 Ml Ld 12 13 La Lis 116 12 13 13.1 132 133 CHAPTER-2 21 24d 242 22 221 2.22 23 24 24.1 242 243 CHAPTER3 3 3.1 341.2 3.13 32 321 322 33 CONTENTS PAGE NO. GENERAL KNOWLEDGE Non Destructive Testing (NDT) 12 Definition and Nature of NDT 12 Characteristic of NDT 12 Reasons for using NDT 12 Types of NDT method 13. Limitations of Eddy Current Test 2 Responsibilities of Level-1 Certificate holder 13 Materials Wis Processes and Defects 18 Primary Processes and Related Defects 18 Processes and Related Defects 119 Service Conditions and Related Defects 130 PHYSICAL PRINCIPLES Electricity 2 Direct Current a Alternating Current 23 Magnetism 27 ‘Magnetic theory 27 Induced Mas Flux 210 Electromagnetism 210 Eddy Current Distribution 23 Plane Conductor 2-13 Cylindrical Bars 2-16 Tubes 217 INSTRUMENTATION Principles and Basic Characteristics of Eddy Current 341 Induction and Reception Function 32 Absolute and Differential Measure 33 ‘Types of Probes 3S Reaction of Different Types of Probes According to Coil Layout 3-7 Reaction to Small Defects, 3-7 Reaction to Long and Continuous Defects 37 Technology and Practical Characteristics of Probes 38 Design Technology 38 Manufacturing ‘Technology 38333 334 34 34.1 342 343 35 35.1 35.2 353 354 35.5 35.6 36 3.6.1 3.6.2 37 37. 3.72 393 374 375 3.7.6 CHAPTER 4 4.1 4Al2 413 42 421 42.2 423 43 43.1 43.2 433 434 4a Electrical Parameters Maintenance Working Principle of Eddy current Equipment Tran Reception Data Presentation Adjustment Frequeney Energizing Device Balance Phase Rotation Output Filter Gain mission Different Types of Eddy Current Equipment Monoparameter, Monochannel and Specialized Equipment Multiparameter and Multichannel Equipment Auxiliary Equipment Ausiliary Devices for Signal Acquisition Driving Mechanism Saturating Unit Demagnetizers Equipment for Signal Storage System for Automatic Processing of Signals TESTING PROCEDURES Influence of Defect Position and Orientation Eddy Current Path Penetration Depth Zone of Probe Action Influence of Material Temperature Heatir Deviations ‘Compensation Influence of Structure and Geometry of Tested Parts Choice of Test Frequency Phase Discrimination Fi B-I1 Curve and Magnetic Saturation Coupling Influence ering 41 41 4 42 43 43 43 43 44 44 44 4s 4644d 442 4A3 444 45 45.1 45.2 46 46.1 46.2 463 47 49.1 472 CHAPTER-S 3a SA 52 S13 S14 52 52.1 32.2 523 33 53.1 53.2 34 sal 54.2 55 55.1 CHAPTERS 6. 6.1.1 612 613 Centering Fill Factor Vibration Sensitivity Compensation Influence of Relative PartProbe Speed ‘Testing Frequencies According to Speed Bend Wiath of Apparatus According to Testing Speed Reference Standards used in Eddy Current Testing Functions of Reference Standards of Reference Standards Fabrication and Reproducibility of Various Types of Reference Standards Inspection Method Range of Inspection Recording of Indications APPLICATION Geometric Defect Characterization Hypothesis of Interrupted Current Case of Point Defects Case of Large Defects Case of Multiple Defects Discontinuities Detectable by Eddy Curres Discontinuities Arising from Product Discontinuities Arising During Hot or Cold Processing Discontinuities Arising During Service Defect Detection Absolute Measurement Differential Measurement ‘Thickness Measurement Thickness ofa Product Thickness of Coating Measurement of Product Composition Measurement by Electrical Conductivity CODES AND STANDARDS Defi Quality Quality Control Standards 46 47 47 48 48 48 49 4-10 ail 4.12 413 413 Se $3 54 55 58 58 58 59 59 5-10 Sel SU S12 S13 S13 ot 6-1 6-1 Gl614 615 6.1.6 617 618 619 61.10 61M 6.1.12 6.113 62 63 64 65 Standardization Guides and Recommended Practices Codes and Specifications Procedure Technique Examination and Testing Inspection Authorized Inspector Report Records Aims of Standardization Standards Relating to NDT Codes and Standards Applicable to Eddy Current Testing Specifications and Procedures which apply to the Method Article 8 Appendix-1 ot Gt 61 61 G1 62 62 62 62 62 62 65 6-6COMPARISON BETWEEN ET-I LECTURE NOTES AND IAEA TECHDOC-628 SUBJECT IAEA TECDOC 628 ET 1 BOOK 1 General Knowledge Introduction Non-destructive testing of materials Definitions NDT asa technology Reasons for using NDT Brief description and field of application of the most common methods: a) Visual testing b) Liquid penetrant testing c) Magnetic testing Radiographic testing ©) Ultrasonic testing ) Eddy current testing g) Leak testing LL Ato L147 Limitations in the application of eddy current testing Materials Properties of materials (metallic and non-metallic) Properties of metals Discontinuities Defects Processes and defects Primary Processes and related defects Processes and related defects a) Casting b) Welding ©) Forging 4) Rolling ©) Heat treatment 1) Machining 2) Plating h) Other processes 132Service and related defects a) Overload b) Fatigue ©) Corrosion @) Brite fracture 133 2 Physical Principals Electricity Direct Current a) Amperage & Voltage b) Ohm's Law & Resistance c)_ Conductivity & Resi Altemative Current a) Amplitude and Phase b) Impedance 2A222124 Magnetism 22 Magnetic Theory 221 a) Indication & Magnet 2211 'b) Magnetic Permeability 22.12 ) Iron Magnetization 22.13 Induced Magnetic Flux 222 a) Definition b) Lines of Force & Force Field 2221 ©) Flux Conservation/Residual Magnetism 2222 Electromagnetism Magnetic field produced by a current. Current a induced by a magnetic ficld, eddy current, inductance, Field current by eddy current, Reactance |_23-125.2 Eddy Current Distribution 34 Plane Inductor aah a) Variation of Amplitude & Phase of Current b) Depth of Standard Penetrate qe ¢)_Defect Reaction According to Position Cylindrical Bars rr a) Characteristic Frequencies ra b) Variation of Amplitude & Phase ©) Depth of Standard Penetration Biase «)_Defect Reaction According to Position Tubes: 243 a) Characteristic Frequencies b) Variation of Amplitude & Phase c) Depth of Standard Penetration 2.4.3.1-2.43.4 4) Defect Reaction According to Posi3 Instrumentation Principles and basic characteristic of eddy current probes Induction and reception functions Absolute & differential measure Type and probes Reaction of different types of probes according to coil layout Reaction to sinall defect Reaction to long defect Reaction to continuous defect 3213.22 hnology & practical characteristic of probes Design technology Manufacturing technology Electrical parameters Maintenance 33 Working principle of eddy current equipment ‘Transmission Reception Data Presentation 34 34.13.43 ‘Adjustment of eddy current equipment Energizing device Balance Phase Rotation Output Filter Gain 3.5 3.5.1-3.5.6 Different types of eddy current equipment Monoparameter, Monochannel and Specialized Equipment Multiparameter & Multichannel Equipment 3.6 3.6.1 3.6.2 Auxiliary Devices Auxiliary devices for signal acquisition Driving mechanism, Saturation unit, demagnetizer equipment for signal storage: strip chart recorders, ‘magnetic tape recorder, digital memories. System for automatic processing of signals a7 3.7.1 03.7.8 4 Testing Procedures Influence of defeet position & orientation Eddy current path Penetration depth Zone of probe action 41 411 412 413 Influence of material temperature Heating Deviations Compensation 42 421 422 4.23Influence of structure and geometry of tested parts 43 Choice of test frequency 43.1 Phase discrimination 43.2 Filtering 433 ___|__ Magnetic Saturation 434 Coupling influence 44 Vibrations 44) Centering, Fill factor 442 Sensitivity 443 ‘Compensation 444 Influence of relation parv probe speed 45 ‘Testing frequencies according to speed. 45.1 Bandwidths of apparatus according to testing. 45.2 Reference standards used in Eddy Current Testing 46 Function of Reference Standards 46.1104.63 Choice of reference standard Fabrication and reproducibility of various types of reference standards. Geometric defect characterization Sa 5 Hypothesis of interrupted currents Applications Case of point defects 5.110 5.14 Case of large defects Case of multiple defects Main type of discontinuities detected by eddy current 52 testing Discontinuities arising from production Discontinuitics arising during hot or cold processing | 5.2.1 to 5.2.3 Discontinuities arising during service Defect detection 53 Absolute measurement 531 Differential measurement $3.2 Thickness measurement 54 Thickness of a product 54.1 Thickness of coating 5.42 Measurement of product congestion 55 Measurement by electrical conductivity 5.5.1 6 General knowledge 6.11063 Codes & Standards, | Codes and standards application to eddy current 64 Specifcationand, | testing 65 Procedures Specifications and procedures which apply to the methods.