Understanding Eddy Current Array Technology

Basic Concepts of Eddy Current Testing

Eddy current array (ECA) is a nondestructive testing technology that provides the ability to
electronically drive multiple eddy current coils, which are placed side by side in the same probe
assembly. Each individual eddy current coil in the probe produces a signal relative to the phase
and amplitude of the structure below it. This data is referenced to an encoded position and time
and represented graphically as a C-scan image. Most conventional eddy current flaw detection
techniques can be reproduced with ECA inspections; however, the remarkable advantages of
ECA technology enable improved inspection capabilities and significant time savings.
ECA technology has the following advantages:
• A larger area can be scanned in a single probe pass, while maintaining a high resolution.
• Less need for complex robotics to move the probe; a simple manual scan is often enough.
• C-scan imaging improves flaw detection and sizing.
• Complex shapes can be inspected using probes customized to the profile of the part being inspected.
Depth of Penetration
Eddy current density does not remain constant across the depth of a material. The density is
greatest at the surface and decreases exponentially with depth (the “skin effect”). The standard
depth of penetration equation (shown below) is used to explain the penetration capability of
eddy current testing, which decreases as the frequency, conductivity, or permeability increases.
For a material that is both thick and uniform, the standard depth of penetration is the depth
at which the eddy current density is 37% of the material surface value. To detect very shallow
defects in a material and to measure the thickness of thin sheets, very high frequencies are
used. Similarly, in order to detect subsurface defects and to test highly conductive, magnetic,
or thick materials, lower frequencies must be used.
Multiplexing
Multiplexing is the process by which multiple analog message signals are combined into one
digital signal. It enables the eddy current system to excite all of the coils in the probe without
ever exciting any two adjacent coils at the same time. An undesirable effect known as mutual
inductance (magnetic coupling between coils in close proximity) is minimized with the use of an
internal multiplexing system.
The signals are then reassembled before being displayed as an image. In addition to the
enhanced imaging capabilities of multiplexed data, multiplexing enables any individual coil (data
channel) to be analyzed after inspection. Multiplexing enables an increased channel resolution,
increased coil sensitivity (through the reduction of mutual inductance), and a reduced noise
level. This ultimately leads to an improved signal-to-noise ratio.

Magnetic
Coils coupling
• High frequency • Low frequency Scanning Scanning
direction direction
• High conductivity • Low conductivity Defect Defect

• High permeability Standard depth of penetration • Low permeability

(skin depth)

Eddy current Eddy current

Depth Depth signal signal

1/e or 37% of
surface density
Eddy current array and conventional eddy current Defects in the part disturb the path of the eddy
With mutual inductance Without mutual inductance
technology share the same basic principle. Alternating currents. This disturbance (in yellow) can be measured
current passed into a coil creates a magnetic field (in by the coil. Eddy current density Eddy current density
blue). When the coil is placed over a conductive part,
opposed alternating currents (eddy currents, in red) are
generated. 661 Where:
δ mm ≈ d
f
= Standard depth of penetration (mm)
= Test frequency (Hz)

ƒμrσ mr
s
= Relative magnetic permeability (dimensionless)
= Electric al conductivity (% IACS)

Typical multiplexing patterns

Applications
Stress Corrosion Cracking
Using ECA technology to inspect pipes for stress corrosion cracking is a faster and less labor-
intensive alternative to penetrant and magnetic particle inspection. With ECA, users can make
their inspections without removing paint or other coatings. Interchangeable wedges fit a range
of pipe diameters, and the continuous mode provides scan imagery in real time.
Doubler Edge Skin Crack Inspection
ECA has greatly reduced doubler edge skin crack inspection time. The C-scan images provided
by ECA enable a higher probability of detection and better reproducibility. Because ECA probes
offer wide coverage, the position of the probe during the inspection is not critical while enabling
both edges of the doubler to be covered in one scan.
Surface Crack Detection
High-resolution ECA probes are used to detect surface-breaking cracks, even through paint
and thin coatings. ECA technology has considerably reduced the duration of these inspections
while, at the same time, increasing the probability of detection. This application is particularly
important for inspecting aircraft fastener rows.

Subsurface Crack Detection Subsurface Corrosion Detection Probe Design

Aircraft are built by joining overlapping aluminum sheets together with thousands of fasteners.
Cracks on the underlying layers of aluminum are often concealed by the first sheet. ECA
technology is capable of scanning through the first layer of an aircraft (the skin) to detect
cracking present in the second layer, without the need for removing paint.
Aircraft are subject to repeated, drastic temperature changes, which can cause condensation
to collect on the inside of aluminum skin, potentially leading to corrosion. ECA technology is
used to detect, size, and evaluate the depth of corrosion between layers of aluminum. With
continuous mode, the scan imagery reveals inspection results in real time.
Probe Parameters
To achieve optimal inspection performance, there are several important parameters to consider
when designing an effective eddy current probe. Key factors include inspection coverage,
sensitivity, frequency, and cost. To optimize performance, it is important to carefully balance
the various probe parameters. For example, high-sensitivity probes require small, high-
frequency coils (providing less coverage); probes capable of greater coverage require larger,
lower-frequency coils (resulting in decreased sensitivity to small defects). As is the case with
conventional eddy current inspections, choosing the correct probe characteristics is essential to
a successful inspection.

r= C
n
Where:
n = Number of channels
r = Resolution (also depends
on the coil configuration)
C = Coverage
C

Probe Structure
Eddy current array probes can be optimized for a specific
application by changing the probe shape and the coil
configuration. Most coil configurations can be expanded
into an array configuration.

Probe Types

Surface Subsurface High Frequency, High Resolution

Surface probes are made with coils designed to be driven at relatively high frequencies (typically
50 kHz to 500 kHz). Using higher frequencies results in less penetration of the eddy current field
into the test part, enabling the area directly below the surface of the part to be inspected. In
addition, the higher frequencies provide a higher resolution for the detection of smaller defects.
The coils in subsurface probes are designed to be driven at relatively low frequencies (typically
1 kHz to 20 kHz). Using lower frequencies results in greater penetration of the eddy current
field into the test part, enabling cracks or corrosion to be detected in thicker structures or in
multilayer structures, such as aircraft lap joints.
Subsurface probes provide greater penetration; however, sensitivity to small defects decreases
as the frequency and penetration are increased.
High-frequency, high-resolution probes are used to detect surface-breaking defects on
aluminum aircraft skins. These probes are made with 32 absolute coils positioned for the
complete coverage of a 26 mm scan area. Although these probes are used for a specific
application, they are very flexible and suitable for various high-frequency surface-breaking
applications.

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