Chapter 7

Eddy Current Testing

The eddy current testing process is also called electromagnetic testing. The
method is based on the general principle that an electric current will flow in
any conductor subjected to a changing magnetic field.
Depending on the type and thickness of material being tested, the testing
frequencies vary from 50 Hz to 1 MHz. The method is used to check welds in
magnetic and nonmagnetic material and is particularly useful in testing bars,
billets, welded pipes, and tubes.

METHOD
In the eddy current testing method, electric currentdeither eddy or Foucault
currentdis induced in the test piece, and the changes in those current are
measured. The changes occur because of the presence of discontinuities. The
test measures the resistivity, caused by changes in chemical composition,
crystal orientations, heat treatment, hardness, or discontinuities.
The commercial test methods have developed systems that use excitation
coils and large magnetoresistance sensors, also referred as GMR, with
adequate system controls in place. The magnetic induction fields are intro-
duced in the material or weld to be tested through eddy current probes. The
control systems often use sinusoidal signal generators as part of the compre-
hensive system.
The process starts with the production of an excitation current, by a
transadmittance amplifier, which is driven by a generator. The voltage signal
obtained from the eddy probe through the GMR is amplified on the low noise
setting on some acceptable gain value. The detected signal is applied to an
analog input processor at about 1.2 MHz. The signals are processed to produce
eddy current image of the flaw, with x and y coordinates for analysis.
Other image improving systems and processing systems are added to
improve the readability of flaws.

ADVANTAGES AND DISADVANTAGES OF THE EDDY

CURRENT INSPECTION SYSTEM
The eddy current inspection process has some very significant advantages and
corresponding limitations.

Applied Welding Engineering. http://dx.doi.org/10.1016/B978-0-12-804176-5.00027-X

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358 SECTION j 3 Nondestructive Testing

Advantages
1. The sensitivity to surface defects is excellent, and the system can detect
defects of 0.5 mm in length.
2. The system can penetrate through several layers of planar interface to
detect defects.
3. Coating up to about 5 mm thick need not be removed for application of the
eddy current inspection process.
4. The system has the ability to measure accurate conductivity through the
use of dedicated conductivity measurement instruments.
5. Preinspection cleaning is not a major concern if major soils and loose or
uneven surface coatings are removed before inspection.
6. The system is often automated, which allows for quick turnaround on mass
inspection of products.
7. The system is portable, allowing it to be used in hard-to-reach spots.

Disadvantages
1. The system is very susceptible to magnetic permeability changes. Small
changes in materials’ permeability can have a pronounced effect on the
eddy currents, especially in ferromagnetic materials. This makes testing of
welds and other ferromagnetic materials difficult but, with modern digital
flaw detectors and probe design, not impossible.
2. The eddy current inspection system is effective only on conductive mate-
rials. The system works only on conductive materials, able to support a
flow of electrical current.
3. The eddy currents always flow parallel to the surface. If a planar defect
does not cross or interfere with the current, then the defect will not be
detected.
4. The flow of eddy current cannot resolve complex geometries of the work to
be inspected. The system also has limitations on the large areas to be
inspected. Large area scanning can be accomplished with the help of
additional aid of special scanning device, supported by a computer, both of
which are not inexpensive.
5. Because of the many factors that affect eddy currents, good training and
expertise are required to interpret eddy current signals. Care is required to
distinguish between relevant and nonrelevant indications.
6. Unless an automated system is used, the inspection data record is not
permanent. Normally, the only permanent record will be a paper print-out
or computer file when automated systems are used.