Introduction to

Eddy Current
 How Eddy Currents works?
 In Eddy Current Testing, an alternating current is
applied to a coil which generates a magnetic field in
and around that coil (also known as the eddy current
probe).
AC Current Magnetic Field

Coil
 How Eddy Currents works?
 When the coil is placed close to a conductive material, the magnetic
field from the coil will create an alternating current in the material.
 This current is in the form of circular loops known as Eddy Currents.
 The eddy currents flowing in the material create an opposing
magnetic field which is detected by the coil.

AC Current
Magnetic Field
in the coil

Eddy Current
Magnetic Field
in the test piece
 How Eddy Currents works?
 Changes in the impedance of the coil are
detected by the eddy current instrument and
can be displayed on an impedance plane.
The impedance plane
is a XY graph where
the X axis represents
resistance and the Y
axis represents
Inductive Reactance.
How Eddy Currents works?
 Definition: The combination of the electrical
properties of a material that affect the flow of
current.
– Resistance (R)
– Inductive Reactance (XL)
 Any change to the eddy currents in the test
material will effect the impedance of the test coil.
 The impedance plane display is a combination of
the amplitude and phase angle of the signal from a
reference point.

5
How Eddy Currents works?
Representation in impedance Air Sound Defect
material material
plane:
– A coil in the air has an
impedance, which results from
a resistance and a reactance.
Lift-off
– If the coil moves closer to a
conductive material, the
Conductive Material
impedance of the coil changes
(because of the eddy currents)
and follows the Lift-off path. Air

Inductive Reactance, X L
– When the coil is over the
surface of the material, the
impedance stabilizes to its Crack
sound value.
– If the coil passes over a defect Lift-off
in the material, the impedance Sound
material
of the coil changes and follows
the Crack path.
Resistance, R
Standard Depth of Penetration
 Depth in a material at which the density of
eddy currents is approximately 37% of the
density at the surface of the material.
– The higher the conductivity, the less the depth of
penetration.
– The higher the permeability, the less the depth of
penetration.
– The lower the frequency of the test coil, the
greater the depth of penetration.
 The frequency of the test coil is the only
parameter controllable by the user.
7
 Standard Depth of Penetration
Eddy Current depth of penetration at High vs. Low Frequencies. As the frequency is
lowered the depth of penetration becomes greater therefore subsurface flaws can be
detected.
EDDY CURRENT200KHz DENSITY AT HIGH VS. LOW FREQUENCIES
200Hz
CURRENT DENSITY
EDDY CURRENTS KEY

HIGH

FLAW

PROBE PROBE

FLAW
LOW

HIGH FREQUENCY LOW FREQUENCY

8
Factors Effecting Eddy Current Testing
 Discontinuities
 Geometry
– Fill Factor/Lift-Off
– Edge Effect
 Conductivity change (in non-ferromagnetic
materials)
 Permeability (in ferromagnetic materials)
 Thickness
– Depth of Penetration
9
Single Channel Instrument

Nortec 500
•EC Flaw detectors
•Conductivity testing
•Coating thickness
measurment
•Dual Frequency
•Rotating scanner
compatible
 Advantages/Disadvantages
 ADVANTAGES:
– Quick, simple and high
sensitive inspection technique
for detecting surface and near
surface defects in conductive
materials.
– Has the ability to determine
electrical conductivity ratings
and non conductive coating
thicknesses.
– Does not require removal of
coatings
– Equipment is handheld and
easily portable
 DISADVANTAGES:
– Limited depth penetration
– Conductive & permeable
material only
– Requires training for
differentiation between many
possible variables effecting the
eddy current test result
– Effected by part geometries
due to edge effects.
Conventional Eddy Current Probe
Common Applications
 Surface Crack Inspections
 Surface crack inspection is the most
common eddy current test.
– Surface probes are used to detect flaws
occurring on the surface of the test piece.
– Factors such as the size and frequency of the
probe as well as the inspection material will
affect the size of the flaws that can be
detected.

0.19 in.

0.25 in.

SURFACE CRACK IN PLATE

2024-T4 ALUMINUM PLATES, 30% IACS.

Surface Crack Inspections

Crack of different
depths

1mm depth 0.5mm depth 0.2mm depth

Corrosion Detection
 Material thinning caused by corrosion on
electrically conductive parts can be detected
using eddy current inspection methods.
 Eddy current can be used for corrosion
detection in both single and dual layer parts.
Corrosion Detection
 Most commonly used in the
aircraft industry for inspecting
aluminum alloys.
 Several inspection methods
are used that require careful
selection of frequency settings
for accurate measurements.
Bolt Hole Inspection
 Eddy Current Bolt Hole Probes can be used
to detect cracking occurring inside fastener
holes.
– Bolt Hole Probes can be rotated manually or
through the use of a rotary scanner.

Manual Bolt Hole Scanning

Rotary Scanner Inspection
18
 Conductivity Testing
 Definition: The ability of a Air Point
material to conduct n
I

electricity. d
– Every material has a different u
ct
conductivity that rates it’s I
inherent ability to conduct v
304 SS
electricity. e
 Only materials that have
some amount of conductivity R Bronze
e
may be tested with Eddy a
Current however the higher ct
the conductivity rating, the a
n
Aluminum
more sensitive the test can c
be. e Copper
 These values can be plotted
on a Conductivity Curve. Resistance

19
Conductivity Testing
 Conductivity is I Air Point

commonly measured n
d
in %IACS, u
ct
International Annealed v
I
304 SS – 2.5%

Copper Standard, in e

which pure copper is R Bronze – 7%

e
rated as 100%. a
ct
a Aluminum – 61%
n
c
e Copper – 100%

Resistance

20
 Conductivity Testing
 Eddy Current inspection is a common way to test a materials
electrical conductivity. It can be used to sort materials as well as
test for heat treatment or heat affected zones of a material.
 Conductivity is commonly measured in units of %IACS based on
the International Annealed Copper Standard or MS/m (Mega
Siemens per Meter).
 As a material’s properties change, it’s conductivity value will also
change allowing for sorting of parts after undergoing various
treatments.

21
Conductivity Testing
Conductivity Testing
 Several factors effect the conductivity of a
material.
– Alloy Aluminum Alloy Conductivity (%IACS)

– Temperature Pure AL 61%

6061-T6 42%
– Hardness 7075-T6 32%

– Coatings 2024-T4 30%

Example of how various alloys effect the conductivity
of a material using Aluminum as a reference.

23
Weld Probe Inspection
 Eddy current weld inspection
probes are used in the
inspection and detection of
open surface cracks on weld
caps and heat affected zones.
 Rapid and cost effective
method of inspecting welds for
surface breaking fatigue
cracks in both ferromagnetic
and non-ferromagnetic
material.
Weld Probe Inspection

Flaw and lift-off

 Weld Probe Inspection
• Paint Probe measures paint thickness to determine if eddy
current is a viable inspection method.
• Eddy current is limited to about .100in (2.54mm) of non-
conductive coating.
• As the coil gets further from the surface, the size of the
detectable flaw will also increase.

1 shim

2 shim

3 shim

4 shim
 Introduction to Eddy
Current Array & Application
Elements in ECA Probe
 Elements are the individual EC probes used to make
the array probe.
 Any type of EC probe can be used as an element. For
example:
1 2 32 Surface array
– Pencil probe:
+ … =

– Sliding probe:
1 2 32 Corrosion array

+ … =
OmniScan ECA multiplexer Time slot #8
#1
#2
#3
#4
#5
#6
#7
 32-channel bridge
probe example: Gen. 1

– For each time slot:

» Generator #1
excites four coils. Input 4
» Inputs #1 to #4
sense the excited
coils. Input 3

– The first acquisition

is completed after 8 Input 2
time slots.
– The process is
repeated at high Input 1

speed.
Representation in C-scan Lift-off Defect
Before calibration
 To calibrate, the signal
from each element is continues very quickly in
The process
The second element data is
rotated in order during to
order to
The cover
first the
element all
acquired shortly after,
the probe.
the elements
data of
is acquired
during time
slot 2,time
andslot 1 and generates
generates the second the
bring the lift-off signalpixel in the C-scan.
first pixel in the C-scan.

to the horizontal axis of Impedance plane C-scan vertical 

By looking at the signal
the impedance plane.
angle in the impedance
Signal from
plane,
The
Whenitlift-off
is there
quite easy
is no to
variation
Acreates
stronger positive element 6
1
2
3
8
4
5
7
differentiate
defect, the a surface
a positive
signal
signal
signalchanges
defect
remains from
onatthe toinred
thein
a vertical
zerolift-off
the
variation.
axis, vertical
thatHowever,
impedance C-scan.
plane.the
corresponds
to vertical
Such thesignals C-scan
orange color ina
produce Rotation to
represents
the vertical
green both
color insignals
C-scan.
the horizontal
with similar colors.
vertical and horizontal C-scan horizontal 
C-scan.

A stronger negative
TheWhen
lift-offthe signal
variation changes
defect creates ato
signal nears
blue in theitsignal
negative
vertical, horizontal
produces C-scan.
on the
only
horizontal
a small color
axis, that corresponds
variation to the light-
on the horizontal C-scan.
blue color in the vertical C-scan.
Representation in C-scan Lift-off Defect
After calibration
 The elements show a
horizontal lift-off signal
in the impedance
plane.
 DefectsLarge
have a strong
lift-off variation may
vertical component.
have a small positive Impedance plane C-scan vertical 
vertical component, that
 Additional gain
creates a yellow maycolor inbe Signal from
element 6 1
used ondetected
the
The Y-axis
the vertical
defect isC­easily
scan.
to
on the vertical C­ Y-gain
increasescanthe
while defect
the small lift-off
However, a small lift-off
signal and variation remains the
improve
variations are not seen.

color contrast in the

horizontal and are not
seen in the vertical C­scan, C-scan horizontal 

vertical C-scan.
which is very useful for
defect detection.

The horizontal
The defectlift-off signal
signal produces
on the horizontal
a clear
C-scan
blue color
is seenon in
theblue,
horizontal
like theC­lift-off
scan.variation.
ECA Advantages
 Time saving
 Large probe coverage
 Easy Imagery (C-Scan)
ECA Instrument
OmniScan ECA:
 Portable (battery operated)
 Modular instrument (ECA, PA, UT)
 C-Scan display
 Up to 32 channel (64 with an external multiplexer)
 Data, Setup and Report Recording capability
 Frequency range: 20 Hz to 6 MHz
 Encoded capability
OmniScan ECA with External Multiplexer
MS5800-E + MultiView 6.1 ACT
Specifications
 Hardware:
– Can use same probe as the OmniScan ECA
– Use standard external Multiplexer for ECA
– Up to 64 channel (128 with two external multiplexer)
– Frequency range: 20 Hz to 6 MHz
– Encoded capability
 Software:
– Data, Setup and Report Recording capability
– Fully Customizable display
– Standard C-Scan
– 3D C-Scan
MS5800 + Multiplexer

External
Multiplexer

ECA Probes
MultiView 6.1 with C-Scan option

Impedance
CScan Plane

3D CScan
ECA Probes
 Standard probe
 Custom Probe
Applications
 ECA in Aerospace
Maintenance procedures already qualified with
OmniScan ECA
 Boeing 737 (NTM 737 NDT 53-30-25 part 6, dec 2004) Update of the
procedure in 2011 with a new probe
– Inspection of doubling edge
– Omniscan ECA + ECA array probe

 Boeing 757 Januray 08

– LAP SPLICE C-SCAN INSPECTION AT THE UPPER ROW OF FASTENERS IN THE OUTBOARD SKIN
– Omniscan ECA + ECA probe

 Boeing 737
– Inspection of lower skin for scribe mark
– Omniscan ECA + ECA probe

 Airbus A330 for corrosion

– Omniscan ECA + ECA probe
Skin lap splices on Boeing 757 airplane
 Inspection of the upper row
of fasteners of the skin lap
splices to detect surface &
near surface cracks.
 The procedure is now
included in the Boeing 757 2.54 mm (0.1”)
nondestructive test 1.6 mm
manual. 1.6 mm (0.063”)
(0.063”)
– It is an optional inspection
procedure to Part 6, 53-30-
06.
– It uses the high resolution
surface array probe SBBR-
026-300-032.
Skin lap splices on Boeing 757 airplane
 Benefits:
– Probe positioning not
critical compared to
EC sliding probe.
– Fast
– Reliable
– Easy to analyze with
the C-scan image.
Scribe mark on Boeing 737 airplane
 Inspection of the lower skin
for detection of scribe
marks.
 These marks appear as
surface crack located
between 1.5 mm (0.06”) to
25.4 mm (1.0”) from the
edge of the upper skin.
 The procedure uses the
high resolution surface
array probe SBBR-026-
300-032.
Scribe mark on Boeing 737 airplane
 Benefits:
– One pass inspection.
– Scribe mark detected
from 1.5 mm (0.06”)
to 25.4 mm (1.0”) to
the edge.
– Reliable inspection
(100% coverage).
– Easy to analyze with
the C-scan image.
Cracks at the doubler edge on Boeing 737
 The inspection is done
from the outside and
cracks as small as 6 mm
(0.240”) long by 0.25 mm
(0.010”) deep located at
the edge of the doubler
can be detected.
 The procedure is now
included in the Boeing 737
nondestructive test Inside of
manual. the skin
 It is an optional inspection
procedure to Part 6, 53-30-
25.
– It uses the SAB-064-030-
032 and an encoder.
 Cracks at the doubler edge on Boeing 737
 Benefits:
– Simple manual inspection.
– Probe positioning is not as
important as for typical EC
sliding probe inspection.
– C-Scan allows easy
location of the doubler
edge for fast and simple
detection of the initiating
cracks.
– Better reproducibility.
– Time saving: up to ten
times faster (typically 10
hours/person for 737
inspections).
Corrosion on Airbus A330/340
 Corrosion between the
first layer and an
internal acoustic panel.
 The procedure uses the
SAA-112-005-032 probe
which has a low
frequency and a large
footprint.
 Raster scanning can be
done to cover larger
area by using the
GLIDER manual
scanner.
Corrosion on Airbus A330/340
 Benefits:
– Simple manual
inspection.
– C-Scan allows easier
detection of small
corrosion
Corrosion
in large area. Rivets
– Better reliability.
– Better reproducibility.
– Time saving:
» Area : 12 m² (1550 ft²)
» Normal time: 9 hours
» With ECA: 1 hour
Raster Scan
 Available with OmniScan ECA
Raster Scan
 Fuselage scan :
– 500mm x 500mm (19,7’’ x 19,7’’)
– Scan resolution: 0,2mm (0,008’’)
GE90 Engine disk dovetail slot Inspection

•100% critical zone coverage

•Inspection time reduced by 70%
•Reliability improvement
•Data saving
GE90 : ECA HF Inspection method
Inspection in the maintenance shop

Disk CHP D1

Tooling
GE90 : ECA HF Inspection method
 Cscan with EDM notches and calibration notches in the
calibration sample

EDM DEFECTS

EDM notch:( 1.5 x 0.7 x 0.1 mm)

INDUSTRIAL
Stress Corrosion Cracking
ECA Detecting SCC
Train Axle Inspection
Gear teeth inspection
Gear teeth inspection
 Time save using ECA probe instead of MPI
 Teeth have only to be roughly cleaned
 No encoder needed but are available
 One probe could be use for a range of gear size
M20-M29, M30-M40 (other range probe could be
design)
 Adjustable carbine
 Custom design for curved teeth could be make
Gear teeth inspection
Gear teeth inspection
ECA Flexible Probe
Specification

 General Purpose ECA probe

 PCB-made, 1 layer
 Coverage of 51 mm (2 in.)
 32 coils
 3mm coil diameter
 Frequency range : 80KHz to 3.125MHz
 Omnidirectional sensitivity (CAB-032-OM2_5)
 Detachable cables (2.5 m, 5 m)
 Bridge and Tx-Rx mode available through two cables
 Encoded capability
 Surface breaking defects detection
 Comparable performance with standard ECA probe (SBB-051-150-032)
Very flexible PCB, not easily destroyed!
FlexArray Applications:
Fan Blade inspection
Fan Blade inspection
Custom
 Customer wants to inspect a specific shape
 Using customer sample or mechanical drawing we can manufacture a probe
holder
Blade root inspection
•Gas turbine generator blade
•Notches at different locations
•Inspection in one pass

Flexible ECA mounted on a shaped holder

Weld Inspection
C-Scan

Scan
Direction

Weld
Area

Position Indications
ruler
Notches identification on 6 in. SS316 sample
length: 6mm, depth: 1,2mm, width: 0.2mm

#1

#2
#3
#4
Notches identification on the C-Scan view

#1
#2 #3
#4

#1
#2 #3
#4
Tubes Inspection
Tubes Inspection
 Tubes inspection:
 Heat Exchangers
 Condensers
 Boilers
 Air Conditioners
 Air Coolers
 Feedwater Heaters
Tubes Inspection
 Common problems found with tubes
 Corrosion
 Erosion
ID Pitting
 Wear
 Crack
 Baffle Cuts
 Pits
Tube Wear at
 Wall Loss Support Sheet

77
Tubes Inspection
 MultiScan MS 5800 designed to meet middle and
high-end NDT testing markets needs
 For maintenance or in-service inspection of
petrochemicals and power plant facilities
 Combines all technologies to tubes
testing
 PC-based
 Powerful software capabilities for
data acquisition and reporting

78
Tubes Inspection
 Multiples Technologies:
 Eddy Current Testing (ECT)
 Remote Field Testing (RFT)
 Magnetic Flux Leakage (MFL)
 Near Field Testing (NFT)
 Internal Rotary Inspection System (IRIS)

79
Multiple Technologies
 Technologies & Applications
IRIS
 

Non-Ferromagnetic Ferromagnetic
oAluminium oCarbon Steel
oBrass o400 Series SS
oCopper oIron
oHastelloy oChromoly 4130
oIncoloy oNickel
Fin Fan
o300 Series SS
oTitanium    

oZirconium

 
ECT RFT MFL/NFT
     
 ECT - GENERAL CONCEPT
 Suitable mainly for non-ferromagnetic material
 Detect pits, corrosion, erosion, axial crack
 Uses multiple frequencies for better analysis and
flaw sizing
 Distinguishes between ID and OD flaws
 The probe needs a good fill factor to remain good
sensitivity (0.85 – 0.9)
 Very fast pulling speed (1m/s)
 Support Plate

Shallow Deep Outside

Outside PIts Pit Hole

ID Groove

Absolute Differential
 Support Plate

Shallow Deep Outside

Outside PIts Pit Hole

ID Groove

Absolute Differential
 Support Plate

Shallow Deep Outside

Outside PIts Pit Hole

ID Groove

Absolute Differential
 Support Plate

Shallow Deep Outside

Outside PIts Pit Hole

ID Groove

Absolute Differential
 Support Plate

Shallow Deep Outside

Outside PIts Pit Hole

ID Groove

Absolute Differential
ECT - GENERAL CONCEPT
ECT - GENERAL CONCEPT
Thank you