Eddy Current
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Transcript of Eddy Current
3 Eddy Current NDE
3.1 Inspection Techniques
3.2 Instrumentation
3.3 Typical Applications
3.4 Special Example
3.1 Inspection Techniques
Coil Configurationsvoltmeter
testpiece
oscillator
excitationcoil
sensing coil
~
voltmeter
testpiece
oscillator
coil
Zo
~
Hall or GMR detector
voltmeter
testpiece
oscillator
excitationcoil
~~
differential coils
coaxial rotatedparallel
Remote-Field Eddy Current Inspection
Remote Field Remote FieldNear Field
exciter coilferromagnetic pipe sensing coil
ln(Hz)
z
low frequency operation (10-100 Hz)
Exponentially decaying eddy currents propagating mainly on the outer surface
cause a diffuse magnetic field that leaks both on the outside and the inside of the pipe.
0
1
rf
/0
zz zH H e
TimeS
igna
l
Main Modes of Operation
single-frequency time-multiplexed multiple-frequency
frequency-multiplexed multiple-frequencypulsed
Time
Sig
nal
Time
Sig
nal
Time
Sig
nal
excited signal (current) detected signal (voltage)
2D
Nonlinear Harmonic Analysis
single frequency, linear response
nonlinear harmonic analysis
Time
Sig
nal
Time
Sig
nal
H
B
ferromagnetic phase(ferrite, martensite, etc.)
3.2 Eddy Current Instrumentation
Single-Frequency Operation
low-passfilter
low-passfilter
oscillatordriver
amplifier
+
_
90º phaseshifter
A/Dconverter
display
probe coil(s)
driverimpedances
processorphase
balanceV-gainH-gain
Vr
Vm
Vq
m s s r o q ocos( ), cos( ), sin( )V V t V V t V V t
m r s s o s o s s1
cos( ) cos( ) cos( ) cos(2 )2
V V V t V t V V t
m q s s o s o s s1
cos( ) sin( ) sin( ) sin(2 )2
V V V t V t V V t
o om r s s m q s scos( ), sin( )
2 2
V VV V V V V V
Nonlinear Harmonic Operation
low-passfilter
low-passfilter
n dividerdriver
amplifier
+
_
90º phaseshifter
A/Dconverter
display
probe coil(s)
driverimpedances
processorphase
balanceV-gainH-gain
oscillatorVr
Vm
Vq
m s1 s1 s2 s2 s3 s3cos( ) cos(2 ) cos(3 ) ...V V t V t V t
r o cos( )V V n t om r s scos( )
2 n nV
V V V
q o sin( )V V n t om q s ssin( )
2 n nV
V V V
Specialized versus General Purpose
Nortec 2000S system Agilent 4294A system*
frequency range* 0.1 – 10 MHz 0.1-80 MHz
probe coil three pencil probes single spiral coil
relative accuracy ≈ 0.1-0.2% ≈ 0.05-0.1%
frequency scanning manual electronic
measurement time ≈ 50 minutes for 21 points ≈ 3 minutes for 81 points
*high-frequency application
I1
V2
11
V1
I2
2212 21,
Probe Considerations
V Z I
*wireZ i L R
sensitivity
thermal stability
eddy current
ferrite-core coil
high coupling
high coupling
eddy current
air-core coil
high coupling
low coupling
eddy current
flat air-core coilhigh coupling
flexible, low self-capacitance, reproducible, interchangeable, economic, etc.
I
V
1 11 12 1
2 12 22 2
V Z Z I
V Z Z I
*
12 12Z i L
topology
3.3 Eddy Current NDE Applications
• conductivity measurement• permeability measurement• metal thickness measurement• coating thickness measurements• flaw detection
3.3.1 Conductivity
Conductivity versus Probe Impedance constant frequency
0
0.2
0.4
0.6
0.8
1
0 0.1 0.2 0.3 0.4 0.5Normalized Resistance
Nor
mal
ized
Rea
ctan
ce
Stainless Steel, 304
CopperAluminum, 7075-T6
Titanium, 6Al-4V
Magnesium, A280
Lead
Copper 70%,Nickel 30%
Inconel
Nickel
Conductivity versus Alloying and Temper IACS = International Annealed Copper Standard
σIACS = 5.8107 Ω-1m-1 at 20 °C
ρIACS = 1.724110-8 Ωm
20
30
40
50
60
Con
duct
ivit
y [%
IA
CS
]
T3 T4
T6
T0
2014
T4
T6T0
6061
T6
T73T76
T0
70752024
T3 T4
T6
T72
T8
T0
Various Aluminum Alloys
Apparent Eddy Current Conductivity
• high accuracy ( 0.1 %)
• controlled penetration depth
specimen
eddy currents
probe coil
magnetic field
0
0.2
0.4
0.6
0.8
1.0
0.10 0.2 0.3 0.4 0.5
lift-offcurves
conductivity
curve(frequency)
Normalized Resistance
Nor
mal
ized
Rea
ctan
ce
= 0
= s
1
23
4
Normalized Resistance
Nor
mal
ized
Rea
ctan
ce
Lift-Off Curvature
inductive(low frequency)
capacitive(high frequency)
“Horizontal” Component
“Ver
tica
l” C
ompo
nent
lift-off
.
conductivity
σ2
σ1
σ
ℓ = s ℓ = 0
“Horizontal” Component
“Ver
tica
l” C
ompo
nent
.
conductivity
lift-off
σ2
σ1
σ
ℓ = s ℓ = 0
Inductive Lift-Off Effect
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
2.0
0.1 1 10 100Frequency [MHz]
Rel
ativ
e Δ
AE
CC
[%
] .
-2.0
-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
2.0
0.1 1 10 100Frequency [MHz]
Rel
ativ
e Δ
AE
CC
[%
] .
63.5 μm
50.8 μm
38.1 μm
25.4 μm
19.1 μm
12.7 μm
6.4 μm
0.0 μm
-10
0
10
20
30
40
50
60
70
80
0.1 1 10 100Frequency [MHz]
AE
CL
[μ
m]
.
-10
0
10
20
30
40
50
60
70
80
0.1 1 10 100Frequency [MHz]
AE
CL
[μ
m]
. .
63.5 μm
50.8 μm
38.1 μm
25.4 μm
19.1 μm
12.7 μm
6.4 μm
0.0 μm
4 mm diameter 8 mm diameter
1.5 %IACS 1.5 %IACS
Instrument Calibration
-0.5
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0.1 1 10 100Frequency [MHz]
AE
CC
Cha
nge
[%]
. 12A Nortec 8A Nortec 4A Nortec 12A Agilent 8A Agilent 4A Agilent 12A UniWest 8A UniWest 4A UniWest 12A Stanford 8A Stanford 4A Stanford
Nortec 2000S, Agilent 4294A, Stanford Research SR844, and UniWest US-450
conductivity spectra comparison on IN718 specimens of different peening intensities.
3.3.2 Permeability
Magnetic Susceptibility
0
0.2
0.4
0.6
0.8
1.0
0.10 0.2 0.3 0.4 0.5
lift-off
frequency(conductivity)
Normalized ResistanceN
orm
aliz
ed R
eact
ance
permeability
Normalized Resistance
Nor
mal
ized
Rea
ctan
ce
0
1
2
3
4
0 0.2 0.4 0.6 0.8 1 1.2
2
3
1
µr = 4permeability
moderately high susceptibility low susceptibility
paramagnetic materials with small ferromagnetic phase content
increasing magnetic susceptibility decreases the apparent eddy current conductivity (AECC)
frequency(conductivity)
Magnetic Susceptibility versus Cold Work
10-4
10-3
10-2
10-1
100
101
0 10 20 30 40 50 60Cold Work [%]
Mag
neti
c S
usce
ptib
ilit
y
SS304L
IN276
IN718
SS305
SS304SS302
IN625
cold work (plastic deformation at room temperature) causesmartensitic (ferromagnetic) phase transformation
in austenitic stainless steels
3.3.3 Metal Thickness
Thickness versus Normalized Impedance
thickness loss due to corrosion, erosion, etc.
probe coil
scanning
0
0.2
0.4
0.6
0.8
1
0 0.1 0.2 0.3 0.4 0.5 0.6
thickplate
Normalized Resistance
Nor
mal
ized
Rea
ctan
ce
thinplate
lift-off
thinning
-0.2
0
0.2
0.4
0.6
0.8
1
0 1 2 3Depth [mm]
Re
{ F
}
f = 0.05 MHz f = 0.2 MHz f = 1 MHz
aluminum (σ = 46 %IACS)
/ /( ) x i xF x e e
Thickness Correction
1.0
1.1
1.2
1.3
1.4
0.1 1 10
Frequency [MHz]
Con
duct
ivit
y [%
IAC
S]
1.0 mm 1.5 mm 2.0 mm 2.5 mm 3.0 mm 3.5 mm 4.0 mm 5.0 mm 6.0 mm
thickness
Vic-3D simulation, Inconel plates (σ = 1.33 %IACS)
ao = 4.5 mm, ai = 2.25 mm, h = 2.25 mm
3.3.4 Coating Thickness
Non-conducting Coating
non-conductingcoating
probe coil, ao
t
d
ℓ
conducting substrate
ao > t, d > δ, AECL = ℓ + t
-10
010
2030
4050
6070
80
0.1 1 10 100Frequency [MHz]
AE
CL
[μm
]
-10
010
2030
4050
6070
80
0.1 1 10 100Frequency [MHz]
AE
CL
[μm
]
63.5 μm
50.8 μm
38.1 μm
25.4 μm
19.1 μm
12.7 μm
6.4 μm
0 μm
ao = 4 mm, simulated
lift-off:
ao = 4 mm, experimental
Conducting Coating
conductingcoating
probe coil, ao
t
d
ℓ
conducting substrate (µs,σs)
approximate: large transducer, weak perturbation
equivalent depth:
e1
AECC( )2 s s
ff
21
( ) AECC4 s s
zz
se 2
analytical: Fourier decomposition (Dodd and Deeds)
numerical: finite element, finite difference, volume integral, etc.
(Vic-3D, Opera 3D, etc.)
zJe
z = δe
Simplistic Inversion of AECC Spectra
AE
CC
Cha
nge
[%]
-0.2
0
0.2
0.4
0.6
0.8
1
1.2
0.001 0.1 10 1000
Frequency [MHz]
AE
CC
Cha
nge
[%]
-0.2
0
0.2
0.4
0.6
0.8
1
1.2
0.001 0.1 10 1000
Frequency [MHz]
uniform
Gaussian
0.254-mm-thick surface layer of 1% excess conductivity
3.3.5 Flaw Detection
Impedance Diagram
Normalized Resistance
0
0.2
0.4
0.6
0.8
1
0 0.1 0.2 0.3 0.4 0.5
conductivity(frequency)
crackdepth
flawlessmaterial
ω1
lift-off
Nor
mal
ized
Rea
ctan
ce
ω2
apparent eddy current conductivity (AECC) decreasesapparent eddy current lift-off (AECL) increases
Crack Contrast and Resolution
probe coil
crack
0
0.2
0.4
0.6
0.8
1
0 1 2 3 4 5Flaw Length [mm]
Nor
mal
ized
AE
CC
semi-circular crack
-10% threshold
detectionthreshold
ao = 1 mm, ai = 0.75 mm, h = 1.5 mm
austenitic stainless steel, σ = 2.5 %IACS, μr = 1
Vic-3D simulation
f = 5 MHz, δ 0.19 mm
Eddy Current Images of Small Fatigue Cracks
Al2024, 0.025-mil crack Ti-6Al-4V, 0.026-mil-crack
0.5” 0.5”, 2 MHz, 0.060”-diameter coil
probe coil
crack
Crystallographic Texture J E
1 1 1
2 2 2
3 3 3
0 0
0 0
0 0
J E
J E
J E
generally anisotropic hexagonal (transversely isotropic)
1 1 1
2 2 2
3 2 3
0 0
0 0
0 0
J E
J E
J E
cubic (isotropic)
1 1 1
2 1 2
3 1 3
0 0
0 0
0 0
J E
J E
J E
σ1 conductivity normal to the basal plane
σ2 conductivity in the basal plane
θ polar angle from the normal of the basal plane
σm minimum conductivity in the surface plane
σM maximum conductivity in the surface plane
σa average conductivity in the surface plane
2 2a 1 2( ) ½ [ sin (1 cos )]
2 2n 1 2( ) cos sin
M 2
1 2
2 2m 1 2( ) sin cos
x1
x3
x2basal plane
θ
surface plane
σn
σm
σM
Electric “Birefringence” Due to Texture
1.00
1.01
1.02
1.03
1.04
1.05
0 30 60 90 120 150 180
Azimuthal Angle [deg]
Con
duct
ivit
y [%
IAC
S]
highly textured Ti-6Al-4V plate equiaxed GTD-111
1.30
1.32
1.34
1.36
1.38
1.40
0 30 60 90 120 150 180
Azimuthal Angle [deg]
Con
duct
ivit
y [%
IAC
S]
500 kHz, racetrack coil
Grain Noise in Ti-6Al-4V
as-received billet material solution treated and annealed
heat-treated, coarse
heat-treated, very coarse heat-treated, large colonies equiaxed beta annealed
1” 1”, 2 MHz, 0.060”-diameter coil
Eddy Current versus Acoustic Microscopy
5 MHz eddy current 40 MHz acoustic
1” 1”, coarse grained Ti-6Al-4V sample
InhomogeneityAECC Images of Waspaloy and IN100 Specimens
homogeneous IN100
2.2” 1.1”, 6 MHz
conductivity range 1.33-1.34 %IACS
±0.4 % relative variation
inhomogeneous Waspaloy
4.2” 2.1”, 6 MHz
conductivity range 1.38-1.47 %IACS
±3 % relative variation
Conductivity Material Noise
1.30
1.32
1.34
1.36
1.38
1.40
1.42
1.44
1.46
1.48
1.50
0.1 1 10Frequency [MHz]
AE
CC
[%
IAC
S]
Spot 1 (1.441 %IACS)
Spot 2 (1.428 %IACS)
Spot 3 (1.395 %IACS)
Spot 4 (1.382% IACS)
as-forged Waspaloy
no (average) frequency dependence
Magnetic Susceptibility Material Noise1” 1”, stainless steel 304
f = 0.1 MHz, ΔAECC 6.4 %
f = 5 MHz, ΔAECC 0.8 %
intact
f = 0.1 MHz, ΔAECC 8.6 %
f = 5 MHz, ΔAECC 1.2 %
0.51×0.26×0.03 mm3 edm notch
3.4 Special Example
Residual Stress Assessment
106102
intact (no residual stress)
with opposite residual stress
Fatigue Life [cycles]
104 1080
500
1000
1500
endurancelimit
service load
life timenatural
life timeincreased
Alt
erna
ting
Str
ess
[MP
a]
Residual stresses have numerous origins that are highly variable.Residual stresses relax at service temperatures.
Surface-Enhancement TechniquesLow-Plasticity Burnishing (LPB)Shot Peening (SP) Laser Shock Peening (LSP)
Depth [mm]0 0.2 0.4 0.6 1.0 1.2
200
0
-200
-400
-600
-800
-1000
Res
idua
l Str
ess
[MP
a]
SP Almen 12ASP Almen 4A
LSPLPB
Ti-6Al-4V
0 0.2 0.4 0.6 1.0 1.2Depth [mm]
Col
d W
ork
[%] 40
30
20
10
0
50
SP Almen 12ASP Almen 4A
LSPLPB
Ti-6Al-4V
Piezoresistive Effect
Electroelastic Tensor:
1 0 11 12 12 1
2 0 12 11 12 2
3 0 12 12 11 3
/ /
/ /
/ /
E
E
E
11 120/
/a
ipip E
Isotropic Plane-Stress ( and ) :1 2 ip 3 0
parallel, normal, circular
F F
Adiabatic Electroelastic Coefficients:*11 11 th *12 12 th
-40-20
020406080
Time [1 s/div]
Axial Stress [ksi]
Time [1 s/div]1.3971.3981.399
1.41.4011.4021.403
Conductivity [%IACS]
IN 718, parallel
Material Types
parallel
-0.004
-0.002
0
0.002
0.004
-0.001 0 0.001 0.002
ua / E
normal
Copper
Ti-6Al-4V
parallel
-0.004
-0.002
0
0.002
0.004
-0.002 0 0.002 0.004
ua / E
normalparallel
-0.004
-0.002
0
0.002
0.004
-0.001 0 0.001 0.002
ua / E
normal
Al 2024
parallel
-0.004
-0.002
0
0.002
0.004
-0.001 0 0.001 0.002
ua / E
normal
Al 7075
Waspaloy
parallel
-0.004
-0.002
0
0.002
0.004
-0.002 0 0.002 0.004
ua / E
normal
IN718
parallel
-0.004
-0.002
0
0.002
0.004
-0.002 0 0.002 0.004
ua / E
normal
XRD and AECC Measurements
-2000
-1500
-1000
-500
0
500
0 0.2 0.4 0.6 0.8Depth [mm]
Res
idua
l Str
ess
[MP
a]
Almen 4A Almen 8A Almen 12A
Almen 16A
-1
0
1
2
3
0.1 1 10Frequency [MHz]
Con
duct
ivit
y C
hang
e [%
] Almen 4A Almen 8A Almen 12A
Almen 16A
0
10
20
30
40
50
0 0.2 0.4 0.6 0.8C
old
Wor
k [%
]
Almen 4A Almen 8A Almen 12A
Almen 16A
Depth [mm]
before (solid circles) and after full relaxation for 24 hrs at 900 °C (empty circles)
-2000
-1500
-1000
-500
0
500
0 0.2 0.4 0.6 0.8Depth [mm]
Res
idua
l Str
ess
[MP
a]
Almen 4A Almen 8A Almen 12A
Almen 16A0
10
20
30
40
50
0 0.2 0.4 0.6 0.8
Col
d W
ork
[%]
Almen 4A Almen 8A Almen 12A
Almen 16A
Depth [mm]
-1
0
1
2
3
0.1 1 10Frequency [MHz]
Con
duct
ivit
y C
hang
e [%
] Almen 4A Almen 8A Almen 12A
Almen 16A
Waspaloy
Thermal Stress Relaxation in Waspaloy
Waspaloy, Almen 8A, repeated 24-hour heat treatments at increasing temperatures
0.1 0.16 0.25 0.4 0.63 1 1.6 2.5 4 6.3 10
Frequency [MHz]
0
0.1
0.2
0.3
0.4
0.5
0.6
App
aren
t Con
duct
ivit
y C
hang
e [%
] intact 300 °C 350 °C 400 °C 450 °C 500 °C 550 °C 600 °C 650 °C 700 °C 750 °C 800 °C 850 °C 900 °C
The excess apparent conductivity gradually vanishes during thermal relaxation!
XRD versus Eddy Current
-0.2
0.0
0.2
0.4
0.6
0.8
1.0
1.2
0.01 0.1 1 10Frequency [MHz]
AE
CC
Cha
nge
[%]
eddy current
0.0 0.5 1.0 1.5Depth [mm]
Col
d W
ork
[%]
.
0
5
10
15
20
XRD
.
-1400
-1200
-1000
-800
-600
-400
-200
0
200
0.0 0.5 1.0 1.5Depth [mm]
Res
idua
l Str
ess
[MP
a]
eddy current XRD
inversion of measured AECC in low-plasticity burnished Waspaloy
0
10
20
30
40
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7Depth [mm]
Col
d W
ork
[%]
.
Almen 4A (XRD)
Almen 8A (XRD)
Almen 12A (XRD)
-1800
-1600
-1400
-1200
-1000
-800
-600
-400
-200
0
200
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Depth [mm]
Res
idua
l Str
ess
[MP
a]
.
Almen 4A (AECC)
Almen 8A (AECC)
Almen 12A (AECC)
Almen 4A (XRD)
Almen 8A (XRD)
Almen 12A (XRD)
50 MHz
XRD versus High-Frequency Eddy Current
shot peened IN100 specimens of Almen 4A, 8A and 12A peening intensity levels