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Eddy current testing uses electromagnetic induction to detect flaws in metal parts. An alternating current is passed through a coil, which creates a magnetic field that induces eddy currents in the part. Flaws that disrupt the eddy currents cause changes in the coil's impedance that are measured to find and characterize defects, making it a quick and cost-effective non-destructive testing method. Factors like material properties, frequency, geometry, and probe type affect eddy current behavior and are considered in test setup and evaluation.
Eddy current testing uses electromagnetic induction to detect flaws in metal parts. An alternating current is passed through a coil, which creates a magnetic field that induces eddy currents in the part. Flaws that disrupt the eddy currents cause changes in the coil's impedance that are measured to find and characterize defects, making it a quick and cost-effective non-destructive testing method. Factors like material properties, frequency, geometry, and probe type affect eddy current behavior and are considered in test setup and evaluation.
Eddy current testing uses electromagnetic induction to detect flaws in metal parts. An alternating current is passed through a coil, which creates a magnetic field that induces eddy currents in the part. Flaws that disrupt the eddy currents cause changes in the coil's impedance that are measured to find and characterize defects, making it a quick and cost-effective non-destructive testing method. Factors like material properties, frequency, geometry, and probe type affect eddy current behavior and are considered in test setup and evaluation.
can test metals for flaws either during the manufacturing process or as a consequence of age or environment. It is a highly sensitive technique and completely Non-Destructive. (No damage to test object) It is quick, safe and cost-effective to use.
Eddy Current Testing-Basic
Training Eddy Current Theory When a voltage is applied to a circuit containing resistive elements, current flows according to ohms law I=V/R or V=I.R
Eddy Current Testing-Basic
Training Eddy Current Theory If a circuit consists of more than one element, the overall voltages, resistance and capacitance can be calculated as follows
Training Theory Electromagnetic Induction Current passing through a coil creates a magnetic field
A moving magnetic field would
induce a voltage in an electrical conductor
Eddy Current Testing-Basic
Training
The meter needle will deflect one
way when current is applied and then back the other way when it is removed A voltage is only induced when the magnetic field is changing.
Eddy Current Testing-Basic
Training
A voltage is also induced in the
first winding, apposing the change in the applied voltage Inductance is defined as Induced Voltage = L di/dt
Eddy Current Testing-Basic
Training
If an AC current flows through an
inductor,the voltage across the inductor will be at maximum when the rate of change of current is greatest. For a sinusoidal wave, this is at the point where the actual current is zero
Eddy Current Testing-Basic
Training
The voltage applied to an inductor
reaches its maximum value a quarter cycle before the current does
The voltage leads the current by
90 degrees
Eddy Current Testing-Basic
Training
The value of the voltage and
current can be calculated as follows V = I.XL
XL = inductive reactance (XL=2 pi f L)
F = frequency in Hz
Eddy Current Testing-Basic
Training
Current flow in AC Circuits Impedance
Same basic principle as in DC circuits, but
the maximum voltage across the resistance coincides with the zero voltage across the inductor and vice versa
Eddy Current Testing-Basic
Training
Current flow in AC circuits Impedance
Eddy Current Testing-Basic
Training
We can represent this graphically
using a vector diagram
Eddy Current Testing-Basic
Training Eddy Current Theory Testing When an AC current flows in a coil in close proximity to a conducting surface, the magnetic field of the coil will induce circulating(eddy) currents in that surface. The magnitude and phase of the eddy currents will affect the loading on the coil and thus its impedance
Eddy Current Testing-Basic
Training
Eddy Current Theory - Testing
Eddy Current Testing-Basic
Training
Eddy Current Theory - testing
Eddy Current Testing-Basic
Training
A deep crack in the surface below
the coil will interrupt or reduce the eddy current flow, thus decreasing the loading of the coil and increasing its effective impedence By monitoring the voltage across the coil we can detect changes in the test material
Eddy Current Testing-Basic
Training Eddy Current Theory Testing Cracks MUST interrupt the surface eddy current flow to be detected
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Material conductivity - Greater the conductivity greater the eddy current flow - conductivity depends on material composition, heat treatment, work hardening etc etc
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Permeability Described as the ease with which a material can be magnetised For nFe metals and austinitic S.Steel, the permeability (mr)is 1 (as for free space) For Fe metals the value of mr may be several hundred, thus influencing the eddy current response Permeability may vary within a metal part due to localised stresses, heating effects etc
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Frequency
Eddy current response is greatly
affected by the test frequency, but this property can be controlled
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Geometry Curvature,edges,grooves etc will affect the eddy current response When the material thickness is less than the effective depth of penetration, this will also affect the eddy current response
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Proximity / Lift-off The closer the probe coil to the surface, greater the effect on the coil. This has two main effects 1. Lift off signal as the probe is moved on and off the surface 2. A reduction in sensitivity as the coil to product spacing increases
Eddy Current Testing-Basic
Training Factors affecting Eddy Current response Depth of Penetration The eddy current density is greatest on the surface of the metal and declines with depth Depth of penetration -decreases with an increase in frequency -decreases with an increase in conductivity -decreases with an increase in permeability
Eddy Current Testing-Basic
Training
Factors affecting Eddy Current
response
Eddy Current Testing-Basic
Training
Effective Depth of Penetration
It is defined as three times the
standard depth, where eddy current density has fallen to 3% of the surface value
Eddy Current Testing-Basic
Training
The Impedance Plane
This is a graphical representation of
the complex probe impedance where the X-value represents the resistance and the Y-value represents the inductive reactance
Eddy Current Testing-Basic
Training
The Impedance Plane
Eddy Current Testing-Basic
Training The Impedance Plane The display of CRT instrument represents a window in to the impedance plane
Above example shows probe on Aluminium
Eddy Current Testing-Basic
Training Coil Configurations Absolute (Single Coil) Surface probes probe axis normal to the surface Encircling coils the product to be tested is inserted through a circular coil ID probes for heat exchanger inspection (normally wound with the coil axis along the center of the tube) Absolute probes are good for metal sorting and detection of cracks
Eddy Current Testing-Basic
Training Coil Configurations Differential (two coils) Differential probe has two sensing elements looking at different areas of the material being tested. The instrument shows the difference between the eddy current conditions at the two points Good for detection of small defects and are relatively unaffected by lift-off, temperature changes and external interference
Eddy Current Testing-Basic
Training
Differential probe response
The figure of 8 is formed based on response from first
element and then the second element move over the defect The lift off is cancelled out, but there is still wobble response as the probe is moved and tilted slightly
oscillator and one of more sensor windings connected to the measurement circuit
Eddy Current Testing-Basic
Training Coil Configurations Reflection/driver pickup probes Advantages Driver and pickup coils can be separately optimised for their intended purpose Wider frequency range The larger driver coil gives more even field, resulting in better penetration and lift-off characteristics
Eddy Current Testing-Basic
Training
Typical Coil Connections Bridge
The two coils (differential or absolute + balancing coil) form
the legs of the bridge. When the bridge is balanced, the measured voltage will be zero. Any change in the condition of either coil will result in an unbalanced bridge, the degree of imbalance corresponds to the change in coil impedance
Eddy Current Testing-Basic
Training
Typical Coil Connections Driver pickup
The essential elements are same as bridge type. The
necessary changes can be achieved by simple switching or probe connection changes
Eddy Current Testing-Basic
Training Practical testing requirements -A suitable probe -An instrument with the necessary capabilities -A good idea of size, location and type of flaws -A suitable test standard to set up the equipment -A procedure or accept/reject criteria -Operator expertise to understand and interpret the results
Eddy Current Testing-Basic
Training Eddy Current Instruments -Special purpose equipment -Crack Detectors -Portable Impedance plane equipment -Systems Eddy Current units
Eddy Current Testing-Basic
Training
Special Purpose Equipment
Coating Thickness Meters,
Conductivity meters etc Generally designed to give a digital readout without demanding interpretation of an indication
Eddy Current Testing-Basic
Training
Crack Detectors
Generally operates at a restricted
number of frequencies typically several hundred KHz, meter or bargraph display Suitable for surface crack detection and simple sorting applications
Eddy Current Testing-Basic
Training
Portable Impedance Plane
Equipment
Impedance plane display on CRT,
wide frequency ranges, multifrequency operation to reduce specific interfering effects
Eddy Current Testing-Basic
Training
Systems Eddy Current Units
Intended for factory operation, often
in automatic or semi-automatic inspection mode.
Eddy Current Testing-Basic
Training Eddy Current testing Applications -Surface crack detection -Non-ferrous metal sorting -Sub-surface crack/corrosion detection -Heat exchanger tube testing -In-line inspection of steel tubing -Ferrous Weld Inspection