Eddy Current Testing

How does it work?

In standard eddy current testing, a circular coil carrying an AC current is plac
ed in close proximity to an electrically conductive specimen. The alternating cu
rrent in the coil generates a changing magnetic field, which interacts with the
test object and induces eddy currents. Variations in the phase and magnitude of
these eddy currents can be monitored using a second 'search' coil, or by measuri
ng changes to the current flowing in the primary 'excitation' coil. Variations i
n the electrical conductivity or magnetic permeability of the test object, or th
e presence of any flaws, will cause a change in eddy current flow and a correspo
nding change in the phase and amplitude of the measured current. This is the bas
is of standard (flat coil) eddy current inspection, the most widely used eddy cu
rrent technique.
The penetration depth of eddy currents is indicated by a parameter known as the
'skin depth'. This is dependent upon operating frequency (lower frequencies give
deeper penetration) and specimen conductivity and permeability, and is typicall
y between 5 m (0.2 thou) and 1 mm (0.04") or more. For most inspection applicatio
ns, eddy current probe frequencies in the range 1kHz to 3MHz are used.
To help simplify the often complex eddy current response, changes in amplitude a
nd phase are displayed on an impedance plane diagram (a plot of system inductanc
e against resistance). In this way, changes in operator variability, such as the
distance between the probe and the test piece (lift-off) will cause a horizonta
l shift in the spot forming the trace, while the presence of any flaws causes th
e spot to shift vertically.
What will it find?
Standard eddy current testing is essentially a near-surface technique. It is use
ful for detecting surface-breaking or near-surface cracking and variations in ma
terial composition. It can also be used to measure the thickness of non-electric
ally conductive coatings on electrically conductive substrates. In most steels,
eddy current testing is limited to surface examination due to the relatively hig
h permeability of these materials. The inspection of welds in ferritic steels ca
n be problematic as the response is dominated by changes in the magnetic permeab
ility across the weld. However, special types of probes have been developed (dif
ferential coils) to lessen the effects to material changes and permit the detect
ion of small flaws.
Where is it used?
In general, standard eddy current methods are only used in plant inspection for
non-ferritic materials (where eddy current penetration is deeper) or for special
applications, such as in the inspection of heat exchanger tubing for cracking o
r corrosion thinning.