Testing of Welded Tubes with the latest developed

Eddy Current Multi Sensor Technology

INSTITUT DR. FOERSTER

Dagmar Sy, Hartmut Kümmel, Rainer Sailer

1. Basic scope

Eddy-current testing is a recognized method of testing longitudinally welded tubing and has
become established for numerous different applications in recent years.

Technological changes in the welding process are impacting on eddy current testing. In this article
we describe new potential applications of eddy current testing in the manufacture of welded
ferromagnetic stainless steel-, NiCr alloy-, Cu- and Ti -Tubes, fig. 1.

Fig. 1 longitudinally welded tubes DEFECTOMAT DS

Multi sensor technology DEFECTOSCAN® and multi channel DEFECTOMAT® DS stand for the
detection of finest surface defects.

This is reflected, in particular, in the national and international test specifications:

• SEP 1925, 1917

• ASTM E309,E 426,E 1033
• JIS G 0583
• ISO 9302, 9304
• EN 10246 - 1 to 3

Different welding methods are used in the manufacturing process, depending on the type of
material used and such geometry factors as diameter and wall thickness. The methods used
include the following, for example:
 • DC welding for tubing made of magnetizable steel, especially for small tube diameters
which may possibly be reduced even further; HF resistance welding is used for larger tube
dimensions.

• Tubing made of non-magnetizable steel (austenitic steel) are normally TIG-welded or laser-
welded.

• Both welding methods can be used for tubing made of Al, Cu, Ti and NiCr-alloys.

• The advantage of laser welding lies in the higher welding speeds and the smaller area that is
actually affected by welding. The weld seam is therefore very narrow. Consequently welding
flaws are much smaller; the tiniest of pores must be detected. Neither encircling nor segment
coils are sufficiently sensitive. Small multi sensors such as those used with DEFECTOSCAN
are perfectly suitable, however. Fig. 2 and 3

Fig. 2 Eddy Current encircling and segment coils

Fig. 3 Descretisation leads to Array Technology DEFECTOSCAN

2. Uses

Eddy-current testing can be performed either during the welding process or in a separate test line
with different objectives. Fig. 4 and 5
 Fig. 4 Eddy Current Testing directly in the Welding Line with Segment coils

Fig. 5 Eddy Current Testing in the Finishing Line with encircling coils

2.1 Off line testing

The final inspection of the finished tubes is performed in finishing lines in accordance with the
above test specifications. Holes of specified diameter through the tube wall are required as
reference defects for setting the test equipment. The diameter of the holes increases in
accordance with the tube diameter. In the case of acceptance tests, the entire tube
circumference is normally tested by an encircling coil. This applies in particular when testing to
SEP 1925/ EN 10246-1and -2 as a substitute for hydraulic leak testing. As a replacement for the
leak-tightness test, however, the test standards for tubes generally demand a test of the
complete tube with encircling through-type coils. Either only the differential channel or both the
differential and absolute channel is used. A catalogue of defects is normally compiled by the user
for the verification of natural defects. Outside the welding line it is also virtually impossible or far
too difficult to position the weld so that it can be tested exclusively.

2.2 Inline testing

Probes or segmented coils with locally limited effect area are used for such tests, since only the
weld itself is tested. Despite the interfering variables coming from the welding process, the test
can also be applied immediately downstream of the welding point. This follows the trend in
quality tests towards in-process inspections, i.e. the test is integrated into a very early stage of
the manufacturing process.

However, that does not mean that acceptance testing at the end of the manufacturing process is
not longer required. Final inspection of the tube as a whole is not only necessary, but also
specified if the tubing is subsequently to pass through additional production stages, such as
drawing, heat treatment, shaping, straightening, etc.

3. Possible applications

3.1 Eddy-current testing in the welding line using sensor arrays, Fig 6
Especially for TIG and laser welded tubing it is realised by setting up two test stations, one
station equipped with a sensor array, the second station with an encircling coil. Each station
works with separate signal recording up to the sorting and/or marking stage. The results of both
stations are collated again for the report and for data saving.

3 sensor array
Encircling
coil

Fig. 6 Two testing stations , one with sensor array and one with encircling coil

In order to cover the weld seam completely, even where the seam drift is minimal, three
sensors at least or multi sensor array are set up immediately after welding. The tracks may
even overlap to be quite sure that the tiniest pores are also detected.

In keeping with the low conductivity of titan and stainless steel, frequencies of around 100 kHz
are used for optimal testing.

3.2 Eddy-current testing in the welding line using segment coils, Fig. 7

Fig. 7 Segment coil holder with or without magnetisation

Segmental coils are the ideal choice if the weld migrates out of range of the probe at the potential
test point. Such segmental coils scan a defined angle section of the tube's perimeter and can be
swung out or lifted off the welding line just as easily as probes. When testing Fe-tubing, however,
DC field magnetization is normally required on account of the larger volume of material scanned
by segment coils in comparison to smaller sensors described above.

The carriage with stand for segmental coils is used if the sensor system has to be mechanically
guided on the tube surface because the tubing is not supported effectively at the test point, to
maintain a constant gap between coil and tube surface.
The segmental coils must match the tube diameter. The number of segmental coils for the
production range can be minimized to cut costs, depending on the degree to which the weld
migrates..

3.3 Eddy-current testing in the welding line using encircling coils, Fig. 8
The encircling coils must match the tube diameter. It may be possible to reduce the number and
cost of the coils required by positioning the tube out-of-centre. One point that must be
remembered is that, compared with segmental coils, the flaw sensitivity of encircling coils
decreases with increasing diameter, especially when large tubes (> 50 mm in diameter) are
being tested.

Fig. 8 Magnetisation yoke and coil holder for encircling coils

3.2 Eddy-current testing of profiled tubing, Fig. 9

Pprofiled tubes are usually used as a design or decorative element and therefore subject to
less stringent requirements.

Testing applies for tubes which are profiled before welding or apply if the tubes are welded as
a round tube and then profiled.

Some users prefer two-fold testing, first on the round tube and again after shaping, so that
any dull welds ruptured during the shaping process can be detected reliably. The two tests
are performed consecutively in the same line and the eddy-current results are compiled and
logged accurately for each location by a DEFECTOMAT DS 2-channel electronic.
 Fig. 9 Multi Station application with EC test before and after forming the tube profile

4. Test Unit: DEFECTOMAT DS

The DEFECTOMAT DS provides the possibility for a simultaneous eddy current testing with
several sensor systems for individual statistics concerning welding process monitoring and
final inspection according to international Standards. Fig. 10

Of course the DEFECTOTEST DS platform with its modern Computer technology is a great
additional benefit. This means simple operation by a touch sensitive active matrix display with
an online help-function. A relational database system offers the opportunity for extended
analysis and storage of test data. World wide standardised data interfaces are
implemented, allowing with the use of the FOERSTERnet® a decentralised operation and
data storage. Via internet or phone our experts can directly communicate with the equipment
at your plant. Fig. 11
Fig. 11 DEFECTOMAT DS Multi channel system offers access via FOERSTERnet and via Ethnernet
interface

Further features:

• WINDOWS-based operator guidance with application assistants

• Real-time visualization of the test process with original signal display
• Comprehensive test documentation for each component and each flaw
• Continuous monitoring of operating safety
• The FOERSTERnet enables free access to the DEFECTOMAT DS by any number of
computers
• An Ethernet interface and TCP/IP protocol enable unrestricted integration in existing
production and quality networks
• Reliable adjustment sets can be stored on the hard disk or centrally in the network
• The test results are saved in a database. Additional evaluations can be implemented
easily using standard Windows software, e.g. MS ACCESS

5. Summary

FORSTER can offer every test variation. The solutions selected by the individual user for his
individual production facilities ultimately depend on his own test philosophy. We will gladly
provide advice and demonstrate the various possible applications in trials on the customer's
own tubes.