EDDY CURRENT TESTING

FEATURED NDT METHOD

INSPECTION KNOWLEDGE

Eddy Current Testing (ECT)

What is Eddy Current Testing? How Does Eddy Current Testing Work?
Eddy current testing is a non-destructive testing (NDT) The process relies upon a material characteristic known as
inspection method used for a variety of purposes, including electromagnetic induction. When an alternating current is
for flaw detection, material and coating thickness passed through a conductor – a copper coil for example – an
measurements, material identification and establishing the alternating magnetic field is developed around the coil and
heat treatment condition of certain materials. the field expands and contracts as the alternating current
rises and falls. If the coil is then brought close to another
Eddy current testing is one of several non-destructive testing electrical conductor, the fluctuating magnetic field
methods that uses the electromagnetism principle for flaw surrounding the coil permeates the material and, by Lenz’s
detection in conductive materials. A specially designed coil Law, induces an eddy current to flow in the conductor. This
energized with an alternating-current is placed in proximity eddy current, in turn, develops its own magnetic field. This
to the test surface, generating a changing magnetic field that ‘secondary’ magnetic field opposes the ‘primary’ magnetic
interacts with the test-part and produces eddy currents in the field and thus affects the current and voltage flowing in the
vicinity. coil.

Variations in the changing phases and magnitude of these

eddy currents are then monitored using a receiver-coil or by
measuring changes to the alternate current flowing in the
primary excitation-coil.

The electrical conductivity variations, the magnetic

permeability of the test-part, or the presence of any
discontinuities, will cause a change in the eddy current and a
corresponding change in phases and amplitude of the
measured current. The changes are shown on a screen and
are interpreted to identify defects.

Any changes in the conductivity of the material being

Standards and Calibration examined, such as near-surface defects or differences in
All the systems must be calibrated using appropriate thickness, will affect the magnitude of the eddy current. This
reference standards – as for any NDT method and is an change is detected using either the primary coil or the
essential part of any eddy current testing procedure. The secondary detector coil, forming the basis of the eddy current
calibration blocks must be of the same material, heat testing inspection technique.
treatment condition, shape and size of the item to be tested.
Permeability is the ease in which a material can be
For defect detection, the calibration block contains artificial magnetized. The greater the permeability the smaller the
defects that simulate defects, whereas, for corrosion depth of penetration. Non-magnetic metals such as austenitic
detection, the calibration block has different thicknesses. The stainless steels, aluminum and copper have very low
eddy current method requires a highly skilled operator - permeability, whereas ferritic steels have a magnetic
training is essential. permeability several hundred times greater.

Eddy current density is higher, and defect sensitivity is

greatest, at the surface and this decreases with depth. The
rate of the decrease depends on the “conductivity” and
“permeability” of the metal. The conductivity of the material
affects the depth of penetration. There is a greater flow of
eddy current at the surface in high conductivity metals and a
decrease in penetration in metals such as copper and
Common eddy current reference standards aluminum.
include:
The depth of penetration may be varied by changing the
► Conductivity standards. frequency of the alternation current – the lower the
► Flat plate discontinuity standards. frequency, the greater depth of penetration. Therefore, high
frequencies can be used to detect near-surface defects and
► Flat plate metal thinning standards. (Step or tapered wedges) low-frequencies to detect deeper defects. Unfortunately, as
► Tube discontinuity standards. the frequency is decreased to give greater penetration, the
defect detection sensitivity is also reduced. There is therefore,
► Tube metal thinning standards. for each test, an optimum frequency to give the required
► Hole (with and without fastener) discontinuity standards. depth of penetration and sensitivity.

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ECT Applications
Inspection of parts or components including: Welded joints - Bores of in-service tubes - Bores of bolt
holes - Metal tubes - Friction stir welds - Gas turbine blades - Nozzle welds in nuclear reactors – Cast Iron Bridge – Lack
of fusion - Identification of both ferrous and non-ferrous metals and with certain alloys in particular the aluminum alloys -
Establishing the heat treatment condition - Determining whether a coating is non-conductive - Heat treat verification of
metals - Generalized corrosion (particularly in the aircraft industry for the examination of aircraft skin and more.

Material
Sorting

Thickness EDDY CURRENT Tube

Assessment Applications Testing

Defect
Detection

Eddy Current Advantages Eddy Current Limitations

► Able to detect surface and near-surface cracks as ► Can only be used on conductive materials.
small as 0.5mm ► The depth of penetration is variable.
► Able to detect defects through several layers, including ► Very susceptible to magnetic permeability changes –
non-conductive surface coatings, without interference making testing of welds in ferromagnetic materials difficult –
from planar defects but with modern digital flaw detectors and probe design, not
► Non-contact method making it possible to inspect high- impossible.
temperature surfaces and underwater surfaces ► Unable to detect defects that are parallel to the test
► Effective on test objects with physically complex object’s surface.
geometries ► Careful signal interpretation is required to differentiate
► Provides immediate feedback between relevant and non-relevant indication.
► Portable and light equipment
► Quick preparation time – surfaces require little pre-
cleaning and couplant is not required
► Able to the measure electrical conductivity of test
objects
► Can be automated for inspecting uniform parts such as
wheels, boiler tubes, or aero-engine disks.
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What is Eddy Current ARRAY? Industries That Benefit from Eddy Current
Eddy current array and conventional eddy current technology Aviation and Aerospace
share the same basic principle. Alternating current injected Eddy current technology is commonly used for crack and
into a coil creates a magnetic field (in blue). When the coil is corrosion detection, and conductivity testing in the aviation
placed over a conductive part, opposed alternating currents and aerospace industries. Eddy current equipment is highly
(eddy currents, in red) are generated. Defects in the part sensitive when detecting surface and subsurface cracks
disturb the path of the eddy currents (in yellow). This and corrosion, which is important in these industries where
disturbance can be measured by the coil. the smallest defects could cause costly or even
catastrophic failures. Conductivity testing can be used to
Eddy current array (ECA) is an assembly of single eddy identify and sort ferrous and nonferrous alloys, and to
current sensors or coils that are multiplexed in a certain verify heat treatment. Eddy current devices are used to
order to obtain the required sensitivity. There are many inspect wheels, struts, propellers, airframes, hubs, engine
different designs of eddy current probes, including flexible components, and other key parts.
probes, padded probes or spring-loaded fingers.
Oil and Gas
Eddy current equipment is used for crack detection in
Eddy current array (ECA) technology provides the ability to welds throughout the oil and gas industry. Nondestructive
electronically drive multiple eddy current coils placed side by testing is critical for both the integrity of equipment and
side in the same probe assembly. Data acquisition is the safety of petroleum refining and extraction operations.
performed by multiplexing the eddy current coils in a special Detecting cracks in welds in metal pipelines is critical in
pattern to avoid mutual inductance between the individual the oil and gas industry.
coils.
Shipbuilding
Most conventional eddy current flaw detection techniques can Eddy current equipment is used for crack detection in
be reproduced with an ECA inspection. With the benefits of welds in the shipbuilding industry. Weld inspection is
single-pass coverage, and enhanced imaging capabilities, important in shipbuilding because, if the welds fail, often
ECA technology provides a remarkably powerful tool and the structure will fail, and this leads to costly repairs and
significant time savings during inspections. potential health and safety risks. The most critical flaws
are cracks, lack of fusion or penetration, and undercut; it is
these flaws that most quality codes and standards in
shipbuilding are designed to avoid. Eddy current technology
is highly sensitive to surface and subsurface cracks in
welds, which helps manufacturers ensure high-quality
welds and respond to any damage quickly.

Automotive
Eddy current equipment is used for inspecting components
for defects and carrying out hardness and heat-treatment
testing in the automotive industry. Eddy current inspection
systems can be automated and added to the manufacturing
Advantages of Eddy Current Array process. A machine picks up a part or component, moves it
► Reduction in inspection time, as: The coils in the probe into the test position, brings the test coil down on the part
have been specifically arranged to cover a particular area the or lifts the part onto the coil, and sends the signal to the
scanning speed can be adjusted A wider range of samples of instrument. Automated eddy current inspections are fast,
can be inspected due to a wider range of probe types that are clean, and keep the line moving. Identifying defects in the
available automotive industry is essential for ensuring quality
control and meeting health and safety guidelines.
► Multi-frequency approach – possible to inspect a test
object with several central frequencies simultaneously – Power Generation and Chemical Refinery
allowing the user to assess the most optimized central Eddy current equipment is used for tube testing and weld
frequency for the inspection inspection in the power generation and chemical refinery
industries. These industries require precise and reliable
► Post analysis of results – the equipment’s built-in technology to inspect critical assets and ensure safe, cost-
software enables the use of filters and other process to effective operations. Eddy current equipment enables
highlight or hide certain features remote inspection of areas unsafe for humans to operate
because of hostile and dangerous conditions. Uses for eddy
current equipment in the power generation and chemical
Limitations of Eddy Current Array refinery industries include the inspection of turbines,
primary and secondary pipes, welds and vessel
► Eddy current array inspections use advanced equipment components, heat exchangers, reactor vessels, nuclear
that requires additional operator training. fuel pools, and more. Eddy current technology provides
reliable and accurate condition inspection. Unidentified
► Longer set-up time than a conventional eddy current defects can be catastrophic in an industry that operates
inspection. with dangerous chemicals and machinery.

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ECT Testing of Chiller Tubes ECT Testing of Heat Exchanger Tubes

Eddy current testing is a nondestructive testing method Eddy current testing equipment is also a reliable and highly
commonly used to inspect tubing in heat exchangers, effective method for measuring wall thickness and cracks in
condensers, air coolers, and other appliances. Eddy current heat exchanger tubes. Like chiller tubes, inspection of heat
testing is a high-speed method that can be performed to exchanger tubes requires quality instrumentation to
inspect through painting and coatings and is used to assess accurately identify defects at an early stage. High-fluid
the condition and lifespan of tubes. Tubes can become pressure causes expansions and contractions in heat
damaged over time through corrosion, pitting, cracks, exchanger tubes, making them more susceptible to surface
erosion, and other changes. Detecting these flaws is a vital and subsurface defects.
process to help keep appliances working reliably and to meet
certain quality and health and safety standards. Different Heat Exchanger Tube Inspection Equipment
tubes are subject to different stresses, meaning their Users have two primary choices when it comes to eddy
inspection often requires different equipment and processes. current equipment for heat exchanger tube inspection. A
In this article, we will discuss what eddy current equipment testing instrument combining multiplex and simultaneous
you need for inspecting chiller and heat exchanger tubes to injection will lead to faster inspection times and more
save repair costs and ensure quality standards are met. accurate data, these are used solely for heat exchanger
testing. Another option would be a tubing/surface instrument,
Eddy Current Testing of Chiller Tubes which can be used for heat exchange inspection along with
Chiller tubes undergo daily stress, which can lead to rust and other applications.
corrosion. This rust can also infiltrate the evaporator tubes of
the chillers, potentially leading to further damage to the Multiplex eddy current equipment enables you to test all the
compressor and preventing the water from chilling different tube types, which is ideal for users who want to use
effectively. Common defects to look out for include: their instrument for a diverse range of applications. These
devices can be used for detecting abnormalities, such as
• Pitting. cracking, putting, and cuts. They can also be used for remote
• Freeze ruptures. field testing (RFT), enabling users to obtain accurate data in
• External corrosion. any testing radius. Using a device with multiplex technology,
• Internal pitting. users can take advantage of:

Left untreated, these flaws can lead to costly repairs. This is • Enhanced detection probability for surface and
why regular nondestructive testing is used to help detect subsurface flaws
these malformations early. • SI technology that increases inspection time,
enables RFT, and supports multiple coil
frequencies.
Chiller Tube Inspection Equipment
Using eddy current testing equipment on chiller tubes is a A final option for users looking to use eddy current
proven and effective flaw detection method. Any irregularities technology to inspect heat exchanger tubes is remote
will disrupt the eddy current flow generated by the probe, acquisition units with tubing and surface array configurations.
signaling to the user that there may be a flaw in the test This enables the detection of surface and subsurface
material. The ideal equipment for chiller tube inspection indications using surface array.
includes a testing instrument that enables simultaneous
injections and multiplexed frequencies. These two features The best eddy current testing equipment for heat exchanger
result in: tubes should possess the following features:

• Improved efficiency • Superior detection quality

• Increased inspection speed • Lightweight portability
• Remote field testing (RFT) • Automated analysis software
• Fast inspection speed
The multitiered frequency is used to detect a range of flaws,
from surface cracks to irregularities deep below the surface. The software is one of the most important aspects when it
You should look for chiller tube inspection equipment that can comes to choosing to eddy current testing equipment for
be used to inspect most tubing materials, including carbon tubes. Your software should be able to provide fast analysis
steel or magnetic alloys. Using cutting-edge technology can results and reporting as data is acquired, as well as being
help inspectors detect these flaws when they’re beginning to capable of distinguishing between circumferential and axial
develop, eliminating costly overhead costs further down the indicators. Quality should be a serious consideration when
line. This makes investing in effective instrumentation investing in eddy current technology for heat exchanger tube
important when inspecting chiller tubes. testing. Inferior equipment can lead to missed flaws,
operational failures, and inflated repair costs.
Eddy current testing is an efficient choice for the inspection of
chiller tubes.

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