WIRELESS EDDY CURRENT PROBE DESIGN AND

APPLICATIONS IN AICRAFT MAINTENANCE

MELIH CEMAL KUSHAN1, TOLGA UNALIR2, ENGIN GODE3 & HAKAN EKINCI4
1
Dept. of Mechanical Engineering, Eskisehir Osmangazi University, Eskisehir, Turkey
2
Graduate School of Engineering, Eskisehir Osmangazi University, Eskisehir, Turkey
3&4
Aircraft Maintenance, 1st Airforce Command, Eskisehir, Turkey

 
Abstract – Eddy Current Testing which is one of the oldest nondestructive testing (NDT) methods have a wide area of use
in aircraft maintenance applications. The primary goal of this study is to assess benefits of designing Wireless Eddy Current
Test Probe in aircraft maintenance applications. Probe design and the advantages of use of this probe in aircraft maintenance
applications were studied in this paper.

Keywords – component; wireless eddy current test, aircraft maintenance.

 
I. INTRODUCTION
Eddy Current Testing method is widely used in
aircraft maintenance applications. Since flexibility in
control proceeding is very significant, wireless
systems are needed in many test procedure
implementations. Cable systems are generally
difficulty for inspection. Especially for on-aircraft
body operations simple equipments are required.
The first prototype wireless eddy current (EC)
probe for on-wing inspection was demonstrated in a
F100 PW-220 engine without external cabling at the
Air National Guard overhaul facility in Des Moines
Iowa [1]. By designing Wireless Eddy Current Probe
for all aircraft maintenance inspection effective and
flexible operation conditions can be reached.

II. EDDY CURRENT TESTING

A. Basic Principles of Non-Destructive Testing
(NDT)
Non-destructive testing is the use of physical
methods which will test materials, components and
assemblies for flaws in their structure without
damaging their future usefulness. NDT is concerned
with revealing flaws in the structure of a product.
B. Eddy Current Testing (ET)
This method is widely used to detect surface
flaws, to sort materials, to measure thin walls from
one surface only, to measure thin coatings and in
some applications to measure casedepth. This method
is applicable to electrically conductive materials only.
In the method eddy currents are produced in the
product by bringing it close to an alternating current
carrying coil. The alternating magnetic field of the
coil is modified by the magnetic fields of the eddy
currents. This modification, which depends on the
condition of the part near to the coil, is then shown as
a meter reading or cathode ray tube presentation. Fig.
1 shows basic ET system.
Fig. 1 : Eddy Current Testing.
1) Types of Probe: The eddy current probes can
have a variety of forms. The choice of the type
depends upon the test situation. Following are the
three major types of probe mainly used in eddy
current testing:
a) Internal (bobbin type) probe.
b) Encircling probe.
c) Surface probe.
Internal probes
Internal probes consist of circular coils used to
test the interior of tubes or circular holes. Fig. 2
illustrates a type of coil which can be inserted into a
tube to inspect discontinuities on the inner
circumference of the tube. As with the encircling coil,
the internal coil induces currents that encircle the
entire circumference of the tube so that the entire
section surrounding the coil is inspected. As the
currents induced in the material are strongest near the
coil, the internal coil is more sensitive to defects lying
on or near the inner surface of the tube.

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 Wireless Eddy Current Probe Design and Applications in Aircraft Maintenance

Fig. 3 : Internal Probe.

Encircling probes
Encircling probes are similar in structure to
internal probes except for the fact that the test
material is passed inside the coils. They are primarily
used to inspect the outside surface of round materials
such as tubes and rods. Fig. 3 shows an encircling
coil. The magnetic field induces eddy currents in the
bar that encircle the entire circumference of the tube
or rod so that the entire section under the coil is
inspected at any one instance. The width of the coil is
a function of the application.
 
Fig. 4. Surface Probe.
III. WIRELESS EDDY CURRENT PROBE
A. Designing of Wireless Eddy Current Probe
The first prototype wireless eddy current (EC)
probe for on-wing inspection was demonstrated in a
F100 PW-220 engine without external cabling at the
Air National Guard overhaul facility in Des Moines
Iowa. The results were compared to a wired EC
tester. Fig. 5 shows a block diagram of the prototype
wireless probe system.

Fig. 3. Encircling Probe.

Wide coils cover large areas, so they respond mostly
to bulk effects, e.g. conductivity, whereas narrow
coils sense small areas and so are more responsive to
small changes such as those produced by
discontinuities. The magnetic field of the coil extends
slightly beyond the ends of the coil.
Surface probes
Surface probes are one of the most widely used
eddy current probes for inspecting surfaces, flat or
contoured for defects or material properties. Defects
can either be surface or subsurface. These are also
called probe coils. Fig. 4 shows a typical surface
probe. The surface probe may be hand held or
mounted in automated scanning equipment. The coil
mounted in the end of the probe is provided with a
protective coating of epoxy to serve as a wear
surface. The magnetic field produced by a coil is
approximately of the size of the coil. Other variations
of surface probe designs are pancake probe, flat
probe, horse shoe or gap probe, spring loaded probe
spinning probe and pencil probe [2].
Fig. 5. Block Diagram of The Prototype Wireless EC Probe
System.
Results were comparable to wired and state-of-
the-art EC technology used to inspect engines. The
study showed that wired eddy current probes could be
converted to wireless probes [1].
In our continuing project firstly after
eleminating wired system we would like to measure
defect size directly instead of obtaining values which
have intervals or are not exact as in convention Eddy
Current inspection. At the same time our aim is to
monitor inspection result on more visual LCD
monitors by which image can be transmitted to
another monitor. Data record related to former
inspections and various statistical knowledge will be
reached by means of these monitors.
Flexible probe holder is our further design. We
will be able to reach girift surfaces easily by using
that probe.

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 Wireless Eddy Current Probe Design and Applications in Aircraft Maintenance

B. Advantages of Wireless Eddy Current Probe Wireless probe system will eliminate all these
destructive effects.
It is thought that Eddy Current Testing Device
will work more efficiently and functionally with
ACKNOWLEDGMENT
wireless probe in aircraft maintenance activities. The
operator will reach complex and narrow workplaces The authors wish to acknowledge 1st Main Jet
swimmingly. Fig. 6 shows this kind of a place. Base NDT aircraft maintenance staffs for their
supports.

REFERENCES
[1] M. Reid, B. Graubard, R. J. Weber, J. A. Dickerson, K.Smith,
D. Raulerson, L.Brasche, G. Y. Baaklini,” Wireless Eddy
Current Probe for Engine Health Monıtoring” Quantitative
Nondestructive Evaluation, AIP Conference Proceedings,
Volume 700, Feb. 2004, pp. 414-420, doi:10.1063/1.1711652
[2] Internaitonal Atomic Energy Agency, Training Course
Series 48,” Eddy Current Testing at Level 2: Manual for the
Syllabi Contained in IAEATECDOC-628/Rev. 2, ‘Training
Guidelines for Non-Destructive Testing Techniques,”
Vieanna 2011, pp. 1-121.

”””

Fig. 6 : A girift Aircraft İnspection Area.

In difficult workspaces in different applications

such as on-aircraft body operations, narrow areas,
unfixed on-ground operations, the cable arise as a
hindering occasion. The cable makes difficult
working conditions and leads to signal deterioration.
Fig. 7 and fig. 8 show an example of unfixed on-
ground operation.

Fig. 7 : Unfixed On-ground Operation.

Fig. 8. Unfixed On-ground Operation.

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