A Seminar report

On
Eddy Current Testing Machine
Submitted in Partial Fulfilment of the Requirement for the Award of
the
Degree of
Bachelor of Technology in
Mechanical Engineering
By
VEDANT MAHESH SAWANT
(2030331612045)
Supervised by
Asst.Prof. Neeraj Kulkarni

Department of Mechanical Engineering

Dr. Babasaheb Ambedkar Technological
University, Lonere - 402103, Dist- Raigad, Maharashtra

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 APPROVAL SHEET

The seminar report entitled “INDUSTRIAL TRAINING

EVALUATION ” is approved for Final year seminar in Department
of Mechanical Engineering.

Asst.Prof. Neeraj Kulkarni

Guide

Dr.HemantWaratkakar
Professor & Head Of Department Mechanical

External Examiner

Dr. Babasaheb Ambedkar Technological University,

Lonere-Raigad 402103

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 ACKNOWLEDGEMET

I convey thanks to my industrial training guide Asst.Prof. NEERAJ

KULKARNI of Mechanical Engineering Department for providing
encouragement, constant support and guidance which was great help to
complete this seminar successfully. I would like to take this opportunity to
express my gratitude to all the individuals whose contribution have helped me
in undergoing training of my internship at ACCURATE Metrology and
Automation . First of all ,I would like to thanks all Senior Section Engineers,
Staff Members and Faculty Members for their valuable help at all the time.Last
but not the least, I wish to thanks my parents for financing for studies in this
college as well as for constantly encouraging us to learn engineering. Their
personal sacrifice in providing this opportunity to learn engineering is grateful
acknowledged.

VEDANT SAWANT
2030331612045

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 PREFACE

Industrial Training is meant to expose the students of engineering of actual Industrial Process
about which they have been studying in detail in semesters. We are gaining theoretical
knowledge of various manufacturing and assembly processes through studies, but to see the
practical relevance helped a lot.
This training has exposed us to actual application of various studied phenomenon .Each
Section was informative and each one of it had applications of our theory-based knowledge.

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 INDEX

Sr.No. Title Page

1 Introduction 6No.
2 Overview Of Eddy Current Testing 7
3 Eddy Current 9
4 Eddy Current
Schaffler Eddy Current 11

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 Chapter1

INTRODUCTION

During my internship at Accurate Metrology & Automation I had the opportunity to delve
into the fascinating world of non-destructive testing (NDT) through hands-on experience with
eddy current testing machines. Eddy current testing is a vital technique used in various
industries, including aerospace, automotive, manufacturing, and more, for inspecting
conductive materials without causing damage.
This internship provided me with a unique chance to explore the principles, applications, and
operation of eddy current testing machines under the guidance of experienced professionals.
In this report, I will detail my experiences, learnings, and contributions during my time
working with the eddy current testing machine.
Throughout the internship, I gained a deeper understanding of electromagnetic principles,
learned to interpret test results, and honed practical skills in operating and maintaining eddy
current testing equipment. This report will provide insights into my journey, including the
training received, tasks performed, key learnings, and recommendations for future
endeavours.
Join me as I share my internship experience with the eddy current testing machine, exploring
the intricacies of non-destructive testing and its critical role in ensuring the integrity and
quality of materials and components in various industries.

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 CHPATER 2

OVERVIEW OF EDDY CURRENT TESTING

Eddy current testing (ECT) is a non-destructive testing (NDT) technique widely used to
inspect conductive materials for defects, cracks, corrosion, and other anomalies without
causing damage to the tested components. This method relies on the principles of
electromagnetic induction to identify discontinuities in the material being examined.

Principle of Operation:
Eddy current testing works on the principle of electromagnetic induction, discovered by
Michael Faraday in 1831.
When alternating current (AC) is passed through a coil, it generates a fluctuating magnetic
field around the coil.
When this coil is brought close to a conductive material, such as a metal component, the
changing magnetic field induces electrical currents, known as eddy currents, within the
material.
These eddy currents generate their own magnetic fields, which interact with the original
magnetic field, causing impedance changes in the coil.
Any disruptions or changes in the conductive material, such as defects or variations in
thickness, will alter the eddy current flow and consequently affect the impedance in the coil.

Components of an Eddy Current Testing System:

1. Probe Coil: The probe coil generates the alternating magnetic field and detects changes in
impedance caused by eddy currents in the material.
2. Eddy Current Instrument: This instrument generates the alternating current for the probe
coil and measures the impedance changes.
3. Display Unit: The display unit presents the test results, showing impedance variations,
amplitude, and phase angle.
4. Calibration Standards: Reference standards used to calibrate the eddy current machine and
ensure accurate defect detection.
Advantages of Eddy Current Testing:
Speed:Eddy current testing can rapidly inspect large areas or volumes of material.
Sensitivity: It can detect small surface and subsurface defects.
Versatility: Suitable for various materials, including conductive metals.

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Portability: ECT equipment is often compact and portable, allowing for on-site inspections.
Non-Destructive: It does not damage the tested components, making it suitable for quality
control in manufacturing.

Applications of Eddy Current Testing:

Aerospace Industry: Inspection of aircraft components for cracks, corrosion, and defects.
Automotive Industry: Quality control of engine parts, testing of suspension components, and
weld inspection.
Manufacturing: Surface inspection of metal sheets, detection of flaws in pipes and tubes, and
sorting of materials based on conductivity.
Limitations of Eddy Current Testing:
Limited Depth Penetration: Eddy currents have limited penetration depth, restricting
detection to near-surface defects.
Material Dependency: ECT effectiveness is influenced by material conductivity and
permeability.
Skilled Operators Required: Proper training and expertise are necessary for accurate
interpretation of test results.
Eddy current testing is a versatile and effective NDT technique widely used across industries
to ensure the safety, reliability, and quality of materials and components. Its applications
continue to expand, driven by advancements in technology and the increasing demand for
non-destructive inspection methods.

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 CHAPTER 3

EDDY CURRENT
‘EDDY CURRENT’ is define as oscillating electrical current induced in a conductive
material by an alternating magnetic field, due to electromagnetic induction.
 Eddy current testing can be used on all electrically conducting material, with
reasonably smooth surface.
 The test equipment consists of a generator (AC supply), a test coil and recording
equipment e.g. galvanometer.
 Used for crack detection, material thickness measurement (corrosion detection),
sorting material, coating thickness measurement metal detection, control dimensions
of tubes, sheets and rods, per service examination of heat exchanger tubes for
detection of defects.`
Principle: Electric current are generated in a conductive material by an induced alternating
magnetic field. Interruption in flow of eddy currents caused by imperfections, dimensional
changes, or changes in the material’s conductivity and permeability properties, can be
detected with proper equipment. An alternating current of frequency 1 kHz -2 MHz is made
to flow in a coil which in turn produces an alternating magnetic field around it. This coil
when brought close to the electrically conducting surface of a metallic material to be
inspected. The presence of any defect or discontinuity in the material disturbs the eddy
current flow.

(Fig 3.1 eddy current sensor)

Properties of eddy current:
 Eddy current density decreases with the depth exponentially. This phenomenon is
known as the skin effect.
 Eddy current are closed loops of induced current circulating in planes perpendicular to
magnetic flux.
 Eddy current travel parallel to the coil’s winding and flow is in limited area of
inducing magnetic field.

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  Eddy currents are created through a process called electromagnetic induction.
When AC is applied to the conductor such as copper wire magnetic field develops in and
around the conductor. This magnetic field expands as AC rises to maximum and collapses as
the current is reduced to zero.
In order to generate eddy currents for an inspection a “probe” is used. Inside the probe is a
length of electrical conductor which is formed into a coil. When an electrically conductive
material is placed in the coil’s dynamic magnetic field electromagnetic induction will occur
and eddy current will be induced in the material.
Now this eddy current flowing in the material will generates their own “secondary” magnetic
field which oppose the coil’s “primary” magnetic field. This entire electromagnetic induction
process to produce eddy current may occurs from several hundred to several million times in
each second which depends on frequency which is been set.
Eddy current is strongest at the surface of the material and decrease in strength below the
surface. This depth that the eddy current is only 37%as they on the surface is known as
standard depth of penetration or skin depth. This depth changes with probe frequency,
material conductivity and permeability. The distance between surface coil and test surface is
called proximity and lift off. Since flux density decreases exponentially with distance
between the coil. The amount of lift of separation between the coil and test specimen has a
significant effect on the sensitivity.

Edge effect:
This refers to effect that components edge or shape changes in geometry due to the eddy
currents. This can be neglected by balancing probe near to edge and scanning at the distance.
Eddy effect is phenomenon that occurs when an inspection coil is at the test piece. This
inspection is done in limited area to avoid noise /confusion with flaws.
Eddy current testing machine:
Components are checked whether they are done with induction haring with the help of eddy
current sensor. First we place the component on convers belt with the help of proxy meter
sensor component is sense and this signals are send to microcontroller and then to air piston
with proxy switch. Once the component passes through eddy current sensor the graph is
shown on the screen which shows that the component is ‘OK’ or ‘NOT OK’ and sorting of
component is done.at the end of the belt or component which are sorted, there is a proxy
meter sensor to sense that the component has reached till end and to start the cycle again.

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 CHAPTER 4

SCHAFFLER EDDY CURRENT

This is an Eddy Current for hard & soft material shorting technology. This
automation is based on current for measurement of different types of component
ASEH & SLH. This customized automation system is specially designed for M/S
Schaeffer India ltd, Talegaon.

This controller based non-contact type system has mechanical structure, conveyor
assembly, servo motors, GUC unit, Elotest IS3 controller etc. The Hardness
detection by non-contact type probe & results are shown on Elotest IS3 Screen.
This software system shows status of the component in Accept and Reject format.
In this system we have Auto cycle: The conveyor has to load the component & all
the operation done in auto mode.

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(fig4.1. Schaffler machine)

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MACHINE -1 FOR SLH
COMPONENT.

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MACHINE -2 FOR ASEH COMPONENT

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 Machine Specification:
Machine-1
 WO No. : 318.
 Weight of Single Machine: 300kg Approx.
 Overall Dimensions of Single Machine: 500 mm x700 mm x1600 mm .
 Component to be checked: SLH.
 Parameters to be checked: Hard & soft sorting.
 Cycle Time: 4 sec Minimum.

Machine-2
 WO No. : 318.
 Weight of Single Machine: 300kg Approx.
 Overall Dimensions of Single Machine: 500 mm x600 mm x1700 mm.
 Component to be checked: ASEH.
 Parameters to be checked: Hard & soft sorting.
 Cycle Time: 4 sec Minimum.

CHECKING PARAMETER

SR.NO
DESCRIPTION PARAMETER
.

HARD COMPONENT - MAX 900HV

COMPONENT FOR ASEH MIN 700HV
1
& SLH SOFT COMPONENT: MAX 300HV
MIN 210HV

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