Eddy Current Testing/Array for Aviation

Agenda

1. Eddy Current Array (ECA) Technology

2. ECA Equipment
3. Engine Applications
4. Conclusion
 ECT & ECA
• Eddy current testing (ECT) as a technique for testing finds its roots in
electromagnetism. Eddy currents were first observed by François Arago in
1824, but French physicist Léon Foucault is credited with discovering them in
1855.
• Basic form — the single-element ECT probe — a coil of conductive wire is excited with an
alternating electrical current. This wire coil produces an alternating magnetic field around
itself. The magnetic field oscillates at the same frequency as the current running through the
coil. When the coil approaches a conductive material, currents opposed to the ones in the coil
are induced in the material — eddy currents.

• Eddy Current Arrays (ECA) have been evaluated since the late 70’s and 80’s
as they were limited due to the computer capabilities.
Single Channel Instrument

Multi Channel Instrument

ECT on surfaces
• When it comes to surface applications, the performance of any given inspection
technique depends greatly on the specific conditions — mostly the types of
materials and defects, but also surface conditions, etc.
• Effective on coatings/paint: yes
• Computerized record keeping: partial
• 3D/Advanced imaging: none
• User dependence: high
• Speed: low
• Post-inspection analysis: none
• Requires chemicals/consumables: no
Eddy current array
• Eddy current array (ECA) and conventional ECT share the same basic working principles.
ECA technology provides the ability to electronically drive an array of coils ( multiple coils)
arranged in specific pattern called a topology that generates a sensitivity profile suited to
the target defects. Data acquisition is achieved by multiplexing the coils in a special pattern
to avoid mutual inductance between the individual coils.
• Faster inspections
• Wider coverage
• Less operator dependence — array probes yield more consistent results compared to
manual raster scans
• Better detection capabilities
• Easier analysis because of simpler scan patterns
• Improved positioning and sizing because of encoded data
• Array probes can easily be designed to be flexible or shaped to specifications,
making hard-to-reach areas easier to inspect
Back to Basics-Physics

• When the wire is shaped into a coil, the interaction of each turn
produces a global magnetic field around the coil.

• This magnetic field oscillates at the same frequency as the

current injected into the coil.

• When this coil is placed over a conductive part, opposed

alternating currents are generated; these are the eddy currents.

• The eddy currents oscillate at the same frequency as the current

injected in the coil but with a small delay; this is the phase lag.
How Eddy Currents works?

Top view:
• If a defect in the part disturbs the path of the Eddy current path and density
eddy currents, it creates a local magnetic field
that changes the balanced condition of the
system.

• Such changes can be detected by monitoring

variations of the coil impedance.
Eddy Current Array Technology
 Eddy Current Array Principles
 ECA is a technology based on the ability to electronically drive several eddy current sensors
placed side-by-side in the same probe assembly

 Data acquisition is performed by multiplexing the eddy current sensors

 Most eddy current probes and techniques (absolute, reflection, etc.) for flaw detection can be
used with eddy current array probes
Eddy Current Array—Advantages
 Provides larger coverage in a single
probe pass while maintaining
high resolution

 Improves flaw detection and sizing

with C-scan imaging

 Enables inspection of complex shapes

with probes customized to the profile
of parts
ECA – Signal Representation

ECA probe over a flaw Each coil produces a Color-coded signal amplitude
signal displayed in the C-scan
ECA – Signal Representation
 The C-scan can display either the vertical or horizontal
component of the signal in the impedance plane.
 In the example below, only the vertical component of the
signal (Y axis) is displayed on the C-scan, ensuring that all
defects are clearly shown. The phase of the signal was
adjusted so the liftoff signal is in the horizontal plane (X
axis).

Defects

Liftoff signal
Eddy Current Array
Equipment
General Hardware Features
OMNI-P-ECT4
− Conventional ECT only
− 4 input channels
− Frequency ranges from
20 Hz to 6 MHz
− Dual frequency
operation
− 2 encoder inputs
− 3 alarm outputs
− 1 analog output

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ECA Probes
 Can be optimized for
different applications
 Can be shaped to the
part to inspect

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ECA — Probe Parameters
r

 Frequency (f)
 Number of elements (n)
 Resolution (r) (also depends on the coil configuration)
 Coverage (C)
C
Example of an absolute bridge probe

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Inside an ECA Probe
• Hard coils
• Many wires
• A lot of soldering
• Labor intensive

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ECA Hard Coiled Array VS Printed Circuit Board (PCB)
Array
Traditional hard coil sensors
 Pros:
 Different type and size of coils
 Cons:
 Time consuming
 Repeatability and coil matching
 Expensive
Flexible array on PCB film
 Pros:
 Excellent repeatability and coil matching
 Versatility, i.e., can be attached to holders of different shapes
 Affordable price
 Cons:
 Price/time for the initial film
Engine Applications
Dovetail Slot Inspection — Current Method
 Manual tooling
 Scanner with eddy current pencil probe
 The operator must perform 40 line scans
 Time consuming
 Operators complain of discomfort

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Engine Disk Dovetail Slot Semiautomated Inspection

 32 coils cover critical zones  Probe mounted on portable scanner  Scanner in position

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ECA Engine Disk Dovetail Results
 C-scan displaying EDM and calibration notches in the calibration
standard

EDM DEFECTS

CALIBRATION LINES

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ECA Engine Disk Dovetail Results

C-scan of an EDM notch: 1.5 × 0.7 × 0.1 mm

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New Engine Disk Slot Inspection System

Scanner improved with OmniScan®

flaw detector remote control
Engine Fan Blade Inspection
Engine Fan Blade Inspection Solution — Development Process
Stage 1: Manual inspection Stage 2: Semiautomated inspection

 2 passes:  Single pass, convex and concave sides

– 1 convex side
 Encoded scanner
– 1 concave side
 Wire encoder
Semiautomated Fan Blade Inspection Solution
Conclusion
ECA Advantages for Aircraft Engine Inspection
 ECA probes cover large areas in a single pass
 Improved Probability of Detection due to full coverage and C-scan imaging
 Probes can be adapted to the complex shapes of components
 Flexible ECA can be used interchangeably with probe holders of different shapes
 Can be used on-site for aircraft engine component inspection during maintenance
 Referenced in procedures for aircraft and engine maintenance