QUESTIONS & ANSWERS RELATED TO EDDY CURRENT TEST SYSTEMS

MAY 2003 1. HOW DOES EDDY CURRENT TESTING EVALUATE PARTS?

Eddy current testing provides an analog means of evaluating mechanical parts. It is not a go/no-go gauge, but a proportional means of reviewing the characteristics of machined components. Although a go/no-go capability can be added to this inspection technique through the addition of a user settable acceptance window, it is fundamentally analog in nature and therefore offers a wide variety of inspection applications and potentials. In addition to distinguishing between properly and improperly threaded holes, eddy current testing techniques can also be used to: distinguish complex features using profiling techniques, find seams in welded tubing, find cracks in machined surfaces, detect features like groves and chamfers in machined rods, inspect for hardness, chemistry and porosity differences between parts, and measure materials thickness, to name just a few of its myriad applications. The principal means of evaluating samples in the NDT Technologies systems is based on statistics. Since the eddy current probe simultaneously extracts four materials characteristics (chemistry, geometry, hardness and temperature) from every sample, the review of any sample population with respect to the eddy current signature of that population, will begin to ascribe a bell curve with a defined average (or x) and plus and minus sigma limits. This bell curve is created by variations in these four parameters between subsequent samples. The NDT Technologies system allows the user to place an acceptance window around the bell curve established by a sample population just outside its three sigma limits, so that parts that fall within this window can be accepted while those that fall outside the window, will be rejected. NOTE: It should be noted that variations in materials chemistry, geometry, hardness and temperature are lumped together in other eddy current literature and referred to as changes in materials "conductivity". Although this is true, NDT Technologies has selected to separate these so that a more comprehensive statistical understanding of the eddy current testing process can be achieved.

2. HOW DOES EDDY CURRENT TESTING WORK

Eddy current testing is a comparative means of part evaluation. In its most basic form, eddy current testing compares the eddy current characteristics of a known good part sample to the eddy current characteristics of the general part population. During a "learn" process, the eddy current signature of a "known good" or "master" part is learned by support electronics and stored in memory. Thereafter, as subsequent samples are inspected, the eddy current signature of the part under test is compared to that learned signature. If the signatures match within user set limits, (that can be set on either side of the learned x value), the part is judged good and passed, otherwise it is judged bad and rejected

3. HOW DO STATISTICS COME INTO PLAY IN THE EVALUATION OF THREADED HOLES?

With reference to figure #1, when a threaded hole is inspected with a single element eddy current probe, the bell curve associated with each part population can be thought of as four individual bell curves that are overlaid, one upon the other. The inner most bell curve, associated with part geometry differences, is usually the one of interest. This population distribution relates to the following differences between parts: Number of threads present Pilot hole diameter Thread major diameter Thread minor diameter Hole out of round condition Thread pitch diameter Thread concentricity with hole centerline Thread roughness Thread tear out at top of hole Tap wear condition The second "layer" of the bell curve relates to differences in the hardness of the part immediately around the hole. Materials hardness is sensed up to about 0.01" into the wall around the hole. The third "layer" relates to materials chemistry and includes materials precocity, also about 0.01" into the material The fourth "layer" is associated with the difference in temperature between subsequent samples. It also represents the temperature difference between the sample population and the temperature of the master part that was initially used to establish the "learned" eddy current characteristic held in system memory. As the general population of the parts begins to deviate with respect to the four sensed parameters, from the average, (or x), established with the master part, the width of the good part and bad part bell curves begin to increase. This increase in turn, causes the tails of the two bell curves at their three-sigma limits to approach each other. The absolute separation between the x values of the good part and bad part bell curves related directly to the size of the defect to be sensed. When the number of threads in a given hole is the parameter in question, the x's are separated in direct relation to the number of threads that are missing in the bad holes. With reference to figure #1, it becomes apparent that as each of the sensed parameters (namely chemistry, geometry, hardness, and temperature) begin to deviate from that of the learned master part, the capability of the system to discern differences in just a few missing threads, between the master and the sample under test, becomes compromised. Further, in sample populations with wide variations in chemistry, hardness and temperature, only relatively large numbers of missing threads can be detected.

4. IS THERE A WAY TO SEPARATE THE EDDY CURRENT SIGNATURES ASSOCIATED WITH CHEMISTRY, HARDNESS AND TEMPERATURE, FROM THAT OF GEOMETRY IN THREADED HOLES?
With reference to figure #1, when a single element eddy current probe is used it becomes obvious that as the deviations in part population chemistry, hardness and temperature begin to increase (as in cast materials such as iron and aluminum) the capability to sort out one or two missing threads from a population of fully threaded holes becomes more difficult. In fact, to accomplish this, large numbers of good parts would have to be rejected to insure all bad parts are also rejected. In one hundred percent sorting applications, this is obviously only marginally acceptable. This situation, however, can be substantially improved with the use of a dual element probe. As the name implies, a dual element eddy current probe utilizes two distinct and separate eddy current sensor elements in each probe. These dual element probes are used as follows: A. The probe is initially positioned in a properly threaded hole so that the element near the probe tip is adjacent to the last fully formed thread and the element farthest away from the tip is located nearer the top of the hole also containing properly formed threads. B. The support electronics is then caused to "learn" the eddy current signature difference between the two elements. Ideally, the differences between these two signatures should be zero. In fact, if the chemistry, geometry, hardness and temperature within any given hole, at the two locations adjacent to the two probe elements, is the same, the difference will be zero. C. As changes occur, however, in the geometry related characteristics of the last fully formed thread that is adjacent to the lower probe element, the eddy current difference signal begins to become significant. Is should be noted that since the difference between the eddy current signatures of the two probe elements is used (as opposed to their absolute value) the eddy current system, in effect, "masters" itself in each hole. As long as no differences in chemistry, hardness and temperature occur in the same hole between the locations of the two probe elements, their signatures are rejected form the information that is utilized by the system to evaluate the condition of each threaded hole. With reference to figure #2, the bell curves associated with the eddy current differences between the two probe elements, contains only geometry-related information. Since the width of these bell curves no longer contain deviations in population chemistry, hardness and temperature, the tails of the good part and bad part bell curves are, in effect, subsequently farther apart.

5. WHAT ARE SOME OF THE ADVANTAGES & DISADVANTAGES OF THE SINGLE COIL OR "AP" SYSTEM?
ADVANTAGES: This is the least expensive system available from NDT Technologies. This system can be used to discern differences in chemistry and hardness as well as thread presence and condition, within a part population. The system is capable of sorting unthreaded holes, or up to half threaded holes, from a population of fully threaded holes. DISADVANTAGES: This system detects all four eddy current parameters from each sample and consequently the associated part population bell curves are unduly wide. As the size of the defect to be detected decreases, therefore, more and more good parts must be rejected form the inspected sample population to insure that all bad parts are also rejected. The AP system requires that a master part be used to establish the position of the x part. Ideally this part should also exhibit the mean, or x of the chemistry, geometry, hardness and temperature populations. If it does not, the resulting sort will be based on a skewed distribution and therefore not represent the good and bad part populations properly For parts with more than one hole that are to be inspected simultaneously, the capability to locate the master part that actually represents the x for all four parameters for all holes, geometrically increased in complexity. In fact, in parts with more than five holes, the likelihood of locating a master part with all holes actually at their x position is near impossible. This problem results in statistically skewed sorts for at least some of the holes. The system requires that a master part be periodically cycled through the test fixture, initially to calibrate it to its "learned" parameters, and then periodically to verify that the system has maintained it initial calibration. Periodically also, a "bad" master part should also be cycled through the system to verify it is, in fact, rejected.

6. WHAT ARE SOME OF THE ADVANTAGES & DISADVANTAGES OF THE DUAL COIL OR "GHP" SYSTEM?
ADVANTAGES: Since part chemistry, hardness and temperature are effectively rejected from the eddy current signature of the "difference" between the two eddy current sensors, only the geometry differences are sensed. This allows one or two missing threads to be discerned from fully threaded holes. In parts that include multiple holes to be inspected, the capability to find a master part that has all it holes at the ideal x location, is considerably easier because the bell curves themselves are considerably narrower than with the AP system Lot to lot variations in base material chemistry, hardness and temperature are effectively rejected by the system and do not effect the sort

DISADVANTAGES: The GHP system still requires a mastering process where a known good part must initially be used to calibrate the system. Periodically thereafter that same master should be recycled through the system so that system calibration can be verified. A known bad part should also be cycled through the system to insure that it is, in fact, rejected.

7. IS THERE A WAY TO ELIMATE THE PERIODICAL MASTERING PROCESS?

The computer based thread detection system available from NDT Technologies, provides the following capabilities: During initial system set up and programming at the factory, the eddy current characteristics of a base line or average part are loaded into computer memory. This is done for each hole that is to be inspected. Once the system is put in service, as each hole is inspected the actual x and three sigma limits are calculated from the data acquired by the eddy current sensors. This is done for each inspected hole. The result is a system that needs no initial or periodic calibration as it utilizes an x baseline that actually represents the population that is being inspected. This system also continually calculates the accept and reject limits between the two bell curves and positions them so that the systems sorts with optimal efficiency. This computer-based electronics can be used with either the AP or GHP systems and represents the absolute state of the art as far as thread detection systems are concerned.

SINGLE ELEMENT PROBE STATISTICAL BELL CURVES FOR IN-SPEC & OUT-OF-SPEC PARTS SHOWING CONTENT OF BELL CURVES AND TYPICAL SEPARATION FOR A FEW MISSING THREADS, BELL CURVE SEPARATION WILL SUBSTANTIALLY INCREASE FOR A THREAD VS. NO THREAD INSPECTION.

BELL CURVE SEPARATION TEMPERATURE VARATIONS CHEMISTRY VARIATIONS HARDNESS VARITIONS GEOMETRY VARIATIONS
FREQUENCY OF OCCURRENCE

FOR SINGLE ELEMENT PROBE, BELL CURVE WIDTH DEPENDS ON FIVE FACTORS: 1. CHEMISTRY VARIATIONS BETWEEN SAMPLES. 2. HARDNESS VARIATIONS BETWEEN SAMPLES. 3. TEMPERATURE VARIATIONS BETWEEN SAMPLES. 4. GEOMETRY VARIATIONS BETWEEN SAMPLES. 5. REPEATABILITY OF PROBE POSITION IN HOLE. THIS PORTION OF BELL CURVE CAN BE THOUGHT OF AS SIGNAL
FREQUENCY OF OCCURENCE

DUE TO THREAD DIFFERENCES

LIMIT TO FEJECT ALL OUT-OF-SPEC PARTS

THIS PORTION OF CURVE CONSTITUTES NOISE

+3 LIMIT

OUT-OF-SPEC BELL CURVE

IN-SPEC PART BELL CURVE

+3 LIMIT

EDDY CURRENT DIFFERENCES OVERLAP OF BELL CURVES CAUSES SOME GOOD PARTS TO BE REJECTED TO ENSURE ALL BAD PARTS ARE REJECTED Figure 1 6

DUAL ELEMENT PROBE STATISTICAL BELL CURVES FOR IN-SPEC & OUT-OF SPEC PARTS SHOWING TYPICAL SEPARATION FOR A FEW MISSING THREADS. BELL CURVE SEPARATION WILL DECREASE AS LESS MISSING THREADS ARE DETECTED.

BELL CURVE SEPARATION

FOR DUAL ELEMENT PROBE, BELL CURVE WIDTH DEPENDS ON TWO FACTORS: 1. GEOMETRY DIFFERENCES BETWEEN TOP & BOTTOM OF HOLE. 2. REPEATABILITY OF PROBE POSITION IN HOLE.

AS FEWER MISSING THREADS ARE DETECTED, BELL CURVE SEPERTION WILL DECREASE.

FREQUENCY OF OCCURRENCE

LIMIT TO REJECT

OUT-OF-SPEC PART BELL CURVE

IN-SPEC PART BELL CURVE EDDY CURRENT DIFFERENCES Figure 2

FREQUENCY OF OCCURRENCE