EBB 405

Failure Analysis &

Non-Destructive Testing

Title:
Detection of Corrosion
Damage on Aircraft Fleet
Structure
SLIDING
DOOR

BEARING
Eddy Current Technology
 based on the electromagnetic induction and the circular electric currents in materials
Primary magnetic fields
Secondary magnetic fields
the alternative current flowing
through the coil- generates a
magnetic field around the coil
any defects or flaw in the
coils is place closely to an
conductive materials will disturbs
electrically conductive materials-
the eddy current circulation-defect
eddy current induced
signal read by the impendence
 allows electronically driving
Eddy
Eddy
• Single coil and reading several eddy
current
current
• Raster
technology scan current
array sensors that locate side
technology
by side in the same probe
Ultrasonic Phased Arrays
• Ultrasonic phased arrays use a multiple element probe whereby
the output pulse from each element is time delayed in such a
way so as produce constructive interference at a specific angle
and a specific depth.

• These time delays can be incremented over a range of angles to

sweep the beam over the desired angular range.

• The main advantages of phased array in NDE are:

i. Ability to sweep a range of angles
ii. Ability to display the image in real time for the swept angles
iii. Ability to focus
PHASED ARRAY UT (PAUT)
 PAUT displays images in 
real time showing the
depth and location of
indication relative to the
probe.
 PAUT simultaneously
takes data from a range of
angles and reconstructs
an image in real time  Manual UT is limited to a
 PAUT image is easy to
comprehend as it gives a 
display of the ultrasound
superimposed on the test
piece
 Using an encoder with the
PAUT probe, all raw A-
scan data can be stored.
MANUAL UT Automated UT (AUT)
Manual UT produces a  AUT reconstructs the
single A-scan at a test piece cross-section
specific angle. Manual (B-scan) after taking
UT evaluation requires data using a single
plotting the indication refracted angle and
using the refracted angle, scanning it back and
metal path and surface forth on the test piece.
distance.  AUT always requires
either a 2-axis scan or
single refracted angle. multiple probes to
There is no data storage reconstruct the image.
capability in manual UT.  AUT requires
significantly less
inspection space for
scanning compared to
PAUT
 AUT store raw A-scan
data that can be
replayed for analysis
A linear phased array (PA) transducer usually consists of 64
elements that can be independently driven. By incorporating
suitable time delays, it is possible to steer the beam to any required
angle as shown in figure below

Probe
Elements
Transmitted
Beam
Time
Delay

Beam Steering in Phased Array Beam Focusing in Phased Array

Sample Preparation

Two layer aircraft fuselage

 Material
SI Immersion in
Damage Type Damage Size removed by
No Electrolyte
EDM

1. Chemically eroded 40 mm x 20 mm 1,2,3 and 4 hrs -

2. Chemically eroded 40 mm x 20 mm 2,4,6 and 8 hrs -

EDM notch and chemically

3. Ø 20 mm 30 minutes 0.2 mm deep
eroded

18 mm and 8 mm square
5 %, 10%,15% of
notches
4. EDM notch - 1 mm and 1.6mm
Ø 18 mm and Ø 8 mm
deep
cicular notches

Dimensions of Corrosion Damage

 Experimental Setup
•Experiments have been carried out using RDTech Omniscan MX equipment (Fig. a).

•The equipment can be used for both ultrasonic phased array and Eddy current array
by changing the acquisition module and probe.

•Ultrasonic linear phased array probe fitted to an encoder (Fig. b) is used which
consists of 64 elements.

•The eddy current array probe (Fig. c) which has 16 elements is balanced on a damage
free area for calibrating the equipment.

•ECA scan results shown is lift off compensated horizontal component containing the
phase information thereby differentiating the corrosion damage at various depths.

•Higher the intensity of the image, more amount of material is lost due to corrosion.
 Fig. b: Phased array probe with encoder

Fig. a: Omniscan MX Equipment

Fig. c: ECA probe with encoder

Results and Discussion
The experiments are carried out for:

Detection of corrosion damage in the

single layer
Detection of corrosion damage in
simulated two layer aircraft fuselage
structure
 Detection of corrosion in single layer
containing corrosion damage
created by immersing the sample
in the electrolyte for 30 minutes
and a circular EDM notch of 0.2
mm deep (as shown in the image
from left to right)

Eddy Current Array result Ultrasonic Phased Array result

ECA scan result for a specimen

with corrosion damage of 40 mm
X 20 mm at four locations created
by immersing the sample in
electrolyte for 1, 2, 3 and 4 hrs

Eddy Current Array result Ultrasonic Phased Array result

Detection of corrosion in two layer fuselage
lap joint
Eddy Current Array result
Eddy Current Array result Ultrasonic Phased Array result
ECA scan result for a
specimen with damage in the
bottom of the top (BOT) layer.
The corrosion damage is two
EDM square notches of 18 mm
and 8 mm with 5% and 10%
material loss of the first layer
thickness respectively. The
Ultrasonic Phased Array result
ECA result has three features
which includes two EDM
square notches and a false
indication at upper left due to
the bulging in the structure.
The vertical cursor lines
measures the distance
between the EDM notches
which is 35 mm.
 Detection of corrosion in two layer
fuselage lap joint

Eddy Current Array result

The scan result does not reveal the corrosion

damage at the bottom layer due to the effect
of scanning

Eddy Current Array result

 Conclusions

Ultrasonic
Phase • Defects within first layer
Array
Eddy • Detect size volumetric 5% of
Current
layer thickness
Array