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Eddy Current Testing (ECT) plays a key role in detecting cracks and defects in conductors. The present study examines for the first time how the subregion method as an effective mathematical and computational technique can be admixed with Finite Element Method (FEM) to study multiple defects parameters for ECT issues. Separating a defect region from the entire domain in any computational technique will save both time and storage space. Examples of different types of defects are presented in this article. A tangible result of processing time reduction by 90% has been achieved which has led us to consider the subregion FEM method as an effective method in solving different Nondestructive Evaluation (NDE) problems. An agreement between our results and others using classical FEM has been achieved which could lead to using this technique in online and field testing problems. The presented subregion FEM algorithm was verified experimentally with good agreement by testing Aluminum (T6061-T6) samples with defects. A Tunneling Magnetoresistive (TMR) sensor was used to measure the component of the magnetic field from normal to the sample top surface. A major component of minimizing processing time was achieved, which could lead to using this technique in online and field testing problems. [ABSTRACT FROM AUTHOR]

A computational technique is presented in this paper which improves finite element method (FEM) in solving inverse problems. Subregion method is used to select and isolate the area of interest where design parameters for defect shape are updated. An elastic mesh generator is developed in this paper to generate optimal meshes in the selected area to save connectivity matrix until having the most accurate design parameters. Using subregion FEM in solving inverse problems will help in minimizing processing time and memory usage in addition of reducing solution complexity. A 2-D eddy current testing (ECT) problem of detecting and characterizing the location and shape of a defect by separating the defect from entire domain is used to validate the presented subregion FEM algorithm. The elastic mesh generator is investigated to update the preselected design parameters of the defect in each iteration. This meshing technique adds the specialty of using subregion method in inverse problems where elements and nodes numberings are saved inside and outside the defect region. Both the genetic algorithm and simulated annealing optimization techniques are developed to get the accurate defect parameters. The presented subregion FEM results have been verified computationally using conventional FEM. Excellent results of signals agreement and processing time minimization with a factor of 90% with an accuracy of 98% have been achieved. In addition, the presented subregion FEM algorithm has been verified experimentally using aluminum (T6061-T6) and mild steel plate (0.15%–0.30% carbon and Fe) samples. This experiment is carried using an elongated excitation coil in a fixed position mounted on the top of the sample and tunneling magnetoresistive sensor to measure magnetic field. The measured magnetic fields were used as input to the inverse subregion FEM solver and the machined artificial defects were characterized with excellent accuracy. [ABSTRACT FROM AUTHOR]

Efficient models are needed in eddy current evaluation to enable fast and accurate predictions also in terms of probability of detection (POD). Here, calculations of the transfer impedance in a transmitter–receiver sensor are considered using the finite element method. It is shown that numerical integration around the flaw gives accurate values even if the solution without the flaw is calculated analytically which also is decreasing the computational time. A closed crack model is validated and used in a model based POD study showing limitations with transmitter–receiver sensors. It is finally suggested how to link the modelled POD to design parameters of components. [ABSTRACT FROM AUTHOR]

The probability of detection (POD) of a well-controlled, automated eddy current (EC) procedure is evaluated in a numerical model and compared with experiments. The procedure is applied in laboratory environment with a single absolute probe which is positioned for raster scan over flat surfaces containing fatigue cracks. The variability of the signal amplitude, due to small fatigue cracks in the Titanium alloy Ti-6Al-4 V, is expected to mainly originate from crack characteristics and the index distance of the raster scan. The POD model is based on the signal versus crack size (versusa) result. The presented procedure provides a well-defined basis for a comparison between a simulated and an experimentally based POD assessment. Finite element analysis is used to model the EC method. A simplified fatigue crack model is first introduced and evaluated experimentally. Numerical computations are then used to build the corresponding model-based POD curve which shows good agreement with the experimental result. The model-based POD curve is generated both by means of a parametric and a nonparametric approach. Differences between model-based and experimental POD are discussed as well as the delta POD approach using transfer functions. [ABSTRACT FROM AUTHOR]

Abstract: The eddy current inspection of small fatigue cracks in Ti–6AL–4V is evaluated in both a finite element model and experiments. The crack was created in a fatigue process and an eddy current measurement was carried out as the resulting crack was subjected to different levels of static load. The signal showed a strong dependency of the time between the creation of the fatigue crack and the eddy current measurement. This dependency is proposed to be related to oxides forming on the crack faces. The oxide is favourable for the detection of fatigue cracks. The narrow width of the fatigue crack is important to consider in eddy current inspection and as static loads are applied across the crack faces, electrical connections arise within the crack, which has a strong influence on the eddy current signal. Four different models of the contact behaviour were implemented within the finite element model. It is shown that the electrical connections that arise within small fatigue cracks, as well as the influence from the narrow opening as tensile loads are applied, can be predicted by a finite element model of the eddy current method. [Copyright &y& Elsevier]