Remote field eddy current (RFEC) testing is an eddy current non-destructive test method that has become widely used for the examination of carbon steel tubes, such as those found in heat exchangers and boilers. RFEC testing relies on the use of very low intensity electromagnetic fields on the exciting probe. The defect detection is carried out considering the phase difference between the exciting and pickup signals. However, various testing effects were produced because the affection of different electromagnetic characteristics of tubes and types of defects The purpose of this study is to analyze the influential factors of RFEC testing accuracy by means of the finite element method (FEM). In order to investigate the numerical simulation, the researcher used the finite element software package FEMLAB to create an electromagnetic model of RFEC testing. Then he applied the mathematics software package MATLAB to plot the voltage plane diagram and defect-phase difference diagram. After the comparison of the simulation with experiments, the researcher confirmed the reliability of electromagnetic simulation. As a result, this study provides the variations in RFEC testing result diagrams for the influential factors. Over all, this study has successfully established an FEM RFEC electromagnetic model. After the FEM simulation, this method can provide many comparable data for experimenter. This study may remedy the different types of defects and reduce assessing error. Therefore, the accuracy and reliability of testing of RFEC can be accessed.

This thesis describes the development of an eddy current instrument and its application in detecting early-stage pitting corrosion. Eddy current testing has previously been used in Non-Destructive Testing (NDT) applications detecting large defects, like cracks. However, the challenge of detecting corrosion pits of less than 1mm³ remains unaddressed. This research involved the design of a Field Programmable Gate Array (FPGA)-based eddy current instrument, and the design and modelling of a novel differential electromagnetic sensor. The FPGA provided accurate synchronisation among the major electronic components. The firmware developed as part of this research allowed for exact interfacing to A/D and D/A converters, performed a real-time demodulation and signal generation, the instrument also supported a multi-frequency eddy current application. The firmware showed promising end-results in terms of sensitivity and stability in relation to pitting corrosion detection. In summary, this instrument offered significant improvement in sensitivity; the size of corrosion detected is improved more than 10 per cent compared to the previously reported, which enabled the detection of pits smaller than 1 mm³. For the sensor probe, a novel differential sensor was proposed to minimise the background signal for plate scanning and improve the sensitivity. The designed probe has an advantageous feature: the sensor response can be analysed using a closed form analytical solution.

Eddy current (EC) based testing and measurement methods are well known in non-destructive testing (NDT) world. EC sensors are extensively studied and used for material health monitoring and its property measurement. Target displacement measurement is one of the well-known applications of EC method. The main advantage of EC sensor is its working capability in harsh environment like humidity, contamination etc. It is non-contact, rugged and requires less maintenance. The range and sensitivity of target displacement is mainly determined by the probe geometry and its construction method. Also displacement measurement depends upon geometry and electromagnetic (EM) properties of the target plate. Any variation of ambient temperature alters the EM properties of the probe as well as EM properties of the target. Thus, many parameters like geometry, EM properties and temperature involved in target displacement measurement. Hence, while using EC sensor for displacement measurement, it demands careful design and measurement procedure to achieve high sensitivity and high precision with low temperature drift. To achieve these, we present the following. 1) A temperature compensation technique 2) Optimization of probe geometry and its construction method to increase the range and sensitivity 3) Selection of suitable probe measurement parameter (Z, R, X) based on target material properties 4) Making the displacement measurement less sensitive to tolerance in probe construction parameter. A temperature compensation technique for target displacement measurement, using a self-running LC oscillator has been presented. A sensing coil is energized by a Hartley oscillator. The oscillator voltage is maintained at a constant level by a closed loop feedback circuit and the average feedback current to the oscillator is measured for target displacement detection. The temperature drift of the feedback current is compensated by applying temperature compensation function (TCF) and this is verified experimentally. Cold rolled mild steel (carbon steel) is taken as a target material and the sensor is tested over a temperature range of 20 °C – 80 °C. It shows that the temperature drift is less than ±30 ppm/°C over 3 mm target displacement. To match all the sensor modules in mass production, components selection procedure is presented. To avoid mismatch across sensors in manufacturing process, the transistor based oscillator is modified with operational trans-conductance amplifier (OTA). The same temperature compensation formula (TCF) is applied to compensate the temperature drift of feedback current and achieved intended accuracy. Geometry and construction parameters of the eddy current sensing probe is optimized for target displacement measurement using Ansoft Maxwell, electromagnetic design software. EC probe with different geometry are analyzed in search of suitable geometry for target displacement measurement. Four shapes of commercially available core have been chosen for probe construction. For each shape of sensing probe, the radius and height of the probe is increased by 0 mm to 9 mm to find the effect of them on sensitivity and range of target displacement measurement. It has been observed that the probe with less height and maximum diameter has shown better performance. In addition to that, the probe geometry is optimized to achieve more sensitivity and range within the space available for probe mounting. It helps to utilize the available space effectively for probe design. Coil winding and mount-ing it inside the core window also important parameter in probe design. It has been observed that de-pressing the sensing coil inside the core window from sensing face by 3 mm decreases the sensitivity by 40 %. Hence, it is recommended to place the coil on the extreme end of the sensing face of the core. To know the effect of core permeability, it is varied from 1000 to 15000. It has been observed that it has no effect on sensitivity and measurement range. Only optimizing the probe geometry and its construction method is not adequate for target displacement measurement. We know that the EC based displacement measurement is also target material dependent. Generally probe impedance is measured and then the temperature drift of the sensing coil resistance is compensated to know the target displacement. Most of the temperature compensation techniques use this compensation technique and it is shown that those are suitable for high conductivity targets like copper. Choosing Z for displacement measurement may not be only best choice for all target materials. The displacement can be measured also through either R or X of the probe. Choosing the proper probe parameter for a given target material will provide a less temperature drift for target displacement measurement. To know about this, a simulation has been made for target displacement measurement with target metal of μr = 1, relative permittivity εr =1, and temperature coefficient of resistivity ∝ = 0.004 K-1. The conductivity (σ) of the target is varied from 1×106 S/m to 62×106 S/m in the temperature range of 20 ℃ – 80 ℃. Now the simulation has been repeated by fixing  as a constant and varying target μr. The metal plate with  = 1×106 S/m, εr=1 and ∝ = 0.004 K – 1 is taken as a target and μr is varied from 100 to 10000. For both conductivity and permeability sweep analysis, the target displacement is measured as a function of Z, R and X independently. The temperature drift in displacement measurement is also analysed for the above temperature range. An experiment has been conducted with copper, stainless steel and mild steel as target metal in the temperature range of 20 ℃ – 80 ℃. The temperature drift is calculated when the displacement is measured as function of Z, R and X. Based on the results, we have identified that the target material relative permeability determines the selection of probe measurement parameter for target displacement measurement. Hence, knowing tar-get r alone suffice to select the probe measurement parameter (Z or R or X) for displacement measurement. Optimizing the probe geometry, selecting the proper probe measurement parameter and temperature compensation technique suffice to provide a good sensitivity, range and low temperature drift for a single probe. But in general, one of the mass produced probes is selected as a reference probe and it is calibrated against the ambient temperature and target displacement. And the calibration curves are loaded to all the probes. Matching the probe construction parameters to each other across the production patches is not possible in mass production. This makes the temperature compensation function and displacement calibration are different for every individual probes for displacement measurement. This degrades the measurement accuracy. A simulation has been performed with pot core with commercial tolerance. Using this, we have obtained 24 probes due to variations in 1) Individual and few combinational variations in core and coil dimensions 2) Core permeability variation and 3) relative position of the coil with respect to core. Finally, we have quantified the displacement error for each probe. We have identified the important probe dimensional parameters that have to be controlled precisely in mass production to improve the measurement accuracy. It shows error of 0.86 % in the displacement measurement when the relative reactance and relative displacement is used for measurement. In practice, error in displacement measurement due to both the ambient temperature drift and the tolerance in probe construction parameter exist simultaneously. Hence, the combined error is computed for the target displacement range of 0 mm – 3 mm for the temperature range of 0 °C – 100 °C. The total error of less than 1 % is achieved for commercial standard probe tolerance. Finally, we have provided general factory production procedure and user calibration procedure of probe design to achieve cost effective displacement measurement with sensitivity and range with low temperature drift.

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The in-mold electromagnetic stirrer is a kind of device which is utilized to stir the molten steel in the steel factory. This thesis provides a detailed three-dimensional electromagnetic analysis of an in-mold electromagnetic stirrer driven by the moving magnetic field produced from stator winding currents. A commercial finite element analysis software will be utilized to calculate the flux density, eddy current, and electromagnetic force from static and dynamic analyses, and the above three physical phenomena are also discussed to obtain the 3-D electromagnetic characteristics. In order to improve the operational properties of the in-mold electromagnetic stirrer, the various position of the stator is modified to observe the distribution of the electromagnetic force. Besides, the magnitude and frequency of the input currents are also adjusted to predict the probable performances during on-site operation.

For the evaluation of non-ferrous heat exchanger tube, there are many non-destructive testing methods; however, the eddy current testing (ECT) method is the most popular one. By using of ECT, you may find out the defects existing inside or outside the tube wall, diagnose the heat exchanger system and find out the latent problems. The problem is that an improper signal analysis will result in error in the range of 15〜25% of the tube wall thickness, or even over 40% error. This is a great discouragement to the ECT inspectors, and will reduce the confidence of the proprietors of power plants or petro-chemical industries to the use of ECT. Therefore, in this thesis, the study is mainly focus on the problems of the aluminum brass tubes in condenser using ECT method. This thesis will analyze the causes of error of aluminum brass tubes when using ECT, prepare calibration and reference tubes, and test them using eddy current instruments. The relationship among the raw data with volts, phase angle and depth has been found. Two data evaluation methods are developed, one is the defect depth modification equation and the other is the auxiliary evaluation curve. The new methods are proved to be more accurate and practical in the evaluation of heat exchanger tube after more than one year of verification by field testing in the power plant. The results obtained in this thesis are very helpful to reduce the probability of tube failure.

A device was developed to directly measure skin friction on an external test plate in transonic flight conditions. The tests would take place on the FTF-II flight test plate mounted underneath a NASA F-15 aircraft flying at altitudes ranging from 15,000 to 45,000 ft. at Mach numbers ranging from 0.70 to 0.99. These conditions lead to predicted shear levels ranging from 0.3 to 1.5 psf. The gage consisted of a floating element cantilevered beam configuration that was mounted into the surface of the test plate in a manner non-intrusive to the flow it was measuring. Strain gages mounted at the base of the beam measured the small strains that were generated from the shear forces of the flow. A non-nulling configuration was designed such that the deflection of the floating head due to the shear force from the flow was negligible. Due to the large vibration levels of up to 8 grms that the gage would experience during transonic flight, a vibration damping mechanism needed to be implemented. Viscous damping had been used in previous attempts to passively dampen the vibrations of skin friction gages in other applications, yet viscous damping proved to be an undesirable solution due to its leakage problems and maintenance issues. Three methods of damping the gage without a fluid filled damper were tested. Each gage was built of aluminum in order to maintain constant material properties with the test plate. The first prototype used a small internal gap and damping properties of air to reduce the vibration levels. This damping method proved to be too weak. The second prototype utilized eddy current damping from permanent magnets to dampen the motion of the gage. This mechanism provided better damping then the first prototype, yet greater damping was desired. The third method utilized eddy current damping from an electromagnet to dampen the motion of the gage. The eddy current damper achieved a much larger reduction in the vibration characteristics of the gage than the previous designs. In addition, the gage was capable of operating at various levels of damping. A maximum peak amplitude reduction of 33 % was calculated, which was less than theoretical predictions. The damping results from the electromagnetic gage provided an adequate level of damping for wind tunnel tests, yet increased levels of damping need to be pursued to improve the skin friction measurement capabilities of these gages in environments with extremely high levels of vibration. The damping provided by the electromagnet decreased the deflections of the head during 8 grms and 2 grms random noise vibrations bench tests. This allowed for a greater survivability of the gage. In addition, the reduction of the peak amplitude provided output with vibration induced noise levels ranging from 24 % to 5.9 % of the desired output of the gage. The gage was tested in a supersonic wind tunnel at shear levels of tw=3.9 to 5.3 psf. The shear levels encountered during wind tunnel verification tests were slightly larger than the shear levels encountered on the F-15 flight test plate during the flight tests, but the wind tunnel shear levels were considered adequate for verification purposes. The experimentally determined shear level results compared well with theoretical calculations / Master of Science

Electromagnetic Acoustic Transducers (EMATs) are advanced ultrasonic transducers that generate and detect acoustic waves in an electrically conducting material without making physical contact with the material unlike its counterpart, the piezoelectric transducers (PZT). The conventional EMAT consists of copper coil that generates the dynamic field when excited with a sinusoidal current, a permanent or electromagnet that provides the bias field and the conducting material specimen. The complex interaction between the bias field and the Eddy current induced within the skin depth of the conducting material by the dynamic field gives rise to the acoustic wave that then propagates within the surface of the material. Within the research a finite element EMAT model was developed using commercial software Comsol Multiphysics, to study and compare the Eddy current density and Lorentz force density generated by three EMAT configurations: The Meander-line, Spiral and Key Type EMAT configuration respectively. It was observed that apart from the ease of fabrication and simplicity of connectivity when stacked in layers, the Key Type coil EMAT showed a high tendency to generate higher amplitude of Eddy current and Lorentz force test materials especially when stacked in layers. Also, the effect of varying some key EMAT parameters was investigated to determine the optimal performance of Key Type EMAT configuration on CS70 pipe steel plate. The research further developed a coupled finite element model using the same software, Comsol Multiphysics to account for the generation, propagation and detection of acoustic wave by the Key Type EMAT configuration on CS70 grade of pipe steel. The model can solve the magnetostatic, electrodynamic and elastic equations that give rise to acoustic wave generation, propagation and detection on the test material. The developed coupled finite element model was validated both analytically and experimentally to establish the validity of the finite element model. The analytical and experimental results obtained were consistent with the numerical result with an average discrepancy less than 9 % percent. Finally, the research developed a novel modelling strategy to decouple and quantify the various transduction forces in operation when normally-biased EMAT and magnetostrictive EMAT configurations are used on various grades of pipe steel materials. The strategy established the value of the critical excitation current beyond which acoustic wave is generated solely by the dynamic Lorentz force mechanism. The critical excitation currents when Magnetostrictive EMAT configurations are used to generate acoustic wave was found to be; 268A, 274A, 279A, 290A and 305A for CS70, L80SS, L80A, TN80Cr3 and J55 respectively. While for Normally-Biased EMAT configurations, the critical excitation current was found to be 190A, 205A, 240A, 160A and 200A respectively. This work also compared the critical excitation current of the two EMAT configurations studied and established that normally-biased EMATs are more efficient in the generation of acoustic waves than their magnetostrictive counterpart due to their lower value of critical excitation current.

Volvo Group Truck Technology has the ambition to automate parts of their routine service. Therefore a project was launched to investigate which parts of the routine that could be automated. The idea of this project is to lower the time spent on the service and also improve the working environment for the personnel. The purpose of this thesis is to develop and build a conceptional prototype for a low-cost crack detecting sensor. This thesis is a part of a larger proof of concept project which Volvo GTT runs in cooperation with Robotdalen and Robot Application Center (RAC). The work done in this thesis has been based on literature studies, interviews and company visits. The gathered knowledge and observations was translated into what would be required to fit the needs. This thesis covers different techniques that could be used to detect flaws in braking discs. However, this thesis is mostly focused on one non-destructive method technique based on induced eddy currents. Several non-destructive techniques and conceptual designs has been tested and evaluated with varying results during this project. The result of this thesis was a design that reacts to discontinuities in conductive materials, such as the grey cast iron material used in the Volvo trucks braking discs. The results are represented as a voltage drop change and can be visualized by an oscilloscope. This study shows that the method of choice has the potential to be used as a crack detecting system and that the system can be built reliable with rather cheap components. Further development should aim towards making the design even cheaper and the components should be assembled on a PCB instead of a breadboard in order to make the system less sensitive to noise and easier to assemble alongside the trucks braking discs.