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Nondestructive method uses powdered iron and eddy current probe to measure the depth/width ratio of cracks in electrically nonconductive materials. The eddy current probe measures the mass of metal in the crack after it has been filled with the powdered iron.
As part of the health assessment of flight spare 40in diameter Kevlar composite overwrapped pressure vessels (COPVs) SN002 and SN027 an eddy current characterization of the composite and liner thickness change during pressurization was requested under WSTF-TP-1085-07.A, "Space Shuttle Orbiter Main Propulsion System P/N MC282-0082-0101 S/N 002 and Orbital Maneuvering System P/N MC282-0082-001 S/N 027 COPV Health Assessment." The through the thickness strains have been determined to be an important parameter in the analysis of the reliability and likelihood of stress rupture failure. Eddy current techniques provide a means to measure these thicknesses changes based upon the change in impedance of an eddy current sensor mounted on the exterior of the vessel. Careful probe and technique design have resulted in the capability to independently measure the liner and overwrap thickness changes to better than +/- 0.0005 in. at each sensor location. Descriptions of the inspection system and test results are discussed.
This report will summarize some results from a multi-year research effort at NASA Langley Research Center aimed at the development of an improved capability for practical modelling of eddy current effects in magnetic suspension systems. Particular attention is paid to large-gap systems, although generic results applicable to both large-gap and small-gap systems are presented. It is shown that eddy currents can significantly affect the dynamic behavior of magnetic suspension systems, but that these effects can be amenable to modelling and measurement. Theoretical frameworks are presented, together with comparisons of computed and experimental data particularly related to the Large Angle Magnetic Suspension Test Fixture at NASA Langley Research Center, and the Annular Suspension and Pointing System at Old Dominion University. In both cases, practical computations are capable of providing reasonable estimates of important performance-related parameters. The most difficult case is seen to be that of eddy currents in highly permeable material, due to the low skin depths. Problems associated with specification of material properties and areas for future research are discussed.
This procedure provides the detailed instructions for conducting Eddy Current (EC) inspections of thin (5-30 mils) titanium membranes with thickness and material properties typical of the development of Ultra-Lightweight diaphragm Tanks Technology (ULTT). The inspection focuses on the detection of part-through, surface breaking fatigue cracks with depths between approximately 0.002" and 0.007" and aspect ratios (a/c) of 0.2-1.0 using an automated eddy current scanning and image processing technique.
A recent identification of cracking in the Space Shuttle Primary Reaction Control System (PRCS) thrusters triggered an extensive nondestructive evaluation effort to develop techniques capable of identifying such damage on installed shuttle hardware. As a part of this effort, specially designed eddy current probes inserted into the acoustic cavity were explored for the detection of such flaws and for evaluation of the remaining material between the crack tip and acoustic cavity. The technique utilizes two orthogonal eddy current probes which are scanned under stepper motor control in the acoustic cavity to identify cracks hidden with as much as 0.060 remaining wall thickness to the cavity. As crack growth rates in this area have been determined to be very slow, such an inspection provides a large safety margin for continued operation of the critical shuttle hardware. Testing has been performed on thruster components with both actual and fabricated defects. This paper will review the design and performance of the developed eddy current inspection system. Detection of flaws as a function of remaining wall thickness will be presented along with the proposed system configuration for depot level or on-vehicle inspection capabilities.
A recent identification of stress corrosion cracking in the Space Shuttle Primary Reaction Control System (PRCS) thrusters triggered an extensive nondestructive evaluation effort to develop techniques capable of identifying such damage on installed shuttle hardware. As a part of this effort, specially designed eddy current probes inserted into the acoustic cavity were explored for the detection of such flaws and for evaluation of the remaining material between the crack tip and acoustic cavity. The technique utilizes two orthogonal eddy current probes which are scanned under stepper motor control in the acoustic cavity to identify cracks hidden with as much as 0.060 remaining wall thickness to the cavity. As crack growth rates in this area have been determined to be very slow, such an inspection provides a large safety margin for continued operation of the critical shuttle hardware. Testing has been performed on thruster components with both actual and fabricated defects. This paper will review the design and performance of the developed eddy current inspection system. Detection of flaws as a function of remaining wall thickness will be presented along with the proposed system configuration for depot level or on-vehicle inspection capabilities.
Eddy current testing (ET) was used to scan bare metallic liners used in the fabrication of composite overwrapped pressure vessels (COPVs) for flaws which could result in premature failure of the vessel. The main goal of the project was to make improvements in the areas of scan signal to noise ratio, sensitivity of flaw detection, and estimation of flaw dimensions. Scan settings were optimized resulting in an increased signal to noise ratio. Previously undiscovered flaw indications were observed and investigated. Threshold criteria were determined for the system software's flaw report and estimation of flaw dimensions were brought to an acceptable level of accuracy. Computer algorithms were written to import data for filtering and a numerical derivative filtering algorithm was evaluated.
This report presents a preliminary analysis of the mathematical modelling of eddy current effects in a large-gap magnetic suspension system. It is shown that eddy currents can significantly affect the dynamic behavior and control of these systems, but are amenable to measurement and modelling. A theoretical framework is presented, together with a comparison of computed and experimental data related to the Large Angle Magnetic Suspension Test Fixture at NASA Langley Research Center.
Magnetically induced eddy current torque effects on earth satellite spin motion
Mixing of impedances measured at different frequencies reduces noise and helps reveal flaws. In new method, one excites eddy-current probe simultaneously at two different frequencies; usually, one of which integral multiple of other. Resistive and reactive components of impedance of eddy-current probe measured at two frequencies, mixed in computer, and displayed in real time on video terminal of computer. Mixing of measurements obtained at two different frequencies often "cleans up" displayed signal in situations in which band-pass filtering alone cannot: mixing removes most noise, and displayed signal resolves flaws well.
Eddy current methods have been applied to characterize the effect of magnetic treatments on component service-life extension. Coil impedance measurements were acquired and analyzed on nickel 200 specimens that have been subjected to many mechanical and magnetic engineering processes: annealing, applied strain, magnetic field, shot peening, and magnetic field after peening. Experimental results have demonstrated a functional relationship between coil impedance, resistance and reactance, and specimens subjected to various engineering processes. It has shown that magnetic treatment does induce changes in electromagnetic properties of nickel 200 that then exhibit evidence of stress relief. However, further fundamental studies are necessary for a thorough understanding of the exact mechanism of the magnetic field processing effect on machine-tool service life.
Work described in this paper confirms and extends work done by Zumwalt, et al., on a variety of in-flight deicing systems that use eddy current repulsion for repelling ice. Two such systems are known as electro-impulse deicing (EIDI) and the eddy current repulsion deicing strip (EDS). Mathematical models for these systems are discussed for their capabilities and limitations. The author duplicates a particular model of the EDS. Theoretical voltage, current, and force results are compared directly to experimental results. Dynamic strain measurements results are presented for the EDS system. Dynamic strain measurements near EDS or EIDI coils are complicated by the high magnetic fields in the vicinity of the coils. High magnetic fields induce false voltage signals out of the gages.
Thin wire welded to bottom of hole down center of bolt permits measurement of tension in bolt. Bolt lengthens under strain, but wire is not loaded, so gap between wire and eddy-current gap transducer mounted on bolt head indicates bolt loading. Eddy-current transducer could measure gap within 0.05 mm. Method does not require separate "standard" for each bolt type, and is not sensitive to dirt or oil in bolt hole, unlike ultrasonic probes.
Lateral shaft vibrations produced by a rotating unbalance weight were damped by means of eddy currents generated in copper conductors that were precessing cyclicly in the gap formed by the pole faces of C-shaped, permanent magnets. The damper assembly, which was located at the lower bearing support of a vertically oriented rotor was completely immersed in liquid nitrogen during the test run. The test rotor was operated over a speed range from 800 to 10,000 rpm. Three magnet/conductor designs were evaluated. Experimental damping coefficients varied from 180 to 530 N sec/m. Reasonable agreement was noted for theoretical values of damping for these same assemblies. Values of damping coefficients varied from 150 to 780 N sec/m. The results demonstrate that passive eddy-current damping is a viable candidate for vibration control in cryogenic turbomachinery.
A multiple magnet bearing can be developed from N individual electromagnets. The constitutive relationships for a single magnet in such a bearing is presented. Analytical expressions are developed for a magnet with poles arranged circumferencially. Maxwell's field equations are used so the model easily includes the effects of induced eddy currents due to the rotation of the journal. Eddy currents must be included in any dynamic model because they are the only speed dependent parameter and may lead to a critical speed for the bearing. The model is applicable to bearings using attraction or repulsion.
Digital computer method for determining eddy current and hysteresis losses in cylindrical rod of No. 1010 steel
Rotatable conductive plate covers sensing coil to varying degree. Curvature of pipe at remote or otherwise inaccessible location inside pipe measured using relatively simple angular-displacement eddy-current probe. Crawler and sensor assemblies move along inside of pipe on wheels. Conductive plate pivots to follow curvature of pipe, partly covering one of eddy-current coils to degree depending on local curvature on pipe.
We report that the eddy current flow meter (ECFM) has been used to measure velocities and temperatures of conductive flows, such as liquid metal flows in a nuclear fission reactor. The goal of this paper is to develop a finite element electromagnetic model that can characterize the ECFM sensor performance and validate this finite element model with detailed velocity measurements of a controlled, well-characterized moving conductive solid rod. Both measurements and modeling were performed for various parameters that are important for ECFM performance such as rod velocity, rod material, ECFM sensor coil length, number of sensor coils, applied alternating current (AC) current amplitude, and applied ECFM AC frequency. For all parametric scans, the measurement and modeling agree well in both magnitude and trend. The normalized root-mean-square error between measurement and modeling is less than 10% for all cases. These results suggest that electromagnetic modeling could eventually be used to cost-effectively design future ECFM sensors in arbitrary geometry for more challenging applications such as liquid metal nuclear fission reactors.