An apparatus for determining the integrity of a tube is provided. The apparatus includes: a body having an extension mechanism and configured to be inserted into the tube; and a flexible eddy current sensor including a flexible housing coupled to the body via the extension mechanism, and one or more coils disposed in the flexible housing. The flexible housing is selectively extendable via the extension mechanism between a first position and a second position. The one or more coils are farther away from the body when the flexible housing is in the second position than when the flexible housing is in the first position. The one or more coils electrically couple with an interior surface of the tube when the flexible housing is in the second position, and the flexible eddy current sensor is operative to selectively induce electrical currents within the tube via the one or more coils.

A crack detection device includes: a sensor unit that has a three-layer structure of conductor-insulator-conductor and is attached to a structure; a frequency characteristics acquisition unit that sweeps a predetermined frequency range to acquire a plurality of frequencies at which the impedance of the sensor unit is maximum or minimum; a crack presence/absence determination unit that determines the presence or absence of a crack based on a nonuniformity of the plurality of frequencies; a crack position table in which a relationship between crack positions and frequency shift directions is recorded; and a crack position detection unit that, when the crack presence/absence determination unit determines that there is a crack, takes a difference between two frequencies acquired by the frequency characteristics acquisition unit to determine a sign, and then refers to the crack position table in accordance with the sign to detect a crack position.

Methods and apparatus for characterizing composite materials for manufacturing quality assurance (QA), periodic inspection during the useful life, or for forensic analysis/material testing. System are provided that relate eddy-current sensor responses to the fiber layup of a composite structure, the presence of impact damage on a composite structure with or without a metal liner, volumetric stress within the composite, fiber tow density, and other NDE inspection requirements. Also provided are systems that determine electromagnetic material properties and material dimensions of composite materials from capacitive sensor inspection measurements. These properties are related to the presence of buried defects in non-conductive composite materials, moisture ingress, aging of the material due to service or environmental/thermal exposure, or changes in manufacturing quality.

A method and apparatus for enhancing inductive sensor sensitivity response, controlling the signal dynamic range, and maximizing linearity. The apparatus includes an inductive sensor-based inspection apparatus with a ferromagnetic core, a transmitter coil, a receiver coil, and a magnetic bias coil. Biasing the sensor with a static and/or dynamic magnetic fields shifts the permeability value on a B-H curve of the ferromagnetic core to the region to provide a better linearity in a controllable dynamic range and stronger signal response with a higher SNR for enhancing detectability and measurability of minor changes of decaying magnetic field deep inside the metal target under inspection. Furthermore, the method includes adaptive biasing capabilities to dynamically adjust the magnetic bias level for an optimal signal response in measurement sensitivity, signal dynamic range, SNR, and linearity from the inductive transducer in the invention. A signal processing method is provided to remove the impacts from the biased magnetic field when needed.

System and method for characterizing material condition. The system includes a sensor, impedance instrument and processing unit to collect measurements and assess material properties. A model of the system may be used to enable accurate measurements of multiple material properties. A cylindrical model for an electromagnetic field sensor is disclosed for modeling substantially cylindrically symmetric material systems. Sensor designs and data processing approaches are provided to focus the sensitivity of the sensor to localize material conditions. Improved calibration methods are shown. Sizing algorithms are provided to estimate the size of defects such as cracks and corrosion. Corrective measures are provided where the actual material configuration differs from the data processing assumptions. Methods are provided for use of the system to characterize material condition, and detailed illustration is given for corrosion, stress, weld, heat treat, and mechanical damage assessment.

Disclose is a system and method for real-time measurement and feedback of metrology and metallurgical data during additive manufacturing (AM) part fabrication. This solution promises to provide higher performance, lower cost AM parts. A sensor is placed either in the rake/roller or following the rake/roller so that it has no impact on the process efficiency and can be used to provide real-time feedback and an archived digital map of the entire part volume. The solution provides non-contact sensing of AM layer's electrical conductivity in a high-temperature environment, metallurgical property verification, porosity imaging, local defect detection and sizing, local material temperature monitoring, and grain anisotropy imaging. Part geometry, the AM powder, and the laser/material interface are monitored in real-time. Dual mode sensing using magnetoquasistatic and optical sensors enhance results. Real-time nonlinear control of the AM fabrication process is performed based on the sensor data.

A method is provided for determining the geometry of one or more real, examined defects of a metallic and in particular magnetizable object, in particular a pipe or a tank, by means of at least two reference data sets of the object generated on the basis of different, non-destructive measuring methods.

A probe 100 includes exciter units 102 arranged in an array and detector units 104 and 106, also arranged in arrays, with the arrays positioned proximal to and in the shape of the exterior circumference of an individual boiler tube 108. The detector units 104 are “absolute” coil detectors which are used to detect and quantify general wall loss, for example, resulting from steam impingement erosion. The detectors 106 are differential, axial pairs which are used for detecting pits in the boiler tubers. The exciter units and detector units are mounted in a stainless steel housing 110 of the probe. The housing 110 is shaped to closely match the contour of the boiler tube 108. The probe can be moved along the boiler tubes by hand to inspect the flame side of boiler tubes, one at a time. Wheels 112 are provided to roll the probe along the boiler tubes.

An embodiment identifies a cause of change in magnetic permeability of an object under inspection and evaluates the state of surface treatment(s) of the object under inspection with high accuracy. An embodiment of the method includes preparing a non-destructive inspection apparatus; placing the object under inspection; generating eddy current in the object under inspection; continuously changing the penetration depth of an AC magnetic field in the object under inspection; calculating the value of impedance at each penetration depth in the object under inspection; and evaluating the state of the surface treatment(s) by: calculating the ratio between the value of impedance at each penetration depth in the object under inspection and the value of impedance at a corresponding penetration depth in steel which has not been subjected to a surface treatment; and identifying a cause of a change in magnetic permeability of the object under inspection based upon the calculated ratio.

The present technology relates to a method for evaluating resistance welding quality of a battery by using eddy current signal characteristics, wherein high reliability can be provided by preventing an error caused by a variation according to differences in physical properties of individual batteries, and an evaluation process is simple and clear by applying a non-destructive method.