Automated eddy current analysis of materials

The use of eddy current techniques for characterizing flaws in graphite-based filament-wound cylindrical structures is described. A major emphasis was also placed upon incorporating artificial intelligence techniques into the signal analysis portion of the inspection process. Developing an eddy current scanning system using a commercial robot for inspecting graphite structures (and others) was a goal in the overall concept and is essential for the final implementation for the expert systems interpretation. Manual scans, as performed in the preliminary work here, do not provide sufficiently reproducible eddy current signatures to be easily built into a real time expert system. The expert systems approach to eddy current signal analysis requires that a suitable knowledge base exist in which correct decisions as to the nature of a flaw can be performed. A robotic workcell using eddy current transducers for the inspection of carbon filament materials with improved sensitivity was developed. Improved coupling efficiencies achieved with the E-probes and horseshoe probes are exceptional for graphite fibers. The eddy current supervisory system and expert system was partially developed on a MacIvory system. Continued utilization of finite element models for predetermining eddy current signals was shown to be useful in this work, both for understanding how electromagnetic fields interact with graphite fibers, and also for use in determining how to develop the knowledge base. Sufficient data was taken to indicate that the E-probe and the horseshoe probe can be useful eddy current transducers for inspecting graphite fiber components. The lacking component at this time is a large enough probe to have sensitivity in both the far and near field of a thick graphite epoxy component.