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<p>Crack detection in weld zones of steel structures is essential for ensuring structural safety and reliability. Eddy current (EC) testing is widely used due to its non-contact nature and high sensitivity to surface and sub-surface cracks. This study reports a flexible eddy current array (FECA) sensor with six bendable channels designed to detect surface and sub-surface cracks in the weld zones of steel structures. The excitation coils are connected in series to enhance signal intensity, while interleaved detection coils minimize lift-off effects and improve sensitivity. A real-time measurement system was developed by integrating the FECA sensor with a LabVIEW-based digital lock-in amplifier. Experiments using 500 kHz and 5 kHz excitation frequencies demonstrated effective detection of surface and sub-surface cracks, respectively, including under zinc coatings. Despite manual scanning, stable and repeatable signals were recorded across multiple channels. The proposed system offers high sensitivity, real-time capability, and adaptability to complex geometries.</p>

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Flexible eddy current array measurement system for crack detection in weld zones of steel structures

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年7月25日

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  • Le Quang Trung,
  • Nguyen Duc Khuong,
  • Tran Thi Hoai Dung,
  • Naoya Kasai,
  • Tran Mach Tuan Kiet,
  • Kouichi Sekino,
  • Honoka Fukuda

摘要

Crack detection in weld zones of steel structures is essential for ensuring structural safety and reliability. Eddy current (EC) testing is widely used due to its non-contact nature and high sensitivity to surface and sub-surface cracks. This study reports a flexible eddy current array (FECA) sensor with six bendable channels designed to detect surface and sub-surface cracks in the weld zones of steel structures. The excitation coils are connected in series to enhance signal intensity, while interleaved detection coils minimize lift-off effects and improve sensitivity. A real-time measurement system was developed by integrating the FECA sensor with a LabVIEW-based digital lock-in amplifier. Experiments using 500 kHz and 5 kHz excitation frequencies demonstrated effective detection of surface and sub-surface cracks, respectively, including under zinc coatings. Despite manual scanning, stable and repeatable signals were recorded across multiple channels. The proposed system offers high sensitivity, real-time capability, and adaptability to complex geometries.