Levels I, II, and III E d d y C u r r e n t / F l u x Leakage T e s t i n g Method Supplement to Recommended Practice No. SNT-TC1A Book E Copyright © 1995 by the American Society for Nondestructive Testing, Inc. All rights reserved. ASNT is not responsible for the authenticity or accuracy of information herein, and published opinions and statements do not necessarily reflect the opinion of ASNT. Products or services that are advertised or mentioned do not carry the endorsement or recommendation of ASNT. SM SM SM ACCP , IRRSP , Level III Study Guide , Materials Evaluation™, NDT Handbook?", Nondestructive Testing 3 SM Handbook*", The NDT Technician " and www.asnt.org are service marks of the American Society for Nondestructive Testing. ASNT , Research in Nondestructive Evaluation" and RNDE* are registered trademarks of the American Society for Nondestructive Testing. 1 ASNT exists to create a safer world by promoting the profession and technologies of nondestructive testing. Published by The American Society for Nondestructive Testing, Inc. 1711 Arlingate Lane PO Box 28518 Columbus, OH 43228-0518 ISBN 0-931403-16-2 Printed in the United States of America first printing 03/88 second printing 05/90 third printing with revisions 09/95 fourth printing 04/96 fifth printing 01/98 sixth printing 01/02 2 Table of Contents References 5 Reference Usage List 7 Eddy Current Test Method C Level I Questions Answers 9 9 19 Level I I Questions Answers 21 21 33 Level I I I Questions Answers 35 35 45 Flux Leakage Test Method Level I Questions 47 47 Level I I Questions 51 51 Level m Questions 55 55 Level I, II, and III Answers 59 3 Recommended Training References Eddy Current/Flux Leakage Testing Method The following references were used in formulating the questions contained in this book. A. * Libby, H.L. Introduction to Electromagnetic Test Methods. Wiley-Interscience. 1971. B. ** McClurg, G.O. "Flaw Detection by Eddy Current Methods." Nondestructive Testing, Vol. XV, No. 2 (1957): pp. 116-119. C* Eddy Current Testing, Classroom Training Handbook (CT-6-5). San Diego, CA: General Dynamics/Convair Division. 1967. (Now published by The American Society for Nondestructive Testing, Inc.) D. * Eddy Current Testing, Programmed Instruction Handbook, Volume 1, (PI-4-5). San Diego, CA: General Dynamics/Convair Division. 1967. (Now published by The American Society for Nondestructive Testing, Inc.) E. * Eddy Current Testing, Programmed Instruction Handbook, Volume 2, (PI-4-5). San Diego, CA: General Dynamics/Convair Division. 1967. (Now published by The American Society for Nondestructive Testing, Inc.) F. * 1976 Annual Book of ASTM Standards, Part 11. Philadelphia, PA. American Society for Testing and Materials. 1976. G. * McMaster, R.C., ed. Nondestructive Testing Handbook, first edition. Columbus, OH: The American Society for Nondestructive Testing, Inc. 1959. H. ** Libby, H.L. "Basic Principles and Techniques of Eddy Current Testing." Nondestructive Testing, Vol. XIV, No. 6 (1956): pp. 12-27. I . ** Allen, J.W. and R.B. Oliver. "Inspection of Small Diameter Tubing by Eddy Current Methods." Nondestructive Testing, Vol. X V , No. 2, (1957): pp. 104-109. J.** Cosgrove, L.A. "Quality Control Through Nondestructive Testing with Eddy Currents." Nondestructive Testing. Vol. X I I I , No. 5, (1955): pp. 13-15. K.** Hochschild, Richard. "Eddy Current Testing by Impedance Analysis." Nondestructive Testing. Vol. X I I , No. 3, (1954): pp. 35-44. L.** Shiraiwa, T., T. Hiroshima, T. Hirota, and T. Sakamoto. "SAM Inspection Systems for Oil Country Tubular Goods," Materials Evaluation, Vol. 35, No. 7, (1977): pp. 52-56. M. Sharpe, R.S., Editor. Research Techniques in Nondestructive Testing, Volume 1. London and New York: Academic Press. 1970. N. Sharpe, R.S., Editor. Research Techniques in Nondestructive Testing, Volume 2. New York: Academic Press. 1974. O.* McGonnagle, W.J. Nondestructive Testing, second edition. New York: Gordon & Breach. 1969. P.** Forester, Dr. Friedrich. "Progress Report — The Nondestructive Inspection of Tubings for Discontinuities and Wall Thickness Using Electromagnetic Test Methods," Materials Evaluation, Vol. 27, No. 4, (1970): pp. 21A-31A. Q.** Black, W.A. "Nondestructive Testing of Steel and Steel Products," Nondestructive Testing, Vol. X V I I I , No. 3, (1960): pp. 185-190. R. Radio Amateur's Handbook. American Radio Relay League Staff. 1977. S. Forester, Dr. Friedrich. (1959, January). "Principles of Eddy Current Testing." Metal Progress. T.* Materials Evaluation. Columbus, OH: The American Society for Nondestructive Testing, Inc. U.* Metals Handbook, Volume 11, Nondestructive Inspection and Quality Control. Metals Park, OH: American Society for Metals. 1976. Sharp, R.S., Editor, Research Techniques in Nondestructive Testing, Volume 3. New York: Academic Press. 1977. w. "NDT Monograph FL." Mathematics and Formulae in NDT. W.H. Houldershaw Ltd. 1978. X. Stumm, W. (1979, July). "Magnetic Stray Flux Techniques in NDT — Theory, Application, and New Developments," British Journal of NDT. Y.** Shiraiwa, T., T. Hiroshima, and S. Morishima. "An Automatic Magnetic Inspection Method Using Magnetoresistive Elements and its Application." Materials Evaluation, Vol. 31, No. 5, (1973): pp. 90-96. Z.** Lord, W., et al. "Residual and Active Leakage Fields Around Defects In Ferromagnetic Materials." Materials Evaluation, Vol. 36, No. 8, (1978): pp. 47-54. AA.**Luz, H . (1973, February). "The Nondestructive Testing of Bars and Billets for Surface Defects by Magnetic Leakage Methods," Journal of Nondestructive Testing, Volume 6, No. 1. BB.** Bergander, Marek J. "Computerized Magnetic Testing of Steel Ropes." ASNT Paper Summaries, National Spring Conference, San Diego. Columbus, OH: The American Society for Nondestructive Testing, Inc. April, 1979. CC. Poffenroth, Dennis N . "Flaw Detection in Mine Hoist and Elevator Transportation Systems." Conference/Show.Niagaia Falls. May, 1979. DD.* 1978 Annual Book ofASTM Materials. 1978. ASNT/CSNDT Standards, Part 11. Philadelphia, PA. American Society for Testing and EE. Bergander, Marek J. (1978, May). "Principles of Magnetic Defectoscopy of Steel Ropes," Wire Journal. FF. Bergander, Marek J., and Julivaz Stachurski. " A New Device for Magnetic Testing of Steel Ropes," 4th International Congress of Transportation by Rope. Vienna, Austria, June, 1976. GG. Egen, Richard A. "Nondestructive Testing of Wire Rope," Offshore Technology Conference. Houston, May, 1977. * Available from The American Society for Nondestructive Testing, Inc. **Available in photocopy form from the ASNT Information Center (800) 222-2768 or (614) 274-6003, X247. Each question found in this book contains letter(s) and page number(s) and sometimes chapter or section number(s) in bold type immediately following the answers. For example, 15. When testing ferromagnetic materials, the depth to which eddy currents are induced in the material will be determined by the: a. b. c. d. conductivity of the material permeability of the material geometrical shape of the material all of the above 3.2.31 In this example, the first number "3" refers to Reference 3 in the list provided above. The "2" indicates the chapter number and the " 3 1 " is the specific page in Reference 3 where the answer to the question can be found. 6 Reference Usage List Eddy Current/Flux Leakage Testing Method Reference A: Total = 49 Level I (14) Level n (15) Level i n (20) Reference I: Total = 0 Level I (0) Level II (0) Level III (0) Reference B: Total = 0 Level I (0) Level II (0) Level III (0) Reference J : Total = 1 Level I (1) Level II (0) Level m (0) Reference C: Total = 105 Level I (46) Level II (46) Level III (13) Reference K: Total == 0 Level I (0) Level II (0) Level III (0) Reference D: Total = 14 Level I (5) Level II (6) Level III (3) Reference L : Total = 3 Level I (1) Level U (1) Level III (1) Reference E : Total = 15 Level I (7) Level II (1) Level III (7) Reference M: Total == 0 Level I (0) Level H (0) Level III (0) Reference F: Total = 2 Level I (0) Level II (0) Level III (2) Reference N: Total = 3 Level 1(0) Level I I (1) Level III (2) Reference G: Total = 77 Level I (24) Level II (24) Level HI (29) Reference O: Total = 10 Level I (4) Level I I (6) Level i n (0) Reference H: Total = 0 Level I (0) Level II (0) Level III (0) Reference P: Total = 3 Level 1(0) Level U (0) Level i n (3) 7 Reference Q: Total = 0 Level I (0) Level 11(0) Level III (0) Reference Z: Total = Level I (2) Level 11(0) Level III (1) Reference R: Total = 1 Level I (0) Level II (0) Level IH (1) Reference AA: Total Level I (1) Level II (1) Level i n (2) Reference S: Total = 7 Level I (0) Level II (6) Level III (1) Reference BB: Total Level I (0) Level II (1) Level III (0) Reference T: Total = 0 Level I (0) Level II (0) Level III (0) Reference CC: Total Level I (0) Level II (0) Level III (1) Reference U: Total = 13 Level I (3) Level II (6) Level III (4) Reference DD: Total Level I (2) Level II (5) Level ffl(0) Reference V: Total = 25 Level I (10) Level II (10) Level III (5) Reference E E : Total Level I (2) Level H (1) Level i n (0) Reference W: Total = 3 Level I (0) Level II (0) Level IH (3) Reference FF: Total = Level I (0) Level II (1) Level IH (0) Reference X: Total = 1 Level I (0) Level H ( l ) Level HI (0) Reference GG: Total Level 1(0) Level n(0) Level III (2) Reference Y: Total = 3 Level I (1) Level II (1) Level m ( l ) 8 Level I Questions Eddy Current Testing Method A test specimen used as a basis for calibrating test equipment or as a comparison when evaluating test results is referred to as a: a. b. c. d. 6. null-balancer phase shifter reference standard high pass filter The process of comparing the reading or output of an instrument, device, or dial with a standard to determine the instrument's accuracy, capacity, or graduations is referred to as: a. b. c. d. C.2.43; G.40.5 calibration differentiation integration phase shifting C.3.28 In an eddy current testing situation, which of the following can provide sources of noise? a. b. c. d. 7. instrumentation electronic circuits nonspecific variations within the test object electrical interference all of the above a. with only the reference standard in one coil b. with the reference standard in one coil and an acceptable test specimen in the other coil c. with the reference standard in one coil and an unacceptable test specimen in the other coil d. with only the test specimen in one coil G.40.21 A.115 The ratio of the response or amplitude from signals of interest to the response or amplitude of indications that contain no useful information for the test being conducted is referred to as: a. b. c. d. Poisson's ratio signal-to-noise ratio the conductivity-to-permeability ratio the reactance-to-resistance ratio When conducting an eddy current test using a differential comparison coil arrangement that compares an external reference standard with the test specimen, the system should be nulled or balanced: 8. The impedance of an eddy current test coil will increase i f the: a. b. c. d. 0.366 IACS is a recognized abbreviation for: test frequency increases inductive reactance of the coil decreases inductance of the coil decreases resistance of the coil decreases C.2.35 a. b. c. d. Induced Alternating Current System Inductively-Activated Comparison System Internal Applied Current System International Annealed Copper Standard C.2-8; G.42.11 9. Some of the products commonly tested using encircling coils are: a. b. c. d. Which of the following is not a basic component of eddy current equipment? rods, tubes, and wire plate when volumetrically inspected sheets and metalized foil all of the above G.40.1 a. b. c. d. amplifier coil liquid couplant detector 10. Which of the following would normally be considered the best fill factor when testing straight tubing with an encircling or feedthrough coil? G.36.2 a. b. c. d. 0.95 1.75 0.50 0.25 (95%) (175%) (50%) (25%) G.36.17 Eddy Current Testing Method, Level I 11. When a magnetic metal part is placed in an eddy current test coil, the impedance of the coil will be changed by which of the following properties of the part? a. b. c. d. 15. When testing ferromagnetic materials, the depth to which eddy currents are induced in the material will be determined by the: a. b. c. d. conductivity dimensions permeability all of the above conductivity of the material permeability of the material geometrical shape of the material all of the above C.2-31 G.36.2 16. 12. An eddy current is a circulating electrical current induced in a conducting article by: a. b. c. d. gamma rays an alternating magnetic field a piezoelectric force any of the above When testing plate with a probe coil, it is noted that the eddy current output indication varies as the distance from the coil to the surface of the test part varies. The term used to describe this action is: a. b. c. d. C.2-5 fill factor lift-off phase differentiation edge effect C.2-24 13. The conductivity of a material can be changed by changing the: a. b. c. d. 17. alloy of the specimen heat treatment of the specimen temperature of the specimen all of the above The main purpose for spring-loaded eddy current probe coils is to: a. b. c. d. C.2-9 to 2-12 minimize lift-off variations minimize wear on the probe reduce operator fatigue eliminate edge effect C.2-24 18. Figure 1 B Lift-off is utilized in: a. measuring permeability changes b. measuring conductivity changes c. measuring the thickness of non-conductive coatings d. determining proper test frequency A C.2-25 19. In eddy current test systems where encircling coils are used, coupling efficiency is referred to as: a. b. c. d. lift-off edge effect fill factor phase differentiation G.36.17 20. B 14. Figure 1 is an illustration of a material's: a. b. c. d. When inspecting products with a uniform cross section, an eddy current signal is produced when the leading end or trailing end of the product approaches the test coil. This phenomenon is referred to as: a. b. c. d. phase analysis loop sine wave hysteresis loop none of the above lift-off end effect fill factor phase discrimination C.2-27 C.2-19 10 Eddy Current Testing Method, Level I 21. Which of the following conditions would be the most difficult to detect when eddy current testing rod with an encircling coil? 27. a. a deep surface crack that has a depth of 30% of the rod diameter b. a small inclusion in the center of the rod c. a 5% change in diameter d. a 10% change in conductivity C.2-29 22. a. b. c. d. When testing tubing with an inside diameter coil, most of the eddy currents: 28. 100 Hz 10 kHz 1 MHz 10 MHz 30. A n eddy current test coil's opposition to the flow of alternating current is called: steel aluminum copper brass C.3-9 31. An increase i n the impedance of an eddy current test coil will: The single absolute coil arrangement can be used in: a. b. c. d. encircling coils only probe coils only probe and encircling coils only probe, encircling, and inside diameter coils C.3-9 32. The primary purpose(s) of the secondary winding in an eddy current coil is to: a. induce eddy currents in the test specimen b. detect changes in the eddy current flow c. induce eddy currents in the test specimen and to detect changes in the eddy current flow d. provide dc saturation C.3-10 Which of the following will affect the impedance of an encircling eddy current test probe? a. b. c. d. Direct current saturation coils would most likely be used when testing: a. b. c. d. resistance inductive reactance impedance capacitive reactance a. cause an increase in the current flow through the test coil b. cause a decrease in the current flow through the test coil c. not affect current flow i n the test coil d. decrease the voltage applied to the coil C.2-34 26. slow changes in dimensions gradual changes in conductivity variation in heat treatment small surface defects C.3-8 C.2-33 25. Eddy current test coils, which are wound to form a narrow coil, would normally be used to detect: a. b. c. d. C.2-31 a. b. c. d. pitting small inclusions changes in conductivity porosity C.3-8 29. 24. Eddy current test coils which are wound to form a wide coil would normally be used to detect: a. b. c. d. Which of the following test frequencies would produce eddy currents with the largest depth of penetration? a. b. c. d. absolute winding secondary winding phase winding none of the above C.3-3 a. flow in a longitudinal direction down the tubing b. flow radially in the tube c. flow around only the outside diameter of the tubing d. flow around the inside diameter of the tubing C.2-30 23. When a test coil consists of a double winding arrangement, and one winding is referred to as a primary winding, the other winding is referred to as the: conductivity of a test specimen in the coil permeability of a test specimen in the coil fill factor all of the above C.2-34,2-35 11 Eddy Current Testing Method, Level I 33. Which of the following eddy current test coil arrangements uses one area of the test specimen as a reference standard against which another area on the same specimen is simultaneously compared? a. b. c. d. a. b. c. d. single absolute coil double absolute coil dc saturation coil differential coil an encircling coil a probe coil a secondary winding none of the above E.l-4 C.3-11 34. The readout mechanism used when testing by the ellipse method is a: a. b. c. d. 39. The entire circumference of a test part is evaluated at one time when using: 40. When attempting to determine the exact point location of a discontinuity, the test system should include: a. b. c. d. meter strip-chart recorder cathode ray tube any of the above a phase shifter a probe coil an attenuator a penetrameter E.l-7 C.3-16 35. Reference standards used for eddy current testing: 41. It is often possible to sort various nonmagnetic alloys of a metal by means of an eddy current test when: a. there is a unique range of permeability values for each alloy b. there is a unique range of conductivity values for each alloy c. the direction of induced eddy currents varies for each alloy d. the magnetic domains for each alloy are different E.3-10 a. must contain artificial discontinuities such as notches and drilled holes b. must contain natural discontinuities such as cracks and inclusions c. must be free of measurable discontinuities d. may contain artificial or natural discontinuities or be free of discontinuities depending on the test system and the type of test being conducted C.3-27 36. A reference standard used to ensure that the amplitude and phase characteristics of an eddy current system do not drift during continuous testing is called a: a. b. c. d. 42. Which of the following products would be most applicable to a test using an inside coil? a. b. c. d. DGS standard calibration standard reference block none of the above sheet rod bolt hole coating thicknesses E.3-33 C.3-28 37. Which of the following could not be tested by the eddy current testing method? 43. When eddy current testing rod for discontinuities, which of the following conditions could produce extraneous indications? a. improper adjustment of the hold-down rollers used to center the rod in the coil b. rod is fed through the coil at varying speeds c. changes in dimension d. all of the above e. none of the above E.3-33 a. a 102 mm (4 in.) thick plate to be tested for small discontinuities throughout the plate b. tubing to be tested for surface cracks c. rod to be tested for laps and seams d. tubing to be tested for variations in outside diameter C.4-36 38. Which of the following is not applicable to eddy current testing? 44. One method of reducing nonrelevant indications when eddy current testing ferromagnetic materials is to: a. decrease the pressure on the hold-down rollers b. use a direct current saturation coil to magnetically saturate the test specimen c. readjust the gain control d. increase the rate of feed through the coil E.3-34 a. can be used for high-speed testing b. can accurately measure conductivity c. can be set up to provide high sensitivity to small discontinuities d. can penetrate up to 152 mm (6 in.) in a test part C.4-36 12 Eddy Current Testing Method, Level I 45. Eddy currents are circulating currents induced in a conducting material by a: a. b. c. d. 51. varying piezoelectric field standing wave front direct current varying magnetic field Which of the following is not a read-out system used to present eddy current test information? a. b. c. d. calibrated and uncalibrated meters litmus paper cathode ray tube strip-chart recorders C.2-5 46. E.2-18,76 52. In order to generate measurable eddy currents in a test specimen, the specimen must be: a. b. c. d. a. the frequency must equal the f/f ratio to give an accurate test b. the frequency must be within ± 3 % of the f/f ratio to give an accurate test c. there is a range of suitable frequencies centered around the optimum frequency d. the frequency should be within ±25% of the characteristic frequency V.84 a conductor an insulator either a conductor or insulator a ferromagnetic material c C.2-8 47. A l l ferromagnetic materials that have been magnetically saturated to suppress permeability variations may retain a certain amount of the magnetization called the: 53. a. b. c. d. coercive force residual magnetism hysteresis loop hysteresis loss An ac current flowing in a conductor will set up: a. an alternating current field around the conductor b. a periodically changing voltage tangent to the conductor c. an alternating magnetic field around the conductor d. none of the above D.l-4 49. Which of the following is not a method that may be used to improve the signal-to-noise ratio? a. change to a test frequency that will decrease the noise b. increase the amplification of the test instrument c. improve the fill factor d. add filter circuits to the instrument A.16,35-36 C. 2-17,2-18 48. Which of the following statements best describes the selection of eddy current test frequency? 54. When conducting an eddy current test on tubing, the magnitude of the indication caused by a discontinuity is dependent on: a. b. c. d. The characteristics of the alternating magnetic field in the vicinity of the ac coil are affected by: the depth of the discontinuity the width of the discontinuity the length of the discontinuity all of the above G.37.11 a. b. c. d. 50. the coil parameters the magnitude of the applied ac current the frequency of the applied ac current all of the above C.2-32 to 2-35 55. A coil's magnetic field may be viewed as a distribution of lines of flux around the coil. The number of lines in a unit area is defined as: a. b. c. d. When using an encircling coil with both primary and secondary windings, the excitation alternating current is applied to: magnetic density flux density magnetic coupling hysteresis density C.2-19 a. the secondary winding b. the primary winding c. either the primary or secondary winding depending on the setting of an instrument control d. both the primary and secondary coils D. l-21,1-23 13 Eddy Current Testing Method, Level I 56. Which of the following discontinuities would be easiest to detect with an eddy current test? a. a crack that lies parallel to the direction of the eddy current flow b. a discontinuity located in the center of a 51 mm (2 in.) thick diameter rod c. a radial crack that extends to the outer surface of a rod d. a subsurface radial crack located at a depth of 13 mm (0.5 in.) in a 51 mm (2 in.) diameter rod C.2-29; V.80 57. 62. a. b. c. d. 63. measure coating thickness measure cladding thickness gauge the thickness of sheet all of the above eliminate overloading detect the possible existence of a third alloy make proper balancing possible phase the readings correctly G.41.6; V.98 Eddy currents cannot be induced in: 64. a. b. c. d. aluminum latex paint steel copper A term used to define a condition of balance in a device or system which results in zero output is: a. b. c. d. D.l-9 59. When sorting a known mix of two alloys with a comparator having a quantitative readout device, it is desirable to hold all indications within the bounds of the readout device in order to: a. b. c. d. J.145 58. start to increase start to decrease show no significant change suddenly drop to zero C.2-21 Eddy current test techniques can be used to: a. b. c. d. For the purposes of eddy current testing, saturation of ferromagnetic material is reached when the current is at such a value that for any further increase in current, the signal-to-noise ratio will: high frequency standardization integration null-balance differentiation A.202 Which of the following characteristics do not apply to magnetic materials? 65. a. b. c. d. high permeability value no hysteresis loop definite saturation point on hysteresis loop appreciable residual magnetism A term used to define a unit of flux density is: a. b. c. d. D.4-51 a maxwell a gauss an ohm a mho G.33.12 60. Which of the following is not an eddy current testing method? a. b. c. d. 66. pulse-echo testing impedance testing phase analysis testing modulation analysis testing a. b. c. d. D.5-115 61. Changes in the hardness of age hardenable aluminum and titanium alloys will normally be accompanied by changes in: retentivity permeability magnetostriction conductivity V.78 Eddy currents always travel: a. b. c. d. in nonconductive materials radially when testing rod with an encircling coil in closed paths in a gas C.2-5 67. A term used to describe holes, grooves, notches, etc., that are introduced into a reference standard to provide accurately reproducible quality levels is: a. b. c. d. a natural discontinuity an artificial discontinuity an ellipse none of the above V.88 14 Eddy Current Testing Method, Level I 68. A term used to define one or more turns or loops of a conductor wound in such a manner as to produce an axial magnetic field when current passes through the conductor is: a. b. c. d. 74. a. the coil would otherwise be out of balance b. parts of the material furthest away from the coil, radially, may receive a less sensitive inspection c. the flow of eddy currents around the product will be disturbed, resulting in improper penetration d. lack of proper centering may change the phase adjustment of the instrument C.2-25 a coil a resistor a capacitor an oscillator V.76 69. Nondestructive tests are commonly conducted to: 75. a. determine the quality of finished products b. locate defective material before excessive fabrication is performed on the material c. monitor production techniques d. all of the above The region around a magnet that attracts other pieces of iron or steel is called: a. b. c. d. 76. a maxwell the magnetic field retentivity alternating current An eddy current coil arrangement that does not make a comparison with either two sections of the test specimen or one section of the test part and a reference standard is called: a. b. c. d. 72. 73. 77. an absolute coil arrangement a self-comparison differential coil arrangement an external reference differential coil arrangement none of the above A.69 size or shape grade or chemistry of the material the way in which the material has been processed all of the above 0.346 A length of tubing containing a notch running from end to end and having uniform width and depth, when tested with an encircling self-reference differential coil system, will produce: a. b. c. d. Which of the following are common applications for eddy current testing? a. measurement of conductivity or a combination of conductivity and permeability b. measurement of the thickness of thin metal sections, cladding, or coating c. detection of surface and subsurface discontinuities d. all of the above G.36.2 An eddy current system (60-cycle comparator type) will measure variations caused by differences in: a. b. c. d. G.30.2 71. When you determine that a flaw detection instrument has been set up incorrectly, or is defective, all material: a. should be retested since the time correct set-up or proper operation was last verified b. accepted should be retested c. rejected should be retested d. none of the above C.4-31 A.7-8 70. Material must be reasonably centered in the test coil of a flaw detection system because: erratic signals a continuous, sustained signal no signal excessive signals G.3-11 78. In eddy current testing, optimum sensitivity to a known defect placed at random on the surface of a nonferrous length of tubing is obtained by: a. b. c. d. proper choice of frequency centering the tubing in the coil proper adjustment of phase all of the above . V.79, 81, 83 Which of the following is not a primary purpose for using an eddy current standard? 79. a. determine i f the eddy current test system is capable of performing the test properly b. determine i f a discontinuity is cause for rejection c. determine the instrument control settings needed to pass the highest percentage of test specimens run d. determine if the sensitivity of a test system has drifted with time A.295 Spinning probe-type eddy current instruments are most useful in the detection of: • a. b. c. d. - surface and subsurface inclusions the smallest surface blemishes internal piping or burst all of the above V.90 15 Eddy Current Testing Method, Level I 80. One principal advantage of spinning probe eddy current instruments is: 86. What causes phase shift in an eddy current test coil? a. a change in the ratio of inductive reactance (X ) to resistance (R) b. a change in the sensitivity setting of the instrument c. use of modulation analysis d. none of the above A.31; G.36.3 L a. the ability to locate the circumferential position of defects b. relative insensitivity to vibration c. the variety of internal and surface defects that may be detected d. all of the above C.3-5 81. A t any given instant, a spinning probe eddy current instrument should be inspecting: a. b. c. d. a. to check the phase selectivity b. to ensure proper centering of the material in the test coil c. to select the modulation analysis setting d. to select the proper operating speed G.39.10-12 one complete circumference of the product an area defined by the size of the probe coil one longitudinal line the length of the product none of the above C.3-5; 0.353 82. A spinning probe eddy current instrument would be most useful in: a. measuring hardness of ferromagnetic steel products b. flaw detection in hexagonal and shaped material c. detecting and precisely locating surface and subsurface discontinuities d. inspection of copper bus bars for electrical conductivity V.90 83. Which of the following is not a nondestructive testing method? a. b. c. d. 87. In a feed-through encircling coil flaw detection eddy current system, what would be the purpose of running a calibration defect several times but in various positions (such as top, bottom left, and right)? 88. In a feedthrough encircling coil eddy current system, dc saturation would probably be most helpful in testing: a. b. c. d. copper water tubing titanium tubing ferromagnetic steel tubing brass rivet wire A.56 89. In a feedthrough encircling coil eddy current system, the test frequency is controlled by the: a. b. c. d. ultrasonic testing fatigue testing eddy current testing radiographic testing oscilloscope sensitivity setting oscillator modulation analysis setting A.250,252 C.l-5 84. Which of the following is not applicable to spinning probe-type instruments? a. the size of product to be inspected is limited by the dc saturation capability of the system b. the frequency may be varied to accommodate various metals and alloys c. they may be used on straight or coiled wire products d. they are useful in seam detection G.38.36 90. Alloy variations in a nonmagnetic material would most likely affect: a. permeability b. conductivity c. diameter d. frequency G.37.6 91. Which of the following frequencies will provide the greatest eddy current penetration m aluminum? a. b. c. d. 85. In a feedthrough encircling coil eddy current system, a calibration standard may be used to: a. b. c. d. 1 kHz 10 kHz 3 kHz 300 Hz A.130 insure repeatability and reliability of the setup precisely calibrate the flaw depth reduce sensitivity to vibration measure the test frequency A.295-296 16 Eddy Current Testing Method, Level I 92. The coercive force of a soft iron electromagnetic core would be the coercive force of a permanent magnet. a. b. c. d. 97. When eddy current testing a nonferrous specimen, a discontinuity will: a. b. c. d. greater than less than twice equal to increase the effective conductivity of the specimen increase the effective permeability of the specimen decrease the effective conductivity of the specimen none of the above A.188 A.175 98. Demagnetization is generally needed when the residual field in a specimen: 93. Metals that do not react or react only slightly to magnetic fields are called: a. b. c. d. a. may affect the operation or accuracy of instruments when the specimen is placed in service b. may interfere with the proper functioning of the part c. might cause particles to be attracted and held to the surface of moving parts d. any of the above reasons could make demagnetization necessary V.67 diamagnetic metals paramagnetic metals nonmagnetic metals all of the above A.170-171; G.30.1 94. A symbol commonly used to express conductivity is: a. n b. a 99. A term used to define testing that requires that the test article be loaded and/or sectioned to verify and/or establish mechanical or physical properties is: C.2-43 a. b. c. d. 95. A symbol commonly used to express permeability is: a. | i b. a c. X d. R C.l-4 L V.54 96. The method used to generate eddy currents in a test specimen by means of a coil can most closely be compared with the action of a: a. b. c. d. impedance testing phase analysis testing destructive testing nondestructive testing transformer capacitor storage battery generator A.32-33 17 6 Level I Answers Eddy Current Testing Method 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. c d b d c a b a a a d b d c d b a c c b b d a c b 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. d b c d a d b d c d b a d a b b c d b d a b c d b 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 19 b c b d b c d b b a c c b c b d b a d b a d c b a 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. d c d b a b c b a a a b c c b d b d b a a c d c i Level II Questions Eddy Current Testing Method 1. A method of minimizing the effect of indications caused by gradual dimensional changes while retaining the indications caused by discontinuities is to: 5. a. include a high-pass filter in the eddy current test equipment b. include a low-pass filter in the eddy current test equipment c. increase the band pass of the amplifier d. use the impedance method of testing A.61 2. a. b. c. d. 6. filtering or differentiation phase discrimination integration all of the above 4. skin effect high-frequency filtration low-frequency filtration any one of the above 0.347; V.80 7. In order to decrease the effect on conductivity readings due to variations in test part thickness: a. b. c. d. A term used to define the phenomenon where, at very high frequencies, the eddy current flow is restricted to an extremely thin outer layer of the conductor is: a. b. c. d. E.2-76 3. fill factor edge effect end effect lift-off 0.357; V.29 Which of the following methods may be used to improve the signal-to-noise ratio of an eddy current test system? a. b. c. d. A term used to describe the effect observed due to a change in the electromagnetic coupling between a test specimen and a probe coil when the distance of separation between them is varied is: a. b. c. d. the test frequency should be increased the test frequency should be decreased the fill factor should be decreased there is no practical method for decreasing this effect 0.347 0.5 (50%) 0.75 (75%) 1.0(100%) 0.25 (25%) V.79 8. When testing by the eddy current method, discontinuities will be most easily detected when the eddy currents are: a. coplanar with the major plane of the discontinuity b. perpendicular to the major plane of the discontinuity c. parallel to the major plane of the discontinuity d. 90 degrees out of phase with the current in the coil G.37.18 The fill factor when a 13 mm (0.5 in.) diameter bar is inserted in a 25 mm (1 in.) diameter coil is: The teim used to define the difference between actual instrument output and expected output as defined by a straight line calibration curve is: a. b. c. d. phase shift nonlinearity lift-off skin effect U.189 9. Which of the following could be used to suppress unwanted high-frequency harmonics? a. b. c. d. low-pass filter oscillator phase discriminator high-pass filter D.5-122 21 Eddy Current Testing Method, Level II 10. The impedance change of an eddy current test coil due to a change in test part characteristics can be most easily analyzed as a combined change in: a. b. c. d. 11. 16. capacitive reactance and resistance harmonic frequencies and inductive reactance signal amplitude and phase retentivity and harmonic frequencies G.36.19-20 a. test material permeability b. test frequency c. geometry of the test object d. all of the above G.36.12 The inductive reactance of a test coil can be calculated using the formula: a. b. c. d. X X X X L L L L In a test coil consisting of both a primary and secondary winding, the voltage across the secondary is a function of: 17. Eddy current testing relies on the principle of: a. b. c. d. = 2rcL = 0.5nL = 27tft = 1R magnetostriction electromagnetic induction piezoelectric energy conversion magnetomotive force A.2 G.36.1 18. When the H field strength around a material is increased and then decreased to zero, the induction field B within the part does not return to zero. The term to define this B value when H has returned to zero is: 12. When conducting an eddy current test, variations in the test material can be detected as variations in: a. b. c. d. test speed impedance of a pickup coil none of the above all of the above a. b. c. d. 0.346 13. A.175; V.54 A term used to define two or more coils electrically connected in opposition such that any electromagnetic condition which is not common to both a test specimen and a reference specimen will produce an unbalance in the system is: a. b. c. d. coercive force residual magnetism saturation value hysteresis loss 19. The term used to define the value of H field required to decrease the remanence of a material to zero is: a. b. c. d. differential absolute laminar flying probes coercive force magnetizing force backemf the overlap value A.175 U.85 20. 14. Tubing is generally inspected using: a. b. c. d. a. electrical conductivity, frequency, and material geometry b. density, permeability, and frequency c. electrical conductivity, permeability, and material geometry d. thermal conductivity, electrical conductivity, and permeability G.36.2 U-shaped coils gap coils encircling coils none of the above U.85 15. When testing small parts in an eddy current encircling coil for permeability measurements, which of the following test parameters may be considered important? a. b. c. d. The three major specimen parameters that influence eddy current testing are: 21. Doubling the number of turns on a coil will: a. b. c. d. length of the test sample thickness of the test sample cross-sectional area of the test sample all of the above double the inductance halve the inductance decrease the inductance by a factor of four increase the inductance by a factor of four G.36.19 G.34.1 22 Eddy Current Testing Method, Level II 22. Frequency ratio, / / / , can be defined as: 28. a. the argument of the mathematical function describing the electromagnetic field within the test specimen b. test frequency divided by limit frequency c. neither of these d. both of these G.36.13 23. a. increasing the rate of displacement of the specimen through the coil b. magnetically saturating the test specimen c. decreasing the rate of displacement of the test specimen through the test coil d. testing in an air-conditioned room C.2-22 When testing tubing, using an encircling (OD) coil, what is the phase relationship of the output signals from identical I D and OD discontinuities? 29. a. the signals are in phase b. the phase of the OD discontinuity leads the phase of the I D discontinuity c. the phase of the OD discontinuity lags the phase of the I D discontinuity d. indeterminate A.25-26 decreases increases remains the same could do any of the above G.37.9 A term used to define an instrumentation technique that discriminates between variables in the test part by the different phase angle changes which these conditions produced in the test signal is: a. b. c. d. I f the test frequency increases while the field strength is held constant, the surface eddy current density: a. b. c. d. 30. 24. The heating effect in magnetic materials caused by the work required to rotate magnetic domains can be eliminated by: As the fill factor decreases, the impedance variation of a pickup coil produced by a given change in conductivity will: a. b. c. d. phase distortion phase shifting phase discrimination phase analysis increase remain the same decrease could do any of the above A.39-40 C.3-13 25. Figure 2 I f the characteristic frequency ( / ) of a material is 125 Hz, the test frequency required to give an / / / ratio of 10 would be: wL 1 wL a. b. c. d. o 1.25 Hz 12.5 Hz 1.25 kHz 12.5 kHz 2.25 0.8 26. A term used to define any change in a sinusoidal signal when the output is not a linear reproduction of the input is: 0.6 a. b. c. d. 0.4 distortion linearity phase shifting dynamic range 1 / 2 / 0.2 / 9 5 49 X100 At a fixed test frequency, in which of the following materials will the eddy current penetration be greatest? 4(M1 0 * 40 000 0.2 a. b. c. d. 6.25 1 6 / G.40.41 27. 4 T G.36.13 aluminum (35 percent LACS conductivity) brass (15 percent IACS conductivity) copper (95 percent IACS conductivity) lead (7 percent IACS conductivity) 0.4 R wL o C.2-31 23 Eddy Current Testing Method, Level I I 31. The abscissa values on the impedance plane shown in Figure 2 are given in terms of: a. b. c. d. 34. In Figure 3, the solid curves are plots for different values of: absolute conductivity normalized resistance absolute inductance normalized inductance heat treatment b. conductivity c. fill factor d. permeability S.101 S.102 32. In Figure 2 (an impedance diagram for solid nonmagnetic rod), the / or characteristic frequency is calculated by the formula: a. b. c. d. / f f f Figure 4 A(oL 2 a = opyd = b\\J2 = 5060/aud = R/L 2 S.101 33. In Figure 2, a change in the / / / ratio will result in: a. a change in only the magnitude of the voltage across the coil b. a change in only the phase of the voltage across the coil c. a change in both the phase and magnitude of the voltage across the coil d. no change in the phase or magnitude of the voltage across the coil S.101 Figure 4 illustrates the fact that eddy current responses: a. can be caused by several parameters b. differ in phase and magnitude with different parameter changes c. can be made selective with regard to the variable of interest d. all of the above S.103 Which of the following would be easier to detect in tubing by the eddy current method using the selfcomparison differential coil arrangement? a. b. c. d. gradual changes in diameter gradual changes in conductivity changes in temperature short flaws S.104 24 Eddy Current Testing Method, Level II 37. The magnetic domains in an unmagnetized ferromagnetic material are: a. b. c. d. 40. To eliminate any dependence upon the number of turns of a test coil, the inductance values of an impedance diagram are: arranged to facilitate the conduction of electrons randomly oriented and neutralize each other uniformly oriented create a major north and south pole in the material C.2-14; V.93 a. b. c. d. disregarded normalized corrected to a value of 1 none of the above A.36-38 38. When a magnetic material is placed in a region of an applied magnetizing force (//), magnetic field (B) is developed in the material by means of: a. b. c. d. 41. A term used to define a system that indicates only the magnitude of variations in the total coil impedance regardless of the phase or direction in which it occurs on an impedance plane is: induction conduction heat transfer magnetic domain transfer a. b. c. d. G.30.6 inductive reactance magnitude system feedback-controlled system impedance-magnitude system impedance vector analysis system D.5-30 Figure 5 42. When eddy current testing tubing with a system that includes a frequency discriminating circuit, which of the following variables would be classified as a highfrequency variable? a. b. c. d. small discontinuities conductivity changes diameter changes wall thickness variations D.5-123 43. A major problem associated with the eddy current test method is the: a. inability of eddy current testing to accurately measure conductivity b. need to test at low speeds to prevent skipping c. large number of known or unknown variables that appear in the output indication d. inability of eddy current testing to detect small discontinuities C.2-7 44. The atoms of a metal showing magnetic characteristics are grouped into regions that are the smallest known permanent magnets. These regions are called: a. b. c. d. Normalized Resistance 39. Figure 5 illustrates the fact that the limit frequency, / , equations and impedance diagrams for long solid rods and long thin-walled tubing are: lattice structures cells domains planetary spins C.2-13 a. different b. identical c. similar d. unrelated G.38.8 25 Eddy Current Testing Method, Level 11 45. When a coil's magnetizing force is applied to a ferromagnetic material, the flux density in the material is: 51. a. less than the flux density generated by the test coil because of heat losses b. less than the flux density generated by the test coil because of resistivity c. the same as the flux density generated by the test coil d. greater than the flux density generated by the test coil C.2-20 46. symbol \i symbol o letter^ letter H C.2-38 52. L c. Z = -^X 53. 54. core coupling magnetic saturation the coil's magnetic field magnetic domains The thickness of nonconductive coatings on a conductive base can be most simply measured by: a. b. c. d. 50. L + R 2 A term used to define a surface coil mounted so that the coil can be rotated about the circumference of a test specimen is: bobbin coil encircling coil spinning coil gap coil C.3-5 55. observing the lift-off effect caused by the coating testing both sides of the specimen varying the current in the test coil varying the test frequency over a given range during the test C.2-25 The use of magnetic shielding around the exciting coil will generally: An out-of-phase condition between current and voltage: a. b. c. d. C.2-22 49. 2 + R a. can exist only in the primary winding of an eddy current coil b. can exist only in the secondary winding of an eddy current coil c. can exist in both the primary and secondary windings of an eddy current coil d. exists only in the test specimen C.2-40 symbol \x symbol a letter B letter// In eddy current testing, the specimen is coupled to the test coil by: a. b. c. d. L C.2-39 C.2-20 48. The formula used to calculate the impedance of an eddy current test coil is: a. Z=2nfL b. Z = X + R The magnetizing force of an eddy current test coil is usually designated by the: a. b. c. d. diameter of coils test frequency overall shape of the coils distance from other coils d. Z = ^X C.2-20 47. a. b. c. d. The flux density in a magnetic material is usually designated by the: a. b. c. d. Which of the following is not a factor that affects the inductance of an eddy current test coil? A term used to define an eddy current test coil which uses magnetic material to purposely shape the magnetic field is: a. b. c. d. bobbin coil encircling coil spinning coil gap coil C.3-7 56. a. increase the magnetic field extension but decrease the eddy current penetration b. increase the magnetic field extension and eddy current penetration c. decrease the magnetic field extension but increase the eddy current penetration d. decrease the magnetic field extension and eddy current penetration C.2-26 The vector-point, ellipse, and linear time-base methods are all subdivisions of the: a. b. c. d. impedance method of testing the modulation analysis method of testing the phase analysis method of testing none of the above C.3-15 26 Eddy Current Testing Method, Level II 57. It is frequently possible to separate the conductivity variable from the permeability and dimensional variables when using: a. b. c. d. 62. The conductivity value for a metal is a function of the: a. b. c. d. the vector-point method of testing the ellipse method of testing the linear time-base method of testing any of the above methods of testing heat treatment given the metal cold working performed on the metal aging process used on the metal all of the above C.4-6 C.3-14 63. The ratio of the specific diameter of a probe to the minimum discontinuity of interest should be: 58. When eddy current testing by the ellipse method, the normal indication when the test specimen and reference standard are the same is approximately: a. b. c. d. a. b. c. d. a straight horizontal line on a cathode ray tube an ellipse on a cathode ray tube a null reading on a meter a clean base line on a strip chart C.3-16 C.5-3 64. Which of the following materials would be more likely used as a mounting material for a probe coil? 59. When eddy current testing by the ellipse method, one variable may be indicated by the angle of the ellipse or straight line while another variable may be indicated by the: a. b. c. d. less than 2 greater than 2 greater than 4 greater than 10 a. b. c. d. aluminum fiberglass copper steel C.5-4 brightness of the ellipse horizontal length of the straight line size of the ellipse opening sinusoidal shape of the waveform 65. A term used to define a surface or internal rupture that is attributed to processing at too low a temperature or excessive working or metal movement during the forging, rolling, or extruding operation is: C.3-16 60. When eddy current testing by the linear time-base method, is applied to the vertical deflection plates of a cathode ray tube when the test specimen and reference standard are the same and the balance controls are properly adjusted. a. b. c. d. a cold shut microshrinkage burst an inclusion C.7-8 a. a sinusoidal wave in phase with the timing voltage b. a sinusoidal wave 90 degrees out of phase with the timing voltage c. a sawtooth waveform d. zero net voltage C.3-18 61. When eddy current testing by the linear time-base method, what is applied to the vertical deflection plates of a cathode ray tube when a condition of unbalance exists between the test specimen and the reference standard? a. b. c. d. 66. A term used to define the timing relationships involved in alternating current signals is: a. b. c. d. magnitude phase impedance reactance A.19-21 67. When eddy current testing a nonferrous material, the choice of test frequency is determined by the: a sinusoidal wave a sawtooth wave a square wave no voltage a. b. c. d. C.3-19 27 degree of phase discrimination required eddy current penetration needed rate of response required all of the above A.27,36; V.84-85 Eddy Current Testing Method, Level II 68. When testing ferrous materials, a small but detectable portion of the magnetic flux in the material will pass outside the metal when a surface discontinuity is encountered. This flux is called: a. b. c. d. 73. a. the specimen should be of the same size and shape as the piece to be tested b. the specimen should have the same heat treatment as the piece to be tested c. the surface finish of the specimen should be the same as the piece to be tested d. i f the material is aluminum, the surface should be anodized C.3-27 air flux leakage flux induced flux none of the above V.330 69. A term to define a property of a test system which enables the separation of signals due to discontinuities in the test specimen that are located in close proximity to each other is: a. b. c. d. 74. dynamic range sensitivity linearity discontinuity resolution A term used to define a material having a permeability less than that of a vacuum is: a. b. c. d. diamagnetic ferromagnetic paramagnetic magnetic A.171 75. 71. The inductive reactance of a coil is measured in units of: a. b. c. d. A n eddy current test coil's magnetic field intensity in air: a. increases with distance outside the coil and varies across the diameter inside the coil b. decreases with distance outside the coil and varies across the diameter inside the coil c. decreases with distance outside the coil and is assumed to be constant across the diameter inside the coil d. increases with distance outside the coil and is assumed to be constant across the diameter inside the coil D.2-7 G.43.49 70. Which of the following conditions are not important when selecting specimens to be used as reference standards? The circuits which make it possible to minimize the effect of signals caused by variables of no interest on the readout mechanism are based on differences in: a. b. c. d. mhos ohms henrys gauss V.77 72. Which of the following coil arrangements would eliminate or decrease the effects of minor variations in diameter, chemical composition, hardness, etc., which occur gradually along the length of a wire? a. b. c. d. 76. amplitude phase frequency any one or a combination of the quantities listed above A.109-116 When a nonmagnetic rod is placed inside an eddy current test coil: a. the magnetic field generated by the coil is increased in intensity b. the distribution of eddy currents is uniform through the rod's cross section c. the distribution of eddy currents is at a maximum at the rod's surface, or near the surface, and decreases to essentially zero at the rod's center d. the temperature of the rod decreases D.2-13 external reference differential self-comparison differential single coil absolute double coil absolute C.3-11 77. The symbol commonly used to signify impedance is: a. b. c. d. Z Xe R X s c C.2-32 28 Eddy Current Testing Method, Level II 78. A decrease in conductivity is equivalent to: a. b. c. d. 83. The two voltages (Vj and V ) shown in Figure 6 are: 2 an increase in permeability an increase in resistivity a decrease in permeability a decrease in resistivity a. b. c. d. in phase 45 degrees out of phase 90 degrees out of phase 180 degrees out of phase C.2-8 C.2-36 79. If the conductivity of a test part in an eddy current test coil decreases, the magnitude of the eddy currents at a given depth in the test specimen: a. b. c. d. increases remains the same decreases may increase or decrease C.2-8 80. When the voltage applied to a circuit and the current through the circuit both reach their maximums and minimums at the same time, the voltage and current are: a. b. c. d. 84. The two voltages (Vj and V ) in Figure 7 are: additive in phase regenerative out of phase 2 a. b. c. d. C.2-36 in phase 45 degrees out of phase 90 degrees out of phase 180 degrees out of phase C.2-37 81. Which of the following is not a commonly used eddy current testing readout mechanism? a. b. c. d. signal generator meter cathode ray tube strip-chart recorder C.2-7 82. Which of the following materials would have the highest resistivity value? a. b. c. d. aluminum with a 42 percent IACS rating magnesium with a 37 percent IACS rating cast steel with a 10.7 percent IACS rating zirconium with a 3.4 percent IACS rating C.2-32 85. In Figure 8, H represents: a. b. c. d. the the the the coil's magnetizing force material's flux density material's permeability material's conductivity C.2-18 29 Eddy Current Testing Method, Level II 86. In Figure 8, B represents: a. b. c. d. the the the the 92. coil's magnetizing force material's flux density material's permeability material's conductivity For age hardenable aluminum and titanium alloys, changes in hardness are indicated by changes in: a. b. c. d. C.2-18 retentivity permeability conductivity magnetostriction V.104 87. In Figure 8, the distance represented by A is a measure of the material's: a. b. c. d. 93. permeability conductivity retentivity coercive force a. test frequency or conductivity of the specimen is decreased b. test frequency is decreased or conductivity of the specimen is increased c. test frequency, conductivity of the specimen, or permeability of the specimen are increased d. permeability of the specimen is decreased A.24 C.2-18 88. In Figure 8, the distance represented by C is a measure of the material's: a. permeability b. conductivity c. residual magnetism d. coercive force 94. The ratio of a material's flux density to a test coil's magnetizing force, (B/H), can be used to determine the material's: a. b. c. d. conductivity resistivity lift-off permeability 95. C.2-14 90. 96. 91. The impedance of a test coil usually can be represented by the vector sum of: a. b. c. d. When testing magnetic materials in an ac field, increasing the field strength: a. b. c. d. The magnetic field generated by eddy currents induced in a test specimen: a. opposes the magnetic field that induced the eddy currents b. reinforces the magnetic field that induced the eddy currents c. cancels the magnetic field that induced the eddy currents d. has no effect on the magnetic field that induced the eddy currents C.2-8 When the electrical current in an eddy current coil reverses direction: a. the direction of the eddy currents in a part remains the same b. the eddy currents in the test part will change phase by 45 degrees c. the direction of the eddy currents in the part also reverses d. the eddy currents in the part remain the same C.2-5 C.2-18 89. The penetration of eddy currents in a conductive material is decreased when: inductive reactance and resistance capacitive reactance and resistance inductive reactance and capacitive reactance inductance and capacitance Impedance diagrams have been mathematically derived and experimentally verified for materials of any conductivity and permeability having rectangular, cylindrical, or spherical symmetry. To test all specimens of similar geometry under the same condition, it is only necessary to choose a test frequency, / , so that frequency ratio / / / lies at the same point on the impedance diagram for each specimen. This principle is based upon: a. b. c. d. G.36.1 has no effect increases eddy current penetration decreases eddy current penetration decreases eddy current penetration to some minimum value, and then increases it to its maximum value when the specimen becomes magnetically saturated G.38.21 Ohm's Law KirchoffsLaw the Similarity Law none of the above G.37.10 30 Eddy Current Testing Method, Level II 97. To be useful, limit frequency equations must be: a. b. c. d. 101. Two test coils are often used in a bridge circuit to: used with their impedance diagrams used to determine their impedance diagrams both of these neither of these A.158 a. eliminate skin effect b. determine the differences between a known standard sample c. increase the conductivity of the circuit d. decrease the system sensitivity A.69 98. When a rod is placed in an encircling type of coil, the density of eddy currents will be the greatest: a. b. c. d. 102. In inspecting ferromagnetic materials, relatively lowfrequencies are normally used because of the: at the surface at the center midway between the surface and the center none of the above a. b. c. d. G.37.8 Low penetrability of these materials higher resolution lower resolution higher penetrability of these materials A.132 99. The term fill factor applies to: a. b. c. d. 103. The actual frequencies used in any specific eddy current inspection should be selected on the basis of the: a surface coil coaxial cable an encircling coil all of the above a. b. c. d. e. C.2-25 100. An eddy current system using handling equipment with automatic marking of the defective areas primarily makes it possible to: thickness of the material desired depth of penetration degree of sensitivity or resolution required purpose of the inspection all of the above V.84 104. In modulation analysis testing, which of the following would not modulate the test frequency applied to the test coil? a. remove defective areas of the product, if desired b. eliminate test surface contamination c. allow an inexperienced operator to establish the defect cause d. pass rejectable material G.41.3 a. b. c. d. discontinuities in the test specimen dimension changes of the test specimen chemical composition of the test specimen a filter in the test circuit D.5-119 31 Level II Answers Eddy Current Testing Method 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. a d a b d a d b a c c b a c d d b b a c d b b d c a 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. d b b c b c c c d d b a a b c a c c d c d c a d b d 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 33 c c d c d a c d a d a b c b d b d a b b d b d c a b 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. c b a d a c a b c d d a a c c c d c a a c a b a e d Level III Questions Eddy Current Testing Method 1. In a feedthrough encircling coil eddy current system, what would be the purpose of running a calibration defect several times but in various positions (such as top, bottom, left and right)? 4. a. to check the phase selectivity b. to ensure proper centering of the material in the test coil c. to select the modulation analysis setting d. to select the proper operating speed F.E571-9.3 2. a. detection of surface and subsurface inclusions b. detection of surface defects such as overlaps and seams c. detection of internal piping or burst d. all of the above A.194 5. In a feedthrough encircling coil eddy current system, a calibration standard may be used to: a. b. c. d. A product can be viewed in terms of electrical magnetic effects. A diameter change of the product in an encircling coil is: a. b. c. d. insure repeatability and reliability of the setup calibrate the approximate depth of detectable flaws both a and b measure the test frequency C.4-30 an electrical effect a conductivity effect a magnetic effect all of the above D.4-6 6. 3. Spinning probe-type eddy current instruments are most useful in: A calibration standard may be used with a spinning probe eddy current instrument to: a. produce an indication relative to the depth of the flaw b. check the instrument for repeatability and freedom from drift c. check probe coil for possible damage d. all of the above C.4-30 In Figure 9, ac flowing through a primary coil set-up a magnetic field and causes a flow of eddy currents in the rod. The voltage of the secondary coil is dependent upon: a. b. c. d. these eddy currents the primary coil the generator all of the above C.2-40 Figure 9 Primary Coil Generator T Secondary Coil 35 v Eddy Current Testing Method, Level HI 7. Which of the following is not a method that may be used to improve the signal-to-noise ratio? 13. Lift-off certainly reduces the amplitude of the flux leakage signal. The other significant effect it has on the signal is a change in: a. change to a test frequency that will decrease the noise b. increase the amplification of the test instrument c. improve the fill factor d. add filter circuits to the instrument E.2-76 8. a. phase b. frequency c. increasing lift-off which reduces the apparent width of the defect d. none of the above P.31A In eddy current testing, the theoretical maximum testing speed is determined by the: a. b. c. d. 14. magnetic flux density testing frequency conveyor drive test coil impedance a. b. c. d. A.57; C.4-33 9. In eddy current testing of ferromagnetic materials, the dc saturating field may be provided by: a. b. c. d. The tubular product parameter having the greatest influence on the flux density of the magnetic field in the part (assuming the magnetizing force, H, remains constant) is the: surface roughness of the product diameter of the product wall thickness of the product length of the product V.330 15. an encircling solenoid a magnetic yoke both a and b none of the above Any handling of equipment used in an eddy current system must take into consideration: a. the operator's abilities b. the use of the product being tested c. speed, frequency of test, sorting speed, and physical control of the product d. all of the above F.E571-11.5 10. Which of the following is a property of eddy currents induced in a conductor by an encircling coil? G.41.19 a. the magnitude of eddy current flow is large compared to the current flow in the coil b. the eddy current flow is affected by permeability variations in the sample c. the eddy current flow dissipates no power in the conductor d. none of the above C.2-21 16. A n eddy current system lends itself to quality ratings such as "Quality Numbers" where the product being inspected: a. b. c. d. 11. Which of the following is a property of eddy currents induced in a homogeneous conductor by an encircling coil? a. they are weakest on the conductor surface b. the phase of the eddy currents varies throughout the conductor c. they travel in straight lines d. they are maximum along the coil axis A.177 is not defective does not allow defective areas to be removed is of inferior quality has inconsistent quality G.41.10 17. When inspecting material with eddy currents in an automatic handling system, it is advisable to calibrate and adjust the sensitivity levels to: a. b. c. d. some electronic source another NDT method an NBS standard an actual test part being inspected G.41.10 12. Which factor does not affect the phase shift between the transmitted signal and the reflected signal for a reflection-type coil (assuming the part is nonferromagnetic) ? a. b. c. d. the the the the 18. A distinct advantage of using handling equipment in an eddy current test system is to reduce the error caused by: a. b. c. d. e. conductivity of the sample magnitude of the transmitted signal thickness of the sample presence of defects in the sample A.177 instrument drift lift-off skin effect all of the above none of the above C.2-24 36 Eddy Current Testing Method, Level III 19. Decreased coupling or fill factor results in decreased test sensitivity because: 23. a. reduced coupling between the driver coil and the specimen induces less eddy current flow in the specimen b. reduced coupling between the specimen and the pickup coil results in smaller voltages across the pickup coil c. electrical circuits designed to provide fill factor compensation may prove to be inadequate, depending upon the extent of fill factor loss d. all of the above A.35 20. a. the coil becomes magnetically saturated b. the permeability raises the inductance of the test coil c. the magnetic test sample's conductivity increases the reactance value of the coil d. this effect is described mathematically by the B _ equation ,7 M— A.53 24. Why is it desirable to hold the fill factor or lift-off constant? a. to avoid arcing between the coil and the specimen b. to minimize tester output signal changes that are not relevant to conditions within the specimen to be tested c. a fill factor or lift-off change will shift the operating frequency d. to minimize the load on the constant current ac excitation circuits A.35 21. The reactance component is decreased by placing a conducting object in the coil's electromagnetic field. Why is this so? 25. The test coil excitation current should be held constant so that the test piece information obtained by an eddy current system will: a. contain only flaw information and not indicate variations in magnetic field strength b. not contain signals generated by cross talk c. not contain electrical noise d. all of the above A.21 26. Test coils may be shielded with conducting material or magnetic material to: a. b. c. d. e. When an excitation voltage is applied to a primary winding, only the magnetic flux is in phase and the secondary magnetic flux is minor. When a test object is inserted in this coil, what action takes place? a. the object gets hot and no information is available b. insertion of the object cancels all information c. the insertion of the test object intensifies the secondary magnetic flux producing a new total magnetic flux which can be used to supply test information d. by subtracting the primary voltage from the secondary voltage, the net voltage is obtained A.21 a. the secondary field is exactly in phase with the primary field b. the secondary field is at precisely 90 degrees with the primary field c. the phase angle between the two field components is always greater than 90 degrees which partially cancels the primary field d. the secondary field is 180 degrees out of phase with the primary field which causes a large phase shift A.53 22. When a magnetic bar is placed in the coil's electromagnetic field, the coil's reactance is increased. What causes this phenomena? Eddy currents flowing in the test object at any depth produce magnetic fields at greater depths, which oppose the primary field, thus reducing its effect and causing what kind of change in current flow as depth increases? a. b. c. d. shape field increase sensitivity increase resolution all of the above none of the above a decrease an increase a frequency change none of the above A.24 A.68 27. Skin effect causes eddy currents to tend to flow near the surface of the test piece. Which of the following factors alter the skin effect? a. b. c. d. e. testing frequency test piece temperature test piece hardness test piece permeability all of the above A.24 37 Eddy Current Testing Method, Level III 28. Which of the following is not a common undesirable effect to the test coil caused by the testing environment? a. b. c. d. e. 31. A n ac current produces eddy currents in a test object. The vector H represents the secondary ac field in the test piece. What function occurs to produce a workable test situation? (See Figure 10.) temperature variation crack in test sample test object making contact with test coil foreign object in the test coil field test coil vibration a. changes in the test specimen such as a crack, metallurgical or dimensional change alter the secondary field phase and amplitude b. the primary ac current must be 60 cycles to produce this effect c. a temperature rise in the specimen d. a mismatch of the H and H fields produces a change in the output G.36.1 A.27 29. There is one function that responds to variations in eddy current flaw and magnetic field conditions. This function actually produces the output signal from the coil. What is this function? p s Figure 11 a. b. c. d. phasing resistance reactance impedance I A^i J J_ d component A.199 30. The inductive reactance of a test coil, which is one of the most important impedance quantities, depends upon which of the following? a. b. c. d. e. frequency, coil inductance, coil resistance coil inductance only coil resistance and inductance only frequency and coil resistance only frequency and coil inductance only G.36.1 Figure 10 32. To separate cracks and diameter effects for steel cylinders, the optimum frequencies correspond to / / / ratios of less than (see Figure 11): a. b. c. d. e. 10 15 50 100 150 G.37.26,37.27 38 Eddy Current Testing Method, Level III 34. Figure 12 -0.3 -0.2 +0.2 —J +0.3 1 10 Figure 13 indicates that the largest eddy current indications from subsurface cracks will occur when the frequency ratio (f/f ) is: g - 2 > a. b. c. d. 5 or less 15 50 150 or more G.37.25 35. Figure 13 indicates that the magnitude of a signal from a subsurface crack will increase when the frequency ratio (f/f ): g a. b. c. d. remains the same decreases increases none of the above G.37.24 Au Figure 14 real 0.06 33. a. b. c. d. 0.1 and 0.4 and 2.4 and 4.0 and -1 1 1 depth of crack in % of diameter Thin-walled tubes should be tested for cracks, alloy or wall thickness at frequency ratios between (see Figure 12): G 0.05 0.4 2.4 4.0 10 G.38.6,38.7 Figure 13 0.12 V \ Subs urface C ack 30% Depth r 5 0.10 50 100 150 ///,g 0.08 P 3" °-° 10 15 36. Figure 14 indicates that when inspecting for surface cracks in nonferromagnetic cylinders, the opdmum frequency ratio ( / / / ) is between: 6 a. b. c. d. flf = 5 g 0.04 flf - 5 and 10 10 and 50 50 and 100 100 and 150 G.37.23,37.24 g 0.02 1 37. = 50 2.5 ~d!5(5 5 7.5 An operating frequency of 100 kHz will have the deepest penetration in: 10 a. b. c. d. % of Diameter titanium copper stainless steel aluminum V.80 39 Eddy Current Testing Method, Level HI 38. As the operating frequency is increased, the impedance of the empty coil: a. b. c. d. 42. Of the following test coil systems, which would be considered best for definitive detection of small discontinuities in tubing? increases decreases remains the same none of the above a. b. c. d. V.81 encircling coils inside probe (ID) coils surface probe coils both a and b G.38.25,38.36 39. Disadvantages of using a surface probe coil for the inspection of small-diameter tubing include: a. b. c. d. e. 43. In a test coil system, when the sensing coil is placed near the excitation coil, which of the following statements is true? inability to detect small discontinuities slow inspection speed inherent mechanical problems both a and c both b and c a. almost the same magnetic flux threads both coils b. signals from either coil can be used to provide information about the test piece c. the arrangement is never sensitive to small discontinuities d. all of the above e. both a and b A.34 G.38.25 Figure 15 44. In linear time-base equipment: a. the balance control will not affect the phase of the signal on the CRT b. the balance control changes the horizontal position of the signal displayed on the CRT c. the phase control permits initial smoothing of the input signals d. the phase control shifts the signal to the left or right on the CRT E.2-60 45. Filters are used in modulation analysis to: 40. Differential coil systems can be of which of the following types? (see Figure 15) a. b. c. d. e. a. amplify crack or other discontinuity signals b. reduce the signal-to-noise ratio c. eliminate effect of small random changes in conductivity and permeability of test sample d. separate conductivity variations from permeability variations E.2-79 sketch no. 1 sketch no. 2 sketch no. 3 all of the above both a and b A.36-38; G.38.25 41. The sensing element in an eddy current system can be which of the following? a. b. c. d. e. 46. In modulation analysis, the type of display usually used is: a. b. c. d. the secondary winding of a differential coil an absolute coil a single winding coil all of the above both a and b A.181-182 cathode ray tube analog meter chart recorder digital voltmeter E.2-70 40 Eddy Current Testing Method, Level III 47. When the slit technique is used with the linear timebase method: 51. a. a straight line trace will appear when the two voltages applied to the deflection plates are 90 degrees out of phase b. the presence of a crack in a test specimen will generally produce a phase shift c. changes in diameter of a rod cannot be separated from crack effects d. a circle w i l l appear on the screen whenever no voltage is applied to the vertical plates G.40.24 a. a shift in phase will move the waveform on the CRT to the left or right b. after calibration, the waveform on CRT will move up or down when a discontinuity appears c. the equipment can be adjusted so that permeability and conductivity changes will show little or no change in the slit value d. dimension effects will not be displayed at the slit, when the conductivity effect is on the horizontal line E.2-68 48. 52. In linear time-base equipment, which type of signal is applied to the horizontal deflection plates? a. b. c. d. In the ellipse method, the following (see Figure 16) indication should be interpreted as: 53. a. b. c. d. change in dimension change in conductivity and dimension change in conductivity no change E.2-44 When using an inspection system having an "ellipse display" readout, the signal applied to the vertical input of the scope is related to that applied to the horizontal input as follows: a. the vertical signal is demodulated; the horizontal signal is not b. the vertical and horizontal signals are of the same frequency c. the vertical and horizontal signals are always in phase d. none of the above G.40.23,40.24 Figure 16 54. 50. Eddy current test instruments that indicate only the magnitude of variation in total impedance of the test coil are: a. unable to sort aluminum rods having different diameters, but the same chemical composition b. normally used to measure wall thickness variations in as-cast pipe c. not used with cathode-ray tube indicators d. more sensitive to dimensional changes than variations in electrical conductivity G.40.7 sinusoidal voltage square-wave voltage sawtooth voltage amplitude-modulated sinusoidal voltage E.2-51 49. In cathode ray tube ellipse testing: Which material should be selected to provide the most effective shielding of a test coil from an external RF field? a. b. c. d. The ellipse test method, used with feed through coils: fiberglass austenitic stainless steel copper brass C.4-7 a. can test rods, tubes, and wires for surface and subsurface cracks b. cannot be used for measuring diameter of rods that have surface cracks c. has limited value in the alloy sorting of nonferrous rod d. is not affected by lift-off variations G.40.28 55. To allow maximum current to flow through the coil, the capacitor should be adjusted so that: a. the capacitive impedance b. the capacitive c. the capacitive reactance d. the capacitive impedance is equal to the generator impedance is minimum reactance is equal to the inductive impedance is maximum G.40.43 41 Eddy Current Testing Method, Level 111 56. A primary-secondary coil inspection system is being used. To suppress the primary coil signal induced in the secondary coil, one might: 62. When performing modulation analysis testing, the type of test coil: a. b. c. d. a. use a differential-type secondary coil b. add a 180 degree out-of-phase signal to the induced signal c. subtract an in-phase signal from the induced signal d. any of the above C.2-40,2-41 C.4-29 63. A major limitation of modulation analysis is that the system is based on: 57. Which type of readout oscilloscope would be best for examining a nonrepetitive flaw indication during high speed testing? a. b. c. d. a. b. c. d. a storage type a sampling type a type having a short persistance screen a dual beam type static tests moving tests absolute coil arrangements differential coil arrangements C.3-26 64. Chemical composition, alloy changes, and heat treat changes usually have a frequency modulation that is: G.38.36 58. An ink-writing strip chart recorder generally provides an accurate representation of its input signal: a. b. c. d. must be of the differential type must be of the absolute type can be any basic type a and b are the best answers i f the signal frequency is 2 000 Hz or greater i f the signal frequency is at least 200 Hz i f the signal frequency is limited to 20 Hz only i f the signal frequency is limited to 2 Hz a. b. c. d. low medium high very high C.3-25 65. Modulation would be defined as: V.88 a. a process of comparing an instrument reading with a standard b. a process of grouping articles by their response to eddy currents c. a process of applying a variable effect to something that is constant d. the point where increases in the coil's magnetizing force does not increase the material's flux density D.5-116 59. A probe coil inspection system is being used to detect cracks in bars. I f the cracks have a minimum length of 6 mm (0.25 in.), reliable inspection is best achieved by making the coil diameter: a. b. c. d. 6 mm (0.25 in.) 13 mm (0.5 in.) any multiple of 6 mm (0.25 in.) coil diameter is irrelevant G.38.31 66. In modulation analysis, the coil's excitation frequency is being modulated by: 60. To ensure reliable flaw detection, the maximum velocity of tubing through an encircling coil must be limited. This limitation is determined by: a. b. c. d. the inspection coil length the desired flaw size resolution the test frequency all of the above a. b. c. d. D.5-126 C.4-29 67. Impedance changes produced by small lift-off variations are greatest when: 61. Normal test speeds for modulation analysis testing is: a. b. c. d. test article conductivity test article dimensions test article defects all of the above a. there is a nonconductive coating on the test material b. the coil is usually in contact with the test material c. lower test frequencies are used d. large diameter coils are used U.280 0-1.2 m (0-4 ft)/min 1.2-9 m (4-30 ft)/min 9-91 m (40-300 ft)/min 91-1 219 m (400-4 000 ft)/min C.4-29 42 Eddy Current Testing Method, Level HI 68. When testing for the unknown conductivity of a metal, the measured conductivity is strongly affected by: a. b. c. d. 74. PR material thickness coil diameter specimen temperature Limit frequency, f , is defined when the argument of the mathematical function describing the electromagnetic field within a test specimen is set equal to: a. b. c. d. V.78 6.25 1 0.37 0 G.36.13 69. In selecting a coil for multifrequency tests: a. b. c. d. 70. Figure 17 bandwidth is of major importance frequency response is of minor importance the Q of the coil should be less than 1 the Q of the coil should be less than the inductance A.216 wL O In developing a multifrequency test, the parameter separation limitations are greatest for those parameters producing: a. b. c. d. • 4 nearly similar signals 0 degrees to 90 degrees phase shifts signals having no electrical relation 90 degrees to 110 degrees phase shifts / the effect two coils have on each other the coupling between the test coil and test part a and b none of the above 6 0.2 / ® X100 yX.400 0 W 40 000 0.2 Leakage flux testing is most applicable for the inspection of: a. shallow surface seams on finished roller bearings b. heavy-wall copper tubing c. surface and subsurface cracks in hot-rolled rough surface ferromagnetic pipe d. soft spots on polished steel bar stock N.122 0.4 R wL o 75. Referring to Figure 17, suppose a test is being conducted at an / / / ratio of 1. Due to a mix in alloys, a new test piece with a conductivity value four times as great as the original material is inserted in the coil. The new / / / ratio will be: a. b. c. d. Increasing the heat-treating temperature of nonferrous metals: a. b. c. d. 1 6.25 9 / 0.4 R.29 73. 1 0.6 Mutual inductance describes: a. b. c. d. 72. ^» 2.25 0.8 A.216 71. 1 c wL increases electrical conductivity will have no effect on electrical conductivity will decrease electrical conductivity may either increase or decrease electrical conductivity, depending upon the alloy and the nature of the heat treatment G.42.19 0.25 4 16 unchanged S.101 43 Eddy Current Testing Method, Level III 77. Figure 18 (PL Figure 19 illustrates: a. b. c. d. imag 78. variations in fill factor for a solid rod variations in fill factor for a thin-walled tube transition between a solid rod and thin-walled tube all of the above G.38.9 Figure 20 illustrates the impedance diagram for tubing where the ratio of the inside diameter to outside diameter is 80 percent. It is possible to calculate an approximate limit frequency, / , by using only the outside diameter. Thus the maximum test sensitivity for effects of conductivity, wall thickness and cracks occurs at a frequency ratio of: a. b. c. d. 6.25 13 25 400 GJ8.11,38.12 Figure 20 76. Figure 18 illustrates that the separation of diameter effects and conductivity effects: a. b. c. d. can be accomplished at any f/f.e can best be accomplished at / / / larger than 4 can best be accomplished at f/f less than 4 cannot he accomplished at any f/f e G.37.2 Figure 19 = too Normalized Resistance 79. The electromagnetic field in a test specimen during eddy current testing is described by: a. b. c. d. Bessel functions exponential functions algebraic functions all of these G.36.13 44 I I Answers Level HI Eddy Current Testing Method 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. b c d b c d b b c b b b b c d b d b d b 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. c d b c a a e b d e a a b a b b c a e d 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 45 d c e d c c a c b a b d b c c d a c a d 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. c c b a c d b d a a c c d b b b c b d 6 Level I Questions Flux Leakage Testing Method 1. In flux leakage testing of a ferromagnetic object, magnetized close to the saturation point using an encircling coil as a sensor, what is a primary condition which needs to be met in order to obtain a response from the flaw? 4. Flux leakage may occur at a surface defect in a ferromagnetic material: a. b. c. d. a. using a coil with a high number of turns b. providing electrical connection between coil and tested object c. moving the tested object in relation to the coil d. shielding the cable which connects the coil with the recorder e. using a strip chart recorder EE.62 when the magnetizing force is present after the magnetizing force has been removed aandb none of the above Z.51 5. Flux leakage inspection can normally be applied to: a. b. c. d. ferromagnetic and nonmagnetic material nonmagnetic materials only ferromagnetic materials only nonconductors only U.330 Figure F L - 1 £§3 Rotational transverse magnetization in bar or pipe testing is used for the detection of: 1 x 7 Strand What will be the relative flux leakage level on the surface of the 1 x 7 strand cable (Figure FL-1) caused by an outer wire break compared with that caused by an inner wire break? (Assume that the gap between the ends of broken wire is the same in both cases.) a. b. c. d. 3. a. b. c. d. e. AA.16 7. greater smaller the same, i f diameters of both wires are the same the same, even i f diameters of both wires are different EE.63 With rotational flux leakage detection systems, distinctions between similar OD and I D defects are accomplished by: a. b. c. d. e. What method of magnetization can be used in flux leakage testing? a. b. c. d. e. transverse defects defects that have a longitudinal component only longitudinal defects both transverse and longitudinal defects only holes observing a difference in amplitude measurement of impedance change observing the signal to noise ratio frequency analysis only by visual observation of test piece L.54 permanent magnet high frequency ac dc a and b a and c Z.43 47 Flux Leakage Testing Method, Level I Figure F L - 2 Point of Interest Lines of Flux 8. Using Figure FL-2, what is the vertical component of the leakage flux at the middle of the defect gap of a surface defect? a. b. c. d. e. 13. The curve shown in Figure FL-3 is called a: a. b. c. d. e. zero maximum equal to horizontal component divergent convergent hysteresis loop minor loop recoil curve magnetization curve permeability curve G.33.3 Y.91 9. In circular magnetization, the recommended magnetizing current in amperes per linear inch of section thickness is: a. b. c. d. e. 200 to 400 400 to 600 600 to 800 800 to 1 000 1 000 to 1 200 G.30.13 10. Flux leakage techniques can normally examine for: a. b. c. d. 14. A Hall effect probe measures: a. b. c. d. e. surface flaws only subsurface defects only defects at any location surface and near-surface defects G.30.1 11. A relative motion between specimen and a. is needed in order to pick-up leakage flux. a. b. c. d. e. 15. The ratio B/H is equivalent to a material's: a. b. c. d. e. search coil hall probe magneto probe magneto resistor piezoelectric crystal O.302 permeability conductivity tangential field strength field strength perpendicular to the probe surface reluctance G.33.11 field strength reluctance permittivity permeability relative permeability G.33.15 12. For a given crack with a given magnetic field, more magnetic lines of force are deflected out of the magnetic path when the: a. length of the crack is parallel to the magnetic lines of force b. length of the crack is perpendicular to the magnetic lines of force c. length of the crack is diagonal to the magnetic lines of force d. edges of the crack are polarized G.30.3-4 48 Flux Leakage Testing Method, Level I 16. Which discontinuity in Figure FL-4 would show the strongest indication? a. b. c. d. 18. In the flux leakage examination of tubular products, which of the following discontinuities can be detected? A B C D a. b. c. d. U.46 longitudinally oriented transversely oriented slivers all of the above DD.627 Figure F L - 4 Magnetic Fiell 19. In the flux leakage testing of tubular products, the amplitude of the signal received from a discontinuity w i l l depend upon: Discontinuity A D B C a. the depth of the discontinuity b. the orientation of the discontinuity c. the distance between the flux leakage sensor and the tube d. all of the above e. a and c DD.629 4> < e - / < — ^ Magnetizing Current 17 20. Flux leakage inspection can reveal the presence of: a. b. c. d. e. The optimum angle at which the magnetic field must intersect a discontinuity in a test specimen is: a. b. c. d. discontinuities voids inclusions either b or c a, b, and c C.10-2 90° 60° 45° 30° U.46 49 Level II Questions Flux Leakage Testing Method i. In flux leakage inspection of wire ropes using an encircling coil as a sensor, the response of the coil depends on what parameters of the wire break? a. b. c. d. 6. cross-sectional area of broken wire location of broken wire within the cross-section gap between the ends of the broken wire all of the above BB.144-46 Using Figure FL-5, flux leakage strength decreases with distance (d) from the defect surface and is approximately proportional to: a. b. c. d. e. d 1/d 1/d 1/d 1/d 2 3 4 Y.91 2. The highest sensitivity of a Hall generator is obtained when the direction of the magnetic field in relation to the largest surface of the Hall probe is: a. b. c. d. e. parallel at an angle of 46° at an angle of 30° or 60° perpendicular none of the above G.33.11 3. The best flaw detection sensitivity is obtained when the magnetizing flux is: a. b. c. d. Using Figure FL-6, the relation between the depth (D) of defects and signal amplitude (A) of leakage flux is approximately ( K = constant of proportionality): parallel to the flaw's longest dimension perpendicular to the flaw's shortest dimension perpendicular to the flaw's longest dimension none of the above U.330 a. b. c. d. e. In flux leakage inspection for flaws, the part being inspected should be magnetized: a. b. c. d. beyond saturation to saturation or near saturation well below saturation using a combination of ac and dc fields = = = = = kl/D kD kD kD kD* 2 3 L.54 U.330 5. A A A A A An advantage that flux leakage testing has in comparison with eddy current testing is that flux leakage testing is: a. less sensitive to interferences due to surface roughness b. useful on products at temperatures above the Curie point c. useful on austenitic steels d. capable of much higher inspection rates N.122-123 51 Flux Leakage Testing Method, Level 11 8. What particular type of defect is not indicated by flux leakage techniques? a. b. c. d. e. 14. The number of broken wires at a particular location on a wire rope cannot always be determined because: overlap grain boundary crack slag inclusion with crack surface contamination longitudinal seam a. the broken ends overlap b. a visual inspection for verification is impossible because the breaks are inside the rope c. the strip chart recorder speed was too slow d. the conditions stated above are all possibilities e. the strip chart recorder speed was too fast C C . l l , 16,18,19 AA.16 9. Electric current flowing in a magnet will alter the direction of magnetic fields in a magnet. 15. As a general rule, hard materials have: a. true b. false a. high coercive force and are easily demagnetized b. high coercive force and are not easily demagnetized c. low coercive force and are easily demagnetized d. low coercive force and are not easily demagnetized e. none of the above G.30.22 G.30.30-34 10. The strength of the magnetic field in the interior of a long solenoid is determined by: a. b. c. d. e. the number of turns in the solenoid the strength of applied current the length of the solenoid all of the above none of the above 16. The point (P) shown on the hysteresis loop in Figure FL-7 is called the: a. b. c. d. e. O.307 11. In longitudinal magnetization by a coil, for most effective magnetization, the part to be magnetized should be: a. b. c. d. 12. G.30.22 held against the inside wall of the coil positioned in the center of the coil held near the outside wall of the coil held half way between the wall and center of the coil G.30.14 Due to the unique construction and great lengths of wire ropes, a practical and reliable NDT technique for testing is: a. b. c. d. e. acoustic emission ultrasonics magnetic techniques radiation none of the above EE.62 13. coercive force initial permeability residual field leakage flux demagnetization point 17. The field strength over a crack is directly proportional to the relative permeability of the steel and the ratio: In dc magnetic testing of steel wire ropes, one type of magnetizing method is preferred over the other for the following reasons: a. crack depth crack width b. crack width crack depth a. permanent magnet: constant magnetic field intensity, no magnetizing current b. electromagnet: fluctuating magnetic field intensity, heavier, more rugged construction c. electromagnet: constant magnetic field intensity, lighter-weight construction d. permanent magnet: fluctuating magnetic field intensity, heavier, more rugged construction FF.4 c. crack length crack depth d. crack length crack width X.194 52 Flux Leakage Testing Method, Level II A calibration standard is prepared using holes. With respect to the reference size, it is considered good practice to: 22. In the examination of tubular products, a circumferential (transverse) magnetic field can be established by: a. include holes larger in diameter than the reference size b. include holes smaller in diameter than the reference size c. include holes both larger and smaller in diameter than the reference size d. include holes of the reference size only DD.630 When testing tubes, i f the sensor bounces along the surface this may: a. b. c. d. In flux leakage testing, the greatest tube wall thickness for which maximum sensitivity can be maintained in mm (in.) is: 24. Calibration standards used in the flux leakage examination of tubular products should be carefully prepared since the flux leakage signal response from the notch will be affected by: 0.08 mm (0.003 in.) 0.8 mm (0.03 in.) 8 mm (0.3 in.) 76 mm (3 in.) a. b. c. d. e. U.330 The following are used in determining magnetic flux leakage: a. b. c. d. e. 23. In the examination of tubular products where the flux 23. sensor measures the leakage field at the outside surface of the tube: a. OD discontinuities are detected b. both OD and ID discontinuities may be detected c. both OD and ID discontinuities can be detected but generally cannot be distinguished from each other d. both OD and I D discontinuities can be detected and can generally be distinguished from each other DD.625 make it difficult to estimate fault severity cause false signals decrease speed of inspection distort the magnetizing system DD.628 a. b. c. d. a. properly positioning north and south poles of a magnet with respect to the tube b. using a central conductor positioned in the tube c. a and b d. neither a nor b DD.629 notch orientation notch width notch length notch depth all of the above DD.630 coil magnetic tape Hall element all of the above a and b 0.316-317 53 Level HI Questions Flux Leakage Testing Method 1. In flux leakage testing of wire rope, the system of two different diameter search coils is frequently used. What is the main reason for using such a system? (See Figure FL-8.) a. b. c. d. e. to compensate the influence of testing speed to find the radial location of wire breaks to detect corrosion to detect small cracks inside the rope to detect gradual decreasing of rope diameter GG.378 Figure F L - 8 Outside Coil 3. Which devices are used to detect flux leakage? a. coils, Hall probes, and transistors b. piezoelectric crystals, Hall probes, and magnetic diodes c. piezoelectric crystals, transistors, and magnetic diodes d. coils, Hall probes, and magnetic diodes N.123 4. In Figure FL-10, the flux leakage at slot A w i l l be than that at slot B. a. b. c. d. Inside Coil Tested Rope greater smaller broader less readily detected Z.50 Magnet Poles 2. Figure FL-10 Detection Probe In flux leakage testing of wire rope, two separate outer broken wires will produce two separate indications i f there is sufficient distance between the breaks. What is the maximum rope speed in feet per minute that would produce two separate indications when the cutoff frequency of the recorder is 60 kHz and the breaks are 25 mm (1 in.) apart? (See Figure FL-9.) a. b. c. d. e. Travel I 0.5 mm (0.2 in.) | 60 fpm 120 fpm 240 fpm 300 fpm 360 fpm GG.378 , 5. Figure F L - 9 10.5 mm (0.2 in.) | | 0.5 mm (0.2 in.. 10 mm (0.4 in.. Slot A Slot B In a properly operating flux leakage system, pipe defects occurring at increased depths from the surface will generate signals with: a. b. c. d. 25 mm (1 in.) I increased phase differences higher frequency characteristics lower frequency characteristics increased signal noise ratios L.54 55 Flux Leakage Testing Method, Level III Figure FL-11 / Leakage Flux c 30 6. A \ 7Defect -T Lift-off reduces the amplitude of the flux leakage signal. The other significant effect it has on the signal is a: a. b. c. d. 10. change in phase change in frequency change in signal noise ratio all of the above The tubular product parameter having the greatest influence on the flux density of the magnetic field in the part (assuming the magnetizing force (H) and the material's permeability remains constant) is the: a. b. c. d. P.31A > Lines of Flux chemistry of the product diameter of the product wall thickness of the product length of the product U.330 7. Eddy current shielding, the name given to the unidirectional eddy current flow in products inspected by the flux leakage method, is caused by: 11. A defect having an inclined angle to the surface has a flux leakage that is (see Figure FL-11): a. the interaction between the test magnetic field and a residual field in the product b. fluctuations in the dc magnetizing current c. rapidly occurring flux changes in the product created by the rotation of the magnetic field d. rapidly occurring impedance changes in the pickup coils AA.16 a. b. c. d. Y.91 12. A flux leakage pipe inspection system with two inspection heads, each having 152 mm (6 in.) long scan paths and rotating at 180 rpm on a 178 mm (7 in.) diameter tube, can have a maximum throughput speed of per minute for 100% inspection coverage. a. b. c. d. e. lower than a similar normal defect equal to a similar normal defect higher than a similar normal defect all of the above Too high a rotational test speed or too high active pole rotating head speed can cause the loss of an indication from an I D defect. What can this be attributed to? a. b. c. d. e. excessive generated surface noise limitations of the flux sensor elements eddy current shielding reverse magnetization effect none of the above AA.16 201 m (660 ft) 55 m (180 ft) 49 m (162 ft) 27 m (90 ft) 25 m (81 ft) 13. A current carrying conductor is surrounded by a tube (see Figure FL-12). Magnetic fields exist in the tube, i f the tube is made of: U.330,338 a. b. c. d. e. A flux leakage pipe inspection system with two inspection heads, each having 152 mm (6 in.) long inspection areas and rotating at 180 rpm on a 178 mm (7 in.) diameter pipe, would require a throughput speed of per minute to provide a 110% inspection coverage. a. b. c. d. e. 60 m 49 m 45 m 25 m 22 m steel copper aluminum lead all of the above G.30.6 (198 ft) (162 ft) (146 ft) (81 ft) (73 ft) P.22A 56 Flux Leakage Testing Method, Level III 16. What is the SI unit for magnetic flux density? Figure FL-12 a. b. c. d. e. U4 Tube W.71 17. A tube is magnetized by passing a uniform current through the tube. There are inside and outside defects in the tube (see Figure FL-13). The two defects have the same dimension and geometry. The defect signal strength: Weber Tesla Ampere Henry Ampere per meter W.71 18. What is the SI unit for magnetic permeability? a. b. c. d. e. a. is stronger for the outside defect than for the inside flaw b. is stronger for the inside defect than for the outside flaw c. is the same for both defects d. is an uncertainty e. depends on the permeability of the tube G.30.6 Ampere per meter Henry per meter Henry Gauss per meter Tesla W.72 19. A ferromagnetic part can be demagnetized by: a. b. c. d. e. Figure FL-13 Inside Defect 1 | -< What is the SI unit for magnetic field strength? a. b. c. d. e. Conductor 14. Weber Gauss Tesla none of the above all of the above 20. 1 u — Outside Defect < Figure FL-14 shows an arrangement of probe-coils in a Forester probe used for measuring: a. b. c. d. e. Probe raising its temperature above the curie point withdrawing the part from an ac coil alternately reversing and reducing the applied field none of the above all of the above G.30.22-23 the static field component the normal component of the tangential field the tangential component of the normal field the field gradient all of the above G.33.1 15. A discontinuity in a steel wire rope may be detected with a dc magnetic instrument if: Figure FL-14 a. the rope is magnetized to saturation, the discontinuity is polarized, the speed of the rope is great enough to induce a detectable voltage across the discontinuity b. the area surrounding the discontinuity is magnetized to saturation, the discontinuity is polarized, the speed of the rope is great enough to induce a detectable voltage across the discontinuity c. the rope is magnetized to saturation, the speed of the rope is great enough to induce a detectable voltage across the discontinuity d the rope is magnetized to saturation, the discontinuity is polarized CC.10 Coil A 1 1 CoilB 57 Flux Leakage Testing Method, Level III 21. In flux leakage testing the maximum permissible speed of probe or tube movement with respect to the other is: a. b. c. d. 914 m/min (3 000 ft/min) 91m/min(300ft/min) 9 m/min (30 ft/min) 0.9 m/min (3 ft/min) U.338 58 Level I, n, and III Answers Flux Leakage Testing Method Level I 1. c 2. a 3. e 4. c 5. c 6. b 7. d 8. a 9. c 10. d 11. a 12. b 13. d 14. d 15. d 16. d 17. a 18. d 19. d 20. e Level II 1. d 2. d 3. c 4. b 5. a 6. c 7. b 8. d 9. a 10. d 11. a 12. c 13. a 14. d 15. b 16. c 17. a 18. c 19. b 20. c 21. d 22. c 23. d 24. e 59 Level m 1. b 2. d 3. d 4. a 5. c 6. b 7. c 8. b 9. b 10. c 11. a 12. c 13. e 14. a 15. b 16. c 17. e 18. b 19. e 20. d 21. b