The traditional remote field eddy current (RFEC) testing is a method widely applied for detecting the corrosion and wall thinning in a ferromagnetic pipe system and shows intrinsic deficiencies in axial defects quantification due to the distinct probe structure. A circumferential alignment probe structure is used to improve the sensitivity to axial defects of pipes. Meanwhile, current approaches typically are incapable of classifying inner diameter (ID) and outer diameter (OD) defects of the pipe, which brings difficulties to the formulation of strategies in pipe repair. In this article, an external pulsed RFEC method is proposed to address these issues. First, we give a thorough analysis of the effects of probe geometry and excitation parameters on the output signal, targeting parameters optimization. Second, the finite-element model is built and used to analyze the relationships between the defect size and signal features under different excitation types. Finally, the improvements in probe performance and the ability to classify ID and OD defects are validated by measuring the defect depths of the pipe. Results showed that the zero-crossing time feature can be used to distinguish ID from OD defects. Thus, the proposed method is an effective complementary measure for the existing RFEC tools.

This paper presents a rotating focused field eddy-current (EC) sensing technique, which leverages the advantages of magnetic field focusing and rotating magnetic field, for arbitrary orientation defects detection. The sensor consists of four identical excitation coils orthogonally arranged in an upside-down pyramid configuration and a giant magneto-resistive (GMR) detection element. The four coils are connected to form two figure-8-shaped focusing sub-probes, which are fed by two identical harmonic currents with 90 degrees phase difference. A finite element model-based study of arbitrary orientation defects detection was performed to understand the probe operational characteristics and optimize its design parameters. Probe prototyping and experimental validation were also carried out on a carbon steel plate specimen with four prefabricated surface-breaking defects. In-situ spot inspection with the probe rotating above the defect and a manual line-scan inspection were both conducted. Results showed that the probe has the capability of detecting defects with any orientations while maintaining the same sensitivity and the defect depth can be quantitatively evaluated by using the signal amplitude. Compared with the existing rotating field probes, the presented probe does not require additional excitation adjustment or data fusion. Meanwhile, due to its focusing effect, it can generate a strong rotating magnetic field at the defect location with a weak background noise, thus yielding superior signal-to-noise ratio.

Pulsed eddy current (PEC) technique has been used to detect corrosion under insulation (CUI) for decades, but whether and how the wire mesh laid in the insulation layer affects the detection remains ambiguous. This paper touches on this issue for the first time. The insulated structure was simplified to a carbon steel plate covered by a cladding with an air gap representing the insulation layer, in which the wire mesh was situated. Finite element simulations were performed on the simplified model and found that the aluminium or stainless steel wire mesh had little effect on eddy currents in the plate, while the mild steel wire mesh could cause a considerable increase in the probe footprint and a significant drop of the eddy current density. For the mild steel wire mesh, the magnetic permeability and wire diameter were the main factors affecting the probe footprint and eddy current density. Afterwards, simulations were conducted to analyse the effect of the mild steel wire mesh on the PEC probe performances for evaluating the CUI depth and found that the mild steel wire mesh led to decreases in both the PEC signal amplitude and decay rate. The simulation results were finally verified by experiments.