Methodology of short fatigue crack detection by the eddy current method in a multi-layered metal aircraft structure

Abstract

The field of non-destructive inspection (NDI) is an integral part of aircraft maintenance and service. It is optimal to apply the eddy current (EC) method on the complex multi-layered metal aircraft structure to detect cracks and other damage. A range of standard eddy current probes giving satisfactory results with respect to crack detection are available. However, these EC probes are not always suitable for the detection of short fatigue cracks hidden under a rivet head. This article presents a new methodology for eddy current inspection of a critical area on the wing. The development of the new methodology was inspired by a catastrophic glider accident in 2010. Because of this accident, all glider service was prohibited. The critical area is located in the structure of the wing spar, which consists of six layers. The position of the critical area is hidden under the countersunk rivet head in the third layer of the spar flange and under two layers of metal sheets. Thus, the actual location of the area is in the fourth layer, created by the countersunk rivet head. In addition, another rivet of a smaller diameter is inserted into the rivet in the flange. This article presents the work related to the development of a special EC probe that is able to measure in an operating frequency range between 200Hz and 100kHz with a single-value interpretation of the individual EC signals.