Numerical analysis of angular defects in bent plates using tone burst eddy-current thermography (TBET)

Tone Burst Eddy current Thermography (TBET) is a new hybrid, non-contacting, Non-Destructive Evaluation (NDT) method which employs a combination of Pulsed Eddy current Thermography (PEC) and Thermographic Non-Destructive Evaluation (TNDE). For understanding angular cracks, fundamental knowledge about the induced current density distribution in the component under test is required. Further, this information enables us to find the amount of heat produced at those locations and how it diffuses to the surface. This paper describes simulation work done for cracks set at an angle to the surface in flat and bent aluminum plates. The investigation is implemented by the simulating transient thermal distribution for 2D angular cracks via finite element package COMSOL multi-physics with AC/DC module and general heat transfer. At crack edges, induced current is seen concentrated thus indicating a localized high heating in those areas relative to other regions. A numerical study was also carried out by varying parameters like crack angle (0°, 22.5°, 45°, 67.5°) and crack length (0.6mm, 1.2mm, 1.8mm) the transient thermal distributions were compared for different plate bend angles (180°, 120°, 90°, 60°, 30°). TBET method was found well suited for the detection of service induced cracks, usually caused by either rolling contact fatigue or stress corrosion, with a high degree of sensitivity.