An improved multi-frequency eddy current array sensor for detecting micro-defects of welding seam in metal plates

This study proposes an improved multi-frequency eddy current array sensor for the accurate detection of micro-defects (under-welding, over-welding, partial welding breakage, and minute penetration holes) of welding seam in metal plates. The primary goal is to further reduce the external and internal noise of the induced coil by optimizing the composition structure of the eddy current probe, thereby improving its sensitivity and signal-to-noise ratio in micro-defect detection. In response to the issue of external noise, this research introduces a gradient differential coil model, which can compensate for initial errors based on a geometrically balanced structure. By establishing a 3D simulation model and a physical mechanical structure, the suppression effect of this structure on excitation magnetic field and external environmental interference is verified. Furthermore, for the internal noise, a mathematical model of the direct stranded litz wire is established. Theoretical calculations and experimental validation confirm that the litz wire exhibits lower eddy current loss and higher Q value compared to traditional copper conductors, thus mitigating internal noise and improving signal-to-noise ratio. On this basis, the excitation mode of the eddy current coil probe array is set to a multi-frequency excitation method based on a center frequency, greatly reducing the electromagnetic interference between channels. Experimental results demonstrate that the improved eddy current sensor can effectively recognize as low as Φ1 mm weld penetration defect at a lift-off value of 0.5 mm, achieving a remarkably high signal-to-noise ratio of approximately 17.7 dB. [Display omitted] •The gradient differential coil structure effectively attenuates environmental noise.•High-frequency Litz wires minimize eddy current losses, consequently enhancing the signal-to-noise ratio.•The multi-frequency excitation method effectively eliminates crosstalk between adjacent coils.•This design achieves a remarkable combination of high sensitivity and rapid detection capabilities.