Model-based probe state estimation and crack inverse methods addressing eddy current probe variability

A model-based calibration process is introduced that estimates the state of the eddy current probe. First, a carefully designed surrogate model was built using VIC-3D® simulations covering the critical range of probe rotation angles, tilt in two directions, and probe offset (liftoff) for both transverse and longitudinal flaw orientations. Some approximations and numerical compromises in the model were made to represent tilt in two directions and reduce simulation time; however, this surrogate model was found to represent the key trends in the eddy current response for each of the four probe properties in experimental verification studies well. Next, this model was incorporated into an iterative inversion scheme during the calibration process, to estimate the probe state while also addressing the amplitude/phase fit and centering the calibration notch indication. Results are presented showing several examples of the blind estimation of tilt and rotation angle for known experimental cases with reasonable agreement. Once the probe state is estimated, the final step is to transform the base crack inversion surrogate model and apply it for crack characterization. Using this process, results are presented demonstrating improved crack inversion performance for extreme probe states.