Alternating Current Potential Drop ProbeAlternating Current Potential Drop Probe
Alternating current potential drop (ACPD) testing is a relative newcomer to the area ofnondestructive evaluation (NDE). Developed in the 1980’s, ACPD testing currently usestwo point probes for single frequency (typically 5kHz) measurements of crack depths,crack growth, and material properties. Although this type of testing is effective, there areseveral limitations, including the need to perform the tests over a wide range offrequencies. To counter these problems, the intent of this project will be to design fourfour-point ACPD probes. Two probes will be used for lower frequencies (1 Hz to 10 kHz)and the others for higher frequencies (100 kHz to 10MHz). As a result of producingthese probes, it will be easier for users to test materials more efficiently, accurately, andeffectively.
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DESIGN TEAM MAY05-17
Jacob Chatterton (EE)
Jennifer Johnson (EE)
Jonathan O’Dell (EE)
Jordan Vos (EE)
FACULTY ADVISORS
Dr. John Bowler
Dr. Nicola Bowler
CLIENT:
Center for Nondestructive Evaluation1915 Scholl Road111 ASC IIAmes, Iowa 50011-3042
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Design Objectives
•Build the in-line and square head probes for each frequency range
Functional Requirements
Ability to work over a wide range of frequencies
Capability to control the effect of the inductive pick-up
Easy to maintain and service as needed
Design Constraints
Must be handheld and portable
Voltage pin connections must be durable and long-lasting
Construction of four prototype probes (December 2004)
Performance testing of prototypes (January 2005)
Finish user’s manual and technical report (April 2005)
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Approach and Considerations
Proposed Approach
Analyze commercially available probes
Build and test prototype probes in lab and compare with theory
Revise probe design until satisfactory
Technologies Considered
Square Head Design
In-Line Design
Testing Considerations
Compare laboratory tests to theory to check accuracy
Provide and reference voltage to the injected current
Provide effective control or regulation of the inductive pick-up
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Estimated Resources and Schedule
Problem Statement
Develop four probes that can be used for two bands of frequencies as well asdifferent alignments.
Solution Approach
Research ACPD theory and probe technologies currently used in the field
Perform laboratory tests on all design prototypes
Investigate the material properties of different types of steels
Intended Uses and Users
Assessment of steel vehicle shafts and case-hardened components
Observation/characterization of cracks and defects in aircraft engine disks
Probe will be operated by trained technicians
Operating Environment
Probes will be used in a laboratory testing setting
Probes will also be used in production line environment
End Product and Other Deliverables
Four probes: two for each frequency range with two different head designs(square and in-line)
User’s manual with usage, calibration, and repair instructions
Assumptions
The developed theory will be accurate
Probe materials and machining will be available
Laboratory testing time and equipment will be available
Limitations
• Probes built for two different frequency ranges
• Low frequency: 1 Hz to 10 kHz
• High frequency: 100 kHz 10MHz
• Voltage pin connections must be made close to test surface
• Probes must be robust and portable
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Alternating current potential drop (ACPD) measurement and testing withinthe area of nondestructive evaluation (NDE) is a rapidly growing field.Currently, the probes used in the field are limited by their size andoperating frequencies. By the end of this project, the team will havecreated four hand-held probes, which will be capable of takingmeasurements over a vast range of frequencies. These new probes willaid in the advancement of ACPD testing within the area of NDE.
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