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An eddy current method was developed to inspect cup-shaped steel parts from the I.D. side. During the manufacturing process of these parts, a thin Al tape foil is applied to the I.D. side of the part. One of the critical process parameters is that only one foil layer can be applied. An eddy current inspection system was developed to reject parts with more than one foil layer. The Al tape foil is cut to length to fit the inner diameter, however, after application of the foil there is a gap created between the beginning and end of the foil. It was found that this gap interfered with the eddy current inspection causing a false positive indication. To solve this problem a sensor design and data analysis process were developed to overcome the effects of these gaps. The developed system incorporates simultaneous measurements from multiple eddy current sensors and signal processing to achieve a reliable inspection.

Inspection of cup-shaped steel parts from the I.D. side using eddy current