In this paper a new non-destructive testing (NDT) system focusing on micro size superficial defects in metals is presented. The innovative system is composed by a new type of eddy currents probe, electronic devices for signal generation, conditioning and conversion, automated mechanized scanning and analysis software. The key original aspect of this system is the new type of eddy currents probe. This new IOnic probe provides enhanced lift-off immunity and improved sensitivity for micro size imperfections. The probe concept was studied using a Finite Element Modeling (FEM) tool and experimental verified using a standard defect.
The testing results on some Friction Stir Welding (FSW) specimens clearly show that the system is able to detect cracks about 50 µm depth, which significantly increases the actual state of the art in NDT reliability for micro imperfections detection. The system can be applied to a broad range of industries which include manufacturing, maintenance and engineering companies.