Discrimination between Fatigue Cracking and Mechanical Damage in Aircraft Fastener Holes by Eddy-Current Phase Rotation

Fatigue cracking in metallic aircraft structure often originates at fastener holes and can be detected using the nondestructive inspection technique of bolt-hole eddy-current (BHEC) testing. BHEC testing is based on detection of a disturbance in the induced current or magnetic field caused by a surface-breaking crack in the bore of the hole. However, if the surface of the hole contains benign mechanical damage or superficial scoring, false positives can be produced leading to potentially unnecessary maintenance on a hole that is otherwise sound. In principle, analysis of the phase of the eddy-current response can assist in distinguishing fatigue cracking from such mechanical damage. In the present work, a systematic BHEC and fractographic study has been conducted by inspecting several hundred fastener holes in ex-service F/A-18 aircraft bulkheads, following fatigue testing. The results demonstrate that measurement of the relative phase of the eddy-current response provides additional information which can assist in discrimination between genuine cracks and mechanical damage.