Depth Evaluation for Metal Surface Defects by Eddy Current Testing Using Deep Residual Convolutional Neural Networks

Eddy current testing (ECT) is an effective technique for evaluating depth of metal surface defects. However, in practice, evaluation primarily relies on the experience of an operator and is often carried out by manual inspection. In this article, we address the challenges of automatic depth evaluation of metal surface defects by virtual of state-of-the-art deep learning (DL) techniques. The main contributions are threefold. First, a highly integrated portable ECT device is developed, taking the advantage of an advanced field-programmable gate array (Zynq-7020 system on chip) and provides fast data acquisition and in-phase/quadrature demodulation. Second, a dataset, termed metal defects of different depths by ECT (MDDECT), is constructed using the ECT device by human operators and made openly available. It contains 48000 scans from 18 defects of different depths and liftoffs. Third, the depth evaluation problem is formulated as a time series classification problem, and various state-of-the-art 1-D residual convolutional neural networks are trained and evaluated on the MDDECT dataset. A 38-layer 1-D ResNeXt achieves an accuracy of 93.58% in discriminating the surface defects in a stainless steel sheet with depths from 0.3 to 2.0 mm in the resolution of 0.1 mm. In addition, the results show that the trained ResNeXt1D-38 model is immune to liftoff signals.