Designation: E 566 – 99 An American National Standard

AMERICAN SOCIETY FOR TESTING AND MATERIALS

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Reprinted from the Annual Book of ASTM Standards. Copyright ASTM

Standard Practice for

Electromagnetic (Eddy-Current) Sorting of Ferrous Metals1
This standard is issued under the fixed designation E 566; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope 3. Terminology
1.1 This practice covers the procedure for sorting ferrous 3.1 Standard terminology relating to electromagnetic ex-
metals using the electromagnetic (eddy-current) method. The amination may be found in Terminology E 1316, Section C:
procedure relates to instruments using absolute or comparator- Electromagnetic Testing.
type coils for distinguishing variations in mass, shape, conduc-
tivity, permeability, and other variables such as hardness and 4. Summary of Practice
alloy that affect the electromagnetic or magnetic properties of 4.1 The two techniques that are primarily used in electro-
the material. The selection of samples to determine sorting magnetic sorting employ the absolute (single-) and compara-
feasibility and to establish standards is also included.2 tive (two-) coil methods. The decision of whether to use
1.2 This standard does not purport to address all of the single-coil or two-coil operation is usually determined by
safety concerns, if any, associated with its use. It is the empirical data. In the absolute-coil method, the equipment is
responsibility of the user of this standard to establish appro- standardized by placing standards of known properties in the
priate safety and health practices and determine the applica- test coil. The value of the tested parameter (for instance,
bility of regulatory limitations prior to use. hardness, alloy, or heat treatment) is read on the scale of an
indicator. In the comparative-coil method, the test piece is
2. Referenced Documents compared with a reference piece and the indication tells
2.1 ASTM Standards: whether the piece is within or outside of the required limits.
E 105 Practice for Probability Sampling of Materials3 4.1.1 Absolute Coil Method—A sample of known classifi-
E 122 Practice for Choice of Sample Size to Estimate a cation is inserted in the test coil, and the controls of the
Measure of Quality for a Lot or Process3 instrument are adjusted to obtain an indication. The test is then
E 543 Practice for Agencies Performing Nondestructive continued by inserting the pieces to be sorted into the test coil,
Testing4 and observing the instrument indication.
E 1316 Terminology for Nondestructive Examinations4 4.1.2 Comparative Coil Method—Known reference pieces
2.2 ASNT Documents: representing the minimum or maximum limits of acceptance,
SNT-TC-1A Recommended Practice for Qualification and or both, are inserted in the reference coil and test coil. The
Certification in Nondestructive Testing5 instrument controls are adjusted for appropriate indications.
ANSI/ASNT CP-189 ASNT Standard for Qualification and The test is then continued by inserting the pieces to be sorted
Certification of Nondestructive Testing Personnel5 in the test coil, leaving a known reference in the reference coil,
2.3 Federal Standard: and observing the instrument indication.
NAS-410 Nondestructive Testing Personnel Qualification 4.2 The range of instrument indication must be so adjusted
and Certification6 in the initial step that the anticipated deviations will be
recognized within the range of readout according to whether
two- or three-way sorts are to be accomplished.
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This practice is under the jurisdiction of ASTM Committee E-7 on Nonde- 4.3 Both absolute and comparative methods require com-
structive Testing and is the direct responsibility of Subcommittee E07.10 on paring the pieces to be tested with the reference piece(s). Two
Emerging NDT Methods.
Current edition approved June 10, 1999. Published August 1999. Originally
or more samples representing the limits of acceptance may be
published as E 566 – 76. Last previous edition E 566 – 94. required. In the absolute method the electrical reference is
2
General information can be found in the Nondestructive Testing Handbook, generated by a test piece. In the comparative method any
(Second Edition), Vol IV: Electromagnetic Testing, Society for Nondestructive electromagnetic condition that is not common to the test
Testing, 1986.
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Annual Book of ASTM Standards, Vol 14.02.
specimen and the standard will produce an imbalance in the
4
Annual Book of ASTM Standards, Vol 03.03. system. The comparative method usually is more stable, as it
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Available from American Society for Nondestructive Testing, 1711 Arlingate normally suppresses noise.
Plaza, P.O. Box 28518, Columbus, OH 43228–0518. 4.4 The testing process may consist of manual insertion of
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Available from Standardization Documents Order Desk, Building 4, Section D,
700 Robbins Avenue, Philadelphia, PA 19111–5904, ATTN: NPODS. one piece after another into the test coil, or an automated

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 E 566
feeding and classifying mechanism may be employed. In overlap and are well defined in the standardization procedure
automated setups, it is sometimes necessary to stop each piece used.
momentarily in the test coil while the reading is being taken, 7.1.2 In sorting magnetic materials, a magnetic field
especially if low test frequencies are employed. strength and test frequency must be used that will result in a
well-defined separation of variables being tested.
5. Significance and Use 7.1.3 When examining magnetic materials at low field
5.1 Absolute and comparative methods provide a means for strength, any influence from the previous magnetic history of
sorting large quantities of ferrous parts of stock with regard to the part on the test (residual magnetism) shall be negated by
composition, condition, structure, or processing, or a combi- demagnetization of the part if it restricts the electromagnetic
nation thereof. sort.
5.2 The comparative or two-coil method is used when 7.1.4 The temperature of the standard and test part shall be
high-sensitivity testing is required. The advantage of this controlled within limits that will permit a well-defined range of
method is that it almost completely suppresses all internal or conductivity or permeability, or both, for which the correlation
external disturbances such as temperature variations or stray of the group or groups is valid. Cooling of the test standard
magnetic fields. The two-coil method is normally used when when high field strengths are used or allowing test parts to cool
harmonic evaluation is employed for sorting. or heat to an established ambient range, or both, may be
5.3 The ability to accomplish satisfactorily these types of required.
separations is dependent upon the relation of the magnetic 7.1.5 The geometry and mass of the standard and test part
characteristics of the ferromagnetic parts to their physical shall be controlled within limits that will permit sorting.
condition. 7.1.6 Speed Effects—See 4.4.
5.4 These methods may be used for high-speed sorting in a
fully automated setup where the speed of testing may approach 8. Apparatus
ten pieces per second depending on their size and shape.
8.1 Electronic Apparatus—The electronic apparatus shall
5.5 The success of sorting ferromagnetic material depends
be capable of energizing the test coils with alternating currents
mainly on the proper selection of magnetic field strength and
of suitable frequencies and power levels and shall be capable of
frequency of signal in the test coil, fill factor, and variables
sensing the changes in the electromagnetic response of the
present in the sample.
coils. Equipment may include any suitable signal-processing
5.6 The degree of accuracy of a sort will be affected greatly
devices (phase discriminator, filter circuits, etc.) and the output
by the coupling between the test coil field and the tested part
may be displayed by meter, scope, recorder, signaling devices
and the accuracy with which the tested part is held in the test
or any suitable combination required for the particular appli-
coil field during the measuring period.
cation.
5.7 When high currents are used in the test coil, a means
8.2 Test Coils may be of the encircling or probe-coil type
should be provided to maintain a constant temperature of the
and shall be capable of inducing electromagnetic field in the
test standard in order to minimize measurement drift.
test specimen and standard and sensing changes in the electric
6. Basis of Application and magnetic characteristics of the test specimen.
6.1 Personnel Qualification—If specified in the contractual 8.2.1 When selecting the test coil, the objective should be to
agreement, personnel performing examinations to this practice obtain a coil fill factor as large as possible. This means that the
shall be qualified in accordance with a nationally recognized inside of the test coil should be filled by the test piece as much
NDT personnel qualification practice or standard, such as as possible. This is of primary importance for tests requiring
ANSI/ASNT-CP-189, SNT-TC-1A, NAS-410, or a similar high sensitivity.
document and certified by the employer or certifying agency, 8.2.2 For complicated test piece shapes, a corresponding
as applicable. The practice or standard used and its applicable insert shall be provided to ensure that each test piece can be
revision shall be identified in the contractual agreement be- placed in the same position within the test coil. These inserts,
tween the using parties. as well as any other accessories, should consist of nonferro-
6.2 Qualification of Nondestructive Agencies—If specified magnetic, electrically nonconductive material.
in the contractual agreement, NDT agencies shall be qualified 8.3 Mechanical Handling Apparatus—A mechanical device
and evaluated as described in Practice E 543. The applicable for feeding and sorting the test specimens may be used to
edition of Practice E 543 shall be specified in the contractual automate the particular application.
agreement.
6.3 Acceptance Criteria—Since acceptance criteria are not 9. Sampling
specified in this practice, they shall be specified in the 9.1 Sampling (see Practices E 105 and E 122) is a method to
contractual agreement. obtain assurance that materials are of satisfactory quality.
Instead of 100 % inspection, a portion of the material is
7. Interferences examined to show evidence of the quality of the whole. There
7.1 The specific influence of the following variables must be are two important needs for this approach: first, in the final
considered for proper interpretation of the results obtained: inspection or tests made to ensure that products delivered are in
7.1.1 The correlation shall be established so that magnetic conformance with specification requirements; second, to con-
or electrical properties, or both, of various groups do not trol parts and asemblies while they are being processed.

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 E 566
Statistical acceptance sampling tables and statistical process- unacceptable standard in the same exact position and adjust the
control sampling tables have been developed to meet these sensitivity of the instrument to maximize the indicator differ-
needs. ence reading without exceeding 90 % of the available scale
9.2 Acceptance sampling may be conducted on an accept/ range.
reject (or attributes) basis, that is, determining whether or not 11.3 When using the comparative coil method, select a
the units of the sample meet the specification. Examination of reference piece (usually one that falls within the acceptable
the samples may also be conducted on a measurements (or limits of the pieces being tested) and place it in the reference
variables) basis, that is, determining actual readings on the coil in such a way that it will not be disturbed, and set this coil
units in the sample. The majority of acceptance sampling is and reference piece out of the way. For this method, when
carried out on a sampling by the attributes basis and the usual confronted with a two-way mix, choose two standards, one of
acceptance sampling table is designed for accept/reject criteria. which represents the acceptable and the other the unacceptable
9.3 Process control sampling may be conducted on material group. Place the acceptable standard to a fixed position in the
during the course of production to prevent large quantities of test coil coinciding with the position of the reference piece in
defective parts being found in the acceptance tests. Many parts the reference coil and balance the instrument. Replace this
and materials are subjected to several successive machining or acceptable calibration standard with one representing the
processing operations before they become finished units. Parts unacceptable group and adjust the test instrument’s phase,
can be most effectively controlled during production by exam- sensitivity, and coil current; then index to maximize the
ining small samples of these parts at regularly scheduled indicator reading without exceeding 90 % of the available scale
intervals. The object of this process check is to provide a range. Reinsert the acceptable standard and alternately readjust
continuous picture of the quality of parts being produced. This the instrument controls to retain a null value for the acceptable
helps prevent production of defective parts by stopping and standard and maximum indication for the unacceptable stan-
correcting the problem as soon as it begins to appear in the dard.
manufacturing process and thereby keeping the process in 11.4 For a three-way sort, it is best to have three standards,
control. Sampling may be by attributes or by variable and two of which represent the high and low limits of acceptability
process control sampling tables. The measurements (variables) for one group or one each of the two unacceptable groups. The
control chart is by far the most effective process control third standard, of course, represents the acceptable lot of
technique. material.
9.4 Statistical sampling tables have four definite features: 11.4.1 A typical case for the former usually consists of
(1) specifications of sampling data, that is, the size of the hardness or case depth measurements where standards repre-
samples to be selected, the conditions under which the samples senting maximum and minimum limits are required. In this
are to be selected, and the conditions under which the lot will instance, insert the third standard representing the acceptable
be accepted or rejected; (2) protection afforded, that is, the lot into the test coil and adjust the instrument for a null or zero
element of risk that the sampling schedules in a given table will reading. Then adjust the controls to maximize the indications
reject good lots or accept bad ones; (3) disposal procedure, that without exceeding 690 % of the available scale range from the
is, a set of rules that state what is to be done with lots after null for each of the other two standards (maximum and
sampling has been completed; and (4) cost required, that is, minimum). Alternate readjustment of the controls may be
average inspection cost required to accept or reject a lot. necessary to retain the null reading, as well as the maximum
and minimum limits for acceptance.
10. Test Specimen or Sample (Standards) 11.4.2 For a three-way sort when three dissimilar grades of
10.1 A known acceptable sample and known unacceptable material become mixed, place the third standard (acceptable
sample of the precise size and configuration of the product to group) into the test coil and null. Then successively insert into
be tested shall be used to set up for sorting by the absolute coil the test coil the two standards representing the other two grades
(see 11.2) or comparative coil (see 11.3) method. and adjust the instrument’s controls to maximize the indica-
10.2 Three known samples are required for a three-way mix tions without exceeding 690 % of the available scale range
(see 11.4). from the null for each of the other two standards. Alternate
10.3 The sample should be selected to represent the ex- readjustment of the controls may be necessary to retain the null
tremes of acceptable and unacceptable groups to assure no reading as well as the indication for the other two standards.
overlap in the sort. 11.5 When high current is used in the comparative testing
method, the reference piece is likely to heat up, which will
11. Standardization change its magnetic properties. It is necessary to provide for
11.1 The electromagnetic sorting method is primarily one of cooling or to have several identical reference pieces so that
comparison between pieces. Empirical data and physical tests they can be interchanged to prevent drift in the balance point.
determine classification. The standardization procedure shall
be governed by the properties of the sample requiring separa- 12. Procedure
tion. 12.1 Connect the required test coil to the instrument. Place
11.2 When using the absolute coil method, insert the known insert(s) or other positioning fixture in the coil(s) if required.
acceptable standard to a fixed position in or relative to the coil 12.2 Switch on the instrument and allow it to warm up for
and adjust the test instrument to get an on-scale meter or scope at least the length of time recommended by the manufacturer.
reading, or both. Replace the acceptable standard with a known 12.3 Make all necessary setup and control adjustments in

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 E 566
accordance with the manufacturer’s recommendation. Adjust 13.6 Shape and surface variations can mask the test results.
frequency, field strength, sensitivity, and other necessary con- If surface hardness is desired as the basis for sorting, all
trols to values determined for the electromagnetic sort. material should have composition and surface roughness under
12.4 Standardize the sorting system in accordance with 11.2 sufficient control so that effects of variations in hardness can be
when using the absolute coil method or 11.3 when using the separated.
comparative coil method. Standardize at the start of the test run
and at least once every hour of continuous operation or 14. Report
whenever improper functioning of the system is suspected. 14.1 The written report of an electromagnetic sort should
12.5 For manual operation, insert the test pieces manually in contain any information about the test setup that will be
the test coil. necessary to duplicate the test at the same or some other
12.5.1 Read the test results on an indicator. location, plus such other items as may be agreed upon by the
12.5.2 Manually remove the pieces from the test coil. producer and purchaser. The following information should be
12.6 For automatic sort, transmit the test pieces continu- recorded:
ously through the test coil. 14.1.1 Description of Apparatus:
12.6.1 Each test piece in passing through the coil is ana- [Link] Type of equipment.
lyzed by the test instrument. [Link] Model No.
12.6.2 A signal, corresponding to the quality of the respec- [Link] Serial No.
tive test piece, is sent to a sorting gate where the tested pieces 14.1.2 Output Device:
are automatically sorted into preselected quality groups. [Link] Type.
12.7 Verify the calibration of the instrument at the end of [Link] Model No.
testing each lot. If the standardization is found to have changed [Link] Serial No.
since the last check so that it affects the sort, retest after 14.1.3 Coil:
standardization all of the material tested since the last check. [Link] Size.
13. Interpretation of Results [Link] Type.
14.1.4 Other Interconnecting Apparatus.
13.1 The results of any nondestructive testing procedure are 14.1.5 Reference Standards.
based on the comparison of an unknown with a standard. 14.1.6 Test Frequency.
Unless all of the significant interrelationships of material or 14.1.7 Description of Materials:
product properties are understood and measurable for both [Link] Geometry.
standard and unknown samples, the test results may be [Link] Chemistry.
meaningless. [Link] Heat treatment.
13.2 Electromagnetic sorting is best used for repetitive tests [Link] Conductivity range.
on material “identical” in shape, composition, and metallurgi-
14.1.8 Method of Calibration.
cal structure, and not for tests on grossly different materials.
14.1.9 Field Strength.
Electromagnetic sorting is generally not useful if there is
14.1.10 Scanning Speed.
limited knowledge of the properties of the unknown or test
14.1.11 Temperature of the Standard.
material.
14.1.12 Temperature of the Test Sample.
13.3 Interpretation of data depends upon the degree to
14.1.13 Sample Demagnetized.
which the test materials compare with the reference materials.
14.1.14 Test Method.
It is necessary to have all variables, except the one selected as
a basis for sorting, under sufficient control if the measured
15. Precision and Bias
variation is to be properly interpreted. Results can often be
interpreted or explained by a processing change, such as in 15.1 Measurement bias depends upon factors including the
temperature, composition, and inclusions, when the measured equipment, techniques, control of temperature of parts and
property is known to be a function of the processing proce- standard, geometry, magnetic history of the part, field strength
dures. used, types of materials, and operator variables. Variations in
13.4 When products grossly different in shape, alloy, per- these factors can affect the bias of the sort. Results in the
meability, or conductivity are to be measured, only a general majority of sorts can be expected to be quite accurate, with a
interpretation of results can be made. The materials can be said single combination of the above factors and selection of a point
to be different, but the how and the why of the difference on the magnetization curves (field strength) at which each
usually is not determinable. curve is displaced from its nearest neighbor by a substantial
13.5 When the spread in value of the measured variable is distance (probably within a 1 % tolerance). The field strength is
sufficient, electromagnetic sorting can be 100 % effective. usually determined empirically and the care with which it is
However, there may be cases where a single test will not show determined will affect the precision and bias.
a clear separation. Often a second test or procedure can be used
to further define the separation of materials. For example, a 16. Keywords
change in test frequency may show the effect of a second 16.1 absolute coil; comparator coils; electromagnetic sort-
variable. ing; sorting

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 E 566
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This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM Headquarters. Your comments will receive careful consideration at a meeting of the responsible
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views known to the ASTM Committee on Standards, 100 Barr Harbor Drive, West Conshohocken, PA 19428.

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