Textual note taken from Eddyfi Technologies on Jul 24, 2025
As aerospace manufacturing evolves, so too must the techniques used to guarantee structural integrity. Friction stir welding (FSW), a solid-state joining process prized for its strength and reliability, presents particular inspection challenges—especially in high-performance sectors such as aerospace. Recent innovations at Eddyfi
Technologies aim to transform this critical step with solutions that combine precision, speed, and practicality.
Addressing Complexity with Simplicity
[post_relacionado]Inspecting friction stir welds has traditionally involved multiple ultrasonic probes, complex configurations, and lengthy calibration processes. These methods often fall short when detecting flaws that deviate from the weld centerline, especially transverse or skewed discontinuities.
To overcome these challenges, Eddyfi Technologies developed a dedicated, highperformance phased array ultrasonic testing (PAUT) probe, optimized specifically for friction stir welds. This 128-element linear array probe simplifies the inspection process by generating ±45° shear waves and 0° longitudinal waves from a single probe orientation— effectively streamlining data acquisition and reducing setup time.
Precision Built In
Thanks to its refined pitch, element size, and center frequency, the new probe delivers enhanced focusing capabilities without sacrificing sensitivity. This results in significantly improved sizing accuracy and defect characterization—even at varying depths and orientations. The result: reliable detection of planar, volumetric, and transverse flaws, all in a single scanning sequence.
Moreover, by merging multiple beam configurations into one scan, inspectors benefit from a consolidated dataset that’s easier to interpret, offers superior signal-to-noise ratio (SNR), and supports faster decision-making.
Powering Productivity with Cypher®
Behind the scenes, inspection quality is driven not only by probe design but also by the performance of the instrumentation. Enter Cypher®, Eddyfi’s rugged and portable PAUT platform engineered for high-speed inspections without compromising usability. With its intuitive interface, embedded software, and onboard data recording, Cypher empowers operators to deploy and scan faster—even in demanding manufacturing environments.
In aerospace applications where repeatability, accuracy, and minimal disruption to production lines are paramount, pairing Cypher with the optimized FSW probe provides a scalable solution. Inspection throughput can be tripled by using up to three probe-unit pairs simultaneously—making it ideal for production-scale deployments.
Ready for What’s Next
This friction stir weld inspection solution is more than a technical upgrade; it represents a step toward smarter, more autonomous nondestructive testing. From reducing technician setup time to improving detection reliability, Eddyfi Technologies’ latest development is helping aerospace manufacturers stay ahead of quality assurance demands.
As the industry continues to push boundaries, tools like Cypher and its dedicated FSW probe ensure that inspections keep pace—supporting safer skies and stronger structures.
Curious to see what Cypher can do for your inspection routines? Learn more here.
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Source and photo: Eddyfi Technologies