The Bottom Line of NDT: Why 100% Eddy Current Inspection Pays for Itself

Ed Korkowski
May 25
2 min read

When most people think about eddy current testing, they imagine flaw detection, signal phase, or impedance plane analysis. But one of the most powerful reasons to use ECT isn’t technical at all—it’s financial.

Kenneth J. Law’s 1984 article “Automatic NDT Inspection for Safety and Savings” might be four decades old, but its message is more relevant than ever: Eddy current testing protects your tools, your time, and your bottom line.

🔁 The Shift from Sampling to 100% Inspection

For years, manufacturers relied on sampling and statistical process control (SPC) to maintain quality. But Law argued—and proved—that sampling fails when the process is unstable or when hidden defects evade detection until it’s too late. That’s when 100% inspection becomes not only safer, but cheaper.

“If the process can’t guarantee all good parts, 100% inspection is no longer optional—it’s essential.” – K.J. Law

Let’s look at the data.

📊 Real-World Case Studies: When Eddy Current Testing Made (or Saved) Millions

1. Pinion Gear Blanks

Defect: Surface cracks
Speed: 3,600 parts/hour
Total parts tested: 230+ million
Payoff: ROI in 9 months through tool savings and defect interception

2. Transmission Shafts

Defect: Improper hardness destroying cutting tools
Result: Immediate savings, system paid for itself every 3 months

3. Differential Gear Blanks

Defect: Cracks that damaged $2,000 broach cutters
ROI: Under 6 months

4. Bearing & Ball Elements

Throughput: 25,000/hour
Detects: Hardness, diameter, case depth, alloy mix
Accuracy: Within ±2 Rockwell C

5. Diesel Cylinder Sleeves

Problem: Carbide inclusions missed by hardness testers
Payoff: System ROI in one year by preventing premature tool wear.

💡 Beyond QA: ECT as a Business Tool

Eddy current systems aren’t just for quality departments—they’re profit-preserving machines. When properly integrated, they:

Stop bad parts before they cause damage downstream
Extend tool life
Eliminate costly warranty returns
Provide supplier accountability
Build customer trust

And if your industry involves high-consequence parts—like munitions, aerospace, or transportation—then 100% inspection isn’t just a business case. It’s a moral one.

💬 Final Thought

Your eddy current system isn’t just a test instrument. It’s a cost control solution, a reputation shield, and a safety guarantee. Whether you're inspecting gear blanks or grenade casings, the logic holds:

If you can’t control the process perfectly, eddy current inspection will control the risk.

🛠️ Ready to Automate?

If you’re looking to implement ECT into your production line, or need help quantifying the return on investment for management, visit eddycurrent.com — your one-stop hub for automated inspection, real-world case studies, and eddy current solutions that actually pay for themselves.