The goal of this paper is to develop an effective and high-precision method for thick coating evaluation in hemispherical steel shells of different sizes using eddy current technology. The key problems of the study include limited capability and low measure precision of eddy current sensor for long liftoff evaluation as well as the influence of shell thickness and curvature on liftoff-evaluation precision for coating in different size shells. To solve these problems, a wide-range sensor was proposed and the influence laws of shell sizes on signals were analyzed using a finite element method-boundary element method (FEM-BEM) hybrid program. Finally, a strategy using cubic spline interpolation method and sample database was adopted for thickness evaluation of coating in different size shells, and its applicability was validated by liftoff evaluation results.
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