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The value of testing after heat treating; coming workshops and more information

It goes without saying that heat treating is a critical part of the production process. Properly executed, heat treatment requires that many process parameters be kept at a constant level over long periods of time, while excluding external influences. Significant costs and time are consumed in laboratory material analyses to verify the quality of the heat treatment process.

ibg non-destructive test systems reduce these costs considerably, as well as providing results immediately after the process. No longer do processors need to wait hours or days for lab results after heat treating.

Both manual and automatic test systems are covered in this issue, plus a schedule of NDT technical workshops to be held in Canada and the Midwest U.S. this coming Spring.

And, don't miss our appearance at the Quality Expo in Novi, Michigan, in June of this year.


Bill Buchur

Informative workshops planned for Spring, 2004

ibg NDT technical workshops on component testing and the handling of special applications will be held again this Spring in the latter half of April. The sites will be in the Midwest and Canada this year, with workshops scheduled as follows:

April 19 - Mississauga, Ontario
April 20 - Ann Arbor, Ml
April 22 - Indianapolis, IN
April 23 - Chicago, IL

As mentioned previously, these workshops have become virtual international forums, which were attended by hundreds of persons in 2003.

To register, contact Laurie Gerben at our North American headquarters: 248-478-9490^or e-mail sales@ibgndt.com.

Web site bulletin: Now available in Spanish

Due to the increasing demand for access by engineers in Mexico, South America and Spain, the ibg international Web site is now available in the Spanish language. Visit it at www.ibgndt.co.uk or www.ibgndt.de

Needle bearing pins tested automatically after heat treat

During their producion process, high quality bearing components are subjected to complex heat treating. Needle bearing pins, for example, must be tested for correct surface hardness and case depth. Most importantly, correct hardness at certain positions must be verified. (See illustration) Each roller has to be 100% tested for quality.

A leading component manufacturer uses ibg's Preventive Multi-Frequency technology to do this. A two-channel eddylinefr®P2, with encircling coils customized to the part length and diameter, verifies both ends of the rollers.

The rollers are fed into the automatic test system's coil head via a tube, where the test takes less than one second. Good parts are then forwarded on a conveyor belt for packaging. Bad parts fall into a Lockable container. With cycle times at about one second, different part lengths and diameters can be tested using exchange tools which can be changed in less than 15 minutes.

Heat treatment monitoring can save up to 80% of destructive analysis cost

Heat treating is a complex process, as many factors influence the result of the treatment. Material analyses to monitor the treated components are costly and time-consuming, and many are carried out destructively, incurring delays in the provision of lab results. With continuous production, this leads to many rejects.

Inline NDT methods provide instant results without influencing the test part. Even better, savings of up to 80% of the costs of destructive material analysis can be realized by ibg material testing according to the experience of our customers.

Drive shafts can be tested at two (or more) locations to verify correct hardness, case depth and hardness/case depth position. Other heat treat processes can also be verified. For example, tempered gears can be tested to verify correct tempering. (See photos)

An investment in an NDT system can pay for itself within a few months when replacing the costs of destructive testing. Contact us today and let us calculate your cost reduction potential.

System performs inline test on automotive piston pins

Automotive manufacturers in the U.S. are expected to do 100% testing for heat treatment on certain components. Typical of this is the piston pin, the cylindrical geometry of which makes this application quite simple.

The test part slides down a chute, with the feed rate controlled by two friction wheels. At the test coil, the ibg eddysorf single-frequency instrument performs the test. Parts not heat treated are sorted out and sent to a lock-able box, while good parts continue to the next process. Cycle time for this testing is approximately one second per part. By using change parts, piston pins of different lengths and diameters are tested, with ok changeover performed in P less than 20 minutes.

The future of manufacturing has arrived at Swiss firm:
automatic control of spring coiling process

Imagine a production machine that monitors the materials entering the process, calculates the optimum process parameters and then adjusts itself, without any human operator.

Eddyliner P with encircling coil, including spring wire in coil, is shown.

Pie in the sky? No, the future already has arrived at 3R Technics in Zurich, Switzerland. In cooperation with Spuhl of St. Gallen, Switzerland, an online process control has been devel- oped for a Bonell spring coiling machine.

At the heart of this control is an ibg eddyliner9 P instrument as data provider and processing tool. The spring wire to be processed is passed continuously through an encircling coil before it comes to the coiling machine. In the coil, testing with eight frequencies is carried out in defined short intervals, with the voltage vector coordinates received at the test instrument forwarded in real time to the 3R Technics evaluation tool.

The corresponding setting parame-ters-e.g. deflector and bender of the coiling machine-are extracted via a mathematical model, are compared with the optimum settings, and then, if needed, are re-adjusted. Production is 100 springs per minute, although the capacity for re-adjustment is up to 300 springs/minute. Expensive downtime and rejects are minimized with this system.

Similar process controls may be used in other machines which process metallic materials, including straightening, heat treating and forming machinery.

Coils-standard or custom-test components for structure following heat treating

Encircling coils usually are used for testing the structure of components for correct heat treatment by ibg's Preventive Multi-Frequency technology. Standard coils are offered from 5 mm up to 300 mm in diameter. Our experience shows that 90% of all applica- tions can be tested successfully with these standard coils. Typical applications include correct hardness, case depth, material mix, alloy, crystalline structure, temper and nodularity, among others.

Some applications, however, require special types of coils or probes, which are designed and built by ibg. An example is the use of rec- tangular coils to test bearing rings. Inside the coil, the rings are subject to optimum penetration by the magnetic field. Con rods also can be tested by these coils.Determining the position of a hardened zone after induction hardening is the challenge facing many manufacturers. Shielded coils are used for this application-i.e. the magnetic field is shielded so that only the critical zone of the part is tested. Outside influences are almost completely excluded in this technique. Differences of 0.5 mm in the position of the hardened zone (depending on part geometry) are reliably recognized.

ID test coils are used to test boreholes and inner diameters for applications such as tripods and CV joints. Coils test for material structure on parts such as those shown.

ibg NDT has booth at Quality Expo in June

This year's Quality Expo is scheduled for June 9-10 at the Novi Expo Center, north of Detroit. ibg will be there to provide information and answer questions in Booth 230. Please plan to stop by to learn about the latest in NDT techniques and applications. Examples of some of the latest systems will be available for your examination.