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NDT Talk

Every two years, ibg has an international technical meeting for us to learn new developments, thereby maintaining the ibg know-how by means of workshops and seminars. More than 40 people attend these meetings, which— in turn—allow us to convey the latest in eddy current technology to you, our customers.

This issue focuses on crack detection systems, a major topic at last year's international meeting. These systems have been integrated into automated production lines. It's important that we learn the latest in this field, because eddy current testing is ideally suited to such applications due to its ability to be automated. Parts are not contaminated, and testing is at production-line speeds.

As a matter of fact, ibg test systems are used by all internationally- known automotive manufacturers and their suppliers.

Bill Buchur

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 text part slides down a chute with the feed rate controlled by two friction wheels. At the test coil, the ibg eddysort single-frequency instrument performs the test. Parsts not correctly heat treated are sorted out and sent to a lockable box, while good parts continue to the next process. Typical 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 changeover performed in tests less than 20 minutes.

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

Automatic crack detection on hubs beats eyeballing

Traditional methods of crack detection usually involved decisions based on examination by the human eye. But the limited ability of the eyesight to detect all defects runs a high risk of defective parts being processed without detection. With so much production now automated, eyeball inspection becomes completely impossible.

Eddy current crack detection has become the preferred and most successful method for component crack testing. Its main advantages relate to its excellent automation opportunities and to its reproducible results, as the decision is reliably made by the eddy current instrument, not by an operator.

The system pictured here scans the bearing journal and the radius transition to the flange of a hub for cracks, without contact. The test process is automatic, and the system was integrated into a production line, with cycle time for each part at 12 seconds. An additional capability of the system is a laser marking station at which each tested part receives an ID.

Cylinder liners tested for cracks and pores, as well as for case depth in the I.D. bore

For many years now, the detection of surface defects on cylinder liners has been a standard application for ibg systems. Dozens of ibg crack detection instruments we call the eddydector® are in use around the world in this application. Most of these cylinder liner tests are for cars. But now, ibg has developed and manufactured a system to test cylinder liners for construction machinery and for trucks. To do this, special design measures had to be considered by our engineers, due to the dimensions required for the test system.

The dimensions of the cylinder (shown in the photo) are 120 to 130 mm (about five inches) in diameter and approximately 300 mm (11.8 inches) in length.

In the system, the test at the first station is for structure. Each cylinder is examined at six selected locations to verify correct case depth according to ibg's.

Preventive Multi-Frequency Technology with eight test frequencies. Then, at the second station, detection occurs for longitudinal and circumferential cracks and pores. At a third station, marking takes place with the "OK" parts being engraved.

The test system processes up to 110 cylinder liners per hour.

Fuel injection system components receive various tests

With the latest developments in diesel and gasoline fuel injection systems, new applications for eddy current testing are upon us, requiring new test methods. One concern is for relatively small parts that must withstand high pressures within the injection systems. Such components must be 100% tested on their complete I.D. and O.D. surface areas for small cracks. Verification of correct hardness on carbonitrided parts is another test by ibg.

ibg is a supplier to all known manufacturers of injection systems around the world.

In the system illustrated, a thin walled tube must be tested to detect circumferential cracks smaller than 2 mm (about 8/100 of an inch) in length and 0.15 mm (6/1000 of an inch) in depth on the inner and outer surfaces of the diameter, ibg developed and manufactured a system which scans the entire part to detect cracks at the rate of one part per second. This speed of detection is achieved by testing three parts simultaneously.

Similar tests for cracks and structure applications are being developed to customers' specifications. Contact us for further details.

The remarkable 10-ball test: material mix and hardness in 1/10th second!

A small ball tester designed by ibg, of precision mechanical and electronic construction, inspects balls with a diameter range of 1.5-6.0 mm. Up to 10 in one second! And changeover from one diameter to another takes only a few minutes.

The balls are forwarded by means of a transport disk to the test position, where each one is examined for correct structure using ibg's Preventive Multi- Frequency Technology. Each ball is sorted to an OK or NOK channel within the system.