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NDT Talk

by Bill Buschur -
General Manager

It has been a significant year for ibg, signaled by the introduction of our new eddyvisor® system, plus other major test achievements. This issue will display some recent applications and solutions for 100% testing of components.

There is little doubt that our test equipment is needed. Perhaps you have read during the past weeks and months about the recall actions of various automobile manufacturers. These may seem trivial to the layman, but a recall may cause incalculable expenses for a major manufacturing company and its suppliers, not to mention a considerable loss of reputation.

Reasons for a recall usually end up as defective quality in safety and function-critical components. We hear of key words such as 100% testing and Zero Defects, but many suppliers still are shy of investing in reliable test equipment. What is certain, however, is that avoiding recall action is much cheaper than having one...and suffering its consequences.

Watch for even more examples of 100% testing...and informational seminars...in future issues of this newsletter.

Bill Buchur

Workshops for 2006

We are pleased to announce a schedule for ibg's 2006 Workshops.

Monday, April 3 - Chicago/Schaumburg, IL

Wednesday, April 5 - Ann Arbor, Ml

Friday, April 7 - Cambridge, Ontario - Canada

The main topics for the Workshops are Technology for Eddy Current Component Testing, as well as a presentation of the new-generation eddyvisor®.

Contact Laurie Gerben at 248- 478-9490 or at sales@ibgndt.com to reserve your spot at the workshop in your area!

The eddyvisor® era has begun; are you using the new standard for NDT testing yet?

ibg is pleased to announce a highly successful start for the new eddyvisor® instrument model. No wonder: all functions of our new instrument correspond exactly to the high requirements of our customers, especially regarding test speed, data documentation and flexibility. Even the basic version of the eddyvisor® is capable of testing for correct heat treatment at up to 32 locations of a test part—e.g. a camshaft—and this is possible within a few seconds.

The well-known Preventive Multi- Frequency Technology is used at each location. Conspicuous on the instrument is the 15-inch touch screen, which displays the test result graphically and numerically in all requested modes. For a presentation of our new instrument, please contact our office for further details.

Tolerance zone editor - New Feature! The tolerance zone editor permits the user to adjust the tolerance zone ellipses via software.

The ellipses can now be moved about and rotated around their centers, and their A and B axes can be increased or decreased independently.

A neat feature is that the original ellipses are remembered, so that the user can always return to the starting point that was determined by measurements on the reference parts.

Consider these key features for the eddyvisor®:

  • Only OK parts required for calibration
  • Proven Preventive Multi-Frequency Testing with eight test frequencies at each test location
  • 32 test locations (each with eight tolerance fields) enable maximum flexibility
  • Basic instrument includes two coil channels (up to 32 as an option)
  • Maximum stability of results due to automatic calibration
  • Highest test reliability, due to PMFT and automatic calibration
  • High-speed testing within milliseconds
  • 15-in. touch screen for easy and clear operation, with many useful graphic options
  • USB 2.0- and Ethernet interfaces for easy data transfer to PC and printer; and remote control, data storage to USB-stick
  • Programmable access levels for different responsibility levels
  • Desktop version (DS) and the new two-part switch panel version

Have you ordered one for demonstration yet?

Eddy current crack detection on steering knuckles beats traditional magnetic particle inspection

A well-known truck manufacturer has found that testing the critical areas of steering knuckles with ibg eddy current technology integrates well with production line techniques. There are numerous advantages eddy current testing holds over the previous magnetic particle inspection, and it is becoming a common trend in the automotive industry.

The advantages include:

  • The test decision does not depend on the human eye, and is always reproducible.
  • Specifications for defects are exactly defined, and are comparable everywhere. The defect size and the critical test area are defined before testing via this eddy current method.
  • Automation of the testing process is accomplished.

The truck manufacturer's test system inspects parts that weigh 55 pounds. Each part is lifted onto a platform in front of the test station.

Then, the protective door is closed and the platform moves to the test station where it is clamped and rotated. Two probes detect cracks, scanning precisely defined critical zones for surface defects.

After the test, OK parts are marked and discharged from the platform. Occasionally, a master part with artificial defects is inserted to confirm that the test system is functioning correctly.

Raw ball studs or machined ball studs-ibg tests them all for cracks and structure

The testing of ball studs has become a standard application with ibg. Several ball studs of various designs are mounted on each automobile produced. Ball studs are mass-produced items with critical safety functions, and thus are subject to strict testing criteria. Test systems for crack detection and heat treat testing on ball studs have been produced by ibg as customized applications for years.

Cycle times for testing ball studs range from 0.75 seconds to three seconds per part, such high testing rates being required due to high production rates.

Rings tested for cracks and struct ure hardness in a mere nine seconds

The test system shown in the photo [above] combines efficiency and high test reliability. This system tests (freewheel) rings, which are tested after being presented from the induction hardening machine to the ibg system via two parallel roller conveyors.

At the first test station, the ring is tested for surface hardness, case depth, hardness profile and core hardness using customized ID coils and Preventive Multi- Frequency Technology. The close-up photos show the ring and the hardness profile to be tested.

At the second test station, the race of the ring is scanned for surface-open defects by the crack-detection eddydector® instrument. The cycle time is nine seconds per part.

The same or similar test systems may also test other ring-shaped geometries, e.g. bearing rings and hubs, for correct structure and surface defects.

Can we design a speedy, customized system for your critical parts?