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NDT Talk

by Bill Buschur -
General Manager

High-quality test instruments and turnkey systems that meet or exceed customers' requirements and that are supported by reliable service have been the basis of our success and the steady growth of ibg. Our goal has been to develop and supply the automotive industry with the best possible state-of-the-art component testing instruments and systems.

Our market presence is worldwide. To enhance our market presence and service quality in Europe and Asia we recently enlarged our international sales team. Furthermore, we have new cooperation partners in India and China in order to support the rapid growth in these countries and to be able to competently serve our customers there. In fact, many such customers are manufacturing operations of North American-based manufacturers. Advice and on-site support for our customers are part of our core philosophy. Our offices and representatives worldwide look forward to being contacted by you.

Our International Sales Meeting took place in September this year, with all the ibg subsidiaries, cooperation partners and sales representative invited. The main topic of this meeting was a presentation of the new crack test instrument: eddyvisor®C, which will be the subject of a future newsletter. While there, I had opportunities to meet and exchange ideas and experiences with more than 40 participants from all over the world at our headquarters in Ebermannstadt, Germany.

Bill Buchur

eddyscan®H63 applied to tubes for air bags

The photo directly above shows automatic crack detection of tubes for air bags, which involves the eddyscan®H63 (for up to 63 mm dia.).

This two-channel eddydector® has a rotating scanner, into which the tubes are fed. Crack detection is on the cylindrical outer diameter surface area of the airbag tubes. The rotating head scans at 3,000 rpm.

Stampings critical to belt safety are ibg-tested for correct heat treatment

Imagine a safety belt failing in an emergency. Then you will recognize how vital a small component such as a buckle can be (see photo above). The buckle could save your life— but to do so, it must be correctly heat treated and be of the correct alloy. It must have correct material properties. Thus, nondestructive eddy current testing becomes critical.

Unexpected mixed microstructures caused by only partially-wrong heat treatment, as well as soft parts from entirely-missed heat treatment, must be reliably detected. Utilization of ibg Preventive Multi- Frequency Testing (PMFT) technology provides reliable detection of such dangerous partially-heat-treated parts. The testing has been successfully applied to many safety-critical stamped parts, including safety belts, seat and door components and parking pawls; plus fuel injector and air bag components.

Testing on such critical parts as these is typically done on 100% of the parts, though it is also done on a sampling basis, with an option to easily 100%-test suspect lots.

The photo at left shows an automatic test system that includes a feed conveyor, test instrument, sorting station and a color marking apparatus. Depending on a customer's requirements for such stampings, cycle times of 1 sec/part can be achieved. With a Twinsorter, the timing can be as short at 0.5 sec/part; and with a Quattrosorter the cycle can be a short as 0.25 sec/part.

More eddyscan®H high-speed roller crack test systems

Roller applications range from small 1.5 mm diameter needles tested with eddyscan®H10 up to rather large 70 mm diameter rollers tested with eddyscan®H70, and they must be fast-up to 36,000 parts per hour-in order to exceed the production process. In the case illustrated in the photo directly above, eddyscan®H 63 tests rollers up to 63 mm in diameter.

The eddyscan®H 63 can be equipped with up to four probes (e.g. four channels) with up to 12,000 rpm rotation.

Thus, feed speeds up to 800 mm/sec. are possible. The rollers are pushed through the rotating head, end to end. Converting to a different part type is possible within a 15-minute sequence.

In the photo shown at the bottom of this column, a test system for needles, in which the needles are fed vertically to a rotating scanner, is illustrated. All the test systems shown here were designed according to customers' requirements.

eddyscan®H10 automatic crack detection for needles with 1.5 mm - 3 mm dia.

In this application, parts are fed via a tube from a vibration feeder. They are then transported end-to-end through the rotating eddyscan®H10 scanner at constant velocity, after which they are sent to an OK or REJECTED parts box, depending on the sorting decision. Test rate is 36,000 pph.

Rollers for highly-stressed roller bearings are scanned with eddyscan®H2/30

The eddyscan®H2/30 two-channel scanner is employed for crack detection on severely-stressed rollers for aerospace bearings. The system, shown at left, can scan diameters from 5.0 mm to 26.0 mm at a test speed of 75 mm/sec. It has two crack detection probes that can be adjusted to the different diameters of the parts to be examined.

Small, but not forgotten: The smallest parts often are responsible for the failure of a complex component

It's hard to believe, but often geometrically inconspicuous—not even precisely manufactured—parts only a few millimeters in length and height can cause a component assembly to fail. If the heat treatment of these parts is incorrect, or if they were not treated at all, and are installed in components such as injector pumps or steering mechanisms, they can cause failure of the total assembly.

Only 100% eddy current testing for correct heat treatment, as well as a safe internal material flow with locked containers, avoids such faults, ibg specializes in the manufacture of coils and probes for testing small and very minute components, and we offer customized solutions to assure part accuracy. Encircling, round or rectangular coils can be produced to suit the geometry of the part being tested.

The optimum test solution for your application can be provided in combination with eddyvisor® and eddyliner®P instruments and our exclusive preventive Multi-Frequency Technology.