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NDT Talk

Expanding capabilities

Looking back, the year 1999 saw an expansion of ibg capabilities both in North America and in Germany. New challenges for eddy current testing of different components were solved resulting in many new high-speed test systems being installed to provide 100% inspection at pro­duction line speeds. As a result, sales were markedly higher than the previous year.

Looking forward, we see more new opportunities to accom­plish zero defects testing on a wider range of vital components. The new millennium looks very promising for ibg NDT Systems.

Some of the new applications included the testing of ball bearings, hubs, spindles, rocker arms and transmission gears and shafts.

Production rates can be very high...cam rollers at 18,000 pph, ball bearings at 36,000 pph, pinion pins at 7,200 pph. Eddy current systems from ibg accomplish 100% testing even at higher rates without slowing the production pace.

Surface flaws detection issue
What is crack detection?

Detecting surface flaws resulting from forming, machining, finishing and hardening processes is vital in the production of a variety of automotive components. These are components critical for safety and function such as those for steering, chassis, suspension, engine and valve trains, transmissions, etc. It is an important issue for components manufacturers.

Monitoring for cracks, seams, porosity and other surface flaws at high production line speeds is what specialized ibg eddy current crack testing systems accomplish. Cracks on components such as needle bearings with depths as shallow as 0.050mm can be reliably detected.

Probes connected to ibg eddydector® instruments, up to eight at a time, can perform 100% scanning for flaws in metal parts with complicated geometries such as camshaft lobes. Testing is performed to detect cracks, seams, pits and other surface flaws.

The systems developed by ibg are-in effect-high-speed, high-precision surface scanning machines, supported by instrumentation and mechanics customized to do the job at high throughput speeds on the factory floor.

What is crack detection 1
NDTalk 1
Scanning cylinder IDS 2
Production line spindle testing 2
Scanning cylinder 3
ibg range of instruments 3
Eddy current abilities 4

Detecting pores and cracks on flat and ID bore surfaces

The rotating ibg eddyscan®F eddy current scanner scans inside cylindrical surfaces, such as cylinder liners and engine bores, as well as flat surfaces such as brake rotors to detect axial and circumferential cracks and pores. Scanner rotation speeds up to 10,000 rpm permit high throughput speeds without loss of resolution. Thus, eddyscan®H has faster throughput speed than the machining, grinding or honing operations that typically precede it in a production line.Testing is non-contact, so that ground or honed surfaces are not scratched or damaged by the scanning process and very small defects can be reliably detected.

ibg NDT Systems Corp. also builds turnkey systems utilizing eddyscan®F technology. For example, automatic testing of free­standing cylinder liners or cylinder liners cast in engine blocks can be accomplished via in-line systems.

Production line testing of automotive spindles

ibg developed crack-detection systems have been installed on the production lines of automotive spindle manufacturers.

The systems automatically scan ground surface areas to detect small cracks. Integrated into the production process, the systems are easily designed to include testing for correct hardening and correct material, too.

Compact in size, including mechanical part feeding and discharge apparatus adapted to the method of transporting the part on the existing production line, these systems perform automatic 100% testing of the spindles for cracks and for correct heat treatment.

ibg eddy current test instruments (after verifying correct heat treatment) scan two critical surface areas on the spindles following grinding. Testing is performed to detect small longitudinal and circumferential cracks, which may be as minuscule as 3.75 mm long and only 0.05 mm deep.

Mechanically, each spindle to be tested is clamped and rotat­ed at about 600 rpm at the crack-detection station. There, two eddydector® crack detec­tion probes scan the spindle's ground area for small cracks. Very precise guidance and control of the scan rate thus assures 100% of the spindle surface is reliably tested every time.

High-speed crack and seam detection for cylindrical shapes

New rotating eddy current scanner scans 100% of the surface area on cylindrical components such as steering racks, roller bearings, needle bearings piston pins, pinion pins and strut rods. ibg's eddyscan®H is capable of reliably detecting longitudinal seams, transverse cracks and pores. Scanner rotation up to 12,000 rpm permits throughput speeds up to 800 mm/sec.--without loss of resolution. With this capability, eddyscan®H has faster through­put than the grinding and super finishing lines on which it is typi­cally installed.

The testing is non-contacting, so ground or super finished surfaces are not scratched or damaged by the scanning process. Defects of only 0.050 mm depth can be reli­ably detected without false rejects.

Keep in mind that Ofeg also builds turnkey systems that utilize our eddyscan®H technology to provide automatic, in-line testing of mass produced cylindrical components such as steering racks, needle bearings, roller bearings, piston rods, strut rods and piston pins.

Noted for our ability to develop such high-speed scanning devices for the NDT testing of metal components, ibg also has earned a reputation for designing and fabricating complete and fully factory-floor-capable systems for 100% testing of cylindrical and other shapes to assure zero defects due to surface flaws and cracks

ibg offers range of crack detection instruments

The ibg stable of crack detection devices is versatile and extensive. Here is the current lineup:

  • eddydector® detects cracks, seams and other shallow surface defects on mass-produced parts
  • eddydector® provides high- volume in-line crack detection on cylindrical parts
  • eddydector® enables high- speed crack detection on flat surfaces and inside cylinders and holes.

All can be integrated into precision mechanical systems that assure accurate, repeatable in-line testing.

ibg offers the design and manufacture of both test instrumentation and the mechanics to automate its systems. In effect, a turnkey approach. Our high engineering standards assure durable, factory-floor-ready, fully error-proofed sys­tems capable of reliable, two- and three-shift operation.

Crack test on ball stud shows part in test position, swivel arm with probe for shank, cone and neck, plus friction wheels for rotating test parts.

Don't overlook other abilities of eddy current testing

eddynomic" instruments and material

While testing for surface cracks is a strength of the ibg eddy current testing equipment, there are other tests in which our instruments and systems perform well.

Verifying heat treatment

Hardness, case depth and pattern, retrained austenite, decarb and other testing to correct material properties are part of testing to achieve zero-defect conditions.

Eliminating material mix-ups

Identification of correct material mix and correct alloying is another important usage of eddy current testing.

Confirming correct "pre-heat treat" conditions

Testing forged and cast components prior to heat coils for treatment is an effective employment of ibg test systems.

properties testing For example, forged parts mistakenly quenched rather than air cooled can be detected.