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MikroMach Microstructure and Stress Analyzer

  
The Situation

Correct heat treatment and machining processes are fundamental for the functional behavior and fatigue strength of stress-imposed components.  Until now, the only methods in common practical use to evaluate surface areas of parts and components are conventional techniques such as metallurgy, X-ray diffraction, and conventional hardness testing techniques.  However, these techniques cannot easily be integrated into production processes, as their testing speed is too slow and as some of these techniques are also destructive.  Nevertheless, the results obtained from these techniques can be used for a statistical process control.

Our Solution

Nondestructive testing techniques, which can be integrated into production processes are available now.  A complete inspection with acceptable testing speeds can be achieved.  Fast evaluation and recording of relevant quality parameters can be accomplished by combining complementary information obtained through various microstructure and stress sensitive measuring parameters simultaneously.  Approximation functions to determine the quality characteristics can be obtained using multiple regression analysis.  The main application areas are the nondestructive inspection of case-hardened components and machined surfaces.  

The objective is the nondestructive determination of the following material characteristics:

  • Surface and subsurface hardness

  • Residual stress

  • Case depth

  • Machining defects

 

Our System

The MikroMach system (Micro Material Analysis and Characterization)  is the portable instrument adequate for these applications.  The MikroMach system consists of a sensor (Type E1030) with integrated power supply for magnetization and communication and data transfer interface (USB 2.0) to measure various micro-magnetic parameters such as: 

  • Low-frequency Barkhausen Noise (BN)
    Analysis of Barkhausen Noise amplitude vs. magnetic field strength (H)

  • Low-frequency Incremental Permeability (Dm)
    Analysis of Incremental Permeability vs. Tangential (magnetic) Field Strength

  • Tangential (magnetic) Field Strength (Ht(t))
    Analysis of the Tangential Magnetic Field Strength

  • Eddy Current Impedance

Sensor System

The sensor is an electromagnetic transmitter/receiver system.  The multi-parameter sensor records different micro-magnetic parameters simultaneously.  The sensors can be designed and built according to the individual requirements of the customer.

Data Evaluation and Documentation

The MMS software permits system-specific data acquisition, regression analysis, pattern recognition, online image evaluation and display and documentation of test results.  The software can be custom-tailored according to the customer's requirements. 

Advantages

  • Fast nondestructive testing

  • Continuous inspection and documentation of quality parameters

  • Replacement of destructive testing

  • Economical production through reduced rejections

  • Complete process control through integration of the MikroMach system into production processes

  • Modular design allows for customized configurations and individual adaptation of the user interface software

  • Standard data interfaces available

Applications

Nondestructive testing and evaluation of:

  • Hardness

  • Case depth of case-hardened parts (induction, flame, laser-hardening, etc.)

  • Hardness and residual stresses (simultaneously)

  • High-resolution residual stresses and microstructures (e.g. welded components)

  • Machining processes (e.g. grinding, turning, etc.)

MikroMach test system consists of the following components:

  • Sensor w/ integrated controller

  • USB 2.0 interface to control MikroMach from any PC

  • Sensor System
    Magnetizing yoke and transmitter/receiver unit; custom-design to accommodate individual requirements available upon request

  • Software
    - Signal evaluation and documentation on Windows XP platform
    - Multiple regression analysis to determine process/quality parameters using
      evaluated approximation functions


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Last modified: June 25, 2015