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:
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
WindowsXP©, Windows7© and
Windows10©
platform
- Multiple regression analysis to determine process/quality
parameters using
evaluated approximation functions
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