Electromagnetics

Nondestructive inspection of presshardened body parts using 3MA

Electromagnetics

Over the last two decades, electromagnetic methods passed through an extensive technical development up to a degree where - in the frame of nondestructive testing technologies - they have to be labeled as "key technologies".

In matters of the upcoming remodeling of industrial high-tech sectors towards "Industrie 4.0" concepts, the embedding of electromagnetic sensors and sensor systems offers forward-looking development potential for the comprehensive digitization and process control of industrial production and processing systems.

Moreover, last decade's developments in automotive industry away from internal combustion engines to electromobility are to be kept in mind. While the inspection of ferromagnetic materials is a matter of course in inspection technology, in the near future development, examination and control of technical magnetic systems will gain considerable economic importance, too.

BetoFlux: Portable Magnetic Flux Leakage Inspection System for ­Detecting Corrosion Damage in Prestressed Concrete Poles

© Photo BauConsulting Dr. Walther

Magnetic flux leakage inspection

Intuitive representation of the location and condition of ferromagnetic prestressing steel

Specifically designed for portable use

Easily adapted to different concrete pole diameters

Less effort compared to alternative inspection methods such as X-ray

Minimal risk of additional pole damage

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3MA-X8: Fast Materials Characterization

© Photo Fraunhofer IZFP

3MA-X8: Three channels, assortment of sensors, plus control and evaluation PC

Determination of hardness, case depth, tensile strength, yield strength, breaking elongation, residual and load stresses

Test for mixed-up components

Determination of dross in cast materials

Area scans with up to 8 sensors and concurrent detection of local material property deviations

Inspection of assemblies and components parallel at several positions

In-line real-time measurements in production processes

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inspECT®: Multi-Channel Multifrequency Eddy Current Inspection Electronics

© Photo Fraunhofer IZFP

Mobile eddy current testing system realized inside a rugged industrial notebook with IP65 protection class

OEM kit: Comprising inspECT® board, backplane, power supply, coordinate ­interface and multi­plexer for integration in customer systems

Integration of any customer-adapted inspection electronics into customer systems

Single or multifrequency operation with up to 16 testing frequencies from 100 Hz up to 10 MHz

High-performance hardware enables signal processing in real-time already on the ­inspECT® board

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MAGNUS: Hybrid Micromagnetic and Ultrasonic Test System

© Photo Fraunhofer IZFP / Uwe Bellhäuser

MAGNUS setup

Smart combination of micromagnetic materials characterization and electromagnetic ultrasound transduction

Demonstrator set up and testing in industrial-like environments

The MAGNUS project is jointly funded by the German Federal Ministry for Education and Research and the French National Research Agency through the Fraunhofer Carnot program, an alliance with the “Centre Technique des Industries Mécaniques” CETIM in Senlis, France.

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GMR Sensors: Optimization of the Layer Properties

© Photo Fraunhofer IZFP

Eddy Current Impedance Analysis

Eddy Current Scans up to Microscopy

Conductivity, Permeability, Permittivity

Layer Thickness, Material and Condition

Sensor Systems: Automatic Configuration and Planning Admissions

Machine-Material-Interaction: 3MA system integrated in the production line in order to monitor mechanical-technological material properties of steel strip during manufacturing

Robot-assisted inline-monitoring system for hardened and tempered steel strip

Continuously self-adjusting positioning of the sensor by robots based on sensor-own signal generation and signal processing

Continuous determination of hardness and residual stresses within the steel strip

Permanent readjustment of the process through independent extraction of relevant information by means of “cognitive sensor systems“

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Hardness, Case Depth, Yield Strength, Tensile Strength

Nondestructive Inspection pf Presshardened Body Parts using 3MA

Nondestructive Evaluation of Hardness and Residual Stress Depth Profiles of Valve Springs by 3MA

Clinching: Offline and Online Measurement of the Wall Thickness in Clinched Joints

© Photo Fraunhofer IZFP

Prototype system for offline determination of base thickness in clinched joints

For a fast quality monitoring of clinched joints, the eddy current method was refined

Combination of several eddy current frequencies

Disturbances such as sensor lifting from the surface or changes in conductivity and permeability can be distinguished from the objective criterion “base thickness“

Calibration needed

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MoniDAQ: Self-Sufficient Platform for Permanent Condition Monitoring of Infrastructure Constructions

© Photo Katharina Wieland Müller- Pixelio

MoniDAQ: Modular, energy self-sufficient board providing eddy current inspection, inclination measurement, magnetic flux leakage inspec­tion, ultrasonic inspection, etc. and recording all sampled data over long periods of time while dissipating extremely low amounts of energy

Self-sufficient and eco-friendly power supply by integrated photovoltaic cell

Maintenance-free long-term operation

Supersensitive defect detection

Telemetric data recovery by radio-controlled interface

Low costs per unit

Unique combination of Fraunhofer IZFP‘s proven nondestructive sensor technology

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3MA-Based Valve Spring Scanner: Nondestructive Evaluation of Hardness and Residual Stress Depth Profiles

© Photo Fraunhofer IZFP / Uwe Bellhäuser

Valve Spring Scanner

Concurrent determination of various relevant quality characteristics of a material (e.g. hardness, residual stresses in different measuring depths)

No destruction of the specimen

Integration in fully automated testing systems

Calibration needed

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