WIRE
1/2008 February

Flaw detection limit by sensor system
Photos: Institut Dr. Foerster

Test coil with nominal size of 2mm

Sensor system Minicoil as an example integrated to a drum wire drawing machine
Testing with the sensor system Minicoil
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The new sensor system improves significantly the detection of flaws for wires and tubes with small diameter. The field of application is diversified and varies from stainless steel with excellent surface for medical use to wires for the chemical and electrical industry.
Test coils from 0.5 to 4.5mm in steps of 0.5mm are available for detection of smallest surface flaws on the test piece. Any test request can be realized quickly by simply changing the test coil.
The sensor system Minicoil permits testing of all conductive metals including ferritic material by using permanent magnets. Different kind of sets of magnets are protected in a stable housing against damage and may vary in their position. So for different quality levels of material the optimum field strength at test piece can be set. Mechanical fixed positions permit a reproducible setting.
The compact design of the sensor system Minicoil allows perfectly the integration to wire drawing machines. The test coil guides itself on the wire and is therefore able to balance variation in the tensile strength and direction. For example the holder may fit directly to the drawing die box and keeps the whole test system to a centric position of the drawing die. In case of wire break the test coil is caught by the flexible holder.
Various acceptance and delivery specifications for semi-finished products demand that these parts should not be magnetized or that their residual field strength lie below a stipulated limit value. This can be reduced back to the prescribed values only by using a magnetic alternating field.
Demagnetizer EMAG Mini has a compact design and is put behind the test coil. Testing of small tubes is also done with the above described principle. A static holder is used to fix the test coil to a centric position. The adjustment of height permits an adaptation to the test section. For evaluation of test results from the sensor system Minicoil use a dual channel Defectomat CI with difference and absolute channel. The differential coil winding of the test coil is best suitable for detection of punctiform and transverse flaws, and the absolute coil winding is best suitable to detect longitudinal flaws.
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