Contact Contents

1st Edition 2013
Contents
ECHOGRAPH-RPTS: Ultrasonic
testing of forged steel bars
ECHOGRAPH 1090: Ultrasonic
testing of laminated glass
ECHOMETER 1076 TC:
Waterways put to the test ECHOGRAPH-RPTS: Ultrasonic testing
of forged steel bars
1
3
3
ECHOMETER 1076 TC Data:
Measurement of residual wall
thickness of ship floors
4
FLUXA and KD-Check: Security
for summer toboggan runs and
water chutes
4
In 2012 a testing system was deliv-
up to 32 t are produced. The scope of
ered to BGH Edelstahl Siegen GmbH.
customers
The privately-owned company em-
branches with highest quality require-
ploys more than 2000 people and
ments: The power industry including
looks back upon a history of more
wind power systems, machinery and
than 500 years. At the facility in the
plant engineering, drive technology,
town of Siegen open-die forgings and
press manufacturing and the off-
forged steel bars with unit weights of
shore industry.
mainly
comprises
RMG 4015: Crack depth measurement in a pumped storage hydro
power plant
5
DEUTROMAT UWE:
Safe landing
5
KARL DEUTSCH expand international distribution network
6
Prof. Dr.-Ing. Volker Deutsch
turned eighty
7
New employees at
KARL DEUTSCH
8
Fairs and trade shows
8
Contact
KARL DEUTSCH
Pruef- und Messgeraetebau GmbH + Co KG
Otto-Hausmann-Ring 101
42115 Wuppertal · Germany
Phone (+49 -202) 71 92-0 · Fax (+49-202) 7149 32
info@karldeutsch.de · www.karldeutsch.de
Typical component in the new 4,000 t press at BGH Edelstahlwerke Siegen GmbH
The testing system is designed for steel
to the part axis, thus yielding a helical
bars with diameters between 300 mm and
scan track.
1,000 mm, lengths between 1.5 m and
10 m and unit weights of up to 35 t. The
Since two separate test stations are in-
inspection surfaces are pre-turned and
cluded the test mechanics needs to be de-
provide a roughness of 25 µm.
signed for a load of up to 70 t.
The forged components are placed into the
The double portal enables typical production
test portal by means of a crane and then
quantities of 4,000 t per month. During the in-
set in rotation.
spection by one of the stations further tasks
can be carried out on the other station, such
Typical peripheral speeds are 0.15 m/s.
as manual post examinations, as well as serv-
The probes are touched down in
ice and cleaning work.
12 o‘clock position and driven in parallel
Continued on page 2
News from your partner for NDT
KARL DEUTSCH
Continued from page 1
fication for the core region and angle beam
two parallel electronic modules were in-
Loading and unloading of such high unit
insonification in both circumferential direc-
stalled in two separate carriers, with the
weights heavily stresses the test me-
tions for the detection of longitudinal flaws.
shot sequence synchronization of the two
chanics. Therefore the roller systems
Further increase of the throughput was
units to be as precise as possible.
were provided with absorber modules,
achieved by employing 8 identical probes
The probes were mounted in link chains in
circumferential direction. The flexible chains
align themselves optimally to the surfaces of
all relevant object diameters. The arrangement of the probes in circumferential direction also provides extremely short untested
end zones and guarantees overlapping of the
identical probes. Overlap is achieved at low
speed and also at full motion speed in axial
direction of the component.
The ultrasound is coupled by means of a
water gap between probe and object surface. A motorized gap adjustment allows
for convenient operation of the testing system with respect to gap optimization according to different surface curvatures or
object diameters. Furthermore wear and
Testing of a large forged shaft with a total of 32 probes in two carriers
tear of the hard metal shoes is minimized.
which are moved pneumatically after
for each inspection task, resulting in a total
charging.
of 32 probes. The motion feed per revolu-
Test results and recording
tion and per probe is 32 mm at full testing
Typical specifications are DIN EN 10228
The base area of the testing system
parts 3 and 4, SEP 1921, SEP 1923 and
- weighing about 40 t - covers 5.3 m by
ASTM A 388. The test sensitivities are
14.6 m. The system was completely put
0.8 mm FBH for the straight beam insonifica-
into service in the assembly hall of
tion in the near-surface region down to a
KARL DEUTSCH in order to check all per-
depth of 50 mm and 1.5 mm FBH for the
formance characteristics prior to shipment.
core region. A careful selection of the probes
concerning roof angles of TR probes or near
The construction focused on most efficient
fields of the straight beam probes was nec-
dismounting and subsequent reassembling
essary to ensure complete coverage be-
at BGH Edelstahl Siegen GmbH. In No-
tween the near-surface region and the core.
vember 2012 the testing system was successfully put into operation and approved.
Carrier for 16 probes with water gap coupling
Probes and probe carriers
Calibration for the angle beam insonification under ±45° is executed with a surface
notch of 2 mm depth, or by means of 6 mm
For increase of throughput special probes
speed, thus yielding 256 mm in total. Of
side drilled holes. The test results are pro-
were developed to enable scans with an
course the achievable defect sizes, pulse
vided also in C-scan format. WD
extra wide test track and yet high sensitiv-
repetition frequencies and testing speeds
ity at the same time.
depend on the material properties.
The four inspection tasks cover straight
Due to the very good sound conductivity of
beam insonification into the near-surface
forgings so-called phantom echoes may
area with TR-probes, straight beam insoni-
occur. Therefore the probes controlled by
2
www.karldeutsch.de »
Products » Ultrasonic Testing Systems » ALPT/RPTS
ECHOGRAPH 1090: Ultrasonic testing of laminated glass
Due to safety reasons front shields of
airplanes, trains and cars are manufactured as laminated glass.
At least 2 panes of glass are joined by
means of adhesive plastic foils. For quality
assurance a flawless adhesion must be
proved. This task can be solved with the
aid of ultrasound.
Damped echo sequence: Good bonding
Long echo sequence: Lack of fusion
As an ultrasonic flaw detector the ECHO-
damped echo sequence. A faulty adhesion
GRAPH 1090 is recommended, together
leads to a strong reflection yielding a long
with the high frequency and broadband
undamped echo sequence. RW
probe DS 6 PB 4-14.
When the probe is coupled to the glass
www.karldeutsch.de »
Products » Ultrasonic
Testing Instruments »
Instruments »
ECHOGRAPH 1090
surface the echo sequence from the first
glass layer can be evaluated. If the adhesion is good, the sound is absorbed by the
plastic foil and this results in a strongly
Front shield of a car
ECHOMETER 1076 TC: Waterways put to the test
The Wasser- und Schifffahrtsverwal-
ure the wall thickness of coated material
tung des Bundes (Federal Waterways
without the necessity to remove the coat-
and Shipping Authority) is responsible
ing beforehand. By means of the probe
for federal waterways and the control
DSE 8.3/15 PB 5C it is possible to deter-
of shipping traffic. Around 13,000 em-
mine wall thicknesses between 2 mm and
ployees make sure that all federally
28 mm under a coating of up to 4 mm.
owned water routes and shipping sites
with related constructions (locks,
weirs, bridges, culverts) are in sound
condition.
Since the culverts need to be examined
Water culvert of the Huenxe Creek at the
Weser-Datteln canal
along their entire length, operation sometimes is extremely tough. Narrowness,
Revisions need to cover the examination of
darkness and wetness are big challenges
Regularly all structures are revised in order
coatings as well as the determination of the
for the inspector and the instrument.
to ensure proper functioning.
remaining wall thickness in order to judge
the stability and water leak-tightness.
Culverts, for example, are underpass tubes
Because of its robustness and easy operation the ECHOMETER 1076 TC is the opti-
for waste and drinking water, groundwater
For some time now, the waterways and
or oil-pipelines underneath roads, embank-
shipping authority in the town of Duisburg-
ments, tunnels, rivers, or other water routes.
Meiderich uses the wall thickness gauge
mal solution for this task. Ki
“ECHOMETER 1076 TC Basic” for this purOften such passages contain straight
pose.
tubes from one side to the other. If steel
pipes are used they need to be protected
TC is short for “Through Coating” and de-
against corrosion by means of coating.
notes the capability of the gauge to meas-
3
www.karldeutsch.de »
Products » Wall Thickness
Gauges » Gauges »
ECHOMETER 1076 TC
News from your partner for NDT
KARL DEUTSCH
ECHOMETER 1076 TC Data: Measurement of residual wall thickness of ship floors
Similar to regular examination of cars by
placing a transmission/receiver probe di-
technical inspection agencies, also ships
rectly on the steel surface. There is no
must prove their reliability of operation in
need to remove adherent paintings or coat-
stipulated intervals.
ings. In this case the gauge uses a 5 MHz
probe and is set to the multiple echo
An important criterion at ships is the re-
method, thus avoiding false thickness val-
maining wall thickness of the ship hull. The
ues caused by the coating.
check is carried out in a dry dock, following
a specified measuring grid. Especially the
The instrument features a coupling moni-
ship floor is tested from the outside be-
tor, background light and a data memory to
Measurement on a roughly cleaned ship
floor
cause it is permanently exposed to water.
store wall thickness readings which later
ably protects the gauge against damages
At all measurement points the minimum
can be transmitted to a PC by means of the
in rough outdoor environments. KS
wall-thickness matching the ship size must
software tool iCom.
still be available.
The operating function “minimum-value”
The ECHOMETER 1076 TC Data is well
automatically records the smallest thick-
suited for this task. After removal of loose
ness value during the dynamic scan of a
rust the wall thickness can be measured by
measurement location. The red holster reli-
www.karldeutsch.de »
Products » Wall Thickness
Gauges » Gauges »
ECHOMETER 1076 TC
FLUXA and KD-Check: Security for summer toboggan runs and water chutes
The company Josef Wiegand GmbH &
penetrants with the KD-Check test system
Co. KG from Rasdorf in Germany pro-
(RDP-1, PR-2, SD-1). With the aid of sur-
duces summer toboggan runs and water
face crack testing by qualified inspectors
chutes. With more than 350 plant constructions the company is the global market leader for summer toboggan runs.
The technical rules for steel constructions
are specified in the quality standard DIN
EN 1090-2. Since its introduction in 2012
Regular nondestructive materials testing ensures untroubled leisure activities on summer toboggan runs
the extent of nondestructive testing of all
weld seams specified therein has widened
tion of employees: During the last months
considerably.
six staff members successfully have passed
Hand magnet with flexible poles for matching
object surfaces
the training courses MT1 (magnetic particle
From design type EXC2 of steel construc-
crack detection) and PT1 (dye penetrant
the usual high safety standards at the com-
tions (i.e. materials up to S700, stairs and
testing) at KARL DEUTSCH.
pany Wiegand now are being improved on
handrails in public and industrial areas) com-
the shop floor already. Thus a secure lei-
plementary magnetic particle or dye pene-
Welds on ferritic steel constructions are
sure time pleasure is guaranteed for the
trant testing is demanded in order to detect
tested with a DEUTROPULS yoke in com-
guests also in the future. MR
irregularities at the surface of welding seams.
bination with black FLUXA magnetic particles and white background painting. Water
The company Wiegand meets the chal-
chutes, in particular, are made from stain-
lenge of increased requirements by the pur-
less austenitic steel. Testing on this mate-
chase of test systems and by the qualifica-
rial is executed by means of red dye
4
www.karldeutsch.de »
Products » Penetrant
Testing » Testing Agents »
KD-Check
RMG 4015: Crack depth measurement in a pumped storage hydro power plant
In the German town of Gemünden am
High centrifugal forces occur because of
Main the company E.ON Wasser-
the high rotating mass of the rotor (total
kraft GmbH operates a pumped storage
weight 220 t, 500 rev/min).
hydro power plant, which provides the
electric power for the train operation of
If a hammer head would break down, a
the railway company Deutsche Bahn AG.
complete damage of the generator combined with a long downtime of the power
During a scheduled examination of a gen-
station would be the consequence.
erator shaft with the magnetic particle
method a multitude of cracks was detected
The depths of cracks in all hammer head
notches were evaluated using the crack
depth meter RMG 4015. This was helpful
for the operators, who are responsible for
grinding the cracks and subsequent repair
works.
Top view of the generator shaft
Additionally, all-clear could be given re-
After repair works all notches were sub-
garding the maximum depth of the existing
jected to examination with magnetic parti-
cracks.
cles. No remaining cracks were found.
Thus, the results of the crack depth meas-
The magnetic particle testing on the generator
shaft indicates a multitude of surface cracks
in the hammer head notches
The measurements were difficult, because
in the so-called hammer head notches. Via
Here the sensor could only be positioned
these notches the four poles of the genera-
by means of a mirror.
urement could be verified afterwards. MR
relevant regions were not directly visible.
tor are connected to the shaft of the generator. Cracks with depths up to 3.0 mm
In addition, a KARL DEUTSCH UV-LED
are allowed to be reworked according to
hand lamp was necessary to make the
the manufacturer‘s specification.
cracks visible for inspection.
www.karldeutsch.de »
Products » Crack Depth
Gauge RMG 4015
DEUTROMAT UWE: Safe landing
Our customer bmt aerospace with pro-
Both components have to be examined
The device offers the inspection with alter-
duction sites in Belgium, the United
with magnetic particles to detect all
nating current and alternating field as well
States and Romania is specialized in
surface cracks. Because of increasing
as full-wave direct current and direct field.
gear drives, gear components, gear
requirements and many special de-
For this purpose corresponding rectifiers
wheels and gear rods for the aerospace
mands of the mainly North-American
were installed. As well, a reconnection de-
industry. Among other components me-
customers a new crack detection sys-
vice for various combinations of the current
chanics for landing flaps of various air-
tem was purchased to meet the Nadcap
flow is provided together with a respective
craft types are produced in the Belgian
audit objectives and the according
security monitoring unit. With deeply pen-
plant Oostkamp.
specifications.
etrating direct fields also cracks just below
The main component assembly, which pro-
By the end of 2012, KARL DEUTSCH deliv-
however, the inspection must be carried
vides an elongation of the wing for landing
ered a customized machine for this task on
out in two steps and the demagnetization
approach, contains a curved gear rod with
the base of the well-proven DEUTROFLUX
of DC fields is complex.
the related bevel.
UWE series.
the surface can be detected. In this case
To be continued on page 6
5
News from your partner for NDT
KARL DEUTSCH
Continued from page 5
low frequency coil, thus obtaining an op-
A low frequency coil is necessary to de-
timal result.
magnetize the parts after the test with direct field so the permissible remanence
Also with regard to the documentation of the
value of 3 Gauss is not exceeded.
test results the machine shows some special
features which were realized via a Siemens
As requested by bmt the demagnetiza-
touchscreen. All part-specific inspection
tion is executed for multiple components
plans are stored in the parameter memory.
at the same time using transport cages.
Two cages, stacked one on the other, are
All changes to the inspection plans are re-
moved on a conveyor belt through the
corded in a table. The magnetization val-
Multiple components are moved in up to two
stacked stainless steel cages through a low
frequency demagnetization coil
ues are selected according to the respective inspection plan. After every inspection
lot the results are transferred to the bmtnetwork, including the data on operator,
components, date and results.
Regular system checks with reference objects have to be confirmed by the operator,
thus ensuring a system operation with all
required verifications. KS
www.karldeutsch.de »
Products » Magnetic Particle
Testing » Stationary Test
Benches » UWE 600/900
Customized crack detection system with demagnetization tunnel for aircraft components
KARL DEUTSCH expand international distribution network
New strategic partners overseas: In the
sales partner for our complete product
and presented ourselves with a shared
last year we kept on extending our inter-
portfolio. After intensive in-company
exhibition booth on the most impor-
national distribution network with the
training in Wuppertal Christian Binder is
tant industrial fair of Thailand, the
aid of Dr. Michael Maass (International
available for all inquiries. He speaks four
METALEX.
Sales).
languages: Spanish, German, PortuIn Korea our long-time representation
guese and English.
We are proud to have won the company
All Int Tech S.R.L. in Argentina as a
Chunsung now gets support from the
Also in Asia we could extend our sales
company JSNT in the area of ultrasonic
and service network: In Thailand we
inspection systems.
trained 10 staff members of our partner
NDT Instruments (Thailand) Co., Ltd.
Furthermore we complemented our international sales net in the USA by winning the company BERCLI as strategic
partner.
The team around Dr. Deborah Hopkins
Christian Binder of our Argentinian representation All Int Tech S.R.L. and Dr. Wolfram
Deutsch during the training in Wuppertal
Mr Uthai (left) and a part of his team of
NDT Instruments (Thailand)
6
(Founder and CEO) and Wayne Johnson (Engineering Director) has many
years of experience in nondestructive
The
company
Tecnica Test S.A.
de C.V. takes over
the technical consultation and sales
in Mexico with a
staff of seven em-
Longtime technical competence in nondestructive testing:
The representation of KARL DEUTSCH in the USA is managed by
Dr. Deborah Hopkins and Wayne Johnson.
ployees.
Senior
partner
Miguel
Saldamando Flana-
The staff of our Mexican agency
Test S.A. de C.V.
gan is convinced of
our large product
testing and provides technical support
portfolio and sees great opportunities in the
and sales with the focus on ultrasonic
Mexican market, especially in the area of
testing.
magnetic particle testing. AL
www.karldeutsch.de »
Agencies Worldwide
Prof. Dr.-Ing. Volker Deutsch turned eighty
On December 13th, 2012 the long-stand-
ideas for the development of products.
After 40 years at KARL DEUTSCH
ing managing director of the company
Very
founder
Prof. Dr. Deutsch handed the business man-
KARL DEUTSCH Pruef- und Messgerae����������
Ing. Karl Deutsch entrusted responsibility
agement over to the next generation. Today
tebau GmbH + Co KG celebrated his 80
to his son. The plant engineering and con-
the expanding enterprise is successfully
th
birthday.
soon
the
company
struction department expanded and a
worldwide sales network was installed.
Already as a doctoral candidate at the
Therefore he used to be on business trips
University of Hanover the young Volker
to Eastern Europe, South America and
Deutsch joined his father‘s company in
China already in the 1970s.
1961. The company was founded in 1949
and provided products for nondestructive
His capability of explaining complex issues
materials testing. Measurement of coating
in a comprehensible manner was the base
thicknesses, ultrasonic testing and surface
for many presentations and publications in
crack detection methods are still in the
technical journals and over 20 specialist
focus today. Already during his doctorate
books. From 1982, Prof. Dr.-Ing. Volker
Volker Deutsch was able to provide many
Deutsch was a honorary professor at the
University of Dortmund and presented lectures on nondestructive testing in the faculty of Mechanical Engineering.
Prof. Dr.-Ing. Volker Deutsch
managed by his two sons: Dr. (USA) Wolfram A. Karl Deutsch as managing director of
Volker Deutsch (standing) at ultrasonic testing of railway axle wheel sets (1965 appr.)
He knew well how to lead and motivate his
the
more than 100 employees, who in general
Olaf Deutsch (MA) as business administra-
worked for the company for many years
tion manager of the branch office in Beijing,
and partly still do today. Being locally in-
China. His daughter Dr. iur. Elke Herbsthofer
volved he was a member of the committee
owns the publishing house Castell-Verlag
on international trade of the local chamber
in Wuppertal, where all printed matters of
of commerce and industry. Also he used to
the company are published. On the occa-
be shareholder and chairman of the board
sion of his big birthday two further books
of the W-Tec, which is a centre for technol-
were added (one NDT book and a crime
ogy and start-up companies in Wuppertal.
thriller). WD
7
two
sites
in
Wuppertal
and
News from your partner for NDT
KARL DEUTSCH
New employees at KARL DEUTSCH
Since October 2012, Karina Windus supports our sales office in Wuppertal as skilled industrial business management assistant with experience in
sales, marketing and purchasing.
Being qualified for stock management Sascha Schäfer strengthens the
team in stock / goods receiving and materials supply / shipment for our
Works 2 and the new storage building since February of this year.
Fairs and trade shows
September 16 - 21, 2013
SCHWEISSEN & SCHNEIDEN
International Trade Fair
Joining, Cutting, Surfacing
Messe Essen
Hall 4.0, booth B110
Essen, Germany
October 14-17, 2013
22nd testXpo
International Forum for Materials Testing
All current dates can be
found on our homepage
www.karldeutsch.de
under the topic “Dates,
Events”
Zwick Company,
Metallinsel
Ulm, Germany
KARL DEUTSCH
NDT instruments, sensors and systems
The privately-owned KARL DEUTSCH
sonic testing systems, instruments and
Application experience, theoretical knowl-
company has been involved in the develop-
accessories for magnetic particle testing,
edge and manufacturing know-how span-
ment and fabrication of NDT instruments
and penetrants are part of our product
ning more than six decades as well as the
since its foundation in 1949. More than
range.
standard compliant quality management
50% of the products are exported worldwide.
guarantee state-of-the-art instruments and
Characterised by continuous innovation
accessories and a leading position with re-
and product reliability, the trade marks
gard to quality, reliability and economy also
Digital and analog ultrasonic flaw detec-
ECHOGRAPH,
for the future.
tors, wall thickness gauges, coating thick-
TROFLUX, LEPTOSKOP, FLUXA, KD-
ness gauges, crack depth gauges, ultra-
Check and RMG are well-recognised.
ECHOMETER,
DEU-
DIN EN ISO
9001
certified
8