2nd Edition 2014

Contact

KARL DEUTSCH

Pruef- und Messgeraetebau GmbH + Co KG

Otto-Hausmann-Ring 101

42115 Wuppertal · Germany

Phone (+49-202)7192-0 · Fax (+49-202)714932

info@karldeutsch.de

www.karldeutsch.de

Increased inspection reliability

at reduced inspection time

The company Bentec GmbH Drilling &

Oilfield Systems in the German town of

Bad Bentheim is one of the globally lead-

ing manufacturers of drilling machines

and systems for oil, gas and geothermal

drilling. The different drilling systems are

divided into fields of application: They

are produced for land and offshore drill-

ing as well as for the use

under extreme climatic

conditions, e. g. in deserts

or arctic regions, and are

subject to high technical

requirements and global

standards.

To improve quality assur-

ance in the production of

these sophisticated drilling

machines KARL DEUTSCH

developed an extremely

universal magnetic particle

testing system of the type

“DEUTROFLUX UWS 3500

special” and shipped it to

Bad Bentheim. With this

system small parts as well

as long and heavy parts up

to a weight of 2 t and a

length of 3.5 m can be

tested for cracks.

To achieve this, the machine

features two field coils in an

open yoke design like the

smaller standard machines

of type UWE for testing parts up to a length

of 900 mm. For longer or heavy compact

parts a large motorized moving coil is ap-

plied to generate the axial magnetic field

(for circumferential cracks). In both cases a

test current of up to 5 kA that generates

the magnetic ring field (for longitudinal

cracks) is passed through the inspected

part. The machine features a traverse

equipped with freely displaceable work-

piece supports and rolls for round parts.

Contents

DEUTROFLUX UWS 3500 special: Increased inspection reliability

at reduced inspection time 1

ECHOGRAPH-TTPS:

Ultrasonic inspection of

aluminium bars 2

ECHOMETER 1077:

Measuring pitting corrosion

with a TR-probe 4

KD-Check: Successful

certification of fluorescent

penetrant systems 5

Review of fairs and events 5

New KARL DEUTSCH

employees 7

Local commitment

in Wuppertal 7

About

KARL DEUTSCH 8

The sophisticated quality assurance of the Bentec Top

Drives enables minimal downtime even under harsh

conditions.

DEUTROFLUX UWS 3500 special

Continued on page 2

In summer 2014 an ultrasonic testing

system was delivered to the Bharat

Forge Aluminiumtechnik GmbH & Co.

KG (BFAT) in the town of Brand-Erbis-

dorf, Germany. BFAT manufactures

forged aluminium chassis compo-

nents, e. g. wishbones and knuckles,

for well-known automobile manufac-

turers.

The testing system ECHOGRAPH-

TTPS is equipped with an immersion

tank for the inspection of aluminium

bars. The tank consists of a robust

welded structure of profiled tubes

with integrated stainless steel water

tank.

For testing the bars are rotated on

servo-driven roller supports, which are

mounted at a fixed distance between

each other. The probes are moved by a

high-precision horizontal support along

the axial direction, thus leading to a

helical testing track.

Detection of volumetric flaws is

achieved by straight-beam scanning

with a line-focused 5 MHz probe. For

surface-near flaws two line-focused

2 MHz probes are applied. They are

moved slightly out of the 12 o’clock

posit ion to obtain angle beam

insonification at 45 degrees clockwise

as well as counter clockwise. To mini-

mize the inspection time three similar

probe systems (nine probes in total)

are mounted on the horizontal support

at a fixed axial distance of 2 m to

each other. Hence, depending on the

2

News From Your Partner for NDTKARL DEUTSCH

the names of the inspectors and

provides customized test reports if

needed.

The parameter software DEUTROFLUX

Memory II stores the testing param-

eters of al l the various test parts,

www.karldeutsch.de » Products » MagneticParticle Testing » Magnetic Particles Test Benches

Round test part with moving coil (left) on freely displaceable roller supports

Continued from page 1

ECHOGRAPH-TTPS: Ultrasonic inspection of aluminium bars

A large inspection cabin with a roof

that can be opened pneumatically for

optimal crane loading of heavy parts

is included. The DEUTROFLUX mag-

netic particle testing system enables

the company Bentec to reduce the in-

spection time by 65 % (compared to

the equipment used before). KS

Probe holder

3

required sensitivity

very short inspec-

tion times can be

realised.

The inspection re-

sults are presented

as a line diagram

for every testing

function on a mon-

itor of the higher-

level data manage-

men t sys tem,

which also man-

ages all parame-

ters of the testing

system. A further

offline analysis of

the inspection re-

sults can be car-

ried out with a

C-scan software.

Calibration of the

s e n s i t i v i t y i s

achieved by using

a calibration bar of

the same aluminium alloy material

with artificial flaws.

The new ultrasonic testing system

enables the company Bharat Forge

Aluminiumtechnik to deliver semi-

finished products to the subsequent

forging process in compliance with

the customer’s specifications. MR

ECHOGRAPH-TTPS with control unit, immersion tank, and testing traverse

www.karldeutsch.de » Products » US TestingSystems » TTPS

Control unit with PLC (left) and user interface for ultrasonic inspection

News From Your Partner for NDTKARL DEUTSCH

4

ECHOMETER 1077: Measuring pitting corrosion with a TR-probe

www.karldeutsch.de » Products » Wall Thickness and Sound Velocity Gauges » ECHOMETER 1077 Data

Passivation is a technique to create a corrosion protection layer on the surface

of metals. Pitting corrosion occurs if this protective layer is punctually damaged.

That is, small corrosive holes on the surface of passivated metals that grow deep

into the metal.

Pitting corrosion

on the inner face

of a tube may be

detected by an ul-

trasonic wall thick-

ness measure-

ment. Due to the

geometry of the

corrosion one can-

not assume that a

well-defined series

of backwall ech-

oes is obtained

(see Figures 2

and 3). Therefore,

it is not possible to determine the wall thickness by a time-of-flight measurement

between two subsequent backwall echoes (BE-BE method). That is why the time-of-

flight between transmitting pulse and the first backwall echo is evaluated (TP-BE

method). After subtracting the travel time in the delay line of the probe the remaining

wall thickness can be calculated if the sound velocity of the material is known. As its

value may be very small a probe with good near surface resolution is needed. Thus,

transmitter-receiver

(TR) probes with

separated transmit-

ting and receiving

crystals are gener-

ally applied. How-

ever, this type of

probe has the dis-

advantage that an

inaccuracy in the

time-of- flight meas-

urement occurs that

is depending on the

length of the ex-

tended v-shaped

sound path.

The ECHOME-

TER 1077 solves

this problem by

means of a multi-point adjustment (Fig-

ure 4). For this purpose the device is ad-

justed with at least two different material

thicknesses. The expected wall thick-

ness has to lie within the range between

the minimum and maximum adjustment

value. Thus, the extended sound path is

corrected automatically and a precise

measurement is obtained. Another useful

feature for this kind of measurement is

the min-max function of the ECHOME-

TER 1077 (Figure 5). With this function

turned on while scanning the minimum

and maximum values of the measured

wall thickness are retained and dis-

played. Therefore, even small pitting cor-

rosion spots cannot be overlooked but

detected reliably.

In the example shown, a tube segment

showing pitting corrosion as well as

other kinds of wear is inspected. In the

inspected section the remaining wall

thickness without corrosion is between

3 mm and 4 mm (see Figure 2 and the

maximum value in Figure 5). At the cor-

roded spots the wall thickness is re-

duced to slightly more than 2 mm (see

Figure 3 and the minimum value in Fig-

ure 5). In Figure 3 it can be seen that at

these spots a BE-BE evaluation is not

possible or rather leads to an incorrect

result. Whereas, applying the TP-BE

method results in the correct wall thick-

ness value. SV

Fig. 1: Detection of pitting corrosion with a wall thickness measuring gauge

Fig. 2: Series of backwall ech-oes at a non-corroded spot

Fig. 3: Series of backwall ech-oes at a pitting corrosion spot

Fig. 4: Multi-point adjustment Fig. 5: Retaining of the mini-mal (2.12 mm) and the maxi-mum (3.93 mm) wall thick-ness values (3.57 mm is the currently measured value).

5

The Internationally recognized stand-

ard SAE AMS 2644 “Inspection Mate-

rial, Penetrant” defines the technical

specifications for penetrant systems in

the aviation sector. The highest de-

mands on safety components in the

aviation sector are reflected in the re-

quirements for penetrant systems in

AMS 2644.

As AMS 2644 generally characterizes

higher sensitivities, the sensitivity

classes defined for fluorescent pene-

trant systems are incomparable to other

specifications. The situation is similar

when the corrosive characteristics of

penetrant and dry developer are consid-

ered. Most other standards merely de-

fine limits for corrosive constituents (e.

g. fluorine, chlorine, and sulphur),

whereas the standard AMS 2644 de-

mands to directly determine the corro-

sive characteristics of the penetrant sys-

tem on different alloys typically used in

the aviation sector. In addition a test at

high temperatures has to be passed.

Penetrant systems that have been qual-

ified in accordance with the standard

SAE AMS 2644 are published in the list

“QPL AMS 2644 (Qualified Products

List)”. Only penetrant systems that are

listed are approved by SAE AMS 2644.

The company KARL DEUTSCH strives for

qualification of all of its penetrant systems

in accordance with AMS 2644, in addition

to be qualified to DIN EN ISO 3452. A start

was made with the water solvent, fluores-

cent penetrants. These are characterized in

AMS 2644 as “type 1, method A pene-

trants” and divided into five sensitivity lev-

els: level ½, level 1, level 2, level 3, and

level 4. Here, level 4 marks the highest and

level ½ the lowest sensitivity. The corre-

sponding dry developer is characterized as

“form a, dry powder” and may be used

with penetrants of any level. Together with

the products KD-Check FWP-2,

KD-Check FWP-22 and D-Check DD-1

KARL DEUTSCH provides already two

complete penetrant systems qualified in

accordance with AMS 2644:

• KD-Check FWP-2: “Type 1, method A”

penetrant of sensitivity level 3

• KD-Check FWP-22: “Type 1, method A”

penetrant of sensitivity level 2

• D-Check DD-1 is the corresponding

“form a” dry developer (usable for both

penetrants)

These penetrant systems are mainly used

in stationary penetrant testing systems.

All three products are listed in

QPL AMS 2644. Wn

www.karldeutsch.de » Products » KD-Check »Penetrants

KD-Check: Successful certification of fluorescent penetrant systems

Penetrants FWP-2 and FWP-22 together with the dry developer DD-1 in containers of different sizes

Review of fairs and events

This year, the company KARL DEUTSCH

presented itself with a new exhibition

booth.

The trade fair year started at the Tube in

Duesseldorf, Germany, which is of inter-

est in particular for the ultrasonic test-

ing systems division. We were glad to

welcome numerous international cus-

tomers and trade partners and to sell

many testing systems for helically

welded tubes. Hence, leading to an ex-

traordinary good workload for manufac-

turing of testing systems in 2015. For

that reason our Works 2 production site New KARL DEUTSCH booth at the Tube in Duesseldorf, Germany, in April 2014 Continued on page 6

had to be extended by another provi-

sional assembly area.

At the trade fair a farewell was bidden to

Dipl.-Ing. Hans-Dieter Harbecke who retired

after five successful years at KARL DEUTSCH.

Together with Dipl.-Ing. Peter Schulte he ac-

complished a record-breaking order backlog

at the end of his career.

The successor of Hans-Dieter Harbecke

had the opportunity to introduce himself

adequately in his second week at

KARL DEUTSCH: Dipl.-Ing. Heinrich

“Heinz” Weber contributes many years of

experience with ultrasonic testing sys-

tems. His proven expertise includes ultra-

sonic testing with mono-element probes

as well as the phased array technology.

Anil Nair from NDT Technologies, our

trade partner in India, could get an im-

pression of the new portable phased

array instrument GEKKO. In the mean-

time, he purchased a demo device to

serve the Indian market competently and

exclusively.

For the Russian market a new trade part-

ner could be acquired. The Russian com-

pany USPS has many years of experience

in the distribution of NDT products. They

already sold several magnetic particle

systems and a lot of magnetic particle in-

spection media in the first year of our co-

operation. Special inspection media for

outdoor use at low temperatures were de-

veloped for this market.

At the European NTD Conference in

Prague in October 2014 the portable

phased array instrument GEKKO was pre-

sented as a private label in red colour for

the first time.

KARL DEUTSCH and the French partner

company M2M (KARL DEUTSCH holds

33 % of M2M’s shares) developed a glo-

bal sales strategy giving KARL DEUTSCH

the exclusive distribution rights for the

phased array instrument GEKKO in

20 countries.

The testing device GEKKO features

64 parallel channels. It provides the

ability to test thick parts with high ul-

trasonic sound energies as well as the

control of matrix arrays. Defect pat-

terns are accurately reproduced by

means of the total focusing method

(TFM), which allows defect sizing di-

rectly in the B-scan.

Generation no. 4, Julius and Philipp

Deutsch visited an NDT trade fair for the

first time and were able to check out their

skills of the English language. As a lot of

KARL DEUTSCH trade partners visited

Prague it never got boring. WD

6

News From Your Partner for NDTKARL DEUTSCH

Continued from page 5

Anil Nair from our Indian agency together with Dr. Wolfram Deutsch

Anton Sevryukov, owner of the company USPS from Russia, visited Duesseldorf

The portable phased array instrument GEKKO with 64 channels and accurate de-fect sizing capability by means of the TFM (total focusing method)

Julius, Philipp and Wolfram Deutsch at the ECNDT gala dinner in Prague

www.karldeutsch.de » Events

Farewell to Hans-Dieter Harbecke by Dr. Wolfram Deutsch

7

Local commitment in Wuppertal

More than 350 companies, institutes

and individuals are committed to

strengthen the social and residential

environment in Wuppertal. The associ-

ation “wuppertalaktiv!” stands for a re-

sult-orientated city marketing and has

a voluntary basis. The company mem-

ber KARL DEUTSCH is involved in two

Wuppertal flagship projects.

The “Junior Uni Wuppertal” offers sci-

ence oriented courses to young stu-

dents. Last year, a new award-winning

building has been taken into service di-

rectly beside the banks of the river

Wupper. What is particular about this

project apart from a unique range of

courses is its complete funding by pri-

vate donations. Foundations and indus-

trial companies from Wuppertal are ac-

tively committed to this project.

Another urban project in Wuppertal is

also close to completion. As part of a

European funded project a former rail-

way track running north along the

Wupper river is converted into a cycle

New KARL DEUTSCH employees

As a trained energy electronics specialist Klaus-Stefan Laukat supports the electric manufacturing in the magnetic particle testing systems division since March 2014.

Contributing many years of experience with ultrasonic testing devices Dipl.-Ing. Heinrich Weber strengthens the international sales team for ultrasonic testing systems at KARL DEUTSCH since April 2014.

Our probes division is glad to have the new colleague Dr.-Ing. Simon Steves, dealing in particular with the further development of ultrasonic probes since April 2014.

The qualified electrician Sebastian Unglaub could be recruited for the mag-netic particle systems division in June this year. He is on the road for certi-fication and maintenance of our customers’ systems.

With a doctorate in chemistry Dr. Oliver Goerz develops chemical products for magnetic particle crack detection. The chemicals division is pleased having this committed colleague since July 2014.

In July this year, the test gauge production section welcomed the qualified electrician Andrea Schubert to strengthen the team.

Welcome to the KARL DEUTSCH team!

The qualified machine fitter Uwe Zwickl supports the magnetic particle sys-tems manufacturing in our Works 2 since October 2014.

Continued on page 8

News From Your Partner for NDTKARL DEUTSCH

8

Continued from page 7

path. The Bergisches Land, named after

the Count von Berg, lived up to its name,

thus requiring lots of tunnels and via-

ducts for the construction of the railway

track by the year 1879. The track was fi-

nally put out of

service in 1999.

Since its founding

in 2006 the asso-

ciation “Wupper-

talbewegung e.V.”

has been trying to

reactivate the

track. Due to lack

of public money

the initial funding

had to be based

on private dona-

tions.

KARL DEUTSCH is financially involved

in the so-called “Nordbahntrasse”

(which means “Northern Rail Trail”)

project. KARL DEUTSCH also provides

immaterial support by godparenting

and therefore taking over some re-

sponsibility for a part of the track. The

track runs in the immediate vicinity of

the KARL DEUTSCH premises. Hence,

many members of staff are now able to

cycle to work. The former train station

“Dorp” awoke from its deep slumber

by a citizens’ initiative and turned into

a true gem.

The track is a part of the cycle path net-

work of North Rhine-Westphalia and con-

nected to the neighbouring cities Solin-

gen, Essen, Bochum, and Düsseldorf.

The 22 km long track will be officially

opened with lots of prominent politicians

on December 19th, 2014. WD

Three young scientists in front of the new building of the “Junior Uni Wuppertal”

Citizens pave the track at the former train station “Dorp”

The graffiti artist Martin Heuwold from Wup-pertal redesigned the old shed at the former train station “Dorp”

The privately owned company

KARL DEUTSCH was founded in 1949

and develops and produces instruments

for non-destructive material testing. Port-

able instruments, stationary testing sys-

tems, sensors and crack detection liquids

are produced by 130 motivated employ-

ees in two works in Wuppertal. Additional

20 employees in international offices and

a worldwide network of dealers support

the export business which accounts for

more than 50% of the turnover. Charac-

terised by continuous innovation and

product reliability, the trade marks

ECHOGRAPH , ECHOMETER ,

DEUTROFLUX, LEPTOSKOP, FLUXA,

KD-Check and RMG are well-recog-

nised. Our customers are metal producing

and processing industries, e. g. steel

works, automotive companies and bear-

ing manufacturers. Typical test tasks are

ultrasonic weld testing, detection of

shrink holes in castings, crack detection

in forgings with magnetic particles and

dye penetrants, safety components for

railway and aerospace as well as the wall

and coating thickness measurement.

KARL DEUTSCHPruef- und Messgeraetebau GmbH + Co KG

About KARL DEUTSCH

DIN EN ISO9001

certified