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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
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