1st Edition 2013

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

Continued on page 2

ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars

The testing system is designed for steel

bars with diameters between 300 mm and

1,000 mm, lengths between 1.5 m and

10 m and unit weights of up to 35 t. The

inspection surfaces are pre-turned and

provide a roughness of 25 µm.

The forged components are placed into the

test portal by means of a crane and then

set in rotation.

Typical peripheral speeds are 0.15 m/s.

The probes are touched down in

12 o‘clock position and driven in parallel

to the part axis, thus yielding a helical

scan track.

Since two separate test stations are in-

cluded the test mechanics needs to be de-

signed for a load of up to 70 t.

The double portal enables typical production

quantities of 4,000 t per month. During the in-

spection by one of the stations further tasks

can be carried out on the other station, such

as manual post examinations, as well as serv-

ice and cleaning work.

Typical component in the new 4,000 t press at BGH Edelstahlwerke Siegen GmbH

In 2012 a testing system was deliv-

ered to BGH Edelstahl Siegen GmbH.

The privately-owned company em-

ploys more than 2000 people and

looks back upon a history of more

than 500 years. At the facility in the

town of Siegen open-die forgings and

forged steel bars with unit weights of

up to 32 t are produced. The scope of

customers mainly comprises

branches with highest quality require-

ments: The power industry including

wind power systems, machinery and

plant engineering, drive technology,

press manufacturing and the off-

shore industry.

Contents

ECHOGRAPH-RPTS: Ultrasonic testing of forged steel bars 1 ECHOGRAPH 1090: Ultrasonic testing of laminated glass 3 ECHOMETER 1076 TC: Waterways put to the test 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 RMG 4015: Crack depth measure-ment in a pumped storage hydro power plant 5 DEUTROMAT UWE: Safe landing 5 KARL DEUTSCH expand inter- national distribution network 6 Prof. Dr.-Ing. Volker Deutsch turned eighty 7 New employees at KARL DEUTSCH 8 Fairs and trade shows 8

2

News from your partner for NDTKARL DEUTSCH

Continued from page 1

Loading and unloading of such high unit

weights heavily stresses the test me-

chanics. Therefore the roller systems

were provided with absorber modules,

which are moved pneumatically after

charging.

The base area of the testing system

- weighing about 40 t - covers 5.3 m by

14.6 m. The system was completely put

into service in the assembly hall of

KARL DEUTSCH in order to check all per-

formance characteristics prior to shipment.

The construction focused on most efficient

dismounting and subsequent reassembling

at BGH Edelstahl Siegen GmbH. In No-

vember 2012 the testing system was suc-

cessfully put into operation and approved.

Probes and probe carriers

For increase of throughput special probes

were developed to enable scans with an

extra wide test track and yet high sensitiv-

ity at the same time.

The four inspection tasks cover straight

beam insonification into the near-surface

area with TR-probes, straight beam insoni-

fication for the core region and angle beam

insonification in both circumferential direc-

tions for the detection of longitudinal flaws.

Further increase of the throughput was

achieved by employing 8 identical probes

for each inspection task, resulting in a total

of 32 probes. The motion feed per revolu-

tion and per probe is 32 mm at full testing

speed, thus yielding 256 mm in total. Of

course the achievable defect sizes, pulse

repetition frequencies and testing speeds

depend on the material properties.

Due to the very good sound conductivity of

forgings so-called phantom echoes may

occur. Therefore the probes controlled by

two parallel electronic modules were in-

stalled in two separate carriers, with the

shot sequence synchronization of the two

units to be as precise as possible.

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 arrange-

ment of the probes in circumferential direc-

tion 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 sur-

face. A motorized gap adjustment allows

for convenient operation of the testing sys-

tem with respect to gap optimization ac-

cording to different surface curvatures or

object diameters. Furthermore wear and

tear of the hard metal shoes is minimized.

Test results and recording

Typical specifications are DIN EN 10228

parts 3 and 4, SEP 1921, SEP 1923 and

ASTM A 388. The test sensitivities are

0.8 mm FBH for the straight beam insonifica-

tion in the near-surface region down to a

depth of 50 mm and 1.5 mm FBH for the

core region. A careful selection of the probes

concerning roof angles of TR probes or near

fields of the straight beam probes was nec-

essary to ensure complete coverage be-

tween the near-surface region and the core.

Calibration for the angle beam insonifica-

tion under ±45° is executed with a surface

notch of 2 mm depth, or by means of 6 mm

side drilled holes. The test results are pro-

vided also in C-scan format. WD

Testing of a large forged shaft with a total of 32 probes in two carriers

Carrier for 16 probes with water gap cou-pling

www.karldeutsch.de » Products » Ultrasonic Test-ing Systems » ALPT/RPTS

3

Due to safety reasons front shields of

airplanes, trains and cars are manufac-

tured 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.

ECHOGRAPH 1090: Ultrasonic testing of laminated glass

As an ultrasonic flaw detector the ECHO-

GRAPH 1090 is recommended, together

with the high frequency and broadband

probe DS 6 PB 4-14.

When the probe is coupled to the glass

surface the echo sequence from the first

glass layer can be evaluated. If the adhe-

sion is good, the sound is absorbed by the

plastic foil and this results in a strongly

damped echo sequence. A faulty adhesion

leads to a strong reflection yielding a long

undamped echo sequence. RW

Front shield of a car

The Wasser- und Schifffahrtsverwal-

tung des Bundes (Federal Waterways

and Shipping Authority) is responsible

for federal waterways and the control

of shipping traffic. Around 13,000 em-

ployees make sure that all federally

owned water routes and shipping sites

with related constructions (locks,

weirs, bridges, culverts) are in sound

condition.

Regularly all structures are revised in order

to ensure proper functioning.

Culverts, for example, are underpass tubes

for waste and drinking water, groundwater

or oil-pipelines underneath roads, embank-

ments, tunnels, rivers, or other water routes.

Often such passages contain straight

tubes from one side to the other. If steel

pipes are used they need to be protected

against corrosion by means of coating.

Revisions need to cover the examination of

coatings as well as the determination of the

remaining wall thickness in order to judge

the stability and water leak-tightness.

For some time now, the waterways and

shipping authority in the town of Duisburg-

Meiderich uses the wall thickness gauge

“ECHOMETER 1076 TC Basic” for this pur-

pose.

TC is short for “Through Coating” and de-

notes the capability of the gauge to meas-

ure the wall thickness of coated material

without the necessity to remove the coat-

ing beforehand. By means of the probe

DSE 8.3/15 PB 5C it is possible to deter-

mine wall thicknesses between 2 mm and

28 mm under a coating of up to 4 mm.

Since the culverts need to be examined

along their entire length, operation some-

times is extremely tough. Narrowness,

darkness and wetness are big challenges

for the inspector and the instrument.

Because of its robustness and easy opera-

tion the ECHOMETER 1076 TC is the opti-

mal solution for this task. Ki

www.karldeutsch.de » Products » UltrasonicTesting Instruments »Instruments » ECHOGRAPH 1090

Damped echo sequence: Good bonding Long echo sequence: Lack of fusion

Water culvert of the Huenxe Creek at the Weser-Datteln canal

www.karldeutsch.de » Products » Wall Thickness Gauges » Gauges » ECHOMETER 1076 TC

ECHOMETER 1076 TC: Waterways put to the test

News from your partner for NDTKARL DEUTSCH

4

FLUXA and KD-Check: Security for summer toboggan runs and water chutes

The company Josef Wiegand GmbH &

Co. KG from Rasdorf in Germany pro-

duces summer toboggan runs and water

chutes. With more than 350 plant con-

structions the company is the global mar-

ket 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

the extent of nondestructive testing of all

weld seams specified therein has widened

considerably.

From design type EXC2 of steel construc-

tions (i.e. materials up to S700, stairs and

handrails in public and industrial areas) com-

plementary magnetic particle or dye pene-

trant testing is demanded in order to detect

irregularities at the surface of welding seams.

The company Wiegand meets the chal-

lenge of increased requirements by the pur-

chase of test systems and by the qualifica-

tion of employees: During the last months

six staff members successfully have passed

the training courses MT1 (magnetic particle

crack detection) and PT1 (dye penetrant

testing) at KARL DEUTSCH.

Welds on ferritic steel constructions are

tested with a DEUTROPULS yoke in com-

bination with black FLUXA magnetic parti-

cles and white background painting. Water

chutes, in particular, are made from stain-

less austenitic steel. Testing on this mate-

rial is executed by means of red dye

penetrants with the KD-Check test system

(RDP-1, PR-2, SD-1). With the aid of sur-

face crack testing by qualified inspectors

the usual high safety standards at the com-

pany Wiegand now are being improved on

the shop floor already. Thus a secure lei-

sure time pleasure is guaranteed for the

guests also in the future. MR

www.karldeutsch.de » Products » PenetrantTesting » Testing Agents »KD-Check

ECHOMETER 1076 TC Data: Measurement of residual wall thickness of ship floors

Similar to regular examination of cars by

technical inspection agencies, also ships

must prove their reliability of operation in

stipulated intervals.

An important criterion at ships is the re-

maining wall thickness of the ship hull. The

check is carried out in a dry dock, following

a specified measuring grid. Especially the

ship floor is tested from the outside be-

cause it is permanently exposed to water.

At all measurement points the minimum

wall-thickness matching the ship size must

still be available.

The ECHOMETER 1076 TC Data is well

suited for this task. After removal of loose

rust the wall thickness can be measured by

placing a transmission/receiver probe di-

rectly on the steel surface. There is no

need to remove adherent paintings or coat-

ings. In this case the gauge uses a 5 MHz

probe and is set to the multiple echo

method, thus avoiding false thickness val-

ues caused by the coating.

The instrument features a coupling moni-

tor, background light and a data memory to

store wall thickness readings which later

can be transmitted to a PC by means of the

software tool iCom.

The operating function “minimum-value”

automatically records the smallest thick-

ness value during the dynamic scan of a

measurement location. The red holster reli-

ably protects the gauge against damages

in rough outdoor environments. KS

Measurement on a roughly cleaned ship floor

www.karldeutsch.de » Products » Wall Thickness Gauges » Gauges » ECHOMETER 1076 TC

Regular nondestructive materials testing en-sures untroubled leisure activities on sum-mer toboggan runs

Hand magnet with flexible poles for matching object surfaces

Our customer bmt aerospace with pro-

duction sites in Belgium, the United

States and Romania is specialized in

gear drives, gear components, gear

wheels and gear rods for the aerospace

industry. Among other components me-

chanics for landing flaps of various air-

craft types are produced in the Belgian

plant Oostkamp.

The main component assembly, which pro-

vides an elongation of the wing for landing

approach, contains a curved gear rod with

the related bevel.

Both components have to be examined

with magnetic particles to detect all

surface cracks. Because of increasing

requirements and many special de-

mands of the mainly North-American

customers a new crack detection sys-

tem was purchased to meet the Nadcap

audit objectives and the according

specifications.

By the end of 2012, KARL DEUTSCH deliv-

ered a customized machine for this task on

the base of the well-proven DEUTROFLUX

UWE series.

The device offers the inspection with alter-

nating current and alternating field as well

as full-wave direct current and direct field.

For this purpose corresponding rectifiers

were installed. As well, a reconnection de-

vice for various combinations of the current

flow is provided together with a respective

security monitoring unit. With deeply pen-

etrating direct fields also cracks just below

the surface can be detected. In this case

however, the inspection must be carried

out in two steps and the demagnetization

of DC fields is complex.

5

In the German town of Gemünden am

Main the company E.ON Wasser-

kraft GmbH operates a pumped storage

hydro power plant, which provides the

electric power for the train operation of

the railway company Deutsche Bahn AG.

During a scheduled examination of a gen-

erator shaft with the magnetic particle

method a multitude of cracks was detected

in the so-called hammer head notches. Via

these notches the four poles of the genera-

tor are connected to the shaft of the gen-

erator. Cracks with depths up to 3.0 mm

are allowed to be reworked according to

the manufacturer‘s specification.

High centrifugal forces occur because of

the high rotating mass of the rotor (total

weight 220 t, 500 rev/min).

If a hammer head would break down, a

complete damage of the generator com-

bined with a long downtime of the power

station would be the consequence.

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.

Additionally, all-clear could be given re-

garding the maximum depth of the existing

cracks.

The measurements were difficult, because

relevant regions were not directly visible.

Here the sensor could only be positioned

by means of a mirror.

In addition, a KARL DEUTSCH UV-LED

hand lamp was necessary to make the

cracks visible for inspection.

After repair works all notches were sub-

jected to examination with magnetic parti-

cles. No remaining cracks were found.

Thus, the results of the crack depth meas-

urement could be verified afterwards. MRThe magnetic particle testing on the generator shaft indicates a multitude of surface cracks in the hammer head notches

To be continued on page 6

RMG 4015: Crack depth measurement in a pumped storage hydro power plant

www.karldeutsch.de » Products » Crack Depth Gauge RMG 4015

Top view of the generator shaft

DEUTROMAT UWE: Safe landing

6

News from your partner for NDTKARL DEUTSCH

A low frequency coil is necessary to de-

magnetize the parts after the test with di-

rect field so the permissible remanence

value of 3 Gauss is not exceeded.

As requested by bmt the demagnetiza-

tion is executed for multiple components

at the same time using transport cages.

Two cages, stacked one on the other, are

moved on a conveyor belt through the

low frequency coil, thus obtaining an op-

timal result.

Also with regard to the documentation of the

test results the machine shows some special

features which were realized via a Siemens

touchscreen. All part-specific inspection

plans are stored in the parameter memory.

All changes to the inspection plans are re-

corded in a table. The magnetization val-

ues are selected according to the respec-

tive inspection plan. After every inspection

lot the results are transferred to the bmt-

network, including the data on operator,

components, date and results.

Regular system checks with reference ob-

jects 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

last year we kept on extending our inter-

national distribution network with the

aid of Dr. Michael Maass (International

Sales).

We are proud to have won the company

All Int Tech S.R.L. in Argentina as a

sales partner for our complete product

portfolio. After intensive in-company

training in Wuppertal Christian Binder is

available for all inquiries. He speaks four

languages: Spanish, German, Portu-

guese and English.

Also in Asia we could extend our sales

and service network: In Thailand we

trained 10 staff members of our partner

NDT Instruments (Thailand) Co., Ltd.

and presented ourselves with a shared

exhibition booth on the most impor-

tant industrial fair of Thailand, the

METALEX.

In Korea our long-time representation

Chunsung now gets support from the

company JSNT in the area of ultrasonic

inspection systems.

Furthermore we complemented our in-

ternational sales net in the USA by win-

ning the company BERCLI as strategic

partner.

The team around Dr. Deborah Hopkins

(Founder and CEO) and Wayne John-

son (Engineering Director) has many

years of experience in nondestructive

Continued from page 5

Christian Binder of our Argentinian repre-sentation All Int Tech S.R.L. and Dr. Wolfram Deutsch during the training in Wuppertal

Multiple components are moved in up to two stacked stainless steel cages through a low frequency demagnetization coil

Mr Uthai (left) and a part of his team of NDT Instruments (Thailand)

testing and provides technical support

and sales with the focus on ultrasonic

testing.

The company

Tecnica Test S.A.

de C.V. takes over

the technical con-

sultation and sales

in Mexico with a

staff of seven em-

ployees. Senior

partner Miguel

Saldamando Flana-

gan is convinced of

our large product

portfolio and sees great opportunities in the

Mexican market, especially in the area of

magnetic particle testing. AL

7

Prof. Dr.-Ing. Volker Deutsch turned eighty

On December 13th, 2012 the long-stand-

ing managing director of the company

KARL DEUTSCH Pruef- und Messgerae-Messgerae-

tebau GmbH + Co KG celebrated his 80th

birthday.

Already as a doctoral candidate at the

University of Hanover the young Volker

Deutsch joined his father‘s company in

1961. The company was founded in 1949

and provided products for nondestructive

materials testing. Measurement of coating

thicknesses, ultrasonic testing and surface

crack detection methods are still in the

focus today. Already during his doctorate

Volker Deutsch was able to provide many

ideas for the development of products.

Very soon the company founder

Ing. Karl Deutsch entrusted responsibility

to his son. The plant engineering and con-

struction department expanded and a

worldwide sales network was installed.

Therefore he used to be on business trips

to Eastern Europe, South America and

China already in the 1970s.

His capability of explaining complex issues

in a comprehensible manner was the base

for many presentations and publications in

technical journals and over 20 specialist

books. From 1982, Prof. Dr.-Ing. Volker

Deutsch was a honorary professor at the

University of Dortmund and presented lec-

tures on nondestructive testing in the fac-

ulty of Mechanical Engineering.

He knew well how to lead and motivate his

more than 100 employees, who in general

worked for the company for many years

and partly still do today. Being locally in-

volved he was a member of the committee

on international trade of the local chamber

of commerce and industry. Also he used to

be shareholder and chairman of the board

of the W-Tec, which is a centre for technol-

ogy and start-up companies in Wuppertal.

After 40 years at KARL DEUTSCH

Prof. Dr. Deutsch handed the business man-

agement over to the next generation. Today

the expanding enterprise is successfully

managed by his two sons: Dr. (USA) Wolf-

ram A. Karl Deutsch as managing director of

the two sites in Wuppertal and

Olaf Deutsch (MA) as business administra-

tion manager of the branch office in Beijing,

China. His daughter Dr. iur. Elke Herbsthofer

owns the publishing house Castell-Verlag

in Wuppertal, where all printed matters of

the company are published. On the occa-

sion of his big birthday two further books

were added (one NDT book and a crime

thriller). WDVolker Deutsch (standing) at ultrasonic test-ing of railway axle wheel sets (1965 appr.)

Prof. Dr.-Ing. Volker Deutsch

www.karldeutsch.de »

Agencies Worldwide

The staff of our Mexican agency Test S.A. de C.V.

Longtime technical competence in nondestructive testing: The representation of KARL DEUTSCH in the USA is managed by Dr. Deborah Hopkins and Wayne Johnson.

News from your partner for NDTKARL DEUTSCH

8

DIN EN ISO9001

certified

Fairs and trade shows

October 14-17, 2013

22nd testXpo

International Forum for Materials Testing

Zwick Company,

Metallinsel

Ulm, Germany

September 16 - 21, 2013

SCHWEISSEN & SCHNEIDEN

International Trade Fair

Joining, Cutting, Surfacing

Messe Essen

Hall 4.0, booth B110

Essen, Germany

New employees at KARL DEUTSCH

Since October 2012, Karina Windus supports our sales office in Wupper-

tal 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.

All current dates can befound on our homepagewww.karldeutsch.de under the topic “Dates, Events”

The privately-owned KARL DEUTSCH

company has been involved in the develop-

ment and fabrication of NDT instruments

since its foundation in 1949. More than

50% of the products are exported world-

wide.

Digital and analog ultrasonic flaw detec-

tors, wall thickness gauges, coating thick-

ness gauges, crack depth gauges, ultra-

sonic testing systems, instruments and

accessories for magnetic particle testing,

and penetrants are part of our product

range.

Characterised by continuous innovation

and product reliability, the trade marks

ECHOGRAPH, ECHOMETER, DEU-

TROFLUX, LEPTOSKOP, FLUXA, KD-

Check and RMG are well-recognised.

Application experience, theoretical knowl-

edge and manufacturing know-how span-

ning more than six decades as well as the

standard compliant quality management

guarantee state-of-the-art instruments and

accessories and a leading position with re-

gard to quality, reliability and economy also

for the future.

KARL DEUTSCHNDT instruments, sensors and systems