Powder Metal Solutions
Quasar is used to test the complete range of powder metal parts. Applications include:
- Engine components - connecting rods, bearing caps and sprockets
- Transmission components - clutch plates and timing rings
- Other components - ABS rings and flanges
Quasar detects all structurally significant defects .
Quasar detects all of the structural defects that occasionally appear in powder metal including:
- cracks
- inclusions
- oxides
- de-carb
- porosity
- incorrect sintering
- coining or powder mixture
- significant non-fill
- missing features
- significant dimensional variations
It is particularly effective at detecting cracked or chipped teeth, a defect that is difficult to detect using other NDT methods.
Quasar provides better NDT
Since a part's resonance pattern provides a measure of the structural integrity of the whole part, a single Quasar test can replace other NDT methods that typically focus on specific defect types. Quasar directly replaces magnetic particle or eddy current (cracks). It also replaces or complements visual inspections for inclusions, non-fill, missing features, and significant dimensional variations. Quasar can also replace many of the met lab tests used to confirm correct density, sintering and powder mixture.
Special Considerations
Quasar testing can be used for any material that is stiff enough to resonate. While Quasar can be used with most powder metal parts, the powder density affects its application. Higher density parts are stiffer and resonate better, resulting in an improved ability to detect smaller defects.
Quasar testing will only detect structurally significant defects - that is, defects that are severe enough to cause premature part failure. Quasar will not detect surface discontinuities associated with parting lines or tool marks, resulting in less scrap for these non-structural blemishes.
In symmetrical parts such as rings, disks and clutch plates, the effect of variations in powder density often produces greater changes in part strength than small cracks. It is often necessary to either accept the parts with small cracks or to reject the parts with significant density variation.
Benefits
The benefits of using Quasar for powder metal include:
- Reliable detection of all structurally significant defects in a single test
- Results that can predict road life by correlating to failure testing (e.g., tensile or fatigue tests)
- Computer based accept/reject decisions, not subject to human judgment
- Reduction in scrap as cosmetic defects are not rejected
- Dry, non-magnetic process eliminates need for pre- and post-inspection treatment
Powder Metal Economic Case Study
Description
| Part
|
Bearing Cap
|
| Method
|
Powder Metal
|
| Part Numbers
|
1
|
| Quasar NDT
|
3200
|
| Loading
|
Automatic
|
| Location
|
US
|
| Amortization
|
2 years
|
| Payback
|
6 months
|
Quasar replaces magnetic particle inspection which costs $0.17 per part.
The Quasar system consists of a Quasar 3200 Dual Test Station NDT System plus an integrated material handling system. The total cost was $200,000.
The cost savings are tabulated below.
| Quasar Cost/Part
|
$0.03
|
| Visual Cost/Part
|
$0.17
|
| Savings/Part
|
$0.14
|
| Payback Parts
|
1,463,415
|
| Payback Months
|
6
|
The Quasar cost per part is based on capital amortization over 2 years. It does not include labor cost because the Quasar system is integrated into the manufacturing process.