The IMPOL company in Slovenia is a leading supplier of aluminium products. It employs about 1000 people and produces more than 170 different alloys. Semi-finished and high-quality finished products for demanding customers, e.g. from the automotive and aviation industries, are manufactured at several locations.
The testing system was designed for bar diameters from 60 mm to 180 mm and lengths from 2700 mm to 8000 mm. During the inspection, the bars are rotated at circumferential speeds of up to 1 m/s. A compact multi-probe with a total test track of 80 mm contains eight straight-beam probes for core defect detection. Eight additional angle-beam probes for clockwise scanning and eight angle-beam probes for CCW scanning detect surface defects. The detectable defect size strongly depends on the surface quality and the material structure, i.e. the aluminium alloy to be tested. Typically, 0.7 mm FBH can be detected for bar diameters up to 80 mm. At the maximum diameter of 180 mm, 1.2 mm FBH can be achieved.
The testing system was delivered in 2022 and subsequently put into operation. IMPOL plant manager Tadej Lozinsek and KARL DEUTSCH service engineer Eduard Komenda worked closely together to ensure a smooth installation phase. The best possible test sensitivities for the various aluminium alloys and short untested ends of 30 mm were achieved.
Loading and unloading of the bars with a gantry crane was part of the scope of supply of the German company UNTERSCHÜTZ. A combined loading/unloading time of 3 s and a helical inspection time of 46 s for the smallest bars and 138 s for the largest bars result in a throughput of 23 to 59 bars per hour.
The stainless steel tray of the ultrasonic testing system collects all the excess coupling water and keeps the floor dry. This rotating bar testing system is already KARL DEUTSCH’s second system at IMPOL. Since 2016, smaller aluminium bars with a maximum diameter of 90 mm have been tested in linear motion and high testing speeds of up to 2 m/s with an ECHOGRAPH HRPS testing system. Polona Turnsek from the IMPOL purchasing department was again satisfied with KARL DEUTSCH’s project management. Therefore, a KD-CHECK penetrant testing system for aluminium forgings could be the next step in our cooperation.