Information about Testing for Microcracking wanted

Ron Rompen

Trusted Information Resource
#1
First, a bit of background. We purchase (and assemble) a retainer ring manufactured in NA and also in Europe. We have a history of failure (fracture of the retainer ring) on the NA parts, but not on the EU parts.
Part design is identical, material is different (1075 vs C67S respectively) and heat treat is identical (HV 440-520)
Due to ongoing issues with the NA rings, we are performing some in-depth analysis, one component of which is testing (before and after assembly) for microcracking. This is not a test with which I have any familiarity.

Is there anyone here in the group that could provide some information, and perhaps (offline via private email) act as a sounding board for some of our ideas and conclusions?

Thanks for your help guys.
 
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Stijloor

Staff member
Super Moderator
#2
First, a bit of background. We purchase (and assemble) a retainer ring manufactured in NA and also in Europe. We have a history of failure (fracture of the retainer ring) on the NA parts, but not on the EU parts.
Part design is identical, material is different (1075 vs C67S respectively) and heat treat is identical (HV 440-520)
Due to ongoing issues with the NA rings, we are performing some in-depth analysis, one component of which is testing (before and after assembly) for microcracking. This is not a test with which I have any familiarity.

Is there anyone here in the group that could provide some information, and perhaps (offline via private email) act as a sounding board for some of our ideas and conclusions?

Thanks for your help guys.

Can someone help Ron?

Thank you!

Stijloor.
 
A

achorste

#3
I wouldn't say I was an expert in this sort of product, however there are a number of NDT methods to detect surface discontinuities.

What surface condition are thae parts supplied in? How big are the cracks you are wanting to detect?

Fluorescent penetrant inspection is a relatively cheap method that could detect surface cracks etc. and magnetic particle inspection also may be an option?
 

Ron Rompen

Trusted Information Resource
#4
Achorste: Surface condition of the parts is not really called out. The parts go through a heat treat (austemper) process, and (for the EU parts) get a subsequent Phos & Oil coating, which would involve a precleaning operation as a part of the process. NA parts do not get the Phos & Oil, so are received 'as-quenched'.
The size of the cracks is part of the concern. My (very limited) exposure to LPI is that it will detect cracks at the macroscopic level (i.e. they are visible to the naked eye if examined under appropriate lighting conditions), the LPI simply serves as an agent to enhance the contrast of the crack to the surrounding surface.
Eddy current testing, from what I have been able to discover, would be more suitable for detecting cracking at the microscopic level, however due to the configuration of the assembly (retainer ring pressed into place over the end of a cross tube, holding a side panel in place, with contact between all three surfaces) I do not believe that it will be very effective.

Thanks for your response, looking forward to hearing more.
 
A

achorste

#5
Hmmm.. it would seem that LPI/MPI may not be sensitive enough for your purposes.

I've not had many dealings with anythign more sensitive, so I will bow out at this point, sorry I couldn't be of more help!

PS - I have heard a few mentions of ultrasonic thermography (applying an ultrasonic vibration to a metal & measuring heat changes that develop from material defects due to friction). It may be something to look into but I couldn't give you any more detail than that.
 

hogheavenfarm

Quite Involved in Discussions
#6
We had a similar situation - we checked out LP, MP, UT, and RT. Of all RT was best but also most expensive, could only be used in small samplings, not on the entire lot.
UT was ok, but required a skilled operator and a specially designed tip for each shape of part, depending on where you wanted the inspection. We ended up using LP, not flourescent, which worked pretty well. Even though the cracks could not be seen, the LP enhanced them enough to be seen with magnification. The surface condition is pretty critical for this however. Ours were polished parts, so they were pretty smooth, if you have a rougher finish, it will be harder to detect what is a crack and what isnt. MP will only work if the part can be magnetized, and even then, will suffer from the same issues as LP (and require degaussing)
 
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