Introduction to:

Magnaflux Resonant
Inspection

B. Keller – March 2009

What is Magnaflux Resonant Inspection?

Magnaflux Resonant Inspection is a

Process Compensated Resonant
Inspection NDT System.

Vibrates part at given frequencies and

records how the part responds.

Compares part ‘resonances’ to a stored

pattern.
What is a Resonance?
Every hard material (metal, ceramic…) has natural ‘resonance's’
or frequencies.
These resonances are determined by
◼ the sample’s dimensions and material properties (hardness,
stiffness, …)
Shifts in the frequency of a given resonance indicate a change
in the dimensions or material properties - defects.

Torsional /
Bending Mode Breathing Mode
‘Twisting’ Mode
What is a Resonance?
This is a ‘Broadband’ Spectrum.
◼ Each ‘Peak’ is a resonance
◼ The Magnaflux Resonant Inspection System records the Frequency that the resonance occurs
(‘peak frequency’)
◼ The relationship (pattern) of two or more resonance peaks determines the sorting criteria.
Developing the Pattern
The Magnaflux Resonant Inspection system
develops a pattern through a training process
Magnaflux Resonant Inspection users collect
sample sets to train the system
◼ Functionally Good Parts
◼ Functionally Bad Parts
◼ Functionally bad parts must have a condition that
increases the probability of part failure, i.e..
structurally significant.
Software sorts production parts according to
the developed pattern.
2 Parts to the Magnaflux Resonant Inspection
System

Hardware
◼ Measures the resonances
◼ Measures the temperature
◼ Fixtures the part for testing
◼ Vibration isolation

Software / Training Process

◼ 2 Magnaflux Resonant Inspection Software
Programs
◼ 5 step Sorting Module development process.
Components of Magnaflux Resonant
Inspection 4000 System
Basic Equipment
Host Computer
consists of:
◼ Work Station
Transceiver
 Transceiver
 Host Computer
◼ Test Station
 Transducers
 Thermocouple Transducers
on Pedestals
 Part Fixture
Magnaflux Resonant Inspection 4000 System

Test
Station
Work
Station
Other Factors
Some external factors can also affect
the measurement of resonances:
◼ Temperature
◼ External noise, vibrations
◼ Nodes (contact points)
◼ Wet parts

Magnaflux Resonant Inspection

Hardware is designed to minimize the
effect of these factors.
Training Process
Magnaflux has developed 2 main
software programs to aid in creating
Sorting Modules.

Develop Sorting Module – Manual

Mode
Production Testing – Automatic Mode
Magnaflux Resonant Inspection System Training
Process

Select Collect Build Create Test

Target Training Design Sorting Production
Defects Set Library Module
Select Target Defects
Definition of Defectiveness
◼ Visual Definition – Parts that “look” bad – unworkable approach
◼ Functional Definition – Part that would fail prematurely in service
◼ Statistical Definition – Part that is statistically weaker than minimum failure level
of good parts

Defect Severity:
◼ B1: Measurable - Measurable degradation in strength.
◼ B2: Concern – Statistically significant degradation in strength.
◼ B3: Significant – Degradation that could lead to failure over time.
◼ B4: Severe – Degradation that will probably lead to failure.
◼ B5: Gross – Catastrophic degradation that would certainly cause failure.

Destructive testing may be required to determine Defect Severity

Collect Training Set
Functionally Good Samples
◼ Represent allowable variation – size and material
◼ Parts from different production conditions; dies,
molds, heats

Functionally Defective Samples

◼ Naturally occurring - collected
◼ Artificially created – process settings such that the
defect condition will occur – nodularity, carbides
Build Design Library
Broad Band Creation - Magnaflux Resonant
Inspection
◼ Determine usable range of frequency
Broad Band Validation - Magnaflux Resonant
Inspection
◼ Further optimizes timing band parameters
Margin Database – Magnaflux Resonant Inspection
◼ Same part measured multiple times to calculate placement /
measurement variation
Design Database – System Analyst
◼ Functionally good parts measured
 Capture all process variations
◼ Functionally bad parts measured
Create Sorting Module
▪ VIPR Software will analyze resonances stored for each part in the
sample set to determine the pattern that separates your good from
bad samples and creates a sorting module.
Validate Sorting Module
Validation of the Sorting Module is key to a
successful production launch.
◼ Find and eliminate potential sorting errors prior to
production operation.
Correct Validation Errors
“Preview” of Possible Errors when Testing Production
Parts
Production Testing / Maintenance
▪ Sorting Module Maintenance
▪ Responding to changes in the performance
of the sorting.
▪ Usually increased reject rate due to ‘unseen’
process variation.
▪ Verification of process variations
▪ Good/Bad
▪ Destructive testing may be needed
▪ Must capture all acceptable process variations
Sorting Module Testing / Maintenance

Accept
Part Evaluate
Testing
Reject

Validate
Sorting Functionally Functionally
Module Acceptable Unacceptable

Update
Sorting Update Data Library
Module
Production Tracker

Production Tracker Provides Statistical Analysis

Keys to Success
Proper Part Classification
Dedicated System Analyst
Management Support
Mechanical Maintenance
Performance Monitoring
Goals and Expectations
Magnaflux Application Engineering will Train the
Responsible people
◼ System Analyst

◼ Production / Maintenance Staff

Magnaflux will assist with the initial Sorting Module

development
Magnaflux will Prepare a plan for the management
team to incorporate the Magnaflux Resonant
Inspection system into their production line.
System Analyst must learn the software, maintain the
Sorting Module, and the system hardware.
Syllabus

Day 1 MGR / ANA Opening Presentation / Sample Set Review

ANA / SUP System set up / Check out / Hardware Functionality

Day 2 ANA Train Analyst on Data Logging / Begin logging of sample set / Build Database

Day 3 ANA Complete Data Logging / Build Database / VIPR

Day 4 ANA VIPR / Create - Validate Sorting Module / Project Registration

Day 5 ANA / SUP Train Analyst and Supervisors on QProduct / Production tracking / Production
Trials
ANA / MGR Discuss Magnaflux Resonant Inspection Implementation Plan

ANA Final Exam