Sonic Analysis

Sonic Analysis System – A Non Destructive Testing Technique
Description: Sonic Analysis System is a Non destructive Testing technique to differentiate between the nodularity of Cast iron

Gray cast Iron vs Ductile cast Iron :

Compared with grey iron, nodular iron has an absolute advantage in intensity. The max tensile strength of nodular iron is 90k psi, while the max tensile strength of grey iron is only 35k psi.
Nodular Irons are generally superior to grey irons, regarding their yield strength. The max yield strength of ductile iron is 40k psi; Grey iron is not very malleable or strong, it fractures easily.
Nodular iron is more flexible and elastic than other cast irons. Nodular iron has higher strengths, greater elongation and better resistance to impact than grey iron.

Why Sonic Analysis System?

Sonic Analysis mechanism operates in the sonic frequency range. Every material produces a different frequency sound when struck with a solid object, such as gong. The captured signal is analyzed for all of its signal parameters such as Frequency, Amplitude etc. The process is as follows:

A mechanism is used to strike the test object with a predetermined force. This produces a sound of particular frequency and amplitude.
This signal is detected by a sensor
The detected signal is analyzed for all its data parameters using the software LABVIEW.
The detected signal is analyzed for all its data parameters using the software LABVIEW.
The software compares the obtained data parameters with the table and generates the appropriate output for further actions

Product Features

Capable to differentiate between objects made of different types of Cast Iron such as Ductile Cast Iron and Gray Cast Iron
It can be extended to any other type of metallic objects as well with appropriate calibration
The end-to-end cycle time is less than 45 seconds. Could be optimized further on case to case basis.
User friendly interface for differentiating objects as Pass/Fail
Non-destructive test type. No waste of parts for testing purpose
This mechanism doesn't use any consumables
No replaceable parts due to wear and tear of the measurement system (sensors) as the measurement mechanism is non-contact type
Requires very little maintenance

Comparison between Velocity and Sonic Analysis methods

Automated

Sl. No.	Feature	Velocity Method	Sonic Analysis Method	Remarks
1	Detection type	Contact type	Non-eontact type
2	Basis of Measurement	Material thickness at the point of measurement	Material profile
3	Operation type	Manual
4	Inputs needed to perform detection	Distance	Not needed
5	Devices needed to perform detection	1) Ultrasonic detection device 2) Distance/Thickness measuring device	1) Sonic analysis device
6	Calibration	At regular intervals to ensure proper functioning of the probe	Only once for a given component
7	Procudure to perform detection	1) Identify the region to place the probe 2) Measure the thickness and feed this value to the device 3) Apply couplant 4) Place the probe on the couplant 5) Obtain the result	1) Identify the region to strike the component 2) Strike the component 3) Obtain the result
8	Detection limitation	1) Thickness of the object at the point of measurment has to be less than 50mm for a sandard probe (A max of upto 300mm using specialized probes) 2) Need a flat surface for probe placement	Not needed	This is the reson why few of the users are not using this guage to defferentiate between Ductile and Gray components. Hence they depend on Manual Sound analysis
9	Cycle time	3 mins per component	Less than 45 sees per component.	Has scope for further improvement upto less than 10 sees per component
10	Comsumables	Couplant	Not needed
11	Replaceable parts due to wear and tear	Probe	Not needed	1) Transducer (Probe) performance will be degraded by excessive wear at the tip and when transducer (probe) tip bemmes too rough, mncave or otherwise non-flat, operation may become erratk or impossible 2) Severe wear will limit transducer (Probe) life Ref: User manual of Panametria; Ultrasonk predsion thkkness guage
12	Cost of replaceable parts	High	Low
13	Probaility of replacement of replacable parts	1 in a year	1 in more than 5 years
14	Failures that stops the process	1) Probe 2) Battery/Power source 3) Couplant 4) Device failure	1) Device failure (Computer failure)
15	Storage limit	9986 values only	No such IIimits
16	Computer dependency	No dependency for detection operation	Always needed
17	Cause of Error in detection	1) I..ack ofcouplant 2) Probe not calibrated 3) Probe failure 4) Device failure 5) Component thickness greater than limit 6) Error in thickness measurement 7) surface irregularities (not flat) at the point of detection 8) Probe not placed at the predefined location	1) Different profile component 2) component not struck at the predefined location
18	Process control to prevent errors	Cnmplex - Need many checks - automation requires adding mechanisms for each cause of error	Simple - Adding a camera can address the issue
19	Operation redundancy on failure	No redundancy - need to wait for replacement - Process stopped	1) Has redundant sonic sensor 2) Having another computer as a backup can continue the peration
20	Post process report	To be created manually	Generated test report automatically
21	Device failure due to improper usage	1) Couplant not applied as desired 2) Mishandling of probe	None
22	Detection error - Ductile detected as Gray	Possible	Possible
23	Detection error - Gray detected as Ductile	Possible	Not Possible
24	Skill level desired	High	Low
25	Decision making	Manual	Automated

User Interface Screen	System Evaluation