SONIC ANALYSIS SYSTEM

In Line Non Distructable Test system

 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.

Sonic Analysis System is a Non destructive • Nodular iron is more flexible and elastic than other cast irons. Nodular
Testing technique to differentiate between the iron has higher strengths, greater elongation and better resistance to
impact than grey iron.
nodularity of Cast iron in a casting environment

The objective of this to achieve 100%

inline testing of cast iron components in a Gray cast iron Ductile cast Iron

manufacturing environment with a defined Pass/ Black lead

Fail criteria. This facilitates eliminating failed

components from going in to the next levels of
manufacturing process there by improving the
overall quality, reduce rejections and thereby
saving costs

Photo 1 Photo 2

Stereo microscope photo of Stereo microscope photo of

gray cast iron (x100) Ductile cast iron (x100)
 Comparison between Velocity and
Why Sonic Analysis System?
Sonic Analysis methods
Sonic Analysis mechanism operates in the sonic frequency range. Sl.
Feature Velocity Method Sonic Analysis Method Remarks
Every material produces a different frequency sound when struck with No
a solid object, such as gong. The captured signal is analyzed for all of 1 Detection type Contact type Non-eontact type
its signal parameters such as Frequency, Amplitude etc. The process Basis of Material thickness at the point
2 Material profile
is as follows: Measurement of measurement

3 Operation type Manual Automated

• A mechanism is used to strike the test object with a predetermined
Inputs needed
force. This produces a sound of particular frequency and amplitude. 4 to perform Distance Not needed
detection
• This signal is detected by a sensor
Devices needed 1) Ultrasonic detection device
5 to perform 2) Distance/Thickness 1) Sonic analysis device
• The detected signal is analyzed for all its data parameters using detection measuring device
the software LABVIEW.
At regular intervals to ensure
Only once for a given
6 Calibration proper functioning of the
• The LABVIEW software is preloaded with the table of data component
probe
parameters of different materials. 1) Identify the region to place
the probe
• The software compares the obtained data parameters with the 2) Measure the thickness and 1) Identify the region to strike
table and generates the appropriate output for further actions Procudure feed this value to the device the component
7 to perform
3) Apply couplant 2) Strike the component
detection
4) Place the probe on the 3) Obtain the result
couplant
5) Obtain the result

1) Thickness of the object at This is the reson why few

the point of measurment has of the users are not using
to be less than 50mm for a this guage to defferentiate
Detection
8 sandard probe (A max of upto Not needed between Ductile and Gray
limitation
300mm using specialized components. Hence they
Product Features probes) 2) Need a flat surface depend on Manual Sound
for probe placement analysis

• Capable to differentiate between objects made of different types Has scope for further
Less than 45 sees per
9 Cycle time 3 mins per component improvement upto less than
of Cast Iron such as DuctileCastIron and Gray Cast Iron component.
10 sees per component

10 Comsumables Couplant Not needed

• It can be extended to any other type of metallic objects as well
1) Transducer (Probe)
with appropriate calibration
performance will be
degraded by excessive
• The end-to-end cycle time is less than 45 seconds. Could be wear at the tip and when
transducer (probe) tip
optimized further on case to case basis.
bemmes too rough, mncave
Replaceable or otherwise non-flat,
• User friendly interface for differentiating objects as Pass/Fail 11 parts due to Probe Not needed operation may become
wear and tear erratk or impossible
• Non-Contact type measurement detection mechanism 2) Severe wear will limit
transducer (Probe) life Ref:
User manual of Panametria;
• This mechanism doesn’t use any consumables Ultrasonk predsion thkkness
guage
• No replaceable parts due to wear and tear of the measurement
Cost of
system as the measurement mechanism is non-contact type 12 replaceable High Low
parts
• Requires very little maintenance
Sl.
Feature Velocity Method Sonic Analysis Method Remarks
No

Probaility of
13 replacement of 1 in a year 1 in more than 5 years
replacable parts

1) Probe

14
Failures that
stops the
2) Battery/Power source 1) Device failure (Computer User Interface Screen
process 3) Couplant failure)
4) Device failure

15 Storage limit 9986 values only No such IIimits

Computer No dependency for detection

16 Always needed
dependency operation

1) I..ack ofcouplant
2) Probe not calibrated
3) Probe failure
4) Device failure
5) Component thickness
greater than limit 1) Different profile component
Cause of Error in
17 2) component not struck at
detection 6) Error in thickness
the predefined location
measurement
7) surface irregularities (not
flat) at the point
of detection
8) Probe not placed at the
predefined location

Cnmplex - Need many checks

Process control - automation requires adding Simple - Adding a camera can
18
to prevent errors mechanisms for each cause address the issue
of error

1) Has redundant sonic sensor

Operation No redundancy - need to wait
2) Having another computer
19 redundancy on for replacement - Process
as a backup can continue the
failure stopped
peration

Post process Generated test report

20 To be created manually
report automatically

Device failure 1) Couplant not applied as

System Evaluation
21 due to improper desired None
usage 2) Mishandling of probe

Detection error -
22 Ductile detected Possible Possible
as Gray
1st Zone
Detection error -
23 Gray detected as Possible Not Possible
Ductile

24 Skill level desired High Low

25 Decision making Manual Automated 2nd Zone

3rd Zone
 Frequency values of Ductile and
Grey Cast Iron
Sample Test Results
FREY SPR END YOKE Component
Date Time Ladel Frequency Result
Sl.No. Frequency Sl.No. Frequency Sl.No. Frequency Type
19-02-16 15:34:03 800 10 2078 Pass
Ductile Grey Ductile Grey Ductile Grey
19-02-16 15:34:05 800 10 2078 Pass
1 6942 4807 1 4665 6922 1 5571 5680
19-02-16 15:35:01 800 10 2086 Pass
2 6943 4816 2 4661 6930 2 5568 5681 19-02-16 15:35:06 800 10 2078 Pass
Location 3 6938 4810 3 4658 6924 3 5568 5641 19-02-16 15:35:16 800 10 2075 Pass
4 6938 4808 Location 01 4 4658 6933 Location 01 4 5562 5662 19-02-16 15:35:27 800 10 2080 Pass
5 5754 3986 5 4666 6928 5 5558 5680 19-02-16 15:35:38 800 10 2078 Pass
19-02-16 15:35:44 800 10 2088 Pass
6 5756 3985 6 4662 6929 6 5571 5681
19-02-16 15:35:49 800 10 2086 Pass
Location 02 7 5754 3984 7 4097 6928 7 2556 5672 19-02-16 15:35:54 800 10 2077 Pass
8 5755 3986 8 4092 6930 8 2558 5673 19-02-16 15:36:04 800 10 2075 Pass
9 4773 2818 Loaction02 9 4091 6928 Location 02 9 2557 5680 19-02-16 15:36:14 800 10 2080 Pass
10 4776 2803 10 4088 6928 10 2558 5680 19-02-16 15:36:26 800 10 2079 Pass
19-02-16 15:36:37 800 10 2088 Pass
Location 03 11 4773 2802 11 4090 6929 11 2551 5648
19-02-16 15:36:47 800 10 2086 Pass
12 4777 2811 12 4096 6922 12 2556 5680 19-02-16 15:36:52 800 10 2078 Pass
19-02-16 15:37:02 800 10 2075 Pass
19-02-16 15:37:13 800 10 2080 Pass
19-02-16 15:37:23 800 10 2078 Pass
19-02-16 15:37:34 800 10 2088 Pass
19-02-16 15:37:39 800 10 2086 Pass
19-02-16 15:37:50 800 10 2078 Pass
19-02-16 15:38:00 800 10 2074 Pass
19-02-16 15:38:05 800 10 2080 Pass

Sonic Analysis System in Action

Repeatability Results

FIRST BOX, CAVITY NUMBER 1 (Sl No 9) Frequency Vs Trials FIRST BOX, CAVITY NUMBER 2 (Sl No 10) Frequency Vs Trials

FIRST BOX, CAVITY NUMBER 1 (Sl No 11) Frequency Vs Trials FIRST BOX, CAVITY NUMBER 2 (Sl No 12) Frequency Vs Trials
 However, it is possible to have a substantial difference in sound velocity
between two otherwise identical castings containing the same percentage of
graphite, one with the graphite in flake form (gray iron) and the other with

CASE STUDY
spherical graphite (nodular iron).

Properties Gray CGI Ductile

Tensile strength (MPa) 250 450 750

SONIC ANALYSIS Young Modulus (GPa)

Fatigue Resistance (MPa)
105
110
145
200
160
250
Heat conductivity (W/(mK)) 48 37 28
Project name : Sonic Analysis Hardness (HB) 179-202 217-241 217-255
Customer : Spicer India Relative Damping Capacity 1.0 0.35 0.22
Requirement : Differentiate Between Ductile Iron and Gray Cast Iron Table.1: Properties of gray, compact graphite iron and ductile iron
Cycle time per analysis : 5-10secs
Requirement: Differentiation of ductile and grey cast iron.
Application : Power transmission components in Automobiles
Usually the yokes made of ductile iron are preferred over the grey cast iron.
The compositions vary for both ductile and grey cast iron, depending on these
As the name indicates sonic denotes to, or of the nature of sound or sound
compositions frequency range will be standardized. If the particular frequency
waves. Here, sonic analysis deals with the study of sound waves produced by
range is satisfied then the ductile iron will be considered and the frequency range
the iron samples which are under evaluation.
produced by grey iron will not be considered and those samples will be discarded.
Ductile iron – also referred to as spheroidal or nodular iron – is actually a Process: It is a non-destructive method of testing, where the iron samples are tested
group of irons that exhibit high strength, flexibility, durability and elasticity without undergoing any physical damage. This evaluation is done by hammering
due to their unique microstructure. Cast ductile iron normally contains over 3 the castings placed on the movable conveyor belts. When the hammer strikes
percent carbon; it can be bent, twisted or deformed without fracturing. the casting which is either grey or ductile iron sample, a sound wave is produced,
Fig.3: Pass indicator the frequency of that sound wave is captured and compared with the standard
Ductile iron has greater strength and ductility then gray iron. Those properties frequency range of the casting, for example the flange yoke sample weighing 2.4kg
allow it to be used effectively in a wide variety of industrial applications, has a minimum frequency of 2890Hz and maximum frequency of 2990Hz; if the
including pipe, automotive components, wheels, gear boxes, pump housings, frequency produced by the metal under inspection is within the standard frequency
machine frames for the wind-power industry, and many more. range then the indicator glows green and the yoke is error free.

Problem Statement: Since cast automotive components are used in safety- When the yoke is producing a frequency which is not within the set frequency
critical applications, such as in braking and steering systems, catastrophic range then the indicator glows red on the front panel and the sample will be
failure of one of these parts can result in damage, injury, and even loss of terminated. Similarly the standard frequency ranges for all the parts which are
life. In destructive testing method, which was in practice earlier, manufacturers Fig.4: Fail indicator to be tested must be fixed in prior.
usually test a few samples out of the entire mass production, this was because
the destructive testing method involved breaking or cutting of the component
in order to test its metallic properties, which was not so economically
acceptable. Testing a few samples out of the entire mass production may lead
to the failure of few samples in the future.

Solution: In order to overcome the failure rate and to limit the loss, a test is
conducted on the castings such as flange yoke, Y-yoke etc, which are used in
the automotives. A non-destructive test method is preferred, enabling 100%
of the components in a production batch to be tested. The non-destructive
approach helps in testing the iron samples without damaging it.
Fig.1: Flange yoke
There is a consistent difference in sound velocity between pure iron, nodular Conclusion: Sonic analysis provides a reliable method for measuring sound
cast iron, and gray cast iron. The frequency range differs for each type. velocity and, therefore, verifying the nodularity of cast ductile iron parts.
Integrating ultrasonic measurement into an automated testing system in
Exact velocities for a given application vary depending on alloy composition, a foundry production line enables fast, reliable inspection of 100% of cast
grain structure, and other process variables. Exact velocities should always be production parts. Applications software enables users to easily adjust the
verified on calibration standards made from the material to be tested. And a system and provides stable, accurate test results. The ductile iron samples are
standard frequency range has to be set for each type of samples. tested, which are error free and can be used for automotive manufacturing.
Fig.2: Y-yoke
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