WIRE AND ROD
Eddy Current technology is the go-to wire and cable testing method for checking continuity, alloy, flaws and other conditions as well as for locating welds and splices.
MAC® instruments can handle a range of metal wire including cut lengths, continuous production, stranded, multi-conductor and insulated cable. Carbon steels, stainless alloys, copper, aluminum, titanium and other nonferrous metals can also be inspected.
Typical flaws and conditions include chevron cracks, laps, seams, slivers, weld line faults, welds, butt welds, breaks, continuity checking, variations in heat treat, grade, alloy, and other flaws and conditions.
Markers, controls, demagnetizers and components for mounting encircling or segment test coils and saturation coils (for testing magnetic material) and positioning and driving the material through the test are combined with MAC instrumentation to make up a complete system.
The bottom line: the choice of equipment depends on the nonconforming conditions you wish to detect and the size and characteristics of the material.Read More
Some typical applications include:
- Testing Cold Drawn Wire
The Eddy Current test can be installed on a processing machine such as a bull block or cold header. Encircling test coils, including DC saturation on magnetic steel wire, are used to detect short defects. Rotating probes are used to find longitudinal defects.
- Testing Insulated Wire & Cable
Multimac® can handle high throughput speed testing of multi-conductor automotive and building wire to detect splices, welds and breaks. Split coils are available to accommodate oversize splices.
- Detecting Defects in Small Diameter Wire
Test frequencies ranging up to 5 MHz are most effective on small diameters as small as 0.0035”. The Rotomac® 20mm HS high speed Eddy Current rotary is designed to detect longitudinal defects such as seams and laps in wire ranging from 2 to 20mm diameter, and operates at speeds up to 18,000 RPM for high production output.
- Short and Long Continuous Surface and Subsurface Defects
For applications that require the detection of both short and long, seam type defects, the MultiMac®, used with encircling coils and a rotary probe type tester, allows simultaneous detection of both types of defects in magnetic or non-magnetic material.
- Continuity Checking in Wire
To check for continuity in single or multi-conductor insulated wire and cable, the Minimac® 50/55 requires minimal operator time and can be installed directly on the production line. Split or segment coils can be used to allow for dimensional changes in the outside diameter of the insulation.
- Alloy, Heat Treat & Hardness Detection
Variations in alloy, heat treatment, case depth and hardness can be detected by MAC’s comparator instruments such as the Varimac® eddy current tester and the Production Comparator low-frequency electromagnetic unit. The Varimac can test a range of product shapes and materials including nonmagnetic stainless steels, while variations in carbon steel wire are best detected by the Production Comparator.
- Testing Nitinol Wire
Nitinol, a SMA (shape memory alloy) made of approximately equal parts nickel and titanium, plays a key role in many critical surgical applications such as insertion of peripheral stents and heart valves. Nitinol wire is often subject to cracks and inclusions, which can form from the melting process during production. Using a MultiMac® SM eddy current instrument with its phase sector output gate and MAC’s Wiretester test coils (as small as .013” ID) for small diameter applications, cracks and inclusions can be detected. The inspection can take place at high speeds during production, and MultiMac® SM provides complete reporting and networking capabilities. MAC also offers a Grading Software option to provide customer specific automatic grading and data for each coil of wire produced.